Bidding Documents

Construction of the New Fuel Unloading Facility
at the Free Port of Monrovia, Republic of Liberia
Contract No.: MPW-IIU/URIRP/FUF-LPRC/001/’11

December 2011

Part 2
Section VI – Employer’s Requirements
Table of Contents

Contents
1

INTRODUCTION

7

2

FUNCTIONAL REQUIREMENTS
2.1
General Criteria and Site Data
2.1.1
Design Life
2.1.2
Units
2.1.3
Standards and Codes of Practice
2.2
Site conditions and Environmental data
2.2.1
Materials and Workmanship
2.2.2
Durability
2.3
Marine structures
2.3.1
General Criteria for Marine Structures
2.3.1.1
Design Vessels
2.3.1.2
Seismic design
2.3.1.3
Analysis
2.3.1.4
Pile Design
2.3.1.5
Mooring Lay-out
2.3.2
Unloading platform
2.3.3
Access trestle
2.3.4
Breasting dolphins
2.3.4.1
Fendering
2.3.5
Mooring dolphins
2.3.6
Catwalks
2.3.7
Pump house
2.3.8
Miscellaneous Items
2.3.8.1
Services and utilities
2.3.8.2
Jetty Lighting
2.3.8.3
Aids to Navigation
2.3.8.4
Corrosion Protection
2.3.8.5
Hose Area and Manifolds
2.3.8.6
Reference coordinate for the position of the main jetty
2.3.9
Dredging works
2.3.10
On shore facilities
2.3.11
Existing facility
2.4
Mechanical and electrical Functional Requirements
2.4.1
General Requirements
2.4.1.1
Design life
2.4.1.2
Standards and Codes of Practice

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16 Site Access 4.3 2.1.2 Issue of Design Submissions 3.1 Site Safety 3.24 Records 47 47 47 47 48 48 48 48 48 49 49 49 50 50 50 50 51 51 52 52 52 52 52 53 53 53 4 .15 Tidal Levels 4.19 Traffic Safety Measures 4.1.4.4 Use and Care of Roads 4.5 Disruption to Neighbouring Works 4.4.8 Contractor’s Laboratory 4.1. Etc.4.23 Scaffolding 4.6 Setting Out 4.1. Water and other Services 4.3 Technical Specifications 3.1.1.4.3 Employer’s Regulations on Site 4.10 Site Cleanliness 4.1 General specifications 4.1.1 Performance testing and Equipment manuals Trestle Pipe Rack Platform Equipment Fire Fighting Corrosion Protection Electrical Works 35 35 36 37 38 39 3 GENERAL EMPLOYER’S REQUIREMENTS 3.22 Removal of Public Utility or Privately Owned Services.1.1.1 Facilities for Personnel 4.3 Training 3.4 Personal Protective Equipment 3.1.1 Project Execution 3.11 Access for Third Parties 4.1.1.6.14 Port Operations and General Information 4.2 Safety Plan 3.1.1.17 Radio Communication 4. 41 41 41 42 42 43 43 43 44 44 45 45 46 46 46 46 46 47 4 TECHNICAL SPECIFICATIONS 4.12 Electricity.4 Construction Drawings 3.1.4 Contractor’s Design and Documentation 3.4.1.21 Existing Services 4.5 2. Etc 4.3 Environmental Compliance 3.4.7 Facilities for Employer’s staff 4.1.4.1. Motorized Rescue Boat.1 Contractor’s Design Submissions 3.5 Progress Control 3.4.13 Publicity and Public Relations 4.4.6.1.4 2.3 2.5 Life Lines.6.6.2 Safety and security of the Site 4.9 Testing of Materials and Workmanship 4.2 Quality Assurance 3.1.1.2 2.2.1.20 Temporary Approaches & Diversion of Existing Rights of Way 4.5 “As-built” Drawings and Final Calculations 3.1.6 Health and Safety 3.18 Restriction on Use of Public Roads 4.1.1.4.6 Operation and Maintenance Manuals 3.5.6.

2 4.1.1 4.1.29 4.43 4.3. Marking.4 4.1.3.2.3.2 4.28 4.3.5 4.1.2.1.8 4.35 4.9 4.8 4.2.32 4.3.27 4.4 4.10 4.1.2.3.41 4.2.1. Handling and Storage of Materials Construction Plant Defective Work Surveys Dredging General Dredging Plant Dredging in Any Materials Tide Levels Position Controls Survey Dredging Tolerances Side Slopes Disposal of Dredged Material Siltation Sweeping Daily Records Existing Operation Method Statement Piling Work General Materials Handling and Storage of Piles Fabrication and Splicing of Steel Piles Pile Identification Damage to Piles Pile Design Piling Method Statement Installation of Tubular Steel Piles Tolerances Preparation of Pile Heads Piling Programme Records Obstructions Reinforced Concrete Riling Pile Testing Dynamic Pile Testing 5 53 53 54 54 54 55 55 55 55 55 56 56 56 56 56 57 57 57 58 58 58 59 59 59 59 60 60 60 61 61 61 62 62 62 62 62 63 64 64 66 66 66 67 68 69 69 70 70 71 71 71 77 .3 4.9 4.26 4.1.1.1.2.37 4.1.39 4.1 4.2.1.15 4.3.2 4.38 4.25 4.36 4.11 4.12 4.3 4.12 4.14 4.13 4.3.3.7 4.30 4.3.3.11 4.16 4.1.1.7 4.33 4.1. Buoying and Watching Navigation Liability for Damage to Shipping Floating Plant Avoidance of Nuisance Underwater Obstructions Temporary Moorings Port Charges Radio Transmissions Diving Removal of Sunken Vessels and Offshore Plant Debris in the Sea Existing Ground Levels Emergency Arrangements Delivery.1.17 Port Regulations Lighting.42 4.31 4.2.3.3.34 4.2.4.2.6 4.3.3.3.6 4.1.2.2.1.13 4.40 4.2.2.1.10 4.3.14 4.5 4.3 4.

16 4.6.32 4.22 4.19 4.4.5.6.9 4. Storage and Transport Fabrication of Steelwork Erection of Structural Steelwork Tolerances Testing and Inspection of Steelwork Miscellaneous steelworks Corrosion Protection Structural Steelwork Schedule of Colour Finishes Protective Treatments Painting Safety Storage of Paint 6 77 78 78 78 79 80 81 82 82 82 82 83 84 86 87 87 87 88 89 90 92 92 93 93 94 94 95 95 95 95 96 96 97 97 98 100 100 100 101 103 104 109 110 112 115 116 116 117 117 117 118 118 .6 4.3 4.4.5.6.27 4.4.4.31 4.23 4.General Materials Documentation and Submissions Handling.26 4.5 4.3 4.4.8 4.15 4.6.4.1 4.4.4.5.4 4.4.4.7 4.30 4.20 4.33 4.4.6 Pile Anchors Concrete Works General Cement Aggregates Silica Fume for Concrete Admixtures Storage and Delivery of Aggregates Washing of Aggregates Water Concrete Trial Mix and Workability Production and Delivery Ready Mixed Concrete Placing Blinding layer Curing Concreting in Hot Weather Testing Formwork Embedded Articles Surface Finish Reinforcement Bending of Reinforcement Welding of Reinforcement Placing of Reinforcement Cover to Reinforcement Cutting Concrete Faulty Works Joints Tolerances Precast Concrete Method Statement Bedding of Precast Units Waterproofing Structural Steelwork Steelwork and Connections .4.4.4.5.4 4.4.10 4.6 4.4 4.4.6.3 4.7 4.13 4.2 4.29 4.4.12 4.4.4.4.4.8 4.6 4.4 4.4.4.4.14 4.9 4.28 4.5.5.4.25 4.18 4.1 4.4.2 4.4.5 4.1 4.4.4.21 4.4.5 4.5 4.17 4.3.4.2 4.4.18 4.5.11 4.5.4.5.6.24 4.4.

7.7.9.8.11 4.7.1 4.6.6.6.10 4.6.7 4.9 4.7.6 Sampling and Testing Paint Trial Prepared Surfaces Preparation of Bare Metal Surfaces Paint Preparation Paint Application Shop Painting Storage of Steel and Fabricated Steelwork Metal Coatings Handling of Coated or Painted Steelwork Repairs to Damaged Area Bolted Connections Welded Joints Treatment of Completed Joints Fixtures and Fittings General Miscellaneous Metalwork Life-Saving Equipment Metal Decking Fendering Quick Release Mooring Hooks Bolted Connections Tide Gauges Navigation Lights Depth Contour Buoys Drainage and Services Floor Drains Jetty Cable Ducts Ducts Geotechnical Investigation Boring activities Boreholes Marine Equipment Laboratory Analyses Deliverables References 118 119 119 120 121 121 123 123 123 124 125 125 125 126 126 126 126 127 127 127 128 130 130 130 131 131 131 131 132 132 132 132 133 133 133 133 5 DRAWINGS 133 6 SUPPLEMENTARY INFORMATION 134 7 ANNEX 1 ESTIMATED BILL OF QUANTITIES 134 1 INTRODUCTION Part 2 of the Bidding Documents set out the Employer’s Requirements.9.7 4.1 4.9 4.6.10 4.6.14 4.6.18 4.9 4.7.15 4.19 4.4 4.6.8 4.8 4.6.6.8. These requirements are divided in the following items: Chapter 2 Functional Requirements This is a description of the works 7 .7.6.5 4.2 4.7.8 4.2 4.4 4.3 4.1 4.5 4.9.3 4.8.16 4.9.12 4.7 4.3 4.7.4.6.6.9.13 4.6.7.2 4.7.9.17 4.6 4.20 4.

Chapter 3

General Specifications
This includes requirements with respect to the project execution, quality assurance,
environmental protection, design and the submission of design information to the
Employer, progress control and health and safety

Chapter 4

Technical Specifications
This describes the material and workmanship specifications

Chapter 5

Drawings
The reference design drawings are included in this chapter, presenting the reference
design for bidding purposes

Chapter 6

Supplementary Information
Reference documents are included in this chapter

2

FUNCTIONAL REQUIREMENTS

This part of the Bidding Documents sets out the performance specifications and design criteria the
Contractor shall follow. This includes both the functional requirements for the civil and marine works,
and the requirements for the mechanical and electrical works.
The civil and marine works are described in chapter 2.3, followed by the mechanical and electrical
works in chapter 2.4.
The new fuel unloading facility (FUF) shall be designed for the import of gasoil, gasoline and Jet A1 /
Kerosene.
The overall scope of work includes the detailed design and construction of the following main
components of the new FUF:
 The unloading platform
 The access trestle
 The breasting dolphins
 The mooring dolphins
 The catwalks
 The pump house
 Dredging works
Based on the functional requirements a reference design is prepared for the new fuel unloading
facility. The following drawings describe the reference design. These drawings are included in
Chapter 5 of this part of the Bidding Documents.
9V1468.03.001 General Layout Existing Situation
9V1468.03.002 Jetty Layout
9V1468.03.003 Loading Platform Layout and cross sections
9V1468.03.004 Access Trestle Layout and cross sections
9V1468.03.006 Pump House Platform Layout and cross sections
9V1468.03.007 Pump House Building Layout, cross sections and views
9V1468.03.008 Electrical Systems
9V1468.03.009 Flow Diagram
9V1468.03.010 Mooring Dolphins Layout and views

8

9V1468.03.011 Breasting Dolphins Layout and views
It must be noted that this reference design is for bidding purpose only. The Contractor may use this
design as reference for the preparation of his design. Ultimately, the Contractor will become fully
responsible for the input data used and for the design of the FUF.

2.1

General Criteria and Site Data

This chapter gives an overview of the general design criteria for the detailed design and construction
of the civil works of the new FUF. This includes:
 Design life
 Standards and Codes to be adopted
 Site conditions and environmental data
2.1.1

Design Life

The design life is defined as the period for which structural elements, services, drainage systems,
etc. are to be used for their intended purposes with acceptable maintenance, but without major repair
and/or replacement being necessary.
At the end of the design life the structures shall comply with the design ultimate and serviceability
limit states. Due regard shall be given in design to any corrosion loss during the design life.
Design life for the Works is defined in the table below.
Element

Design Maintenance Routine Maintenance Unacceptable Repair
Life
Interval
by Employer
or Maintenance

Buildings,
including services
and utilities

50 years

5 years

Routine inspection of
services and utilities.
General repairs and recoating

Replacement and repair of
walls, roofs, floors and
foundations required for
structural integrity

Slopes and
revetments

50 years

15years

Routine inspection and
replacement of minor rock
damage

Steelwork

50 years

15 years

Re-coating of protective
treatment systems

Fencing, barriers
and gates
Marine structures
– reinforced
concrete

50 years

15 years

50 years

50 years

Replacement of corroded
mesh & straining wires
None

Replacement or re-grading
of rock armour, involving
damage exceeding 5% of
revetment area. Repair of
slumping
Cutting out/replacement of
defective/corroded steel.
Welding of steel plates
onto existing steel
structures/elements
Replacement of posts &
foundations
Cutting out/replacement of
defective/spalled concrete
and corroded
reinforcement

Other concrete
work

50 years

25 years

Routine inspection of top
surface, visible and
accessible parts

9

Cutting out/replacement of
defective/spalled concrete
and corroded

Element

Design Maintenance Routine Maintenance Unacceptable Repair
Life
Interval
by Employer
or Maintenance
reinforcement
Cutting out/replacement of
defective/corroded steel.
Welding of steel plates
onto existing steel
structures/elements;
Replacement of cabling or
bonding.

Marine structures 50 years
– steel piling;
cathodic protection

20 years

Re-coating of protective
treatment system;
Replacement of anodes,
power supplies

Other piling works/ 50 years
foundations

25 years

Routine inspection of
surface, visible and
accessible parts

Corrosion
10 years
protection (coating
of piles)
Pavements
50 years

5 years

Routine inspection of
Replacement of coating
coating and repairs after
damage
Repair of localised damage Any removal/ replacement
to correct out of tolerance
settlement

2.1.2

20 years

Cutting out/replacement of
concrete or steel elements

Units

Metric units shall be used, in accordance with the Système International d'Unités (SI).
2.1.3

Standards and Codes of Practice

Wherever reference is made in the Contract to specific standards and codes to be met by the goods
and materials to be furnished, and work performed or tested, the provisions of the latest current
edition or revision of the relevant standards and codes in effect shall apply, unless otherwise
expressly stated in the Contract. Where such standards and codes are national, or relate to a
particular country or region, other authoritative standards that ensure a substantially equal or higher
quality than the standards and codes specified shall be accepted subject to the Project Manager’s
prior review and written consent.
Differences between the standards specified and the proposed alternative standards shall be fully
described in writing by the Contractor and submitted to the Project Manager at least 28 days prior to
the date when the Contractor desires the Project Manager’s consent. In the event the Project
Manager determines that such proposed deviations do not ensure substantially equal or higher
quality the Contractor shall comply with the standards specified in the documents
The design shall comply with the latest versions of internationally recognised codes of practice such
as the Eurocodes (EN), the British Standards (BS) or the German Codes (DIN). Where the British
Standards referred to in these Bidding Documents are superseded by Eurocodes, the equivalent
Eurocodes (with British National Annexes) shall be used.
The Contractor shall confirm the codes and design standards proposed for the works prior to starting
the design. The codes and design standards shall be subject to the approval of the Employer.
It shall be the responsibility of the Contractor to ensure that the codes and design standards used
shall fulfil the mandatory minimum requirements of Liberian Codes of Practice.

10

Materials and Workmanship: The design and construction of all buildings shall generally be in accordance with Part 2 Chapter 4 of these Bidding Documents unless otherwise approved by the Employer.0m and is sloping up towards the south breakwater (first 50m 1v:10h and further 1v:70h). Foundations: Eurocode 7: Geotechnical design BS8004: 1986: Foundations. Design of concrete. 2001 (WG34) and ‘Performance-Based Seismic Engineering of Buildings’. Item Reference Level Coordinate System Bathymetry and Design levels Specification The Chart Datum (CD) is Mean Low Water Spring (MLWS) UTM coordinates (WGS84) shall be used. Part 1 Steel Structures Design: Eurocode 3: Design of steel structures BS 5950: Structural use of steelwork in buildings. The current bottom level at the fender line of the existing jetty is CD -10. Jetties and Dolphins BS6349: Maritime structures. 11 . Minimum factor of safety for foundations shall be 2. PIANC Working Group 34. SEAOC.6m/s2. (refer section 2. including environmental conditions. Part 1 – General Criteria BS6349: Maritime structures.2 Site conditions and Environmental data Relevant site data.1. Site Data) The seismic design of the jetty structure and its components shall be carried out using performance-based design methods as described in the ‘Seismic design guidelines for port structures’. 2. Marine Structures BS6349: Maritime structures. Version 2000 Committee. Part 1 – Fendering and Mooring Seismic Loads: Eurocode 8: Design of structures for earthquake resistance Design of all buildings and foundations shall include seismic loadings. is summarized in the following table. The peak ground acceleration is 0. in accordance with the seismic hazard map. steel and foundations: Eurocodes including but not limited to: 1990 Eurocode 0 Basis of design 1991 Eurocode 1 Actions on structures 1992 Eurocode 2 Design of concrete structures 1993 Eurocode 3 Design of steel structures 1997 Eurocode 7 Geotechnical design 1998 Eurocode 8 Design of structures for earthquake resistance Reinforced Concrete Design: Eurocode 2: Design of concrete structures BS 8110: Structural use of concrete. Foundation design shall allow for the possible settlement of the existing fill and shall limit settlement to prevent damage to the structure.3 of this part.A suggestion for codes to follow is given below. Part 2 – Quay Walls.5.

The bathymetry is also shown on reference drawing 9V1468. topographic etc) is provided without warranty regarding accuracy. For the design a Peak Ground Acceleration (PGA) at bedrock level of 0. The design bottom level will be CD -15. there is a possibility of the presence of bedrock below 30m depth. clay. In his tender submission the Contractor shall provide details of the testing that he intends to carry out. These additional geotechnical site investigations are included in the scope of work in order to determine the local soil conditions and design parameters for the foundations. A copy of the survey results is presented in Chapter 6 for information purpose. The Contractor is required to check and confirm accuracy before commencing the Works. Any reduced accelerations based on local seismic hazard data may be used after approval by the Employer.6m/s2 shall be used.0m. It is the responsibility of the Contractor to provide a design which will accommodate the ground conditions as encountered during investigation and construction. The Contractor shall undertake further surveys as he deems necessary. Earthquake Monrovia is located on a transition of green and dark green area on the GSHAP map of the UN for Africa. silt and sand over the first two meters. till the existing bottom profile is reached. In addition.Item Specification A survey has been performed by the Royal Dutch Navy in December 2009. Details of this investigation are included in Chapter 6. 12 .0m at the fender line of the new FUF and sloping up with 1v:5h.03/001 Construction bottom level of the new FUF will be CD -11. Soil Conditions At the location of the new FUF the top layer consist of mud. Geotechnical investigations were carried out in 1978/79 by Rhein Ruhr Ingenieur Gesellschaft Mbh. refer to the seismic hazard map on the following page. The Contractor shall be responsible for the interpretation of this data and shall confirm the soil conditions by performing additional soil investigations before commencing the Works. This and any other survey information (bathymetric. Sloping up with 1v:5h till the existing bottom profile is reached. In deeper layers sand mostly prevails.

Highest High Water (HHW): CD +1.57m .Mean Sea Level (MSL): CD +0.00m . Tp = 5s – 10s Extreme condition: Hs = 1.50m Storm set up A storm set up of 0. Tp = 5s – 10s Currents Current conditions inside the port: ≤ 0.10m Long term sea level rise years SLR Average SLR Upper limit Sea Level Rise (SLR): 5 10 25 0.0m.Lowest Low Water (LLW): CD -0.18m 0.5m. Waves Wave conditions inside the port area: Operational condition: Hs = 0. At higher wind speeds the tankers will no longer be moored at the new FUF.Item Specification Tidal levels The following tidal levels apply: .02m 0. A maximum stay-at-berth wind speed of 17m/s must be considered for the design.13m 1 0.1m/s 13 .01m 50 0.09m 0.70m .03m 0.04m 0.35m 0.00m 0.50m shall be taken into account in the design Wind Limited information is available for wind speeds across the project area.05m 0.25m 100 0.Mean Low Water Spring (MLWS): CD +0.

2 Durability All structures shall be designed to meet the durability requirements set forth in the Bidding Documents and the Codes used. Relevant extracts from the report are included in Chapter 6. wind and waves. The Contractor will be responsible for the interpretation of this data and shall confirm the information by performing additional (site) investigation. 2.1 Materials and Workmanship Materials.3. The design of the concrete mix for all structures shall take account of the location of the Site and the nature of the products to be handled over the jetty.1 General Criteria for Marine Structures Within this section. the Functional Requirements for particular elements of the marine works are set out based on the following subheadings as appropriate:  Work Scope  Function  Particular Requirements All items within each section shall be taken into account both individually and in combination in order to achieve the required finished product.2.3 Marine structures 2. All steelwork shall have a suitable corrosion protection system capable of achieving the required design life. equipment and workmanship including testing shall conform to the following:   The latest revision of the applicable standards The minimum requirements stated in the Materials and Workmanship Specifications contained within Part 2 Chapter 4 of the Bidding Documents. such as silica fume. In case of discrepancy the more onerous requirements shall govern. Full details are available to view in the Employer’s office. 2. This shall consist of a coating.The report mentioned for the soil investigations that was produced in 1978/79 by Rhein Ruhr Ingenieur Gesellschaft GmbH.2. 14 . The detailed work scope and function for the individual elements are included in separate sections below. a corrosion allowance on the steel thickness. galvanising. cathodic protection. also contains information with respect to the tides. 2. designed to reduce the porosity of the concrete. or a combination of these. The concrete mix shall include suitable additives.

0 50.460 1.Ballasted Condition .5 13.4 32.8 12.0 173.0 30.090 1.8 7.830 1.2 18.000 40.2 14.3 4.1 25.0 35.0 216.000 79. WG33.600 196.8 9.9 3.4 5.000 27.1.0 189.0 6.800 180.3 5.0 40.5 2 1. Guidelines for the design of fender systems.000 223.3 2.2 3.7 7.Ballasted Condition .0 20.The main structural elements are:  The unloading platform  The access trestle  The breasting dolphins  The mooring dolphins  The catwalks or access walkways  The pump house  Dredging works The other elements include.010 2.400 211. table C1.3 17.8 10.000 DWT.9 30. Dead Weight Tonnage Displacement Length Overall Length Between Perpendiculars Breadth Depth Ballasted Draught* Loaded Draught Ballasted Freeboard* Loaded Freeboard* Wind Lateral Area .650 1.6 8. The design vessels presented in the following table are taken from PIANC Report nr.090 688 1.000 53.  Pile design  Fendering  Mooring The design criteria to be used for the structures are stated and the design requirements for particular elements including are given.9 6.300 127.270 2.8 7.0 151.0 60.4 3.3.700 158.8 16.870 2 303 255 443 355 554 430 644 489 734 548 809 595 [m ] 2 [m ] [m ] 2 [m ] * Estimated values .0 [m] [m] [m] [m] [m] [m] 20.1 Design Vessels The new FUF shall be designed to accommodate tankers ranging between 10. 2.000 66.9 11.Full Load Condition Wind Front Area .2 8.0 204. 2002.3 9.4 10.2 29.6 9.8 8.Loaded Freeboard = Depth – Loaded Draught .690 3.150 1.6 9.Ballasted Freeboard = Wind Lateral Area Full Load Condition / Wind Lateral Area Ballasted Condition * Loaded Freeboard 15 .000 14. Appendix C.2 12.Full Load Condition [te] [te] [m] [m] 10.0 121.6 5.480 2.000 DWT and 60.

Guidance on damage criteria can be obtained from WG34.3g for a return period of 72 years.6g for a return period of 475 years. the peak horizontal ground acceleration at rock head level shall be taken as 0. 2..Ballasted Draught = Depth – Ballasted Freeboard 2. For the Level 1 event.3.1.2 Seismic design In accordance with the definitions of the Level 1 and Level 2 seismic events given in WG34 (Pianc). reduction in overall stability and reduction in strength of primary load bearing elements shall not be permitted.3 Analysis The following requirements make reference to Eurocode and Pianc guidelines. equivalent to a 10% probability of exceedance in 50 years. For the Level 2 event. Should the Contractor adopt alternative codes of practice for the design the design submissions shall contain a table 16 .3. these terms can be further defined as follows:  Serviceable – ship loading operations can recommence immediately after the seismic event while minor repairs are carried out  Repairable – the structure can be reasonably repaired and restored to operation in a reasonable period of time. not exceeding 3 months. the peak horizontal ground acceleration at rock head level shall be taken as 0. The Contractor shall prepare and submit a fully comprehensive design submission demonstrating that the specified performance requirements are satisfied by his design. The design earthquakes shall consider the Site amplification effect. After a Level 2 event.1. equivalent to a 50% probability of exceedance in 50 years. reasonable repairs could include:  Reinstatement of the berthing line by modification to the fenders to accommodate forward movement of the structure  Modifications to the cope edge to restore the minimum hull clearance to vessels during berthing and mooring  Repairs to expansion joints between sections of the jetty and between the jetty and adjacent pavement  Repair of localised damage to structural elements to restore durability Damage resulting in excessive forward movement of the structure. For the jetty structure. the over-riding requirements for the seismic design shall be:  Level 1 – Serviceable  Level 2 – Repairable This is equivalent to performance grade ‘A’. The peak horizontal and vertical ground acceleration shall be modified as required by the adopted design standard.

This peak ground acceleration shall be assumed to relate to a Level 2 earthquake as defined in the PIANC Seismic Design Guidelines for Port Structures publication.2. assuming normal loading conditions and incorporating both f and f3. However. Analysis shall take account of the pedestal mounted crane. etc  Liquefaction assessment  Verification of software to demonstrate that the software can correctly carry out the required analysis 17 . It is considered that quasi-static analysis is not sufficient for demonstration of performance under the seismic event because movements are not adequately addressed by this method. quasi-static analysis may be used to determine strength requirements and overall stability. The choice of analysis shall reflect the form of construction and design earthquake event and shall follow the recommendations of Tables 5. The self weight of the liquid bulk handling equipment including the pedestal mounted crane may be considered as ‘dead load’. Seismic Condition Same as static condition except:  Berthing shall not be considered  50% of imposed loads to be considered. The analysis shall cover the following as a minimum:  Modelling of the jetty structure and miscellaneous facilities (pump house. The pedestal mounted crane loader shall be as static case with zero wind and maximum operational load. Static Condition Load factors should generally be in accordance with Eurocode 1. The structure shall be designed to provide continued stability and strength during the design earthquake.4 of WG34. Where load combinations are not covered by Eurocode 1. the factors from Table 2 of BS6349 Part 2 may be used.0.3 and 5. etc)  Pedestal mounted crane interaction  Site amplification effects  Cracking of reinforced concrete (sensitivity analysis)  Sensitivity analysis to determine the effect of uncertainties in input motions.0 on loads with a material factor of 1. for example for the marine structures. 1. the dynamic loads from the equipment shall be considered as ‘live load’.comparing the requirements of the adopted code of practice with the equivalent requirements in the Eurocode and Pianc guidelines.  The structure shall be designed for the design earthquake peak ground acceleration referred to in section 2.  Design shall take account of ρ-delta effects  The possibility of spalling of cover concrete under cyclic loading shall be considered. geotechnical parameters.

In his design submission.4 Pile Design Static Condition Piles working loads shall be based on the worst loading caused by one of the following load combinations:  Dead Load + Max Live load  Dead Load + Berthing Load  Dead Load + Mooring Load  Dead Load + Pedestal mounted crane (in operation . Therefore additional items have been included in the Bill of Quantities (BoQ) in Part 1 of the Bidding Documents for the material. transportation and installation of different pile sizes. Two breasting and two mooring dolphins are required for a safe and efficient operation of the full range of vessels. the peak horizontal ground acceleration shall be increased by a subsoil condition or soil foundation factor to account for the soil properties at the Site. Where the adopted code requires the use of an importance factor. 2.0.3. This factor is codedependent but shall in all cases exceed 1. this shall be taken as not less than 1.5 Mooring Lay-out The new FUF shall facilitate in unloading 10.000 DWT tankers up to 60.5 Tension piles: Overall safety factor 2. The Contractor shall analyse the critical mode of failure using an appropriate level of analysis as defined by WG34 to demonstrate that the performance requirements are met.0. the envisaged pile size and pile length may be subject to change. 18 . 2.For quasi-static analysis.wind) + UDL  Dead Load + Seismic Load The minimum factors of safety for ultimate static capacities (ultimate static capacity ÷ working load) shall be as follows: Compression piles: Overall safety factor 2. Because the soil information presently available is rather limited.0 Seismic Condition Same as static condition except:  Berthing shall not be considered  50% of imposed loads to be considered with the exception of the pedestal mounted crane. the Contractor shall identify the possible modes of failure of the jetty structure. The pedestal mounted crane shall be as static case with zero wind and maximum operation load.000 DWT tankers.5 Compression / Tension piles: Overall safety factor 3.3.1. The Contractor shall carry out and submit separate analyses to define the critical mode of failure.1.

Function The unloading platform structure and associated fittings is required to:  provide unloading facilities for liquid bulk vessels carrying oil products in the range 10.  support pedestal mounted crane. The unloading platform shall incorporate the following: Piled foundations.The breasting dolphins are to be placed with a centre to centre distance of 70m at both sides of the platform. a pedestal mounted crane. and 40m behind the berthing line. with a length of 20m (parallel to fender line) and width of 15m (perpendicular to fender line). commissioning and for the duration of the contract. manifolds and hose connections. commissioning and maintenance of the platform furniture. and the like as required. This mooring layout is shown on reference drawing 9V1468. hose area. deck structure.3. construction. auxiliary equipment. and communication ductwork. services. installation. 2.  provide access to the breasting and mooring dolphins 19 . power supply (LV) distribution ductwork.  provide manifolds and pipe work for the connecting product lines on the trestle.000DWT. 100m at both sides of the centre line of the platform.03/003. The reference design of the unloading platform is shown on drawing 9V1468.2 Unloading platform Scope The scope of works includes but is not limited to the design.  support equipment required for the erection. maintenance of the following.03/002 in Part 2 Chapter 5. safety hand railing. The mooring dolphins are to be placed with a centre to centre distance of 200m.000DWT to 60.  Pedestal mounted crane  Gangway access  Cathodic protection system  Jetty deck drainage system (with collection in slop system)  All necessary ancillary works and services tied in with the utilities including drainage. including facilities for unloading.  provide access to the vessels (using ships gangway)  provide access for victualling and stores to vessels (using the ships gangway)  provide access for emergency escape routes  be serviceable or repairable after the specified design seismic event.  provide a hose area for handling and connecting hoses to the product lines. ladders. equipment and services. testing and quality assurance. access to trestle and dolphins and jetty furniture. support beams. monitoring.  Platform for unloading oil products. supply.

Ladders shall extend 1m below MLWS and shall comply with the requirements of ILO regulations. Any rainwater falling outside the limits of the collection pit may be drained to the sea. It is envisaged that the deck is constructed with prefabricated concrete beams. Edge Protection Hand railing shall be provided as edge protection to all sides of the platform. incorporate provisions. Rainwater falling within the limits of the collection pit shall be treated as slop water unless the pit is considered clean due to either extensive cleaning or extended period of disuse.00m CD.00m CD -15. 20 . except for the vessel side. and an in situ reinforced concrete deck with precast concrete formwork. The platform shall receive the product pipelines coming from the Trestle and reroute them such that the end is placed above a slop pit of 4 meters wide and 16 meters long running lengthwise across the platform. The sump will house a pump to remove slop waters as they accumulate. Design loading Uniform distributed load: 10 kN/m2. Ladders to be provided at either side of the platform. and internationally recognised codes of practice. including fire water monitor: Capacity 15kN at 20m. Horizontal loading: 10% x vertical load The reference design of the unloading platform shows a suspended deck structure with steel tubular piles and a concrete deck. Ponding or standing water is not permitted. pits and ducts for the following: o product lines from the trestle o electrical. Particular Requirements Unloading Platform Item Requirements Overall length of Platform Structure Width of Platform Structure Cope level Design seabed level 20m Safety ladders Surface Water Drainage 15m +5. Sufficient surface falls to ensure storm water is shed to drainage collection points (the hose area or the slop system). instrumental and communication cabling o fire water supply and fire monitor o lighting o hose area o slop area o spill pump  provide for drainage of the jetty and collection of spill in a slop system  provide a cathodic protection system for immersed steelwork. This pit is to be covered with a grating and the interior is to be slopped towards a sump. Pedestal mounted crane. In addition a scour allowance of 1m shall be taken into account.

The incoming pipelines shall have a drain at their lowest point on the platform and the runoff from this point will be pumped towards a slop tank on the platform.3.  provide support for the product pipelines between the shore and the unloading platform. 21 . Once the tank has reached an adequate level its content will be pumped towards the slop system of the terminal over a dedicated pipeline. the following:  Allow for safe access to the jetty structure from the access trestle. Two lighting poles at the side most distant from the mooring vessel will illuminate the working area with no less than 50 lux. Should for any reason the remote control of the fire monitor fail. support beams. A distribution cabinet at the platform shall provide power to all power drains on the platform and on the dolphins. hand railing. In addition to the product pipelines a Firewater pipeline will arrive at the platform. It is to be capable of carrying a full 1. To connect the pipe endings to a tanker ship a crane will be placed on the platform. It is to be a pedestal mounted crane capable of reaching a 20 meter envelope such that it can reach a ship manifold in any predicted mooring position. The cabinet will house a 400 to 115 VAC transformer. etc. This pipeline will be rerouted to provide firewater to a monitor mounted on the pedestal of the crane. The structure shall incorporate the following: Piled foundations. A nitrogen pipeline will arrive at the platform. Function The access trestle is required to:  provide access between the shore and the off-shore structures. The hoses will be approximately 20 meters in length and be adequate to handle petrochemical products in a marine environment. pipe supports.  Abutment at the interface with shoreline and the start of the piled trestle to support the on-shore end of the trestle.3 Access trestle Scope The scope of works includes. 2. lighting and the like as required. The tank shall be equipped with a level indicator and low and high level alarms. hand railing. The slop waters recovered from the pit will similarly be pumped towards this tank.5 tonnes for the full extent of its reach. supporting structures for the walkway and the product pipelines and utilities. walkway. but is not limited to. it will be controllable locally. This line will be prepared to serve any required task at the platform such as the pigging of the pipelines. The works shall include all associated structural aspects including supporting piles and foundations. The platform will also house the relevant control systems for the equipment on the platform with exception of the fire monitor. A set of 8”hoses will be stored over the pit.

The reference design of the trestle is shown on drawing 9V1468.43 kg/m 2” nitrogen line: 9. instrumental and one spare) o 1m wide walkway  provide a cathodic protection system for immersed steelwork.368 kg/m 2” fresh water line 9.  incorporate provisions.7 kg/m (between pump house and the loading platform) 12” HFO: 151. provide access emergency escape route  provide protection of the walkway and product pipelines for waves  be serviceable or repairable after the specified design seismic event.0m Top level +5.  provide adequate lighting Particular Requirements Access Trestle Item Requirements Overall length of Trestle Structure Walkway 251m Loading Product pipelines Width between hand railing 1.03/004 in Part 2 Chapter 5.0 kg/m 8” Jet-A1/kerosene: 74.368 kg/m (non-potable) It is envisaged that the walkway consists of a 50mm thick. At both sides of the walkway hand railing is foreseen.7 kg/m 10” gasoline: 111. 22 .0m wide grating supported on UNP profiles. 1.45m CD Uniform distributed load walkway: 5 kN/m2 (pedestrian access only) Horizontal load: 10% x vertical load (water filled weight for testing): 12” gasoil: 151.7 kg/m (spare) 3” spill line: 13.71 kg/m 12” Fire Fighting: 151. and ducts for the following: o 2’’ water line o 3’’ spill line o 2’’ nitrogen line o 12’’HFO line (spare) o 12’’ Gasoil line o 10’’ Gasoline line o 8’’ Jet-A1/Kerosine line o 12’’ Fire fighting line o Three cable trays (electrical.

 Support the Quick Release Hooks  Provide for the safe and adequate working area for the mooring crews  Provide access from the unloading platform  incorporate provisions. The trestle is divided in two sections: section 1 is located between the access shore and the pump house. fender with fender panel. communication equipment. 2. 120 tonnes per twin hook. the following:  Two breasting dolphins capable of supporting the loads arising from the berthing and mooring of vessels. The fire water pipeline runs connects the fire water intake at the pump house with the fire monitor on the loading platform.  Remote and local release stations for the QRHs. safety ladder. low voltage power.  A fender connected to the dolphin facing.3. Function The breasting dolphins are required to:  Provide for the safe and adequate berthing and mooring of the design vessels.The walkway and product pipelines shall be supported at a fixed spacing. All pipelines are to be welded for their complete length except where they tie in on the platform or in the pump house. but is not limited to. Lighting posts placed at regular intervals of approximately 30 meters will illuminate the walkways with no less than 10 lux.e. section 2 between the pump house and the unloading platform. life saving equipment. pits and ducts for the following: 23 .  A twin-hook Quick Release Hook (QRH) mounted on each dolphin of sufficient capacity to resist the mooring loads from the design vessels with an adequate factor of safety but with a minimum capacity of not less than 60 tonnes/hook.4 Breasting dolphins Scope The scope of works includes. hand-railing. The trestle shall have longitudinal expansion joints and each section shall provide sufficient longitudinal stability of the trestle structure.5 tonne at a rate of not less than 30m per minute. The facility shall incorporate the following: Piled foundations. i. rope guards. This spacing is limited to the maximum spacing of the pipe supports. A cable tray will house all power and signal cables for the full length of the trestle.  A capstan capable for providing a winding force of 1. lighting. quick release hook. reinforced concrete deck. and the like as required.

testing and installation of a fixed fendering system comprising elastomeric rubber cone fenders with low friction frontal panels and galvanised restraining chains 24 . 365 Required for safe access 8m x 8. The use of other fender types is subject to approval by the Employer.1 Fendering Scope The scope of works for the fender system includes. be serviceable after the specified design seismic event.0m at each end. Particular requirements Breasting Dolphins ITEM REQUIREMENTS No of breasting dolphins Fenders 2 One cone type fender for each dolphin.3. but is not limited to. low voltage power supplies.1 x Reaction force fender Line loads: minimum 2 x 600 kN = 1. 1 x Twin QRH per dolphin. with integrated capstan 60 Tonnes 0o to 90o 0o to 45o above horizontal 5. To be provided over the length of deck covered by the horizontal operating range of the hooks plus 1. and internationally recognised codes of practice. To be provided over the length of deck not covered by the horizontal operating range of the hooks less 1.0 kN/m2 One per dolphin. In addition a scour allowance of 1m shall be taken into account. shall be mounted on the fender.o  lighting.4.00m CD.00m CD LV electricity. 2. the following:  The provision.200 kN Lean-on: 50% x 1. -15. communications. and mooring loads. lighting. A steel fender panel.5m +4. Ladders shall extend 1m below MLSW and shall comply with the requirements of ILO regulations.0m at each end and at ladder positions. 1. with UMHW-PE facing.00m CD -15. The interfaces between the structures shall be designed to accommodate movements arising from environmental (including seismic).1 x Reaction force fender Quick Release Hook (QRH) Minimum hook capacity Operating range Horizontal Operating range Vertical Design deck load Safety Ladders Handrails Rope guard Days in service/ annum Lighting Minimum deck area Deck level Design seabed level Design seabed level Services/ utilities Berthing loads Mooring loads One lighting pole at the side most distant from the mooring vessel shall illuminate the working area of each dolphin with no less than 10 lux.

Particular requirements.000t loaded displacement 15° Fender performance to take account of bow radii Fender design to take account of bulbous bows 25 .000t loaded displacement 6o for vessels over 50. fendering ITEM Berthing mode Maximum eccentricity Maximum vessel berthing angles Bow flare angle Bow radii Bulbous bows REQUIREMENTS Side berthing (dolphin berthing). the design of the fendering system  the fender system shall be compatible with the provision of a 10-year warranty for the entire system. parallel berthing to be considered Third point vessel impact 10o for vessels up to 50. Function The fendering system and associated works are required to provide a safe and effective fendering system.

Reduction in rated fender rated energy and deflections values shall be reduced. berthing and flare angles Distance between cope edge To be the minimum dimension which will allow 400mm and berthing line clear between the vessel hull and the cope with the fender fully compressed. Allowable hull pressures 20 tonnes/m2 maximum Fender panel The steel fender panel shall be designed to accommodate a horizontal line load equal to the abnormal fender reaction at any point. Approach velocities to be based on unfavourable berthing conditions as defined in PIANC Guidelines The fender calculations are to be carried out in accordance with the requirements of BS6349 Part 4. 150% of berthing energy from normal impacts. fendering shall be tested in accordance with the recommendations of PIANC/INA ‘Guidelines for the Design of Fender Systems: 2002’. shall be provided in chains to avoid damage to any fixings cast into the jetty structure. yellow. within rated deflection Approach velocity To be appropriate for the location of the jetty and the vessel size. Rated energy and deflections The rated fender energies and deflections shall be based on the test speed recommended in PIANC Bulletin No 45 (1984): Annex 4. energy where necessary. Berth configuration coefficient to be appropriate to the type of jetty construction. A ‘weak’ link in the form of a chains and fixings shackle.Not less than 0.1. For the calculation of the berthing energy a misalignment of 10m shall be taken into account to allow vessels berthing eccentric to the spotting line of the new FUF.3 26 . In addition. within rated deflection For vessels ≥ 30.ITEM REQUIREMENTS Energy absorption For vessels < 30. using manufacturer’s factors. Coefficient of friction UHMW.0. The fender size and spacing selected to satisfy this criterion. to take account of temperature. The following fender reaction forces shall be taken into account in the structural design of the dolphin:  Horizontal fender reactions (perpendicular to jetty)  Horizontal fender shear forces (parallel to jetty) based on a co-efficient of friction not less than 0. Maximum permitted 60% of height of fender unit compression of fender units under abnormal berthing Fender panel facing UHMW – PE low friction. All fenders shall be pre-compressed prior to installation.2 PE to steel (dry) Chains between jetty and Required fender (to prevent rope snagging) Restraint chains Required Factor of safety on restraint Factor of safety of 3.000DWT. Softness coefficient to be appropriate to the type of jetty construction. 175% of berthing energy from normal impacts.000DWT. minimum 40mm thick.

03/011 in Part 2 Chapter 5.e. and the like as required.5 Mooring dolphins Scope The scope of works includes.3 The design fender shear forces shall be considered co-incident with the design fender reaction forces. pits and ducts for the following: o  lighting. low voltage power. and mooring loads.5 tonne at a rate of not less than 30m per minute. constructed of a concrete deck and raked tubular steel piles. but is not limited to. Function The mooring dolphins are required to:  Provide for the safe and adequate mooring of the design vessels. reinforced concrete deck. 180 tonnes per triple hook. the following:  Two mooring dolphins capable of supporting the loads arising from the mooring equipment to be mounted on the dolphins. The facility shall incorporate the following: Piled foundations. low voltage power supplies. lighting. communication equipment. be serviceable after the specified design seismic event. quick release hook.  A capstan capable for providing a winding force of 1. The design shall take into account variation of fender performance with temperature.  Remote and local release stations for the QRHs. rope guards. Vertical fender shear forces (vertical to jetty) based on a co-efficient of friction not less than 0. i.3. hand-railing. The interfaces between the structures shall be designed to accommodate movements arising from environmental (including seismic). 2. A reference design is show on drawing 9V1468.  A triple-hook Quick Release Hook (QRH) mounted on each dolphin of sufficient capacity to resist the mooring loads from the design vessels with an adequate factor of safety but with a minimum capacity of not less than 60 tonnes/hook. life saving equipment.  Support the Quick Release Hooks  Provide for the safe and adequate working area for the mooring crews  Provide access from the unloading platform and the breasting dolphins  incorporate provisions. Rigid structures are envisaged for the two breasting dolphins. safety ladder. Particular requirements Mooring Dolphins ITEM REQUIREMENTS No of mooring dolphins 2 27 .

6 Catwalks Scope The scope of works includes. The level of the walkway shall be level with the upper surface of the platform and the dolphins. without the area where the mooring lines are able to run. Line loads: minimum 3 x 600 kN = 1.  corner protection. to handle the spring lines of the vessels. the catwalks between the unloading platform and the breasting dolphins will be at a gradient.00m CD LV electricity.800 kN Handrails Rope guard Days in service/ annum Lighting Minimum deck area Deck level Services/ utilities Mooring loads Similar to the breasting dolphins rigid structures are envisaged for the two mooring dolphins. Because of the difference in top level of the platform and the breasting dolphins.  a safety ladder is placed along the dolphin. One lighting pole at the side most distant from the mooring vessel shall illuminate the working area of each dolphin with no less than 10 lux.0m at each end. the following: Access walkways to provide safe personnel access between the unloading platform structure and the breasting and mooring dolphins. 365 Required for safe access 6m x 6m +4.3. The access walkways shall incorporate the following: 28 .  1. consisting of a reinforced concrete deck.  Each mooring dolphin is equipped with:  a triple 60 tonne QRH unit with integrated capstan. The reference design of the mooring dolphins is shown on drawing 9V1468. lighting. communications. To be provided over the length of deck covered by the horizontal operating range of the hooks plus 1.0m at each end and at ladder positions. The ladder is at both sides protected with vertical fendering.0m. 2. Ladders shall extend 1m below MLSW and shall comply with the requirements of ILO regulations.ITEM REQUIREMENTS Quick Release Hook (QRH) Minimum hook capacity Operating range Horizontal Operating range Vertical Design deck load Safety Ladders 1 x Triple QRH per dolphin 60 Tonnes 0o to 90o 0o to 45o above horizontal 5. but is not limited to.03/010 in Part 2 Chapter 5 of the Bidding Documents.0 kN/m2 1 per dolphin. to prevent chamfering of the mooring lines over the concrete deck. To be provided over the length of deck not covered by the horizontal operating range of the hooks less 1. Both the ladder and the fendering shall extend to CD -1.0m high railing. and raked tubular steel piles. and internationally recognised codes of practice.

Alternatively. the following:  A covered pump house for the intake of fire water. Function The pump house and associated works are required to:  Provide for safe and adequate intake of fire water from the port basin. and the like as required. communications.0m 365 LV electricity.Open grid steel flooring. kick plates.  incorporate provisions for the following: o  lighting. The steelwork. including the foundation.03/003 in Part 2 Chapter 5. The design shall comply with the deformation and vibration requirements of the applicable standards. low voltage power supplies.  An electrical and instrumentation cabinet.  meet the requirements for design life and corrosion protection. heavy duty hand-railing.3. meet the specified performance requirements during and after a seismic event. but is not limited to. The structural steelwork frame may be used as the supporting structure. lighting.  An electric pump and back-up diesel powered pump  A foam tank and foam injection pump  Jockey pump and pipe work related to the fire water intake. lighting.7 Pump house Scope The scope of works includes. 29 . 2. Function The catwalks and associated works are required to:  provide for safe access to and from the dolphins for personnel.  provide emergency escape routes (from the dolphins to the shore). communications.0 kN/m2 1 in 100 year wind condition 1. open grid flooring and hand railing shall have a suitable corrosion protection system capable of achieving the required design life. a tubular steel beam may be used as shown in the reference design on drawing 9V1468. Construction shall be a structural steelwork frame with open grid flooring and hand railing. Particular requirements Catwalks ITEM REQUIREMENTS Design load Design wind load Minimum width Days in service/ annum Services/ utilities 5. support bearings.  Access to and from the trestle walkway.

 Provide sufficient access and windows. Windows shall have fenestration as appropriate. For the building a steel frame of HE and UNP sections is envisaged to support the walls and roof. The pump house shall have one electric firewater pump capably of delivering 450m³/h of water to the monitor on the jetty at no less than 6 bar. All window frames and doors shall be clear anodised aluminium. for easy access to the pump house from the walkway on the trestle. Concrete beams and vertical steel tubular piles are envisaged to support the platform. pits and ducts for the following:  o lighting. The reference design of the platform for the pump house consists of a reinforced concrete floor.  Protect the pumps from external weather influences. The top part of the roof is elevated for good ventilation. fresh water. o communication cabling Be serviceable after the specified design seismic event. includes equipment loading) Horizontal load: 10% x vertical load Protected from external weather influences 365 LV electricity. a 1m wide door mounted. A backup diesel powered pump will also be present and have a capacity no less than its electric counterpart. the steelwork shall be cased in concrete or otherwise protected. Cladding shall be coloured profiled metal sheeting. These are described in Chapter 5.  Provide for storage of mechanical. with prefabricated elements and an in situ concrete layer on top. Windows are located at two sides of the building In the East wall. The layout of the building shall provide sufficient room for the required equipment.5kN/m2 (uniform distributed load. These pipes will be of sufficient length to be able to 30 .  Support all equipment associated with the fire water intake.  Incorporate provisions. Particular requirements Pump House The workshops and the substation room shall be designed in accordance with the mechanical and electrical requirements. ITEM REQUIREMENTS Dimensions L X B X H Minimum clear headroom Top level floor Loading 6x7m 3m +5. telephone/network Climate internal Days in service/ annum Services/ utilities The building shall be of steel-framed construction or other acceptable design approved by the Employer. Where necessary for fire protection (in accordance with local building guidelines / regulations). but shall provide good shelter during the rain season. Provide for a safe and sheltered environment for maintenance work of the pumps and other equipment. Both pumps shall have vertical collection pipes extend into the waters below the pump house. low voltage power supplies.45m CD 17. electrical and general spare parts for the pumps and other equipment. Concrete floor shall be treated with hardener or granolithic finish.03/006 and 007. Layout and reference design of the workshop is shown on Drawing 9V1468.

3. 2.1 Services and utilities Provision shall be made for the following services on both the unloading platform and the trestle:  LV electricity supply  HV electricity supply  Fresh water supply  Fire-fighting water supply (from the pump house to the unloading platform)  IT/communication cables With the exception of fire-fighting water supply.8. Fire fighting facilities shall be in accordance with local fire fighting regulations and fire fighting standards from the international shipping industry.collect water at the lowest predicted low water level. It shall also house all equipment necessary for automatic and manual control and for periodic testing of all fire fighting equipment. This cabinet will contain a 400 to 115 VAC transformer. The pump house will also contain personal protective equipment and two 75kg wheeled dry powder extinguishers suitable for class A. The anticipated requirements for ducting within the approach bridges. The cabinet will also contain the relevant control systems for all equipment in the pump house and the monitor on the platform. A jockey pump will use fresh water supplied by the terminal to keep the system under pressure while not in use. Main jetty and Landside jetty are as follows: HV electricity supply Minimum inside diameter: 150mm Minimum bend radius: 1700mm LV electricity supply Minimum inside diameter: 150mm 31 . B & C fires and be compatible with the foam system. The pump house should be equipped with adequate ventilation and climate control necessary for safe operation. Fire-fighting water supply pipes may be supported on the external faces of the structures providing they do not obstruct or encroach on working areas. Four 9kg portable extinguishers of equal characteristics will either be stored in the pump house or available at the platform or along the trestle.3. A foam tank will supply foam concentrate to the water flow by means of a pump.8 Miscellaneous Items 2. The tank is to contain sufficient foam to maintain a full capacity supply during no less than 30 minutes. services which run on the unloading platform shall be contained within ducts cast into the structure. A cabinet at the pump house shall hold the distribution cabinet to supply power to the pump house itself and the walkways (and connected equipment) that extend from it. The pipes will be capped with strainers to prevent the entry of debris.

8. When in addition a coating is applied.3. min 50 lux 5m high.4 Corrosion Protection The marine steel piles shall be protected from corrosion by means of a cathodic protection system. The top level of the grating does not need to be flush with the deck level of the platform.3. The slop waters recovered from the pit will similarly be pumped towards this tank. 2. The Contractor shall prepare and submit for the approval of the Project manager sufficient details of the services to show how they shall be installed.3 Aids to Navigation Aids to navigation shall be provided on the dolphins and corners of the unloading platform as per international standards and guidelines. 2.8. as long as safety precautions are taken for access to the hose area. The hoses will be approximately 20 meters in length and be adequate to handle petrochemical products in a marine environment.8.3. All services shall be confirmed to the Contractor by the Start Date. 32 . 2.03/008 shows a layout with the envisaged location of light poles.5 Hose Area and Manifolds All product pipelines coming from the trestle will be rerouted on the unloading platform such that the end is placed above a slop pit / hose area running lengthwise across the platform. installation and commissioning of lighting are included within the scope of this Contract.Fresh water supply IT cabling Suitable to accommodate pipe diameter of: 50. The lighting towers shall be of the type where the crown is lowered vertically for maintenance purposes. temporary open ends of pipes and ducts shall be plugged/ sealed to prevent entry of material into the pipe/duct. The following lighting tower heights are envisaged:    Unloading platform (2) Trestle Dolphins (1for each dolphin) 10m high. min 50 lux Reference design drawing 9V1468. and power points. A set of 8”hoses will be stored over the pit.8. The sump will house a pump to remove slop waters as they accumulate.2 Jetty Lighting Supply.8mm Minimum inside diameter: 100mm During installation. The incoming pipelines shall have a drain at their lowest point on the platform and the runoff from this point will be pumped towards a slop tank on the platform. min 10 lux.3. 2. spacing 30m 5m high. this shall protect the intertidal zone from soffit of concrete up to 2m below low water. This pit is to be covered with a grating and the interior is to be slopped towards a sump. All ducts shall incorporate draw strings.

8. These coordinates define the position of the jetty.3. valves. 2. diesel driven fire pumps. fires on the unloading platform. 2. handling. 33 . 2. but is not limited to.  Fire fighting system to supply water and foam to combat.3. testing and setting to work of the product pipelines.11 Existing facility The existing facility will be operational during the construction of the new unloading facility. control systems. installation. The tie in point is located at the start of the trestle.4 Mechanical and electrical Functional Requirements The Scope of Works provides for the design.6 Reference coordinate for the position of the main jetty Layout drawing 9V1468. fire fighting system. 2. The scope of work for the Mechanical and Electrical Works of the new FUF includes. including associate infrastructure and equipment.10 On shore facilities No onshore facilities are included in the scope of work. The sides are sloping up with 5v:1h.g. Details are shown on reference drawing 9V1468. pipeline pressures. approval shall be obtained from the Project Manager beforehand. sea surface and vessel. together with any minor building works required inside or outside the fire fighting pump house and on the jetty as set out or implied in the Bidding Documents and the accompanying drawings. the pocket will be perpendicular to the fender line. the abutment.  Platform equipment. the following elements:  Trestle pipe rack with product and utility lines. corrosion protections systems. commissioning. The Contractor shall take these operations into account in his construction methodology and planning of the works.  Spillage collection and drainage systems including associate utilities and equipment. control systems and all such related works as outlined in the Bidding Documents. The contractor shall be responsible for verifying if there is an need for upgrade/ rehabilitation of the ‘‘On shore facilities” to adapt to the specifications of the new FUF (e.03/002 shows the coordinates of the outline of the berth pocket in northing and easting. pipe work. supply.  Supply of electricity to the equipment and lighting of the facility.3. safety inter-faces for shut-downs. If the operations need to be stopped temporary. fire pump house. and prevent the spread of.3. etc). till they reach the existing bottom profile.2. fittings.9 Dredging works A berth pocket has to be dredged in front of the unloading platform. delivery.03/002. pumping rates.

1. As part of the overall work scope.4. but no major repairs or rebuilding. The design shall fully take into account this requirement for durability. It includes the presumption of adequate regular inspections and maintenance. The codes and design standards shall be subject to the approval of the Project Manager. The following codes and standards are suggested for the mechanical and electrical works:  ASTM or API standard  American National Standard Institute (ANSI)  American Society of Mechanical Engineers (ASME)  British Standards  Engineering Equipment and Material Users Association (EEMUA)  International Electrical Commission (IEC)  ILO Publication “Safety and Health in Ports”  IP codes (Energy Institute)  International Standards Organisation (ISO)  Joint Inspection Group for Jet Fuel A1 (JIG)  National Fire Protection Association (NFPA) 34 .4.4. At the end of the design life period the asset will continue to be serviceable. the Contractor shall liaise with the following organisations where local regulations are important for the design and construction of the Works:  National Port Authority of Liberia (NPA)  Liberia Petroleum Refining Company (LPRC)  Local Fire Brigade  Environmental Protection Agency of Liberia 2. 2. will take place.1. the British Standards (BS) or the German Codes (DIN).The general and particular requirements will be further elaborated in this chapter.1 Design life The design life for the mechanical and electrical equipment shall be 20 years.2 Standards and Codes of Practice The design shall comply with the latest versions of internationally recognised codes of practice such as the Eurocodes (EN).03/009 shows the flow diagram for the product lines and also shows the details of the slop system at the unloading platform. The Contractor shall confirm the codes and design standards proposed for the works prior to starting the design. Reference design drawing 9V1468.1 General Requirements 2.

rotational tests and the like are not acceptable). with proper considerations for the context of the facility.3 Performance testing and Equipment manuals A complete set of operation and maintenance manuals for each item of equipment shall be supplied by the Contractor. All pipelines. pump.1. A corrosion allowance of 1. fitting material and welds shall be in accordance with ASME standards.  One 12” carbon steel pipeline for Diesel.4.5mm shall be used for the pipe work. and all relevant standards and regulations. The pumps and engines shall be works tested as matched pairs.  One 2” carbon steel pipeline for fresh water (non-potable). The installation shall be pressure tested before entering into operation. hoses and associate equipment shall comply with its intended use. 35 .4. All pipe lines shall be made of carbon steel. The Jet-A1 pipeline system shall be in accordance with JIG regulations and be conform to all required regulations for the handling of aviation fuel. as they will be installed on site. Provisions shall be taken for the possible addition of an electrically traced 12” pipeline for unloading of HFO.  One 10” carbon steel pipeline for Gasoline.  One 2” carbon steel pipeline for nitrogen. Provision shall be made by the Contractor for carrying out all the required tests on the equipment/pump set complete with all necessary instrumentation for the implementation of these tests. of the diesel driver.  One 12” carbon steel pipelines for fire water from the pump house to the platform only.. Pipes. If any faults are discovered during testing the Contractor shall rectify them and retest at the Contractor’s cost. gearbox and electric motor and pump and control instrumentation. Full operational performance tests shall be concluded in the works (type testing. 2. Quality certificates of materials used in the construction of the equipment.2 Trestle Pipe Rack The access trestle shall support the following product pipelines:  One 8” carbon steel pipeline for Kerosene and Jet A-1. Oil Companies International Marine Forum (OCIMF) 2. including chemical analysis/mechanical properties shall be supplied together with shop proving test results/power/flow curves. etc. The following utility pipelines shall be installed:  One 3” carbon steel pipeline for spillage.

4.The hydrostatic test pressure shall not be less than the greater of the two following values (EN 13480-5:2002): 1 .Ptest = 1.  The dimensions are to be sufficient to store all hoses when not in use without excessive stress on any hose.25 x PS x ftest / f 2 . Any rainwater falling outside the limits of the collection pit is permitted to flow into the sea.  From this low point a pump of sufficient capacity will pump the slop liquid to the slop tank on the platform. 36 . A pump will empty the slop tank by pumping its content to a slop system at the terminal. 2. and the test medium shall be potable water.Ptest = 1.  The slop tank is to be equipped with a level indicator and High Level and Low Level alarms.3 Platform Equipment The jetty platform shall be equipped with a pedestal mounted crane including but not limited to:  Pedestal mounted crane  Pedestal with access ladders and platform  Hydraulic Instruments and hydraulic control system  Electrical Instruments and electric control system  Radiographic remote control unit All equipment shall be suitable for hazardous area Atex Zone 1 EExd IIB T3 For spill prevention a collection pit shall be included:  The pit must be placed in such a manner that the connection point between pipeline and hose falls well within its limits.  The interior of the pit will be sloped as to collect all liquid at one point via gravity flow. Furthermore a slop tank is required:  The slop tank collects slops from the collection pit and from the drainage point on all product lines.  The pit is to be covered with a mesh grating so as to permit the unobstructed flow of liquids and prevent injury. Any rainwater falling within the limits of the collection pit will be treated as slop water unless the pit is considered clean due to either extensive cleaning or extended period of disuse.43 x PS The test temperature shall be between +5 oC and +50 oC.

check valves shall be placed to prevent draining of the pipes in case of an emergency disconnection or rupture of the hoses during unloading operations.The Contractor shall employ any necessary additional precautions to minimise spillages. The diesel pump is to come equipped with a fuel tank of sufficient capacity to maintain operations for the longest expected fire fighting scenario  Fire monitor o The water pressure at the monitor is to be no less than 6 bar o Placed on the pedestal of the crane o Capable of launching foam at the platform. given ship sizes and dolphin location. Flexible hoses of 8” for each product with sufficient length shall be attached to the fixed pipes of the manifold at the platform and the vessel (approximately 20 meters total length). In case of a fire the electrical pump is assigned to be the duty pump. The unloading platform shall be equipped with a crane to assist in attaching the hoses to ship manifolds in case ships are not equipped with cranes or the ship cranes are for any reason not in operation.4. It must be able to reach the full length of the hose storage area and to every possible manifold location. Between the hoses and the pipelines. or fail to supply adequate water flow. while carrying the maximum expected load. The crane is also expected to serve as support for the fire monitor and its associate equipment. The crane will be locally controlled and will be either electrically or hydraulically operated. Should the electric pump for any reason fail to start. ship and sea surface o The fire monitor is to be controlled from the pump house 37 . 2.4 Fire Fighting The following fire fighting equipment is required at the unloading facility:  One 12” carbon steel pipelines for fire water from the pump house to the Fire monitor  One 2” fresh water (non-potable) pipeline from the shore to the jockey pump  Sea Water Fire Pump house  Electrical Fire pump o Duty pump capable of delivering 450 m³/h at no less than 6 bar at the monitor  Electrical Jockey pump  Diesel-powered Fire pump o Backup pump capable of at least equal performance of the Electrical pump During regular stand by time only the jockey pump will activate to keep the system under pressure. then the diesel powered pump will be activated. Both electrical and diesel fire pumps must be capable of individually supplying the full required load of the fire fighting system and be in accordance with all other requirements by NFPA.

 Piping to be installed in the field shall be: o Prepared and painted after installation. Foam tank with sufficient foam concentrate for no less than 30 minutes continuous application Dry Powder Extinguishers o Four 9 kg portable o Two 75 kg wheeled o The powder will be suitable for class A.  Surfaces that will be inaccessible after assembly shall receive the complete painting system before assembling. The Contractor shall liaise with the Port Authority. stairs. but not limited to. 38 . all mechanical and electrical items in the facility are to have adequate corrosion protection in accordance with EN 12944. gangways and stair beams shall receive the complete painting system before the gratings or stair treads are mounted. The strategy shall not be reliant on the provision of a fire fighting vehicle.o  Foam system o   A flow measuring instrument must be placed in the pump house to confirm the flow of 450 m³/h. grating. platforms and handrails shall be hot dip galvanized. followed by final painting after installation. The zinc layer shall not only achieve the required thickness.  Shop primed surfaces shall be touched up as soon as possible after erection.  Structural steel.5 Corrosion Protection Similar to all structural items. 2. should also be considered for each component potentially at risk. protective coating. over thick areas. Sufficient fire detection sensors and fire alarm provisions shall be foreseen in accordance with OCIMF regulations. supporting. Personal Protective Equipment is to be supplied and stored at the pump house to protect people involved in a fire fighting effort Additional passive fire fighting methods such as. Final painting shall follow immediately after mechanical completion.  Grit blasting on site is not allowed. or after successfully completed pressure testing. Local Fire Brigade and port operators to finalize the port fire fighting strategy. pipe supports. to identify fire scenarios and to confirm the fire protection system shall meet the requirements of the strategy. pinholes and lacking adhesion between zinc and steel. B & C fires and be compatible with the foam system employed. sharp edges. Platforms. o Prepared and primed before installation when blast cleaning is required. burrs. Contact surfaces of bolted connections are to be primed only. but also be smooth and free of irregularities like droplets.

 All cable trays and supports.  All cables shall be fire retardant and halogen free. cos phi.and signal cables for process equipment (pumps.1 Electrical Works Scope of work: All required electrical equipment for a safe and functional operation of the jetty equipment • Supply. 50/60Hz (herein referred to as 115VAC) and corresponding distribution rail shall be installed. To this board all 400 VAC consumers and 400 VAC supplies shall be connected. kW.5. mounted outside shall be stainless steel. I. f.  All equipment shall be suitable for the explosion zone it is to be placed in.  In a separate cabinet or a separated part of the distribution board. etcetera) and instrumentation & control equipment • Emergency stop circuit • Provision of all cable support systems and fixings • Provision of earthing. the distribution of 110 VAC and 120 VAC.  Distribution boards placed at the pump house and on the platform shall house additional 400 to 115 VAC transformers.  All electrical distribution equipment and switching equipment shall be installed in free-standing cabinets with lockable doors. 50/60Hz (herein to be referred to as 400VAC) shall feed the main distribution board. A multifunctional energy meter (V.  All equipment shall have a local maintenance switch. kWH) shall be installed. 39 .  The protection level of electrical cabinets and distribution boards with doors open shall be at least IP21. ventilation. cabinets and the main supply cable shall be at least 20%. The cabling shall be designed and installed in accordance with the following requirements:  Voltage between 380 and 415VAC. installation and termination of all power.  Over voltage protection shall be applied. valves etcetera).2. utilities (lighting. bonding and lightning protection to the facilities • Provision of exterior lighting installations throughout the marine works • Provision of interior lighting for the pump house • Provision of lighted navigation aids at extremities of the marine structures Excluded are the power generation and power supply to berthed vessels The following general requirements apply for the electrical design:  Spare capacity of electrical distribution equipment.

Following automatic circuits shall be provided as a minimum:  Automatic starting of fire fighting pumps (water and foam) at adjustable pressure levels. tees and other accessories that are purpose made by the manufacturer of the cable tray. In the control cabinet all circuits shall be installed. required for:  Automatic operation. when the fire fighting will be used.  Safety (emergency stop).  Corresponding indicators for ON – OFF.and spill pumps on level of the tanks / collectors.  The minimum free space between the footpath and the luminaries shall be 3 meters of the raising and lower type. Cable trays shall be installed in accordance with the manufacturer’s recommendations. with a minimum of 10 lux luminance along the walkways and not less than 50 lux luminance on all working areas. published by the International Labour Office (ILO). where the luminaire(s) mounted at the head of the column can be lowered to the jetty deck level for maintenance.  Automatic starting of slop.Failure 40 . The deflection shall not exceed that recommended by the manufacturer. All cable tray runs shall be continuous and constructed of bends. lamps changes and/or cleaning. Following manual intervention controls shall be available on the front of the control cabinet:  Automatic – 0 – Manual switches for all equipment. The installation shall cater for the expansion and contraction that will occur. From there the cables extend to the distribution points on the jetty.  Where cables are to be installed in a designated potentially explosive atmosphere they shall be of the correct type suitable for use in a potentially explosive atmosphere.  400/115V electrical distribution cables shall be laid in cable trays along the jetty.  Manual operation.  Automatic switching lighting on both timer and darkness. The cables will generally comply with all relevant requirements of IEC. Both 400VAC and 115VAC cables to be available at the tie-in point. The lighting design shall be in accordance with the following requirements:  The lighting along the jetty and at the jetty head shall comply with the requirements of the Safety and Health in Ports. They shall be placed at intervals of approximately 30 meters along the walkways  The lighting shall be switched ON/OFF on basis of timer and light sensor or manually. Cable trays shall have adequate mechanical strength for the load to be carried and shall have provision for the addition of a minimum of 25% of the initial installed cable and/or load.  The lighting supporting structures shall be positioned on the jetty so as to not impede any traffic movement along the jetty and/or operational staff.

provide and install a lightning protection installation to enhance the safety of the jetty structure and product pipeline services. 3. The installations shall be provided with all earthing. wherever practicable. 2. 6. 5. Project Execution Quality Assurance Environmental Protection Design and the Submission of design information to the Employer Progress Control Health and Safety Both the General Employer’s Requirements and the Technical Specifications are 3. its facilities and personnel. etc. and pipe work support systems. The installation shall incorporate all requirements and recommendations of IEC standards The Contractor shall. supply and install an integrated system of earthing. methodology and time span of the Project.Earthing. required for compliance with the specified Design Standards. Possible project risks shall be identified and accordingly risk management plans shell be developed. Interfaces with other Works to be executed interrelated shall be clearly identified. 41 . bonding. hand railing. bonding and lightning protection facilities. Lightning protection The Contractor shall design. protective conductors. take advantage of the metallic structure to provide a self protecting structure to ensure the provision of the lowest possible impedance in the connection to earth and ensure that all metallic element of the structure are maintained at the same potential. 4. 3. The Project Quality Manager shall maintain all Quality Documentation and be available at all times to deal with enquiries from the Employer or from the Project manager regarding the Contractor’s Quality Management System. 3 GENERAL EMPLOYER’S REQUIREMENTS This chapter of the Employer’s Requirements set out the general requirements the Contractor shall follow in respect to: 1.2 Quality Assurance The Contractor shall operate a Quality Assurance system according to ISO 9001. pipe work. The Contractor shall nominate a senior member of his personnel to act as his Project Quality Manager.1 Project Execution The Contractor shall prepare a Project Execution Plan (PEP) which extensively describes the chronology. The Contractor shall present maximum flexibility to adapt the Works to be executed with respect to day-to-day operations. The Contractor shall design. Bonding .

The Project Manager shall be entitled to audit the Contractor’s Quality Management System at any time subject only to giving the Contractor’s Project Quality Manager 24 hours notice of his intention. international and local legislation regarding the environment and marine conservation requirements. The Project Manager shall be supplied with a copy of each audit report.  Outline of an Environmental Management Plan (EMP) for construction (CEMP) and operation (OEMP). All Contractor’s Documents are to be submitted to the Employer. The timing of such audits shall be clearly indicated on the programme of the Works. 3. When the Contractor has employed a firm of Consulting Engineers to carry out the design of the works he shall ensure that his agreement with this firm contains a provision for the Project Manager to similarly audit their Quality Management System at any time. 42 . Contractor’s Documents that are required to be submitted to the Employer will be submitted to the Employer in hardcopy (three copies) and a digital file. During construction the Contractor shall prepare and submit the following documents to the Employer:  Outline of the Project including construction and operations activities and a Construction Method Statement (CMS).The Contractor shall ensure that the approved Quality Plan for the project is subject to a full internal audit at least two times during the course of the project. unless otherwise specified. to minimise spillage and to minimise the extent/frequency of maintenance and its disruptive effect to operations. each submission shall be for the purpose of information only.  Detailed Description of the Project including construction and operations activities and a Construction Method Statement (CMS). During Construction the Contractor shall carry out environmental monitoring.  Construction Quality Plan.  Detailed Environmental Management Plan (EMP) for construction (CEMP) and operation (OEMP).3 Environmental Compliance The Contractor must identify and comply with restrictions. 3. Unless otherwise stated. The results of the monitoring program shall be submitted to the Employer. The documents required for environmental clearance shall be reviewed by the Employer.  Master Construction Programme  Baseline Environmental Study. The Contractor shall give full consideration in the design to minimise the operating and maintenance costs. The language of all documents shall be English and all units shall be applied in accordance with the metric system.4 Contractor’s Design and Documentation The design of the Works is the responsibility of the Contractor and shall satisfy the Employer’s Requirements contained within This Document.

fully indexed and referenced. Preliminary engineering design drawings including dimensions and setting out of structures. The design submissions shall cover. bearings. 3. The number and scope of the packages shall be subject to the approval of the Project Manager. pipe rack etc. 3. If it becomes necessary to revise the design submission programme the revised programme shall be submitted 2 weeks before any further design package is submitted. the following project elements:         Dredging. 43 .1 Contractor’s Design Submissions Design submissions shall be prepared for the various elements of the project before finalising the detail of the construction drawings and commencement of the physical work. Fire Fighting system Utilities systems (potable water. pedestal mounted crane) for safe mooring of the vessels and scour protection. marine loading equipment. Each submission shall be a complete package. codes and standards used and demonstrating how the design complies with the Employer’s Requirements.). update and issue at appropriate intervals in accordance with his Quality Assurance system a register of all drawings in circulation and their status. The Technical Specifications shall form part of the Contractor’s Documents and shall be reviewed by the Project Manager. Control and Automation system. Jetty structures (including fenders and mooring systems.4. This programme shall allow a period of 21 days for the assessment of each design package. Power supply and electrical system. Any superseded drawings shall be clearly marked S/S and removed from circulation.4. nitrogen.4. maintain. Checked Calculations. but not be limited to. Method statement. drainage).3 Technical Specifications The Contractor shall prepare a complete set of Technical Specifications for the execution of the Works in line with or in addition to Technical Specifications contained within the Employer’s requirements. The Contractor shall also produce. pumps.2 Issue of Design Submissions At the start of the Contract. Approach Trestle structure (including: pedestrian walk way. the Contractor shall prepare a design submission programme to identify the scope of each design package and its submission date. The design submissions shall include as a minimum the following:     Design basis statement covering all assumptions. abutments. Liquid bulk handling system: pipe lines and pipe rig.3. The design submissions will form part of the Contractor’s Documents and shall be reviewed by the Project Manager.

3. The As-built Drawings shall be suitable for reduction and inclusion in the operating and maintenance manuals. revised and updated to indicate the final "As-built" construction details.4 Construction Drawings Once the Project Manager’s no objection to the design reports and design drawings has been obtained. These shall be provided as a single package fully co-ordinated and cross-referenced. design certificates and check certificates as appropriate. Prior to requesting a Certificate of Completion for the whole of the works.  three electronic copies of the As-built Drawings written to CD or DVD (three sets of CD’s or DVDs) in o AutoCAD 2004 format.3. The Final Calculations shall be set out in sections to suit the particular discipline. Final Calculations and other details and information fully marked-up. as and when these particulars differ from what is shown on the For Construction Drawings prepared by the Contractor. Subject to the Project Manager’s approval an electronic system of submitting and approving drawings may be considered. The drawings and details shall comply with recognised international drawing standards. The document shall be fully indexed and include a commentary for ease of reference. the Contractor shall provide the Project Manager with three full sets of drawings. 44 . These records shall be available at all reasonable times on the Site for inspection and use by the Employer and by any other person authorised in writing by the Employer.TIF format. The Contractor shall be responsible for ensuring that the construction drawings are in accordance with the approved design drawings and technical specifications.  Three electronic copies of the Final Calculations written to CD or DVD (three sets of CDs or DVDs). reduced to A2 size. the Contractor shall produce the construction drawings which shall sufficiently define the design to provide the basis for the preparation of fabrication drawings and construction of the Works listed in this document and any other matters necessary for the completion of the Works. Upon approval of this single package of information the Contractor shall provide the following:  three sets of bound prints of the As-built Drawings. The Construction Drawings form part of the Contactor’s Documents.4. be fully crossreferenced to the drawings and incorporate all the supplementing technical information to substantiate the design. and o Compressed *. They shall be used to maintain a record of the dimensions and other particulars of the works as they are actually constructed.4.5 “As-built” Drawings and Final Calculations One set of all drawings shall be kept on Site and shall be marked up by the Contractor to show variations in the works.  Tree bound copies of the Final Calculations. The calculation document (bound hard copy and electronic version) shall incorporate the validation certificates.

Each activity shall be uniquely referenced. Float times within the programme shall be clearly shown. logic diagrams / tables and any other necessary tabular and graphical reports shall be submitted to show the following information for each activity on the network:       Reference Description Duration Relationship with other activities Early and Late Start and Finish Dates Resources or Unit Production Time 45 . The duration of activities to be undertaken by the Contractor shall be broken down into periods of one (1) week.The Contractor shall submit. The Operation and Maintenance Manuals form part of the Contractor’s Documents. including the operating parameters.6 Operation and Maintenance Manuals The Contractor shall supply an Operation and Maintenance Manual for the Works. major equipment and their physical and operating and maintenance characteristics. rehabilitation. The work headings to be shown in the programme shall be the main elements of the Work and the structure shall be aligned with the work breakdown structure established and agreed with the Project Manager. Long lead-in items and their lead-in times shall also be identified. The computer software packages for these submissions shall be to the approval of the Project Manager. design. version 2007 or later. delivery. Times allowed for review by the Project Manager and for Third Party Approvals shall be shown in the programme. The “As-built” Drawings and Final Calculations form part of the Contractor’s Documents.4. schedules and submittals in electronic form. construction. The Operations and Maintenance Manuals shall be prepared and submitted for each system and shall be supplemented with Vendor’s instructions and data covering the operation and maintenance of individual items and equipment. 3. covering all installed equipment and setting out of maintenance activities required. The programme shall clearly show the inter-relationship between approvals.5 Progress Control A programme shall be prepared by the Contractor using Microsoft Project software. Work to be undertaken by statutory undertakers and other third parties shall be shown as separate activities. interfaces with other systems. 3. procurement. Each work heading shall be split into detailed activities. copies of all his documents. Bar charts. fabrication. testing and commissioning of each work heading. as well as hard copies. Each system shall be described in brief. in addition to the requirements of this Clause. The programme shall clearly indicate the critical path.

3. 3. and the Project Manager. and design shall be carried out accordingly to avoid risks to health and safety as far as is reasonably practicable. operation and maintenance of the Site.2 Safety Plan Prior to the start of construction.6 Health and Safety The Contractor shall prepare a Construction Health and Safety Plan to fully consider the hazards and risks that may arise during construction. 3.6. 3. and the relevance of personal protective equipment (PPE). as part of the plan. Where slippage has occurred. The Employer or the Project manager shall attend these meetings. such that they understand the risks involved in the works being undertaken. and his proposed procedure for dealing with them should they arise during construction.The Contractor shall assess and report progress on each activity and all other input data not more than 2 days after the scheduled time for an update. which shall be chaired by the Contractor or his designated representative. 3. Changes in the network logic may only be made after consultation with the Project Manager.3 Training The Contractor shall ensure that all personnel employed on or about the Works regularly receive appropriate training by way of tool-box meetings and the like. The plan shall be reviewed and developed / updated as necessary during the construction phase. The Programme shall form part of the Contactor’s Documents and shall be submitted to the Project Manager for review in accordance with the Conditions of Contract.4 Personal Protective Equipment The minimum personal protective equipment (PPE) to be worn by any Contractor’s Personnel on the Site includes: Hard hat Fall protection equipment (Harnesses) 46 .6.1 Site Safety The Contractor shall be solely responsible for all aspects of Site safety within the project area. the safe use of tools and equipment. the Contractor shall give explanations together with his proposals for recovery of critical activities. It shall be co-ordinated with Other Contractors and operators working on Site or on adjacent sites. all potential risks and hazards. The Contractor shall identify. A proper standard of safety supervision and care shall be exercised by the Contractor during the construction and rehabilitation works. The Contractor and all Sub-contractors shall be represented at senior management level together with their nominated Site Safety Officers. This plan shall form part of the Contractor’s Documents and shall be submitted to the Project Manager for his consent prior to the start of construction.6. the Contractor shall prepare a Construction Phase Health and Safety Plan covering all aspects of the Works. The Contractor and Subcontractors shall attend monthly Site Safety Meetings. The plan shall include co-ordinated emergency evacuation procedures for both land and marine based activities.6.

4. 4. Additional PPE. However.1. maintain and adjust fencing. guarding and watching until completion and Taking over.2 Safety and security of the Site The Employer’s premises are completely surrounded by fencing (except for the water front) and guarded full time by watchmen. In case the Contractor has to perform works outside this restricted area he shall obtain the necessary work permits (general work permit. 47 . electrical works. hot works.Reflective vest (except when operating rotating tools) Safety boots/shoes. eye protection and gloves.1 General specifications 4. Motorized Rescue Boat. lighting. The Contractor shall provide. Etc. 4 TECHNICAL SPECIFICATIONS This specification is to be read in conjunction with the relevant Functional Requirements and General Employer’s Requirements respectively and the more onerous requirements shall apply.1 Facilities for Personnel The Contractor will be held responsible for all his personnel. such as hearing. Contractor shall provide life lines and life buoys at all times in easily accessible positions together with a motorized safety boat for rescue work prepared and ready with a skilled crew of a minimum of two persons available for instant use. shall be worn as required by the operations being undertaken and ascertained by risk assessment. The Contractor is responsible for his own HSE & QA/QC plans during design and construction.5 Life Lines. etc. The Employer will indicate a suitable location for the Contractor to set-up his offices. Whenever any floating craft is in use as a ‘safety boat’ such use shall be exclusive and the craft shall not be used for or in connection with any other purpose.6. Life jackets when working over or near water. including the personnel of his subcontractors and suppliers required facilities. No Site accommodation is allowed. canteen and wash/locker room and other facilities required for the execution of the Works. during Rehabilitation Works the Contractor shall adhere to the Employer’s HSE plans.) from the Employer. Such location will be at the premises of the Employer in the vicinity of or at the Site. The area within the Site fence (for a particular Section) will be a restricted area.1. 3. workshops.

1. the Contractor shall keep strictly to the following rules and regulations:   General rules for contractors.1. The Contractor shall establish a permanent benchmark on the Site and arrange for the benchmark to be independently verified by an approved authority or survey company. The Contractor shall carry out a pre. Besides the safety rules and regulations prescribed by Law.4.7 Facilities for Employer’s staff The Contractor shall provide and maintain for the period of the Contract.6 Setting Out The Contractor shall verify and agree the co-ordinates of existing benchmarks. with windows and air conditioning containing:           Desk (with drawers) Table 2 chairs 4-draw filing cabinet 4 shelf book-case Tea/coffee making facilities Telephone Computer Stationery and office equipment Surveying equipment 48 . Site office.1. lines or levels of reference he requires for the execution and completion of the Works and the remedying of any defects therein. minimum size 3m x 4m.and post survey of applicable roads in the presence of the representatives of the relevant Authorities to document the state of these roads. the following accommodation and facilities for use by the Employer’s staff. including those of the neighbouring site and port operations and to co-ordinate and cooperate to ensure health and safety on the Site. 4.4 Use and Care of Roads The Contractor shall take care to avoid damages to existing roads and shall repair any damages to roads caused by his activities at no cost to the Employer. and shall remove on completion of the contract.1. A copy of the above mentioned rules and regulations will be made available to the Contractor before the Date of Commencement.5 Disruption to Neighbouring Works The Contractor shall liaise with the Project Manager and Other Contractors to minimise disruption to all works.3 Employer’s Regulations on Site The Site is located next to and on the Employer's Terminals. The Contractor shall provide additional setting-out points. 4. The Contractor shall protect and maintain all permanent benchmarks until the end of the Defects Liability Period.1. General safety regulations for contractors. 4. 4.

8 The contractor shall provide cleaning and maintenance of these facilities throughout the contract. The Test reports are part of the Contractor’s Documents. 4. water pollution. the codes. with windows and air conditioning containing:  Table  chairs 4.1. The result of such tests shall be submitted to the Project Manager at the times specifically stated or if none is stated as soon as possible. The Site shall be kept clean and tidy at all times. The activities on the Site shall not be permitted to create excessive noise. Attending of tests The contractor shall invite the Project Manager and employer to witness the laboratory and insitu tests.11 Site Cleanliness The Contractor shall at all times be responsible for the proper upkeep and maintenance of the Site and the Works. Schedule of Tests Contractor shall provide a schedule of Tests and details of laboratory and equipment to Project Manager for review and approval prior to starting any testing.9 Contractor’s Laboratory General In order to carry out the specified tests the Contractor shall arrange a Site laboratory or employ a laboratory to carry out the tests needed to control the works. 1 set of waterproof clothing Meeting room.1. dust. 4. the Design Report and the Technical Specifications.1. The Project Manager shall be given reasonable opportunity to witness all testing. 4.10 Testing of Materials and Workmanship General The Contractor shall for the purpose of checking the compliance of materials and workmanship with the requirements of the Technical Specifications carry out tests at the frequencies stated in the approved QA Manual. Schedule of Tests Contractor shall provide a schedule of Tests and details of laboratory and equipment to Project Manager for review and approval prior to starting any testing. etc. 49 . The contractor shall provide two (2) 4x4 cars (Toyota Landcuiser type or alike) including the insurance and the running cost.1. minimum size 3m x 4m. Attending of tests The contractor shall invite the Project Manager and employer to witness the laboratory and insitu tests.

Water and other Services The Contractor shall be responsible for the provision of all power. Contractor shall promptly remove any vehicle. In particular. The Contractor shall be responsible for making his own arrangement for suitable and adequate supply of water for the purpose of executing construction and erection works. No polluted water shall be disposed to the sea. tidied up and left to the satisfaction of the Project Manager. water and other services he may require. the Site area cleaned. the Project Manager. to provide. On the instruction of Project Manager. 50 .12 Access for Third Parties The Contractor shall ensure that he maintains safe and unobstructed access for third parties as specified and agreed between the Contractor and the Employer. 4. showing name and logo of the Employer. The Contractor shall make on Site his own arrangements for telephone and potable water supply and discharge of foul water. the Contractor shall supply and erect a notice board. The Contractor shall comply with the requirements of the Authorities having jurisdiction over such supplies and installations. 4. the name of the Project. all temporary fences and structures shall be removed. 4. Contractor shall ensure that his activities are conducted not to interfere at all with shipping and navigation or any vehicular traffic. and maintain electrical generator(s)). The layout and location of the notice board shall be agreed between the Project Manager and the Contractor. 4.13 Electricity. operate.1.1. the name and logo of the Main Contractor and of the Sub Contractors on Site.In addition the Contractor shall arrange for the collection of rubbish by the provision of suitably located and regularly cleared bins. Contractor shall allow in his programme for any interruption or effect on his working due to vessels berthing and un-berthing at the Port or other shipping movements in the area. including loading/unloading operations.14 Publicity and Public Relations Within one week of commencing work on Site. and after-hours telephone numbers. The Contractor shall be responsible for making his own arrangement for electrical power supply for the purpose of construction and erection works (i.1.1. vessel or other equipment within his control that may be causing obstruction to the use of the existing facilities by others. Contractor shall be responsible for consulting regularly through Project Manager with the port authorities to confirm that his method of working is such as not to impede in any way the operation of the Port and for modifying his method of working if Port operations are adversely affected by his activities. On completion.e.15 Port Operations and General Information Contractor shall note that other port terminals and approaches thereto will be in full operation during the progress of the Contract and the Work must be programmed and executed in such a manner as not to cause inconvenience or interference to port operations and users.

1. for the duration of the Contract. moorings and buoys shall be arranged so as to cause a minimum of interference with the normal shipping traffic in the area. Contractor shall be responsible for complying with any conditions that may be imposed regarding the use of the waterfront facility. All parking of Contractor’s vehicles and those of his employees and people under his direct control shall be confined within his working areas. removing such temporary works on completion or when no longer required and reinstating any works disturbed.16 Tidal Levels Contractor should make himself fully aware of times. he shall take all necessary precautions to prevent damage thereto. executing all temporary works necessary for his utilization of the waterfront facility. The motor boats shall be suitable for the local conditions and in good condition. 4. executing all temporary works necessary for his utilization of the facilities. however. and making all necessary arrangements with and paying any charges due to the appropriate authority. Contractor shall inform his sub-contractors of these restrictions and ensure that they comply with them. in the event of an emergency. Contractor shall maintain. Contractor shall be responsible for complying with any conditions that may be imposed regarding the use of the berthing facilities. removing such temporary works on completion or when no longer required and reinstating any works and/or ground disturbed. Emergency Access In addition to all floating craft. ranges and depths of tides and make due allowance in his manner and mode of working. Such precautions shall not.Contractor shall obtain all necessary permits required by different authorities. sufficient motor boats to be able to rapidly evacuate all members of Contractor’s and Employer’s staff employed on construction of the jetty. By Sea Where Contractor brings working equipment or Materials to the Site by sea. he shall be responsible for obtaining the consent of.17 Site Access By Road If it is unavoidable that Contractor has to drive tracked vehicles along existing roads or tracks.1. 51 . Subject to the approval by the Project Manager is Contractor to bring plant and/or materials onto the Site by sea. The Contractor shall give The Ports Authority and the Employer and any other relevant statutory authority prior notice of the commencement of marine operations and shall keep them informed of the transfer of operations from one area to another. relieve Contractor of his responsibility for reinstating any damage caused to the roads or tracks to the satisfaction of Project Manager. The progress of the work. safety boats etc. 4. The Contractor's operations shall not interfere with work being carried out by other contractors except when in the opinion of the Project Manager such interference is unavoidable. prior to commencing work on Site. the movements of the contractor's floating plant and vessels and the location of temporary works.

All such approaches bridges.1. Contractor shall provide suitable temporary approaches.1.19 Restriction on Use of Public Roads Contractor shall not make use of roads for depositing or storing plant. Contractor shall provide and maintain temporary diversion ways wherever the Work will interfere with existing public or private vehicular or pedestrian rights of way. All members of staff employed on the jetty shall be fully conversant in the operation of the motor boats and be instructed as to the location of the boats at the beginning of every shift. to permit rapid evacuation. Where. gangways and roads shall be maintained in service until it is agreed with Project Manager that this use is no longer required.H. Such diversion ways must be constructed in advance of any interference with the existing rights of way and shall be of a standard suitable in all respects for the class or classes of vehicles or pedestrians requiring using them. 4. gangways and roads.22 Existing Services Contractor shall make his own investigations to establish the exact location of existing services which may affect or be affected by the construction of the Work. Equipment. All floating plant or other vessels navigating within the Port Area must carry a V. etc. it is necessary to provide safe and expeditious access to different parts of the Plant. before using 52 .20 Traffic Safety Measures Contractor shall maintain all traffic safety measures in good working order and condition at all times and shall reposition. 4. crossovers. tools implements and temporary works shall be placed in such a way as to cause minimum interference with the use of any right of way by Project Manager or other parties. Notwithstanding these requirements. 4.18 Radio Communication Contractor shall be responsible for all necessary communications with the Port Authorities.1. hard standings. bridges. materials. footpaths. cover or remove them as necessitated by the progress of the Works. In addition Contractor shall. tools or implements. Contractor shall ensure that his transmissions and equipment comply with the requirements of the appropriate Statutory Authorities. materials.F. 4. radio capable of working on Marine Channels as required by Port Authorities.The motor boats shall be located adjacent to working areas whenever work is being undertaken on the jetty. within Employer Site and shall provide temporary protected footpaths outside the boundary if required to protect Third Party properties.1. tracks. 4. Contractor shall remove temporary diversion ways when no longer required and shall reinstate any disturbed ground or works. all radio equipment shall be operated on a private frequency which shall not interfere with any other local transmission or other equipment of any type. in the opinion of Project Manager.1.21 Temporary Approaches & Diversion of Existing Rights of Way Contractor shall form all temporary roads.

26 Port Regulations Contractor shall at all times observe the regulations of the port authorities regarding navigation and safety and shall obey all local instructions. including sourcing certification and other supporting documentation as specified within this Specification shall be maintained by Contractor. All floating plant operated by Contractor shall display at all times such lights and/or shapes as are laid down in the “International Regulations for Preventing Collisions at Sea” relating to such craft or its nature of work and shall keep a listening watch on an appropriate radio frequency channel so that when necessary he can be made aware of traffic movements in the vicinity.1. lighting and watching the Work or any structure vessels or offshore plant which may be used in connection with the Work and for the 53 . All drains. 4.mechanical plant in the vicinity of existing services. whether above or below ground.24 Scaffolding Where necessary Contractor shall provide. Contractor shall draw this to the attention of Project Manager and if required to do so Contractor shall arrange with Service Authorities to divert. Contractor shall exercise the greatest care during the construction of the Works to avoid damage to or interference with any existing services and shall be responsible for any such damage caused by him or his agents directly or arising indirectly from anything done or omitted to be done. that are encountered during the course of the work shall be left in position and be carefully supported and guarded from damage by Contractor to the satisfaction of all owners and proper authorities so that such drains. A detailed description and quantified breakdown of all imported material. Etc If any Public Utility or privately owned services or other obstructions are required to be removed during the construction of the Work. 4.1. 4. erect.1. 4. dismantle and clear away on completion proper and adequate scaffolding.1. Buoying and Watching Contractor shall be responsible for complying In every way with the requirements of any statutory or other authority having jurisdiction so to require in respect of marking.27 Lighting. maintain.1. Contractor shall carry out all temporary works necessary to adequately support and protect any existing services. 4. Any damage to mains or services shall be notified immediately to Project Manager.23 Removal of Public Utility or Privately Owned Services. to verify the location of existing services. protect or take whatever action is required. pipes and cables may continue in use until the completion of the Work or until no longer required. carry out full and adequate preliminary investigations by means of hand-dug trial holes and the like.25 Records Contractor shall ensure that his own copies of all records for matters relating to the Contract are kept available on Site for inspection by Employer. Contractor shall be entirely responsible for all safety precautions in connection with the scaffolding and for its entire sufficiency for the work. pipes and cables. Marking.

Should Contractor in any way obstruct or affect lights. lines and moorings and shall be fully equipped with lights. or for the safety and convenience of the public or others. signals. shall be fully provided with sound and satisfactory ropes.. If in the opinion of a person having authority at the port management any craft is unsafe to be used to transport staff.1.30 Floating Plant Whenever floating plant is employed by Contractor for the purpose of the Work. markers.issue of local notices to mariners. Contractor shall provide all vessels and offshore plant with approved fog warning devices which shall be operated in accordance with the requirements of the said authorities. At all times Contractor shall be wholly responsible for the protection and safety of all floating craft engaged by him. Contractor shall provide all buoys and other markers required for the proper indication of submerged work and moorings for his vessels and offshore plant. as required by the said authorities commensurate with the nature of the work in which they are engaged. etc. markers.1. Contractor shall be responsible for ensuring that all moorings have lights and marker buoys which conform to International Association of Lighthouse Authority Regulations. fencing and lighting in sound condition until either the Work is completed or Project Manager decides that such services are no longer required. Contractor shall maintain all such lights. for diving operations or as a safety boat. 4.1. lighting and maintenance required in connection with the foregoing and he shall also provide and maintain any guards. Contractor shall ensure that all his vessels and offshore plant carry at all times the correct lighting.28 Navigation Contractor shall be responsible for complying in every way with the requirements of any statutory or other authority having jurisdiction with respect to the navigation and movement of his vessels and offshore plant in and around the area of the Works.29 Liability for Damage to Shipping Contractor shall be held responsible for any damage or injury to shipping or craft of whatever description which may occur during the execution of the Contract through any act or omission or default of Contractor or of any person in his employ or for whom he is responsible. If such attendance is not possible they must be moved to an approved mooring location. signals. shall have adequate attendance by competent seamen at all times. he may order the craft to be withdrawn and 54 . All lights required by Contractor shall be so placed or screened so as not to interfere with or be mistaken for any navigation lights or with or for any signal lights. fencing required for the protection of the Plant. buoys or navigational aids then he shall at his own expense pay all costs whatsoever for the resetting and reinstating or providing alternatives for the aforesaid to the satisfaction of the said authorities. such plant shall be maintained in a satisfactory and seaworthy condition. radar reflectors. He shall also provide every description of watching. 4. 4. guards. buoys. All vessels and offshore plant working or moored shall be attended at all times.

Contractor shall provide on his floating plant a VHF radio receiver/transmitter with authorised channels for the purpose of maintaining contact with the Port Authority concerning shipping movements. Contractor shall submit to Project Manager for review detailed sketches showing the dispersal of his proposed moorings within the Port. Contractor shall not lay down or provide moorings at any locations where they may present a hazard to any shipping using the Port. charges on goods. Contractor shall ensure that there is no spillage of oil or other contaminant into the sea. wharfage.H. and anchorage charges. 4.31 Avoidance of Nuisance Contractor shall ensure at all times that spillage does not occur of concrete.1.F.replaced by another which. all radio equipment shall be operated on a private 55 . All craft must be fitted with V. in his opinion is in all respects suitable for the work. which must be operational at all times whilst the craft is under way. conservancy charges and other charges in respect of the conveyance to Employer Site of all materials and plant required for use in or in connection with the Work. oils or other deleterious material into any new or existing drainage.1. radio provided with channels in accordance with the requirements of the Port Authorities and any statutory or other authority having jurisdiction with respect to the navigation and movement of his vessels and offshore plant. Nevertheless. to the satisfaction of Project Manager. Notwithstanding these requirements. should any drainage or duct system or water course be fouled by such materials Contractor shall clean the drainage or duct system or water course at his own expense. 4.1.35 Radio Transmissions The use of radio communication equipment on the Site by Contractor shall be subject to prior review by Project Manager. duct system or water course. 4. charges on vessels and offshore plant.32 Underwater Obstructions Contractor shall mark all temporary underwater obstructions with buoys and lights and do all things necessary for the safety of navigation while the obstruction remains and shall remove any such obstruction at the earliest possible time. 4. Before commencing any work which could involve spillage into the sea.33 Temporary Moorings Contractor shall not lay down or provide moorings for his vessels and offshore plant apart from temporary moorings in such position and laid or provided in such a manner and such conditions as may be permitted by Project Manager.1. The costs involved in such replacement shall be borne entirely by Contractor. 4. Contractor shall consult Project Manager and provide such effective anti-pollution measures as may be required to prevent such spillage. In the event of any such spillage it must be immediately reported to the Port Authorities.1.34 Port Charges Contractor shall pay all dock charges.

. at his own expense.frequency which shall not interfere with any other local transmission or other equipment of any type. Contractor shall give both Project Manager and the said authorities’ immediate notice of the occurrence of any such sinking. 4.1. to enable Project manager to contact Contractor’s vessels from shore. Contractor shall ensure that his transmissions and equipment comply with the requirements of the appropriate Statutory Authorities. Contractor shall be responsible for obtaining all necessary approvals from all statutory or other authorities prior to undertaking diving operations. Contractor shall provide a suitable two-way radio complete with all necessary licenses.37 Removal of Sunken Vessels and Offshore Plant Contractor shall forthwith and with dispatch raise and remove any vessel or offshore plant belonging to him or to any Subcontractor or to any person employed by him which may be sunk or stranded or gone adrift in the course of the Work or otherwise deal with the same as Project Manager may direct until the same shall be raised. check.1.1. remove from the sea. before commencing work. Contractor shall buoy and light and do such things for the safety of navigation as may be required by Project Manager or any statutory or other authority having jurisdiction. removed or recovered. On completion of the Works Contractor shall guarantee that the area around the jetty is clear of all debris. The fact that the vessel and offshore plant sunk. When required by Project Manager. 4. etc.40 Emergency Arrangements The Contractor shall maintain arrangements whereby he can quickly call out labour outside normal working hours to carry out work needed for an emergency associated with the Work or an emergency at the site. which may in any way cause damage to vessels using the jetty.38 Debris in the Sea Contractor shall. Before any excavation or breaking out. stranding or going adrift as is referred to in this clause. 4. solid. He shall not discharge into the water area any oil. 4. verify and satisfy himself as to the existing levels of Employer Site and existing structures and agree them with Project Manager. the sea bed and foreshore any floating or submerged debris caused by the construction of the Work.39 Existing Ground Levels Contractor shall. stranded or gone adrift is insured or has been declared an actual or constructive loss shall not absolve Contractor from his obligations under this clause.1. noxious or floating material and all water discharged into the sea shall be reasonably free from impurities. Project Manager shall be provided at all times with a list of addresses and telephone 56 . 4.1.36 Diving No diving operations within the Port Limits shall take place without the prior authorization of all authorities having jurisdiction over the area concerned. Contractor shall define reference lines for setting out the Plant.

1. crane. 4. All work classed as defective work shall be removed and replaced so as to be acceptable to Employer. containers. size and of such method or working as is acceptable to Project Manager. concrete mixer. In particular the Project Manager may prohibit or suspend the use of machinery which in the Employer’s opinion is likely to remove more material than is necessary.42 Construction Plant All constructional plant used on the performance of the Works shall be of such type. cutting out of defective concrete work shall be carried back to form satisfactory construction joints before the replacement of defective work and any other work thereby affected is commenced.1. vibrator. bearing the name of the manufacturer and the brand. Similarly the Project Manager may prohibit the use of machinery causing a nuisance by noise or otherwise. Two copies of a certificate verifying that the materials meet the specified requirements shall be provided by Contractor to Project Manager with each main delivery of prime materials. 57 .1. or any other property or works of any kind. 4. Damaged materials or manufactured items damaged during and after fixing in position shall be removed and repaired or replaced by and at Contractor’s expense. Materials shall be carefully loaded. does not comply with all the relevant requirements of this Specification. protected from damage and exposure to weather or dampness during transit and after delivery to the Site. together with the results of any tests that are required by the Specification and the relevant Standards. etc. e.g. Handling and Storage of Materials All Materials that are liable to damage shall be delivered in the original package. In all cases.numbers of the Contractors staff who are currently responsible for organizing emergency work. that part of the FUF shall be classed as defective work. 4. or that any such machine or appliance employed or proposed to be employed by the Contractor for the purpose of the Works shall not be used. mechanical digger. The extent of the work to be removed and the methods to be used in the removal of this work shall be in accordance with Project Manager’s directions. Any change of the method of performing the work as a consequence of such order shall be at the cost of Contractor who shall have no cause for claim against the Project Manager on account of having to carry out the work by another method or for the idleness or removal of any constructional plant. then such equipment shall be immediately withdrawn from use. or the Materials or workmanship in any part of the FUF.41 Delivery. Contractor shall acquaint himself and his employees with any relevant local arrangements which are in existence for dealing with emergencies at the Port. transported unloaded and stored in the approved manner. damage or render unstable any structure.43 Defective Work Where any of the finished work. or that any such machine or appliance as aforesaid is unsuitable for use on the Works or any part of them. If for any reason whatsoever Project Manager shall be of the opinion that any excavator. aggregates or cement or as required by Employer.

44 Surveys Initial Survey Before any temporary or permanent works are carried out. The levels shall be taken at intervals not exceeding 1m. except as amended herein. Three copies of all survey plots and the visual records shall be given to the Project Manager. The bathymetrical survey shall include a level survey of the dredge location as well as the disposal location. The bathymetrical survey shall include the dredged berthing pocket.1. e) Diving Survey A final visual diving survey shall also be carried out to confirm that the seabed in the vicinity of the berths is free of obstructions on the seabed. The levels shall be to an accuracy of + 2mm. the Contractor shall carry out a number of initial surveys of the Site. d) Bathymetrical and level Survey A final positional and level survey on the site (including the Jetty and bathymetric survey) shall be carried out by the Contractor on completion of the works.1 Dredging General All dredging works shall comply with BS 6349 Part 5 1991. including full particulars of all dredging and other plant. Final Survey Upon completion of the construction works a number of final surveys shall be undertaken.2. The method and sequence of dredging shall be such as to ensure that no damage is caused to existing Port facilities and that the tolerances given herein can be achieved.2 4. craft and equipment which he proposes to use. in accordance with clause 4. 4. Before any dredging plant is brought to the Site the Contractor shall agree with the Project Manager the method and detailed program for carrying out dredging work.10 of this section of the Bidding Documents. The survey shall define the positions and levels of all items to be effected by the works or for reference.4. 58 . The location and level surveys shall be plotted to a suitable scale to each single A0 sheet. All measurements shall be to an accuracy of + 5mm. size and location of any existing obstructions on the seabed. c) Diving Survey A visual diving survey shall be carried out to confirm the existence. The scope of the surveys shall include but not be limited to the following items: a) Geotechnical Soil Investigation A soil investigation shall be carried out by the Contractor. The required scope of work of the investigations shall be determined by the Contractor. b) Bathymetrical and Topographical Survey A positional and level survey of the onshore Site as well as the offshore site.

pipes. concrete. Contractor shall be responsible for the clearance and disposal off Site of any manufactured or fabricated items that are encountered in the dredging areas. The method statement shall confirm and expand upon the information previously provided with Contractor’s tender and shall include the following: i) ii) iii) iv) Details of proposals for conveying dredged material to the disposal site.2.2. Contractor shall immediately inform the Project Manager and await instructions before proceeding with the removal of same. ropes. Detailed program. Methods to be employed in all dredging operations shall be issued for review by Project Manager in advance of any work commencing. Any other details required by the Employer. tires or similar. cables.2 Dredging Plant Contractor shall provide and maintain in good order all plant and equipment required for the successful execution of the Work.2. The gauge shall be accurately leveled and related to Port Datum and periodically checked for level monthly during the duration of the Works. before the required dredged profile has been achieved. 4. 59 .5 Position Controls The methods by which the horizontal dredging limits are to be established shall be presented to Project Manager for review. timber. for the duration of the Contract. Where major items of wreckage are encountered. wires. Contractor shall ensure that his dredging operations do not in any way interfere with or endanger shipping or navigation and shall at all times take full account of all relevant requirements of this Specification.Contractor shall take every precaution to minimize the possible negative effects on the environment due to the dispersion and deposition of silt in the waters in and around the area of his dredging operations and he shall provide detailed proposals in this respect for review by Project Manager. Details of all plant and equipment to be employed on the dredging works. 4. rock in varying states of weathering. 4. including fresh rock and materials or items of a manufactured nature such as chains. or a combination thereof. Contractor shall submit to Project Manager for review a detailed method statement for undertaking the dredging work. which shall include natural bed materials. Due regard shall be paid to limitation on access to the areas for dredging and the required tolerances. Details of the types and outputs of dredging plant to be employed shall be provided for the Project Manager which shall confirm and expand upon information supplied with Contractor’s bid.3 Dredging in Any Materials Dredging shall be carried out in any type of material which may be encountered. anchors. Dredging shall be carried out using suitable floating or shore-based plant. Within 28 days after the acceptance of his tender.2. castings. steelwork. a tide gauge of approved pattern at an agreed location. 4.4 Tide Levels Contractor shall establish.

Contractor shall notify Project Manager of his intention to survey at least 24 hours prior to the survey. shall be 300mm. If required by Employer. Contractor shall provide a motor boat. which have been achieved as the work progresses and to provide a basis for evaluating interim payments. fully manned with experienced staff and equipped with echo sounding apparatus.7 Dredging Tolerances No part of the finished dredging work shall. 4. together with competent operators to ensure that the position of dredging plant can be accurately located to within 0. Contractor shall allow for all surveys to be witnessed by Project Manager and provide suitable facilities accordingly.5m in plan.2. any over.8 Side Slopes Side slopes shall be formed to profiles designed by Contractor.lm. Contractor shall prepare record drawings of the pre-dredge and post-dredged surveys carried out for review by Project Manager and shall provide copies of each agreed drawing to Project Manager. Contractor shall demonstrate to the satisfaction of Project Manager that the slopes to be provided in the various material types shall be stable.5m and recovered whilst dredging is being undertaken. be higher than the specified dredged level or profiles. which shall record output onto a paper tape. interim and post-dredge level surveys. 60 .6 Survey During the course of the dredging. Contractor shall make good. The paper printout shall have minimum scale of 1 in 100 from which the water depths can be scaled. 4.excavated areas with such material and in such a manner as Project Manager shall direct.2. Project Manager may require Contractor to extend the surveys to cover other areas in order to determine whether material is being deposited within these areas as a result of the dredging operations or for any other purpose in connection with the Work. When the dredging has been completed. Contractor shall carry out interim surveys as Project Manager may require for the purpose of checking the dredged depths. the dredged areas shall be surveyed by Contractor jointly with Project Manager to ensure that the dredging has been carried out to the required levels and profiles. Within 30m of any existing structure or proposed new structure the maximum permitted over dredge. at his own cost. 4.2. on completion. The levels of the seabed shall be recorded by means of echo sounding equipment with an accuracy of not less than ±0. below the required dredged levels. available for use at any time throughout the duration of the Contract.Contractor shall provide and maintain on board all dredging plant adequate position fixing systems. For the purpose of carrying out pre-dredge. Equipment used for determining the locations of the sounding positions shall be capable of fixing positions to an accuracy of 1 .

Failure to submit track plots shall result in a deduction from the contract value of USD 5.10 Siltation Contractor shall dredge and dispose at his own cost any material which. The dumping site has to be surveyed to ensure that disposal would not do any harm to that location. Trailing suction hopper dredgers will overflow their hoppers only to the extent that economic loads are achieved and the Contractor will undertake to give their utmost co-operation to the Engineer to minimize deleterious influences caused by overflow and any migration of fines beyond the dredging area. The Contractor shall carry out a pre-dredging and post-dredging survey and present these results to the Engineer for approval. 4. the sediment to be disposed off has to be tested to ensure that its pollution content is within the legal limits. 61 . all vessels involved in the dumping operation shall be equipped with a track plotter integrated with a computer/DGPS receiver.0 m above the outside sea level the retained water level is maintained. Prior to signing of the Contract the Employer will advise the selected Tenderer the exact details of the sea disposal site. All non-contaminated dredge material shall be disposed of in a designated sea disposal site at a distance of 3.9 Disposal of Dredged Material The Contractor shall make his own arrangements for the disposal of surplus or unsuitable material off Site. To verify that dredge material is disposed of at the designated sea disposal area. such that when the hopper is filled with water to a level of 1. He shall be responsible for all liaisons and for obtaining any appropriate licenses.11 Sweeping On completion of dredging Contractor shall undertake a physical sweep of all dredged areas to ensure that the seabed is level and free from projections above the respective specified minimum levels.2. or at least does not fall at a rate greater than 300 mm per hour. Over dredging will not be permitted within 30m of any structure for the purposes of forming of side slopes by over dredging or slope instability. Contractor shall remove any such projections and sweep the area again to check that their removal is complete.2.000 per trip. copies of which shall be provided for Project Manager prior to the commencement of dredging.No portion of the finished work shall be higher than the approved lines and levels unless directed by Project Manager. The track plots shall be submitted to the Engineer on a daily basis and not later than 24 hours after the respective trip has been completed. All hoppers or barges used for the transport of dredged materials shall only be used with good door or aperture seals. 4.5 nautical miles (nm) West South West of the heads of the breakwaters. The Engineer may at any time require that the effectiveness of hopper seals be proved by means of the test described. Such slopes shall be accurately formed to the required profiles. The use of automatic or manual "light mixture overboard" shall not be operated when the density of the pump mixture is in excess of 1050 kilograms per cubic meter. 4. The route of each trip of the vessel(s) shall be plotted.2. during the period between the dates of commencement and completion of all dredging operations. accumulates above the specified dredged levels within the area to be dredged.

3. e. Methods of anchorage and positioning of dredger. Method of position control. Methods of investigations to determine extent of material requiring pre-treatment. l.12 Daily Records Contractor shall keep daily records of the dredging work.2. Procedures for handling and storage of explosives. The records shall include the following information:a) Type of material(s) dredged b) Areas of materials dredged c) Estimated volume dredged d) Weather and sea conditions e) Tide plot f) Times. vessel movements and construction works by others within the Port. sequencing and programming.2. Pre-treatment methods. surveys and soundings to be used.) and references can be provided by Contractor. n. g. 62 . k.14 Method Statement Not less than 14 days before commencement of any rock pretreatment or dredging work Contractor shall provide a full and detailed Method Statement for the dredging and pre-treatment works to Project Manager for review. h. duration and causes of all stoppages 4. c. Methods of achieving stable dredged slopes. welding.4. m. Measures to be taken to control dispersion and deposition of silt and to absolutely minimize adverse environmental effects. b. 4. fabrication etc. Demurrage will only be paid should Contractor be prevented from working by order of Employer. Methods of dredging adjacent to existing or new structures. d. No demurrage will be paid for any effects on dredging operations due to shipping movements or construction works by others within the Port. j. 4. Methods of disposal of dredged material. 4. i.1 General This Section describes the minimum piling requirements for supply. Methods of control and placement of dredged material placed as fill (if any). Sequence and programming of dredging.2. Type and capacity of dredgers and barges.13 Existing Operation Contractor’s attention is drawn to the restrictions on his operations due to Port operations.3 Piling Work Spirally welded tubular steel piles may be used as an alternative to longitudinally welded tubular steel piles (described and specified below) provided satisfactory documentation (material. delivery and construction of piling works associated with the construction of the Jetty. f. Measures to be adopted to avoid interference with port operations and ferry movements. Methods of ensuring vibration limits are not exceeded and monitoring procedures to be adopted. The Method Statement shall cover all aspects of dredging works including the following: a.

including the sequence of piling and type of plant which he intends to employ prior to commencement of any piling work. Project Manager may require piles so positioned to be withdrawn and re-driven or take such other action as considered necessary. The piles shall be anchored using approved means. Where piles have not been positioned or driven within the limits described in the Contract. All piles shall be longitudinally seam welded tubular steel piles with concrete plugs at the top and bottom. In the event that the piles cannot be driven to their design penetration the Contractor shall notify his Designer and propose a solution to achieve the required penetration.Piling work shall conform in all respects with the principles contained in BS 8004 . Contractor shall be responsible for ascertaining the available capacity of partly completed piles and for demonstrating to the satisfaction of the Project Manager. Contractor shall ensure that the method and sequence of piling operations does not in any way interfere with or endanger shipping or navigation. 63 . Longitudinal seam welds shall be carried out by automatic welding by a metal arc process in accordance with BS 5135 with full penetration butt welds. The manufacturing tolerance shall be such that the actual weight of any section does not differ from the theoretical weight by more than -2. The Contractor shall provide the necessary piling plant required to install the piles to achieve the required programme. that adequate capacities are available at each stage to facilitate the construction of the works in the temporary condition without overstressing the pile casings or sockets. if so required. fabricated from steel conforming to BS EN 10025 or equivalent. Materials to be used for the Contract shall be new. The pile shall be cleaned out to toe level. The Contractor shall give due and reasonable notice of his intention to drive piles so that the Project Manager may make arrangements for inspection if he so requires. pile penetrations and bearing capacities.3. Contractor shall take full responsibility for determining the length of casing after the pile test described in this Specification.2 Materials Tubular steel piles shall have dimensions and steel grades as shown on the Drawings.Foundations. Contractor shall submit to Project Manager for review detailed proposals. The external dimensions at any section measured by using a tape on the circumference shall not differ from the theoretical dimensions by more than -1% to +1%. as required by Contractor’s design. 4. or unused in good condition as new. no method of forcible correction shall be permitted. In addition to submitting the records required by this Section Contractor shall report immediately to the Project Manager any circumstances which indicate that the ground conditions differ from those expected by Contractor from the site investigation to be undertaken so as to affect materially the bearing capacity of the pile.5% to +5%.

Welding All welding shall be by the metal-arc process in accordance with BS 5135 using consumables / processes producing a diffusible hydrogen content greater than that specified in BS 5135. 4. i. or an alternative supply of tubes to be identified. Stick electrodes for the manual metal arc welding of mild and medium tensile steel shall comply with the requirements of BS EN 499. when it is necessary to lengthen piles after installation. PQR test shall be done to confirm the compatibility of the welding electrodes and the steel grade.e. by welded splices using full penetration butt joints. BS EN 10113-1. prior to delivery of the tubes. Where original test certificates are not available or cannot be directly identified with unused second hand material Contractor shall arrange for mechanical and chemical tests to be carried out in accordance with BS 7668. samples cut from each size of tubes from each source. BS EN 10210-1 upon a minimum of 3 No. Where the results from such tests are inconsistent or otherwise unsatisfactory Project Manager may require additional tests to be carried out. Where pile splices are to be made in situ. The chemical composition and mechanical properties of welding consumables shall be compatible with the grade of steel to be welded and shall produce a joint equivalent in strength to the parent metal. Electrode wires for the metal inert gas or metal active gas arc welding of carbon steel and medium tensile steel shall comply with the relevant requirements of BS 2901. these shall also be full penetration butt joints. He shall also submit details of any temporary fixtures to the piles he wishes to use to facilitate handling. less than l0ml of hydrogen per 100g of weld metal deposited. Electrodes for welding shall be compatible with the grade of steel to be welded and shall produce a weld equivalent in strength to the parent metal of the tubular steel casing. Table 1. before taking possession of the piles.4 Fabrication and Splicing of Steel Piles General Tubular steel piles shall be fabricated for installation in one piece by Contractor. transporting and pitching shall be carried out in a manner which shall avoid damage to the piles. All operations such as handling. 4. BS EN 10155.3.3. 64 . submit to Project Manager for review detailed proposals for storing handling and transporting the piles. Scale C.3 Handling and Storage of Piles Contractor shall. Longitudinal seam welds of lengths of piles forming a completed pile shall be even staggered at joints whenever possible and always by not less than 100mm.Contractor shall record and retain certified copies of test sheets covering each consignment of piles received by Contractor stating the process of manufacture and giving the results of each of the mechanical tests applied and of the chemical analysis. Contractor shall note that paint and other surface treatment to unused second-hand materials is to be fully removed and the ends of tubes shall be prepared as necessary for welding.

The acceptance criteria for butt welds shall be to BS 5135 Table 18. Quality Category B for circumferential butt welds for bearing piles designed primarily to resist axial loads and Category A for 65 . Where required. with inter-run cleaning carried out between each weld pass to remove all slag and any other non-metallic deposits. They shall be thoroughly cleaned and fused with the final weld. free from rust. Weld Testing and Approval Approval testing of welding procedures and operators shall be in accordance with BS EN 288:3. electrodes shall be re-dried to restore them to a satisfactory condition. together with the details of the manufacture. shall be submitted to the Project Manager for review and no changes in procedure shall be made without Employer’s prior agreement. in each case accompanied by diagrams showing the build-up of all welds. All welds shall be finished full and made with the correct number of runs. Indirect earth returns will not be permitted. and all irregularities. all adhering slag being carefully removed from the exposed faces immediately after each run. Completed welding shall be subjected to 100% volumetric examination together with surface flaw detection in accordance with BS EN 1435. Temporary tack welds shall be subject to the same quality requirements as the final welds. When carrying out welding operations on installed piles Contractor shall ensure that the earth return to the welding site is attached to the pile.Electrode wires and fluxes for the submerged arc welding of carbon steel and medium tensile steel shall comply with relevant requirements of BS EN 756. loose scale. Welders shall be qualified in accordance with BS EN 287:1 and copies of approval test certificates shall be made available for review by Project Manager. classification. The acceptance of welded work shall depend upon correct dimensions. Surfaces to be welded shall be dry. undercutting and porosity shall be eliminated to ensure good corrosion resistance. including details of any preheating required. code (as defined in BS EN 499) and size of electrodes. Welding consumables shall be handled in accordance with the manufacturer’s recommendations with instructions for the storage. Full details of the welding procedure proposed by Contractor. Welding sequences shall be such that distortion is reduced to a minimum. alignment and absence of distortion in the finished work. and local distortion is rendered negligible in the finished work. the soundness of the welds and general good workmanship. Particular care shall be taken to ensure the smoothness of finished welds. satisfactory results from the examination and testing (where required by Project Manager) of the joints. which shall be smooth and flush with the adjoining surfaces of the parent metal. baking and re-drying of fluxes and/or electrodes strictly adhered to. Contractor shall be responsible for the consequence of any distortion that may occur. BS 3923 and BS 6072 as appropriate. All welds shall be finished to produce a smooth weld profile and full throat thickness having been deposited in accordance with an approved welding procedure. grease and paint. the welds being kept free from slag and other inclusions.

7 Pile Design The piles shall have working load capacities appropriate to their design. All testing operatives carrying out ultrasonic weld testing shall be approved for the relevant connection type and copies of their qualification certificates shall be made available for review by Project Manager. Piles shall have a safety factor as detailed in of 2. radiographic and magnetic particle methods shall be carried out 200mm in each direction on the transition between welded circumferential and longitudinal butt joints. Table 19. Rejected piles shall be removed from the Site and replaced at Contractor’s expense. Contractor shall be responsible for determining the depths to which all the piles shall be advanced and/or the related driving criteria to achieve the required load carrying capacities. All butt welds shall have full penetration throughout their length to develop the full strength of the tube.5 Pile Identification Each fabricated pile shall be clearly marked in white paint with its number and overall length. Before the commencement of production welding. butt weld test plates shall be fabricated for each plate connection type and shall be subjected to non-destructive and mechanical tests by an accredited laboratory.0 against failure for piles with both 66 . 4.3. Piles which have in the opinion of Project Manager been damaged in handling or during installation may be rejected. Tests on fillet welds shall be carried out on 10% of shop welds and all site welds. 100% testing using ultrasonic. 4. If Contractor proposes to use ultrasonic testing in lieu of radiographic testing he shall provide full details of proposed testing procedures to Project Manager for review. 4. For fillet welds the acceptance criteria shall be BS 5135. Three copies of examination results shall be submitted to Project Manager as soon as they are available and in any case before the pile is installed.6 Damage to Piles Contractor shall ensure that damage does not occur to piles at any time. Quality Category A. All testing and interpretation work shall be carried out by an accredited testing laboratory nominated by Contractor and accepted by Project Manager.5 against failure under vertical load for piles with only compression or tension loads and 3. He shall be responsible for demonstrating the adequacy of the depth assessment prior to installing piles and for confirming that the completed piles have achieved the specified load carrying capacity and to conduct the load piles test prior to commencing its driving activities in order to confirm the piling design. The sequence and timing of driving of piles shall be such as to ensure that completed piles are not damaged as a result of driving of adjacent piles.3. In addition each pile shall be marked at intervals of 250mm along the top 3m of its length before being installed. Contractor shall submit details and calculations of his determination of the depth of piles a minimum of 28 days prior to commencement of pile installation and shall allow a period of 14 days for review by Project Manager. Tests on butt welds shall otherwise be carried out on 25% of shop welds and all site welds.piles designed to resist lateral loads.3.

compression and tension loading. d) Details of method of pre-boring. m) Disposition of piling plant during piling operations. The Method Statement shall confirm and expand upon information previously supplied and shall include: a) Type and Details of permanent piles including materials. g) Details of the method of forming rock sockets beneath pile toes into bedrock and for maintaining the temporary stability of the bore prior to placement of the concrete (if applicable). chiselling or other such technique to permit the installation of pile casings to the minimum design penetrations required.3. internal diameter and wall thickness. p) Pile driving acceptance criteria and the basis of assessment. e) Details of proposals for the use of any reinforcing to pile toe and/or head which together with c) and d) above will ensure that a pile achieves the minimum design penetration. 4. handling and transporting the piles. h) Details of method of fixing reinforcement. b) Details of the method of fabricating and details of method of installation of permanent piles and service piles including all temporary works and details of method by which required verticality or rake will be achieved. q) Installation of temporary bracing between the driven piles. c) Details of the methods to facilitate the installation of the pile to top of competent bedrock including methods of advancing a pile in the event that obstructions are encountered during piling. n) Details of proposals for storage. k) Details and numbers of plant and personnel to be used for pile installation. failure being defined as a settlement of the pile toe whilst under load of greater than 15mm (to be confirmed after soil investigation). o) Method of extending a pile. I) Details of method of placing concrete. j) Details of the method of applying any surface treatment to the piles and details of the method of repair of such treatment. 67 . grubbing out. to be compatible with item e) below. I) Detailed construction programme showing the sequence of and periods for pile construction. f) Details of method for demonstrating that the casing has reached competent bedrock and the criterion for determining the toe level of individual piles.8 Piling Method Statement Not less than 28 days before commencement of piling works Contractor shall provide a full and detailed Method Statement to Project Manager for review for the fabrication and installation of each type of piling required for the various structures.

u) Any other details required by Employer. The equipment shall be sufficiently robust. the pile shall be cut down to sound material and the joint prepared and the splices shall be made with butt joints as specified. Contractor shall be responsible for determining the installation requirements at each pile location and the need to employ additional measures including pre-boring or pre-chiselling in order to advance the piles to the required penetration and resistance without causing damage to the piles. in which case Project Manager will require the set to be revised to take into account the reduction in effectiveness of the hammer blow. Contractor shall inform Project Manager without delay if an unexpected change in driving characteristics is noted. Where tubular steel piles are lengthened after driving. dollies and anvil blocks shall be provided which shall be the correct size to suit the section of pile to be driven and to avoid distorting or damaging the pile.9 Installation of Tubular Steel Piles All plant and equipment to be used for the installation of piles may be subject to review by Project Manager and all work shall be carried out in compliance with BS 8004 . A detailed record of the driving resistance over the full driven length of each pile shall be taken.3. A follower (long dolly) shall not be used unless approved. temporary supports or other guide arrangement as required to maintain position and alignment and to prevent buckling. except that driving may be suspended where this is necessary to permit any pre-boring or pre-chiselling to facilitate the further advancing of the pile.Foundations. Contractor shall satisfy Project Manager regarding the suitability. t) Disposal of the waste material. efficiency and energy of the driving equipment. Each pile shall be driven continuously until the approved set and depth has been reached. vibration or movement of any free-standing pile length can occur. helmets. At all stages during installation and until incorporation in the superstructure the piles shall be adequately supported and restrained by means of leaders. s) Pile cap requirements.r) Drilling requirement inside the piles till the end of the sockets and cleaning of the piles and the sockets. 68 . 4. trestles. suitable driving caps. heavy and powerful to drive the piles as specified without damaging them and the size and type of equipment shall be changed as necessary when driving a pile. As necessary. Contractor shall ensure that piles are temporarily braced or stayed immediately after driving to prevent loosening of the piles in the ground and to ensure that no damage resulting form oscillation. These arrangements shall be such that damage to the piles is avoided.

The maximum permitted deviation of the finished pile from the specified rake is 1 in 25. openings or the like shall be formed in the piles. no forcible method of possible correction shall be permitted. shall be in sound condition. A detailed record of driving resistance over the full length of each pile shall be taken. shall be carried out to an approved procedure. The verticality of the piles shall be correct within a slope of 1 in 75. Contractor shall submit to Project Manager proposals for correcting this and the avoidance of it in subsequent work. if required. The piling rig shall be set and maintained to attain the required rake. openings or the like shall be formed in the piles. When a pile has risen as a result of adjacent piles being driven. no holes.10 Tolerances The maximum permitted deviation of the position of any pile centre at cut-off level from the centre point shown on the setting out drawing shall be 70mm in any direction.3. To ensure complete water-tightness of driven tubular steel piles. to provide a clean square true and level head for the seating of the superstructure. 4. if required. Re-drive checks. Re-drive checks.To ensure complete water-tightness of driven tubular steel piles. b) The dolly and packing. e) The temporary compression of the pile shall be recorded if required. Project Manager may require piles so positioned to be withdrawn and re-driven. When a final set is being established the following requirements shall be met.11 Preparation of Pile Heads Following completion of driving.3. Where piles have not been positioned or driven within the limits specified. if necessary. if any. no holes. all at Contractors own expense. or take such other action as Project Manager considers may be necessary. shall be carried out to an approved procedure. 69 . When required. levels and measures shall be taken to determine the movement of the ground or any pile resulting from the driving process. the pile shall be cut to the required level and. Contractor shall give adequate notice and provide all facilities to enable Project Manager to check driving resistances. 4. c) The hammer blow shall be in line with the pile in sound condition. d) The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angles to the pile and hammer axis. if necessary. a) The exposed part of the pile shall be in good condition without damage or distortion. The final set to each pile shall be recorded as the penetration in millimetres per 10 blows.

13 Records Contractor shall keep records as indicated below of the installation of each pile and shall submit two signed copies of these records to Project Manager not later than noon of the next working day after the pile was installed. drop and mechanical condition of hammer and equivalent information for other equipment. t) Volume of concrete placed in pile.Contractor shall take all due care to prevent the redundant sections of pile being damaged whilst being removed. r) Date of concreting. structure. 4. (levels of the concrete to be indicated. delays and other interruptions to the sequence of work. colour. n) If required brief description of materials encountered in pre-boring and socketing including consistency. o) If required. penetration rate and depth of change of each stratum. type. v) Length of the socket and the concrete socket. All cut-off sections of pile shall be stored on Site for the duration of the piling works and Contractor shall keep a detailed list of these which shall be submitted to Project Manager as and when required. unless agreed otherwise with Project Manager. The signed records will form a record of the work. m) Record of driving resistance over the full length of pile including the final set of pile or pile tube in mm per 10 blows or number of blows per 25mm of penetration. Pile Record Data: a) Contract b) Pile Reference Number (Location) c) Pile type d) Nominal cross-section dimensions or diameter e) Length of preformed pile f) Date and time of driving or re-driving or boring g) Ground or bed level at commencement of installation of pile h) Working level i) Toe level j) Type of drilling equipment and method of pre-boring equipment. u) Length and details of reinforcement. p) If required. Contractor shall not weld or fix any temporary attachment to the piles without prior agreement with Project Manager. I) Number and type of packings used and type and condition of dolly used during driving the pile. k) Type.3.3. 70 . 4. be removed on completion of the Work and the piles made good. weight. s) Concrete mix. q) All information regarding obstructions. the sets taken at intervals during the last 3m of driving. Any unexpected driving or boring conditions reported in accordance with the Specification shall be noted in the records. Any such attachment shall be fixed in accordance with this Specification and shall. temporary compression of ground and pile from time of a marked increase in driving resistance until pile reaches its final level.12 Piling Programme Contractor shall inform Project Manager each day of the programme for piling for the following day and shall give adequate notice of his intention to work outside normal hours.

Placing of Concrete infill to Piles and Sockets Prior to placing of concrete within sockets Contractor shall ensure that all loose and disturbed material is removed from the sockets. Pile casings shall be cut to level prior to placing concrete and prior to the positioning of reinforcement.16 Pile Testing General Testing of piles shall be carried out in accordance with BS 8004. undertake full scale trials to demonstrate the suitability of the proposed concrete mix and placement methods to form satisfactory pile infill. Concrete infill to piles shall be placed without such interruption as would allow the previously placed batch to have hardened. 4. 4.3.4. The piles shall be reinforced as shown on drawings and filled with concrete as specified. Contractor shall submit to Project Manager for review full details of testing equipment. Notwithstanding any such review.15 Reinforced Concrete Riling General Piles shall not be concreted until all piles within a radius of 5 meters from both the head and toe of the pile to be concreted have been driven.3. No spoil.3.14 Obstructions If an obstruction to normal driving is encountered. Contractor shall if required by Project Manager. Internal vibrators shall not be used to compact Concrete unless Contractor is satisfied that they will not cause segregation or arching of the concrete. Welding of steel reinforce is not accepted. Reinforcement to Piles and Sockets Joints in reinforcement shall be such that the full strength of the bar is effective across the joint and shall be made so that there is no relative displacement of the reinforcement during the construction of the pile. 71 . Approved spacers shall be provided on reinforcing cages to ensure that the minimum required concrete cover to reinforcement will be achieved. Reinforcement shall be left projecting from the top of the pile as appropriate to the design. Contractor shall be entirely responsible for ensuring that the piles will be repositioned in such a way as to ensure that the required bearing capacity is assured. liquid or other foreign matter shall be allowed to contaminate the concrete. Contractor shall take all precautions in the design of the mix and placing of the concrete to avoid arching of the concrete in a casing. The method of placing and workability of the concrete shall be such that a continuous monolithic concrete shaft of the full cross-section is formed. mechanical couplers shall be used for the steel bar joints. driving shall cease and Contractor shall employ the measurers previously proposed to Project Manager for review. Piles are to be kept thoroughly clean of all foreign matter whilst driving. temporary works and the testing procedure he proposes to adopt.

Contractor shall carry out Maintained Load Tests to one and a half times the vertical working load of piles. pipes. As a minimum the Contractor shall carry out one static load test in addition to dynamic pile testing. couplings and other apparatus to be operated under hydraulic pressure shall be capable of withstanding a test pressure of 1. orders. The maximum test load or test pressure expressed as a reading on the gauge in use shall be displayed and all operators shall be made aware of this limit. Extension of rods by welding shall not be permitted unless it is known that the steel will not be reduced in strength by welding. Means shall be provided to enable dial gauges to be read from a Position clear of the kentledge stack or test frame in conditions where failure in any part of the system due to overloading buckling. Where kentledge is used Contractor shall construct the foundations for the kentledge and any cribwork. regulations and other statutory instruments that are applicable to the Work for the provision and maintenance of safe working conditions and shall in addition make such other provision as may be necessary to safeguard against any hazards that are involved in the testing or preparations for testing. beams or other supporting structure in such a manner that there will not be differential settlement bending or deflection of an amount that constitutes a hazard to safety or impairs the efficiency of the operation The kentledge shall be adequately bonded. or becoming unstable because of deflection of the supports The weight of kentledge shall be greater than the maximum test load and if the weight estimated from the density and volume of the constituent materials an adequate factor of safety against error shall be allowed. hoses. a sleeve shall be installed and kept in place during testing to eliminate friction which would not arise in the working pile. Alternatively. In all cases Contractor shall ensure that when the hydraulic jack and load measuring device are mounted on the pile head the whole System will be stable up to the maximum load to be applied. conducting and dismantling a pile test Contractor shall carry out the requirements of the various acts. 72 . but the calculated friction must be taken into account in assessing the load being applied to the pile. Bond stresses of rods in tension shall not exceed normal permissible bond stresses for the type of steel and grade of concrete used. Safety Precautions When preparing for. loss of hydraulic pressure and so on might constitute a hazard to personnel The hydraulic jack. Where the pile shaft is extended above the cut-off level of a working pile in a soil which would influence the load bearing capacity of the pile. tied or otherwise held together to prevent it falling apart.5 times the maximum working pressure without leaking. pump. a sleeve need not be used. if the friction above the designed cut-off level can be calculated with reasonable accuracy. Where tension piles or ground anchors are used Contractor shall ensure that the load is correctly transmitted to all the tie rods or bolts. Preparation of a Working Pile to be tested The pile shaft shall be extended where necessary above the cut-off level of working piles so that gauges and other apparatus to be used in the testing process will not be damaged by water or falling debris.

The method employed in the installation of any reaction piles. The centre to centre spacing of vertical reaction piles from a test working pile shall be not less than three times the diameter of the test pile or the reaction piles or 2m. Loading Equipment The equipment used for applying load shall consist of one or more hydraulic rams or jacks. load is not transmitted to the ground except through the pile. The bearing pressure under supporting cribs shall be such as to ensure stability of the kentledge stack. no part of the section of the anchor transferring load to the ground shall be closer to the test pile or working pile than three times the diameter of the test pile. Full details shall be submitted to Project Manager prior to any work related to the testing process being carried out on the Site. shall be such as to prevent damage to any working pile. sufficiently large to accommodate the loading and settlement measuring equipment and adequately reinforced or protected to prevent damage from the concentrated application of load from the loading equipment. The load shall be measured by a load measuring device and by a calibrated pressure gauge included in the hydraulic System. The loading arrangement used shall be designed to transfer safely to the pile the maximum load required in testing. The total capacity of the jacks shall be at least equal to the required maximum load. Where kentledge is used for loading vertical piles in compression. Where kentledge is to be used. it shall be supported on cribwork disposed around the pile head so that its centre of gravity is on the axis of the pile.3m. whichever is the greatest. The sizes. Where rock anchors are used to provide a test reaction for loading. Sufficient clear space shall be made under any part of the cap projecting beyond the section of the pile so that. In interpreting the test data the values given by the load measuring device shall normally be used the pressure gauge readings are required as a check for gross error. The jack or jacks shall be arranged in conjunction with the reaction system to deliver an axial load to the pile. the joint between the cap and the pile shall have a strength equivalent to that of the pile. The complete system shall be capable of transferring the maximum load required for the test. the distance from the edge of the pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall be not less than 1. 73 . lengths and number of the piles shall be adequate to transmit the maximum test load to the ground in a safe manner without excessive movement or influence on the test pile.The pile head or cap shall be formed to give a plane surface which is normal to the axis of the pile. Reaction Systems Compression tests shall be carried out using kentledge tension piles or specifically Constructed anchorages. at the maximum expected settlement. The pile cap shall be concentric with the pile. Readings of both the load measuring device and the pressure gauge shall be recorded. Kentledge shall not be carried directly on the pile head.

Where another method of levelling is proposed this shall be submitted for prior review by Project Manager. kentledge support cribs. The dial gauges shall be placed in diametrically opposed positions and be equidistant from the pile axis. A spherical seating shall be used in conjunction with any devices that are sensitive to eccentric loading. No datum point shall be affected by the test loading or the Operations on Employer’s Site. Alternatively the gauges may be fixed to the pile and bear on surfaces on the reference frame.The load measuring device may consist of a proving ring. The pressure gauge and hydraulic jack shall be calibrated together. pressure cell or other appropriate system. anchorages and rafts that movements of the ground in the vicinity of the equipment do not cause movement of the reference frame during the test which will affect the required accuracy of the test. Each datum point shall be situated so that only one setting up of the level is needed. Check observations of any movements of the reference frame shall be made and a check shall be made of the movement of the pile head relative to an external datum during the progress of the test. The maintained load test movement of the pile head shall be measured by one of the following methods: 1) Levelling Method An optical or any other levelling method by reference to an external datum may be used. from the centre of the test pile. At least two datum points shall be established on permanent objects or other well-founded structures or deep datum points shall be installed. care must be taken to avoid any risk of buckling. load measuring column. the level and scale of the staff shall be chosen to enable readings to be made to within an accuracy of O. 74 .5mm. The supports for the frame shall be founded in such a manner and at such a distance from the test pile. reaction piles. The load measuring device shall be calibrated before and after each series of tests whenever adjustments are made to the device or at intervals appropriate to the type of equipment. A scale attached to the pile or pile cap may be used instead of a levelling staff. whichever is the greater. 2) Independent Reference Frame An independent reference frame may be set up to permit measurement of the movement of the pile.1mm. The loading equipment shall be capable of adjustment throughout the test to obtain a smooth increase of load or to maintain each load constant at the required stages of a maintained loading test. Certificates of calibration shall be supplied to Project Manager. Where a level and staff are used. The dial gauges shall enable readings to be made to within an accuracy of 0. Load measuring devices and jacks shall be short in axial length in order to achieve the best possible stability: Contractor shall pay attention to details in order to ensure that axial loading is maintained. The measurement of pile movement shall be made by two dial gauges rigidly mounted on the reference frame that bear on surfaces normal to the pile axis fixed to the pile cap or head. In no case shall the supports be less than three test pile diameters or 2m.

Protection of Testing Equipment Throughout the test period all equipment for measuring load and movement shall be protected from the weather. Maintained Load Test Procedure Contractor shall give Project Manager at least 24 hours notice of the commencement of the test. During the progress of a test. Construction equipment and persons who are not involved in the testing process shall be kept at a sufficient distance from the test to avoid disturbance to the measurement apparatus. the load shall be held for not less than the period shown in the Table 4-1 or until the rate of settlement is less than 0. For any period when the load is constant.The reference frame shall be protected from sun and wind. The loading and unloading shall be carried out in stages as shown in Table 4-1 below. the testing equipment and all records of the test shall be available for inspection by Project Manager. The maximum load which shall be applied shall be not less than 1. and at 1 hour intervals between 4 hours and 12 hours after the application of the increment of load. Contractor may submit any other method for measuring the movement of pile heads for review by Project Manager. The rate of settlement shall be calculated from the slope of the curve obtained by plotting values of settlement versus time and drawing a smooth curve through the points. Each stage of unloading shall proceed after the expiry of the period shown in Table 4-1. Following each application of an increment of load. at 30 minute intervals between 1 hour and 4 hours.25mm/hr and slowing down. time and settlement shall be recorded immediately on reaching the load and at approximately 15 minute intervals for 1 hour. Table 4-1: Test Loading Cycle to Working Piles 75 .5 times the working load on a working pile.

0 1 hour The criteria for acceptance of working piles shall be a defined limit for settlement of the pile toe whilst under test load or a reduced limit after removal of the load to be defined by Contractor from his designs and submitted for review by Project Manager. Completion of a Test On completion of a test all equipment and measuring devices shall be dismantled checked and either stored so that they are available for use in further tests or removed from Employer’s Site. 100 10 mins. g) Plan of test arrangement showing position and distance of kentledge supports rafts. 0 1 hour 100 6 hours 125 1 hour 150 6 hours 125 10 mins. percentage of Minimum time of working load working load 25 1 hour 50 1 hour 75 1 hour 100 1 hour 75 10 mins. f) Weight of kentledge. ground heave.Load. 50 10 mins. 75 10 mins. 25 10 mins. I) Effect. Details of Tests to be Submitted In addition to pile information specified in Clause 4. on adjacent structures. h) Jack type and capacity. tension pile of ground anchor details. etc. Settlement of the pile toe is defined as the total elastic and plastic deformation of the ground which is assumed to be the gross settlement measured less the elastic pile compression calculated for an appropriate proportion of the total pile length.5. c) Head level at which test load is applied.3. k) Test results in tabular and graphical form with load/settlement and time/settlement curves. if any. 76 . d) Details of pile cap including date and time of casting. j) Method of penetration measurement. or tension piles and reference frame to test piles. 50 10 mins. e) Condition of pile head after driving. b) Ground level at pile position. i) Method of load measurement. Contractor shall submit the following additional information: Pile Test Data: a) Position relative to adjacent piles. 25 10 mins.

trimmed and strengthened to safely withstand and dissipate the impact stresses.5.3.Kentledge and its supporting structure shall be removed from the test pile and stored so that they are available for use in further tests or removed from Employer’s Site as directed by Project Manager. c) Energy transmitted to the pile. b) Load achieved for selected test blow in terms of equivalent static load. specified in Clause 4. 4. e) Temporary compression 4.3. In addition to pile information.3. The testing and the interpretation of the test results shall be carried out by persons experienced in this particular method of testing. Temporary piles and ground anchors shall be removed and cut off as specified.18 Pile Anchors Pre-stressed anchors for bearing piles shall not be used in the Works. b) Pile head velocity. Heads of piles to be tested shall where necessary be cleaned. Contractor shall include the following additional information in his report on dynamic pile testing: a) Length of pile from instrument to toe of pile. the test cap shall be stripped and left in a state ready for incorporation in the Plant and the resulting material disposed of off the Site.17 Dynamic Pile Testing Contractor shall submit to Project Manager for review details of equipment to be used. Dynamic pile testing on tubular steel piles shall be carried out at times to be agreed with Project Manager which shall in no event be less than 24 hours after the completion of driving the respective pile. c) Pile head movement at: i) Equivalent design verification load ii) Equivalent design verification load +50% specified working load iii) maximum test load d) Permanent movement of pile head after each blow. The hammer which shall be of sufficient size to deliver the force necessary to induce the required test load without causing damage to the pile shall impact on a flat surface at right angles to the axis of the pile. Anchors shall comply with the requirements of BS 8081. the method of fixing and location of equipment and the method of analysis of test results not less than 7 days prior to the proposed commencement of testing Strain transducers and accelerometers shall be located within two pile diameters of the top of the pile. Passive anchors may be used but Contractor shall first submit full details to Project Manager for review and acceptance. 77 . Initial test results shall be submitted to Project Manager within 2 days of the completion of a test and shall include the maximum values of the following criteria: a) Force applied to the pile head. On completion of a test on a working pile.

Supplies of cement shall be obtained from one specific source unless otherwise accepted by Project Manager. The source of supply of cement shall be subject to Project Manager’s acceptance and Contractor shall furnish the manufacturer’s test certificates and proof that the required Standard Specification has been complied with.1 General Contractor shall submit to Project Manager for review all details of all materials which he proposes to use in the concrete including the names of manufacturers or suppliers and sources of supply. or bulk containers specifically designed for the purpose.Composition.Part 1: Common Cements. Cement which has deteriorated in any way shall not be used. Materials or sources of materials shall not subsequently be changed unless it can be demonstrated that such change will not be to the detriment of the properties of the concrete.4. certified by an independent agency. During transport and storage cement shall be fully protected from all weather elements. Any cement which fails to pass the test shall not be used.4 Concrete Works 4. All cement shall be fresh and shall be delivered either in unbroken water resistant bags containing approximately 25kg cement. 4. together with a note of the date of manufacture. soundness and setting time before being used in any part of the Plant. Consignments of cement shall be used in order of delivery.5” Cement shall conform to the requirements of ENV 197-1 Cement . Cement shall be stored off the ground in a suitable dry shed or in a self-clearing silo and shall be protected against deterioration. The cement shall be tested in accordance with ENV 197-1. Certificates for tests referred to in this Specification shall be provided by Contractor to Project Manager. Contractor shall provide all necessary samples of materials for the testing of concrete and its constituent parts and carry out all the necessary testing as described in this Specification applicable British Standards and Codes of Practice and other procedures to suit local laws and standards.2 Cement Cement shall be: - Pozzolanic cement ENV 197-1 CEM Il/A-P 42. bearing the manufacturer’s name and the date of manufacture. Materials shall not be used in the permanent Work until trial mixes have been concluded. 78 . Testing shall be carried out by an independent testing laboratory. Specification and Conformity Criteria .4. A laboratory shall be established on Employer's Site to undertake as many of the Specified tests as is practicable. Any cement which has been stored on Employer’s Site for more than one month shall be re-tested for moisture content.4.

when tested in accordance with BS 812: Part 118 shall not exceed 0. All aggregates shall have a specific gravity not less than 2.Sieve Analysis . Aggregates shall in general comply with the requirements of BS882.25% by weight for both fine and coarse aggregates. All-in aggregate shall not be used. No aggregates shall be delivered to the Site without satisfactory initial sampling and testing.Fine Aggregate -0. The shell content (as calcium carbonate) as a percentage by weight of dry single size aggregates shall not exceed 20% for 5mm to 10mm and 8% over 10mm. The following tests as described in BS 812 shall be carried out as appropriate on both fine and coarse aggregates: . The grading and shape of aggregates shall be such that a concrete can be produced with the specified proportions and consistency and which will readily work into position without segregation and without the use of excessive water and which can readily be compacted into a dense impervious mass. Contractor’s attention is drawn to the need to maintain a consistent aggregate quality and he will be expected to undertake adequate testing to ensure that the quality does not vary significantly. Notwithstanding the above figures every effort shall be made to obtain aggregates with as low a chloride and sulphate content as possible. Fine aggregate shall not contain appreciable amounts of flaky and/or elongated material.Determination of Flakiness Index and Elongation Index .3 Aggregates General Aggregates shall be from a source accepted by Project Manager. 79 .Coarse Aggregate -0. Aggregates shall be hard. The sample of fine aggregate shall be 25kg in weight and that of the coarse aggregate shall be 50kg in weight.6.03% by weight The acid soluble sulphate salt content for the aggregates.Determination of Particle Size and Shape . They shall not contain any deleterious material in sufficient quantity to adversely affect the strength at any age or the durability of the concrete or to cause corrosion of reinforcement. durable and clean and shall not be chemically reactive.06% by weight .4.Determination of Ten Percent Fines Value The flakiness index and elongation index when determined in accordance with BS 812 Part 105 for each of the predominant size fractions in each single sized coarse aggregate shall not exceed 20% and 25% by weight respectively. When tested in accordance with BS 812: Part 4 the total acid-soluble chloride salt content for the aggregates shall not exceed the following figures: .4.

80 . sand. The amount of hollow shells. The water absorption of both fine and coarse aggregates. Under no circumstances shall the mixing of different sizes of coarse aggregates be done by loading the vehicles at the pit with calculated amounts of each respective size from individual hoppers. Part 120 shall not exceed 0. determined in accordance with BS 812. organic matter and other impurities. 50 shall not exceed 30%. The percentage passing the sieve No. quarry refuse. present in material retained on a BS No.4. determined in accordance with BS 812 (Decantation Method) shall not exceed 1 % by weight.Silica Fume for Concrete. 4. shall not exceed 2% by weight of the entire sample. Coarse Aggregate When the coarse aggregate is obtained by combining aggregates of different screen sizes the respective quantities of the various sizes of coarse aggregates shall be premixed by the supplier at the pit and loaded into vehicles from one hopper for transportation to the batching plant and stored separately until weighed for batching. silt and fine dust content shall not exceed the appropriate percentage stated in BS 882: Table 6 by volume when using the field setting test given in BS 812 or such other equivalent test. shall be clean.075%. shall not exceed 30 except where specified minimum compressive strength or characteristic strength of the concrete is 50 N/mm2 or higher in which case the AIV shall not exceed 25. free from shell.All aggregates which are to be used shall have negligible alkaline reactivity. Part 121. 200 shall not exceed 3% and the sand equivalent shall be not less than 50%. The stone shall not be thin or flaky. organic matter and other impurities. dust. The 10% fines value tested in accordance with BS81 2 Part 111 in 90% of the test samples shall be 100kN with an absolute minimum of 80kN. The coarse aggregate shall be from an approved source. determined in accordance with BS 812 and using standard 14mm to 10mm test sizes. 200 (75 micron) sieve in each size of the single-sized course aggregate. clay. shall not exceed 2. Silica fume shall comply with the latest international Standard .0%. 7 sieve determined by direct visual separation. When fine aggregate is subjected to five cycles of the sodium sulphate soundness test carried out in accordance with BS 812. The gradation of fine aggregate shall be in accordance with grading C M or F of BS 882 Table 5 and the percentage by weight passing the sieve No. The Aggregate Impact Value. The shrinkage of the coarse aggregates tested in accordance with BS 812. mica shale. The clay. Fine Aggregate The fine aggregate shall be from an approved source and shall be sharp and free from clay. and the loss shall not exceed 10% by weight.4 Silica Fume for Concrete Silica fume shall be used in all structural concrete. which are likely to form voids. The amount of material passing a BS No.

03% by weight of the cement content of the concrete mix. Formulations shall be available to provide varied setting times relating to conditions of climate and Contractor’s Site requirements at a constant dosage rate as recommended by the manufacturer. f) Manufacturers' storage and use requirements. Where it is proposed to use more than one admixture Contractor shall obtain from the manufacturer a written confirmation that the combination of admixtures will have no harmful effects either short or long term upon the concrete.S1O2 85% mm. Contractor shall carry out underwater trials to demonstrate that his proposed admixture is capable of producing concrete with the required properties.4. Admixtures shall comply with one of the following British Standards as appropriate: .The silica fume shall be supplied and used in strict accordance with manufacturers’ instructions. e) Records of previous usage in similar environments. supplier and brand.5 Admixtures Admixtures shall be permitted if Contractor demonstrates to the satisfaction of Project Manager that they do not lead to a reduction in strength. g) Any precautions necessary for health and safety when handling. . durability. additional shrinkage or bleeding or any other undesirable effects. Contractor shall supply the following details of the silica fume to Project Manager: a) Manufacturer. BS 4887 or BS 5075. 4. Admixtures containing calcium chloride or chloride salt shall not be used under any circumstances.BS 1014. If the use of the admixtures is permitted they shall be used strictly in accordance with the manufacturer’s instructions and any method statement accepted by Project Manager after site trails have been carried out. special precautions shall be taken to ensure the dispersion of the silica fume in the mix. d) Samples for testing in sufficient time to enable assessment without delaying Contractor’s programme. Concrete to be placed underwater shall be mixed with a suitable admixture which produces concrete that is free flowing without segregation when placed underwater and self-levelling and selfcompacting provided by approved supplier. b) Chemical composition. They shall not contain chloride ions in excess of 2% by weight of the admixture or 0. 81 . Fineness shall be minimum 12 000m2/kg and the maximum density of densified silica fume shall be 650kg/rn3. c) A design of the mix where the use of silica fume and possible admixtures are considered. If densified silica fume is used.LOI (Loss on Ignition) 2. Type D. particularly hot climates.5% max. Chemical composition of silica fume . If concrete is made using a water reducing set retarding admixture it shall conform to the requirements of BS 5075 or ASTM C494.

4. Stockpiles shall be formed in bins or bags of suitable concrete foundations and to falls to allow drainage and shall be sheltered from the sun and wind blown dust. washing of aggregates may be required.6 Storage and Delivery of Aggregates Coarse and fine aggregates shall be delivered to Employer’s Site or to the mixing plant by means that prevent contamination due to environmental effects. Contractor shall avoid water being contaminated by earthy. 4.All concrete shall be produced with the use of super plasticizer. curing concrete and any other operation affecting steel or formwork which could subsequently come into contact with fresh concrete shall at all times comply with the requirements of BS 3148. All storage areas and bins and hoppers shall be regularly emptied and cleaned to remove any accumulated containments. The water shall enter the mixers at as low a temperature as possible.4. 4.0 and not more than 8.0. by burying. 82 . on striking of formwork. shading. e. 4. Where flaked or crushed ice is added to the water for concreting it shall be stored in such a manner as to prevent thawing and refreezing into larger pieces. vegetable or organic matter. acid or alkaline substances.g.7 Washing of Aggregates In order to comply with the requirements in the specification. insulation or painting white.4. It shall be fresh.8 Water Water which is to be used for mixing concrete. Every effort shall be made to protect water pipes and tanks from the sun. and shall be stored separately. sufficient quantities of each type of aggregate to ensure continuity of work. present a uniform face free from honeycombing and crazing. the concrete shall have the required strength. Contractor shall at all times maintain. The pH of water used in concrete work shall be not less than 5. clean. Under no circumstances shall sea water be used for mixing or curing concrete. The water used shall comply with the requirements of the mixing water. When hardened.9 Concrete Contractor shall design the proportion of each concrete mix in accordance with the recommendations of BS 5328 to obtain concrete of a homogeneous structure which can be worked into the corners and angles of the formwork and around reinforcement without segregation of the material or excessive bleeding of free water at the surface and shall also. 4. on Site or at the mixing plant. if necessary in covered containers. maximum density and low porosity. potable and free from any substances that may be deleterious to concrete or steel. The final proportions of cement aggregates and water shall be such that the weight of cement used is the least amount which will produce concrete complying with the Specification.4. Care shall be exercised in the handling and storage of the aggregates to prevent the segregation of the various particles and to prevent contamination from deleterious materials. substances or other deleterious matter in solution or suspension which will impair the strength or durability of the concrete.

The initial design mix shall have a preliminary target mean strength of at least 15 N/mm2 greater than the specified minimum cube strength for concrete having a characteristic strength of 40N/mm2 and above. Nature and source of all materials. For the chloride permeability reference is made to the Rapid Chloride Permeability Test (RCPT) (AASHTO T-277-831 and ASTM C1202).05% chloride ion as a % of the weight of cement in the mix (0. cube strengths to be achieved will be correspondingly higher. Where actual curing temperatures are higher than within the standard range. for the C40/50 concrete. Project Manager will determine the increases in cube strengths to be achieved with increases in mean curing temperatures. The required characteristic cube crushing strengths. Cement Content in Size (+ silica fume) Concrete Ratio by weight kg/m3 C40/50 20 0.4.5 The preliminary and works cube strengths detailed above are for concrete cured within the standard curing temperature range specified in BS 1881. water and admixtures shall not exceed 4. The total chloride content arising from all ingredients in a mix including cement. maximum water ratio and nominal maximum aggregate size for each class are shown in Table 4-3. One series of the C40/50 shall be with micro silica 83 . Contractor shall submit the following data to Project Manager for review before using any concrete mix: 1. The total sulphate content. 2. 3. Proposed quantities of each ingredient per cubic meter of compacted concrete. Water/ Concrete Max Agg. cement type. water and admixtures shall not exceed 0. expressed as S03 of all the ingredients in a mix including cement. minimum cement content. Table 4-3: Maximum water ratio and nominal maximum aggregate size. Cement 400 II/A-P 42.38 Cement Type ENV197-1 CEM Min.The classes of concrete mix that shall be used for new jetty are set out in Table 4-2: Table 4-2: Class Section of the jetty work and application C40/50 Structural concrete All C40/50 concrete shall contain silica fume as a cement replacement to a minimum of 5% and a maximum of 10% by weight of the total cement content.10 Trial Mix and Workability Trial mixes shall be produced under full scale production conditions using representative samples of cement and aggregates of both the C40/50 mix. Full details of tests on trial mixes. 4. The RCPT value shall not be greater than 1000 coulombs after 28 days.08% when expressed as an equivalent NaCl).0% of the weight of cement in the mix. Class of Nominal Max. No single result shall be less than 85% of the specified characteristic strength.

and the other without, otherwise they shall be identical. Three separate batches shall be produced
each on a separate day. The workability of each batch shall be determined and at least 9 cubes shall
be made for each batch, three for test at 7 days, three for test at 28 days, and three for chloride
permeability testing.
The trial mix proportions will be accepted if the average strength of the nine cubes tested at 28 days
is not less than 3.5N/mm2 below the target mean strength. If the range of the strength of the three
cube results in any one batch should exceed 15% of the average of that batch the trial mixes shall be
repeated.
Contractor shall take suitable precautions to ensure that the approved mix proportions are
maintained in the concrete that is actually deposited.
The quantity of water used in mixing the concrete shall be controlled by an approved water
measuring device. The workability shall be adjusted by the use of a super- plasticizer and mix of
aggregates. The water content of the mix shall be maintained at the limits given. Contractor is to
maintain on Site a suitable apparatus for checking the water content of the aggregate.
Concrete will only be accepted for placement if its workability is within the following limits at the time
of placement:
Slump test “1/3rd of the trial mixes mean or 20mm whichever is the lesser value Compacting Factor
“0.03 of the trial mix mean.
The slump of the concrete will be determined from samples taken from the mixed concrete just
before the concrete is placed. The slump tests and/or compacting factor tests shall be carried out in
accordance with BS 1881.
4.4.11 Production and Delivery
Batching
The proportions of cement and aggregate in the concrete shall be measured by weigh-batching. The
weigh-batching plant shall be of a type which will accurately control the quantities of materials. The
equipment shall have an automatic system that records the amount of each constituent material in
each batch.
Cement shall be weighed on a separate weighing device to that used for the aggregates.
Alternatively, the cement may be measured by using a whole number of bags in each mix (split,
damaged or partly full bags shall not be used).
Each ingredient shall be measured to an accuracy of better than plus or minus 2.0%.
The amount of water shall be measured by volume or by weight.
Separate containers and measuring devices shall be used for admixtures.
The scales of all weigh batching plant and all liquid dispensers shall be zeroed daily and calibrated at
intervals not exceeding one week. Contractor shall provide all weights, materials and labour for
calibration and tests and shall retain all certificates as record documents.
Truck mixers shall not be used for the batching and mixing of concrete.

84

Mixing
Concrete shall be mixed using a batch type mixer/s of approved design. Mixing shall continue until
there is a uniform distribution of the materials and the mass is uniform in colour and consistency. The
minimum mixing time shall be not less than that recommended by the manufacturer of the
equipment.
The mixer shall have mechanical/electrical controls to ensure that concrete cannot be discharged
until the required mixing time has elapsed and that the entire batch is discharged before the mixer is
recharged.
If densified micro silica is used, the mixer must be suitable for breaking up the granules and
dispersing the micro silica into the mix.
Detailed procedures for the batching and mixing of the concrete giving the sequence of adding
materials and mixing time, dry and wet, shall be worked out and included in Contractor’s quality plan.
Plant production capacity, with the chosen mix design, shall be specified in the quality plan.
The method of releasing the water into the mixer shall be such that the full measured quantity is
discharged in one operation and the flow is stopped automatically by a valve or syphon arrangement
only when the full quantity of water has been released. Arrangements which allow the discharge of
partial quantities of mixing at the discretion of the mixer driver shall not be used.
The amount of concrete mixed in any one batch shall not be less than three quarters of, nor exceed,
the rated capacity of the mixer. The whole of the mixed batch shall be removed from the mixer before
materials for a fresh batch enter the drum.
Contractor shall ensure that the mixing efficiency of the equipment is not impaired by the build-up of
cement and mortar on the mixing drum blades. On cessation of work, including all stoppages
exceeding 15 minutes, the mixer and all handling plant shall be washed out with clean water.
The first batch of a production run shall contain 15% less coarse aggregate in order to compensate
for the coating of the interior of the mixer.
Transporting
The concrete shall be discharged from the mixer and transported to the Plant by means which shall
prevent contamination, segregation or loss of ingredients, and ensure that the concrete is of the
required workability at the point and time of placing.
Concrete shall be transported in truck mixers or agitators. The concrete shall be continually agitated
during transportation and until discharge. Transportation of such concrete shall be in accordance with
BS 5328.
The drum of the truck agitator or truck mixer shall be completely clean and empty before it is filled
with concrete. Trucks shall not be loaded in excess of the manufacturer’s rated capacity, which shall
be displayed on the vehicle in terms of volume of mixed concrete. Trucks shall be discharged within
45 minutes after the introduction of the water to the cement.
Transit mixer trucks shall have their drums painted with heat reflective paint or covered with hessian
which is to be kept wet to achieve evaporative cooling.
The concrete shall be placed in the form as soon as possible after mixing before the initial set of the
concrete has started. No concrete shall be placed after this period has elapsed.

85

Contractor’s attention is drawn to the need to ensure that every precaution is taken to minimize the
loss of workability of the concrete during transit. Concrete shall be transported from the mixer to the
forms as quickly as conditions will allow and the work shall be streamlined and co-coordinated so that
delays are eliminated. Also the temperature of the concrete shall be kept as low as possible, see
Clause 4.4.15.
No additional water shall be added to the concrete after it has been discharged from the mixer.
Under no circumstances shall water be added if the initial set of the concrete has taken place.
Each consignment of concrete shall be accompanied by a docket giving the class of concrete and the
time when the mixing water was added.
4.4.12 Ready Mixed Concrete
The supply and delivery of Ready Mixed concrete shall comply with the recommendations of BS
5328 and all relevant provisions of this Specification.
Prior to obtaining concrete from a ready-mixed supplier Contractor shall submit the following
information to Project Manager for review:
-

Ready Mixed Concrete Supplier
Location of Plant
Details of suppliers of all materials to be included in the concrete including
relevant test certificates
Standard Deviation (strength) currently achieved by Plant (N/mm2)
Design Standard Deviation (strength) (N/mm2)
Target Mean Strength (N/mm2)
Total chloride and sulphate ion content of concrete (%)
Total equivalent alkali content of concrete (Kg/rn3)

Contractor shall arrange for the supplier to provide the facilities stated in Clause 13.1 of BS 5328.
A ticket shall accompany each delivery and shall contain the following information:
-

Name or number of ready-mixed Concrete depot
Serial number of ticket
Date
Registration number of delivery vehicle
Name of purchaser
Name and location of project
Concrete mix designation
Cement content
Free water/cementitious material ratio
Workability
Type of cement
Nominal maximum size of aggregate
Type name and quantity of admixtures, if included
Quantity of concrete in Cubic meters
Time of loading.

86

and shall be placed in such a manner as to avoid segregation to the concrete and displacement of the reinforcement.13 Placing Every delivery of concrete must be sampled and checked for workability by the slump or compaction factor method prior to placement. Contact between the vibrators and reinforcement or formwork shall be avoided and on no account shall vibration be used for the purpose of distributing concrete horizontally.000 cycles per minute. waterbars or formwork The concrete shall be consolidated by high frequency mechanical vibrators in such a manner as to obtain complete compaction without segregation or excessive laitance or the formation of "cold" joints.Tickets shall be retained as record documents by Contractor. Contractor shall place the blinding layer of concrete in such a way. Contractor shall be prepared to demonstrate the adequacy and effectiveness of his proposed method.15 Curing All concrete shall be adequately cured and protected from the harmful effects of sunshine.4. All exposed surfaces shall be protected immediately on completion of placing and compaction of the concrete. No water shall be added to the mix after it has left the ready mixed concrete plant.4. Concrete outside the workability limits shall not be used. The concrete shall be deposited as nearly as Possible in its final Position. particularly during the early stages of hardening. 4. Curing shall be such as to ensure full hydration of the concrete and shall be carried out by keeping all exposed surfaces on the concrete moist by means of wet hessian or similar absorbent material. the concrete shall be rejected and not placed if the initial set has taken place in any part of the batch.4. Particular attention shall be made to ensure that concrete is thoroughly worked into the corners of the formwork and around all reinforcement. Contractor shall submit to Project Manager for review all details of his proposed method of placing and curing the concrete before commencing work. 4. 4. waterbars and pipes. drying winds. rain or running water. All shuttering shall be loosened as soon as possible and provision made for curing water to run down inside them.14 Blinding layer All horizontal or sloping surfaces of reinforced concrete that bear on the ground shall be protected by a layer of blinding concrete 75mm thick. Vibrators shall operate at a frequency of not less than 5. traffic or other reasons. All surfaces shall be free of standing water. and at such a time. If required. Contractor shall be aware of the importance of adequately curing the concrete. Also. The surface of the concrete shall be protected by application of an approved curing membrane until the concrete has set sufficiently to take the weight of coverings. as to ensure that the exposed surface of the ground on which the blinding layer of concrete is to be placed does not deteriorate after excavation through exposure to weather. 87 .

2. special measures shall be taken to control the temperature. Contractor shall submit with his Method Statement proposals for identifying the actual temperature gradient of the cast elements. 3. metal conduit. Every effort shall be made by Contractor to keep the temperature of the concrete at the time of placing as low as possible. 4. Water for mixing concrete shall be cooled by means of mechanical equipment or the addition of ice. painted white or otherwise protected during the curing period. The mixing plant and delivery equipment shall be painted white and sited under shade wherever possible.Timber formwork covering the concrete shall be covered and moistened with water at frequent intervals to keep it from drying out during the curing period. The stockpiles shall not be watered. The temperature of the concrete at the time of placing shall not exceed 32 °C.16 Concreting in Hot Weather In general the recommendations ACI 305 ‘Recommended Practices for Hot Weather Concreting’ and ACI 308 “Recommended Practice for Curing Concrete shall be followed. If the temperature of the concrete is likely to exceed 24 °C at placing. Under no circumstances shall seawater be used for curing concrete. Such measures shall include some. During curing Contractor shall undertake all measures necessary to ensure that the temperature gradient between the core and the surface of all concrete elements being cast does not exceed 20 °C. and if necessary all.4. The wet curing shall continue for a minimum of 7 days. The interval between mixing and placing shall be kept to a minimum. Metal formwork exposed to the sun must be shaded from its direct rays. shall be kept in the shade for a minimum period for four hours before concreting. Storage tanks shall be painted white or sited under shade and distribution pipes shall be insulated or painted white. 5. Throughout the curing period all the exposed surfaces shall be adequately protected from excessive heat gain from the sun by tenting or reflective covering. Exposed surfaces shall be protected against contamination by atmospheric chlorides until 28 days after the concrete was placed. All concrete shall be protected from anything which may interfere with the process of setting or cause damage before the concrete has set. of the following: 1. Aggregate stockpiles shall be protected from the direct rays of the sun by shades. Following completion of wet curing concrete shall additionally be cured by having its exposed surfaces sealed by approved membranes. Bulk storage containers shall be painted white. Cement shall be stored in the shade. etc. Reinforcement. 4. 88 . Any concrete not cured strictly in accordance with this Specification shall be broken out and re-cast. Application of liquid curing membrane shall be by a lowpressure spray at the rate recommended by the manufacturer.

at 28 days: a) The average strength determined from any group of four consecutive test results exceeds the characteristic strength by: 3N/mm2 for concrete having a characteristic strength of 20N/mm2 to 40N/mm2.17 Testing Samples of concrete being placed shall be taken and 150mm test cubes made.6. The slump test and/or compacting factor test will be required for each set of test cubes. In general. Concrete shall not be mixed or placed when the shade air temperature on Site is 37°C or above. etc. The method of making. Contractor shall ensure that every precaution is taken during hot weather to take samples and form cubes as quickly as possible and to then immediately protect the cubes from drying and temperature rise by placing them in damp Conditions. Contractor shall prepare and test at his own expense additional concrete cubes where he requires to demonstrate to Project Manager that a concrete element has achieved a particular compressive strength after a period other than specified for routine tests. cubes will be required from each concrete pour. 4. Such cubes shall be cured under the same conditions as the related element. 7. 89 . During the curing period exposed concrete surfaces shall always be protected from the direct rays of the sun. in metal moulds. hose and fog nozzles.4. 8. temporary wind breaks shall be provided. conduit. In a prevailing arid wind. Sea water will not be allowed for any concrete. The quantity of concrete represented by any group of four consecutive test results shall include the batches from which the first and last samples were taken together with all intervening batches. The temperature of the concrete shall be recorded at the time of deposition. and the formwork shall also be protected. b) The strength determined from any test result is not less than the characteristic strength minus 3N/mm2 for concrete having a characteristic strength of 20N/mm2 to 40N/mm2 and 2N/mm2 for concrete having a characteristic strength less than 20N/mm2 and shall not be less than 85% for concrete having a characteristic strength of 50N/mm2. 21mm2 for concrete having a characteristic strength of less than 20N/mm2 and 3. Contractor shall provide and use an ample and clean water supply. formwork. 3 No. The Cubes shall be transferred to standard moist curing conditions in a laboratory after a day. Concrete shall be assumed to have achieved its characteristic strength when. During the transfer they shall be protected and handled carefully. curing or compaction works. storing and testing of work cubes shall comply with BS 1881.8N/mm2 for concrete having a characteristic strength of 50NJmm2. shall be sprinkled with cool water. Immediately before the concrete is placed. A test result failing to comply with clause (b) above shall represent only the batch from which the sample was taken.

90 . BS 8110 and Technical Report 13 of the Concrete Society and the Institution of Structural Engineers. Sample storage and measurement shall be as described in clause 11 of draft BS 4 812 Part 123. The drill dust shall be collected underneath the drill in a polythene bag. Cores shall be tested for chloride permeability in accordance with ASTM C-1202. It shall. For each concrete mix to be tested one prism shall be made using mix constituents and proportions identical to those used in the Works and a second prism made from concrete with its alkali content artificially raised to 6kg/m3 equivalent sodium oxide by the addition of potassium hydroxide. unless otherwise stated. d) Each test shall be the average value of three individual tests collected in the same area of the concrete member. The formwork shall be fixed in perfect alignment and securely braced so as to be able to withstand deflection. 4. Samples from each class of concrete in production shall be tested for potential alkali-aggregate reaction by casting into prisms of dimensions not less than 200 x 75 x 75mm. As an alternative to the prism test specified above. Part 117 and 118. b) The area above the sampling point shall be cleaned with a brush. be made either of sound and seasoned timber wrought and of sufficient thickness. The density of silica fume shall be tested weekly if densified micro silica is used. Core samples from on Site poured concrete shall be obtained at a rate of one for each day of concreting for the first 4 weeks. materials and plant. Sampling for chloride and sulphate content tests shall be in accordance with the following procedure: a) The material shall be collected from a dry vertical surface at least 28 days old. One sample shall contain concrete from a 30mm deep hole. In the event that the expansion of the prisms exceeds 0. c) The material shall be sampled by drilling with a hammer drill with a 20mm drill bit. Cores shall be taken randomly from concrete that is at least 28 days and not more than 90 days old. The formwork shall be in every way adapted to the structure and to the required finish of the concrete.4. The prisms shall be fitted with measuring points such that change in length can be measured at intervals during storage in conditions of 100% R.Where the concrete is proved unsuitable by the above criteria Contractor shall remove the related concrete and replace it by new concrete of the specified strength. Chloride and sulphate content of hardened concrete shall be tested at a rate corresponding to one test for each week of concreting.94 and shall meet the requirements of the acceptance testing of the concrete. thereafter twice weekly provided stable and acceptable results are achieved. Project Manager shall immediately be informed. Contractor may perform mortar-bar tests to ASTM C227-81. The tests shall be performed in accordance with BS812. displacement or movement of any kind. or of treated plywood or other approved material suitably supported.05%.18 Formwork Formwork shall be to BS 5975. the weight and pressure of the moist concrete and the weight and movements of men.H and 38°C.

Before soffit formwork and props are removed the concrete shall be exposed by removal of the side formwork in order to ensure that it has sufficiently hardened. Any liquid applied to the formwork surfaces in contact with concrete shall be compatible with any finish to be applied to the concrete. such spacers or ties shall be of approved pattern. including those in form linings and between forms and completed work. Where the finished surface of concrete is at a slope greater than 1:50 a top shutter shall be used. The work of removing such formwork or supports shall be carried out under the personal supervision of a competent Foreman in Contractor’s employment. before re-use. which must not come into contact with the reinforcement or be allowed to collect in the bottom of the formwork. Joints. shall be constructed to prevent loss of grout or fine materials. Concrete shall not be placed against vertical or inclined blinded earth faces in lieu of formwork. Portions of shutters at the level of each lift shall be removable to ensure a thorough clearing out of any rubbish. Where it is necessary to use spacers or ties through a wall for supporting the shutter above. No metal part of any fixing device for securing forms shall remain within the concrete cover stated in Clause 4.25 or otherwise shown on the Drawings. Formwork shall be in good condition.The supporting struts to formwork shall be adjusted and fixed in position by suitable means and where necessary placed on timber bearers to prevent them from sinking into the ground or from causing injury to finished work. The responsibility for the removal of any formwork after concreting rests with Contractor. Formwork and supports shall resist all loads to which they will be subjected without detriment to the finished concrete. Release agents shall be applied to formwork surfaces in contact with concrete using the minimum quantity necessary to obtain a clean release. Care shall be taken to keep the steel reinforcement. The holes left in the concrete shall be neatly pointed with an approved expanding grout as soon as the formwork is stripped. Contractor shall be responsible for any injury to the work and any damage caused by or arising from the moving or striking of formwork or supports. whichever is the greater. if necessary. shall not be less than that required for the concrete to achieve a minimum compressive strength of 10N/mm2 or twice the stress to which the member will be subject at the time of striking. and the inside face shall be treated with an approved mould oil. Before any concrete is placed all formwork shall be carefully examined and cleaned out. embedded items or hardened concrete free from any such coating material. A 50mm x 50mm chamfer shall be formed on all arises exposed in the finished work. clean and free of concrete remnants. Upon every occasion on which the formwork is stripped it shall be thoroughly cleaned and oiled. 91 .4. Formwork shall be removed without causing damage or excessive deflection to the concrete. The minimum time which must elapse between pouring concrete and removal of formwork.

A smooth true surface is required to all exposed surfaces of the concrete work formed using formwork.40. Contractor shall accurately and securely install in the formwork all required inserts. all broken corners and such parts of the surface where the face has been removed shall be made good with suitable cement mortar to bring same to the general level of the surrounding surface. All arises shall be formed with a 50mm chamfer unless otherwise shown. The CPF liner shall be shall be used strictly in accordance with the manufacturer’s written guidelines. The CPF liner shall be used on all in situ and precast reinforced concrete surfaces which in their final construction shall be either soffits or vertical sides. adequately reduce the potential ingress of corrosion inducing elements. laminated plywood shuttering or other approved material.20 Surface Finish Contractor’s attention is drawn to the importance of producing concrete work having maximum possible durability. if necessary with power operated carborundum grinders. sleeves and any other items as required. Contractor shall take all means possible during striking of shutters to avoid the necessity for surface treatment after removal of the shuttering.4. and made true by rubbing in cement mortar with a wood float. Items to be embedded in concrete shall be clean and free from oil or foreign matter that would weaken the bond of the concrete to these items. joint elements. In this regard Contractor shall pay particular attention to ensuring that the surface finish to concrete work shall. to obtain alignment of the surface. A Controlled Permeability Formwork (CPF) liner shall be installed against the inside face of the formwork. The upper trafficked surfaces of the jetty head and approach shall be wood float finished. by appropriate reduction of porosity. All fins and work out of true which cannot be rectified by rubbing down must be tooled off with power operated machines. 4.4.19 Embedded Articles Special care shall be taken to ensure that articles to be embedded are securely fixed in the correct position and templates and other temporary supports shall be provided as necessary. For this purpose the shuttering used for such surfaces shall be wrought and thickened boards of a properly seasoned timber accurately and closely fixed together or lined. together with any surfaces which are in any way defective. the mortar shall be composed of one part of the binder (cement and silica fume) to two parts of approved fine sharp sand with a maximum water to binder ratio of 0. anchors. All exposed surfaces shall be thoroughly rubbed down. 92 . Directly after the shuttering has been removed. Such surfaces shall be perfectly true and free from all imperfections and every endeavour must be made to obviate the necessity for surface treatment of the concrete after the removal of moulds. bolts.4.

grit blasting down to bare metal.4.21 Reinforcement Mild steel reinforcement shall conform to BS 4449 with a specified characteristic strength of 250 MN/rn2 and high yield reinforcement shall conform to BS 4449 or BS 4461 with a specified characteristic strength of 460 MN/rn2. Immediately prior to placing concrete all reinforcement shall be washed liberally with water of equal quality to that used for mixing the concrete to remove windblown dust. Straight portions of reinforcement shall be true and without kinks and bends and shall be kept in the correct plane. oil and grease and shall be stored on or near the Site in a dry weatherproof building of adequate size. The chemical analysis of the reinforcement shall also be provided. Placing of concrete shall be carried out as soon as is practicable after fixing of reinforcement. Bending and subsequent straightening of reinforcing bars projecting from existing concrete shall be carried out as follows: 93 . Unless otherwise specified the minimum mandrel diameter to be used in the bending of reinforcement rods shall be 4 times the diameter of the bar for mild steel reinforcement and 6 times the diameter of the bar for high yield reinforcement. Mesh fabric reinforcement shall comply with the requirements to BS 4483. The reinforcement shall be inspected prior to fixing and all rust. Contractor shall supply Project Manager with a certificate stating the process of manufacture and test sheet signed by the maker of the reinforcement giving the results of mechanical tests applicable to that type of reinforcement.22 Bending of Reinforcement All reinforcement is to be cut in accordance with BS 4466. paint.4. The reinforcement shall at all times (in store. test specimens from the reinforcement delivered on Site shall be taken by Contractor and sent for testing. Reinforcement intended for use in the Plant shall be delivered clean and free from dust. retardants or preservatives and harmful other matter removed by wire brushing or. The chemical analysis reported in the manufacturer’s certificate shall include the nitrogen content. 4. Reinforcement shall be bent cold by hand or power operated machines producing a gradual and even bending motion. Contractor shall obtain the manufacturer’s certificates for each delivery of reinforcement which he shall retain as record documents. Bending shall be completed before the steel is fixed in position. grease. Reinforcement shall not be re-bent. mill scale. If required. oil. mill scale. if necessary. during cutting and bending and prior to fixing) be kept on racks or supports of sufficient height to keep the bars clear of the ground and suitably placed to prevent excessive deflection of the bars. These certificates shall state that the reinforcement complies with and has been tested at the frequency specified in the appropriate British Standard Specification. salts or other contaminants Excess water shall be removed from the forms prior to placing the concrete. and no reinforcement shall be used in the Works until such testing has been carried out.4.

4. To prevent displacement 94 . the relevant reinforcing bars shall be welded together.a) The minimum distance from an existing Concrete surface to the beginning of a bend. Care shall be taken to prevent quenching of heated bars either by application of water or by a high volume of air. c) Heat shall be applied as uniformly as Possible over a length of bar equal to 10 bar diameters. C. size.23 Welding of Reinforcement If reinforcement in concrete is used for providing electrical earthing. heating is required for subsequent straightening or bending. Bars to be butt welded shall be held in a suitable jig sufficiently rigid to prevent movement during welding and cooling. and the area of the bend is inspected for cracks. stirrups and other members of the reinforcement shall be in exact accordance with the working drawings. form and position of all steel bars. d) Straightened bars shall be visually inspected before and after straightening to determine whether they are cracked or otherwise damaged. and the min inside diameter of the bend shall be: Bar Size 10 – 25 mm 32 mm over 32 mm Min Distance from Surface to Beginning of Bend 3 Bar Diameters 4 5 Min Inside Diameter 6 Bar Diameters 8 10 b) Bars of 10mm to 16mm diameter inclusive may be bent once without heating. Bars having a diameter greater than 32mm may be bent only after review by Project Manager. The bar temperature shall not exceed 350 Deg. The temperature shall be maintained constant during bending or straightening operations Temperature measuring crayons or a contact pyrometer shall be used to determine the temperature. The slag shall be such that in making the vertical run the metal lies reasonably flat and free from overhanging folds. heating IS required in all cases. Reinforcement shall not be cut using oxy-acetylene or electric equipment. Bars not exceeding 32mm in diameter not Projecting from concrete may be bent without heating in accordance with this Section providing no local section is re-bent or straightened. The centre of the heated length shall be at the middle of the arc of the completed bend. All welding shall be carried out by fully trained and experienced workmen capable of carrying out vertical and overhand as well as down hand welding to the satisfaction of Project Manager.4.24 Placing of Reinforcement The number. Bars 20mm to 32mm inclusive may be bent once and subsequently straightened heating is required in all cases. links. Suitable provision shall be made to prevent distortion of the reinforcement. 4. 4.

shall not exceed 50mm in length or breadth. Spacers are to be purpose made cement mortar blocks of a thickness corresponding to the necessary cover. 4. No other material whatsoever shall be used to keep the reinforcement in the shuttering. subject to review by Project Manager. defect or injury from any cause whatsoever which may Prejudicially affect the strength. Wherever practicable as at horizontal joints. immediately prior to placing concrete.4.26 Cutting Concrete No concrete or steel in the reinforced concrete work shall be cut in any way.4. The end of typing wire shall be bent inwards away from the concrete faces. The whole surface of concrete which has set shall have been thoroughly roughened and cleaned of all loose and foreign matter and laitance before further concrete is placed. except that in certain cases. They shall be fixed by means of soft annealed mild steel wire of 1 .28 Joints Contractor shall submit details of the type and location of all Construction joints he wishes to make to Project Manager for review. etc. Contractor may use plastic spacer blocks of an accepted design. in accordance with the Specification herein. Where concrete already deposited has set but not set hard. or which give any evidence of fault. All construction joints will normally be required to be keyed or toothed and four clear days allowed between adjacent pours. durability. and shall be composed of one part of the binder used (cement and silica) to two parts fine sand with a maximum water to binder ratio of 0. Such blocks. water tightness or alignment of the work. laitance shall be removed whilst the concrete is still green so as to expose the tops of the larger aggregate particles without undue erosion of the mortar.27 Faulty Works Contractor shall at his own expense remove and reconstruct any portions of the work which give evidence before or after the removal of the formwork that the concrete was insufficiently compacted in the formwork or that any bars of the reinforcement have been omitted. 4.6mm thickness (16 gauge) or proprietary ties.4. In the case of the principal items of concrete work. Tying wire shall be embedded into one face of the blocks.4. laitance shall be removed and the surface roughened by wire brushing and washing. these proposals will be regarded as major temporary works and sufficient drawings. All reinforcement shall be washed with clean water. cares being taken not to disturb the underlying mass.40. standing water is to be removed from the formwork. 4. incorrectly placed or displaced. The distance between spacers shall be sufficient to ensure that the correct cover is maintained throughout the length of the reinforcement. or that the formwork has been incorrectly positioned or displaced. Spacer blocks shall be used to ensure the correct cover to reinforcement.25 Cover to Reinforcement Concrete cover to all reinforcement shall in no case be less than 75mm. 4.before or during concreting the bars shall be secured one to the other and steel supports shall be provided between layers of reinforcement. covering the whole structure must be submitted in advance of the start of the work to enable the complete concreting plan to be accepted. Where the concrete first 95 .

Table 4-4: Positive Tolerances. care shall be taken to avoid breaking off the arises of the joint face or shattering or loosening exposed particles of coarse aggregate.4. The compounds shall be of a type resistant to chemicals that they may be exposed to. 4. Joint filers and sealing compounds shall be of approved manufacture. Abrupt changes of surface alignment of concrete such as may occur at badly made construction joints will not be allowed even though the concrete surfaces are within the permissible tolerances. any skin or laitance shall be removed and the surface roughened by hammering with an approved pattern Power Operated “bush’ hammer followed by wire brushing to remove all loose particles When carrying out this method of preparation. Immediately before depositing fresh concrete.30 Precast Concrete The manufacture of precast concrete components shall be in accordance with the recommendations contained in BS 8110. Moulds shall be thoroughly cleaned before each casting. The fresh concrete shall be forced hard on to set faces of concrete by means of compacting and vibrating tools.29 Tolerances Positive tolerances given in Table 4-4 are the measurements by which the concrete is permitted to exceed the stated dimensions. vertical. Structure Tolerance Concrete placed in Dry (mm) Concrete in structures against which backfill is placed +25 -05 Concrete in structures not backfilled +10 -05 Upper surfaces of concrete +05 -05 Cross-sectional dimensions of concrete members +05 -05 Departure from alignment of precast units +10 -10 Overall plan dimensions of precast units +10 -10 Position of embedded items +05 -05 4.4. contraction or shrinkage shall be formed at positions appropriate to the design of the structure. Departure from alignment is the permissible deviation from the centre line horizontal or vertical face or edge of the concrete. Exposed faces shall be trowelled smooth. inclined or horizontal. No reduction shall be permitted in the cover to reinforcement because of a specified negative tolerance in a concrete section. All edges of the precast units shall be formed with a 25mm chamfer. 96 . the face of the joint shall be thoroughly washed after which the excess water shall be removed.poured has set hard. The moulds of all precast concrete works shall be to the accurate dimensions and shapes as shown on the drawings and shall be of sound construction. Negative tolerances are the measurements by which the concrete can be short of the stated dimensions. Free joints to allow for expansion. and used in accordance with the makers’ instructions as appropriate to the type of joint.

All other internal surfaces of precast units shall have surfaces prepared as construction joints as described in Clause 4. 4. formwork and methods of achieving specified finishes including proposals for trial panels. Contractor shall adequately protect installed precast concrete units and other concrete associated therewith to prevent damage to permanently exposed concrete surfaces. cubes. Methods of storage of materials and production. At all stages of construction. The Method Statement shall cover all aspects of concrete works including the following: a) b) c) d) e) f) Sources of all materials for use in concrete mixes with test certificates and results. Contractor shall be fully responsible for supplying adequate lifting points and any additional reinforcement and equipment as necessary to ensure the safe handling.. transport and erection of the precast members. Detailed records of mixes. Holes left in the precast units to facilitate lifting shall be neatly pointed with an approved expanding grout as soon as the planks are finally positioned.20. g) Details for production of precast concrete 4. especially arises and decorative feature Damaged concrete elements shall not be dispatched to Employer’s Site and elements which Sustain damage during transportation shall be removed from Employer’s Site and replaced at Contractor’s expense. False work. delivery and quality control.31 Method Statement Not less than 28 days before the commencement of concrete works Contractor shall provide a full and detailed method statement for concrete works to Project Manager for review. The same provision shall apply to precast elements damaged prior to or during erection or thereafter. shall be kept and submitted to Project Manager within 7 days of manufacture.4. 97 . Methods of placing of concrete. Stacking of precast units shall be properly carried out after curing in a separate area set aside for that purpose and so arranged that the units may be removed and used in the order in which they were cast. All precast members shall be marked with a unique reference.32 Bedding of Precast Units Precast concrete units shall be bedded in cement mortar composed of one part cement to three parts sand. Arrangements for carrying out cube and other tests. Generally the external faces of precast units which will be visible after their inclusion in the Jetty shall be finished with a fair face equivalent to that described in Clause 4. Only minor repairs will be permitted to be carried out to precast elements at the Site.28.4. curing methods.4. Levelling devices shall only be released or removed with Project Manager’s approval. etc.4. Details of proposed concrete mix designs and program me for trial mix production. dates of manufacture.The standard of workmanship and the quality of materials used in the manufacture of all precast components shall comply with the relevant clauses of this Specification. The surface of precast units which will act as bearing surfaces for further precast units shall be given a steel trowel or equal approved finish.

All materials shall be accurately gauged by gauge boxes and mechanically mixed and used within 30 minutes of first mixing.3. Mortar plasticizer if used shall be subject to acceptance by Project Manager shall comply with BS 4887 and shall be used in the proportions and manner recommended by the manufacturer. Mortar that has begun to harden shall not be used in any part of the Plant.Sand for mortar shall be naturally occurring sand or consist of crushed rock or gravel or a combination thereof. 270 N (UEAtc MOAT27:1983) Transv. when towelled or worked into place. Joints between or around precast members which are cast into the Plant shall be carefully sealed using an approved tape or other means to ensure there is no grout loss during concreting. 4. 330 N (UEAtc MOAT27:1983) Not perforated at 25 kg.33 Waterproofing This work shall consist of furnishing and placing approved waterproofing membrane to concrete surfaces. It shall be clean hard and free from impurities to BS 1199 and 1200 and in accordance with Clause 4.4. 900 N/5cm (BS747/1977) Long. Re-tempering of mortar will not be permitted. Mortar joints shall be pointed with a neat flush joint as the work proceeds. Reinforcement is made of heavy non-woven polyester and fibre glass mat. 950 N/5cm (UEAtc MOAT27:1983) Long. Sand shall be well graded from 4.3mm down in accordance with Table 1 of BS 1199 and 1200. 50% (BS747/1977) Transv. The water content of mortar shall be just sufficient to ensure a dense mortar with adequate workability. 1100 N/5cm (UEAtc MOAT27:1983) Transv. Material . Thickness Weight Reinforcement Penetration at 25ºC Softening Point Heat Resistance Cold Pliability Tensile strength Ultimate Elongation Lap Joint Strength Tear Strength Resistance to Static Indentation 5mm (ASTM D5147-95) 5. 50% (BS747/1977) Long. 1050 N/5cm (BS747/1977) Transv. Joints shall be protected from the harmful effects of the environment for a minimum of three days after completion. (Class L4) (BS747/1977) 98 .Waterproofing Membrane: Dual Reinforcement-APP Modified Bitumen Waterproofing 5 mm thick Membrane.3 kg/m2 Nonwoven spun bonded polyester 220 g/m2 and reinforced fibre glass mat 60 g/m2 (BS 747/1977) 15-25 dmm (ASTM D5) ≥ 155ºC (ASTM D36) Non flowing after 2 hours at 145ºC No cracking at -10ºC Long.4. Gauge boxes and mixers shall be kept clean.

4. All materials shall be delivered to the work in original containers. After delivery of the materials. diluted acids and alkalies Surface Preparation: 1. be sent to him for test prior to shipment of the materials. representative check samples shall be taken which shall determine the acceptability of the materials. Any damage which may occur shall be repaired by patching. nor when the temperature is below 2º C. 99 . seal or other mark of identification. and. Inspection. salt solutions.2 g/m2 day (ASTM E96-90) Resistance to alcohol. properly identified. the surface shall be thoroughly cleaned of dust and loose materials. a copy of the test results shall be sent to the Project Manager by the chemist or the inspection bureau which has been designated to make the tests. or by throwing any material on it. immediately before the application of the waterproofing. showing that it has been tested and found acceptable. the Project Manager may order that representative samples. Factory inspection is preferred. Proprietary waterproofing membranes shall be repaired according to the manufacturer’s specifications and as directed by the Project Manager. No waterproofing shall be done in wet weather. protected place.Resistance to Water Pressure Water Vapour Trans. when so tested. joints between sheets shall be lapped with ends of at least 150mm and side laps of at least 100mm. 3. 2. Rolls of waterproofing membranes shall not be stored on end. and each package shall have affixed to it a label. as far as possible so. Unless otherwise ordered by the Employer. plainly marked with the manufacturer’s brand or label. and identifying the package with the laboratory tests. The surface shall be dry. Care shall be taken to prevent injury to the finished membrane by the passage over it of men or wheelbarrows. All concrete surfaces which are to be waterproofed shall be reasonably smooth and free from projections or holes which might cause puncture of the membrane. All waterproofing materials shall be tested before shipment. The joints shall be arranged so. without special authorisation from the Project Manager. Unless otherwise specified. 2.3m beyond the outermost damaged portion and the second ply shall extend at least 0. Installation of Waterproofing Membranes: Waterproofing membranes shall be installed strictly in accordance with the manufacturer’s instructions and shall be laid so that no air is trapped between it and the concrete surface or between successive layers of sheeting. so as to prevent the formation of steam when the hot asphalt or tar is applied. Resistance to Chemicals No leakage at 1000mm water head/24 hours (BS747/1977) 0. that water will drain away from the exposed edge. 2. that at no points are there more than three thicknesses of sheeting and. and. Damage Patching of Waterproofing Membranes: 1. Delivery and Storage 1. Patches shall extend at least 0. they shall be tested at the place of manufacture. Waterproofing material shall be stored in a dry.075m beyond the first. but in lieu thereof.

4. Welded connections if necessary shall performed in accordance with the Employer’s HSE plans. Fillet welds shall be of minimum size 6mm.Testing: Unless otherwise agreed by the Project Manager in writing. The profile of the joint shall enable satisfactory non destructive testing to be carried out. Butt welds shall be full penetration. As far as possible. 4.0m wide and 5. Shop connections shall be bolted. at least one Site trial application of the waterproofing system shall be carried out to determine the suitability of the surface preparation. The grade of steel shall comply with Table 4 of BS 5950: Part 1 assuming k = 1 and the appropriate conditions of exposure.General Contractor shall allow for deformation due to permanent loads and the process and sequence of fabrication. supports and details in accordance with this Specification. The effective length of fillet welds shall be the full length less 25mm at each end. Contractor shall carry out the fabrication and erection design of all connections. 100 . Reduced areas and sectional properties shall be computed and members strengthened as necessary. Drainage holes shall be provided in members and connections where water can collect during and after erection. method of application and effectiveness of the protective layer.5. All connections shall be designed in accordance with BS 5950. Connection design shall provide adequate access for welding and inspection during fabrication. Compatibility of dimensions and setting-out data of steelwork shall be verified by Contractor before fabrication of steelwork commences.2 Materials Structural Steel All structural steel shall be new and comply with BS EN 10025: 1993 and with BS 5950: Part 2. The size of membrane laid shall be not less than 2. All steel work shall be designed and constructed in accordance with the relevant standards.0m long. Fabrication drawings shall be submitted to the Project Manager for review prior to commencement of fabrication process. steel work shall be designed in tubular sections in order to minimise dust deposits and to allow easy cleaning. All steel shall be Grade S235 JR for all sections other than steel sheet and tubular piles which shall be grade S355 JO. and for welded connections with BS 5135.5. Minimum bolt diameter shall be 20mm.1 Steelwork and Connections . Section 2.5.5 Structural Steelwork 4. and Employer’s approval shall be granted prior to any site welding works. erection and construction such that steelwork is completed to within the specified tolerances. Bolted connections shall have a minimum of two bolts. Intermittent welds shall not be used.

The strength of the material shall in no way be affected by the work it performs. Welding consumables and the procedures used shall be such that the mechanical properties of the deposited weld metal shall not be less than the respective minimum values of the parent metal being welded.5% under the specified or calculated weight. Plain washers for black bolts. Use of Rivets will not be permitted. All steel shall be delivered in good condition undamaged and generally free from corrosion. Use of High Strength Friction Grip (HSFG) may be used with the structure that subject to vibration. plates. end plates. Holding down bolts shall be in accordance with BS 7419. and Nuts.8 with grade 8. Washers and Direct Tension Indicators All bolts shall be grade 8. Every piece of material shall be free from rust. 4. the materials shall not be used. stiffeners. Screws and Nuts.. Black bolts shall have the short thread length.3 Documentation and Submissions Particulars of Steel 101 . plates or rolled sections shall be straightened. Screws. screws and nuts shall comply with BS 4320. All rolled sections.0 nuts to BS 3692 unless noted otherwise on the drawings. Welding Consumables Welding consumables used in metal-arc welding of grades of steel complying with BS EN 10025:1993 shall comply with BS 5135. Minimum Thickness All gusset plates. Precision bolts shall comply with BS 3692 ISO Metric Precision bolts. Bolts. etc. Corrosion allowance shall be considered. All bars. Where the actual weight is more than 2. Any steel bent or otherwise damaged shall not be used in the Work. to satisfy Project Manager that the weights of the various sections are those as shown on the approved drawings.5. Contractor shall take any steps that may be directed. flanges and webs of rolled sections and elements of built up sections shall not be less than 12mm thick. Nuts. freed from twist or otherwise trued before any other work is done upon them. The minimum wall thickness for hot rolled hollow sections will be 8mm. subject to the rolling margins as given in the relevant specification. shall be of the sections and weights specified. scale and pitting and perfectly true to thickness throughout and out of winding. Stainless Steel Stainless steel for sliding surfaces shall be Grade 316 S33 complying with BS 1449. circular and square taper washers shall comply with BS 4320 ‘Metal Washers for General Engineering Purposes’. Black bolts shall comply with BS 4190 ISO Metric Black Bolts. Flat.

Fabrication shall not be commenced until approval has been received in writing. g) bolted connections tightening sequence. plan for structural steelwork together with full details of the stage control and inspection documents. a period off at least two weeks shall be allowed from receipt of the documents by Project Manager to their return. terms and symbols relating to the welding and cutting of metals shall be in accordance with BS 499 where applicable.The manufacturer’s certificates for steel shall be made available for review by Project Manager in accordance with BS EN 10025. etc. welding procedure sheets. Fabrication Details Contractor shall provide the following documents for review by Project Manager: a) b) c) d) e) f) marking plans and details for holding down bolts and other embedded items. Two copies of the approved drawings shall be submitted to Project Manager before fabrication of the steelwork starts. welding symbols to BS 499. welding procedure details. crane positions and working radius e) method of preventing damage to protective coatings on steelwork during handling f) procedure for aligning. fabrication drawings in accordance with BS 1192. Two copies of each document or two negatives of each drawing shall be submitted to Project Manager for review at least four weeks before fabrication of the steelwork starts. connection details including calculations. 102 . complete contact shall be secured at the connecting face. Calculations and drawings shall be checked and Signed by Contractor before submission to Employer.A. The drawings shall be submitted in related batches such that Project Manager has sufficient time and information to give full consideration to the proposals on the documents and for any changes to be incorporated and resubmitted for approval. crane capacity. including but not limited to: a) erection marking plans b) routes for delivering steelwork and laydown areas c) sequence and methods of erection of steelwork including calculations and details of temporary bracing/works to ensure stability d) method of lifting and handling the components. Where web cleats are fitted to beams for stability. levelling and plumbing steelwork. Method Statement for Erection A detailed method statement shall be submitted to Project Manager with all relevant supporting drawings and calculations setting out the sequence of erection. On all drawings. The face of the web cleat shall project no more than 3mm beyond the end of the beam. fabrication method statement details of the Q. including temporary supports and method of making beddings for bearings and measures to protect existing works. Where beams are fixed by end cleats to other members. the length of these cleats shall be not less than 1/3 of the overall beam depths. Unless otherwise specified or agreed in writing.

Free ends shall be stiffened. 4. plant and material costs with respect of testing of welding operatives including independent testing authority costs. Routine testing of all operators will be required every six months. Certificates endorsed by an inspecting authority shall be made available for review by Project Manager to show that each welder has been approved in accordance with BS 4871 : Part 5. plant and material costs with respect to the testing of welding operatives including independent testing authority costs. Contractor shall pay all labour. Welder Certificate Only welding operators who satisfy the appropriate tests shall be employed on welding.4 Handling. Every care shall be taken when lifting painted steelwork to avoid damage to the paintwork. During handling and transport of coated steelwork. Welder certificates shall be submitted at least 3 weeks before fabrication of the steelwork starts. measures shall be taken to prevent permanent distortion and machined surfaces and faying surfaces shall be protected. Nylon ropes and slings shall be used wherever possible. Storage and Transport Handling and Transport of Steelwork Steelwork shall not be subject to rough handling. BS 4870. two further tests shall be undertaken immediately and for the operator to qualify. It shall not be moved by sliding or skidding. Steelwork shall not be lifted from the painting bed until the last applied coating is sufficiently dry or cured for handling. must satisfactorily pass both these tests. BS 4871 and BS 4872 as appropriate to the corresponding weld position and using specimens of the parent metal to be employed. Should an operator fail in a first test.The particulars shall be submitted to Project Manager at least 4 weeks before erection of the steelwork starts. The extent of approval of the welder shall be appropriate to the categories of welds which he will carry out. other than those engaged on tube welding. shall be tested by the tests as detailed in BS EN 288-3. Project Manager also reserves the right to have any welding operator retested at any time during the Contract.5. except that Project Manager reserves the right to have any welding operator retested at any time. Contractor shall pay all labour. Projecting ends of steelwork shall be adequately protected during transit. the steelwork shall be separated from wires and lashings by rubber padding in such a manner that the coatings are not damaged or discoloured. Operators. All machined surfaces shall be suitably protected against corrosion before leaving the works. Where chain slings are used padding shall be inserted between chains and painted steelwork. All bolts shall be suitably packed and labeled. Works coated steelwork shall be loaded and unloaded by hoisting equipment. shock loading or dropping from a height. The re-approval of welding operators shall be to BS EN 287-1. 103 .

the contaminating agent shall be removed immediately by swabbing or brushing and the surfaces washed thoroughly with clean water. Storage of Steelwork Steelwork shall be stored off the ground on level supports above rainwater splash zones in well drained areas in a manner which will not result in damage or deformation to the steelwork or coatings or in contamination of the steelwork or coatings. 4.Before. Steelwork shall be stored in an enclosed workshop and protected from conditions which may affect the steelwork after the steelwork has been cleaned until the following times: a) When the second undercoat to painted steelwork has hard dried. steelwork surfaces which are to be primed or over coated and joint surfaces which are to be assembled shall be protected from exposure to conditions which may affect the film or surface. The ends of all beams shall be square where required and flanges neatly cut away or notched where necessary. Vertical timber packing shall be used to separate members when required and to prevent chafing to coatings. Bearers shall be level and sufficient in number to prevent distortion of members. during and after delivery to Site. Steel shall be stacked in an orderly manner so that no dirt or pools of water can accumulate on the surfaces. electroplated or metal sprayed steelwork has been completed.5 Fabrication of Steelwork Fabrication of Steelwork: General Fabrication of steelwork shall comply with BS 5950: Part 2. Should any contamination occur. nuts and washers shall be protected and stored in dry conditions. Special consideration shall be given to the arrangement of bearers if articulated vehicles which allow differential movement of bearers are used to transport steelwork. Adequate precautions shall also be taken to ensure that threads are not damaged or contaminated with dirt. and d) When the first undercoat to metal sprayed and painted steelwork has hard dried. Wet paint films. All bolts. Different types and sizes of steelwork shall be stored separately. 104 . All notches shall be kept as small as possible and shall be rounded in the inner corner. Steelwork shall be protected from exposure to conditions or deleterious agents which may affect the steelwork or coatings. b) When the coating process to galvanized. c) When the sealer to metal sprayed and sealed steelwork has been completely absorbed. Sections 3 and 4 as appropriate and with the following clauses. all steelwork shall be stored clear of the ground or other supporting surfaces. Softwood timber bearers with a sufficient contact area to prevent crushing shall be provided at all stages including transportation to Site. Covered places in which steelwork is stacked shall be ventilated.5. Where cover is provided it shall be adequately ventilated.

All bolts shall be of the exact diameter figured and the holes for these must not exceed the diameter figured by more than 2mm. Holes of not less than 40mm diameter shall be provided in all base plates to facilitate grouting. to within 0. These shall be sealed after the galvanizing process has been completed unless otherwise instructed. All burrs shall be removed from the edges of drilled or reamed holes. The edges of all rolled sections shall be true and fair and they shall hold full to profile throughout. Where stiffeners are required to be fitted they shall be ground or machined and the surfaces on which the stiffeners bear shall be cleaned of all loose mill scale or any deleterious matter to allow tight bearing contact. fair and free from burrs throughout. Min. gussets. Flame is not permitted to use for making holes. Hollow section fabricated structures that are to be galvanized shall be provided with vent holes to allow the expanding air to escape and to enable surplus zinc to drain from the sections when the structures are withdrawn from the bath. The nuts shall be a good fit on the bolts so that they can only just be turned by hand. have their abutting faces machined after fabrication so that they are square to the member axes and in tight bearing contact when erected. The accuracy of all holes shall be such that when the work is assembled a steel gauge of 2mm less diameter than the hole can be passed through irrespective of the number of thicknesses. The edges of all plates. All holes shall be drilled. 105 . shall be perfectly straight. 2 threads shall be beyond the nut after bolts tightening Where bolt heads or nuts bear upon beveled surfaces. Ends of columns at intermediate splices and where they bear on bases or caps shall be machined after fabrication so that they are in tight bearing contact. No drifting enlargement or elongation of any of the holes will be permitted. and one clear thread is to show through the nut after tightening is completed. All bolts shall have washers under the nuts and shall be so screwed that the threaded portion does not bear upon the thicknesses connected. The underside of base plates bearing on concrete need not be machined. All machining operations shall be performed after welding.e. i. Base plates and caps shall be accurately machined over the steel bearing surfaces and shall be in tight bearing contact over the whole area of the machined end of the stanchion or column. markings will be inspected and where necessary repaired or replaced upon delivery to Site and at regular intervals before erection. The pitch of bolts shall not exceed that as specified in BS 5950. except where bolts carry compressive loads. rolled shapes and similar parts where sheared.5 degrees. All members of mass exceeding 5 tons shall have their mass marked by cold stamping and painting. they shall be provided with square taper washers in accordance with BS 4320 to afford a seating square with the axis of the bolt.Butt ends of compression members shall. No hole shall have its centre nearer to the edge or end of any piece than a distance equal to the requirements of BS 5950.

all steelwork shall be stamped or suitably marked with paint stencils in conformity with erection diagrams furnished by Contractor. repaired and replaced as necessary and further inspected and made good at regular intervals before erection. Site welding as well as flame cutting needs the Project Manager's written approval. etc. Burrs left by the cold or hot saw shall be removed and gas cuts shall be dressed free from oxidised metal to a neat and workmanlike finish. Ends of tubes welded to plates. These are NOT to be painted. etc. Erection tags shall also be provided and all members of mass exceeding 5 tons shall have the weight marked on the tag. Surfaces of steel in permanent contact are to be thoroughly cleaned and painted with one coat of lead-based primer paint of a high build type where appropriate and brought together whilst still wet. When sealing the ends of tubes. shall be accurately formed so that the tube butts over its entire area. Hot sawing or machine gas cutting will be permitted for the ends of beams and other parts not bearing in compression. shall be accurately shaped to fit the profile of the member stiffened. Plates. angles or plates to brackets. As much as possible and practical. other than those cold sawn. to avoid the trapping of excessive moisture.. The only exception to this is friction grip bolt joints. as regards resistance and quality class. Welding. rolled and hollow sections to be cut to exact lengths. Tube ends. so as to minimize any distortion and induced stresses. Frames of tube or box connections shall be jig assembled and the ends of all tubes shall be sawn and not flame cut. flanges to joints.Before leaving Contractor’s factory. at least 15 mm high. etc. shall be accurately cold sawn or machined. Heating and Cutting The layout and procedure shall be approved by the Project Manager and the sequence of all operations shall be arranged to the Project Manager's approval. Upon arrival at Employer’s Site stencils and tags shall be inspected. shall be hand flame cut and dressed to fit accurately the profile of the tube. Fitted stiffening tubes. and shall be able to satisfy tests. All structural components shall be clearly marked at their ends by punched figures. this must be carried out under the correct climatic conditions. The Contractor is to satisfy the Project Manager that the welding operators are suitable for the work upon which they will be employed. Welding electrodes shall be appropriate for the used base metals and the chosen welding method. except for irregular profiles. The names of the operators qualified in accordance with the foregoing 106 . The Contractor must always be able to produce documentation indicating that the electrodes used comply with the Standards for the base metal on which they are applied. For this purpose details of qualifications obtained by the operators under any appropriate standard laying down qualification tests shall be submitted as evidence of their efficiency and suitability. to which they are jointed. tubes. welding shall be done at the manufacturer's workshop and not on the Site.

Preheating shall comply in all respects with the requirements of BS 5135. this shall be achieved by the use of extension pieces. Temporary welded attachments shall not be used. Butt welds shall be complete penetration butt welds made between fusion faces. lines and squares and shall be held temporarily in position by the use of wedges and clamps. steps shall be taken.1. BS EN 287-1 or BS 4872 Part 1. either by pre. On rolled sections. to ensure the flanges are rendered flat at the completion of the welding. Hollow section steelwork shall be assembled in jigs or on suitable surface plates on which shall be drawn out the whole section of the structure. The end of one hollow section shall be accurately shaped to fit the other. pre-bending. gouging. back-step techniques and other measures shall be taken as necessary to counteract shrinkage or distortion due to welding. Welding shall be carried out by welders who possess a valid welding certificate for the appropriate category of welding. and the ends of the welds shall have full throat thickness. Coated surfaces to which welded attachments are to be made shall be cleaned to bare metal and all contaminants removed. Welding of Structural Hollow Sections Welding of hollow sections to BS EN 10210-2 shall comply with BS 5135. thermal cutting or heat treatment. The correct fusion bevel shall then be cut. dry and free from loose scale and shall be completely sealed. The welding procedure thus laid down shall be strictly maintained and no variations will be permitted without approval of the Project Manager. together with particulars of any test passed by each of them. Pre-setting. welding shall only be allowed where special precautions are taken to prevent too rapid a rate of cooling and loss of heat. Where bolted flanges for connections. shall be recorded and made available to the Project Manager as and when required. skip welding. either by pre or post heat treatment or by other suitable method to ensure that the flanges are rendered flat at the completion of the welding. by the use of scribing blocks. The Contractor shall provide each welding operator with adequate details of the approved welding procedure to be adopted as necessary.g. steps shall be taken. cross runs or other suitable means. Butt welds in each component part shall be completed before the final assembly of built-up assemblies. When correctly aligned the structure shall be tack welded to BS 5135. Where bolted or flanges for connections etc are welded to tubular structures. Where the combined plate thickness is equal to 50mm or over and ambient or plate temperature is under 1OEC.. etc. are welded to hollow section structures. Clause 25. No welding of mild steel shall take place where the ambient or plate temperature is OEC or below. Members shall be aligned e. such information may be given by means of charts or drawings as found convenient.or post-heat treatment or by equal approved methods. 107 . Intermittent welds will not be permitted in view of the risk of moisture or salt ingress. Hollow section steelwork shall be continuously welded and the interior of all hollow sections shall be kept clean. A welder shall cease to carry out welding if any of the circumstances stated in BS 4570. Clause 6 as appropriate occurs. This shall be done by using properly prepared templates or equal approved methods.requirements.

strictly in accordance with the manufacturer’s instructions. Contact Surfaces All contact surfaces which are to be bolted together shall have all bloom. rust and mill scale completely removed and shall be treated in accordance with Section 9 of this Specification. BS 4190. After such connections have been completed the surface coating shall be made good by thoroughly cleaning by mechanical wire brushing as necessary and applying two coats of a cold galvanizing compound. and which remain exposed. Where bolt heads or nuts bear on beveled surfaces they shall be provided with square taper washers conforming to BS 4320 affording a seating square with the axis of the bolt. 108 . Defects in Steelwork Defective components for steelwork shall not be used in the permanent work.In addition to the testing specified in Section 8.8 section of this Specification. Tightening of Bolts Bolts shall be tightened in such a manner that the contact surfaces of permanent bolted joints are drawn into close contact. any welding operator engaged in welding tubular steelwork shall prove his proficiency by welding a specimen junction where tubes intersect at an angle. to all surfaces from which the galvanizing has been removed or damaged. Length of Bolts The length of bolts complying with BS 3692. Surfaces of connections which have been treated in accordance with the Specification require no further treatment. All contact surfaces which are to be bolted together shall have all bloom rust and mill scale completely removed. The provisions of this clause apply to surfaces brought together at Employer’s Site. Length of Threads The length of threads on bolts shall be determined in accordance with BS 3692. Where additional locknuts or other nuts are specified. the thread length shall be increased by one nominal bolt diameter for each additional nut. The junction shall represent the most acute tube intersection on which the welder will be engaged and the tubes used shall be representative with regard to material. diameter and thickness. BS 4395: Part 1 or BS 4933 as appropriate. Use of Nuts Nuts shall not be used with bolts or screws which comply with a different standard. BS 4190 and BS 4933 under the nut. BS 4190 and BS 4933 shall be such that the end of the bolt will project above the nut by at least two threads. Trial Assembly Sufficient trial assemblies shall be carried out in Contractor’s works to prove the accuracy of the workmanship. Use of Washers Washers shall be provided for bolts complying with BS 3692. Washers shall be provided under both the nuts and heads of bolts in oversized and slotted holes. but by no more than one nominal bolt diameter. after tightening.

Erection of structural steelwork shall be generally in accordance with BS 5950: Part 2. Measures shall be taken to ensure that steelwork will remain stable before temporary supports and fastenings are slackened or removed for lining. Anchor bolts shall be of quality 8. allowance shall be made for the effects of temperature on steelwork. storage and erection of the steelwork. leveling. to enable erection to proceed without hindrance or delay. 4. Determination of the types. nuts and washers shall be hot dip galvanized. numbers and dimensions of the anchor bolts and nuts shall be done within one month after the Date of Commencement. tackle and equipment for unloading. plumbing or other purposes. Approval of Fabricated Steelwork Fabricated steelwork shall not be: a) Covered with protective coatings. b) Erected. complies with the specified test and inspection requirements. both in line and level. Contractor shall make adequate provision to ensure a correct fit. 109 .Where parts which have to fit together are manufactured in different works or for any reason cannot be matched before dispatch to the Site. to ensure such stability and safety under all erection conditions. The temporary supports and fastenings shall be re-tightened or replaced as soon as the adjustments are complete and at the end of each continuous period of working.5. cranes and plant during all stages of the work and shall provide all necessary temporary bracing. Contractor shall be responsible for the stability and safety of the structures. including any repaired areas. Steelwork shall be secured in position by temporary supports and fastenings until sufficient permanent connections are complete to withstand the loadings liable to be encountered during erection.8. Bolted connections shall be aligned using drifts and shall be temporarily fastened using service bolts. Contractor shall. 1. The temporary supports and fastenings shall be capable of withstanding loadings which may be encountered during erection and shall not damage the steelwork or the protective coatings. concrete or other material. or c) Dispatched from the plate of fabrication if fabricated off Employer’s Site Until the steelwork.6 Erection of Structural Steelwork Alignment of Steelwork Contractor shall be responsible for erecting the steelwork in such a manner that the alignment and levels of the steelwork comply with the tolerances stated in this Specification. etc. Contractor shall provide all necessary cranes. Foundation Bolts for Steelwork All anchor bolts. prior to the commencement of any stage of erection. satisfy himself that holding down bolts are correctly positioned and set.

Fabrication tolerances for steelwork shall comply with BS 5950: Part 2. Bolt pockets shall be kept dry and clean. Damage Damage to any part of the structure either before or during erection shall be immediately brought to the notice of Project Manager. Measures shall be taken to ensure that the full movement tolerances are achieved and the bolts are not displaced during concreting. splay. shall be protected against damage.2 and the following: Length of any member 9. The tape and steel to be measured shall be at the same temperature and proper precautions shall be taken to tension the tape correctly. Bundles of materials shall be secured by proper lashings so that the pieces will not separate. including the threads. All necessary anchorage materials which are to be built into the foundations shall be supplied to Site in time to be cast into the concrete works. or slip out when raised. Bolts and nuts. Slinging and Hoisting The slinging and hoisting shall be under the control of fully experienced skilled personnel. “Box Outs for subsequent inclusion of holding down bolts will not be allowed. Plumbing of Stanchions Plumbing of stanchions shall be carried out by means of a theodolite and facilities for the checking of stanchions shall be made available to Project Manager when required. one on each corner of the base slab.7 Tolerances Tolerances on Fabrication of Steelwork All measurements shall be made with a steel tape related to a standard tape which has been certified to be correct at 20°C.The anchor bolts. nuts. Leveling of Column Slab Bases Slab bases shall be leveled by means of suitable bolts and bearing plates. corrosion and contamination. Foundation bolts for steelwork shall be held firmly in the set position during fixing. 4. If required separate lifts shall be made.0m long and under: +0mm/-2mm 110 .5. sub-section 7. Tubes which are cast in concrete for grouting bolt pockets shall be securely fixed and sealed to prevent ingress of grout during concreting. Bolts in bolt pockets shall be installed in such a manner that the bolt can be moved inside the pocket as designed without hindrance. Staging Staging to approved safety standards of adequate strength and area shall be provided by Contractor to facilitate the work of erection and inspection. No damaged part may be assembled in the structure without prior reference to Project Manager. washers and steel templates shall be supplied within three months after the Commencement Date.

The above acceptable tolerances shall be uniformly distributed over the whole of the abutting parts. Deviation from squareness of machined ends to axes of columns: 0. the structure shall be erected to comply with the specified erection tolerances. the gap shall not exceed 0. Tolerances: Erection of Steelwork Steelwork shall be erected to within the tolerances stated below after lining. the abutting parts shall be deemed to be in contact when the following requirements have been fulfilled: a) Over at least 60% of the bearing surfaces the gap between the surfaces shall not exceed 0. Tolerances: Foundation Bolts The position of cast-in foundation bolts at the top of base plates shall be within 3mm of the specified position. The line of bolts shall not be tilted from the specified line by more than 1 in 40.5mm. It should be noted that limits given are absolute and should not be considered as cumulative.25mm. b) Over the remainder. plumbing and making the permanent connections. Deviation of centre line of web from centre line of flanges in built-up members at web/flange junction: Depth/200 or 10mm Tilt of flanges of built-up members (measured as the offset from square of the underside of the toe of the flange from its intersection with the centre line of the web): For flanges up to 450mm width: 2mm For flanges over 450mm width: 3mm Where a tight bearing contact is required. Deviation from squareness of machined faces of end plates to axes of beam: 0.0m long: +0mm/-3mm Deviation from straightness: Length of the finished member/1000 or 10mm whichever is the lesser value.5mm. The position of foundation bolts in bolt pockets at the top of base plates shall be within 5mm of the specified position. leveling. Linear Dimensions Permissible Deviation per l0m of length ± 6mm Maximum Deviation in 25m or over (Except as under) ± 15mm Plumb Permissible Deviation per 1 5m of Height ± 5mm Maximum Deviation in 45m or over ± 15mm 111 .5mm. Deviation from squareness of fixed base plates to axis of column: 1:500.Length of any member greater than 9. Notwithstanding the above permitted fabrication tolerances.

the test shall be carried out on additional samples from the batch. Tests shall be carried out by the Fabricator on samples selected by the Fabricator. and Conclusion as to the overall acceptability of the parts of steelwork examined by the approved testing consultant.5. The batch shall be considered as not complying with the specified requirements for the test if the result of any additional test does not comply with the specified requirements for the test. The rate of sampling shall be as stated in the 112 .Levels Alignment of Columns ± 3mm Mean Level of Bases ± 3mm Difference in level between bases of adjacent columns in line 3mm 4.2. with any non-complying results highlighted. Samples to be Tested Contractor shall give full access to Project Manager at all times to the place of fabrication and storage for the purpose of inspection and testing. Mill test certificates shall be provided by Contractor to Project Manager upon request. Non-compliance: Steelwork If the result of any test on steelwork does not comply with the specified requirements for the test. Reports of Tests on Steelwork Contractor shall keep records of tests on steelwork. Clauses 5. The records shall contain the following details as a minimum:a) b) c) d) Procedure tested and exact location in the steelwork.3.8 Testing and Inspection of Steelwork Tests at Fabricator’s Works Tests shall be carried out on structural steel in accordance with BS 5400: Part 6. Samples: Steel Samples of steel shall be provided from each batch of steel within 3 days after delivery of the batch to the fabricator’s works or to Employer’s Site. Tests are to be carried out as detailed in the following clauses. Contractor shall give Project Manager not less than 7 days notice of tests being carried out. 5. Results of tests compared to the required values.2 and 5. cracking or other defects. e) PQR Reports shall be certified by Contractor’s authorized representative or by the approved testing consultant who carried out the tests. The number of additional tests shall be twice the number of original tests.1.2. Testing of Steelwork All materials provided under this Contract shall be tested in accordance with the relevant British Standard (BS). Any tearing.

5. flats. Examination and testing of welds shall be carried out after any post-weld heat treatment and before the application of corrosion protective coatings. Quality grading of structural steel shall be carried out on steel which has not been tested for quality grades by the manufacturer. BS EN 10113-1. BS 5996: Grade LC2E). BS EN 10155. Clause 3.6 as appropriate. Any material that does not meet the specified requirements shall be rejected. When tests are to be made away from the steelworks Contractor shall provide sample pieces 500mm x 75mm for plates. Deburring. BS EN 10210-1. The sample pieces will be selected and stamped by Contractor and as soon as selected shall be dispatched to the Testing Works where test pieces will be made and tested and Test Certificates obtained. Clause 2. BS EN 10210-1. In the event of any material not meeting the specified requirements being found incorporated in the Plant Contractor shall remove the substandard material and replace it with material meeting the Specification at his own expense. Except where specified otherwise the standard of acceptance shall be Grade LC2E in accordance with British Standard BS 5996: 1980 and ‘Methods for Ultrasonic Testing and Specifying Quality Grades of Ferritic Steel Plate’ (i. All main plate materials for welded lattice girders shall be examined. (b) Plate Material to BS EN 10025 Grade S355JR and S355J0 113 . joists. Testing: Steel The tensile test and the impact test shall be carried out on each sample of steel. etc. surface pores and joint fit-up and before other inspections and tests are carried out. The extent of testing may be varied and will depend on the results obtained. BS EN 10113-1.4 or BS 5950: Part 2. and the position and direction of the samples shall be in accordance with BS 7668.Contract. The extent of ultrasonic tests shall be as follows: (a) Plate Materials to BS EN 10025 Grade S235 and S235J0 Initially all main material for welded plate girders and welded box columns shall be examined in accordance with BS 5996: 1980 and in accordance with the requirements of BS 5950. and machining shall be carried out after the visual inspection for cracks. Testing: Welds General The acceptance of the welded work shall depend upon the correct dimensions and alignment and absence of distortion in the structure. the relevant tests are to be carried out when the material has been reduced to its approximate size prior to fabrication and assembly. Quality grading shall be carried out in accordance with BS 5400: Part 6.5. from the examination and testing of the joints and the test specimens. the soundness of the welds and evidence of adequate training and upon general good workmanship. or as near that as practicable and samples 500mm long of full section for angles. rods. The method of testing shall be in accordance with BS 7668. dressing. BS EN 10155.e. channels. When plates are to be cut to size away from the mills. These Test Certificates shall be made available to Project Manager if required. grinding. Ultrasonic testing Ultrasonic testing for laminations and/or inclusions shall be carried out before fabrication. upon satisfactory results.

v) All column web and flange plates which are composed of grade 43A steel will be deemed to be in compression and radiographic or ultrasonic examination shall be carried out on the butt joints for 10% of the butt length. table plates to stalk plates or fabricated ‘tee’ sections and end plates to girder flanges forming beam end moment connections shall have 100% ultrasonic inspection for laminations. (d) Runway Beams The flanges of runway beams shall be tested for freedom from laminar defects and inclusion clusters such as would preclude fitness for their purpose. iv) Butt welds in top (compression) booms of trusses shall have 20% ultrasonic or radiographic inspection. (e) Plate Material for Beam or Stanchion End Plates (all grades) All plates to be used as end plates for beams or stanchions. Lamellar tearing and weld defects. Dye penetrate testing shall not be used for the examination of ferrite welding. In the case of fabricated ‘tee’ sections the inspection shall be car9ied out prior to bolting or welding to main members. iii) Butt welds in bottom (tension) booms of trusses shall have 100% ultrasonic or radiographic inspection. shall be examined and be in accordance with BS 5996 Quality Grade L3 Non Destructive Testing of Welding (NDT) Contractor shall satisfy himself as to the quality of welds by visual. vii) Tee butt welds connecting diaphragms to column plates.All plate material Grades S355JR and S355J0 shall be tested in accordance with BS 5996: 1980 and the requirements of BS 5950. 114 . magnetic particles inspection (MPI). Fillet Welds Magnetic particle inspection (MPI) shall be carried out on 5% of all fillet welds. ii) In addition to the testing specified below Project Manager may indicate any other areas which require further destructive or non-destructive testing. Extent of Non-destructive Testing Butt Welds The extent of non-destructive testing of butt welds shall be as follows: i) All welds shall be subject to 100% visual inspection and 10% magnetic particle inspection. vi) Column plates which are composed of steel other than grade 43A steel will be deemed to be in tension and radiographic or ultrasonic examination shall be carried out on the butt joints for 100% of the butt length. Welds which are to be examined by magnetic particles inspection shall be dressed in order to ensure a meaningful examination. ultrasonic or radiographic inspection as appropriate. diaphragms to large plates. Independent Testing Project Manager may also require independent radiographic or ultrasonic or other non-destructive testing examinations of butt and fillet welds to be undertaken. All NDT shall be carried out by qualified operators. in particular where moment connections and subsequent heavy concentrations of weld occur. (c) Welded Lattice Girders All members fabricated in the form or plate or box girders shall be tested in accordance with (b) or (c) above as may be appropriate.

Balustrade. ducts. equipped with kick rims and hand railing Stair risers and supports shall be fabricated from rolled steel sections. All solid type flooring shall be hot dip galvanized. Fixing shall be done by means of fixing clips. All hand railing shall include kick rims and knee railing. including covers for passage of conveyors. shall be fabricated of chequered plates supported by steel beams. Stairs and ladders shall have corrosion protection in accordance with the corrosion protection specification. Knee railing and vertical supports shall be made of steel pipes with a minimum diameter of 33 mm. Minimum life load shall be 5. All bars shall be welded together and hot-dipped galvanized after fabrication.0 KN/m2. adequately braced to form rigid steel structures. Solid type flooring All solid type flooring.The frequency of independent examinations will depend on the results obtained.. etc.m2.5. Dimensions shall be in accordance with actual live load. Stairways and ladders Stairways shall be of the square grid type.and knee railing All balustrades and hand railing shall be of a welded steel construction with bolted connections to the foundations or the stair risers. hand. in accordance with the in accordance with the corrosion protection specification. Minimum life load shall be 5. Testing: Repairs Defects which have been repaired and adjoining areas which in the opinion of Project Manager may have been affected by the repair shall be retested as instructed by Project Manager 4. 450 mm wide and 25 mm single ring type with safety loop and landings at intervals not exceeding 6 m. 115 . Fire escape ladders shall be hot dip galvanized. Dimensions shall be in accordance with actual live load. Ladders shall be of a welded steel construction.0 KN.9 Miscellaneous steelworks Open type flooring Grating shall be fabricated of flat steel bars 30 * 5 mm with surrounding supporting flat bars. Balustrade and hand railing shall be made of steel pipes with a minimum diameter of 42 mm or as specified on the relevant drawings. All balustrades and hand railing shall have corrosion protection in accordance with the corrosion protection specification.

walkways 10 yrs Paint system A5M. All workmanship and materials shall be in accordance with BS EN ISO 12944 standards.4.5 Table A. BS EN 1461 10 yrs Stainless Steel Fendr Chains and Chain Anchorages Fender Panel Cast-in Sockets BS EN 12944 Table A.8 .07 with gloss finish – black Hot dip Galvanise plus paint system A8. For corrosion protection of marine piles. except for use in specialist applications where the appropriate grade shall be used. members which are to be metal sprayed or galvanized at Contractor’s works shall have all marks hard stamped in addition to being painted. galvanised steel members and aluminium surfaces or between galvanised and un-galvanised steel members. Contact between dissimilar metals such as stainless steel and carbon steel. studs. Any reference to galvanising shall be defined as galvanising in accordance with BS EN 1461.03 (2 pack epoxy paint) Galvanise. the marks must be painted with a white paint that can easily be covered with the final Site anti-corrosion treatment.6. Where steel is given part of the surface protection before arrival on Site.4436) for forged steel and BS EN 10088-1 and BS EN 10088-3 for flat rolled and long rolled forms. system A7. screws. Unless otherwise agreed with Project Manager. other than stainless steel equipment. The hard stamping.7 Mooring Bollards 10 yrs Ladders. nuts and washers shall be grade A4-80 according to BS EN ISO 3506.1 Structural Steelwork The Contractor shall provide protective treatment to all metallic items.13 (2 pack polyurethane gloss finish) Fender Panel Steelwork 10 yrs Hot dip Galvanise plus paint system A7.7 Table A. shall be done at one end of the member and shall be ringed with a paint mark. refer Chapter 2) 10 yrs Galvanise plus paint. to such a depth that it will not be obliterated by the coating. Stainless steel shall be grade 316 S33 in accordance with BS 970 : Part 1 (EN Steel Number 1.13 (Polyurethane Paint system under warranty) 10 yrs Hot dip Galvanise. shall be prevented by means of insulating washers and grommets. The acceptable level of coating failure at first major maintenance shall be level Ri4 as defined by ISO 4628 / 3 and its included references.6 Corrosion Protection 4. Stainless steel bolts. unless stated otherwise. of neoprene or equal and approved. fittings and fixings. Table 4-5: Schedule of protective treatment to steelwork and metalwork Item st Time to 1 major maintenance Protective Treatment Jetty structures (For general steelwork only. The Contractor shall ensure that protective treatments provided have a minimum life to first major maintenance of 15 years under exposure C5-M and Im2 as appropriate in accordance with BS EN ISO 12944 (see table below for specific requirements). BS EN 1461 116 Table A. The following protective treatment schedule indicates the minimum requirements for protective treatment of steelwork and metalwork.

117 .5 Table A. 4.02 10 yrs Hot dip Galvanise.5 Table A.7 Schedule of Colour Finishes The colour shall be to the approval of the Employer.13 (2 pack epoxy system) 4. under which the paints are to be applied. Dry film thickness (DFT). System reference together with manufacturer's brand name and product reference.02 (Two pack epoxy . humidity and other conditions at the workshop or on Employer’s Site under which the paint is to be applied. 4.03 (2 pack polyurethane gloss finish) Hot dip Galvanise plus paint system A7.4 Painting All paints shall be from an approved manufacturer. the Contractor shall submit to the Project Manager for approval a Paint System Sheet stating full details of each paint system proposed indicating the following information: Surface preparation. The requirements of the Paint System Sheets shall only be adopted for the Works following the Project Manager’s approval. provided by the paint manufacturer. for each of the paints he proposes to use.2 BS EN 12944 Table A. The complete paint system shall be obtained from one supplier only.min dft 320 µm). (not mating faces) Step Irons to Storm water Manholes and draw pits 10 yrs Hot dip Galvanise plus paint system A7.3 Protective Treatments For all painted items.6.st Time to 1 major maintenance Item Pipework brackets/hangers 10 yrs Structural Steelwork (Marine side) 10 yrs Structural Steelwork (Land side) Vehicle Barriers and handrails Protective Treatment Hot dip Galvanise plus paint system A8.6.13 (2 pack polyurethane gloss finish) 10 yrs Paint system A5M. Colour. including temperature and humidity. copies of a Paint Data Sheet. The fullest possible use shall be made of the Technical Services of the manufacturer concerned.8 Table A.7 Table A.6. The Contractor shall submit with this information. The Contractor shall ensure that the paint manufacturer’s data sheets cover the conditions at Works or at Site. BS EN 1461 Manhole Covers & Frames 10 yrs Paint system A5M. Duplicate copies of the manufacturer’s data sheets including temperature. Time to repaint.

6. A sample of painted tin plate for each painting system may be required by Project Manager. Intended purpose. Any work coated with materials. and work on which the paint is found to be unduly thin shall be repainted.7 Sampling and Testing Samples for testing may be taken both from the sealed containers and from the workmen’s kettles on the works. Batch number. all to the satisfaction of the Project Manager and at the Contractor’s own expense. date of manufacture. No materials of any description shall be added to the contents of the containers except in strict accordance with the manufacturer’s instructions and paints of different types or of different manufacturers shall not be mixed together. 4. Colour. Details of the method of plugging vent holes required for hot dip galvanizing of hollow sections shall be submitted to Project Manager for review. explosion or toxic fumes being experienced by any person on the Site. The temperature of the store shall be kept between 4°C and 27°C unless the storage conditions recommended by the manufacturer allow temperatures outside this range. The plates shall be brush cleaned and painted on one face with the painting system in such a manner that each coat is stepped back from the underlying coat in equal strips. Paint shall be stored in sealed containers in a locked store where it will not be exposed to extremes of temperature.4.whichever is the lesser. colourless. 4. Paint not used within the ‘shelf life’ period specified on the containers or within 18 months of the date of manufacture . drying time and flash point. The sample shall be 150mm x 150mm x 6mm and shall be enclosed in a sealed. transparent wrapping.6. the samples from which prove unsatisfactory. gloss. Each batch shall be dated on delivery and shall be used strictly in order of delivery. masks and barrier creams to prevent the risks of dermatitis or other complaints from occurring. shall be cleaned off and re-executed. expiry date and pot life.5 Safety All due care shall be taken by the Contractor in the handling of materials and equipment for painting. A high standard of personal hygiene shall be practised by all operatives including the use of protective clothing.6 Storage of Paint Paints shall be delivered in sealed containers of not more than 5 Liters. Any special storage conditions recommended by the manufacturer shall be observed. 118 . shall be replaced.6. Each plate shall be 150 mm x 75mm x 1mm and shall have smooth edges and 10mm corner radii. A sample of blast cleaned steel plate may be required by Project Manager for review. Each container shall be marked on the side to show the following:       Manufacturer’s name. Instructions for storage. type of pigment and binder. Manufacturer’s paint reference number. and the correct disposal of waste materials to prevent danger from fire. gloves. The grade of steel and the method of blasting shall be representative of those which will be used in the permanent work.

the materials and methods of application used in a painting trial which complies with the specified requirements shall not be changed. Surfaces that have been galvanized are to be thoroughly cleaned to remove all dirt. the cause of failure shall be established by Contractor and particulars of proposed changes shall be submitted to Project Manager for review. Surfaces of steelwork or metalwork that have been previously primed are to be examined to ensure that they have been properly prepared before priming and that the primer is of a suitable type. The surfaces are then to be primed immediately with the appropriate primer. If the condition of the surfaces or of the primer is unsatisfactory and if the surfaces of any small items remain un-primed. Painting shall not commence until the painted surface produced in painting trials complies with the specified requirements for paintwork. Unless previously agreed with Employer. The Contractor shall keep all working surfaces clean and properly brushed off as the work proceeds. firmly adhering and in good condition. The surface shall then receive an etched primer compatible with the specified paint system. and all salts remaining from the galvanising process neutralised. 119 . other than an adjustment in the amount of thinner. If the painted surface produced in a painting trial does not comply with the specified requirements for the paintwork.6.4. Any metal exposed as a result of damage to the primer is to be wire brushed and scraped to remove rust and primed immediately with the appropriate primer. After preparation. shall be carried out at the paint manufacturer’s works before the final painting trial and before the first batch of paint is delivered. grease. the required protective treatment shall be applied. grease. If the condition of the surfaces and the primer is satisfactory then the surfaces are to be thoroughly cleaned to remove all dirt.6. The Contractor shall carefully inspect and prepare all surfaces to the approval of the Project Manager.9 Prepared Surfaces The Contractor shall advise the Project Manager in good time of his blasting and painting operations to enable inspection and testing to be carried out.8 Paint Trial A painting trial shall be carried out for each painting system to demonstrate that the proposed materials and methods of application will produce a painted surface which complies with the specified requirements. etc. Painting trials shall be carried out on blast cleaned steel. then the surfaces are to be thoroughly cleaned by mechanical chipping or wire brushing to remove all defective primer and all rust and loose scale back to the bare metal. 4. Proposed changes to the paint formulation. Paint trials shall be carried out at the place where painting to the permanent work will be carried out and using the employees and equipment which will be used to carry out painting to the permanent work. If necessary. the primer shall be stripped off completely. The Contractor shall examine all surfaces prepared by others and if the working surfaces or conditions are in any way unsuitable he shall advise the Project Manager immediately in writing.

The Contractor shall take appropriate measures to ensure that pre-painted piles make allowance for
any variation in toe level of the driven piles. Tubular steel piles shall be finished with a surface
coating down to a minimum of 2m below LAT or 0.5m below bed level whichever is the lower.
4.6.10

Preparation of Bare Metal Surfaces

Soil, concrete and other adherent matter shall be removed immediately from steelwork or coated
surfaces and the surfaces shall be made good.
Dust, soot, grit, detritus, metallic or other loose particles shall be removed by vacuuming after
steelwork surfaces have been blast cleaned or before coated surfaces are washed or steam cleaned.
Oil and grease shall be removed by emulsion cleaners, by steam cleaning or by high pressure water
jets before removing rust and mill scale or over coating. Oil and grease shall not be removed by
turpentine or other solvents. If steam cleaning is used, steam cleaning shall be carried out after the
greasy deposits have been removed by scraping and a detergent shall be added to the feed water of
the steam generator.
Salts, chemicals, corrosion or paint degradation products, including rust-spotting on blast cleaned
surfaces and zinc salts on zinc coatings or zinc-rich paints, shall be removed by washing with
detergent solution before coating steelwork surfaces or over coating.
Surfaces which have been cleaned using cleaning agents shall be rinsed with fresh water to remove
all traces of cleaning agent.
Blast Cleaning
All steelwork to be blast cleaned shall be treated in accordance with BS 7079 “Preparation of steel
substrates before application of paints and related products” Grade Sa 2½ using automatic impeller
machine blasting or manual blasting as appropriate. The maximum grade of abrasive permitted shall
be as specified in the above British Standard. Non-metallic abrasives will only be permitted for use
with portable equipment where agreed with the Project Manager.
The abrasive used for blasting shall be free from contamination and any recovered material shall be
cleaned to the satisfaction of the Project Manager before reuse. The maximum amplitude peak to
trough of the blast cleaned surface shall not exceed 100 microns.
A sample blast-cleaned panel measuring not less than 150 x 150 x 6 mm adequately protected by
sealed transparent wrapping, shall be submitted to the Project Manager for approval before any work
is commenced. The approved sample shall be retained by the Project Manager for comparison with
prepared steelwork.
Blast cleaning shall be carried out in a fully enclosed space separated from the place of painting. The
enclosed space shall be fitted with dust extractors and filters to prevent the dispersal of dust outside
the enclosed space.
Hand Cleaning
All steelwork to be manually cleaned, by grinding disc, power wire brush, chipping hammers, or
needle guns shall be of a type which will not result in damage to the surfaces being cleaned and
treated in accordance with BS 7079 Grade St 2.
Wire brushes and brooms shall not be used for cleaning coated surfaces.
Mechanical Cleaning of Steelwork

120

Mechanical cleaning of steelwork shall be carried out using carborundum grinding discs or other
power-driven tools followed by steel wire brushing and dusting to remove all loosened material which
is not firmly bonded to the metal surface.
Excessive burnishing of the metal through prolonged application of rotary wire brushes shall not be
carried out. Visible peaks and ridges shall be removed. Pneumatic chipping hammers shall not be
used.
Pickling
All steelwork to be galvanized shall be pickled in diluted hydrochloric acid.
Unless otherwise described in the Contract, exposure times for blast cleaned or coated surfaces
other than at joints shall not be longer than those in table below. “Outside” refers to any area outside
a fully enclosed workshop. The exposure times tabulated refer to any part of the surface cleaned in
accordance with this clause:
Table 4-6: Maximum Exposure Times

S1 Blast Cleaned

Max Exposure Times
Enclosed Workshop
1 hour

S2 Metal Sprayed

4 hours

S3 Mechanically Cleaned

48 hours

S4 Chemically Cleaned

As agreed with Project Manager
Maximum exposure of 8 weeks with up to 2 weeks of
this time outside
24 hours
Nil
48 hours
Nil
48 hours
Nil
As agreed with Project Manager

Surface

S5 Blast Primer on S1
S6 Etch Primer on S1
S7 Primer on S3
S8 1st Undercoat on S4, S5, S6 or S7
S9 Subsequent Undercoats

Outside
Nil
Nil
Nil

For surface condition S5 where blast primed steelwork is exposed outside, the minimum dry film
thickness of paint over the peaks of the blast cleaned steel shall not be less than 13 microns.
4.6.11

Paint Preparation

All paint shall be prepared and applied strictly in accordance with the manufacturer’s instructions. All
painting shall be carried out by skilled and experienced painters under constant supervision of
competent qualified staff.
Paint shall be thoroughly stirred when the containers are opened and when fresh supplies are being
transferred to paint pots. All paints shall be strained free from skins, etc. Paint shall be supplied from
the Contractor’s paint store to the painters ready for application.
Two pack or any similar chemically cured type paint shall not be used after the expiration of the ‘pot
life’ stipulated by the manufacturer and such paints shall not be mixed with fresh paints.
4.6.12

Paint Application

All paint coatings shall be applied in accordance with BS EN 12944 and the manufacturer's
instructions.

121

All brushes, tools, pots, kettles, etc., used in carrying out the work shall be clean. They shall be
thoroughly cleaned before being used for a different type or class of paint.
A controlled working procedure shall be adopted for all painting and surface preparation. Blasting
primer shall be applied as soon as possible after blasting operations are complete and shall in any
case be applied within 3 hours for an enclosed workshop. The paint system shall be built up to the
required dry film thickness (DFT) prior to removing the steelwork from the controlled environment to
an external situation.
Paints shall not be applied when the ambient temperature or the relative humidity falls outside the
limits recommended by the manufacturer, nor shall such paints be applied when the temperature is
likely to fall below the specified minimum during the curing period.
Paints shall not be applied externally during rain, fog or mist, or where the amount of moisture on the
surface, or that likely to be caused by subsequent condensation, may have a harmful effect.
Unless otherwise described in the specification, a coat of paint shall be applied by one of the
following methods:
Brush;
Roller supplemented by brush where necessary;
Air pressure spraying;
Airless spraying;
Spray-painting will not be allowed where the soiling of adjacent surfaces is likely to occur, unless
these surfaces are adequately protected, and neither will spray-painting be allowed in the case of
paints containing lead.
The Contractor shall ensure that the spreading capacity of the paint is fully in accordance with the
manufacturer’s instructions and that the spreading rate is controlled to maintain the required paint
thickness. The specified dry film thickness of the adopted paint system shall be adhered to at all
times and any areas exhibiting a lower film thickness shall be brought up to the required standard.
The Contractor shall note that the addition of diluents to painting materials shall only be permitted
with the agreement of the Project Manager. Any solvent used shall be fully compatible with the paint
product, shall be approved for use by the paint manufacturer and shall be limited to adding up to 5%
of solvent per unit volume.
In cases where the specified film thickness is insufficient the Project Manager shall determine
whether re-preparation of the surface and re-application of the complete paint system is necessary or
Making Good by rubbing down and re-applying the coating.
The Contractor shall allow for adequate drying periods between successive coats and shall consult
with the paint manufacturer regarding drying periods for each individual coating.
A minimum of 24 hours drying time shall be allowed for between each composite coat of paint and
the Contractor shall take particular care with areas of flanges, bolt holes and sharp angle edges
where a build up of paint may occur.
The Contractor shall take particular care with areas that are susceptible to corrosion such as welds,
sharp edges and joints etc., in addition to areas where there may be difficulty in achieving the
required dry film thickness. The Contractor’s attention is specifically drawn to Clause 4.3.5 of BS

122

Any defective area resulting from non-compliance with this specification shall be Made Good at the Contractor's expense. rubber protected chocks. assembly and erection.15 Metal Coatings Where metal coating are required for threaded fasteners the following standards shall apply: 123 . stacking and erection of any painted steelwork to minimise damage to the protection system. Steelwork shall not be moved outside the paint shop until the shop-applied protective treatment is complete. trucks and decks. Fabricated steelwork which is stored.13 Shop Painting The paint shop in which the protective system is to be applied shall be approved by the Project Manager before the work commences and shall be of such design and construction that the specified conditions of temperature. Prior to the application of further coats while on Site and after installation. awaiting delivery to Site or erection. Areas of paint damaged during handling. harnesses. Dry film thickness achieved shall be demonstrated to the Project Manager for each coating in accordance with the procedures set out in BS 3900. the original coat shall have all damaged and defective areas repaired and made good and the entire surface cleaned to remove any dirt. The Contractor shall Make Good to the approval of the Project Manager all paint work damaged during fabrication. The Contractor shall also provide the Project Manager with all equipment as necessary to undertake his own inspections including wet and dry film thickness gauges of an approved design. transport.6. 4. ropes and chains used to handle the steelwork shall be protected with rubber sheaths or similar. unloading. oil or grease or contamination by salts. 4. humidity and cleanliness are maintained throughout the Contract period. shall be kept clear of the ground and shall be laid out or stacked so as to prevent water or dirt accumulating on or against any of the surfaces. Care shall be taken during loading. The Contractor shall take care in the handling of all steelwork after the application of the blast primer. chains and lashings on vehicles. All slings. The paint layers shall be feathered and shall overlap the existing paint system by a minimum of 50 mm. 4. Where cover is provided it shall be ventilated sufficiently to keep condensation to a minimum.6. A stripe coat shall be applied to all such areas before the application of each coating providing the additional coat does not result in a dry film thickness in excess of that recommended by the paint manufacturer.5400: Part 6. Any steelwork to be stored on Site shall be suitably supported on timber packers such that no painted surfaces shall be in contact with the ground. Suitable packing shall be placed between layers of stacked steelwork. transportation or erection shall be cleaned back to base metal and the full specified paint system re-applied. re-prepare the surface and re-apply the complete paint system.14 Storage of Steel and Fabricated Steelwork The Contractor shall take precautions to minimise exposure to chemical pollution of steel awaiting fabrication. Particular care shall be taken during transportation of steelwork to the Site and the Contractor shall make full use of suitable lifting slings.6. The defective area shall be identified by the Project Manager and the Contractor shall remove the paint system completely.

to give a repair coating thickness of 100 microns. Nuts shall not be tapped oversize by more than 0. Articles shall be evenly coated on all sides. All hot dip galvanising shall be in accordance with B. continuous and free from flux strains. Where nuts and bolts are to be metal coated.6. 4. BS 3382 Parts 1 and 2.BS 4921 Sherardized coatings on Iron and Steel Articles. welding and fitting has been completed. Damaged areas of metal coatings shall be rubbed down to remove excessive roughness. Metal coatings which will be over coated with paint shall be passivated.4 mm.S. attentions is drawn to the additional clearances required on screw threads as shown in BS 4921. filing. Where the metal coating is by a hot dip process the Contractor shall be responsible for the provision of all holes required for purposes of filling. Table 2. The minimum thickness of coating shall be 5 microns. transportation and erection of protected steelwork so that damage to the coating may at all times be avoided. This Standard shall cover the electroplating of components up to and including 36 mm in diameter. The coating weight shall be not less than 610 g/m2. trimming. The coating shall be sufficiently adherent to withstand normal handling conditions without peeling or flaking. The Contractor shall propose the location. Where a metal coating is required only on part of an assembled section it shall be applied before the rest of the section receives its priming coat. Electroplated Coatings on threaded Components (Cadmium and Zinc). The coating shall be smooth. 729: "Hot dip galvanised coatings on iron and steel articles". Allowance for the thickness of the metal coating shall be made in the sizes of the threads of metal coated threaded components. Hot dip galvanising shall be carried out after all shaping. cleaned and made good by the use of an aerosol zinc rich paint containing an aluminium pigment. which is equivalent to a coating thickness of 85 micrometer. Metal coatings required on part of a component shall be completed before the rest of the component is painted. size and method of plugging where required of all such holes which must be approved by the Project Manager before fabrication commences. venting and draining. The use of properly assigned slings and soft non-adherent packs shall be used throughout. 124 .16 Handling of Coated or Painted Steelwork The Contractor shall exercise the maximum care in handling.

All steelwork which is to be painted in coal tar/epoxy which has been damaged or been stripped to permit welding shall be repaired using an equivalent approved coal tar/epoxy suitable for application on wet or damp surfaces.6.19 Welded Joints The Contractor shall ensure that areas within 200 mm of known Site welds shall not be painted until all welding and testing is completed. Welds and surfaces which have been affected by welding shall receive the preparation and protective systems which are applied to the parent surfaces. they shall be stepped back at 50 mm intervals commencing at 200 mm from welded joints and at 10 mm from the perimeter of all other joints. Blast primer or metal spray as appropriate shall be taken 10 mm to 20 mm inside the perimeter of the joint area. The Contractor will submit full proposals for the approval of the Project Manager which demonstrate the paint manufacturer’s agreement to the proposal. Before the joint is made the facing surfaces shall be lightly hand wire-brushed to give a clean surface free of corrosion products and any foreign matter. left unpainted masked off to protect them until the joint is bolted up. storing. Subsequent paint coats shall be stopped off progressively at intervals of 75mm from the bolted joint. In all circumstances the steel surface shall be adequately cleaned as specified in BS EN 12944 and coated to provide the paint thickness corresponding to adjoining surfaces. 4. The full specified painting system shall then be re-applied and the new paint shall overlap the existing paintwork by at least 50mm.18 Bolted Connections High Strength Friction Grip (HSFG) Bolted Joints The interfaces of all HSFG bolted joints shall be cleaned as specified. transporting and erecting shall be cleaned to bare metal by grit blasting. Other Bolted Joints For shop joints the Blast primer shall be applied to parent and joint material. grinding wheels or other approved means and the edges of the undamaged paint bevelled by at least 50 mm. loading and off loading. Where this is not practicable the Contractor shall ensure that the paint coat is removed by grinding and each coat is stepped back to enable preparation of fusion faces for welding. 125 .6. Immediately after the joint has been made the primed steelwork shall be hand wire-brushed and the specified painting systems completed.17 Repairs to Damaged Area Areas of paint which have been damaged during handling. For Site joints all surfaces. shall receive in the shop the paint system which is applied to the parent surfaces. In some instances this will have to be carried out under tidal conditions. excepting those of fasteners.4.6. The joint shall be assembled immediately after the first undercoat of the painting system has been applied to the parent and contact surfaces. 4. Where paints other than blast printers are to be applied to the parent surfaces before the making of a joint.

nuts and washers. exposed parts of bolts. All bolted joints shall be sealed against the ingress of moisture.7. Full details of the proposed handrail layout shall be submitted to Project Manager for review prior to commencement of fabrication. The perimeter of all joints shall be sealed with subsequent coats of paint.5. weld and weld affected areas shall be prepared and painted. fabricated generally in accordance with Section 4. All handrails shall be steel.5 of this Specification.25mm wall thickness. Handrails and standards may be solid bar or hollow tube with minimum 3. and subject to the approval of the Project Manager. the parent and joint materials.1 General Contractor shall submit to Project Manager for review the names of all suppliers and manufacturers of proprietary or fabricated items prior to entering into any agreement for the supply of such items. 126 . and shall be finished with a galvanized metal coating and decorative paint system in accordance with this Specification.20 Treatment of Completed Joints Within 14 days of the joints having been made and passed by the Project Manager.4. Steel used in fabrication of Miscellaneous Metalwork shall be new material of Grade S275 to BS EN 10025: 1993 or equivalent unless noted otherwise on the drawings. Handrails shall be designed and detailed by the contractor in accordance with BS 6399: Part 1 and BS 5395: Part 3 as appropriate. gaps at joints shall be plugged with approved filler. Handrail standards shall be at maximum 1. Materials and Workmanship Materials and workmanship for Miscellaneous Metalwork shall comply generally with the requirements of Section 4. Minimum 100mm high kick plates shall be provided.3 of this Specification. 4.5 of this Specification. Before painting commences.7. Surface preparation galvanizing and painting of Miscellaneous Metalwork shall be in accordance with the requirements of Section 4. Project Manager may order the removal from Employer’s Site of any materials not so approved.2 Miscellaneous Metalwork Fabrication Drawings Contractor shall prepare fabrication drawings and associated documentation for all items of Miscellaneous Metalwork. Handrails and Ladders Handrails shall be provided to stair cases and elevated platforms except where their provision would obstruct mooring lines.5 of this Specification.7 Fixtures and Fittings 4. 4.6.5 meter centres. and copies of these shall be submitted to Project Manager for review in accordance with Clause 4.

chains and fittings for fendering shall be obtained from approved specialist suppliers and manufacturers and shall be fabricated.5 Fendering General Contractor is responsible for the detailed design of fendering to the jetty including support steelwork. fixings. having physical properties totally suitable for the climatic and environmental conditions at Employer’s Site and for the use required in service. 4.Access. Open type steel decking shall comply with BS 4592 except where amended below. Fender Units Rubber fenders shall be of approved manufacture. The minimum thickness of load bearing bars shall be 5mm and the load bearing bars shall have a minimum depth of 1/40 x span but not less than 20mm.7.5 of this Specification and shall be protected against corrosion in accordance with Section 4.3 Life-Saving Equipment The life-saving equipment shall ne provided in accordance with international standards. where practical. All panels shall be removable and fixing shall be such that where a panel is removed. and all fittings. They shall span in the shortest direction and. Each panel shall have an edge bar on the bearing edges. Fender units.7.7. the remaining panels will remain firm and replaced panels are safe against displacement and dropping through before the clips have been fastened.6 herein. The lifesaving equipment shall be mounted on posts. facings. Generally steel decking shall be designed to support a uniformly distributed load of 5kN/m2 with a maximum deflection not exceeding 1/200 of the span and to withstand three times the design load without collapse. maintenance and safety ladders shall generally comply with BS 4211 and the recommendations of BS 5395 Part 3. the pattern shall be continuous at the meeting point of separate pieces of decking. Contractor shall submit to Project Manager for review full details of the physical properties of the proposed fendering including: 127 . Steelwork shall comply with Section 4. assembled. Rolled steel sections shall comply with BS 4: Part 1 and BS 4848: Part 2. Floor panels shall be clipped down to the supporting steelwork so that each individual panel is held by a minimum of four clips.4 Metal Decking Materials used in construction shall comply with BS 4360: 1990. which shall have a thickness not less than the load bearing bars. installed and tested in accordance with manufacturer’s instructions and recommendations. 4. Studs shall be welded to the supporting steelwork. 4.

Manufacturer’s literature. Mooring hooks and bases shall be manufactured in cast steel to BS 3100 or similar equal approved standard.7.5. turnbuckles and any other fittings shall have equivalent loading capacities to the chains in which they are installed. or other suitable means of adjusting the chains to the accurate lengths required. The chains shall be provided with shackles at each end and turnbuckles. Polyethylene Fender Panel Facings The front faces of fender panels shall be fitted with approved ultra high molecular weight low-friction polyethylene rubbing pads and shall be installed in accordance with the manufacturer’s instructions. A report on compression load tests and characteristic load-deflection and energy-deflection curves. 128 . The safe working load of each hook in single. All materials shall comply with the relevant British Standards. Quick release mechanisms and shall be single.25 and against ultimate failure shall be 2. Shackles. by the provision of suitable turnbuckles and the inclusion of non-standard links. Fender Chains Fender chains shall be electrically welded and stud link chain complying with Grade 30 Class 1 to BS 6405 or equivalent approved. The mooring hooks shall be capable of operation both manually and by an electric remote control system.6 Quick Release Mooring Hooks Quick Release Mooring Hooks shall be of the self-supporting open type fitted with safety catches as necessary and connected to a swivel bracket in such a manner as to allow the free movement of the hook assembly in any plane. All hooks shall be capable of being released separately from the mooring point area under both full load and no load conditions. that the lengths of chains to be provided will be as recommended by the fender manufacturer and that the orientation of the links at the ends of the chains will be as required for the steelwork connections thereto.   Contractor shall check all tender dimensions and fixing details with the fender manufacturer before preparing his fabrication details for the suspended steel fender faces and support steelwork. Project Manager may require fenders supplied by Contractor to be tested at the place of manufacture and test certificates submitted for review before dispatch. including a list of physical properties of the rubber for the fenders. as necessary. The minimum factor of safety against yield shall be 1. 4. double or triple hook assemblies shall be as dictated in Contractor’s design and acceptable to Project Manager. Holding down bolts shall be suitable for casting into the reinforced concrete deck structure. Contractor shall ensure. double or triple hook units with integral capstans. Contractor shall be responsible for checking the lengths and details of all chains and shall submit to Project Manager for review full details of all chains and fittings.

Mooring hooks shall be designed to accept loading in the vertical plane from the horizontal to a minimum angle of inclination above the horizontal of 300. maintenance instructions and made into a finished handbook ISO Standard 210 x 297 (A4 size).6 to give a final paint system. Electrical isolation of the mooring hooks shall be possible. All electrical components shall comply with the requirements of Electrical System Specification. Assemblies shall be designed to require the minimum of maintenance in service.5 tonnes and a minimum line speed of 30 meters/minute. Contractor shall provide instruction manuals for review by Project Manager. junction boxes and emergency stop buttons. 129 . Hooks in single hook assemblies shall be designed to accept loadings in the horizontal plane through minimum load sectors of 180 deg. Motors shall be suitable for multiple starts and shall be supplied with foot switches. Material test certificates shall be provided. through a minimum load sector of 1100. Capstan motors shall be reversible in operation and capable of holding loads when stopped. Test certificates shall be issued for all hooks. The assemblies shall be suitably primed prior to leaving the manufacturer’s works with an inorganic zinc rich or other approved coating applied in accordance with the manufacturer’s recommendations to give a total minimum dry film thickness of 75 to 100 microns applied to a surface blast cleaned to Swedish Standard SA21/2. motors shall be designed for the maximum ambient temperature. Hooks in double hook assemblies shall be designed to accept loading in the horizontal plane through minimum load sectors of 1300. The capstans shall be of the integral type mounted with a vertical axis on the top of the hook base and shall have a minimum load capacity of 1. Notwithstanding the information given therein. Outer hooks in triple hook assemblies shall be designed to accept loading in the horizontal plane through minimum load sectors of 130° and the inner hook. Proof load testing to working load shall be carried out on all hooks under supervision of Lloyds’ Register of Shipping or equivalent body using approved apparatus and include testing of the quick release system. After installing and testing quick release hook assemblies shall be painted in accordance with Clause 4. operating instructions. The instructions are to include a detailed description of each item accompanied by drawings. The capstan motors shall have motor enclosures to lP65 and shall be Exe.

The lights shall be installed so as not to interfere in any way with the operations of other equipment on the jetty. etc. The size and location of all bolts shall be clearly shown on Contractor’s shop drawings. The lights shall be designed and installed to provide minimum maintenance and maximum ease of access. unless otherwise approved by the Project Manager.7.7. 4. The diameters of holes shall not exceed the size of the bolt under its head by more than 2 mm. In all cases the bolts shall project not less than one full thread through the nut after tightening. 4. 130 . Holes for turned and fitted bolts shall be reamed to give a light drive fit. No holes shall be gas cut.7 Bolted Connections All connections shall be bolted with bolts and nuts to BS 3692 which shall be fitted with one flat circular washer conforming to BS 4320 under each nut. either during fabrication in shops or during erection at Site. Where bolt heads or nuts bear on bevelled surfaces they shall be provided with square taper washers conforming with BS 4320 to afford a seating square with the axis of the bolt. All bolt connection shall have one bolt. Drift pins will be allowed only for bringing together the several parts of the structures. The lights shall be fitted with devices to deter sea birds from alighting on them.9 Navigation Lights Navigation lights shall comply with the requirements of the International Association of Lighthouse Authorities Regulations. Holding down bolt assemblies shall be of approved manufacture and shall be fitted with washer plates of angles and nuts. Purpose made templates shall be provided to facilitate accurate positioning of holding down bolts during the placement of concrete.8. Holes shall be drilled accurately to template.4.8 Tide Gauges Contractor shall provide and maintain 225mm x 50mm hardwood tide gauges fixed in positions accepted by Project Manager.7. etc. Gauges shall be painted with three coats of oil paint on the marked face with alternate meters in red and white respectively and all markings picked out in black. Bolts and nuts shall be of quality 8. as required by their design. and shall not be used in such a way as to distort the work or enlarge the bolt holes. Holes shall not be punched unless the Project Manager gives permission. Burrs and arises shall be removed from the edges of holes before the parts are assembled. one nut and two washers.

The drain bodies shall be cast into the structural concrete topping at the levels and locations to be designed by Contractor. The pipes shall project 150mm below the soffit of the concrete deck and shall be surrounded by Grade C40/50 in situ concrete. The characteristics of the lights shall be to the approval of the port authority. Every duct or set of ducts shall be proved and its draw-wire shall be installed. with a focal height of 3. 4. The cast iron drain body shall have a 150mm diameter outlet. The buoys will each be fitted with North Cardinal topmarks.8 Drainage and Services 4. The length of draw-wire installed shall be such that 1mm of draw-wire extends from each end of each duct. The outlet pipe shall be 150mm diameter uPVC to BS 4660 and shall be internally caulked into the cast iron drain body.1 Floor Drains Jetty The surface-mounted drains to the jetty shall be from the 1460 Series by Wade International (U. The buoys will be appropriate for open sea conditions.7.An emergency back-up power supply shall be provided and kept available for immediate use in the event of a break in the main power supply. Wade Specification Code F106 with a hinged square opening grating code M501.) Limited or similar approved manufacturer. Contractor shall provide suitable formwork for the surround. Such formwork shall subsequently be carefully removed. solar powered lantern and radar reflector. 4.8.10 Depth Contour Buoys Depth contour buoys shall be steel skirted. which shall be of galvanized steel or 6mm nylon rope. Special precast concrete planks shall be provided with holes to accommodate the drain bodies and outlet pipes.2 meters diameter. Each electrical duct whose length exceeds 3 meters shall be provided with a draw-wire. 4. shall then be sealed to a depth of 50mm with plastic sealing compound and a single coat of bitumastic paint shall then be applied over the ends of the ducts and the seal. moored with 38mm chain and sinker adequate to anchor the buoys in design extreme environmental conditions.2 Cable Ducts Cable ducts shall be of either of the following types: (a) PVC Cable Ducts Shall be of an approved manufacture with flexible joints (b) Concrete Cable Ducts Shall be concrete pipes with ogee joints to BS 5911.0 meters. standard class. 131 . of 2. buildings and basements shall be provided with approved bell-mouths. The free ends of the draw-wire shall be neatly coiled or otherwise stowed. The ends of the duct or its bell-mouth where provided. All electrical ducts entering draw-pits.8.K.

fittings and valves shall be carefully installed in such a manner as to prevent damage to the materials. drilling holes.8.9 Geotechnical Investigation The Contractor shall be fully responsible for the planning.9. Each length of and duct shall be accurately laid and shall be true to line and gradient from point to point. 4. When pipes pass through walls a flexible joint is to be fitted.Execution of 15 Vibro-core boreholes until a depth of 4 meters below the seafloor . junctions and other special pipes of whatever pattern required. All glass reinforced plastic pipes used in the Plant shall be installed and tested in accordance with BS 5480: Parts 1 and 2 and shall comply in full with the manufacturer’s recommendations.3 Ducts All pipe-laying shall be done by skilled and experienced men. coring. 132 .9. 4. and  1 borehole at the location of each of the 4 mooring dolphins. detailing and specifying the soil investigations and shall obtain approval of the Project Manager before starting the investigations.2 Boreholes A total 15 boreholes are required:  9 boreholes along the axis of the FUF at intervals of 50 meters  2 boreholes at the location of the unloading platform.1 Boring activities The following describes the activities required to obtain the required information: .Laboratory analysis of the extracted samples and cores .Site supervision by a geotechnical engineer . All ducts shall be clean before laying and jointing. All service systems shall include bends.Shipping of the samples to a qualified geotechnical laboratory . tapers. tools and facilities shall be provided and used by Contractor for the safe and convenient performance of the work. making good and connection to new and existing work. Proper implements. All pipes and fittings shall be assembled strictly in accordance with the written instructions of the manufacturer. No damaged or defective pipes shall be used.Execution of 15 Dynamic Penetration Tests (DPT).Delivery of marine equipment . Provision shall be made for all cutting.Delivery of the geotechnical report. All pipes. each one at the same location as the boreholes) .Set-out borehole locations by means of a D-GPS system . 4.Drilling of 15 geotechnical boreholes until a depth of approximately 25 to 30 meters below the seafloor (or less due to refusal of bedrock) .4. situated as close as possible to the outside face and permitting a minimum deflection between adjacent pipes of 3 degrees.

Vol.Laboratory test results .Organic content . (1981) edition. 9V1468. showing the reference design. pp5l-60.All borehole logs and DPT graphs .R. 4.03.Foundation advice (exclusive pile calculations for the FUF).Triaxial testing . E.Atterberg limits . Testing and Monitoring. Mm. The geotechnical engineer has to propose the number of samples to be used for each of the tests listed below.4.T. 2.M. Suggested Method of Determining Point Load Strength.Grain size analyses.Calcium Carbonate content. In general these tests fit the requirements of the assignment: .S.002 9V1468.03.Geotechnical longitudinal profiles and cross sections.03. & Geomech. This reference design is for bidding purpose only.006 General Layout_Existing Situation Jetty Layout Loading Platform_Layout and cross sections Access Trestle_Layout and coss sections Pump House Platform_Layout and cross sections 133 . 3. Brown.Location map with exploratory holes .5 Deliverables The Geotechnical Report should present the following data: . International Society of Rock Mechanics (1985). including hydrometer .R. Abstr.03.004 9V1468. 4.Code of Practice for Site Investigations.Minimum/maximum density . 22.Methodology. I.Oedometer tests .003 9V1468. including soil layers and boring logs . Rock Characterisation.03.001 9V1468. International Society Rock Mechanics Commission on Testing Methods 5 DRAWINGS This section includes the following drawings. 4. equipment and photographs .9.Particle shape determination . BS 5930: 1981 .M.9. Suggested Methods.S.4 Laboratory Analyses The geotechnical engineer will have to propose a laboratory testing program to the client to be executed upon completion of the field work. the contractor is required to ship his own facility (for instance a sectional barge) to Monrovia.6 References The following References shall apply to this Specification: 1. BS 1377: 1990: Parts 1-9 Methods of test for soils for civil engineering purposes. I. 4. Sci.Gamma plus water content .9.9.3 Marine Equipment Due to the lack of adequate marine equipment fit for the execution of the activities described above.

S355. 1978 Environmental Soil Investigation.03. Survey Report.03. The Oil Jetty.00x1. June 2005 Extracts from “Preliminary Engineering and Economic Investigations for the Rehabilitation and Extension of the Freeport of Monrovia”.00x0.010 9V1468. Liberia. Port of Monrovia. Volume 2. Rhein-Ruhr Ingenieur-GES MBH. Royal Haskoning.007 9V1468. cross sections and views Electrical Systems Flow Diagram Mooring Dolphins_Layout and views Breasting Dolphins_Layout and views SUPPLEMENTARY INFORMATION This section includes the following supplementary information: 1 2 3 4 7 Bathymetric Survey Freeport of Monrovia.80m nr 14 2 Coating length 20m m2 580 3 Reinforced concrete fill length 3.9V1468.2mm. Actual situation of the port and site investigations.008 9V1468. Classdiving.80m nr 3 134 .000 UNIT QTY LOADING PLATFORM ITEM ITEM DESCRIPTION 1 Steel pipe pile ø660x14. June-July 2005 ANNEX 1 ESTIMATED BILL OF QUANTITIES This BOQ is based on preliminary design and is not to be considered reliable by the bidders.80m m3 18 4 Reinforced concrete beam 20. DREDGING ITEM ITEM DESCRIPTION UNIT QTY 1 Dredging and disposal of material m3 39.03. Royal Haskoning. March 2006 Report of the underwater inspection at the Freeport of Monrovia.011 6 Pump House_Building Layout.03.009 9V1468. length 29.03.

30m nr 70 2 Coating length 10m m2 1.80m nr 80 7 Steel girder HE700A m 930 8 Steel girder HE200B m 310 9 Walkway Steel girder UNP200 m 930 135 . length 22. S355.80m nr 1 6 Reinforced concrete deck t=500mm m2 300 7 Reinforced concrete edge beam m 70 8 Ladder including sliding fender nr 2 9 Railing m 43 10 Catwalk support nr 2 11 Hose area Reinforced concrete beam m 43 12 Grating m2 79 UNIT QTY 1 Trestle foundation Steel pipe pile ø660x14.00x0.2mm.5 Reinforced concrete beam 8.50m (from pump house to loading platform) 4 Coating length 16m m2 332 5 Reinforced concrete fill length 3. S355.450 nr 10 ACCESS TRESTLE ITEM 3 ITEM DESCRIPTION Steel pipe pile ø660x14.50m m3 11 6 Reinforced concrete beam 5.00x1.00x1.2mm. length 16.00x0.

10 m 658 11 Grating m2 465 12 Railing m 930 PUMPHOUSE ITEM ITEM DESCRIPTION UNIT QTY 1 Pump House foundation Steel pipe pile ø660x14.100.10 Steel bracing L100.25m m2 94 3 Reinforced concrete fill length 3.00x1.75m nr 4 2 Coating length 11.00x0. S355. length 17.2mm.80m nr 2 5 Reinforced concrete deck t=500mm m2 42 6 Reinforced concrete edge beam m 26 7 Pump House Steel column HE160A m 38 8 Steel column HE160A (roof) m 31 9 Steel column UNP140 m 38 10 Construction Pump House nr 1 DOLPHINS ITEM ITEM DESCRIPTION UNIT Mooring Dolphins 136 QTY .25m m3 5 4 Reinforced concrete beam 7.

2mm.2mm.00x6.00m m3 292 13 Corner protection m 13 14 Ladder including sliding fender nr 2 15 Railing m 32 16 Double Quick Release Hook nr 2 17 Fender SCN2000 including Fender Panel nr 2 18 Catwalk support nr 2 19 Catwalk Steel girder ø813x14.2mm.5m m2 945 11 Reinforced concrete fill length 2. S355.00m m3 144 5 Corner protection m 18 6 Ladder including sliding fender nr 2 7 Railing m 25 8 Triple Quick Release Hook nr 2 9 Breasting Dolphins Steel pipe pile ø813x14.2m m2 339 3 Reinforced concrete fill length 2.50x8.DOLPHINS ITEM ITEM DESCRIPTION UNIT QTY 1 Steel pipe pile ø660x14.00x2. S355 M 42 20 Coating steel girder m2 110 137 .00x2.25m m3 22 12 Reinforced concrete base 8.20m m3 11 4 Reinforced concrete base 6. S355. length 38.7m nr 16 2 Coating length 10. length 32.25m nr 20 10 Coating length 18.

24m nr 1 5 10" flexible hose for Gasoline.DOLPHINS ITEM ITEM DESCRIPTION UNIT QTY 21 Steel girder IPE200 m 42 22 Grating m2 42 23 Handrail m 83 UNIT QTY INSTALLATIONS ITEM ITEM DESCRIPTION Product pipelines 1 12" CS pipeline for Gas oil m 485 2 10" CS pipeline for Gasoline m 485 3 8" CS pipeline for Jet-A1/Kerosene m 485 4 12" flexible hose for Gas oil. 24m nr 1 Utility Pipelines 7 3" CS pipeline for slops m 485 8 2" CS pipeline for nitrogen m 485 9 2" CS pipeline for fresh water m 415 Spill prevention 10 2 m3 Slops nr 1 11 1 kW slops pump nr 2 nr 1 m 80 Pedestal mounted crane 12 Pedestal mounted crane Fire fighting 13 12" CS pipeline for firewater 138 . 24m nr 1 6 8" flexible hose for JetA1/Kerosene.

manifolds.) sum item 139 . injection pump sum item 18 Fire water monitor (mounted on crane) nr 1 sum Item Fire detection and alarms 19 Fire detection and alarms Electrical 20 Illumination Posts walk ways nr 19 21 Illumination Posts work areas nr 2 22 400 VAC Cable m 465 23 115 VAC Cable m 685 24 400 to 115 VAC Transformer nr 2 25 Cable tray m 685 26 Auxiliary Items (valves. instrumentation etc.INSTALLATIONS ITEM ITEM DESCRIPTION UNIT QTY 14 Diesel-powered fire pack nr 1 15 Electric fire pack nr 1 16 Jockey pump nr 1 17 5 m3 Foam tank incl.