GPM Gold Project

Technical Specification
XSTRATA technology Pty Ltd

Report ref:
226767-001
22 March 2012
Revision 1

Document prepared by:
Aurecon Australia Pty Ltd
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Document ID: 226767 GPM Gold Project Technical Specification rev 1.doc
Rev No

Date

Revision details

Typist

Author

Verifier

Approver

0

21/04/11

Issued as draft

JBW

GRF

SLH

GRF

1

22/03/2012

Issued for construction

SLH

GRF

GA

GRF

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GPM Gold Project
Technical Specification
XSTRATA technology Pty Ltd

Contents
1. 

Excavation

1.1 

Extent of work

1.2 

Geotechnical information

1.3 

Excavation

1.4 

Backfilling and compaction

1.5 

Erosion control and maintenance

2. 

Concrete

2.1 

Scope

2.2 

General requirements

2.3 

Supervision

2.4 

Inspection

2.5 

Materials for concrete

2.5.1 

Cement

2.5.2 

Aggregates

2.5.3 

Water

2.6 

Admixtures

2.7 

Storage of materials

2.8 

Supply of concrete

2.9 

Measurement of materials

2.10 

Quality of concrete

2.11 

Sampling and testing

2.12 

Rejection of concrete

2.13 

Formwork

2.14 

Formwork ties

10 

2.14.1 

Preparation of formwork surfaces

11 

2.14.2 

Removal of formwork

11 

2.15 

Placing of concrete

12 

2.16 

Pumping

15 

2.17 

Finish of concrete surfaces

16 

2.18 

Tolerances for unformed concrete surfaces

17 

2.19 

Construction joints

17 

2.20 

Curing of concrete

18 

2.21 

Steel reinforcement

18 

2.22 

Core holes and building in

19 

2.23 

Anchor bolts

20 

2.24 

Joint fillers

21 

2.25 

Joint sealants

21 

2.26 

Grout

22 

2.27 

Mortar

22 

Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.doc 22 March 2012 | Revision 1

Aurecon

Page i

3.doc 22 March 2012 | Revision 1 Aurecon Page ii .3.32  Fibrecrete 24  2.4  Fly ash 24  2.34  Preparation of surfaces before placing of concrete 25  2.3  Inspection during erection 29  3.28  Joint seals 22  2.6.3  Executing 23  2.4.30  Electrical conduits 23  2.1  General 29  3.31.3  Materials 26  3.35  Concrete blinding layer 25  3.6.3.33  Stabilised sand 24  2.3  Marking 31  3.5  Fibrecrete mixes 24  2.8.4  Testing of materials 27  3.7  Handling.5  Supervision 29  3.2  Materials 23  2.31  Sprayed concrete 23  2.6  Precamber 32  3.1  General 33  3.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 2.4.7  Protective treatment 32  3.6.2  Aggregates 24  2.1  Scope 26  3.32.32.2  Bolt holes 34  Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.1  General 24  2.2  Inspection during fabrication 28  3.  Fabricated steelwork 26  3.1  General requirements 23  2.8  Erection 33  3.2  Steel 26  3.31.32.4  Inspection 28  3.31.32.29  Waterstops 23  2.32.6.4  Weld splices 31  3.2  Workshop drawings 30  3.4.1  General 28  3.32.6.3.6.5  Cutting and holing 31  3.6  Finishing 24  2.1  General 26  3.3  Stainless Steel 27  3.3  Admixtures 24  2.2  General requirements 26  3.6  Fabrication 29  3.6. delivery to site and storage 32  3.8.

  Masonry blockwork 49  4.2  Installation of bolts used in snug tight condition 38  3.1  Fabrication tolerances 35  3.10  Weld quality 42  3.6  Pre-weld heat treatment 41  3.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 3.12  Welding 39  3.12.1  Cement 50  4.11  Welding operators 42  3.11.11  Bolting 37  3.3  Installation of high strength bolts used in friction grip mode 38  3.2  Floor plate 46  3.12.9.12.7  Materials 50  4.8.3  Stairways 47  3.1  Scope 49  4.8  Welding consumables 41  3.9  Tolerances 35  3.14  Examination and testing 43  3.13.5  Manufacturer’s certificate 49  4.12  Welding supervision 42  3.4  Installation of fitted shoulder bolts 39  3.9.1  Grating 45  3.12. walkways.5  Ladders 47  3.12.1  General 37  3.6  Acceptance 50  4.12.13  Platforms.12.3  Joint preparation 40  3.12.2  Lime 50  Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.4  Handrails and kickplates 47  3.14  Monorail beams 48  4.12.13.13.13.doc 22 March 2012 | Revision 1 Aurecon Page iii .13.11.12.4  Butt welds 41  3.7.2  General requirements 49  4.2  Erection tolerances 36  3. stairways and ladders 45  3.10  Grouting of base plates 36  3.4  Delivery 49  4.5  Fillet welds 41  3.13  Welding procedures 43  3.3  Masonry units 49  4.11.12.12.7  Post-weld heat treatment 41  3.12.7.11.1  General 39  3.9  Welding equipment 42  3.3  Site welding 35  3.12.2  Welding of stainless steel 40  3.

9  Protective coating systems 57  5.D.9.1  Extent of work 54  5.7.9  Reinforcement 51  4.5  Application 55  5.9  Tolerances 53  4. building-in 52  4.2  Cutting 52  4.3  Surfaces not to be coated 54  5.9.8.8.6  Top coats 56  5.7  Cleaning down 53  4.7.9.7.2  Inspection 54  5.4  Sand 50  4.8.8.7.6  Chasing.4  Joints 52  4.5  System 9: Hot Dipped Galvanizing 60  Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.9.4  Surface preparation 55  5.8  Lintels 53  4.10  Protective treatment 53  5.1  System 1: Epoxy Primer plus HS Epoxy and Recoatable Acrylic 58  5.7.doc 22 March 2012 | Revision 1 Aurecon Page iv .  Protective treatment 54  5.2  System 2: Inorganic Zinc 58  5.5  Water 50  4.3  System 3: Galvanized Touch-up 59  5.7.9  Temporary bracing 53  4.8.3  Additives 50  4. Galvanizing + Epoxy Primer & Recoatable Acrylic 59  5.10  Caulking and sealants 51  4.8.5  Clean-out blocks 52  4.6  Mortar 50  4.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 4.8  Repair of painted damaged coatings 57  5.8  Workmanship 51  4.1  Laying of blocks 51  4.7.8.7  Warranty 57  5.8  Grout 51  4.7.8.4  System 6: H.3  Bond 52  4.8.9.7  Straps 50  4.

The levels of backfilling on two sides of a structure shall at no time differ by more than 400mm. Backfilling of foundations. disposal of surplus material and backfilling and compaction as shown on the drawings and as specified. cleaning and inspection. or approved imported material. brace and/or sheet such excavations shall be rectified and any materials. Material excavated from foundations which is suitable for use as "approved backfill" shall be stockpiled in the stockpile adjacent to the site in a manner acceptable to the Superintendent. props and progressive backfilling to ensure the safety of the works. Excavations for structures shall extend a sufficient distance from the structure so as to permit placing and removing forms.2 Geotechnical information Geotechnical information relating to the site is contained in the two geotechnical reports produced by Geoter Project LTD. and at the Contractor's expense. The Contractor shall report immediately to the Superintendent. Any slips or falls of the sides of excavations due to the Contractor's failure to shore. 1/12/2011. Any dewatering or drainage of the excavations necessary for the construction of the works shall be carried out by the Contractor and shall be deemed to have been included in the Contractor's price. planking. equipment or structures damaged by such slips or falls shall be repaired or replaced as directed by the Superintendent. Yerevan 2010 and by EPMS. Excavation 1. lumps of concrete. shall be carried out in layers not exceeding 200mm in thickness using the uncontaminated "approved backfill" material. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.3 Excavation The Contractor shall carry out all excavation to the extent and depths necessary for the construction of the works to the levels. installing drainage facilities where required. grades. 1.doc 22 March 2012 | Revision 1 Aurecon Page 1 .4 Backfilling and compaction Approved excavated material from stockpile. bracing and/or sheeting shall be satisfactorily maintained during the whole of the excavation and construction operations and shall be removed in a manner to prevent caving as the excavations are concreted and/or backfilled. any circumstance which tends to indicate that the ground conditions encountered during excavation differ from those expected by the Contractor from his interpretation of site investigation information. ground slabs and pits. 1. The Principal does not accept any responsibility for any conclusions or opinion expressed in site investigation reports nor for any conclusions or opinions drawn by the Contractor from information supplied by the Principal. The Contractor shall adequately support all excavations as the work proceeds and shall exercise every reasonable precaution by means of intermediate shoring. sheet piling and timbering as necessary. shall be used for all backfilling. Such shoring. dimensions and in the positions shown on the drawings including for provision of working space. reinforcing steel or other rubbish and organic matter or lumps of material greater than 40mm in size. 1.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 1. "Approved backfill" material shall not contain pile off cuts.1 Extent of work The work described in this part includes excavation for the retaining wall foundations.

On completion of all backfilling. and controlled disposal of stormwater runoff from site. capture of stormwater runoff. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. and the measures are to be adjusted or repaired as necessary to maintain their effectiveness. No disturbed area is to remain denuded for longer than 30 days. To achieve the specified compaction for loose thickness layer of 300mm the require compactor will need to be at least 1500kg. and shall take such measures as required to ensure that stormwater runoff across the site does not result in the erosion and loss of soil from the site.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Compaction of backfill shall be carried out using a heavy vibrating plate compactor to at least 95% of the modified Maximum Dry Density and at its optimum moisture content as determined by Australian Standard 1289 Test 5.5 Erosion control and maintenance The Contractor shall be responsible for erosion control and maintenance of the site. Regular inspections are to be carried out by the Contractor. separation of silt from runoff. The Contractor shall be responsible to ensure the sediment control measures are monitored to a good operating standard at all times throughout construction. Any damage caused by earthworks. including treatment to exposed earthworks. For 200mm loose thickness this can be reduced to 600kg and for 150mm loose thickness the compacter should be 400kg. or the transport of soil and other debris to neighbouring areas which may cause nuisance. Non-potable water from an approved source may be used for adjustment of the moisture content of the fill material to its optimum moisture content prior to compaction. All trenches not in roadways are to be mulched and seeded within 15 days of backfilling. When compacting within 5 metres of the retaining wall a maximum loose thickness of 150mm shall be used with a 400kg weight single roll pedstrain roller-compacter. surplus stockpiled material shall be removed to an approved disposal area off site.doc 22 March 2012 | Revision 1 Aurecon Page 2 . Any nuisance or damage sustained by neighbouring properties as a consequence of the Contractor's activities shall be rectified at the Contractor's cost. It is the Contractor's responsibility to ensure that disturbance of the site is minimal and that all construction on site is to be carried out in such a manner that erosion and associated water pollution are minimised. A temporary cover of mulch or an annual grass species shall be applied to disturbed areas which will otherwise remain exposed for more than 30 days before permanent stabilisation works are undertaken.1. particularly after every storm event. The erosion control and maintenance of the site shall be in accordance with the relevant plan that indicates the measures proposed for controlling erosion.2. 1. All erosion and siltation measures are to be installed prior to the commencement of earthworks. and loss of soils (including topsoil) due to erosion shall be made good at the Contractor's cost.

4 Inspection The Superintendent reserves the right to inspect and approve or reject the formwork and reinforcement for each concrete placement before any concrete is placed in that section of the Work. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 2.1 Scope This specification applies to the supply. 2. The Contractor shall implement an effective Quality Control System covering all concrete works. placing and finishing of all concrete work.doc 22 March 2012 | Revision 1 Aurecon Page 3 . The concrete supervisor shall organise and direct the placing. and shall submit the proposed Inspection and Test Plans (ITP’s) to the Superintendent for review and approval prior to commencement of any concrete works. as shown on the drawings and as necessary for completion of the Works. mixing. Concrete 2. together with details of their previous experience. 1379. Before construction commences the Superintendent will nominate to the Contractor those elements that the Superintendent considers to be critical and no concrete shall be placed in those elements except in the presence of the Superintendent. Notwithstanding previous approval having been given. and shall be in continuous attendance during all such activities. the Superintendent may at its absolute discretion require the removal of any concrete supervisor whom the Superintendent considers to be unsuitable for the supervision of the concrete works. Any inspection by the Superintendent does not absolve the Contractor from its responsibility to implement an effective Quality Control System. unless noted otherwise on the drawings. 25MPa cube 28 day strength. The Contractor shall have ready access to each of the Australian Standards 1012. 2. A copy of AS 3600 shall also be kept at the place of manufacture of precast units. compacting and finishing of the concrete.2 General requirements All concrete work shall conform to the requirements of AS 3600 and standards referenced therein except where varied by this Specification. Before any concrete work is commenced the Contractor shall submit to the Superintendent for approval the name of the concrete supervisor proposed to be employed on the Works. The characteristic compressive strength (f’c) of not less than 20 MPa cylinder.3 Supervision The Contractor shall employ on the site an experienced concrete supervisor. whose sole responsibility shall be the supervision of the concrete work. 3600 and 3610 on the job at all times. The Contractor shall keep on the site and have available for inspection by the Superintendent at any time a logbook in which is recorded the following information regarding each placement of concrete:       Date of placing concrete Portion of the work constructed Specified Grade of Concrete and source Slump measurements taken Volume of concrete placed Test specimens made 2.

conduits and the like shall be in position and the Superintendent notified at least one clear working day before concrete is placed in any section of the Work. All fine and coarse aggregates used in concrete shall be normal weight (not lightweight) non slag aggregates and shall comply with the requirements of AS 2758. Fine aggregates shall consist of sharp. organic matter or other deleterious substances.2. reinforcement. Coarse aggregate shall consist of crushed stone or gravels composed of clean.5. The amount of fly ash incorporated shall not exceed 25% of the cement/fly ash blend and the amount of slag shall not exceed 30% of the cement/slag blend. holding down bolts. reinforcement supports. Cement shall not be more than six months old when used in the Work and any cement that has become lumpy or partially set prior to mixing shall not be permitted to be used in any concrete to be supplied under the Contract. Except where noted otherwise on the drawings or in this Specification. hard and durable particles. Subject to approval.1 shall be:  Water absorption (Clause 7. other sizes may be used to suit the spacing of the reinforcement. clean siliceous sand. The Work shall be maintained in a clean. sound.1) shall be based on `submitted gradings. the maximum aggregate size for all concrete shall be 20mm.5 Materials for concrete Details of proposed material sources shall be included in the Contractor's Tender. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. which shall be supplied to the Superintendent  Durability requirements (Clause 9) for all aggregates shall be as for severe exposure classification concrete  The materials listed in Clause 12 shall be unacceptable  All of the aggregates shall comply in every respect with the requirements of Clause 14.3) shall not exceed 2%  Grading requirements (Clause 8. All aggregates shall be free from dust. 10mm to 7mm and sand.5. The concrete supervisor shall be present and assist the Superintendent during inspections. 2. Prior to an inspection by the Superintendent. coarse.doc 22 March 2012 | Revision 1 Aurecon Page 4 . 2.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All formwork. Fly ash shall comply with AS 3582.1.2 Aggregates Aggregates shall generally comprise three sizes: 20mm to 10mm. all requirements of the Contractor's Quality Control System shall have been fulfilled. clay. satisfactory condition until concreting is completed. cores.1 Cement Unless noted otherwise on the drawings or approved by the Superintendent all cement used shall be Type GB Blended Cement and shall comply with the requirements of AS 3972. The Superintendent reserves the right to inspect and approve or reject before concreting commences any or all materials to be used in the concrete.3 for alkali reactive materials The variation in moisture content of each aggregate shall be closely monitored and adjustments made in the batching to ensure that the agreed mix proportions for each grade of concrete are maintained.1 and slag shall comply with AS 3582. 2. Special requirements under AS 2758.

7 Storage of materials The following requirements apply to the storage of materials on site.doc 22 March 2012 | Revision 1 Aurecon Page 5 . Under no circumstances will the use of calcium chloride as an additive be permitted. Should any other substance. 2. in sufficient volume to guard against possible stoppage of works by irregular delivery. salts. be added to the concrete without the written approval of the Superintendent.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd To ensure that aggregate used in concrete is not susceptible to adverse reaction with high alkali cements the Contractor shall submit the following information to the Superintendent for approval prior to the first use of any particular source of fine or coarse aggregate:  A statement from a recognised authority that the aggregate is not susceptible to adverse reaction with the cement to be used  The results of the Standard Test for the Potential Reactivity of Aggregates (Chemical Method) in accordance with ASTM Designation: C227-B1 If the aggregate source is changed during the course of this Contract. Cement shall be stored so as to permit access for inspection. refuse to authorise payment for any such concrete and may require the removal of any concrete in which the said substance has been used. Cement supplied to the batch plant for use in concrete under this Contract shall be tested to determine its Equivalent Sodium Oxide Content and the test results submitted to the Superintendent for approval. at his absolute discretion. aggregate and water as specified. if the Contractor proposes using water which is non-potable.7 per cent may be rejected for use in concrete under this Contract. Any batch of cement which exhibits an equivalent sodium oxide content of greater than 0. and the Contractor shall permit samples of up to 5kg being removed for testing. 2. At least seven (7) days prior to the placing of any concrete. or at the batch plant of any supplier of ready-mix concrete or pre-cast concrete for use in the Works covered by this Contract. rejection or other cause. the Contractor shall submit to the Superintendent for approval test results demonstrating that the proposed aggregate conforms to the above requirements.3 Water Water for concrete shall be:  Potable  Clean and free from oil and injurious amounts of alkalis. the above procedure shall be repeated. identification and sampling. and sufficiently in advance of use to permit satisfactory tests to be made. Such water shall not be used unless approved in writing by the Superintendent. different consignments being stacked separately. apart from cement. Salt water shall not be used.5. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. fly ash. organic or other substances that may be deleterious to concrete or reinforcement Attention is drawn to the requirements of Clause ‘Sampling and Testing’ and. Cement shall be transported and stored in approved water-tight containers. the Superintendent may.6 Admixtures No admixtures or air entraining agents shall be used unless approved in writing by the Superintendent. 2. necessary samples of the water shall be submitted to the Superintendent for testing.

the Contractor shall make two separate trial batches of each mix. Where the Contractor proposes to mix concrete on the site. they shall be adjusted and tests of the trial mixes shall be repeated. and to the satisfaction of. hardened concrete and foreign matter shall be removed from the inner surfaces of the mixing and conveying equipment.8 Supply of concrete All concrete used in this Contract shall either be obtained from an approved ready-mixed concrete supplier or produced in an approved batch plant.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Any portion of work constructed with cement that is found to be unsatisfactory shall be demolished and rebuilt with approved materials. Hand mixed batches shall not exceed 0. The Superintendent shall be given at least three day's notice of the Contractor's intention to conduct trial mixing and testing and no such work shall be accepted for the purposes of this clause unless the Superintendent or its representative is present. Mixing by hand will not be permitted except in an emergency and then only with the approval of. without the approval of the Superintendent. 7 and 28 day characteristic strength tests in accordance with AS 1012. and 3. The concrete shall be mixed in the quantities required for immediate use and shall be placed in position as rapidly as possible.2 cubic metres in volume and the mixing shall be done on a clean watertight platform. The moisture content of the fine and course aggregates shall be regularly measured and the mass of water and aggregate in the concrete mix adjusted to suit. Aggregate stockpiles shall be arranged and used in a manner that will prevent excessive segregation or any contamination with other materials. If the trial mixes fail to meet the specified requirements. Ready-mixed concrete shall be delivered to the site in trucks of the revolving drum type and the use of non-agitating equipment for this purpose will not be permitted. 2. Delivery of coarse and fine aggregate shall be sufficiently far in advance of construction to enable the Superintendent to select samples for testing. After the mix design has been approved by the Superintendent. Before supply of any concrete from the site batching plant. or with other sizes of aggregates. Before commencing a run of concrete. the Superintendent. In no circumstances shall water or any other substance be added to the concrete. and shall carry out slump tests. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. if desired.doc 22 March 2012 | Revision 1 Aurecon Page 6 . after the initial introduction of water to the cement. The Superintendent reserves the right to withhold approval of any supplier until satisfied that the supplier can provide adequate quantities of concrete complying with the requirements of the Specification. it shall not be changed throughout that section of work. All concrete mixing shall be done in mechanically driven rotating batch mixers of approved type. No permanent concrete shall be produced from site mix plant until the results of these trial mixes are available and have been accepted and authorised by the Superintendent. details of the mixing plant or of the batching plant and transit mixers shall be submitted to the Superintendent for approval. The Contractor shall submit to the Superintendent details of all materials and the design of mixes proposed to be used in the Work.

The water/cementitious ratio for all concrete shall not exceed 0. No batch shall be based on the use of broken bags unless the cement is weighed. Minimum cementitious content for all concrete shall be 400 kg per cubic metre. 2. Water shall be supplied directly from an approved water measuring device with a visible indicator showing the quantity of water measured and with the controls so arranged that only measured quantities of water shall flow into the mixer. The project control method shall be used. Cement shall be measured by mass. Fine and coarse aggregates shall be measured by mass. in the opinion of the Superintendent. Batching procedures shall be such as to enable the necessary allowance to be made for variations in the moisture of aggregates. a corresponding correction to the proportioning shall be made.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Concrete shall be delivered to the site at a rate and in sufficient quantity to ensure the uninterrupted placing of the concrete. and shall be adjusted if the error exceeds 1% of the indicated mass. The chloride ion content of the concrete as placed shall not exceed 0. whichever is the more frequent.11 Sampling and testing The Contractor shall test concrete supplied to the project in accordance with AS 3600. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. Volume batching equipment for dispensing water shall be checked each time the equipment is relocated or once a week. The slump shall be within the limits specified in AS1379 for the slumps shown on the drawings. Where.8 kg/m3. In no case shall the quantity of water used be sufficient to cause the collection of a surplus in the forms. a construction joint shall be formed in the placed concrete in accordance with Clause ‘Construction Joints’ and to the satisfaction of the Superintendent. During the addition of water. The volumes specified are the volumes of dry materials. Scales on weigh batching plants shall be checked for correct operation at least once per month. Sufficient water only shall be used to produce a workable mixture which can be conveyed from the mixer to the forms without separation of the coarse aggregate from the mortar.doc 22 March 2012 | Revision 1 Aurecon Page 7 . unless an approved flow meter is used. placement of concrete is sufficiently delayed that initial set of the placed concrete has taken place.10 Quality of concrete The Specification of the concrete shall be by required properties as defined in AS1379.45 by weight. The mass of each material required to give the correct volume shall be determined by actual tests made under the supervision of the Superintendent. to ensure that the requisite amount of dry sand is used. against dead weights. Standard slump testing apparatus shall be provided by the Contractor and slump tests shall be carried out by the Contractor as often as the Superintendent may direct. the supply to the measuring device shall be cut off. 2. including water. Where the cement is supplied in paper bags.9 Measurement of materials All concrete materials. shall be accurately measured. If there is more than 10% bulking of the sand owing to contained moisture. with the required properties for each element of the Work being as shown on the drawings. AS 1379 and this Specification. each unopened bag shall be taken as containing the weight of cement printed on the bag and all batches shall be based on the use of one or more complete bags of cement. 2.

70. as specified. shall be carried out by a NATA certified laboratory nominated by the Contractor and approved by the Superintendent. When the concrete compressive strength of any group of samples falls below the acceptance criteria specified in Section 19 of AS 3600. one additional sample shall be taken. the concrete represented by the group of samples shall be regarded as not having attained the specified compressive strength required by the designers and shall be classed as defective concrete and shall be liable to rejection. additional test cylinders to a number not exceeding 10 per cent of those required for the project in accordance with Section 6 of AS 1379 shall be made as and when directed by the Superintendent. The test results so obtained may be taken into consideration by the Superintendent at its sole discretion when accepting or rejecting the concrete represented by the samples. Requests to vary the criteria for acceptance of concrete may be considered provided details of such variation and confirmation by test results are submitted in writing to the Superintendent at least seven days before any concreting operations are to commence. and also all Testing Laboratory fees (where applicable) entailed in making the tests shall be borne by the Contractor and shall be allowed for and included in its Tender price. the approximate equivalent strength at twenty-eight days may be obtained by dividing the actual test strength at seven days by the factor 0. Testing shall be carried out by a NATA registered laboratory approved by the Superintendent. Seven-day tests are not regarded as acceptance tests. If specimens are tested at seven days for the purpose of preliminary information and control. These additional cylinders shall be forwarded for curing and testing to an independent NATA certified testing laboratory agreed to by the Superintendent. Minimum site sampling and testing shall be as follows: Number of Batches per Day Number of Samples 1 1 2 to 5 2 6 to 10 3 11 to 20 4 For each additional 10 batches. The Contractor must assess the number of test samples required for the particular programme envisaged. The sampling and testing. including the additional test cylinders specified in the previous paragraph. materials.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd The Contractor shall be responsible for the manufacture and testing of all concrete test cylinders. labour. packaging and cartage. The Contractor shall record the following information:         Date and time of taking the sample Name of the supplier and location of plant Number of delivery docket and number of the transport vehicle Location of sampling Method of identifying the test cylinders taken Location of batch of concrete after its placement Slump of sample Date of test Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. Should the testing laboratory carrying out the sampling and testing be under the ownership or control of the concrete supplier.doc 22 March 2012 | Revision 1 Aurecon Page 8 . The cost of moulds.

and the location from which they are cut shall be subject to the approval of the Superintendent. the responsibility for the structural sufficiency of the whole of the formwork shall remain entirely with the Contractor.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd  Test results (strength and density) This information shall be incorporated into a cumulative weekly report and shall be issued to the Superintendent. The Contractor shall design and test trial mixes of proposed concrete mix designs. The Superintendent will then consider the test results and other information and may. It should be noted that all concrete floors in buildings are intended to act as structural diaphragms unless noted otherwise. This feature would have to be accommodated in any sacrificial formwork design. for structures in external environments. the criteria for rejection shall be as set out in Section 19 of AS 3600. The number. and so the action of shear studs welded to beams and cast into cast-in-situ concrete is important.13 Formwork The outside faces (both above and below ground) of all foundations shall be formed. at its absolute discretion. Notwithstanding any inspection or approval by the Superintendent. and undertake any additional testing required due to proposed changes in materials or proportions of the mix requested by the Contractor.doc 22 March 2012 | Revision 1 Aurecon Page 9 . form and dimensions of the specimens. supply and deliver to a testing laboratory nominated by the Superintendent suitable samples of all materials proposed to be used in the manufacturing of the concrete. The Contractor shall not use precast concrete as concrete formwork. specimens cut from the completed work. the use of sacrificial steel formwork such as Bondek is not permitted. unless shown otherwise on the drawings. including reinforcement. 2. the Contractor may submit for testing. In the event that specimens are cored from the completed work. determine whether the strength of the specimens cut from the work and adjusted for the age. The Contractor shall. and. The Contractor shall design and construct formwork and falsework in accordance with AS 3610. Because of corrosion concerns.12 Rejection of concrete Where concrete already placed is classed as defective and liable to rejection. and as specified elsewhere herein. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. shall be replaced with concrete complying with the Specification. as part of the Work under the Contract. 2.14. Concrete classed as defective and rejected by the Superintendent shall be removed from the Work. unless details have been submitted to the Superintendent and approved. diameter and height to diameter ratio of the specimens is to be taken as the actual strength of the concrete for acceptance purposes. the Contractor shall fill the holes with concrete and finish the surface to match the surrounding areas. The standard of surface finish to be achieved shall be in accordance with AS 3610 – Section 3. Coring and testing shall be in accordance with AS 1012. together with any other work subsequently erected thereon. Should any concrete be liable to rejection. as well as any additional testing occasioned by failure to meet the Specification requirements.

2. All dimensions. Forms shall be erected true to line with all joints either vertical or horizontal. if not shown. all formwork corners where the enclosed angle is less than 120 degrees shall be filleted. Forms shall be accurately made and of sufficient strength to prevent any appreciable deflection due to the pressure from wet concrete. Forms shall not be disturbed until the concrete in contact with them has hardened sufficiently to withstand such action without damage. construction joints shall be formed and the section of work reconstructed. The following categories of formwork in accordance with AS 3610 shall be used in the Work:  Pre-casting Forms Class 2  Other Cast-in-situ concrete Class 3 Aluminium alloy sheeting shall not be used as formwork. at his absolute discretion.doc 22 March 2012 | Revision 1 Aurecon Page 10 . the tolerance shall be minus 0 plus 6mm. Clear cover to embedded ties shall be not less than the cover to nearby reinforcing bars. The number of re-uses and the conditions of faces and edges of forms shall be consistent with the formwork surface class specified.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All formwork shall be checked prior to placing the concrete. Embedded ties for holding forms shall remain embedded. wedges. and shall be rigidly braced and adequately supported by falsework. The number of re-uses and the conditions of faces and edges of forms shall be consistent with the formwork surface class specified. Notwithstanding the provisions of AS 3600 and AS 3610 the deviation of any point on the surface of a concrete element from its correct position in space shall not exceed 10mm. this last concession shall not apply to the measurement of flatness of formed surfaces. or other means so as to carry the weight of the concrete to be placed without sagging or moving from true line and position. Except in the case of Class 5 formwork. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. particularly those affecting the construction of subsequent portions of the Work. of 20mm on each side with equal angles in all cases. Nevertheless. No permanent loading shall be imposed on the concrete member while it is still supported by formwork. reject any forms which he considers are incapable of producing a concrete surface to the specified criteria. the bevel in each case having a width as shown or. slabs and walls. after the formwork has been strengthened and adjusted. beams. Forms shall be so designed and constructed that they may be removed without injuring the concrete surfaces and without excessive jarring or hammering. The relative deviation of any two points on the surfaces of concrete elements from their correct positions in space shall not exceed 1/500 of the dimension between them except that in the case of cross-sectional dimensions of structural members such as. shall be checked. props. Should any formwork be displaced during concreting or within the period specified for the retention of formwork.14 Formwork ties Formwork ties shall be used consistent with the class of surface finish specified for the members as a whole and with the approval of the Superintendent. The ties shall be constructed so that removal of the ends or end fasteners can be accomplished without causing spalling at the faces of the concrete. The Superintendent may. the concrete shall be removed between such limits as the Superintendent may determine.

regardless of subsequent patching and reinstatement. The responsibility for the safe removal of any part of the formwork or falsework shall rest entirely with the Contractor. Sufficient tests shall be undertaken prior to use to ensure that no reaction which will adversely affect the concrete surface will occur between any form release agents. Form spacers resulting in full depth penetration in walls will not be permitted. All form linings shall be treated prior to placing of concrete with an approved release agent. particular attention being paid to corners and the bottom ends of columns. Adequate temporary openings of approved size and location shall be provided by the Contractor to facilitate this. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. Recesses resulting from the removal of form ties. the formwork shall be checked for accuracy and tightness. surface coatings or curing compounds. No recesses shall be filled until they have been inspected and approved by the Superintendent. which shall be applied before the forms are erected or any reinforcement is placed. 2. Cone spacers shall be removed within 2 working days of form stripping.14. 2. and all joints and holes shall be effectively sealed.14. Immediately before the concrete is placed. All rubbish shall be removed from the space to be occupied by the concrete and the work blown clean before the Superintendent’s inspection. Cone spacers shall not be welded to the reinforcement or fixed in any way which will impede their removal from the concrete. Recesses formed by cone spacers shall be cleaned on removal of spacers and filled with mortar in the proportion of one part of cement to 3 parts of the sand used in the concrete in which the recess occurs. and floated flush. Tie wire passing through the concrete will not be permitted. However. further treatment using the mortar specified above and rubbing down with a medium coarse carborundum stone shall be carried out until a surface is produced which is clean. smooth and consistent with the class of surface finish specified for the member as a whole. formwork and/or falsework shall not be removed without the prior approval of the Superintendent.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Form ties shall be kept clear of the steel reinforcement and in no circumstances shall steel reinforcement be used to support the formwork. shall be thoroughly cleaned and saturated with water. well rodded.1 Preparation of formwork surfaces Before commencing to place concrete in any section of the Work. If in the opinion of the Superintendent the finished surface is not satisfactory.doc 22 March 2012 | Revision 1 Aurecon Page 11 . then filled with mortar in the proportion of one part of cement to three parts of sand.2 Removal of formwork Removal of forms and falsework shall be in accordance with AS 3610 unless stated otherwise in this clause. any absorbent surfaces to come in contact with the concrete shall be sprayed with water and all ponded water then removed. Sample patching shall be carried out by the Contractor and approved by the Superintendent before proceeding.

the minimum stripping time for forms shall be governed by the time required for concrete to gain sufficient strength to support its own dead load and construction loads between shore support points but in no case shall be less than three days. the concrete shall be removed between such limits as the Superintendent may determine. When the predicted evaporation rate during placing and finishing operations exceeds 0. erecting wind breaks. Such precautions may include carrying out concrete placing early or late in the day. the Contractor shall take reasonable precautions to ensure that the temperature of the concrete does not exceed 30°C and that the concrete can be placed and finished without defects. 2. All repairs shall blend with the adjacent concrete surfaces in colour and in texture. In particular. Should any formwork be displaced during concreting or within the periods specified for the retention of the formwork.15 Placing of concrete If the ambient air temperature at the point of placement is likely to be more than 35°C during placing and finishing operations. construction joints shall be formed and the section of work shall be reconstructed after the formwork has been strengthened and adjusted. To compute the evaporation rate. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.75 kg/m2/hr. shading aggregate stockpiles. Forms to horizontal surfaces may be removed before supporting shores are removed provided that the formwork system is designed to facilitate the operation without disturbing shores.doc 22 March 2012 | Revision 1 Aurecon Page 12 . No concrete shall be covered up until it has been inspected and approved by the Superintendent. cooling the formwork with water sprays and the use of aliphatic alcohol or other approved evaporation inhibitor. Figure 1 can then be used to estimate the evaporation rate. relative humidity. Where forms to horizontal surfaces are removed prior to the removal of supporting shores. when finishing slab surfaces under such conditions. Concrete work that does not comply with the tolerances specified or has other defects due to the inadequacy of the formwork shall be removed and replaced or the defects shall be remedied as directed by the Superintendent. concrete temperature and wind velocity. adding ice to the mix. measures such as described above shall be adopted.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Forms shall not be disturbed until the concrete in contact with them has hardened sufficiently to withstand such action without damage. the following information is required: air temperature. an evaporation inhibitor shall be applied to the concrete surface immediately after initial screeding. Neither walls nor any permanent loading shall be erected on any part of the structure while it is still supported by formwork. Particular attention shall be paid to prevent damage to the concrete surfaces if form bolts or ties are bent during removal operations. Forms to vertical surfaces shall not be removed until the recommended stripping times tabulated in AS3610 have elapsed.

Evaporation rate Note: Courtesy of Cement and Concrete Association of Australia.doc 22 March 2012 | Revision 1 Aurecon Page 13 . Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Figure 1 .

Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. the thickness of which shall generally not exceed 300mm. no concrete shall be placed under water and permission to do so will only be given in the most exceptional circumstances. skips. his procedure for placing concrete in thin walls and columns in lifts exceeding 1. No layers shall be tapered off but shall be stopped against forms to produce square ends. The Superintendent reserves the right to require the Contractor to implement a different procedure should the required standard not be maintained. pile caps and column capitals shall be concreted in the one operation. concrete shall be deposited in continuous horizontal layers. Tamping. beams. Notwithstanding the provisions of AS1379. unless the arrangement of the forms and reinforcing steel allows a hopper and drop chute to be used in which case the concrete shall be discharged directly into the hopper. Approval will only be given if the Contractor can establish. and is rising. Where the ambient temperature is 5 degrees Celsius and falling. Concrete shall not be dropped more than 600mm during placement. his capacity to place the concrete without segregation. Unless instructed otherwise by the Superintendent. The Contractor shall keep on the site sufficient "stand-by” vibrators in correct working order to ensure continuity of work in the event of plant failures. in writing. for the Superintendent’s approval. footings. Care shall be taken to avoid over-vibration and the method of handling the vibrators shall at all times be to the approval of the Superintendent. The full thickness of all slabs. ‘honey-combing’ or other deleterious effects. Compaction of the concrete by external vibration methods or by a vibrating screed may be considered provided the Contractor can satisfy the Superintendent that the concrete will be compacted as specified above and that no distortion of formwork will occur. Permission for night work will not be given unless adequate lighting is provided and approved.5m.doc 22 March 2012 | Revision 1 Aurecon Page 14 . Vibrators shall not be permitted to rest against formwork or reinforcing steel and shall not be used to move concrete laterally. Unless approved by the Superintendent. Vibrators shall be used in sufficient numbers to keep pace with the rate of placing of the concrete and shall be handled by trained operators to ensure that the pattern of inserting the vibrators produces even and regular compaction. spading and slicing shall be used in those locations where it is not possible to use vibrators effectively. The Contractor shall submit. Concrete for walls and columns shall be conveyed to and dumped upon a water-tight platform alongside its final resting place and thence shovelled into position.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All chutes. All concrete shall be placed in daylight and the placing of concrete in any portion of the Work shall not be started without the approval of the Superintendent and unless it can be completed in daylight. to the Superintendent’s satisfaction. the Contractor shall cease concreting operations and shall not recommence pouring until the temperature again reaches 5 degrees Celsius. hoppers and the like shall be thoroughly cleaned and flushed with water before each concreting operation. all concrete shall be completely discharged. placed and compacted in its final position prior to initial set of the concrete. Concrete shall be compacted by means of approved high frequency mechanical vibrators of the immersion type with a minimum frequency of 120 Hz and with sufficient energy output to ensure complete compaction of all parts of the concrete sections.

at the point of stopping. Delivery lines shall be of an approved metallic type. the concrete in the receiving hopper and lines may be placed in the work on the resumption of pumping. when approved by the Superintendent. In the event of delay or breakdown in the equipment not exceeding 20 minutes during which time concrete cannot be placed. wet hessian or other approved means. During delays in delivery of concrete to the pump. concrete in the lines shall be pumped at approximately 10 minute intervals (5 minutes in hot weather) to ensure that the concrete is 'live. transport or placing. Where delivery lines will be exposed to hot sun they shall be protected by covering with bags. the concrete shall be discarded.doc 22 March 2012 | Revision 1 Aurecon Page 15 . For piston type pumps at least two strokes of the piston shall be made at each pumping interval. Should the atmospheric (shade) temperature on the site not exceed 18 degrees Celsius. When work is resumed the treatment of the concrete at the cold joints shall be as specified under ‘Construction Joints’.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Concrete ‘kickers’ for subsequent wall construction shall be cast monolithically with base concrete using suspended formwork. The pump shall have a variable speed control and shall be capable of pumping concrete containing 20mm aggregate through delivery lines not less than 75mm diameter. 2. a construction joint shall be formed as specified in Clause ‘Construction Joints’.16 Pumping Approval to use concrete pumps to place concrete may be given by the Superintendent subject to the Contractor submitting full details of the type and capacity of the pumps. If a cessation of work becomes unavoidable. the receiving hopper and lines shall be cleaned out and the concrete contained therein discarded. the use or discarding of the concrete shall be determined by the Superintendent. and all concrete in the pipeline discarded. the concrete already in place shall have the wet edges maintained in an approved manner. Where the temperature lies between 18 degrees Celsius. Direct efficient communication shall be maintained at all times between the pump operator and the concrete placing crew. and satisfactory evidence that any modifications to the concrete proportions and consistency to suit pumping procedures shall comply with the provisions and intent of this Specification. Under no circumstances shall aluminium alloy pipes or fittings be used nor shall concrete be permitted to come in contact with aluminium during its manufacture. and 30 degrees Celsius. if initial setting of the concrete has begun in the hopper or discharge lines. In any case. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. pipe-work and procedures to be adopted. Placement of concrete ‘kickers’ after the initial set of the base concrete has begun will not be permitted. Should the temperature exceed 30 degrees Celsius. If the delay exceeds twenty minutes an emergency construction joint shall be formed where directed by the Superintendent.

Unless noted otherwise on the drawings. to attain a uniform colour. all irregularities shall be rubbed or chipped off.17 Finish of concrete surfaces All formed concrete surfaces which are to remain exposed shall finish clean and even when the forms are stripped. as laid down in AS 3610. Repair procedures will depend on the extent of defective areas and may require the use concrete or proprietary mortars. the Contractor shall remove the affected concrete and replace it with concrete producing the specified surface finish as directed by the Superintendent.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 2. after stripping of the formwork. If. In the event of defective work and where directed by the Superintendent. that part shall be demolished and replaced at the Contractor’s expense. the upper surface of slabs and concrete screeded to line and level shall be floated. No concrete shall be covered up until it has been inspected and approved by the Superintendent. areas of segregation or honeycombing are found. trowelling. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. or a mixture of sand and cement. Care shall be taken to ensure that the surface so produced is 'tight' and not subject to flaking. All screeding. these shall be cut out and made good in a manner approved by the Superintendent. the Contractor shall apply to the surface of the concrete. If the surface treatment is not acceptable. Immediately after the formwork has been removed and while the concrete has still not fully hardened. in the opinion of the Superintendent. a polymer-modified grout equal to Durafloor Leveltop Rapid or another compound suited to the particular application and approved by the Superintendent. jointing and edging of surfaces shall be done by specialist workmen thoroughly experienced in such work. Rendering will not be acceptable. or other driers to absorb moisture or to facilitate trowelling. Any places not entirely filled with mortar shall be pointed up or cut out square and replaced with new concrete as directed by the Superintendent. trowelled to a smooth even finish and lightly broomed to the requirements of the Superintendent so that it may be easily swept. Should any surface fail to meet the specified requirements as determined by the Superintendent. If. defects present in any part of the concrete works cannot be repaired to the satisfaction of the Superintendent. brush or roller. or otherwise treat the surface to achieve the required standard of finish as directed by the Superintendent. The surface finish shall meet the requirements for the formwork category specified elsewhere herein or shown. by trowel. During trowelling the surface shall not be dusted with cement. No traffic shall pass over fresh concrete unless it is protected by planks or other method approved by the Superintendent.doc 22 March 2012 | Revision 1 Aurecon Page 16 . the Contractor shall grind. All joints shall be marked and formed to a straight line with a jointing tool Edges that do not finish against steelwork shall be rounded and formed with a similar edging tool. floating. Only cementitious products with performance characteristics similar to the concrete shall be used. All road slabs and other paved areas shall be so graded that the surface will shed water to the drains.

When placing concrete above a horizontal construction joint appropriate measures shall be taken to ensure that aggregate segregation does not produce honey combing at the joint. All construction joints shall be truly vertical or horizontal. The face of the chamfer shall not be scabbled so that a straight line is maintained on the face where the new concrete is cast against the existing. The face of the first poured concrete joint surface.doc 22 March 2012 | Revision 1 Aurecon Page 17 . if indicated on the drawings shall be formed and constructed to the details and in the locations shown and they shall not be varied without the approval of the Superintendent. 12mm x 12mm chamfers shall be formed in both faces to provide a clearly defined limit for scabbling as specified elsewhere herein. Where directed by the Superintendent. Such joints shall if possible be planned and their number shall be kept to a minimum. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. the Contractor shall remove such concrete already placed as will enable a satisfactory construction joint to be formed where directed by the Superintendent. Construction joints. the point of stopping shall be deemed a construction joint and formed accordingly. shall be finished to a uniformly rough surface having an amplitude of roughness of approximately 3mm by one of the following methods:  Thorough scabbling by the use of a tool that will not cause damage to the underlying concrete. whether formed or un-formed.18 Tolerances for unformed concrete surfaces The finished surface of concrete shall not deviate by more than 10mm from the specified design level at any point. Within 24 hours of stripping the form the joint surface shall be thoroughly scabbled so as to remove all laitance and to expose the coarse aggregate in the concrete. At all construction joints in walls. and other vertical surfaces. 2. Where such a point of stopping occurs at a location considered unsuitable by the Superintendent. Inclined or feathered joints will not be permitted. has taken place. The finished surface of floors and drainage channels shall not deviate by more than 6mm from the testing edge of an approved straight edge of 3m length laid in any direction.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 2. Additional construction joints may be made to details and in locations approved by the Superintendent. Construction joints in suspended elements shall be made within the middle third of the span and no joints will be permitted at the ends of the span or close to the point of application of heavy concentrated loads. The stop-end form at vertical construction joints shall be coated with ‘Redalon’ or other approved equivalent surface set retarder. construction joints shall be sealed with an approved joint sealant as specified in Clause ‘Joint Sealants’ or as detailed on the drawings. Where shown and/or directed by the Superintendent.19 Construction joints A construction joint is the junction between two successive concreting operations in an element intended to act monolithically. or  Retarding the set of the surface concrete and water washing after an appropriate time interval to create an exposed aggregate surface. as determined by the Superintendent. areas of floor or drainage structures surfaces which do not comply with the above shall be corrected by grinding or other means approved by the Superintendent. Whenever the work of placing concrete is delayed so that the initial set.

GPM Gold Project
Technical Specification
XSTRATA technology Pty Ltd

When placing concrete above a horizontal construction joint, appropriate measures shall be taken to
ensure that aggregate segregation does not produce honey-combing at the joint.

2.20 Curing of concrete
The Contractor shall ensure that all concrete is properly and adequately cured. The curing methods
shall be submitted for approval by the Superintendent before any concrete is placed and the
Contractor shall modify or change the curing procedures as directed by the Superintendent at any time
during the Work if the Superintendent is not satisfied that the concrete is being properly cured.
Initial curing of exposed concrete surfaces shall be commenced as soon as the surface of the
concrete has hardened sufficiently to prevent damage and in any case the same day that the concrete
is mixed and placed and shall continue for not less than twelve hours. The concrete surface shall be
kept continuously moist, preferably by ponding but, where this method is considered impracticable, by
the use of an absorbent cover kept continuously wet. Undisturbed formwork provides an acceptable
means of curing.
Final curing shall commence immediately following the initial curing period and shall continue for not
less than seven days or such longer period as the Superintendent may direct. During this period, the
curing shall be carried out either by continuing the method used during the initial curing period or by
covering the concrete with waterproof sheeting which shall be maintained in close contact with the
surface of the concrete.
The edges of the sheeting shall be taped or shall overlap by at least 200mm and the whole shall be
held securely in position. Any damage to, or displacement of, the sheeting during construction shall be
made good immediately and, should the concrete surface show signs of drying out during the final
curing period, the sheeting shall be temporarily removed, the surface of the concrete wetted and the
sheeting replaced as before.
Steel forms exposed to direct sunlight and all wood forms in contact with the concrete during the final
curing shall be kept wet. If forms are removed during the curing period, one of the previously
described curing methods shall be employed and continued for the remainder of the period.
Alternatively, liquid membrane curing compounds conforming to the requirements of AS 3799 may be
used provided that the Contractor establishes to the satisfaction of the Superintendent that they can
be applied and maintained effectively and that they are compatible with any subsequent surface finish.
Full details of the proposed curing compound shall be submitted in writing to the Superintendent for
approval before use. The application rate shall be in accordance with the manufacturer's instructions.
Liquid membrane curing compounds shall not be used on floors or paving that will be trafficable during
the curing period unless the surface is protected against scuffing or damage by means approved by
the Superintendent.

2.21 Steel reinforcement
All steel reinforcement and the placing and fixing of all steel reinforcement shall comply with the
requirements of AS 3600 and AS/NZS 4671.
The Contractor shall, upon request by the Superintendent, supply copies of test certificates
representing routine tests for yield and ultimate strengths, elongation and cold bend performances
carried out by the Steel Supplier confirming that the steel supplied conforms to the specified
requirements.
Reinforcing bar call up on drawings:
Reinforcing steel H=500MPa deformed bar
Reinforcing steel D=300MPa deformed bar
Reinforcing steel R=300MPa deformed bar

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All reinforcement shall be furnished in the full lengths shown and laps and splices shall be made only
in the positions and to the dimensions shown or otherwise approved by the Superintendent.
Welded joints other than those specifically detailed, shall not be made without the approval of the
Superintendent. Any such approval will only be given subject to the provisions of AS 1554 - Part III
being strictly adhered to.
Proprietary mechanical/welded bar splices will only be permitted where specified and/or shown.
Reinforcement shall not be bent without the approval of the Superintendent, except as shown in the
bending lists.
Bars specified to be cast into the concrete and subsequently bent out shall be 500 Plus Tempcore bar.
Microalloy bars shall not be used for this application.
Notwithstanding the provisions of AS 3600, the heating of reinforcement will not be permitted. All
bends and hooks shall be cold bent and, where not dimensioned, cogs, hooks and bends shall be bent
in accordance with the requirements of AS 3600.
Reinforcement shall be free from loose mill scale, loose rust, mud, oil, grease and other coatings that
would reduce the bond between the concrete and the reinforcement.
Steel shall not be supported on pieces of wood, stone or aggregate. Steel shall likewise not be
supported on metal supports (other than stainless steel), which extend to the surface of the concrete.
Where concrete strips or blocks are used to support reinforcement the concrete shall be of the same
strength and density as the concrete itself, and shall be thoroughly compacted.
The clear cover to the reinforcement shall be as shown or, where not shown, shall be in accordance
with the requirements of AS 3600 for the condition of exposure nominated by the Superintendent.
Hard drawn steel wire fabric shall be delivered to the site in flat sheets, except that the fabric for slabs
supported permanently on the ground may be supplied in rolls.
The Contractor shall be responsible for the preparation of steel bending lists and the ordering of all
reinforcing steel, whether in Australia or elsewhere, and his Contract Price shall be based on assured
sources of supply. The Contract time will not be extended on account on nondelivery of steel and no
extra payment will be made to cover additional costs involved in the procurement of steel from retail
sources or from other than Australian sources. The Contract Price shall include Customs Duty if
applicable.
The Contractor shall supply three (3) complete sets of steel bending lists and drawings showing his
bar notation to the Superintendent for approval prior to commencement of reinforcement bending.
However, the Contractor shall remain completely responsible for the provision of all reinforcement in
accordance with the drawings and appropriate standards.

2.22 Core holes and building in
The Contractor shall supply where required and build into the concrete all holding down bolts,
coreholes, pipes, pockets and inserts, and all collars, sleeves, or thimbles required for piping and
wiring anchors, pockets or inserts for supporting strips, hanging wires, steel frames and cable
supports, Unistrut fittings and other metal fittings, and all other items required or shown.
The Contractor shall notify all Sub-Contractors and other Contractors whose work is in any way
connected with or influenced by the concrete work and give them reasonable time to complete all
portions of their work that must be placed before concrete is deposited in the forms.

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In the case of items and trades not covered by this Contract, the Contractor shall at all times confer
with the Superintendent and shall make full provision for all connections with the same.
All such fittings shall be in their intended position at least one working day prior to the proposed time
of pour to allow inspection by the Superintendent, if desired.
The Contractor shall ensure that all items to be cast into the concrete are firmly secured in the forms
so that they will not move during placing of the concrete.
All items to be cast into concrete shall be free of loose rust, mill scale, dirt, paint, grease, or any other
deleterious substances.
All formwork for all core holes to be formed in the concrete for holding down bolts shall be painted with
a set-retarding agent.
On removing the formwork the surface of all core holes shall be vigorously water washed to remove
the retarded concrete surface and to produce a sound, rough surface in the hole.
All forming material, debris and water shall be completely removed from core holes and pockets
before the work shall be deemed completed. No holes will be permitted in concrete members, other
than for form bolts, unless shown or specifically approved by the Superintendent.
Unless otherwise specified or approved all holes and openings shall be formed and all inserts cast in
place at the time of concreting. No part of the work shall be drilled or cut away without the approval of
the Superintendent.

2.23 Anchor bolts
Anchor bolts shall be Grade 4.6 unless noted otherwise.
Where Grade 8.8 anchor bolts are specified, under no circumstances shall they be heated, nor shall
any attachments be made to them by means of welding.
Where specified, threaded high strength reinforcing bar shall be Tempcore or approved equivalent,
with a minimum yield strength of 500 MPa.
All anchor bolts and cast-in fittings not fabricated from stainless steel shall be hot dip galvanised in
accordance with AS 1214, and each bolt shall be provided with two galvanised nuts and washers for
levelling purposes.
Anchor bolts shall, wherever possible, be cast in position when the concrete is being placed although,
at the discretion of the Superintendent, bolts for minor members such as ladders and cable tray
support brackets may later be epoxy-grouted into holes cored or drilled in the concrete. All bolts shall
be set truly vertical or horizontal.
The thread of all anchor bolts shall be protected during concreting operations by an approved means
such as PVC tape.
The wrapping shall be moved after the concreting is completed, the thread shall be cleaned out and,
together with the nut and washer, thoroughly greased to prevent rusting.
Where the anchor bolts are for the subsequent erection of steelwork or the installation of machinery by
others, the Contractor shall produce a certificate from a Registered Surveyor to show that they have
been correctly placed within the following tolerances.
The exposed threads of cast-in stainless steel bolts shall be coated with nickel-based anti-seize.
Anchor bolts shall be positioned within the following tolerances:

Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.doc 22 March 2012 | Revision 1

Aurecon

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The polystyrene strips shall be removed by mechanical means only and not by use of solvents or heat. All sealants shall be placed in recesses specially formed to receive them. Where practicable. The surfaces of the recesses shall be free from laitance and contamination and. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. but prior to the handing over of the area for occupation or use by others. Details of all proposed sealants shall be submitted to the Superintendent for approval before being used in any joint. joint fillers shall be supplied pre slit to the dimensions necessary to facilitate removal of excess filler prior to installation of the joint sealants.24 Joint fillers Joint fillers shall be supplied and fixed in a pre formed condition to each joint where specified. applied strictly in accordance with the manufacturer's instructions. The joint filler in tied or dowelled joints between adjacent independent slabs shall be bitumen impregnated fibre board. shall be cleaned with an abrasive disc or other approved means. mixed and applied strictly in conformity with the manufacturer's requirements. prior to the application of the sealing compound.  Location of bolts relative to each other  RL of top of holding down bolts +/-3mm +/-2mm + 12mm / -3mm The Contractor shall undertake any adjustments necessary as a result of these tolerances not being achieved. if necessary. The joint filler in expansion or rotation joints shall be closed cell polyethylene foam joint filler fixed to the concrete already cast using an approved adhesive. Prior to the commencement of any concrete works. sealing compounds shall be applied not less than twenty-eight (28) days after placing of the last concrete in contact with them.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd  Location of centroid of a group of bolts. The recesses shall be formed with strips of polystyrene or other approved material which shall remain in place until just before the sealants are applied so as to prevent the recesses from becoming contaminated with dirt and grease. 2. Where joint sealants are to be applied. All anchors must be installed to strictly achieve the above tolerances as bending of bolts or cutting any excess from the top of the bolt shall not be permitted. Details of all products proposed for use in the Works shall be submitted to the Superintendent for acceptance prior to work commencing.25 Joint sealants Sealants for joints in non-trafficked horizontal and vertical faces shall be an approved single component polyurethane such as Sonolastic Ultra (by Master Builders Technologies) or an approved equivalent. the Contractor shall develop and submit to the Superintendent for approval. The recesses for the sealants shall be primed with Sonolastic Primer 733 or an approved equivalent. a method outlining how the cast in bolt assemblies will be positioned. 2. supported and measured by survey to ensure the required tolerances are satisfied. All joint sealants shall be formulated.doc 22 March 2012 | Revision 1 Aurecon Page 21 . Care shall be taken to ensure that any adhesive used to hold the recess forming in position is completely removed.

ready to use. The grout shall be mixed and placed strictly in accordance with the Manufacturer's written instructions. The Superintendent's acceptance of the proposed grout types and curing compound is required prior to grouting operations being carried out. etc. and the forming. premixed and packaged at the Manufacturer's factory and delivered to the job site requiring only the addition of water. chlorides or nitrates shall not be used. sand and water with or without the inclusion of admixtures or fly ash as approved in a combination to produce a workable but not fluid material. packs or levelling devices used to hold the column in position shall be removed and the resultant cavities in the grout made good.26 Grout The grout shall be a non shrink. After all laitance and dirt and dust have been removed from the interfaces.75mm. An additive designed to produce increased fluidity and/or expansion of grout may be used subject to the Superintendent’s approval. Dimensions of the seals shall conform to the ICL type indicated on the drawings. The grout shall comply with Section 19 of AS 3600 and AS 1478 and shall have a characteristic strength of not less than 40 MPa at twenty-eight (28) days. No grout shall be placed if the temperature of either the grout. or concrete base is above 30 degrees Celsius or below 5 degrees Celsius. placing and curing of this grout material. All exposed areas shall be cured with a curing and sealing component complying with AS 3799 in accordance with the Manufacturer's recommendations. Any such additives shall not reduce the strength of the grout. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. baseplate. Precautions shall be taken to avoid the formation of air pockets and the edges shall be neatly bevelled off on completion. the joint seals shall be installed in formed grooves using a lubricant-adhesive recommended by the manufacturer. 2. all in accordance with the manufacturer’s instructions. When the grout has cured sufficiently to be able to carry the load of the structure without any detrimental effects. fluid precision grout material.doc 22 March 2012 | Revision 1 Aurecon Page 22 . 2. the water content shall be the minimum necessary to allow the mortar to be compacted without crumbling. Additives containing aluminium powder.27 Mortar Mortar shall consist of cement. Grout between ends of deck girder units shall be of the above type with an approved expansion additive or an approved proprietary non-shrink grout.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 2.28 Joint seals Joint seals shall be ICL cellular neoprene-rubber compression seals supplied by Industrial Chemical Laboratories or approved similar. Unless specified otherwise the mortar shall develop a characteristic compressive strength of 25MPa at 28 days and the maximum size of aggregate shall be 4. Such items may only be left permanently in position with the approval of the Superintendent. In the case of dry-packed mortar. any steel wedges.

sprayed concrete shall be applied to the excavated face a s required to stabilise the excavation. the Contractor shall supply and cast in place waterstops in accordance with the requirements of this Specification. or other coating interfering with bond 2. The welded wire fabric shall be clean and fee of loose mill scale. PVC waterstops shall be extruded from virgin polyvinyl chloride containing no reclaimed or scrap material and shall be homogenous. Where directed or approved by the Superintendent. oil. Waterstops shall be of the same material and of symmetrical section. Sprayed concrete as specified on the drawings. Care shall be exercised in compacting concrete around waterstops to ensure that no voids or porous areas are left in the finished work and that the waterstop is not displaced from its true position. Welded wire fabric shall be attached firmly in proper position as shown on drawings to prevent vibration while the sprayed concrete is being applied.31.3 Executing The sprayed concrete mix shall be prepared.31 Sprayed concrete 2.31. and shall comply with BS 2571 Grade G4 Class 3. and splicing shall be carried out strictly in accordance with the manufacturer’s instructions. All laps shall extend at lease 2 cross-wires in both directions. 2. except where special webs are provided for this purpose. Sprayed concrete shall comply with all relevant clauses of this Specification for concrete except where the following clauses apply. All splicing equipment shall be submitted for approval by the Superintendent. free from porosity and other imperfections.1 General requirements This section shall apply to all sprayed concrete as specified on the drawings. Areas where ravelling develops shall be immediately treated.31. Welded wire fabric shall conform to Australian Standard AS 4671.30 Electrical conduits Electrical conduits shall be Rigid uPVC Heavy Duty conduits conforming to AS2053. No holes shall be made through any waterstops. After splicing. 2. conforming to the requirements of the relevant Australian Standard. All intersections shall be factory moulded so that butt splices only are made on site. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 2. all beads and excess material shall be cut back flush with the adjacent surface. 2. rust. The ducts shall be installed in the positions and to the dimensions and levels shown on the drawings. All field butt splices shall be fused using electric heating equipment supplied by the manufacturer of the waterstop for that purpose. tested and submitted by the Contactor to the Superintendent for approval.29 Waterstops Where waterstops are shown on the drawings. All waterstops shall be securely held in their correct position during placing of the concrete.doc 22 March 2012 | Revision 1 Aurecon Page 23 . Tie wires shall be bent flat in the place of the fabric and shall not form large knots. All joints in ducts shall be solvent welded in accordance with the manufacturer’s recommendations true to line. A sample profile of each type or pattern waterstop shall be submitted to the Superintendent for approval before being used.2 Materials Sprayed concrete shall be a pumpable mixture with a minimum 7 day compressive strength of 40Mpa.

mixed in a concrete batch plant and delivered to the point of discharge in trucks of the revolving drum type. Adequate measures shall be taken to ensure that subsequent sprayed concrete bonds completely to the previously placed sprayed concrete. or which contains any dry patches. to provide support to the bottom edge of the sprayed concrete. 95kg of cement Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. wire fabric.2 Aggregates All Aggregates shall comply with the requirements of AS2758. ‘The Specification and Manufacture of Concrete ‘. except the maximum amounts of material finer that 75 m in aggregates. which exhibits segregation. Readymixed fibrecrete shall comply with the requirements of AS1379-1997.6 Finishing Finishing shall be by powered rotary trowel or steel hand towel. All sprayed concrete which lacks uniformity.32 Fibrecrete 2.4 Fly ash Fly Ash shall not be used in fibrecrete mixes without the Superintendent’s prior approval. 2.5 Fibrecrete mixes The slump shall normally be 80mm + 15mm. shall not be more that 4% for fine aggregate and 0. Horizontal construction joints in the sprayed concrete shall e formed against either temporary framework or placed backfill. When skid resistant surfaces are required.32.33 Stabilised sand Except where other mixes are specified for certain applications. cement. Admixtures containing calcium chloride shall not be permitted. 2. Superplasticisers may also be used to achieve high workability or a lower water requirement. provided they comply with the requirements of the above standard. 2.32.doc 22 March 2012 | Revision 1 Aurecon Page 24 .32. voids or sand pockets shall be removed and replaced with fresh sprayed concrete. All fibrecrete referenced on the drawings shall be F6/75TV. fly ash and clean sand. stabilised sand shall comprise a mixture of water. Reinforcement damaged or destroyed by such repairs shall be replaced by additional. properly lapped. or approved equivalent. Other admixtures may be used with the approval of the design Superintendent. honeycombing or lamination. Burlap drags shall not be used. 2. The combined aggregate grading and content shall be such as to produce a workable mix and give uniform fibre distribution throughout.1 General Fibrecrete shall comply with all relevant clauses of this Specification for concrete except where the following clauses apply.32. unless otherwise noted. The mass of cement and fly ash in each batched cubic meter of stabilised sand shall be not less than:  For mixes without fly ash. Lower slump mixes may be specified.5% for coarse aggregate. these shall be provided by subsequent brooming or raking.32. 2.3 Admixtures Fibrecrete shall normally contain a water reducing admixture complying with the requirements of AS 1478-1992 ‘Chemical Admixtures for Concrete’. The maximum nominal aggregate size shall be 20mm. 2. slugs.32. Wood floating is not permitted. 2.1-1998 ‘Concrete Aggregates’.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Surface defects shall be repaired as soon as possible after initial placement of the sprayed concrete.

34 Preparation of surfaces before placing of concrete Horizontal surfaces in tight soil comprising fine grained. comprising Grade 10 concrete shall be placed below the underside of all footings.35 Concrete blinding layer A concrete blinding layer 50mm thick. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. foundations and slabs placed on the ground. Any rubbish or loose material which might contaminate the blinding concrete shall be removed. This blinding concrete shall be placed as soon as possible after the excavation has been completed and the foundation material prepared as above and approved. relatively non-porous material. such as clay and loam. firm and level surface on which to support the reinforcement and formwork. or as shown on the drawings. Its purpose is to protect the foundation material and to provide a clean. pilecaps. 70kg cement plus 35kg fly ash The amount of water shall be such as to result in a slump of between 60mm and 100mm. The surface of concrete shall be screeded to an even finish level with the underside of the structural concrete to be placed over. 2. shall be sprayed with water if necessary to ensure that the material is moistened to a depth of 100mm. 2.doc 22 March 2012 | Revision 1 Aurecon Page 25 .GPM Gold Project Technical Specification XSTRATA technology Pty Ltd  For mixes with fly ash.

monorails and grouting of base plates 3. Steel castings shall conform to the requirements of AS 2074. and with any additional requirements of this Specification and/or shown on the Drawings. 3.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 3. Hollow sections shall conform to the requirements of AS 1163.3. CES2 or other equivalent international standard (subject to the approval of the Superintendent).3. except where varied by this Specification. AS 3678 and AS 3679. DIN 536. grating.1 General The Contractor shall be responsible for the ordering of all steel except those items that are specifically identified as being supplied by the Principal. steel grades shall be as summarised below. Basic Oxygen (L. Parts 1 and 2. The Contractor shall ensure that supplies of all materials can be effected without delay to the Works. 3. All steel used in this Contract shall be manufactured in Australia unless prior approval is obtained from the Superintendent. kickplates. Fabricated steelwork 3. Rails shall comply with AS 1085. fabrication. The use of steel manufactured by the Bessemer or Thomas processes will not be permitted.2 General requirements The supervision. Structural steel plates and rolled sections shall conform to the requirements of AS 1594. The Quality Plan and Inspection and Test Plans (ITPs) shall provide for the Contractor's and the Superintendent's hold points and witness points as necessary. workmanship and tolerances in fabrication and erection of structural steelwork shall be in accordance with AS 4100.D. Section Hot rolled and welded structural sections Grade 300 Hot rolled plate and flats: < 100mm thick 350 ≥ 100mm thick 250 Circular hollow sections: Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. delivery and erection at site of all structural and other fabricated steelwork shown on the Drawings and/or necessary for completion of the Works. Unless noted otherwise.2 Steel All steel used in this Contract shall be hot rolled structural grade steel manufactured by the Open Hearth.1. It also covers miscellaneous items such as floor plate. ladders. handrails.3 Materials 3.1. The work shall be carried out in accordance with the Quality Plan.doc 22 March 2012 | Revision 1 Aurecon Page 26 .1 Scope This specification applies to the supply. Cold-formed steel sections shall conform to the requirements of AS 1397.) or Electrical Furnace processes.

and shall be re-passivated where the oxide layer has been damaged during fabrication or construction by working. Unless noted otherwise.3. Alternatively. Unidentified steel shall not be used in structural members. Stainless steel shall be Grade 316. in the opinion of the Superintendent. sparks or the like. All stainless steel including fasteners shall be passivated.doc 22 March 2012 | Revision 1 Aurecon Page 27 . Alternative sections proposed for use in place of those shown on the documents shall have section properties not less than those for the member specified. such defects could cause undue stress concentration or weakening or uncertainty as to life of the component. Steel sections shall be roll-straightened before fabrication into a structural member where such action is required to comply with dimensional and tolerance requirements for steelwork. All steel shall be free from excessive rust.4 Testing of materials General All ultrasonic and other non-destructive testing shall be performed by a National Association of Testing Authorities (NATA) registered laboratory or equivalent as approved by the Superintendent.D. or Grade 316L for items which require welding. > 168 dia C350 Square and rectangular hollow sections C350 The Contractor shall obtain manufacturer/test certificates for all structural steel demonstrating compliance in all respects with the specified standards. < 168 dia (for members offshore below wharf deck level) C350 O.D. < 168 dia (for all other members) C250 O. pitting and other defects likely to impair the structural capacity of the member or the quality of the protective coating system. 3.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Section Grade O. 3.3 Stainless Steel Stainless steel shall conform to the requirements of AS 2837. Any defects found in items ultrasonically tested shall be sufficient cause for rejection of the item if. where specified. welding. shall have a Titanium content of at least six times the Carbon content to stabilise weld zone Carbon and minimise the susceptibility to intergranular corrosion after welding.3. Material that has been split or permanently injured shall not be used. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. grinding. Materials taken from stock to be used for the structural members must be of a quality at least equal to that required by this Specification. Certificates shall be made available for viewing by the Superintendent upon request prior to the commencement of fabrication work and at any other time during the Contract. Stainless steel 3CR12.D. 5CR12 may be used.

In a like manner. prior to the commencement of cutting or fabricating. All steel 40 mm thick and over shall be tested ultrasonically for laminations in accordance with AS 1710 quality steel classification Level 2. The Welding Inspector’s scope of duties and privileges shall be as specified in AS 1554. 3. the entire cost of preparing that test specimen and carrying out the test shall be borne by the Contractor.4. Units shall be laid out and fabricated as necessary so that all parts are accessible for inspection before transportation to the site. The entire cost of preparing test specimens and carrying out nominated tests on materials shall be borne by the Company except in the event that a test specimen fails to meet the required specification.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Testing by the Contractor Mill certificates.2 Inspection during fabrication During fabrication the Contractor and its Subcontractor(s) shall permit the Superintendent free access to the fabricator's works at all times for the purpose of carrying out inspection and shall afford all necessary facilities for the carrying out of such inspections. Where steel has been inspected by the Superintendent at the works before being delivered to the site. The Contractor shall at all times facilitate inspection and testing by the Superintendent. in which case.4 Inspection 3. All steel shall be subject to final approval in-situ.1 General The Contractor shall provide to the Superintendent reasonable advance notice of its fabrication and erection programme to enable inspections to be arranged by the Superintendent. such inspection shall not relieve the Contractor of responsibility to provide correct fitting together on erection. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. castings and forgings imported for the purpose of manufacture in Australia shall be tested ultrasonically for laminations and other unacceptable defects to a standard approved by the Superintendent prior to shipment. All welding included in this Contract is subject to inspection by a qualified Welding Inspector who will work under the direction of the Superintendent. Testing directed by the Superintendent The Contractor may be required to prepare and submit for testing.4. 3. heat numbers. All rolled sections and plates or special fabricated components. Any inspection by the Superintendent shall not prevent the ultimate rejection of any work or materials in which defects have been found at any time prior to the completion of the Contract.doc 22 March 2012 | Revision 1 Aurecon Page 28 . Records of test results in accordance with AS 1710 shall be submitted with the relevant mill sheets. the Contractor may also be required to prepare and submit test specimens cut from a fabricated member forming part of the primary structure. All castings and forgings shall be tested ultrasonically prior to machining in accordance with a relevant standard approved by the Superintendent. This level of traceability of materials is to be maintained by the Contractor during the progress of the work and made available to the Superintendent upon request. etc. shall be supplied for all materials used in the works and shall be cross-referenced to the item numbers to be cut from the materials. specimens of material intended to be used for the primary steel members.

doc 22 March 2012 | Revision 1 Aurecon Page 29 .1 General The fabrication of all steelwork shall be carried out in accordance with the requirements of AS 4100 and AS 1554 together with any other requirements of this Specification and the Drawings.4. unless approved in writing by the Superintendent. 3. Hollow section members shall be provided with 6mm plates welded all around at open ends to exclude the entrance of moisture. The Contractor shall also employ on site an experienced welding supervisor whose sole responsibility shall be to ensure that correct and approved welding procedures are followed for all welded connections. Methods for correcting distortion or damage shall be submitted in writing for review before any remedial work is commenced.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd The appointment of a Welding Inspector by the Superintendent shall not relieve the Contractor of its responsibility to properly supervise and carry out quality control over all works carried out either in the workshop or on site. One such foreman shall be assigned to each workfront.6. erection and welding. Suitable jigs and supports shall be used to fabricate structures accurately to the dimensions shown on the Drawings. Flattened ends shall not be permitted. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. All members shall be fabricated true to shape and size.3 Inspection during erection The Contractor shall provide adequate and safe scaffolding to enable the Superintendent to inspect any unit or connection and shall be deemed to have made due allowance in the Tender Price for such work. All cutting and shearing shall be neatly done and all portions exposed to view shall be neatly finished with all edges ground off to a smooth radius of not less than 2 mm. without distortion and with all necessary provisions for transport. The Contractor shall implement a Quality Control system to cover all aspects of the Structural Steelwork. Such approval shall be at the Superintendent’s discretion. 3.6 Fabrication 3. 3. handling. At least one month's notice shall be given of the time and place at which fabrication is to commence. and erection. whose sole responsibility shall be the supervision of structural steelwork for this Contract. No inspection by the Superintendent shall in any way relieve the Contractor of its responsibility to have in place an effective Quality Control Program.5 Supervision The Contractor shall employ foremen experienced in all facets of steel fabrication. Any plate or section injured by hammer marks or otherwise marked or defaced shall be rejected. Welding sequences shall be planned and adjusted where necessary to control distortion and achieve dimensional accuracy. Structural steel hollow sections shall be profiled to fit the shape of the members to which they are to be welded. All steelwork fabrication shall be carried out in Australia.

These drawings shall be supplied before erection commences. The Contractor shall verify all dimensions from the site and shall be responsible for the same and any discrepancies in the drawings shall be brought to the attention of the Superintendent before fabrication commences. In addition. Welding Technology Institute of Australia (WTIA) Technical Note 6. had been attached. When the details have been examined. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. surface treatment and adequacy of structural connections only. resubmit drawings requiring correction. soundness of the structure and quality of the paint coatings shall be as if no such erection cleats. all major assemblies of machinery that can be demounted for maintenance or replacement shall be fitted with permanent lifting eyes. three copies each of full framing plans and such further details as will enable the Contractor to prepare full shop details of all members. should be used as a guide in this regard. including column set out and floor levels. The final appearance. The details will be reviewed by the Superintendent for member size. Temporary erection cleats and the like will be permitted. subject to approval. While details have been prepared with due regard to all reasonable requirements as to practicability of fabricating. The submission of the shop details will be taken as an acceptance by the Contractor of the practicability of fabricating and erecting the structure to the required specification and tolerances. Notwithstanding the above. but on completion they shall be removed and the structure made good. and other matters affecting erection and to amend any details on his shop drawings in order to comply with these requirements. the ability to erect to the required tolerances. entry between gussets and attachments.doc 22 March 2012 | Revision 1 Aurecon Page 30 .GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Welding procedures and orientation of cutting of steel plates relative to the direction of rolling shall be designed to minimise the risk of lamellar tearing. Each shop drawing shall be provided with all information required for checking without reference to other drawings.  Accepted  Accepted subject to amendments  Resubmit The Contractor shall. Notwithstanding these provisions the Contractor shall be solely responsible for all dimensions. and general agreement with the Specification. the Contractor shall report them to the Superintendent before making such alterations. Should any such be of a major nature.6. The Contractor's marking plans shall be submitted in the first batch of shop drawings and updated issues shall be progressively supplied as required to enable examination of the drawings to proceed. transporting and erecting to the required tolerances. The Contractor shall supply to the Superintendent two copies of all such shop details in accordance with the General Conditions. where directed and at his own expense. jacking points and so forth. Control of Lamellar Tearing. Magnetic particle testing of the affected area shall be performed to demonstrate that there is no surface cracking or defects. the Contractor shall allow for supplying one final reproducible of each shop detail for the Superintendent's use on the site and one final print of each shop detail to the steelwork erector for his use on the site. Drawings and other information supplied by the Principal.2 Workshop drawings The Superintendent will supply to the Contractor as final details. one copy shall be returned bearing the Superintendent's endorsement as follows. 3. etc. it shall remain the responsibility of the Contractor to check the clearances for transportation and for erection.

5 Cutting and holing All structural steel components shall be machine flame cut. Items or parts fabricated from other than structural grade mild steel shall be marked for identification. where permitted by AS 4100. Drilling of bolt holes shall be accurate and any slight misalignment or alteration required shall be corrected by reaming. nuts and washers shall be suitably bagged and tagged to ensure their use in the correct place. Flame Cutting of Steels. shall be subject to the approval of the Superintendent. shop splicing (other than those shown on the Drawings) by complete penetration butt welds may be permitted on a case-bycase basis.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All welds and non-destructive testing requirements shall be detailed on the workshop drawings. Exposed flame cut surfaces shall have a Class 2 finish as defined in WTIA Technical Note 5. subject to approval by the Superintendent following consideration of the applicable design actions. Burnt holes will not be permitted under any circumstances. handling. the procedure and preparation for which shall be submitted with and shown on the shop drawings. and joined on site by qualified complete penetration butt welds. Such scribe lines shall show the true theoretical centre lines of the column. 3. punched full size. 3. cleats and other small pieces required in making field connections shall be temporarily shop bolted to their respective members for delivery.3 Marking All components shall be marked with a durable and distinguishing erection mark to ensure that they are erected in the correct position and orientation. Marking shall be by means of punch stencils having characters at least 12mm high. the holes shall be filled by electric welding and redrilled to the satisfaction of the Superintendent. The location of all shop and field splices shall be clearly shown on the “As Built” Drawings. Fatigue sensitive welds in accordance with AS 1554. 3. Field splices.6. Where excessive misalignment occurs. All holes shall be drilled or. transportation or erection reasons.6. but required by the Contractor for fabrication. the splices in individual component plates and sections shall be spliced before compounding and shall be staggered by not less than 60mm. where not shown on the Drawings. to the profile as shown on the Drawings. sheared or sawn neatly and accurately in accordance with AS 4100.6.4 Weld splices Where stock lengths of steel are shorter than the required length of member. Splice plates.doc 22 March 2012 | Revision 1 Aurecon Page 31 . Where structural steelwork is to receive surface treatment after fabrication and before erection the marking shall be made in such a manner that the item may be identified at all times and scribe lines and levelling marks readily located. All columns shall be provided with clear and adequate levelling marks and scribe lines or centre marks to enable them to be easily plumbed in two directions at right angles and accurately levelled. Flame cutting by free-hand will not be permitted without prior approval. Welding symbols on workshop drawings shall be in accordance with AS1101. Welding of mark numbers is not permitted.3 and shall include a reference to the relevant welding procedure sheet for the type of weld shown.5 shall be designated FP and shown as such in the tail of the welding symbol. Adjoining members shall be match marked as necessary. Bolts. Under no circumstances shall bolt holes be enlarged by flame cutting. All such welds shall be tested by non-destructive means. In the case of compound members. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.

or loss of the lubricant.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Where slotted holes are shown or specified they shall be accurately shaped with the sides smooth. Where directed by the Superintendent. Holes shall be clean cut without torn or ragged edges and free from burrs. 3. In particular. The fabrication programme shall be arranged to ensure close cooperation between the protective coating subcontractor and the fabricator.6 Precamber Where individual members or fabricated assemblies are required to be cambered. at its absolute discretion. all fabricated work shall be handled and stored so as to prevent damage or corrosion. All steelwork shall be provided with ready means for lifting and handling including suitable lugs or slings as required. straight. will decide whether the repairs are to be carried out in the field or the damaged portions returned to the shop. at its absolute discretion. High strength structural bolts. 3. parallel and circular at the ends. who.6.doc 22 March 2012 | Revision 1 Aurecon Page 32 . during transit and while on the site all structural steelwork shall be handled and stacked so that it is not damaged. nuts and washers shall be stored and handled in the Works and in transit to the site in a manner that will prevent damage.7 Handling. during and after fabrication. 3. structural steelwork shall be stacked clear of the ground and so that the collection of water in troughs. is reduced to a minimum. the amount will be specified on the Drawings and the means of achieving the correct camber shall be submitted to the Superintendent for approval prior to fabrication of the member or assemblies concerned.7 Protective treatment Protective treatment shall be in accordance with Standard Specification – Protective Treatment. Standards of steel finish prior to protective treatment of the steelwork shall comply both with this Specification and Standard Specification – Protective Treatment. sufficient time must be allowed for protective coating to cure before packaging and transportation. On completion. handling or transportation shall be replaced or repaired and straightened by the Contractor. the Superintendent may. reject any or all of the material affected or direct that its use be confined to a particular part of the structure. nuts and washers. Such action shall be undertaken only with the consent of the Superintendent. contamination or corrosion occur to the bolts. All steelwork shall have sharp edges and corners rounded and ground smooth to a minimum radius of 2mm to promote adherence of protective coating in these critical areas. Steelwork which is damaged during storage. bent or twisted. delivery to site and storage Before. damaged sections shall be replaced. At the Works and on site. pockets and the like. contamination. corrosion. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.6. Should damage.

Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. equipment and personnel as required for the completion of the work and for the spreading of high local loads which may occur under lifting equipment. The Contractor shall be deemed to have visited the site during the Tender period and ascertained conditions on the site including surface conditions. The Contractor shall be responsible for planning erection procedures including the provision of all temporary works such as guying. overhead wires and other obstructions and to have made due allowance in its price for the effect of these and for the movement of plant. All erection shall be carried out in accordance with the requirements of AS 4100 and of this Specification and the Drawings. columns. or other steelwork will not be allowed. Specifications and Drawings. The Contractor shall have at the site. holes plugged and the steelwork. No section of the Work shall be erected unless copies of the relevant shop details. means of access.1 General All work shall be carried out in accordance with relevant AS 4100 and other relevant Standards. all temporary bracing and connections shall be removed.doc 22 March 2012 | Revision 1 Aurecon Page 33 . Trusses and other units shall be transported and erected in such a manner and lifted from such points that members shall not be overstressed or distorted during lifting operations and transportation. so as to ensure the safety of the structure under all conditions of wind and erection loads occurring during the construction period. and fix and maintain marks for the erection and checking of positions of steelwork and shall arrange all plant and temporary loads during erection so as not to exceed in any part the allowable relevant capacity as determined in accordance with AS 4100. the temporary bracing shall remain in position until such elements have been completed. bracing and the like. the number of field erection bolts used shall be sufficient to ensure that the structure is adequately and accurately held together and in position. nuts. If the stability of the completed structure is dependent upon elements such as decks and beams or bracing to be constructed after the erection of the structural work. During erection.8 Erection 3. equipment and personnel for the proper performance of the work and so as to ensure completion within the times specified or agreed upon. made good.8. sufficient and adequate plant. drains and ducts.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 3. the use of sledge hammers in driving or hammering beams. approved and signed by the Superintendent. and erection drawings. Statutory Regulations. The work shall be supervised by a capable foreman experienced in this class of work. packers and shims necessary for erection of the Works shall be supplied by the Contractor. Wooden mauls shall be used whenever practicable. At all times. presence of underground services. All bolts. Upon completion of the work and when approved by the Superintendent. Care shall be exercised to prevent the material from falling or from being in any way subjected to heavy shock. The Contractor shall set out lines and levels. Any such stability requirements shall be ascertained before erection commences. are held on the site by the Contractor. including the protective coating specified.

and shall be provided with neoprene washers against the base plate. plasma. plug welded. No holing or cutting of structural work. All portions of the framework shall be true and plumb within the tolerances specified in AS 4100.2 Bolt holes Bolt holes shall not be altered on site without the approval of the Superintendent. Levelling and plumbing shall begin as soon as practicable after commencement of erection and shall proceed at the same rate as the erection of new steelwork. Any major errors by the fabricator that prevent the proper assembly of the steelwork shall be promptly reported to the Superintendent. shall be done in the field without prior written approval.8. and these pins shall not be used in such manner as to distort or damage the metal. Otherwise the holes shall be reamed out.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Contacting surfaces of parts being joined shall be free from distortion and all burrs or ridges shall be removed. etc) in the field for correcting errors shall not be permitted. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. All brackets. Holes that are badly punched or drilled shall be reamed out to accept a bolt of larger diameter if approved by the Superintendent. Before erection of any member supported on concrete. Levelling nuts shall be of the same material as the other nuts on the holding down bolts. All field bolting and welding shall be inspected as the work progresses. stainless steel shims or nylon shims but shall not be grouted in until the superimposed steelwork has been erected to a stage where it can be plumbed and checked for line and level and maintained in its final position. at its own expense.doc 22 March 2012 | Revision 1 Aurecon Page 34 . All base plates shall be carefully positioned and packed up to the correct level by means of levelling nuts. fittings and splices shall be aligned accurately before bolting or stressing and shall be checked after bolting or stressing. The use of thermal cutting (oxygen. All machined butt splices shall be inspected by the Superintendent and checked before any reaming or bolting is carried out. particularly in cases where column base-plates are recessed below ground level. The amount of steelwork erected without levelling and plumbing shall not be so great that proper adjustment cannot be achieved without damage to or distortion of members. chipping or cutting. the Contractor shall. the bearing surface shall be thoroughly cleaned of all dirt and debris and adequate precautions shall be taken to ensure that this surface condition is maintained. dismantle such of the erected steelwork that the proper standards of workmanship can be achieved. Drift pins may be used only to bring together several parts. If in the opinion of the Superintendent damage or distortion is likely to occur due to the erection of steelwork proceeding too far in advance of levelling and plumbing. The Contractor shall correct any minor misfits by moderate use of drift pins. other than as shown on the Drawings. and moderated amounts of reaming. tested and redrilled to the sizes shown on the Drawings. 3. Cored holes for holding down bolts and shear keys shall likewise be thoroughly cleaned of all dirt and debris and all traces of forming material shall be removed.

where shown on the Drawings or approved by the Superintendent. and shall be stiff enough so as not to deform or damage the protective treatment upon tightening. filing or other works necessary to remove build up of paint to enable insertion of a bolt in a bolt hole shall be followed by repair of the protective treatment in and around the bolt hole prior to installation of the bolt. A stiffened panel is defined as an area of stiffened plate bounded by diaphragms. conform to the appropriate tolerances allowed by AS 3679 and as prescribed in Clause 14.4 of AS 4100 except for specific requirements as set out in this Specification. Tolerances for plate panels and stiffened plate panels shall be in accordance with BS 5400. Completed members shall be free from twists.8. after fabrication and unless otherwise specified. testing and acceptability in accordance with this Specification. 3. bends and open joints.9 Tolerances All structural work shall be supplied and fabricated to tolerances such that it is possible to achieve the specified erection tolerances.9. Built-up structural members shall conform to the tolerances allowed for universal beams by AS 3679 or as prescribed in Clause 14. Any drilling. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. Plate panels For the purposes of this Specification a plate panel is defined as an area of plate bounded by stiffeners (whether located on one face or not) or by other stiff parts of a section.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd After assembly of the parts to be joined. 3. site welding shall not be permitted without approval from the Superintendent. Slotted or oversized holes.4 of AS 4100. All site welds shall be to the standard of shop fabrication and welding and shall be subject to inspection. Welded end plates and web cleat angles shall be free from such distortion as will prevent the connected faces from being in full contact when bolted snug tight. shall require plate washers sized to completely cover the slotted or oversized holes for all positions of bolts in the holes. webs and flanges each capable of preventing out of plane distortion of the panel edges.3 Site welding Other than where shown on the Drawings.doc 22 March 2012 | Revision 1 Aurecon Page 35 .1 Fabrication tolerances Structural members consisting primarily of a single rolled section shall. The tolerances specified herein apply to individual members or units and shall not be interpreted as permitting a cumulative error over the whole or part of any structure. Drilled holes shall be of suitable size such that bolts can be freely installed when the hole is painted. 3. perpendicular to the face of the member and aligned so as to permit the bolts to be positioned without damage to the threaded portion. all holes shall be true throughout.

the structural work shall be erected so as to conform to the appropriate tolerances allowed by Clause 14. or intended to perform a similar operational function.10 Grouting of base plates All grout shall be a non-shrink. fluid precision grout material. 3. 10 mm over length if localised. All exposed areas shall be cured with a curing and sealing component complying AS3799 in accordance with the Manufacturer's recommendations.1 and 3. The grout shall comply with Section 19 of AS 3600 and AS 1478.doc 22 March 2012 | Revision 1 Aurecon Page 36 .2 Erection tolerances Notwithstanding any fabrication tolerances allowed by this Specification. 3 mm over affected area Depth of Section ± 3 mm Width of Section ± 3 mm Twist ± 3 mm over flange width from horizontal ± 3 mm over depth of web from vertical Box sections shall be supported at their ends on level supports.8.11.9. 3. Shims and packers as defined in Clauses 3.4 of AS4100 except as specifically set out herein or on the drawings. 5 mm over affected length Lateral Kink 6 mm over length of girder Hog or Sag if gradual. Long boxes capable of significant deflection under self-weight may also be supported at an intermediate position beneath an internal diaphragm in such a way as to eliminate deflection without inducing twist. The grout shall be mixed and placed strictly in accordance with the Manufacturer's written instructions.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Fabricated box sections The tolerances as shown in Table 3-1 shall apply to fabricated box sections: Table 3-1 Fabricated Box Section Tolerances Deformation Limitation Lateral Bow if gradual. In addition.2 and shall have a characteristic compressive strength of not less than 50 MPa at twenty-eight (28) days. shall be fitted up such that misalignment is imperceptible in the joint’s required function.1 shall be supplied as required to undertake any other adjustments and corrective measures necessary to ensure that the finished position of the structural work is within the required tolerance of the position shown or inferred on the drawings. placing and curing of this grout material. ready-to-use. pre-mixed and packaged at the Manufacturer's factory and delivered to site requiring only the addition of water. 6 mm over length of girder if localised. The Contractor shall obtain the Superintendent's approval of the proposed grout types and curing compound prior to grouting operations being carried out. Alignment of welded splices Tolerances for abutting plates at welded splices or butt joints shall be as set out in AS1554 and AS4100. abutting flanges supporting a rail or forming a running surface. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. and the forming.

Bolts shown as 8.11 Bolting 3. if specified. Such items may only be left permanently in position with the approval of the Superintendent. When the grout has cured sufficiently to be able to carry the load of the structure without any detrimental effects.6). perpendicular to the face of the member and aligned so as to permit the bolts to be positioned without damage to the threaded portion.11. Bolted connections shall consist of a minimum of two bolts of 20mm minimum diameter. shall conform to the requirements of AS 1111.8 or 8.doc 22 March 2012 | Revision 1 Aurecon Page 37 . Commercial bolts (Property Class 4. Impact guns (electric or air) shall not be used to tighten stainless steel bolted assemblies. kickplate. or concrete base is below 5 degrees Celsius or above 30 degrees Celsius. 3.11.11. handrails. and minor angle bracing. packs or levelling devices used to hold the column in position shall be removed and the resultant cavities in the grout made good. nuts and washers. unless noted otherwise. Bolts shown as 8. High strength structural bolts (Property Class 8. Bolted joints between aluminium extrusions and painted steel shall be made with stainless steel bolt assemblies together with rigid PVC insulating washers. any steel wedges.8). Mating surfaces shall be coated with inorganic zinc silicate primer in accordance with the Standard Specification – Protective Treatment.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd No grout shall be placed if the temperature of either the grout. Precautions shall be taken to avoid the formation of air pockets and the edges shall be neatly bevelled off on completion. all holes shall be true throughout.8/TF shall be fully tensioned in accordance with Clause 3. baseplate.1 General Unless specified otherwise herein or on the Drawings.2. bolts used for this Contract shall be:  High strength structural bolts for all bolts 16mm diameter and larger. and  Stainless steel Gr 316 Bolts for all bolts less than 16mm diameter. After assembly of the parts to be joined. Stainless steel bolts and threaded rods shall be coated with nickel based anti-seize prior to tightening and shall be provided with stainless steel Nyloc nuts and two stainless steel washers (one each under the head and nut). A manual torque wrench shall be provided on site to allow checking of bolt tightness by the Superintendent.8/S shall be tightened to snug tight condition in accordance with Clause 3.8/TB or 8. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. After all bolts have been tightened to their specified torque. the nut or bolt shall be marked with a permanent marker or similar to provide visual evidence that the bolted connection has been completed. No other coatings shall be applied to the mating surfaces unless it can be demonstrated to the Superintendent’s satisfaction that the resulting coefficient of friction will not be less than that assumed for uncoated steel.3. nuts and washers shall conform to the requirements of AS 1252. Bolts of 16mm minimum diameter may be used for fastening tertiary members such as purlins and girts.

doc 22 March 2012 | Revision 1 Aurecon Page 38 . then labelled and packaged for transportation. 3. cleats and the like shall receive the full specified protective treatment before assembly. bolts at sliding interfaces. The bolts shall not be overstressed and the applied torque shall not exceed that recommended by the bolt manufacturer. The assembly and tensioning of high strength structural bolts for friction grip connections shall not be commenced until the Superintendent is satisfied that the team or teams carrying out the work have been instructed in the procedures to be followed and that they are capable of carrying out those procedures correctly. Where practicable. shall be fitted under the non-rotating part. all surfaces of individual members. Bolts subject to tensile loads. Fitted precision bolts in accordance with AS 1110 shall be used in bolted splices. Where possible.11. Where bolted connections are used. All structural steel bolts shall be coated with suitable lubricant to facilitate the initial tightening. shall be locked in position in a manner approved by the Superintendent. Match marking shall be permanent. bolted joints may be packed to achieve the required tolerances.11. sized to result in a 5mm recess around the perimeter of the bolted joint. the assembly and tensioning of friction grip connections shall be carried out by the same team or teams throughout the whole of the work of the Contract. In no case shall the bolt tension exceed 65 percent or be less than 50 percent of the guaranteed yield load of the bolt. Holes shall be reamed to achieve a minimum interference fit in accordance with AS1654. At least one washer but not more than two washers shall be placed under the part being rotated in tightening. unless otherwise approved by the Superintendent. 3. All high strength structural bolts for friction grip connections shall be tensioned using the part-turn method. Each bolt shall be match marked against the appropriate hole for which it was fitted. if required. The nuts shall run "finger free" on the bolts after galvanising of both. bolts subject to vibration. Such packing shall consist of a maximum of two stainless steel packers. and all bolts carrying crane and/or hoist loads. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. are not permitted. The recess shall be neatly and completely filled with a polyurethane-based sealant (Sikaflex or approved equivalent) prior to top coating of the entire joint.3 Installation of high strength bolts used in friction grip mode All high strength structural bolts for friction grip connections shall be assembled and tensioned in accordance with AS4100. “Finger shims”. bolts shall be positioned so that the taper washers. preferably made with a heavy centre punch. Taper washers shall be used where the part under the bolt head is not perpendicular to the axis of the bolt. Where shown on the Drawings or approved by the Superintendent. Bolts shall not be used to force fit the abutting material together and any lack of fit shall be referred to the Superintendent who shall determine the action to be taken. with slots allowing installation with the bolts in place.2 Installation of bolts used in snug tight condition Commercial grade bolts and high strength structural bolts used in the "snug tight" condition shall be tightened so that the joined parts shall be firmly drawn together using a standard ring spanner or podger spanner or a calibrated torque or pneumatic impact wrench.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd The length of each bolt shall be such that the threaded portion will project through the nut for at least two complete threads and such that the nut will be at least one thread apart from the thread run-out.

they shall be tensioned by the part-turn method only.  Butt welds shall be complete penetration butt welds. Unless noted otherwise. Care shall be taken not to over-stress the bolts and the bolt tension stress shall not exceed 65% of the guaranteed yield stress of the bolt material. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. 3. designated as FP on the Drawings. the torque control method may be used for tensioning high strength structural bolts. Load-indicating washers shall not be used for tensioning high strength structural bolts. All welds shall be continuous around the perimeter of the parts being joined to provide a sealed joint. the joined parts shall be firmly drawn together using a standard ring spanner or podger spanner or a calibrated torque or pneumatic impact wrench. The nominal tensile strength of weld metal (fuw) shall be not less than 480 MPa. unless noted otherwise.  Flange end connections . The nut shall be held in position with a split pin or other approved locking device. the Superintendent may direct that any bolt or any number of bolts be tensioned by the part-turn method.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Where bolts are not galvanised and where approved by the Superintendent. high strength structural bolts that have been fully tensioned once. as specified in AS4100. shall be carried out in accordance with AS1554. The bolt. Such approval will only be given when the bolts have been removed entirely from the joint and handed to the Superintendent for examination and acceptance. the following shall apply:  All welds shall be continuous fillet welds all around (on both sides) – 8mm for marine structures and 6mm for other structures. and  Seal welds shall be a minimum of 6mm fillet welds.5.1.12. The procedures shall be on sheets in a form similar to Appendix E of AS1554. 3. shall not be re-tightened and shall be discarded.11. Where bolts are approved by the Superintendent for re-tightening.doc 22 March 2012 | Revision 1 Aurecon Page 39 . Notwithstanding any approval by the Superintendent of the general use of torque control methods of tensioning. shall be connected by complete penetration butt welds. unless noted otherwise. All torque wrenches or pneumatic impact wrenches used for tensioning shall be calibrated on site at least once per shift. the washers and the faces of the rotating parts in contact shall be greased with an approved proprietary grease containing molybdenum disulphide.1. Unless approved otherwise by the Superintendent. Structural steel welding shall be Category SP (Structural Purpose) in accordance with AS1554.1 General All welding shall be in accordance with AS1554 – Parts 1 to 6. and adjacent welds of stiffener plates at such connections. Fatigue sensitive welds. Detailed welding procedures shall be submitted in accordance with specified Drawing and Document requirements in the Scope of Work.4 Installation of fitted shoulder bolts Where fitted shoulder bolts are to be clamp tightened. the nut shall be tightened firmly but so as not to prevent the joined parts from rotating as required. Where fitted shoulder bolts are used as a trunnion pin.12 Welding 3. Welding of pressure piping shall be in accordance with AS4458.

virgin steel surface and fit up equivalent to machining. all flame cut surfaces (if any) shall be ground back a minimum of 2 mm to provide a slag free. All completed welds shall be subject to inspection by the Superintendent.6. Where field welding is to be employed. 3. Unless noted otherwise. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. gas cutting or gouging and the finished surface shall be of an even contour and free from oxide.2 Welding of stainless steel Welding of Stainless Steel shall be in accordance with AS1554. All slag. the weld shall be replaced or repaired or that the surface be ground until a satisfactory finish has been achieved. The Contractor shall take measures during fabrication to minimise such distortion. rust or any other foreign matter shall be removed by the use of wire brush or other suitable means such as flame cleaning or grit blasting.12. Priming and painting in the vicinity of welds shall not be carried out until after inspection.3 Joint preparation All material(s) shall be properly prepared in a suitable manner by machining. For FP welds. profiling. the work shall be held in frames or jigs to ensure that the completed work will be dimensionally acceptable. Where in the opinion of the Superintendent. scale or slag. Surfaces to be incorporated in a weld shall not have a surface roughness greater than Class 3 as defined in WTIA Technical Note 5. a satisfactory finish has not been achieved. Welding shall not proceed on wet surfaces and such surfaces shall be dried before welding is commenced. In assembly.doc 22 March 2012 | Revision 1 Aurecon Page 40 . Unless the welding operator and the work are properly protected. Due allowance shall be made for the warpage and shrinkage of welded parts and where necessary. welding shall not be carried out when rain is falling or under strong wind conditions. Oil. grinding.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All tubular and boxed members shall be hermetically closed by seal welding for complete corrosion protection. The Contractor shall conduct ferrite testing and certify during qualification of the welding procedure that all stainless steel welds and adjacent areas are free from “carbide precipitation” which will lead to “intergranular corrosion”. all parts shall be accurately positioned and held in the required alignment with special attention directed to abutting plates of unequal thickness. which may lead to significant warping distortion during welding. the following shall apply:  Internal weld quality  External weld quality  Surface finish 1 B II Stainless steel has a higher coefficient of thermal expansion than carbon steel. weld spatter. the Contractor shall plan the assembly of structural work in sections which will permit a maximum amount of welding to be done on the ground. paint.12. The finished surface and profile of all welding shall be smooth and free from sharp edges or crevices that would be detrimental to the performance of the structure or to the protective treatment. porosity and irregular weld contours shall be totally removed and the weld surface replaced and ground back until a smooth surface is achieved to the satisfaction of the Superintendent. 3.

Over-reinforcement of butt welds and pronounced humps shall be ground off to produce a smooth profile.1 or AS 2717.12. unless shown otherwise on the Drawings. and upon completion of welding shall be removed and the surface ground flush. unless indicated otherwise. No fillet welds smaller than these sizes will be permitted.1 for processes other than manual metal-arc welding.doc 22 March 2012 | Revision 1 Aurecon Page 41 . Intermittent welds shall be continuously seal welded.1 requirements and WTIA Technical Note 1. Butt welds in sections 25mm or more in thickness shall be made with low hydrogen electrodes. No heating or welding shall be performed on stress-relieved items unless approved by the Superintendent. All fillet welds shall be continuous welds. post-weld heat treatment procedures shall be submitted to the Superintendent for approval and shall describe support details and thermocouple placement. Prior to the commencement of treatment. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. AS 2203. shall be double V-butt welds.4 Butt welds All butt welds shall be qualified completed penetration butt welds unless shown otherwise on the Drawings and.6 Pre-weld heat treatment Preheating of welded joints shall be carried out in conformity with AS1554. all fillet welds shall be continuous welds of 8mm leg length for steelwork at or below deck level in offshore environs and 6mm leg length for all other steelwork. 3. temperature records shall be submitted to the Superintendent to demonstrate compliance with AS1210. or ground flush as specified on the Drawings. 3.7 Post-weld heat treatment All post-weld heat treatment shall be carried out in accordance with AS1210.8 Welding consumables Electrodes shall comply with the requirements of AS 1554 and shall be of minimum Grade E48XX to AS 1553 for manual metal-arc welding and Grade W50XX to AS 1858. All pre-weld heat treatment procedures shall be submitted to the Superintendent for approval prior to commencement of treatment.12. unless noted otherwise on the Drawings.1. unless shown otherwise on the Drawings. Surface preparation for all butt welds shall be shown on the shop drawings. Run-on/run-off tabs shall be provided for butt welds. All butt welds designated on the Drawings as “Incomplete Penetration Butt Welds” shall be qualified incomplete penetration butt welds to AS1554. 3. For assemblies requiring post-weld heat treatment and the machining of components. where possible. where required. 3.12.5 Fillet welds Unless shown otherwise on the Drawings. and shall have full depth preparation.12. machining shall be carried out after the completion of the heat treatment. they shall be completed without the use of permanent backing plates unless shown on the Drawings or approved by the Superintendent. Electrodes for welding of stainless steel shall be Grade 309 or equivalent and shall be compatible with the materials being welded. If the weld cannot be completed from both sides. At the completion of treatment.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 3.12.

All low carbon and carbon manganese steel consumables must meet grade 2 impact requirements or better. All craters shall be filled to the full cross-section of the weld.9 Welding equipment Welding plant and equipment shall be in accordance with AS 1966. repaired and ground as directed by the Superintendent until a satisfactory surface finish has been achieved. Electrodes that have been exposed to weather and especially to atmospheric moisture shall be discarded. and the weld surface shall be replaced. The finished surface and profile of all welding shall be smooth and free from sharp edges or crevices that would be detrimental to the performance of the structure or to the protective treatment. 3. the low hydrogen electrodes shall be kept in their sealed packets until the time of actual welding.12 Welding supervision All welding shall be carried out under the supervision of a qualified welding supervisor who satisfies the requirements of AS 1554 or AS 1665 as appropriate. All welding operator's performance shall be monitored. or at any stage during the progress of the work. In protected areas undercutting shall not exceed 0. 3. Immediately after opening a new pack of electrodes they shall be transferred into a portable drying oven where they shall be kept at a temperature recommended by the manufacturer.12.12. the operator shall be replaced with another who will provide the required standard.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd In addition to the requirements of AS 1554. Cracks or blemishes resulting from arc strikes shall be ground to a smooth contour and checked to ensure soundness. prior to the commencement of production welding. All slag and weld spatter shall be thoroughly removed. All consumables shall meet low hydrogen requirements of 5-10 ml per 100 g of deposited weld metal as defined by AS 3752. Additional weld metal to compensate for deficiency in size shall be deposited using an electrode preferably smaller than that used for making the original weld. There shall be thorough fusion between weld metal and base metal and between successive passes in the weld. 3.10 Weld quality Undercutting will not be permitted in any welding exposed to the weather. Welding operators shall be qualified in accordance with AS 1554 or AS 1665 as appropriate for the class of weld to be performed. Automatic welding procedures and electrode wire shall be of a quality exceeding the requirements for weld quality specified herein. Welding operators shall pass a proficiency test.12.11 Welding operators Welding operators employed on the works shall be suitably qualified and experienced and evidence of qualification shall be submitted.5mm deep. Should an operator consistently deposit welds which are below 95% conformance. 3. The surfaces shall be cleaned thoroughly before welding.doc 22 March 2012 | Revision 1 Aurecon Page 42 . Arc strikes outside the area of permanent welds shall be avoided on any material. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.12.

Results of non-destructive weld testing shall be made available for inspection by the Superintendent. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.13 Welding procedures All welding procedures shall be the responsibility of the Contractor and shall be in accordance with AS 1554. and/or  Radiographic examination. If new welding preparations have to be developed. Tack welds shall be made with the same type of electrode that is used for depositing the root pass. Increases in design throat thickness and exemption from back gouging for welds made with fully automatic welding processes shall only be allowable if the extent of NDT on the joint considered is increased to 100 % ultrasonic testing (UT) or 100 % radiographic testing (RT). machining. or in such positions that natural light is impaired.doc 22 March 2012 | Revision 1 Aurecon Page 43 . When necessary to machine grind in lieu of arc or oxy gouging. then procedures shall be qualified and the Procedure Qualification record submitted to the Superintendent. Non-destructive weld testing shall comply with the requirements of AS 1171.12. AS 2062. 3. Procedures should allow maximum freedom of movement of the parts being welded so as to reduce distortion. Approval by the Superintendent shall not relieve the Contractor of responsibility for the suitability of any welding procedure and for the satisfactory execution of the work. Each weld bead must be free from slag and brushed bright with a wire brush before succeeding runs are applied. unless the tack weld is to be removed prior to welding. The Contractor shall submit details all of welding procedures to the Superintendent for approval. The reverse side of complete penetration butt welds shall be gouged back to sound metal by arc/air or oxy gouging. visual examination. Where welding is carried out during night hours.12. in order to minimise distortion and residual stresses.14 Examination and testing Non-destructive testing of shop and field welds shall be performed as necessary to qualify welding procedures and to ensure the quality of finished welds during the course of the works. and related Standards. This may include:  Surface examination (including visual scanning. AS 2177 or AS2207. Welding procedures for tack welds are required. Special care shall be taken with the application of weld sequence procedures. Preheating and/or post heating may be necessary under certain conditions. or grinding. All welds shall have good fusion with the parent metal. "Dye penetrant" testing shall be carried out to ensure all defects are removed. Test pieces for any qualification procedure shall be cut from the representative material to be used in the actual construction and all welding shall be carried out in locations as close as practicable to the actual positions to be used in construction. Where possible.  Ultrasonic examination. as appropriate. the adjacent area shall be adequately illuminated to allow close inspection of each weld pass for cleanliness before proceeding with the next pass. Special care shall be exercised to ensure that slag inclusions are not present between weld beads. prequalified welding preparations shall be used.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 3. dye penetration and magnetic particle testing).

GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Non-destructive weld testing shall be conducted by an accredited Inspection Authority. The programme of testing should then involve a progressive reduction in frequency (to the minimum levels specified in Table 3-2) subject to the ongoing compliance of each subsequent test. Where materials less than 10 mm thick are subjected to Ultrasonic Testing. but greater than or equal to 8mm thick. Ultrasonic testing of materials less than 8mm thick shall be performed to determine weld thickness only. Any additional or penalty examination/testing requirements shall be fulfilled in accordance with the appropriate standard. Legend: VS – Visual Scanning VE – Visual Examination UT – Ultrasonic Testing RD – Radiography MP – Magnetic Particle In the case of welding stainless steel. Magnetic Particle Testing shall also be conducted to detect surface and sub-surface defects. Hot rolled sections and plate having welded connections on the rolled face. All welds shall be examined and tested in accordance with the following specified requirements.doc 22 March 2012 | Revision 1 Aurecon Page 44 . shall be inspected by ultrasonic techniques and no unacceptable Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. dye penetrant testing shall be used in lieu of magnetic particle testing. the next major component or group of welds shall be tested consecutively. which shall be submitted to the Superintendent for approval. the Contractor shall submit to the Superintendent for approval the name of the inspector and the company. Examination and testing of the fabrications shall be undertaken in accordance with the Quality Plan. Table 3-2 Minimum Weld Examination and Testing Requirements Type of Weld Method of NDT1 Location VS VE UT/RD MP Fatigue Sensitive Butt Welds Shop / Field 100% 100% 100% 100% Fatigue Sensitive Fillet Welds Shop / Field 100% 100% - 100% All other Butt Welds Shop 100% 100% 10% 10% Field 100% 100% 100% 100% Shop 100% 100% - 10% Field 100% 100% - 25% All other Fillet Welds 1. Acceptable levels of imperfections shall be in accordance with AS1554. Welds that fail to meet the specified requirements shall be specifically noted on examination/testing reports or weld records. If testing indicates non-compliance. Where possible. Ultrasonic testing of materials less than 10mm thick. the minimum level of weld examination and testing shall be in accordance with Table 3-2. shall be performed to determine weld thickness and to detect defects in the root and lower section of the weld only. the inspector’s experience and the method of reporting. which impose a tension component normal to the face. Unless noted otherwise on the Drawings. The programme of testing shall involve full testing of the first major component or group of welds in order to detect and be able to correct the cause of any major defects as early as possible. radiographic testing shall be used in preference to ultrasonic testing for parent metals of less than 10mm in thickness. Prior to the commencement of fabrication.

Any examination and testing of items shall not prevent the ultimate rejection of any work or materials in which defects are found at any time prior to the completion of the Contract. If any of these welds prove defective. unless noted otherwise. The thickness of the zinc coating shall be not less than 100 micrometres. when fixed in position. the Contractor shall select. walkways.1 Grating In the sense that it is used elsewhere in this specification. Acceptance standards for laminations or lamellar tearing defects in weldments shall be as for lack of fusion. cut and trim each panel so that. Grating shall be ‘Webforge’ (or approved equivalent) heavy duty industrial grating with serrated load bars.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd lamination or part of such lamination will be permitted within an area extending 3 plate thicknesses beyond the weld boundaries. If in the opinion of the Superintendent. All fasteners shall be manufactured from galvanised steel for fixing of galvanised grating or from stainless steel for fixing of aluminium grating. Grating panels on all inclined walkways and on walkways capable of tilting from the horizontal shall be fixed using proprietary saddle-type clips bolted through shop drilled holes in supporting steelwork (or in external cleats for hollow sections).13. re-examined and retested to the Specification requirements. then it shall be rejected and a replacement member fabricated by the Contractor.doc 22 March 2012 | Revision 1 Aurecon Page 45 . if 10% or more of a weld type proves defective. All faulty welds shall be removed. If this constraint is not provided to each panel edge by continuous kickplate or at least two discrete members (eg handrail Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. the maximum difference in level between adjacent edge bars of adjoining panels shall be not more than 5 mm and the maximum gap between such edge bars shall be not more than 10 mm. Grating panels shall be hot-dip galvanised in accordance with AS 4680 after fabrication has been completed. Grating panels shall be in sizes suitable for manhandling and shall be suitably marked or tagged. To account for the possibility of clips dislodging or not being reinstalled after temporary removal. Any faulty welds and details of proposed weld repairs shall be brought to the attention of the Superintendent. All fasteners shall be restrained using Nyloc nuts. Grating shall be manufactured from galvanised steel for onshore works and aluminium for offshore works. incomplete penetration. Grating shall be fastened at the corner of each panel and at not greater than 600 mm centres to the supporting structural work. replaced and retested. and shall be to the approval of the grating manufacturer. all grating panels shall be fully constrained from movement in the load bar direction. 3. replaced. 3. Notwithstanding any tolerances nominated by the grid manufacturer. the level of NDT for both of the prescribed methods in Table 3-2 shall be increased to 100% for the welds already completed. and no component shall be less than 5mm thick. The layout of the panels shall be such as to facilitate their installation and securing in position by the steel erector. they shall be removed.13 Platforms. slag or other inclusions. The minimum depth of grating shall be 32mm. stairways and ladders All structural steel surfaces intended for walkway access shall be treated with an anti-skid coating in accordance with the Standard Specification – Protective Treatment. it shall be removed for regalvanising after modification and prior to final installation. In any group of steelwork tested. grating shall be considered as structural steelwork. Where grating is required to be modified on site. Site fixing of grating using site welding or site drilled holes and self-tapping screw fasteners shall not be permitted. the proposed repair procedure will induce excessive distortion or residual stresses in the fabricated members.

Grating panels shall be provided with banding bars to all cut edges of grating panels and at notches and penetrations. Grating panels in front of electrical cubicles shall have 3mm thick floor plate continuously welded to the top of all load bars and cross rods. All edges of plates shall be continuously seal welded to the adjoining plate or to the support at a discontinuous edge. bearing blocks). floor plates shall be considered as structural steelwork. The bearing pad shall be wide enough to cover the full width of all supporting steelwork. column flange. The floor plate shall be isolated from the supporting steelwork using Tremco Alta 300-40 tape. a minimum of two keeper bars shall be provided to the underside of each panel edge. Floor plate shall have a non-slip surface provided by a raised angular pattern rolled onto the top surface of the plate. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. All panels of grating shall have edge bars on all sides. and shall be provided in single lengths where possible. stringer legs.5 mm centres.doc 22 March 2012 | Revision 1 Aurecon Page 46 . or approved equivalent.13. The interface between floor plate and supporting steelwork shall be sealed with a continuous bead of flexible sealant (Sikaflex or approved equivalent) to prevent ingress of moisture.2 Floor plate In the sense that it is used elsewhere in this specification. The edge of each panel along the end of the load bars shall be continuously supported on a structural member and the Contractor shall provide all cleats and the like to meet this requirement. All aluminium grid flooring shall be insulated from direct contact with supporting steelwork by 3mm thick neoprene bearing pads bonded to the supporting steelwork. All plate edges which are not supported directly on structural members shall be stiffened. The maximum gap between the face of the keeper bar and the face of the beam flange shall be not more than 10mm. The layout of the plates shall be such as to facilitate their installation and securing in position by the steel erector. Banding bars shall be of the same section as the load bars and fully welded to each load bar. bracing gusset. The thickness of plate nominated on the Drawings shall be exclusive of the pattern thickness. Where specifically noted on the Drawings or otherwise approved by the Superintendent. Steel floor plate shall be precut into shapes and sizes suitable for manhandling and shall be suitably marked or tagged. floor plate shall be bolted to supporting steelwork at 300mm centres using stainless steel countersunk bolts.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd stanchions. 3. Each keeper bar shall be fabricated from 20mm square bar and shall be a minimum of 80mm long to enable continuous shop welding to at least two load bars. Floor plate shall be continuously welded to floor beams so as to provide a flat uniform surface. The face of the bearing pad to be bonded to the supporting steelwork shall be cleaned with toluene solvent and then bonded to the supporting steelwork with an approved contact adhesive applied over the entire contact area. Floor plate panels shall be fabricated and installed so that the horizontal gap between adjoining plates does not exceed 5mm in width and the vertical misalignment does not exceed 2mm.5 mm high at approximately 22. Floor plate in external applications shall be provided with drainage holes (16mm diameter holes on a 500mm x 500mm grid) unless the inclination of the floor plate in its installed position exceeds 5 degrees to the horizontal. The pattern shall consist of regular bi-directional raised ridges approximately 20 mm by 5 mm by 1.

Special bends are defined as bends having a radius of less than 125mm on the centreline of the rail.3 Stairways All stairways shall comply with the requirements AS 1657 and the Building Code of Australia. stair stringers shall be deemed to be structural work. 3. Fixing brackets shall be provided at the top and bottom of the stringers and at intermediate points not greater than 1500mm apart. Sudden offsets in the line of the stanchions requiring unnecessary bends will not be permitted.doc 22 March 2012 | Revision 1 Aurecon Page 47 .13. stanchions. floor plate shall be regarded as structural work. The layout of the handrails and kickplates shall be fully detailed by the Contractor and the shop details shall be submitted to the Superintendent for examination and endorsement in accordance with the requirements for the remainder of the structural steelwork.13.4 Handrails and kickplates In the sense that the term is used elsewhere in this Specification. 3.5 Ladders All ladders required shall be considered as Structural Steelwork The use of ladders shall be avoided where possible and shall only be used where specifically shown on the Drawings or otherwise approved by the Superintendent. The top rail shall be continuous throughout its full length and particular attention shall be paid to the run of the handrail at the top and bottom of each stair flight. For the purposes of protective coating. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. For the purposes of protective treatment.13. Unless otherwise specified and/or shown. Unless noted otherwise on the Drawings.13. Handrailing on stair flights shall be continuous between landings and shall comply with Clause 3. All ladders shall comply with the requirements of AS 1657 and shall. Rails and kickplates shall be supplied by the Contractor in stock lengths with an adequate margin for cutting and waste and they shall be cut and fitted on site by the steelwork erector. The size and spacing of rails. Fixing brackets shall be fixed to the stringers to suit the slope. be fixed at a slope of 15 degrees to the vertical. Ladder and Handrail Details drawing. The shop details shall indicate the layout of the stanchions and the details of their attachment to the supports. stair treads shall be ‘Webforge’ Type T4 (or approved equivalent) heavy duty industrial grating. Bolted connections between handrail stanchions and steel supporting members shall be made using M16 high strength structural bolts.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All floor plate shall be coated with an approved non-slip surface coating in accordance with the Standard Specification – Protective Treatment. and kickplates for two and three rail systems shall be as shown on the Standard Stair. snug tightened. All stanchions and rails shall be galvanised. the run of the rails and kickplates. Handrails shall be a two rail system unless noted otherwise on the drawings. Rungs shall be manufactured from N20 deformed bar in accordance with AS4671 unless noted otherwise on the drawings.4. ladders shall be 400mm wide between 50mm x 10mm stringers with 20mm diameter rungs at centres not less than 250mm nor greater than 300mm. 3. where space permits. Rails shall be sealed at all stanchions on handrails exposed to the weather. handrails and kickplates shall be considered as Structural Steelwork. the location of closure bends between the top and mid rails and of special bends and the method of securing kickplates.

At the top of the ladder the stringers shall in general extend above the landing to handrail height.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd The distance from floor or landing level to the rung of the ladder shall be 300mm at the top and as near 300mm as is practicable at the bottom.14 Monorail beams Monorails shall comply with the requirements of AS 1418 and the relevant statutory authority. Monorails shall be provided at the locations detailed on the Drawings. For the purposes of protective coating. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. Wherever practical.doc 22 March 2012 | Revision 1 Aurecon Page 48 . the centreline of the monorail shall be located over the centre of gravity of the component so that all lifts are vertical only. and return to the landing. including rated capacity. 3. ladders shall be deemed to be structural steelwork. Monorail beams shall be clearly and permanently marked in accordance with the requirements of the relevant standards and statutory authority.

The Contractor shall make proper allowance for 10mm bed and perpend joints and the actual sizes of the manufactured blocks. complete and as shown and/or specified. The Quality Plan and Inspection and Test Plans (ITP’s) shall provide for the Contractor's and the Superintendent's hold points and witness points as necessary. wall ties.3 Masonry units Concrete blocks shall be full height and of the thickness shown on the drawings. The work shall be carried out in accordance with the Quality Plan. grout and concrete infills. the Contractor shall supply a Manufacturer’s certificate in accordance with the requirements of AS 4455. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. 4. lateral restraints. Masonry blockwork 4. halves. 4.doc 22 March 2012 | Revision 1 Aurecon Page 49 . damp proof courses. excepting only such parts as may be expressly modified by this Specification:     AS 4671 – Steel reinforcing materials AS 1316 – Masonry cement AS 3700 – Masonry structures AS 4455 – Masonry units and segmental pavers Blockwork dimensions given on the drawings and in the Specification are “nominal”.5 Manufacturer’s certificate When requested by the Superintendent. Blocks shall be completely protected from the weather both during transit from the manufacturer’s works to the job site and when stored on the site. Blocks shall be standard natural grey in colour and shall be properly cured before deliver to site. mortar. laying.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 4. bondbeam and lintel blocks. either hollow or solid as noted and complete with all special blocks required such as corners. flashings and all accessories necessary for the proper construction of the walls. cleaning down and making good of all masonry construction including masonry units.2 General requirements Materials and workmanship shall comply with the following standards and codes.1 Scope This specification applies to the supply. reinforcement.4 Delivery Delivery shall be made on pallets and shall be unloaded on the site on pallets. Concrete blocks shall have a characteristic unconfined compressive strength not less than 15 MPa at 28 days and shall comply with the requirements of AS 4455. 4. 4.

etc at 600mm centres vertically with 25 x 1.7.7.7.7.7.7. Web cracks which appear on both faces of the web and exceed 24mm in length. Waterproofing admixtures will not be permitted.6mm galvanised steel straps 400mm maximum overall in length. Straps shall be fixed with approved fastenings and built into bed joints. Proprietary fasteners (eg Brunswick Sales or approved equivalent) may be used where appropriate.2 Lime Hydrated lime shall comply with AS 1672.6 Acceptance Only those blocks which pass all the requirements of AS 4455 and which have not been damaged during manufacture or subsequent handling will be accepted for use in the work.7 Straps Where shown on the drawings. 4. 4.6 Mortar Mortar for blockwork generally shall be Class M3. subject to approval by the Superintendent. 4. sharp. Badly damaged edges. 4. having the proportions of 1 part GP or GB cement to 5 parts sand. insoluble in water and free of any deleterious matter. 4. Note that some defects which will not be permitted are:      Face cracks. suitable for human consumption.doc 22 March 2012 | Revision 1 Aurecon Page 50 . Testing of mortar shall be in accordance with AS 2701.1 Cement Cement shall be Type GP complying with AS 3972. prepared in small batches and used fresh.7. well mixed dry in a machine before water is added.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 4. Mortar shall be accurately proportioned. crimped and forked with 75mm turn up. block walls shall be secured to abutting walls.4 Sand Sand for the mortar shall be clean. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. 4. with a methyl cellulose water thickener.3 Additives No admixtures will be permitted except with the written approval of the Superintendent. columns. No hand mixing or retempering of mortar will be permitted. and Excessive variation in colour or toning of the blocks. Lime substitutes will not be accepted.7 Materials 4. Arrises at corners exceeding 6 x 6mm. 4.5 Water Water shall be clean. washed plastering sand.

with no part rising more than 1. and a characteristic compressive strength (f’c) of not less than 20 MPa cylinder. Blocks shall be laid to straight and vertical lines and to layout as shown on drawings. 25MPa cube 28 day strength. No bending schedules will be supplied by the Principal. “Sonolastic Ultra” or approved equivalent.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 4.7. 4. 4.1 Laying of blocks Broken or damaged blocks shall not be used. Blockwork walls shall be laid and grouted in lifts not exceeding 1.5m in height and reinforcement shall be spliced accordingly allowing for a lap length as shown on the drawings. The Contractor shall ensure that the surface on which the base course is laid is clean. lintel beams.8 Grout Grout used to fill cores in reinforced blockwork. The testing of grout shall be in accordance with the relevant provisions of AS 3600 and Standard Specification – Concrete. All cavities shall be cleaned to the approval of the Superintendent prior to grouting and all detritus shall be removed from clean-out blocks provided at the base of all grouted cores. Blocks subsequently damaged after laying shall be cut out and replaced. Sealant material shall be one-part polyurethane. when tested in accordance with AS 1012 Part 3. loose aggregate or anything that will prevent bonding of mortar and the provision of a firm base for the blockwork. 4. All structural reinforcement shall be deformed Grade 500N bar with the exception of 10mm diameter reinforcement which may be round Grade 250N bar. and free from all laitance. Sealants shall be in standard colours to match adjoining surfaces. except for the bottom lift which shall not exceed 2. Steel wire and fabric reinforcement shall be Grade 500L.doc 22 March 2012 | Revision 1 Aurecon Page 51 . bond beams. The maximum aggregate size shall be 10mm.2m in height. The footings shall be checked for vertical and horizontal alignment and any discrepancies corrected before commencing construction of blockwork walls. Tops of all walls shall be covered upon stoppage of work to prevent moisture penetration. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. in accordance with the manufacturer’s instructions and with AS 3700.2 metres above any other position. The grout shall have a slump of 230 +/.7.8 Workmanship 4. piers and similar elements shall consist of cementitious materials and aggregate to which sufficient water has been added to produce a pouring consistency without segregation of the constituents.30mm at the time of pouring.8. All blocks shall be laid dry and stockpiles of blocks on the job shall be well protected from weather.9 Reinforcement All steel reinforcement shall comply with the requirements of AS 4671.7. The grout shall be rodded or lightly vibrated by means of pencil vibrators. Grout shall be kept 50mm below the top of the blockwork for the bottom and intermediate lifts and shall be struck off level with the top of the top lift.10 Caulking and sealants Joint filler shall be “Expandafoam” strip closed cell polyethylene joint filler manufactured by Fosroc Australia or approved equivalent.

fans.8. 4. All cutting shall be done with a masonry saw. Voids behind all fire rated doorframes shall be completely filled with mortar during the building-in process. the bottom course of the wall shall be formed using standard clean-out blocks. cutting of blocks shall be avoided: half.8. chases shall be made with an abrasive saw and chiselled out.doc 22 March 2012 | Revision 1 Aurecon Page 52 .8.8.5 Clean-out blocks Where blockwork is to be filled. All bolts. Where approved. 4. half height and other special block shapes shall be used where applicable. immediately above and below all wall openings and at the bottom and tops of all walls. Where required. with bonded piers where shown on the drawings. straps. or special purpose products. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. for 140mm and 190mm thick concrete blockwork. anchors.3 Bond Walls generally shall be laid in stretcher bond. All bed joints and perpends in fair faced blockwork shall be ironed with a rounded jointing tool to approximately 3mm depth. 4. building-in No chasing shall be done where blockwork is left unrendered. holding down bolts and similar items shall be built in as work proceeds.6 Chasing. The joint reinforcement shall be laid in the longest lengths possible. All holes through walls for air-conditioning ducts. three quarter. joint reinforcement shall be ‘Brick-tor’ joint reinforcement for 90mm thick concrete blockwork and ‘Krimplok’ joint reinforcement or approved equivalent which complies with AS 1303. the face of the concrete shall be rendered to present a uniform finish. Where unreinforced block walls intersect.2 Cutting In general. 4. After stripping. 4. pipes. corner return. made continuous around corners and lapped 300mm at end joints.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd All perpends in external walls shall be fully filled with mortar. Where block surfaces are to be rendered. approved for such a purpose. joints shall be left flush and not ironed. and similar items shall be formed.4 Joints Bed joints and perpends shall be 10mm thick. plugs. Joint reinforcement shall be installed in all unreinforced block walls at a vertical spacing not exceeding 400mm. All fixings into blocks shall be with approved brand plugs of the required sizes. formed up flush with the face of the wall. embedded in mortar or core filling concrete.8. the joints shall be tied vertically at 400mm centres with 400mm long strips of an approved galvanised weld mesh.

shall be constructed where indicated on the drawings. bond beams etc. where necessary. Set work shall be scrubbed down. Mortar shall be prevented from adhering to face of blockwork.9 Temporary bracing Blockwork shall be braced against lateral loads and shall be adequately supported.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 4. 4. No acids shall be used for cleaning. Cavities shall be hosed out each day for inspection by the Superintendent. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. Formwork supporting lintel beams shall not be removed until the in-fill grout is either 14 days old or has reached a compressive strength of 15 MPa.10 Protective treatment Protective treatment systems for Masonry Blockwork are noted on the drawings where required.9 Tolerances All masonry shall be built plumb and true to line and level within the following tolerances:     Deviation from the vertical: 12mm per 4m in height Deviation from line on plan: 6mm per 3m Deviation from plan position: +/.3mm per 3m All other deviations shall be in accordance with the structural tolerances given in AS 3700. whichever is the sooner. 4.8.8. The whole of the blockwork shall be finished clean and free from all defects and stains.8 Lintels Reinforced blockwork lintels.8.12mm Deviation of bed joint from horizontal: +/. 4. 4. but work shall be washed and brushed down after each day’s work.doc 22 March 2012 | Revision 1 Aurecon Page 53 . to ensure its stability at all stages during construction. using clean water only.7 Cleaning down Concrete blockwork shall be kept clean as work proceeds.

Alternative coating systems shall have at least the performance and life as the specified preferred systems. the applicator.masonry. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. unless otherwise noted. Any alternative systems shall be proposed at time of Tender. the surfaces concerned shall be cleaned back to bright metal.1 Extent of work All equipment supplied in this Contract shall be given one of the protective treatments specified in accordance with the table below (Protective Treatment Systems). For the purpose of inspection. All fabricated steelwork in locations enclosed by cladding. Protective treatment 5. the technical representative and of the coating manufacturer and the Superintendent. SYSTEM 9 All externally located cast-in items. Bolts. both on site and in the applicators works. The procedure associated with surface preparation and the application of each coating shall in the first instance be carried out in the presence of the Contractor.2 Inspection The Contractor shall make arrangement with the coating manufacturer for his technical representative to be available for consultation on site and to inspect work.5. and recoated. tiles. when requested by the Superintendent. bronze and aluminium. as directed by the Superintendent.3 Surfaces not to be coated Surfaces not to be coated are:  Stainless Steel  Non Ferrous Surfaces  Building materials. both internally and externally located. data and case histories to enable the Principal to evaluate the proposed system. 5. concrete. Inspection will be carried out in accordance with the recommendations of the Standards Association of Australia’s Code of Practice SAA MA 1.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 5. 5. shall supply all assistance required during the inspection to permit examination. stanchions. SYSTEM 6 All handrails. copper. the Contractor shall give the Superintendent five (5) days written notice of his intentions to apply the paint coats to the steelwork. Protective Treatment System Item SYSTEM 1 All externally located fabricated steelwork. The contractor. If these procedures are not in accordance with the coating manufacturers published data. in conjunction with the Superintendent’s inspector. including hold down bolts. SYSTEM 2 All cast-in items in internal environments. and kickplates. The system to be used for any items not included in the table below will be advised by the Principal or shown on the drawings.doc 22 March 2012 | Revision 1 Aurecon Page 54 . nuts and washers. and shall be supplied with all necessary information. brass.

All work cleaned on one day shall be coated on that day before the dew point is reached and before any contamination or discolouration of the surface can take place and in any case within four (4) hours of blast cleaning. All surfaces shall then be dry abrasive blast cleaned to Class SA 2.4 Appendix C shall be not less than 25 microns or more than 35 microns. Mixing. Abrasive type and size shall be such as to ensure that maximum profile height as measured by AS1627. the surface shall be thoroughly washed with fresh water and reblasted. dust or other contamination by thoroughly washing the surface with Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. An efficient air line filter shall be fitted as closely as possible to the pressure pot to eliminate line condensation and oil in air supply to the spray gun.5 Application Unless otherwise specified all primers and subsequent coats used throughout the contract shall be applied according to the manufacturer’s recommendations. shall be to the Superintendent’s approval.4.4 Surface preparation All rough edges. Sharp irregularities in the welds and all slag and spatter and weld dags shall be removed by appropriate means. the entire primed surface shall be cleaned of all dirt. If sand is used as an abrasive.5 as defined by AS1627. burrs etc. this is an indication that the surface contains salts.doc 22 March 2012 | Revision 1 Aurecon Page 55 . Under these circumstances. All equipment. ie. If necessary. All steel surfaces to be coated which show traces of oil. Mating surfaces of friction grip connections shall be SYSTEM 2 only. including receptacles. it shall be dustless and its salt content shall be not more than 50 parts per million. Any blasted area not coated within the above specified times shall be reblasted to the satisfaction of the Superintendent before coating application.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Areas to be field welded shall be masked after blasting to leave a 50mm unprimed margin. c) When the relative humidity of the surrounding air is greater than 85%. grease or other contamination shall be thoroughly cleaned by an approved solvent washing and washed with clean water before commencing blast cleaning. All surfaces to be coated shall be completely dry and free from all oil. Particular care shall be taken to ensure that spent abrasive material and other foreign matter is not allowed to impinge on and adhere to freshly coated surfaces. d) When the surface metal temperature exceeds 50 deg C or is lower than 10 deg C.1. b) On surfaces where condensation is likely to form. Degreasing after blasting shall be in accordance with AS1627. which will be detrimental to the paint coating. and other foreign matter at time of coating. 5. Work shall not be performed in the following circumstances: a) If the surface is wet or likely to become wet after blasting or before or during application of prime coating or top coating. when the surface temperature of the steel is less than 3 deg C above the dew point of the surrounding air. A further 50mm of primer shall be masked before top coating to facilitate final touch up of field welds. Where a surface shows discolouration within a short time after blast cleaning. thinning and application instructions as nominated by the coating manufacturer shall be absolutely adhered to and no other addition to the mixed coating shall be used. the procedure may need to be repeated. shall be ground smooth. Where a primer surface has become dusty prior to application of the topcoats. 5. dust.

Where the installation of plant. Further to the requirements of AS 1250. to comply with recommended maximum recoat times. 5. be cleaned as specified and protected by an approved brand of corrosionresistant material compound which can be readily removed prior to erection of the steelwork. at his own expense. unprimed areas of steelwork shall.doc 22 March 2012 | Revision 1 Aurecon Page 56 . shall be removed so as to leave the site and all adjacent structures in a clean condition acceptable to the Superintendent. The Contractor shall provide. in shop application of a mist coat shall be required. Maximum interval between successive topcoats shall be in accordance with the Manufacturer’s recommendations but in no case shall be more than 48 hours. Personnel with shall perform all coating operations in a neat and workmanlike manner proven experience in the field. The surface shall be flushed off with clean fresh water and allowed to dry before application of the topcoat.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd clean water and/or degreasing solution and scrubbing with a nylon bristle brush or other method as recommended by the paint manufacturer. In the case of the polyurethane gloss finish. free from runs and sags and shall be allowed to dry and/or cure in accordance with the manufacturer’s instruction.9.6 Top coats Topcoats shall be as specified with each system. the dry film thickness shall be achieved using a mist coat and multi-passes. Clause 11. all paint spots. the surface shall be washed with copious quantities of fresh water and allowed to dry before application of that coat.3. The Contractor shall also provide. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. such equipment and take such measures as are necessary for the adequate protection of adjacent structures. In the case of high build epoxy paints. At the completion of the Contract. Where polyurethane gloss finish is to be field applied subject to the approval of the Superintendent. such equipment and to take such measures as are necessary to obviate health hazards arising from the use of specified paints and coating materials and to satisfy all requirements within the trade. stains. at his expense. the surfaces that will be inaccessible shall be finish coated prior to erection or installation of plant. The Principal shall confirm the required colour. if necessary. All maximum and minimum recoat times given are for average temperature and humidity conditions and are subject to change under extreme conditions. A minimum of 24 hours shall be allowed for curing after application of a topcoat before applying further coats or 4 days before transporting or erecting. before being transported to site. flooring and/or similar items will prevent surfaces from being satisfactorily coated after erection. If the presence of salt is indicated on the primer surface or on the surface of a previous topcoat prior to application of any topcoat. etc. permanent plant and coating operations.. Each coating shall be uniform. the coating thickness specified may not ensure total hiding of the intermediate coat colour. For both spray and brush application it may be necessary to apply two coats to ensure total hiding.

for the particular information relating to mixing. If applying the system by brush/roller it may be necessary to apply additional coat(s) so as to achieve the nominated dry film thickness. the topcoat shall be sanded back to a feathered edge and recoated as for the original topcoating. at site welds or at damaged paintwork or galvanized surfaces. i) Flaking. It shall cover all breakdown of the coatings due to inferior materials and/or workmanship but not that due to fair wear and tear or damage. Breakdown or failure of the coating system shall be deemed to have occurred if any of the following definitions have been reached. and the primer surface is undamaged. blistering. application. general rusting (6-G). or pinpoint rusting (6-P). The period of the warranty shall be for five years from the date of Practical Completion and shall be in a form approved by the Superintendent. Where the substrate temperature and/or the relative humidity is outside those stated on the data sheet.5) and de-grease. drying. curing and recoating. exceeds 1% as defined in SSPC-Vis 2 (2000) Rust Grade 6). apply zinc rich epoxy primer to dry film thickness not less than 75 microns.  Apply the original primer to the specified primer coat thickness or. the minimum/maximum recoat times will change.doc 22 March 2012 | Revision 1 Aurecon Page 57 . which has been damaged. 5.7 Warranty The Contractor shall provide a full warranty on all coating materials and workmanship in the name of the Employer.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 5. for spot rusting (6-S). The coating should be feathered back around the cleaned area. the coating shall be reinstated to the original standard:  Blast clean back to bare metal (Class 2. If the damage is confined to the topcoats only.9 Protective coating systems The following standard protective coating systems shall be used for the areas specified in each system. Refer to the manufacturer’s technical data sheet for the relevant products before use. upon request. cracking or loss of adhesion which affects more than 1% as defined in SSPC-Vis 2 (2000) Rust Grade 6) of the surface of a contiguous area. in the case of the galvanized surface. The particular manufacturer/s coatings specified shall be used unless specific approval is given by the Superintendent to use an alternative. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. ii) Corrosion of the substrate as an average measured on any contiguous area.8 Repair of painted damaged coatings After erection. the primer surface at the damaged area shall be reinstated as specified elsewhere and then be topcoated in accordance with the procedures for original topcoating. 5. Material safety data sheets are available from the manufacturer. Where an item which has been partially or fully topcoated is subject to coating damage.

Surface preparation:  Abrasive blast all surfaces to a minimum Class 2½ blast as per AS1627.9.  Grind all sharp edges and corners to a radius of 2mm.  Remove all blast residue. spatter. Surface preparation:  Abrasive blast all surfaces to a minimum Class 2½ blast as per AS1627.  Remove all salt deposits. and grind all welds and high spots smooth. oils.1 to remove all grease. and grind all welds and high spots smooth. surface profile of 4070 microns. etc. A surface profile of 4070 microns shall be achieved.doc 22 March 2012 | Revision 1 Aurecon Page 58 .GPM Gold Project Technical Specification XSTRATA technology Pty Ltd 5. etc.4. Maintenance Platforms Service conditions: External: Industrial / Marine Pretreatment:  Degrease surface using biodegradable degreasing solution as per AS 1627.2 System 2: Inorganic Zinc Item/Location: New Mild Steel. Externally Located Structural Steel. (µm) 1st Coat Sigma EP Universal Primer LT 75 2nd Coat Epinamel HSE 707 175 3rd Coat Paracryl IFC 50 Maintenance: Refer Protective Treatment Maintenance System M1 5. fats. Any surface showing flash rusting shall be re-blasted to a minimum Class 2½. spatter.  Remove all blast residue. fats. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1.1 System 1: Epoxy Primer plus HS Epoxy and Recoatable Acrylic Item/location: New Mild Steel. Internally Located Structural Steel / Silo Roof Support Beams Service Conditions: External: Industrial / Marine Pretreatment:  Degrease surface using biodegradable degreasing solution as per AS 1627. A surface profile of 4070 microns shall be achieved.  Remove all weld slag.  Grind all sharp edges and corners to a radius of 2mm. and before any flash rusting is evident. surface profile of 4070 microns.  All blasted surfaces shall be coated within four (4) hours.  Remove all weld slag. Coating System: Dry film thickness min.9.  All blasted surfaces shall be coated within four (4) hours.  Remove all salt deposits. Any surface showing flash rusting shall be re-blasted to a minimum Class 2½.1 to remove all grease. and before any flash rusting is evident. oils.4.

Service Conditions: External: Industrial / Marine (Up to 200°C) Pretreatment:  Degrease surface using biodegradable degreasing solution as per AS 1627. Galvanizing + Epoxy Primer & Recoatable Acrylic Item/Location: Hot Dipped Galvanized Mild Steel as per System 9.9. (µm) 1st Coat Sigma EP Universal Primer LT 75 2nd Coat (1. – Remove all salt deposits. spatter.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Coating System 1st Coat Galvit ES510 Maintenance: Dry film thickness min.) Paracryl IFC 50 Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. – All weld slag. etc. fats.  Inspect and ensure: – Remove all weld slag. (µm) 50 5.1 to remove all grease. Coating System 1st Coat Galvit EP102 Rapid Recoat Dry film thickness min.  Inspect & ensure: – All sharp edges and corners are ground to a radius of 2mm. All Handrails. (µm) 75 Refer Protective Treatment Maintenance System M13 5. etc. Kickplates & other galvanized items where colour is required.1 to remove all grease. and grind all welds and high spots smooth. Feather back repair edge to a sound surface. fats.  Solvent wipe using Wattyl Thinner 91-92 immediately prior to spot priming.  Vacuum / dust down to remove preparation residue.  Vacuum / dust down to remove preparation residue.doc 22 March 2012 | Revision 1 Aurecon Page 59 . Coating System Dry film thickness min. and zinc dags are removed. oils. Surface preparation:  Abrade surface using P80 grit paper/disc to produce a roughed surface. – Remove all salt deposits.D. oils.4 System 6: H.9.3 System 3: Galvanized Touch-up Item/Location: Damaged Galvanized Surfaces Touch Up for Galvanized Bolted Connections Service Conditions: External: Industrial / Marine Pretreatment:  Degrease surface using biodegradable degreasing solution as per AS 1627. Surface preparation:  Mechanically abrade the entire surface using P80 grit paper/disc to produce a roughed surface. spatter. and all welds and high spots are ground smooth.

doc 22 March 2012 | Revision 1 Aurecon Page 60 .4. Design of all hardware to be galvanized shall conform to the procedures set out in Appendix A of AS1650. and at their cost prior to delivery to the galvanizing shop. Project 226767 | File 226767 GPM Gold Project Technical Specification rev 1. dross and projections.9. black spots. The zinc coating shall be free from blisters. all items shall be cleaned of paint. Class 2.GPM Gold Project Technical Specification XSTRATA technology Pty Ltd Maintenance: Refer Protective Treatment Maintenance System M15 5. buffing and chipping. by the Fabricator or Supplier. Where these substances are not satisfactorily removed by degreasing. Where welding is necessary after galvanizing. grease. Ductwork. Bolts. oil. Gridmesh. welding slag and spatters and any other substance not readily removed by the normal cleaning methods used in the galvanized trade. which will interfere with the proper use of the article or other defects not consistent with good galvanizing practice. Floor Plate.5 System 9: Hot Dipped Galvanizing Stair treads. flux. the affected areas shall be surface prepared and touched up using System 3. Nuts and Washers Before delivery to the galvanizing shop. grinding. All items shall be hot dip galvanized to AS 1650 to provide a minimum of 600g/m3 zinc coating. the Superintendent may require a partial or complete abrasive blasting of these items to AS 1627. Ladders. The galvanized articles shall be free from uncoated spots. Piping.