S05 Sewerage

EDTP GEMAS-JOHOR BAHRU TECH. SPEC. FOR ARCH.
, C&S AND MEP
SECTION 5: SEWERAGE WORKS
TABLE OF CONTENTS
CONTENTS PAGE
5.1 Introduction ......................................................................................... S5-1

5.1.1 General Description Of Works ................................................. S5-1
5.2 Wastewater Treatment Plants ............................................................. S5-3
5.2.1 Scope ...................................................................................... S5-3
5.2.2 Process Description ................................................................. S5-3
5.2.3 Design And Construction Requirement .................................... S5-3
5.2.3.1 General Requirement ............................................. S5-3
5.2.3.2 Standard And Regulation ....................................... S5-5
5.2.4 Electrical Services ................................................................... S5-6
5.2.4.1 Power Supply Reticulation...................................... S5-6
5.2.4.2 Motor Control Center (MCC) .................................. S5-6
5.2.4.3 LV Cable Installation .............................................. S5-7
5.2.4.4 Electrical Earthing System...................................... S5-7
5.2.4.5 Lightning Surge Protection ..................................... S5-7
5.2.4.6 Interior Lighting ...................................................... S5-7
5.2.5 Control System ........................................................................ S5-8
5.2.5.1 Local Control Panel (LCP) ...................................... S5-8
5.2.5.2 PLC panel .............................................................. S5-8
5.2.5.3 Control and Operation Mode .................................. S5-8
5.2.5.4 Control and Instrument cable installation ................ S5-9
5.2.5.5 Lightning surge protection ...................................... S5-9
5.2.5.6 Instrument Earthing System ................................. S5-10
5.2.5.7 Interfacing Requirements ..................................... S5-10
5.2.6 Miscellaneous ........................................................................ S5-10
5.2.6.1 Training ................................................................ S5-10
5.2.6.2 Warranty Requirements........................................ S5-11
5.2.6.3 Spares.................................................................. S5-11
5.2.6.4 Maintenance Support Upon Completion Of The
Warranty Period ................................................... S5-12
5.2.6.5 Manufacturing Inspection and Factory Test .......... S5-12
5.2.6.6 Programme .......................................................... S5-13
i
Revised on 4 Oct. 2011
EDTP GEMAS-JOHOR BAHRU TECH. SPEC. FOR ARCH., C&S AND MEP
5.2.6.7 Testing, Commissioning And Acceptance Tests ... S5-13

5.3 Pipeline Materials And Installation .................................................... S5-13
5.3.1 Precast Reinforced Concrete Sewer Pipes ............................ S5-13
5.3.1.1 General ................................................................ S5-13
5.3.1.2 Types of Pipes ..................................................... S5-13
5.3.1.3 Minimum Internal Diameter .................................. S5-14
5.3.1.4 Work Tests for Concrete Pipes............................. S5-14
5.3.1.5 Joints to Concrete Pipes ...................................... S5-15
5.3.2 Vitrified Clay Sewer Pipes ..................................................... S5-15
5.3.2.1 General ................................................................ S5-15
5.3.2.2 Testing and Acceptance of Vitrified Clay Pipes .... S5-15
5.3.2.3 Flexible Joints to Vitrified Clay Pipes .................... S5-15
5.3.3 Ductile Iron Pipes for Force Main .......................................... S5-16
5.3.4 General ................................................................................. S5-16
5.3.4.1 Joint for Ductile Iron Pipes ................................... S5-16
5.3.4.2 Lining for Ductile Iron Pipes ................................. S5-17
5.3.4.3 Surface Protection Coating for Ductile Iron Pipes . S5-17
5.3.5 Transporting and Inspection of Materials ............................... S5-17
5.3.6 Excavation and Backfilling For Pipes ..................................... S5-18
5.3.7 Pipelaying.............................................................................. S5-18
5.3.7.1 General ................................................................ S5-18
5.3.7.2 Handling............................................................... S5-18
5.3.7.3 Setting Out ........................................................... S5-19
5.3.7.4 Soft Trench Bottom .............................................. S5-19
5.3.7.5 Cleaning............................................................... S5-19
5.3.7.6 Temporary Stops ................................................. S5-19
5.3.7.7 Changes In Line and Grade ................................. S5-20
5.3.7.8 Deflection at Certain Joints .................................. S5-20
5.3.7.9 Connection to Existing Sewer Mains .................... S5-20
5.3.8 Jointing .................................................................................. S5-20
5.3.8.1 Jointing Concrete Sewer Pipes ............................ S5-21
5.3.8.2 Jointing Vitrified Clay Pipes .................................. S5-21
5.3.8.3 Rubber Rings ....................................................... S5-21
5.3.8.4 Mechanical Joints (K-Type Joint) ......................... S5-22
5.3.9 Prevention of Flotation........................................................... S5-22
5.3.10 Bedding, Haunching and Surround to Pipes .......................... S5-22
5.3.11 Cutting Pipes ......................................................................... S5-23
ii
5.3.12 Testing of Sewers .................................................................. S5-24

5.3.13 Completion of Works ............................................................. S5-31
5.3.13.1 Cleaning Up ......................................................... S5-31
5.3.13.2 Inspection Upon Completion ................................ S5-31
5.3.13.3 Maintenance......................................................... S5-32
5.3.14 Manholes ............................................................................... S5-32
5.3.14.1 Excavation and Backfilling .................................... S5-32
5.3.14.2 Precast Concrete Manholes ................................. S5-32
5.3.14.3 Brick Manholes ..................................................... S5-34
5.3.14.4 Manholes Covers and Frame ............................... S5-34
5.3.14.5 Ladder .................................................................. S5-35
5.3.14.6 Channels in Manholes .......................................... S5-35
5.3.14.7 Tumbling Bays and Backdrops ............................. S5-35
5.3.15 Service Sewer Connections ................................................... S5-35
5.3.15.1 General ................................................................ S5-35
5.3.15.2 Excavation and Backfilling .................................... S5-36
5.3.15.3 Laying and Jointing .............................................. S5-36
5.3.15.4 Overhead Connections ......................................... S5-36
5.3.15.5 Household Manholes ............................................ S5-36
5.3.16 Stream, Canal, Channel and River Crossing ......................... S5-36
5.3.17 Pipe Jacking .......................................................................... S5-37
5.3.17.1 General ................................................................ S5-37
5.3.17.2 Jacking Heads...................................................... S5-39
5.3.17.3 Jacking Pipes ....................................................... S5-39
5.3.17.4 Steel Collars ......................................................... S5-39
5.3.17.5 Jacking Operation ................................................ S5-39
5.3.17.6 Grouting Generally ............................................... S5-41
5.3.17.7 Backpacking and Grouting of Voids ...................... S5-42
5.3.17.8 Grouting and Special Grouting Outlets ................. S5-42
5.3.17.9 Grouting .............................................................. S5-43
5.3.17.10 Connections at Ends of Jacked Pipeline ............... S5-43
5.3.17.11 Safety ................................................................... S5-43
5.3.17.12 Railway Crossing.................................................. S5-44
5.3.17.13 Road Crossing ..................................................... S5-45
5.3.17.14 Alternative Methods.............................................. S5-45
5.3.18 Anchors and Thrust Blocks .................................................... S5-45
5.3.19 Sewage Valves and Appurtenances ...................................... S5-46
iii
5.3.19.1 General ................................................................ S5-46

5.3.19.2 Protection Against Damage During Transit .......... S5-46
5.3.19.3 Inspection ............................................................ S5-47
5.3.19.4 Painting of Valves After Installation ...................... S5-47
5.3.20 Works Test ............................................................................ S5-47
5.3.21 Materials................................................................................ S5-49
5.3.21.1 Castings ............................................................... S5-49
5.3.21.2 Forgings ............................................................... S5-49
5.3.21.3 Workmanship ....................................................... S5-50
5.3.21.4 Lubrication ........................................................... S5-50
5.3.21.5 Protection Against Climatic Conditions ................. S5-50
5.3.21.6 Coating of Valves ................................................. S5-51
5.3.22 Mechanical Couplings, Flange Adapters and
Expansion Joints ................................................................... S5-51
5.3.23 Sluice Valves ......................................................................... S5-52
5.3.23.1 General ................................................................ S5-52
5.3.23.2 Material ................................................................ S5-53
5.3.23.3 Pressure .............................................................. S5-54
5.3.24 Non Return, Reflex and Check Valves .................................. S5-54
5.3.24.1 General ................................................................ S5-54
5.3.24.2 Material ................................................................ S5-55
5.3.24.3 Pressure .............................................................. S5-55
5.3.25 Plug Valves ........................................................................... S5-56
5.3.25.1 General ................................................................ S5-56
5.3.25.2 Material ................................................................ S5-56
5.3.26 Air-Release, Air/Vacuum and Combination Air Valves ........... S5-57
5.3.26.1 General ................................................................ S5-57
5.3.26.2 Definitions ............................................................ S5-57
5.3.26.3 Data to be Supplied.............................................. S5-58
5.3.26.4 Valve Design Requirements ................................. S5-59
5.3.27 Scour Valve Assembly........................................................... S5-62
5.3.28 Penstocks.............................................................................. S5-62
5.3.28.1 General ................................................................ S5-62
5.3.28.2 Frame and Gate ................................................... S5-62
5.3.28.3 Faces ................................................................... S5-62
5.3.28.4 Spindles ............................................................... S5-62
5.3.28.5 Headstock and Handwheel .................................. S5-63
iv
5.3.28.6 Extension Stems .................................................. S5-63

5.3.28.7 Hydraulically Operated Penstock .......................... S5-63
5.3.29 Sluice Gates .......................................................................... S5-64
5.3.29.1 Submittals ............................................................ S5-64
5.3.29.2 Materials, Products and Equipment ...................... S5-65
5.3.29.3 Heavy Duty Gates ................................................ S5-66
5.3.29.4 Operators ............................................................. S5-70
5.3.29.5 Installation ............................................................ S5-71
5.3.30 Equipment Testing ................................................................. S5-71
5.3.31 Tidal Flap Valves ................................................................... S5-72
5.3.32 Fittings ................................................................................... S5-72
5.3.32.1 Cast or Ductile Iron Fittings .................................. S5-72
5.3.33 Cast Iron Specials ................................................................. S5-72
5.3.34 Valve Operating Tee Wrenches ............................................. S5-73
5.3.35 Protective Coatings ............................................................... S5-73
5.3.35.1 Shop Painting ....................................................... S5-73
5.3.36 Floor, Wall Collars ................................................................. S5-74
5.3.37 Hose Bibbs ............................................................................ S5-74
APPENDIX
5.1 Sixth Schedule: Environmental Quality Act 1974 S5-75
v
SECTION 5: SEWERAGE WORKS
5.1 Introduction
The wastewater generated from each of the Proposed Station shall be

treated to comply with “Sixth Schedule of the Environmental Quality Act
1974”. The wastewater consists of mainly domestic wastewater, and a
smaller quantity from workshop and Depot washing facilities.
The wastewater shall be collected by a network of sewers and convey by

gravity to the Proposed Wastewater Treatment Plant (WTP) for treatment
before being discharged to the nearby water course.
The proposed package Wastewater Treatment Plant (WTP) will be under

the design and build concept, and shall be handed over the relevant
Authority upon successful testing and commissioning of the system.
5.1.1 General Description Of Works
(a) Works contained in this document cover the Design and Build of a
new Waste Water Treatment Plant (WTP).
(b) The proposed WTP shall be capable of treating all waste

generated from the station facilities to the standard as specified in
the Sixth Schedule of the Environmental Act 1974.
(c) This treatment system covers the treatment of effluent discharges

from the following facilities.
These facilities are:
i Staff Quarters
ii Canteen, Surau, Store
iii Offices and Administration Buildings
S5-1
iv Depot, Maintenance Workshops and etc.
(d) The proposed scope of works including the submission, obtaining

authorities approval, and handing over the completed system to
relevant authorities including all civil, structural, mechanical and
electrical systems.
(e) The locations of the new WTPs are as shown in drawings, and the
lands provided for the wastewater treatment plant are
approximate.
(f) The effluent generated from each facility will be delivered to the
treatment plant by pipelines, which will be aligned both above and
below ground depending on site conditions.
(g) The treated water must comply with “Sixth Schedule of the
Environmental Quality Act 1974”, which is noted to be very
stringent comparing with similar standards in the other countries.
See “the Sixth Schedule of the Environmental Quality Act 1974” in
Appendix 5.1.
(h) Since the proposed WTP will be located in the area as indicated in
the drawing, special design considerations should be given to its
aesthetic view, minimum emission of noise, fume and odour.
(i) The WTP shall be enclosed in a structure with proper access and
ventilation and in accordance with authorities requirement.
(j) The Contractor shall engaged the Malaysian Engineering

Consultant (MEC) for the design, submission and obtaining all
necessary authorities approvals for the works.
S5-2
5.2 Wastewater Treatment Plants
5.2.1 Scope
The purpose of this specification covers the minimum requirement for the
design, supply, fabrication, installation, testing and commissioning,
warranty and maintenance provisions for the Wastewater Treatment
System. The Contractor, with the S.O., shall ensure full compliance with
authorities.
5.2.2 Process Description
The proposed treatment process shall have a proven treatment record

and accepted by relevant authorities.
The system shall consists of (but not limited to) Oil and Grease
Separators, Holding Tank / Equalising Tank, Influent Tank, sludge tank,
Aeration, all mechanical and electrical system, associated works and etc.
5.2.3 Design And Construction Requirement
5.2.3.1 General Requirement
In the design and implementation of the Waste Treatment Plant the

Contractor shall comply, with good engineering practices, the local criteria
for discharges, all codes and statutory requirements required by the
country of origin of the systems and equipment and the relevant
Malaysian codes and statutory requirements.
The Contractor shall, prior to development of the design, submit a

proposal for the concept treatment process to the S.O.. The proposal shall
address but not be limited to the following issues:
(a) Design Parameters.
(b) Design Guidelines.
S5-3
(c) Treatment process.
Appendix 1 details the Effluent Quality Criteria for Discharge to Sewer. All
discharge to the sewer should meet the quality of the standard to comply
with Department of Environment.
Proposed design, product and installation should be tested and accepted

by SPAN.
5.2.3.1.1 Design Requirement
(a) Minimum free board of 600mm
(b) System shall have overflow by pass system which divert flow back
to inlet tank / sump
5.2.3.1.2 Civil and Structural Requirement
(a) Concrete for all tanks shall of grade 35A.
(b) All internal surfaces of tanks or structures in contact with wastes

shall be lined for protection as per authorities requirements
(c) All metal in contact with wastewater or in wastewater enclosure

shall of stainless steel.
5.2.3.1.3 Mechanical Requirement
(a) Materials for all equipment shall be corrosion resistance to the

wastewater or medium in contact with the equipment.
(b) Piping materials shall be robust and resistance to any chemical

attacks
(c) All pumps shall be seal shall be of mechanical seal
S5-4
5.2.3.1.4 Electrical and Instrumentation Requirement
(a) Motors shall be weather proof to IP55.
(b) Electric motors and equipment installed shall be explosion proof in

accordance to SPAN requirement.
(c) MIMIC Flow Diagram shall be provided with
5.2.3.2 Standard And Regulation
The design shall conform to the contemporary rules and regulations laid
out by the following authorities, standardization institution and utility
operators’ requirements:
(a) Suruhanjaya Tenaga
(b) Tenaga Nasional Berhad ( TNB )
(c) Standards and Industrial Research Institute of Malaysia ( SIRIM )

– Malaysian Standard ( MS )
(d) British Standard Institution ( BSI ) – British Standard ( BS )
(e) The Institution of Electrical Engineers ( IEE ) – Latest IEE Wiring

Regulations
(f) International Electrotechnical Commission (IEC)
(g) International Commission on Illumination CIE 115 – 1995
(h) Illumination Engineers Society (IES)
(i) Keratapi Tanah Melayu (KTM)
S5-5
5.2.4 Electrical Services
5.2.4.1 Power Supply Reticulation
Power supply to this project shall be sourced by the Contractor including

all necessary works.
5.2.4.2 Motor Control Center (MCC)
MCC will be provided near the respective plant equipment. The MCC shall
be type tested to form 4B construction. Busbar of the panel shall be
insulated by PVC sleeving with appropriate colour. The major components
for the MCC are as follow:
(a) Voltmeter for incomer only
(b) Ammeter comes with maximum demand for incomer only.
(c) Ammeter for motor circuit
Note: All the instrument meter shall be of 240O deflection.
(d) Hour run meter
(e) Electronic energy measuring meter for all the incomer.
(f) Motor starting device
- Autotransformer (2.5kW above)

- Direct on line (2.5kW and below)
(g) Thermal overload relay
(h) Contactor
(i) Emergency stop push button
S5-6
(j) MCCB
(k) Input/output signal to PLC
5.2.4.3 LV Cable Installation
All the cable to plant equipment shall be armoured and installed on hot
dipped galvanized cable tray. For small power and lighting, the cable shall
be PVC insulated type in cable GI conduit or GI cable trunking. Cover
shall be provided for cable exposed to sunlight. The type of cables
proposed shall be as follows:
PVC/PVC or PVC/SWA/PVC for cable cross section area below 25mm2.
XLPE/PVC or XLPE/SWA/PVC for cable cross section area of 25mm2 and

above.
5.2.4.4 Electrical Earthing System
All the electrical installation shall be provided with will earthing system.
Earth resistance shall be 1 ohm or less.
5.2.4.5 Lightning Surge Protection
Lightning surge suppressor shall be provided at the MCC incoming to

reduce any possible high voltage spike and transient impacted on the LV
electrical system.
Shunt type lightning surge suppressor to BS6651, Appendix C, category B

shall be provided.
5.2.4.6 Interior Lighting
Combination of weatherproof type fluorescent lighting and metal halide

lighting will be provided for the Waste Treatment Plant. The proposed
S5-7
illuminance levels is 300 lux.
Keluar signs and emergency lights shall be provided for emergency and
during power failure. These will be of the self-contained type with nickel-
cadmium batteries providing 3 hours back up and automatic charging
facilities.
5.2.5 Control System
5.2.5.1 Local Control Panel (LCP)
Local control panels shall be provided. The LCPs shall come with LED
type indicating light for monitoring and push button for control during LCP
mode. The material for the LCP panel shall be stainless steel.
5.2.5.2 PLC Panel
The panel shall include PLC, UPS (2 hours back-up), MIMIC diagram,
alarm annunciator and marshalling compartment. All the equipment shall
be connected to PLC’s input and output points via the marshalling
compartment.
5.2.5.3 Control and Operation Mode
The treatment process shall be operated in the following modes – auto or

manual.
(a) Local Manual Mode
Under this mode, all equipment shall be controlled by the operator

through the MCC or Local Control Panel located in front of the
equipment. PLC is only for monitoring without any control. All the
equipment shall be hard wire control under this mode. This mode
will only be used for commissioning and maintenance purpose.
S5-8
(b) Supervisory Panel Mode
Under this mode, the equipment shall be control from the

supervisory panel via the touch screen. Operator could select
Manual/Semi-Auto/Auto operation. The treatment process will be
operated under this mode until link-up to Control Centre is
completed.
i Manual operation
- Operator could control the individual equipment as per
local manual mode via the touch screen.
ii Semi-Auto operation
- Operator select the sequence shall be control by PLC.
iii Auto operation

- The PLC is fully control of the system.
5.2.5.4 Control and Instrument cable installation
All control and instrument cable be armoured type and installed on hot
dipped galvanized cable tray or cable trunking. Separate cable tray or
trunking from electrical cable shall be provided. Cover shall be provided
for cable exposed to sunlight. The type of cables proposed shall be as
follows:
Control cable – 2.5 mm2 multi core PVC/SWA/PVC.

Instrument cable – 1.5 mm2 twisted pair armoured overall and
individually screen
5.2.5.5 Lightning surge protection
Lightning surge suppressor shall be provided to protect sensitive

equipment from high voltage spike and transient.
S5-9
Shunt type lightning surge suppressor to BS6651, Appendix C, category B

shall be provided at the PLC/supervisory panel incoming and series type
lightning surge suppressor to BS6651, Appendix C, category C shall be
provided for UPS, PLC and instrument equipment.
For data circuit (analogue signal only), lightning protection unit (LPU) shall
be provided at PLC end for indoor equipment installation. For outdoor
equipment installation, LPU shall be provided at equipment and PLC end.
5.2.5.6 Instrument Earthing System
All instrument earthing system shall be provided. Instrument earthing shall

be linked to existing earthing system at the earthing pit after completion.
Earth resistance shall be 1 ohm or less.
5.2.5.7 Interfacing Requirements
The Contractor shall be responsible for all interfacing works within and
beyond the boundary of the project sites.
5.2.6 Miscellaneous
Provide required spares for the equipment as specified in all relevant

guidelines.
List and cost all optional available equipment.
Delivery time from receipt of purchase order.
5.2.6.1 Training
The Contractor is to provide training of personnel for the Operation and

maintenance of the Wastewater Treatment Plant Training shall include but
not be limited to the following:-
S5-10
(a) Provision of a qualified and competent personnel to train

personnel at the treatment facilities. The on-site training provided
should include training in the operation and maintenance of the
system.
(b) The Contractor shall provide training aids, manuals and

documentation required for testing, operating and maintaining the
Facilities. Training shall include both classroom and hands on
instruction.
5.2.6.2 Warranty Requirements
Contractor shall provide a comprehensive warranty and maintenance

programme to cover equipment repair and replacement of parts for a
period of twenty four months commencing upon successful
commissioning of the system and acceptance by the S.O.. The warranty
shall also cover design, product, installation and all liabilities on the
operation of the facility. During the warranty and maintenance period the
Contractor shall:
(a) Provide all recommended spare parts freely available in sufficient

quantities.
(b) Perform analysis on the treated effluent to ensure full compliance

to the requirements stipulated herein.
5.2.6.3 Spares
Contractor shall provide a recommended spare parts list that includes

spare parts normally used during maintenance, spares required for
periodic replacement due to wear and tear and critical parts failure of
which may cause system inoperable.
Contractor shall provide a spare parts catalogue complete with lead time
and prices and will provide revision services.
S5-11
Upon expiration of warranty period, the Client shall have the option to
order spares directly from original equipment manufacturer or any local
agent.
5.2.6.4 Maintenance Support Upon Completion Of The Warranty Period
The Contractor is to provide a detailed proposal for the Maintenance

Support upon completion of the Warranty Period which shall include but
not be limited to the following :
(a) Training for local staff to operate and continue maintenance of the
system upon completion of 2 year maintenance service.
(b) Detailed recommendations on methods of performing maintenance

functions.
i Details of the location of the product support offices.
ii Details of the established after sales support facilities in

Malaysia.
iii Details of the costs/labour rates for routine scheduled and

unscheduled maintenance. Details of the proposed
manpower, rotation, duration and maintenance procedures
shall be provided.
5.2.6.5 Manufacturing Inspection and Factory Test
Contractor shall obtain approval from all relevant Authorities including

SPAN, Indah Water Konsortium (IWK), Majlis Bandaraya Johor Baru
(MPJB) (within Johor Bahru City limit) and etc.
Equipment and materials shall be tested and inspected at place of

manufacturing and relevant factory tests shall be conducted.
S5-12
5.2.6.6 Programme
The Contractor shall provide a Programme in sufficient detail to show how

the Contractor intends to perform section of the Works and must integrate
with the Overall / Master Programme.
5.2.6.7 Testing, Commissioning And Acceptance Tests
The Contractor shall provide detailed procedures for the Testing and
Commissioning of the systems and equipment proposed by him.
Acceptance tests shall be as specified by relevant local authorities, codes

and standards.
5.3 Pipeline Materials And Installation
5.3.1 Precast Reinforced Concrete Sewer Pipes
5.3.1.1 General
Reinforced concrete pipes shall comply with BS 5911: Part 1 or AS 1342

and shall be obtained from an approved manufacturer.
5.3.1.2 Types of Pipes
All concrete pipes shall be centrifugal spun pipes of minimum length

3.05m or such other length as approved by the S.O.. They shall be
minimum Class 'Y' unless otherwise shown on the Drawings or directed
by the S.O.. Unless otherwise stated all concrete pipes up to 975mm
diameter shall be integrally spun lined with 12mm thick high alumina
lining. Concrete pipe 1050mm diameter and bigger shall be PVC lined
internally.
If the S.O. is not satisfied with the pipe design calculations submitted by
the Contractor, the S.O. shall establish the test load for each pipe size
and class by physical testing as follows:-
S5-13
(a) Upon the instruction and in the presence of the S.O., the
Contractor shall manufacture two (2) number standard pipes.
(b) All the pipes shall be suitably marked for identification, cured and
tested to failure to establish the respective crushing load strengths.
It shall be the Contractor's responsibility to prove compliance with this

Specifications and all additional costs shall be borne by the Contractor.
5.3.1.3 Minimum Internal Diameter
Pipes sizes stated in the Drawing and Bill of Quantities refer to nominal
internal diameters. The plastic liner plate and high alumina lining are
additional requirements to those specified in the above-mentioned
Standards and hence the finished internal diameters shall not be reduced
accordingly as shown in the table below:
---------------------------------------------------------------------------------------------
Nominal Internal Minimum Finished Internal
Diameter (mm) Diameter (mm)
Class Y/Class Z/Class ZZ/Class 1.5Z
---------------------------------------------------------------------------------------------
375 375
450 450
525 525
600 600
675 675
750 750
900 900
975 975
1050 1050
1200 1200
1350 1350
1500 1500
1650 1650
------------------------------------------------------------------------------------------
5.3.1.4 Work Tests for Concrete Pipes
Concrete pipes shall be subjected to the following tests which shall be

applied on one in every 50 or part of 50 pipes of the same nominal
internal diameter for all sizes and classes of pipes.
(a) The load test shall be conducted in accordance with the methods
described in para 4.22 and Appendix B of Australian Standard AS
1342:1973.
S5-14
(b) The hydrostatic pressure test shall be carried out in accordance

with para 4.2.2 and Appendix 'C' of Australian Standard AS
1342:1973.
5.3.1.5 Joints to Concrete Pipes
Concrete pipes shall have spigot and socket rubber ring joints to BS 2494.
5.3.2 Vitrified Clay Sewer Pipes
5.3.2.1 General
Vitrified clay pipes, bends and fittings shall be obtained from a approved
manufacturer and shall comply in all respects with BS 65 and BS 2494.
5.3.2.2 Testing and Acceptance of Vitrified Clay Pipes
The pipe shall be tested for crushing strength, barrel impermeability,

hydraulic proof and acid and alkali resistance in accordance with Clauses
10 to 14 of BS 65.
The S.O. may require these tests to be carried out in his presence or
alternatively properly substantiated test certificates for each batch of
consignment of pipes shall be submitted for approval. The pipes shall not
be dispatched from the place of manufacture until the approval of the
pipes has been given by the S.O. following whatever test or inspection the
S.O. may have called for. Notwithstanding the approval of the pipes at
the place of manufacture by the S.O., the Contractor shall be responsible
for the fault that may be found in the pipes on sites.
5.3.2.3 Flexible Joints to Vitrified Clay Pipes
Flexible joints to vitrified clay pipes shall be of rubber ring or polyester

type complying with BS 2494.
S5-15
The joints shall be of a type which can remain completely watertight while
accommodating a deflection of 5 degrees in any direction.
Where polyester joints are supplied, the polyester must be securely

bonded to the clayware, and pipes having damaged or loose polyester
rings or socket packings shall be rejected.
5.3.3 Ductile Iron Pipes for Force Main
5.3.4 General
All Ductile iron pipes and fittings shall conform to BS 4772. Ductile iron
pipes with flexible joints or welded flanges shall be Class K9. Fittings
without branches and screwed-on flanges shall be Class K12. Fittings with
branches shall be Class K14.
5.3.4.1 Joint for Ductile Iron Pipes
(a) Flexible Joint for Ductile Iron Pipes shall be K-Type unless
otherwise approved by the S.O. and shall employ the circular
rubber gasket for sealing purposes unless specified otherwise.
The gasket shall be of such size and shape that, when jointed in
accordance with the manufacturer’s instructions, it provides a
positive seal within the manufacturer’s range of maximum joint
deflection and withdrawal under all combinations of joint and
gasket dimensional tolerances, and in the range of pressure likely
to occur in the pipeline.
(b) Flanged Joints shall be used in all cases when sewers are laid
above ground. They shall have faces that are at right angles to an
concentric with the axis of the bore. The faces of the flanges on
fittings shall be at right angles to the directional axes. Flanges
shall be faced over the jointing surface with a tool mark finish
having a pitch of 1 + 0.33mm; serrations may be spiral or
concentric. Pipes having screwed on flanges shall be sealed at the
S5-16
thread joint between the pipe and the flange by a sealing

compound suitable for use in sewers.
5.3.4.2 Lining for Ductile Iron Pipes
All ductile iron pipe and fittings shall be lined with sulphate resisting
cement mortar to the thickness shown in Table 49 of BS 4772. The
surface of the lining shall be substantially smooth but “fine crazing”
associated with cement rich surfaces shall be permitted. Isolated
shrinkage cracks shall be acceptable provided their width does not
exceed 0.8mm. The surface shall be substantially free from laitance and
any sand segregation present shall be minimal.
5.3.4.3 Surface Protection Coating for Ductile Iron Pipes
All pipes and fittings shall be factory-coated internally and externally with
a corrosion resistant coal tar pitch varnish to a type and grade generally
used for ductile iron pipe or bitumen complying with the requirements of
BS 3416. The coating may be applied by dipping, spray, brush or roller
but coating that does not bond firmly or shows voids or holidays shall be
rejected. The internal coating shall be applied while the cement mortar
lining is still moist.
5.3.5 Transporting and Inspection of Materials
All pipes, specials, fittings, joints and jointing materials shall be

transported to the points where they are to be laid. At every point of
loading or unloading pipes or castings shall be handled by approved lifting
tackle. Unloading by rolling down planks or any other form of inclined
ramp shall not be allowed. Pipes shall be carefully stacked on site with
timber packing under and between the pipes.
All pipes, specials, fittings, etc. shall be carefully inspected for damages
which may have been caused during loading, transit and unloading before
lowered into the trench. Damaged pipes shall not be used in the Works.
S5-17
5.3.6 Excavation and Backfilling for Pipes
All excavation and backfill shall comply with Section 3 of this

Specification. Bedding for:
(a) RC and VC pipes shall be granular material in accordance with

Clause 5.3.10 and as shown on the Drawing.
(b) Steel and ductile iron pipes shall also be 150mm compacted
sandfill with at least 150mm sandfill cover all over or as shown on
the drawing.
5.3.7 Pipelaying
5.3.7.1 General
Pipes shall be laid only after the trench has been inspected and approved
by the S.O. on site. The trench shall be kept sufficiently firm and dry for
making joints.
5.3.7.2 Handling
Pipes shall be handled only by means recommended by the

manufacturers, by means of fabric slings, or other methods approved by
the S.O.. Bumping, dragging or rolling of pipe will not be permitted.
Damaged pipes shall be repaired, if approved by the S.O. or otherwise
replaced at the Contractor's expense.
Pipes shall be inspected for defects before being gently lowered into the
trench by means of a crane or suitable shear logs and chain blocks with
rope slings. Pipes shall be laid true to invert, alignment and fall. Care shall
be exercised to ensure that the barrel of every pipe is evenly bedded
throughout, with suitable excavation to receive the socket or collar.
S5-18
5.3.7.3 Setting Out
The Contractor shall provide and fix at such points as may be directed,
properly painted, black and white sight rails set to correct levels. At least 3
such rails shall always be in position for each length of sewers. Pipes
shall be accurately boned and laid to even gradients, centered and in
straight lines between manholes. Sight rails shall be 1.8m long and
painted black and white. Such rails shall be fixed and maintained at the
changes in grade or lines at not more than 15m apart. Invert levels to be
set out shall be referred to protected level pegs near such manhole and
change of grade or line. Boning rods shall be designed to show the pipe
line invert level below the sight rails. When excavation is completed and
before any further work commenced wooden pegs shall be driven into the
bottom of the trench at not more than 4m centres, the level of each peg
being adjusted to the proposed sewer invert by the use of the sight rails
and boning rods.
5.3.7.4 Soft Trench Bottom
If soft, spongy, unstable material is encountered upon which the bedding

material or pipe is to be placed, this unsuitable material shall be removed
to a depth ordered by the S.O. and replaced with suitable granular
bedding material.
5.3.7.5 Cleaning
The internal surfaces of all pipes, specials, etc., shall be cleaned to

remove any debris, sticks, rags or other foreign matter before they are laid
and fixed in position.
5.3.7.6 Temporary Stops
Temporary stops for effectively closing the open ends of the mains shall
be used to prevent rain water from washing earth and other foreign matter
into the main. These stops shall be used at all times and shall be moved
forward as the work of laying and jointing progresses.
S5-19
5.3.7.7 Changes In Line and Grade
In the event obstructions not shown on the plans are encountered during
the progress of the work which requires alterations to the proposed works,
the S.O. shall have the authority to change Drawings and order the
necessary deviation from the line or grade shown. Contractor shall not
make any deviation from the specified line or grade without approval of
the S.O..
5.3.7.8 Deflection at Certain Joints
Where the S.O. orders or allows a change of direction to deflect force

mains from a straight line, either in the vertical or horizontal planes to
avoid obstruction or where long radius curves are permitted, the amount
of deflection allowed shall not exceed that required for satisfactory
connection of the joint and shall be approved by the S.O.. Where a
change of direction cannot be made by deflection at the joints or ordinary
straight pipes, bends shall be used. The locations of such bends and
other specials are indicated on the Drawings and their exact positions will
be determined by the S.O. on the Site.
5.3.7.9 Connection to Existing Sewer Mains
At the locations shown on the Drawings the Contractor shall connect to

the existing sewer main or existing manholes and construct new flow-
through fittings in each manhole base to accommodate the new sewer line
as required. Actual connection between the existing piping and new piping
shall not be made until the new work has been approved by the S.O..
5.3.8 Jointing
All pipes shall be laid and joint upgrade.
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5.3.8.1 Jointing Concrete Sewer Pipes
Pipes shall be bedded, true to line and grade with uniform bearing for the
entire barrel length. All materials shall be removed from the interior of the
pipe and the inner surface of the bell or socket and the other surface of
the spigot end shall be thoroughly cleaned so that good joints can be
made. Pipe sections shall be laid such that the offset of the inside of the
pipes at any joint will be held to a minimum at the invert. The maximum
offset at the invert of pipe shall be one percent of the inside diameter of
the pipe or 10mm, whichever is smaller. Unavailable offsets shall be
distributed around the circumference of the pipe such that the minimum
offset occurs at the invert. After the joints have been made the pipe shall
not be disturbed in any manner. The interior of each pipe, after being laid,
shall be thoroughly cleaned.
The jointing of spigot and socket shall be done with approved flexible
rubber ring joints.
5.3.8.2 Jointing Vitrified Clay Pipes
The spigot and socket of each pipe shall be thoroughly brushed clean
before laying. The pipes shall then be laid to line and level and secured in
position with the socket ready to receive the next pipe. The rubber ring
shall be fixed properly onto the spigot of the next pipe and this shall be
pushed into the socket of the laid pipe. It shall be checked that the rubber
ring has properly "rolled" into place and that the joint is tight. Otherwise
the pipe shall be refixed.
5.3.8.3 Rubber Rings
Rubber sealing rings for pipe jointing shall comply with BS 2494 and shall
in addition contain anti-ozonants. The hardness of the rubber shall be
such that the joint when made on the installed pipes will be watertight as
specified under any combination of working or test loads. Immediately
before assembling each joint incorporating a rubber ring seal, the rubber
shall be inspected for cracks, every part of the ring being deformed by
S5-21
hand to about 15cm radius. If under this deformation any cracks appear or
are revealed, the ring shall be rejected, cut through completely to prevent
inadvertent use, and the matter reported forthwith to the S.O.. If more than
three successive rings inspected in this way are rejected the Contractor
shall on the instruction of the S.O. stop all pipe jointing until the cause of
the defect has been proved and remedied to his satisfaction.
5.3.8.4 Mechanical Joints (K-Type Joint)
The mechanical joints are flexible joints and shall conform to BS 4772.
They are used for Ductile Iron pipe unless otherwise shown on the
Drawings or instructed by the S.O.. They shall employ the circular rubber
gasket for sealing purpose unless specified otherwise. The seal is
affected by compressing a rubber gasket, onto the jointing surface in the
pipe socket and the outside of the pipe spigot by means of a pressure
gland and a series of T-head bolts and nuts. When jointed in accordance
with the manufacturer’s instructions, it provides a positive seal under all
combinations of joint and gasket dimensional tolerances, and in the range
of pressure likely to occur in the pipeline. It is capable of axial movement.
5.3.9 Prevention of Flotation
Certain portions of sewer pipelines may not be heavy enough to resist the
possible uplift due to water pressure until the pipelines have been properly
covered. The Contractor shall make adequate arrangement to keep the
excavation dry until the filling of the pipelines is completed or shall adopt
other approved means of ensuring the stability of the Works.
5.3.10 Bedding, Haunching and Surround to Pipes
The material for granular bedding shall meet the following requirements:
S5-22
(a) For 150mm to 300mm diameter sewer:
B.S Percentage Passing

Sieve Size Min. Max.
20 mm 100 -
9.5 mm 80 90
4.75 mm 10 25
2.36 mm 0 15
(b) For 375mm and above diameter sewer:
B.S Percentage Passing

Sieve Size Min. Max.
28 mm 100 -
20 mm 80 90
9.5 mm 10 25
4.75 mm 0 15
When required, concrete for bedding, haunching and surround to pipes

shall be of Grade 20. The concrete shall be well rammed or vibrated and
worked under and around the pipes. No concrete shall be placed around
the pipes until the pipe joints have been inspected and approved by the
S.O.. Concrete encasement shall be to the minimum dimensions shown
on the Drawings. Flexibility at pipe joints shall be maintained by providing
12mm thick joint filler in not more than two pieces per joint.
5.3.11 Cutting Pipes
The Contractor shall be responsible for taking the measurements required

to determine the lengths of cut portions of pipes for insertion as closing
lengths in pipelines. The pipe and methods of jointing shall be such that
the locations of fittings and lengths of pipe can be adjusted in the field to
suit field conditions and variations in stationing and no extra payment will
be made for such adjustments nor for any welding, couplings, fittings, or
special lengths required to meet this requirement. A reasonable tolerance
S5-23
in the location of lines will be permitted by the S.O.. The Contractor shall
make all closures with suitable pipe and approved connections to
compensate for cumulative errors in pipeline installation. The cutting of
reinforced spun concrete pipes for inserting specials, fittings or closure
pieces shall be carried out in a neat and workmanlike manner with an
approved cutting machine without damage to the pipe and so as to leave
a smooth end at right angles to the axis of the pipe. Cast and ductile iron
pipes may be cut by hand, using a hacksaw or may be machine cut. Only
experienced men shall be employed by the Contractor on this work. Steel
pipes shall be machine cut at the maker's works or the Contractor may
make arrangements for them to be cut by an approved local engineering
firm. Flame cutting of pipes on Site will not be permitted. After making any
cut to steel pipes the cut end shall be fettled and all damaged portions of
lining and sheathing shall be cleaned from the pipe which shall be
scraped and wire brushed to bare metal in areas stripped and then primed
with a rust inhibitor, the lining and sheathing being then made good to the
full original thickness. The Contractor shall take every precaution to
ensure that both the measurements and the cutting of pipes are to the
accuracy required and should any errors occur the Contractor shall
remedy the same at his own expense and as the S.O. directs.
5.3.12 Testing of Sewers
5.3.12.1 Notification of Test
The Contractor’s attention is drawn to the fact that, on completion, the

sewers to be constructed under this contract are to be taken over by
SPAN / Indah Water Konsortium (IWK) / Majlis Bandaraya Johor Bahru
(MBJB).(where applicable). All sewers are therefore subject to the
inspection requirements set out in the ‘Guidelines for Developers on the
Design and installation of Sewerage System”. These inspections will be
made by a representation of the SPAN or IWK or MBJB.
Completed pipelines will therefore be subject to inspection:
(a) by the S.O. as work proceeds
S5-24
(b) jointly by the S.O. and / or an IWK / MBJB inspector, at anytime at

the IWK /MBJB inspector’s discretion or in request to a formal
request for an interim inspection.
(c) by the S.O. and / or on IWK / MBJB inspector on completion of

construction and following submission of the as built drawings but
prior to commissioning of the new sewers.
The Contractor shall agree with the S.O. the programme for all interim and
final inspection. The necessary form requesting such inspections will be
prepared by the S.O. for formal submission by the Employer but all fees
and costs of such inspection are to be borne by the Contractor.
The Contractor’s attention is drawn to the need to provide IWK with a

minimum of four days notice of each inspection and he shall therefore
give the S.O. at least 10 days written notice of each inspection.
5.3.12.2 Testing Gravity Pipelines
(a) By the Contractor and the S.O.
Pipelines will be subject to testing as work proceeds as follows.
i. Gravity pipelines laid in open cut shall be tested after they

are jointed and before any concreting or backfilling is
commenced, other than such as may be necessary for
structural stability whilst under test.
ii. The pipelines shall be tested by means of an air or water

test or by a visual or closed circuit television (CCTV)
examination, in lengths determined by the course of
construction, in accordance with a programme approved by
the S.O..
iii. A further test shall be carried out after the backfilling is

complete.
S5-25
(b) By IWK inspectors on behalf of the SPAN
The sewerage system will be formally inspected when the works

are at appropriate stages of construction. As set out in detail in the
Guidelines, these inspections will include:-
i General inspection
ii CCTV inspections of 100% of pipelines, plus additional

inspection should the initial inspections prove
unsatisfactory.
iii Infiltration checks
iv Level checks
In addition to the above, a final inspection will be undertaken by

IWK’s inspector on completion of all work and submission of the
as-built drawings. As set out in the Guidelines, this shall involve
repeat inspection of those lengths and components of the system
deemed necessary by the inspectors, plus inspection of any work
competed since the last final inspection.
The costs of all inspection work including provision of approved

CCTV equipment are to be borne by the Contractor.
The contractors attention is drawn to the fact that should

inspection prove the completed work to be unsatisfactory then the
SPAN and/or IWK may charge the Employer for their additional
costs in repeating inspections. All such charges imposed shall be
reimbursed by the Contractor.
The contractor should note that work will not be considered to

have been completed satisfactorily until such time as it is accepted
by the IWK inspector on behalf of the SPAN.
S5-26
5.3.12.3 Water Test for Gravity Pipeline
(a) The test pressure for gravity pipelines up to and including 750mm
nominal bore shall be not less than 1.2m head of water above the
pipe soffit or ground water level, whichever is the higher at the
highest point, and not greater than 6m head at the lowest point of
the section. Steeply graded pipelines shall be tested in stages in
cases where the maximum head, as stated above, would be
exceeded if the whole section were tested in one length.
(b) The pipeline shall be filled with water and a minimum period of 2
hours shall be allowed for absorption, after which water shall be
added from a measuring vessel at intervals of 5 minutes and the
quantity required to maintain the original water level noted. Unless
otherwise specified, the length of pipeline shall be accepted if the
quantity of water added over 30 minutes period is less than 0.5
litre per linear metre per metre of nominal bore.
5.3.12.4 Air Test for Gravity Pipelines
Gravity pipelines to be air tested shall have air pumped in by suitable

means until a pressure of 100mm head of water is indicated in a U-tube
connected to the system. The pipeline shall be accepted if the air
pressure remains above 75mm head of water after a period of 5 minutes
without further pumping, following a period for stabilisation. Failure to pass
the test shall not preclude acceptance of the pipeline if a successful water
test, ordered by the S.O., can subsequently be carried out in accordance
with the Clause above.
5.3.12.5 CCTV Inspection of Pipelines
(a) Where internal inspection of pipelines by CCTV is required, the

Contractor shall provide all necessary equipment, including
suitable covered accommodation for viewing the monitor screen,
together with personnel experienced in the operation of the
equipment and interpretation of results.
S5-27
(b) The intensity of illumination within the pipe and the rate of draw of
the camera shall be such as to allow a proper examination of the
inside of the pipe. Provision shall be made for the movement of the
camera to be stopped and its position recorded and for permanent
photographs to be taken at any point requested by the S.O..
5.3.12.6 Infiltration
(a) Gravity pipelines (including tunnels) and manholes shall be tested

for infiltration after backfilling. All inlets to the system shall be
effectively closed, and any residual flow shall be deemed to be
infiltration.
(b) The pipeline, including manholes, shall be accepted as satisfactory

if the infiltration, including infiltration into manholes, in 30 minutes
does not exceed 0.5 litre per linear metre per metre of nominal
bore.
(c) Notwithstanding the satisfactory completion of the above test, if

there is any discernible flow of water entering the pipeline at a
point which can be located either by visual or CCTV inspection,
the Contractor shall take such measures as are necessary to stop
such infiltration.
5.3.12.7 Hydraulic Testing of Force Main
(a) Testing in Sections
Pipelines shall be tested in sections of about 600m (in open

ground) and 300m (along roads) after it has been laid, jointed and
anchored with all fittings and thrust blocks in position and partly
backfilled. Only sufficient backfilling of the trench to prevent
snaking of the pipes shall be allowed with all joints and fittings
exposed before the satisfactory completion of tests. Water
pressure/leakage test shall be carried out in accordance to MS
1228.
S5-28
(b) Test Ends
The open ends of the section to be tested shall be temporarily

sealed with caps. For this purpose “Test End” units consisting of
short lengths of pipes permanently fitted with caps to the
satisfaction of the S.O. shall be used. These units shall be jointed
to the section of the pipeline to be tested with standard cast iron
or steel couplings which can be easily removed when the
standpipe complete with valve outlet and pressure gauge to
serve as an air relief vent or for use when filling the pipeline with
water. The pressure gauge shall be of sufficient range and tested
and the Contractor shall submit test certificate for the S.O.
inspection. When one end of the section to be tested
commences at a sluice valve, the valve may used in place of the
“Test End” unit to close this end of the section during test. The
ends of the section of pipeline under test shall be braced with
temporary thrust blocks to withstand the end thrust which
develops from water pressure. Thrust blocks specified for the
pipeline shall be constructed in place and the concrete properly
cured before the test are carried out. Temporary bracing at
locations of permanent thrust blocks shall not be permitted as the
test includes the testing of permanent thrust blocks and fittings in
addition to the pipeline.
(c) Water for Testing
The water used in the test shall be of fair quality, reasonably free
from sediment and from a source approved by the S.O..
(d) Test Preparation
The section of pipeline to be tested shall be filled with water

through the valve in the “Test End” unit at the lower end of the
pipeline. During filling provision shall be made for air to escape
from all high spots in the pipeline and from the valve in the upper
“Test End” unit. Where the section of pipeline is on a level grade,
it may be necessary to drill the main at several points to ensure
S5-29
the escape of air. Any vent hole drilled shall be plugged and
saddled before the test is applied. Where the main runs up-hill
the pressure gauge shall be situated at the bottom of the section
as otherwise excessive pressure may be imposed upon the lower
part of the pipeline with a risk of damage to anchorages designed
to withstand the specified test pressure. Pressure for the test
shall be applied by means of an approved force pump at the
highest convenient point on the main so as to minimise the
pressure against which the pump will have to be operated. The
test section shall be completely filled with water for at least 24
hours prior to testing to allow for absorption of water into the
pipes and/or jointing materials.
The test equipment shall be sealed against any possible

tampering.
(e) Pressure Test
Water shall be pumped into the main rising the pressure slowly in
increments of 10.0 m head of water with pauses of one minute
between each increment. When any appreciable drop in pressure
is noted during one of these pauses the test shall be stopped
until the cause of the pressure drop has been investigated and
rectified. The pipes shall be tested to the pressure of 1.5 times
maximum working pressure head to be determined by the S.O..
An engine pump may be used until 1.0 times maximum working

pressure head is attained and thereafter full test pressure shall
be applied by a hand pump. The pressure/strength test shall be
considered to have been passed when the pressure gauge
shows no reduction from the strength test pressure during the
period of ten minutes after full test pressure has been attained.
(f) Leakage Test
The leakage test shall follow after the pressure test. The
pressure in the pipes shall be maintained to the maximum
S5-30
working pressure head to be determined by the S.O..
The pressure shall be maintained as constant as possible for a

period of 24 hours by pumping in make-up water if necessary.
The leakage test shall be considered to have passed if the
measured quantity of make-up water pumped into the section of
pipeline does not exceed 2.84 litres per km of pipeline per 24
hours for every 25mm diameter of pipe and every 30m head
pressure.
5.3.13 Completion of Works
5.3.13.1 Cleaning Up
On completion of the Contract Works sewer pipelines and manholes

shall be thoroughly cleaned and washed throughout. No sewers or part
of a sewer may be put into use until a detailed inspection has been
carried out and the sewers cleaned and certified satisfactory by the
S.O./Authority.
All water retaining and other structures shall be pumped dry and washed
and swept out free of all debris mud dirt and construction materials.
All equipment and fittings shall be cleaned, greased and oiled and all
necessary adjustments made to ensure their full working efficiency.
All site roads, paths and drains shall be swept clean and dry and all
construction plant and materials removed from site.
5.3.13.2 Inspection Upon Completion
Following the cleaning up of the whole or a section of the Works for the
taking over by the Employer, a detailed inspection shall be carried out by
the appropriate Authority together with the S.O. who shall be
accompanied by the Contractor or his Representative.
S5-31
Any defects found during the detailed inspection of the Works shall be
rectified, as required by the appropriate Authority. The works shall then
be cleaned again and re-inspected. The cost of making good any defect
shall be borne by the Contractor.
5.3.13.3 Maintenance
One month before the end of the Defects Liability Period the Contractor
shall inform the S.O. of the expiry date and arrange for the cleaning up
and ventilation of the Works and the provision of all necessary ladders
etc., required for inspection of the works by the S.O. accompanied by
the Contractor or his Representative. Any default resulting from faulty
material or workmanship used in the execution of the works shall be
rectified by the Contractor at his own cost to the satisfaction of the
S.O./Authority.
5.3.14 Manholes
Manholes in sewers shall be constructed in position as shown on the

Drawings or directed by the S.O.. The manhole dimensions and details
shall be to the appropriate type specified in the Drawings or directed by
the S.O..
5.3.14.1 Excavation and Backfilling
All excavation and backfilling of manholes shall be as specified in

Section 3 of this Specification.
5.3.14.2 Precast Concrete Manholes
At each change of gradient or direction, at each intersection with other

sewers and at such other points as shown on the Drawings or as
directed by the S.O., a manhole shall be constructed to the form and to
the dimensions shown on the Drawings. Manholes are to be constructed
in circular precast reinforced concrete sections as shown on the
Drawings and directed by the S.O.. The bases of all manholes are to be
S5-32
formed of concrete of the full thickness shown on the Drawings. Channel

inverts shall be accurately laid to meet pipe invert elevations at the same
time as the sewer pipes are laid, the bends being as "slow" as possible
by siting the manholes "off- center" at changes in direction. Short lengths
of pipe with flexible joints shall be provided at entry and exit to
manholes. Precast concrete manhole sections shall conform in all
respects to BS 5911:Part 1. The dimensions and joint for the chambers
and the shafts shall be as shown on the Drawings. Manhole benching
and channels shall be constructed with insitu concrete formed to the
required shapes and levels. The top of the in-situ benching shall be
sloped back at 1 in 12. Provision shall be made for future sewer
connections to manholes by laying one length for sewer pipe sealed by
a stopper or end cap where ordered. The pipes shall be laid at the
levels, slopes and in the directions instructed by the S.O.. Ductile iron
covers shall be laid with their frames bedded on the precast concrete
rings. Manhole covers generally shall be set to the road profile and be
flush with the road surface. Manhole covers located in unimproved areas
shall be set at an elevation to prevent the entry of surface water as
directed by the S.O.. Where drop manholes are indicated they shall be
as shown on the Drawings and shall be formed where the upstream
length of sewer enters a manhole at a higher level than the manhole
invert level. All manholes shall be watertight on completion and where
leakage is discovered the Contractor shall perform such work and
provide all materials as are necessary to render such faulty work
watertight. The Contractor is warned that he should expect rubbish and
debris to be deposited in the manholes during the course of construction
and he should take the necessary measures to ensure that the
manholes are not used as rubbish and waste dumps. The Contractor
shall keep pipelines and manholes clear of such rubbish and debris
Standard precast manhole sections shall be Class 'S' to AS 1342.

Reinforced concrete sections may be either vertically cast or spun,
factory made or otherwise. Spun section shall have 12mm thick 1:3 high
alumina cement mortar lining. Vertical cast sections shall be painted
internally with two coats of coal tar epoxy.
S5-33
5.3.14.3 Brick Manholes
Brick manholes shall be for house manholes only. They shall be

constructed with mass concrete foundation of the class shown in the
Drawings, the walls shall be constructed of bricks bonded in 1:2 cement
mortar and rendered internally with 20mm thick layer of 1:3 high alumina
cement mortars. All bricks and rendering shall comply with BS 3921.
Internal and external joints of brick manholes shall be flushed pointed in
1:2 cement mortars and finished off to a smooth surface. No brickwork
shall be laid upon the concrete foundation until the concrete has set.
End of pipes shall be built into the walls of manholes and finished off in
cement mortar.
The reinforced concrete slabs covering the chambers of the manholes

shall be set and jointed in cement mortar as specified to form watertight
joints.
5.3.14.4 Manholes Covers and Frame
Manhole covers and frames shall comply with BS 497: Part 1 and be of
the type and size specified in the Drawings.
The heavy duty type shall be used in roadways and paved areas unless
otherwise directed by the S.O.. The medium duty type shall be used in
public areas inaccessible and unlikely to be inaccessible to vehicular
traffic, while the light duty type shall be installed in household manholes
within owner's properties.
Manhole covers and frames shall be well fitting, flush at the top and
should not rock. Where required by the S.O., the covers and frames
shall be tested in accordance with BS 497, the cost of which shall be
deemed to be included in the cost of the manhole covers.
S5-34
5.3.14.5 Ladder
Ladder, where required shall be of stainless steel and shall be of the

type specified and shown in the drawing.
5.3.14.6 Channels in Manholes
Main channels, branch channels, bends etc., up to 300mm diameter

shall be of vitrified clay. All channels shall be properly bedded as shown
on the Drawings. Channels 375mm and above shall be of unreinforced
precast concrete lined with 20mm thick high alumina cement and shall
be formed with approved forms and moulds.
All channels, bends, benching, etc., in manholes shall be formed and

shaped to details as shown on the Drawings.
5.3.14.7 Tumbling Bays and Backdrops
Where required, tumbling bays and backdrops are to be constructed in

accordance with the details shown on the Drawings, and at positions
indicated by the S.O..
The tumbling bay or backdrop pipes shall be laid on a concrete

foundation and completely encased in 150mm Grade 20/20 concrete
surround as shown on the Drawings.
5.3.15 Service Sewer Connections
5.3.15.1 General
All service sewer pipes between local reticulation sewer and household
manhole in owner's premise shall be of the type and size as shown on
the Drawing. All materials and workmanship shall comply with all the
provisions of this Specification.
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5.3.15.2 Excavation and Backfilling
All excavation and backfilling of service sewer pipes shall be in

accordance with Section 3 of this Specification.
5.3.15.3 Laying and Jointing
Service connections from the local reticulation sewer to the household

manholes in owner's premise shall be accomplished by means of
relevant joints approved by the S.O.. All joints shall be fully encased in
150mm Grade 20/20 concrete cover. The gradient of the service sewer
shall comply with the requirements shown in the Drawings unless
otherwise directed by the S.O.. As far as possible service sewers shall
be laid, connected up to the local reticulation sewer and backfill before
commencement of the construction of the roadside drain or main drain.
Where the portion of the service sewer is laid beneath the drain, a
minimum clearance of 300mm between the base of the drain and the
crown of the sewer pipe shall be provided unless instructed by the S.O.
to be otherwise.
5.3.15.4 Overhead Connections
Where overhead service sewer connections are required, steel pipes

with external bituminous coating and internal high alumina cement lining
to BS 534 may be used in part or the entire length of the service sewer
pipe with the approval of the S.O..
5.3.15.5 Household Manholes
Household manholes in owner's property shall be constructed of the

types shown on the Drawings and at suitable positions decided on site
by the S.O..
5.3.16 Stream, Canal, Channel and River Crossing
Work at any crossing of a watercourse shall be carried out as

expeditiously as possible to the satisfaction of the S.O. and Authority
S5-36
concerned with the minimum interference to the free flow of water in the
watercourse. Details of any temporary works which may affect the
watercourse shall be submitted to the S.O. at least 14 days before
starting work. Where the pipelines passes underneath a river, stream,
canal or ditch, unless otherwise detailed on the Drawings it shall be
encased in concrete. The minimum thickness shall be 150mm. Unless
otherwise shown, the depth of cover shall be not less than 60cm from
the bed of the river, stream or ditch to the top of the concrete. The
Contractor shall fill the trench in both banks with rockfill or concrete up to
levels as shown on the Drawings or as directed by the S.O.. The extent
of this work may be varied to suit each individual crossing. Unless
otherwise ordered, the concrete encasement of the pipe shall extend at
least to a section vertically below the tops of the banks. Provide
protection against erosion to the banks by means of stone pitching or
riprap.
5.3.17 Pipe Jacking
5.3.17.1 General
Pipe jacking shall be the process of installing pipes below a surface

obstruction by driving them successively through the insitu soil from one
pit (the driving pit) to another (the receiving pit) such that the finished
pipe forms a watertight continuous conduit between the pits on the
desired alignment.
Plans and details of the equipment, materials and the methods of

construction to perform and complete the work shall be submitted by the
Contractor and must be approved by the S.O. before commencing these
operations. Approval by the S.O. shall not relieve the Contractor of his
sole responsibility for the efficiency, reliability and soundness of the
method employed in completing the work in a satisfactory manner and
meeting the criteria set herein.
The Contractor shall satisfy himself as to the soil conditions along the
pipe jacking route and if he consider it to be necessary, he shall carry
out further soil investigations at his own cost.
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It shall be the responsibility of the Contractor to maintain stable soil

conditions at the jacking face to prevent loss of ground above the
jacking operation and movement of the surrounding earth. The methods
of maintaining face stability and preventing ground movement and
subsidence shall be by means of compressed air or other plenum
methods where fluid slurry or earth pressure is applied to the tunnel
face. Alternatively, unstable ground ahead of the jacking face may be
stabilised by the injection of suitable chemicals. Methods which require
dewatering of the ground will not be accepted, nor will methods which
may lead to significant ground loss. The Contractor's proposal must be
submitted to the S.O. for his approval.
Movement or settlement of structures, utilities and pavement shall be

monitored by the Contractor during the jacking operation and reported to
the S.O.. The Contractor shall incorporate in his pipe jacking method
measures to arrest settlement or upheaval of soil so as to safeguard the
integrity of the structures and other property. The Contractor shall
ensure that the traffic flows along railway lines and roads are not
affected in any way by his work.
If movement or settlement occurs which in the opinion of the S.O. may

cause damage, the Contractor shall take immediate action to prevent
further movement, settlement or damage. He shall repair at his own cost
any damage and restore structures or pavements to the satisfaction of
the S.O..
The Contractor shall be responsible for inspecting the location and

familiarising himself with the conditions under which the work will be
performed and with all necessary details as to the orderly execution of
the work. The omission of any details shall not relieve the Contractor of
full responsibility for the satisfactory installation of the work in its entirety.
No monetary or other claims made by the Contractor on the grounds of
want of knowledge will be entertained.
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5.3.17.2 Jacking Heads
The Contractor shall safeguard against caving, running or other loss of

ground at the heading by means of a steel jacking head. The jacking
head shall be fitted to the leading section of pipe in such a manner that it
extends around the outer surface of the upper two thirds of the
circumference of the pipe and projects at least 60cm beyond the driving
end at the top of the pipe but does not protrude over 12.5mm outside of
the outer surface of the pipe. Excavation shall be carried out entirely
within the jacking head and no excavation in advance thereof will be
permitted. Every effort shall be made to avoid any loss of ground outside
the perimeter of the jacking head.
5.3.17.3 Jacking Pipes
The pipes for jacking operation shall be precast reinforced concrete

pipes, manufactured by an approved manufacturer. Design,
manufacture and factory testing of the pipes and special shall be to BS
5911 Part 1 or AS 1342.
The precast concrete pipes shall be sufficiently reinforced with steel to

withstand all stresses induced by the jacking operation without cracking,
spalling or distortion. The pipes shall be of the class and minimum
effective thickness shown on the Drawings.
5.3.17.4 Steel Collars
Stainless Steel collars shall be installed between the sections of the pipe
to permit proper joining of the pipe sections.
5.3.17.5 Jacking Operation
The Contractor shall be fully responsible for the materials, equipment

and facilities required in conjunction with jacking the pipes.
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Before starting work, the Contractor shall submit to the S.O. for
approval, a detailed schedule of the entire jacking operation. Approval of
such schedule shall not relieve the Contractor of his responsibility to
provide a fully satisfactory installation. The Contractor shall include with
his submission evidence that he has successfully completed a jacking
installation using the procedures similar to those proposed.
Where chemical stabilisation of soil is used, a chemical grout shall be

pressure injected into the soil over and ahead of the pipe jacking to
stabilise the soil. The chemical grout used shall have a demonstrated
history of success for stabilising soils similar to that through which the
pipe is to be jacked.
Where a mechanical shield is used, the Contractor must provide proof

that the particular model of shield has been used successfully in soils
similar to that on the site. The crew for the operation of the shield must
be specialist, with experience in the use of that particular type of
machine.
After the jacking operation has begun, the Contractor shall work
continuously and expeditiously in accordance to programme until the
complete length of jacked pipes is installed. This continuous work where
required shall not be construed as overtime work.
The pipes for the jacking operation shall be 3.05m long and shall be
jacked into place to line and level.
The Contractor shall be required to furnish and install and remove to the
extent required, thrust blocks or whatever provisions that may be
required for backing up the jacks employed in jacking the pipe forward.
The jacking pit shall also be equipped with steel rails or beams
embedded in concrete for placement and alignment of each pipe during
the jacking operation.
The Contractor shall be fully responsible for the design and construction
of the jacking and receiving pits, thrusting wall, installation of jacking
equipment, sheeting, bracing, etc and for the efficient execution of the
S5-40
jacking operation. Full details of the proposals, including plant, shield

machine, equipment, operating procedures, jacking pit and intermediate
jacking stations etc shall be submitted to the S.O. and shall be fully
satisfactory to him before construction. However, review of the plans
shall not relieve the Contractor from his responsibility to provide a safe
and satisfactory jacking pit. On successful completion of the jacking
operation, jointing of the length of jacked pipes, hydraulic pressure
testing of the pipelines have been made, the Contractor shall remove
completely the jacking pits and receiving pits together with all the
temporary works.
The Contractor shall be required to monitor closely the progress of the

jacking operation. Daily site records of thrusting pressures, rate of
thrusting, the line and level measurements of the jacking pipes and any
movement or settlement of existing structures and other property shall
be properly maintained and shall be submitted to the S.O..
The Contractor shall ensure that the completed pipeline is watertight. If

leakage occurs before completion or during the maintenance period, the
Contractor shall carry out any remedial work that may be necessary to
make the Works watertight all at his own expense.
5.3.17.6 Grouting Generally
The Contractor shall provide all plant and equipment for mixing and
injecting grout. The apparatus shall be of a type approved by the S.O.
and shall be capable of mixing effectively and stirring the grout and then
forcing it into the grout connections in continuous uninterrupted flow.
Grout pipes shall be secured to the grout holes in such a manner that no
leakage shall occur during grouting. After completion of grouting,
pressure shall be maintained by means of polyvinyl chloride stop plugs
or other suitable devices until the grout has set sufficiently. The grout
holes shall then be completely filled with dense concrete and finished
neatly without voids and projections.
The Contractor shall ensure that fouling of the equipment and lines is
prevented by constant circulation of grout and by periodic flushing out of
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the system with water. Flushing shall be undertaken with the grout
intake valve closed, the water supply valve open, and the pump running
at full speed.
5.3.17.7 Backpacking and Grouting of Voids
Excavated material shall be removed from the conduit as jacking

progresses, and no accumulation of excavated material within the
conduit will be permitted. Should appreciable loss of ground occur, the
voids shall be backpacked to the extent practicable with soil cement
consisting of a slightly moistened mixture of one part cement to five
parts of granular material. After jacking is completed the Contractor shall
drill holes in the casing at the locations of ground loss and elsewhere
where voids are suspected and shall force grout into fill voids to refusal
at pressures determined by the S.O., but not to exceed 3.5kg/sq cm.
The annular space between the pipe and the casing shall be completely
filled with sand. The sand shall be gunite sand. The details of the
method and locations of introducing the blown sand shall be submitted
to and approved by the S.O. prior to commencing jacking work.
5.3.17.8 Grouting and Special Grouting Outlets
Systems of fittings and hose of grouting connections embedded in the

pipe walls shall be provided by the Contractor. Grout composed of one
part of cement to five parts of sand slurry shall be forced under pressure
into the grouting connection at the invert with all other holes left open
and shall continue until grout escapes from the two connections on the
horizontal diameter of the pipe. The bottom grouting connection shall
then be plugged. Grout shall be injected through both horizontal
connections. When grout escapes through the vertical connection at the
crown of the collar, the two horizontal connections shall be plugged.
Grouting shall continue through the top most connection and finally be
plugged.
S5-42
5.3.17.9 Grouting
The void at the joint between two adjacent pipes and the steel thrust
collar shall be completed by pressure grouting and finished neatly
without voids and projections to ensure a smooth continuous surface
throughout the pipeline. The composition of the grout shall consist of
Portland cement and sand slurry, the crushing strength of which when
set shall be equal to that of the pipe.
5.3.17.10 Connections at Ends of Jacked Pipeline
The connections at the extreme ends of the jacked pipeline shall be

made only upon successful completion of the hydraulic pressure test of
the jacked pipeline.
The connections at the two ends of the jacked pipeline shall be made at
the jacking and receiving pits. The Contractor shall maintain and keep
these pits intact and in a safe condition to facilitate the connections. The
Contractor shall remove all other temporary works and any concrete
blocks including cutting and removing part of the walls of the pits that
are in the way of the pipework connections.
When the Contractor has completed the connections of the pipelines

and has completed the protection of these connections with sand or
concrete surround, he shall then backfill the pits with well compacted
suitable approved materials. The removal of the temporary bracings and
struttings shall be carried out systematically together with the backfilling
of the pits to prevent collapse of the pit walls. The walls of the pit shall
only be removed when the backfill of the pits are completed.
5.3.17.11 Safety
The minimum of plant shall be used in the pits, and any which produces
noxious gases or is operated by electricity at a greater voltage than
240V shall be permanently outside the pit at ground level.
S5-43
A ladder shall be fixed permanently in the receiving pit. Two ladders

shall be permanently fixed on opposite sides of the driving pit, one on
each side of the pipe jacking line. These ladders shall be kept clear of
obstructions to allow rapid exit in an emergency. Excavated materials
and plant other than small tools shall not be passed via the ladder but
shall be handled by crane.
Pits shall be securely fenced to prevent unauthorised persons from

entering in.
All persons entering the pits shall wear safety helmets constantly, and
shall leave the pits for meal breaks, rests and the like.
At the beginning of each shift and after any break for refreshment or
other reason, the Contractor shall provide and use an approved
instrument to check for noxious gases before anyone re- enters either
pit.
All costs associated with the provision of safety equipment and

measures shall be deemed included in the Contract Rates.
5.3.17.12 Railway Crossing
All jacking operations within the Malayan Railway right-of-way shall be in

conformance with the Specifications, the Drawings and the requirements
stipulated by the KTMB.
The Contractor shall ascertain for himself and comply with all the
requirements of KTMB in connection with the pipe jacking work under
the railway line and within the railway reserve. The Contractor shall pay
particular attention to the high fill embankment of the railway line and
shall ensure that the stability of the embankment will be safe-guarded in
connection with his pipe jacking work. No heaving of the ground beneath
the railway tracks shall be permitted during the duration of the pipe
jacking operation.
S5-44
5.3.17.13 Road Crossing
All pipe jacking operations where required beneath road carriageways

shall be to the requirements and approval of relevant Local Authority,
Public Works Department and Traffic Police.
5.3.17.14 Alternative Methods
The Contractor may use alternative methods of pipe jacking other than
as detailed above. The alternative method shall be submitted to the S.O.
for approval with a description of the proposed method of operations
before proceeding with the construction. Approval of the alternative
method by the S.O. shall not relieve the Contractor of the responsibility
for making satisfactory installation meeting the criteria set herein above.
5.3.18 Anchors and Thrust Blocks
The Contractor shall construct all anchors and thrust blocks as required
and where directed by the S.O. and as shown on the Drawings. In
general, thrust blocks will be placed at all changes in pipe direction
greater than seven (7) degrees. Each thrust block shall be designated to
have a sufficient bearing area and shall be placed to safely transmit to
the surrounding point. Thrust devices shall be cast-in-place concrete
metal harness, or other suitable devices. Thrust blocks shall be
constructed of Grade 20/20 concrete and shall be placed between fitting
and trench wall or trench bottom, as the case may be. The bearing faces
of the block shall be placed against freshly cut and undisturbed trench
wall or bottom of sound material. If the thrust exceeds the bearing value
of the surrounding soil, the soil shall be pre-compacted before placing
concrete. All concrete shall be kept behind the bells of fittings. Formwork
shall be constructed wherever necessary to confine the concrete to the
prescribed dimensions for the block. All form lumber shall be removed
prior to testing.
S5-45
5.3.19 Sewage Valves and Appurtenances
5.3.19.1 General
Sewage valves, fittings, supports, hangers, specials, and all required

appurtenances as shown on the Drawings and as required to make the
piping system operable shall conform to this section of the Specification
unless noted otherwise. Building, drain and vent lines shall conform to
Uniform Building By-Law Standards. All flanges, fittings, coupling,
valves, and appurtenances shall be rated for the indicated line pressure,
except as noted on the Drawings. Shop Drawings shall be submitted for
all equipment for the S.O.’s approval.
All valves shall be designed to avoid cavitation and vibration in all

positions, to minimise head loss in the open position and to seal the
water passage completely when shut. Operating spindles and gears
shall be provided with adequate points for lubrication. Valves shall be
closed in a clockwise direction.
All protection coatings shall be non-toxic and shall not impart any odour
or taste to the water. All ferrous surfaces in contact with water shall be
given two coats of epoxy coal tar bitumastic paint. The external surfaces
shall be painted with two coats of approved zinc rich epoxy paint.
Valves flanges shall conform to ANSI B16.1 Class 125. They shall be of
the raised face type, square to the longitudinal axis and truly faced over
their whole width. Bolt holes shall be drilled off centre lines and shall be
truly in line end to end with the longitudinal axis.
5.3.19.2 Protection Against Damage During Transit
All valves shall be securely packed in crates or boxes for protection

against damage during transit. Valves of 450mm diameter and above
shall be individually crated, battened and bound with 25mm wide steel
strip.
S5-46
Flanges of valves shall be protected by wooden discs temporarily bolted

on or secured by steel strapping. Spindle caps of sluice valves shall be
removed and where possible, shall be secured to the inner side of one
of the wooden discs by means of steel strip. Otherwise they shall be
packed in a case. The projecting end of the spindle shall be well
wrapped with straw rope covered by Hessian cloth and secured in place
by binding wire which shall be carried under the flange of the gland.
All plain ends shall be adequately protected by straw rope secured in

place by binding wire or strap. The costs of packing shall be included for
in the Contract Rates.
5.3.19.3 Inspection
All Goods to be supplied under the Contract may be inspected by the

S.O. at the Contractor’s premises or at the places of manufacture. The
Contractor shall provide such office facilities, assistance, labour,
materials, apparatus and instruments as may be necessary to allow an
inspection to be carried out.
The S.O. shall be entitled at all times during manufacture to inspect,

examine and test on the Contractor’s premises or at the places of
manufacture, the materials and workmanship of the valves or fittings,
such inspection, examination or testing shall not release the Contractor
from any of his obligations under the Contract.
5.3.19.4 Painting of Valves After Installation
Unless otherwise specified, all valves shall be cleaned and painted with
2 coats of coal tar epoxy paint with a resin base after installation.
5.3.20 Works Test
Valves shall be hydrostatically tested at the place of manufacture and

shall satisfactorily pass the specified tests before they are packed for
S5-47
delivery. All valves shall be body tested to one and half the working
pressure. Seat tests to the working pressure as specified or as required.
All valves shall be subjected to “open end” test in accordance with

AWWA C504 and each valve shall be subjected to three separate
hydrostatic tests as follows:
(a) Seat Test
i. With the edge or disc closed and with the valve fixed at
one end only, the test pressure shall be applied to that
face of the wedge or disc, the other face being at
atmospheric pressure.
ii. The above procedure shall be repeated with the valve

fixed at the other end and the test pressure applied to that
face of the wedge or disc.
There shall be no visible leakage past the wedge or disc

at the hydrostatic test pressure (gauge).
(b) Body Test
With the wedge or disc open the test pressure (gauge) specified
shall be applied to the whole body of the valve. There shall be no
visible leakage through the metal, the flanged joint or the valve
packing gland nor shall any part be permanently deformed.
The test durations for all tests shall be as in the table below:
Minimum Test Duration (Minutes)

Nominal Diameter Body Seat
(if applicable)
150 mm 1 1
200 mm to 300 mm 2 2
350 mm and above 5 2
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All valves shall be marked with cast-on or stamped lettering

stating the body test pressure in bars. The cost of testing shall be
included in the Contract Rates.
5.3.21 Materials
Materials used in the valves shall be of a quality as specified and shall

not be inferior than the following:-
Cast Iron : Flake graphitic heavy duty iron to

BS 1452 Grade 14 or superior.
Spheroidal Graphitic Cast Iron : To BS 2789 SGN 37/2
Stainless Steel : To BS 970 304 S-15
Gun Metal : To BS 1400 LG2-C
Cast Steel : Plain carbon steel to BS 1504 161-
B of BS 3100
High Tensile Brass : To BS 2872 CZ 114
5.3.21.1 Castings
Castings shall be homogeneous, free from non-metallic inclusions and

other injurious defects, close-grained, sound, smooth, symmetrical and
shall be carefully cleaned and dressed off. No stopping or plugging will
be permitted in the case of holes or flaws appearing therein, and casting
shall be made from first running. The S.O. shall have the power to reject
any defective casting and the Contractor shall replace it at his own
expense.
5.3.21.2 Forgings
All major stress bearing forgings shall be made to a standard

specification which shall be submitted if required to the S.O. for approval
before work is commenced. Forgings shall be subjected to non-
destructive tests to detect any flaws and heat treated for the relief of
residual stresses. The name of the maker and the heat treatment
proposed for each such forging shall be submitted to the S.O..
S5-49
5.3.21.3 Workmanship
Workmanship and general finish shall be of first class commercial quality

and in accordance with best workshop practice. All similar items of the
valve and their component parts shall be completely interchangeable.
Machined fits on renewable parts shall be accurate and to specified
tolerances so that replacements made to manufacturer’s drawings may
be readily installed.
5.3.21.4 Lubrication
The Contractor shall submit full details of the method of lubrication for
valves to be supplied under the Contract. He shall supply all necessary
lubricating equipment, grease and other lubricants for setting valves to
work, of which the cost of supply shall be included for in the Contract
Rates.
5.3.21.5 Protection Against Climatic Conditions
Vales supplied shall be of the appropriate grade and quality for and
adequately protected against the climatic conditions in Malaysia. Valves
found to be unsuitable for use under these conditions shall be removed
and replaced by suitable ones by the Contractor at his own expense.
Valves bodies, surface boxes and all other castings shall be coated in
accordance with BS 5163 for tropical conditions. Where this is not
applicable, they shall be thoroughly cleaned and be given two coats of
coal tar epoxy with a resin base. Machined surfaces shall be covered by
a suitable rust inhibitor, such as a high melting point grease of approved
quality.
All submerged moving parts of the valves, including pins, spindles, face
rings, etc. shall be of non-corrodible materials. Any parts that show signs
of corrosion or wear during the Defects Liability Period shall be replaced
by non-corrodible material of special quality for the purpose at the
Contractor’s expense. Care shall be taken in selection of metals for use
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in the valves to reduce the effects of bimetallic corrosion to a minimum.

The foregoing shall apply also to the moving parts of valves exposed to
the weather. Parts which can be worn or damaged by dust shall be
totally enclosed in dust-proof housings.
5.3.21.6 Coating of Valves
Unless otherwise specified, all iron castings shall be coated with a

bituminous solution in accordance with BS 3416. All internal faces shall
be coated with a semi gloss anti friction epoxy paint.
5.3.22 Mechanical Couplings, Flange Adapters and Expansion Joints
Mechanical couplings for jointing plain ended pipes shall be of an

approved make capable of maintaining a watertight joint over a range of
axial movement between the pipe ends of at least 80mm and with up to
3 degrees angular deflection between the longitudinal axes of the pipes.
Flange adapters for jointing plain ended pipes to fittings shall be of an

approved make capable of maintaining a watertight joint over a range of
axial movement of at least 25mm and an angular deflection of not less
than one and a half degrees. All flanges shall be drilled in accordance
with details as shown in the Drawings.
Expansion joints shall be provided to conform to details as shown on the

Drawings. They shall be supplied complete with all accessories.
All necessary Hexagonal bolts, nuts and washers shall be to BS

4190/BS 916, couplers, joint rings, etc required for completing joints
shall be supplied by the Contractor.
Coupling shall be supplied with or without a central register or locating

plugs as required. The central collar shall be at least 1.5mm thicker than
the equivalent standard pipe thickness.
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Every coupling, flange adapter and expansion joint shall be capable of

withstanding without leakage the pressure required for the works
hydraulic test of the section of pipeline in which it will be incorporated.
The pressure rating shall be clearly tamped on all couplings and
adapters. The rubber joint rings shall be Type 1 to BS 2494 having a
hardness range of 45 - 65 degrees measured in accordance with BS
903 and tensile stress - strain properties detailed in Table 3
corresponding to the relevant hardness.
All metallic parts are to be descaled to second quality standard in BS

4232 and protected in accordance to the requirements of the Contract.
All welding protrusion shall be machined finished. Mechanical couplings

and flange adaptors shall be hydraulic tested at the place of
manufacture. The number to be tested is one in every five for each size
of coupling and adaptor.
Every expansion joint shall be hydraulic tested at the place of

manufacture prior to delivery.
5.3.23 Sluice Valves
5.3.23.1 General
All sluice valves shall be of approved made and suitable for the intended
use. They shall generally be to BS 5163, of double flange, parallel seat,
non rising spindle type and shall be of the inside non-rising screw
wedge-gate type. The valves gates shall be double faced cast iron made
in one piece. The wedge seats (ring faces) and corresponding body
seats shall be gunmetal, machined and having broad bearing surfaces
securely and accurately fitted and faced to machined recesses to give a
watertight bearing. The recesses for the spindle nuts shall be smooth
and even so that on opening or closing the valve stresses are evenly
distributed over the bearing areas. Internal surfaces of the valves shall
be smooth and clear.
S5-52
The valves shall be so designed that the gates may be removed without
removing the bodies from the connecting pipework. The gate guides
shall be cast integrally with the valve bodies and be of adequate
strength and of sufficient length to guide the gates throughout their full
travel. In the fully open positions, the gates shall be fully withdrawn well
clear of the stream and the spindles shall not protrude into the bores of
the valves.
Flanges shall be to BS 4504 PN 16 and to match with the flanges for the
steel pipes.
5.3.23.2 Material
The body shall be of closed grained, high duty, grey cast iron to BS
1452 Grade 220 (minimum). The wedge shall also be cast iron to BS
1452 with ample guides and gunmetal rings. For valve with resilient
seat, the wedge facing shall be of resilient nitrile rubber bonded to the
cast iron wedge using the latest rubber technology.
The spindles shall be of the inside screw non-rising type of high tensile
brass or bronze to BS 2872 CZ114/CZ116 with machined square or
acme threads. They shall be truly circular throughout their lengths and
be of such lengths that when the valves are closed the bottom ends of
the spindles engage fully in the spindle nuts. The spindle collars or
thrust plates shall be concentric and machined suitable for the specified
test pressure. The spindle nut shall be gunmetal to BS 1400 LG2,
square or acme threaded to suit the spindles. The thickness and bearing
areas of the nut shoulders shall be adequate to resist operating thrusts.
All spindle contacting surfaces in the gland and neck of stuffing box shall
be bushed with gunmetal. Packed gland shall be arranged for easy
replacement of the packing. The valves shall be replaced with valve
wedge fully open and valves under pressure.
Valves of 400mm diameter and above shall be supplied complete with

built-in sluice valve bypass and operated by suitable reducing gears
where specified. The gearing shall be arranged for smooth operation of
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the valves and suitable for operation by one man with a mild steel tee
key and bar under the maximum working pressure. Gears and bearings
shall be protected by suitable water-tight enclosures permanently
packed with grease. Gearing assemblies shall be enclosed in boxes or
corrosion resistant material.
Handwheels shall be cast iron to BS 1452 Grade 220 and be supplied to

fit the spindles or operating gears for all the valves. They shall be
secured by brass or bronze set screws with the direction of closing
(clockwise) indicated on the handwheels. Opening/closing indicators
shall be provided and mounted on all valves of 300mm diameter and
above.
5.3.23.3 Pressure
All valves shall be subject to a minimum body test pressure of 150m (15
bar) and seat test pressure of 100m (10 bar). Valve pressure rating shall
equal the class of pipe unless otherwise specified.
5.3.24 Non Return, Reflex and Check Valves
5.3.24.1 General
Check valves shall be of approved made, suitable for their intended use
and generally to BS 5153. They shall have an unrestricted opening with
non-slam closure upon instantaneous power failure or pump shut-off.
Valves shall preferably be mounted horizontally and suitable for
velocities up to 5.0m/s.
Check valves shall be of the swing type, full body flanged type, with a
top access cover and only one moving part, the valve disc.
The valve body shall have 100 percent pipe flow area, with no
restrictions at any point, through the valve. The seating surface shall be
on a 45 degree angle to minimise disc travel. The top access port shall
S5-54
be full size, allowing removal of the disc without removing the valve from
the pipeline.
The access cover shall be domed in shape, to allow the disc to fully
open should waste solid get collect behind the disc.
The valve function is to permit flow in only one direction, close tightly
when its discharge side pressure exceeds its inlet pressure and to close
without a slam or bang.
Backflow capabilities shall be available by means of an optional screw

type backflow actuator. The actuator shall be field installable without
modification to the valve or a need for special tools or removal of the
valve from pipeline.
All internal parts shall be replaceable without removing the valve body
from pipeline.
5.3.24.2 Material
The valve body and cover shall be cast iron ASTM A 126, Class B
internally coated with two parts hi-build epoxy suitable for sewerage
service. The exterior shall be primed coated with a universal base
primer.
The disc shall be Buna-N, ASTM D 2000-BG and be of a one piece

precision compression molded construction with an integral O-ring type
sealing surface and contain steel and nylon reinforcement in both the
pivot and central disc areas.
Non-slam closing characteristic shall be provided through a short 35

degree disc stroke and a memory flex disc return action.
5.3.24.3 Pressure
All valves shall be subject to a minimum body test pressure of 150m (15
bar) and a working pressure of 100m (10 bar).
S5-55
5.3.25 Plug Valves
5.3.25.1 General
Plug valves shall be of approved made with handwheel, suitable for their
intended use and resilient seated eccentric and non-lubricated type
capable of handling abrasive and raw sewage. The plug valve shall have
flanged ends as shown.
They shall have round ports with a flow area not less than 90 percent of
the connecting pipe area or rectangular ports equal to the pipe area.
Valves pressure rating shall be rated for 120m (12 bar) up to 300mm
diameter and 100m (10 bar) for sizes 350mm diameter and larger. Drop
tight shut-off shall be provided at full rated working pressure in the
standard flow direction and 35m (3.5 bar) in reverse flow direction. Full
pressure rating in reverse flow shall be provided when indicated in the
valve schedule. An adjustable close position stop shall be provided for
field adjustment. The seat end and standard flow direction shall be cast
on valve body.
5.3.25.2 Material
The shaft seal shall comply with AWWA specification C504-80, section
3.7 and be of either the bronze cartridge type with two O-rings, V-type or
pull down packing. If V-type or pull down packings are utilised, they shall
be self adjusting. All shaft seals shall be replaceable without
disassembling the valve and while the valve is under system operating
pressure.
The plug shall be of a one piece with a precision molded resilient facing.
Resilient body seats are not acceptable. The resilient seating surface
shall not be in the flow way pattern when the valve is in the open
position. The body seating surface shall be welded nickel overlay
containing a minimum of 90 percent nickel and machined to a 16 micro-
inch finish contained no stress cracks.
S5-56
Radial journal bearings shall be stainless steel, of the permanently

lubricated type. Two thrust bearing/plate shall be provided in the upper
journal area, one of stainless steel and one of teflon. The lower journal
shall have one stainless steel thrust bearing/plate of the non-adjustable
type. A mechanism shall be furnished in the upper and lower journals to
prevent abrasive media from entering the bearing/plate areas.
The valve interior shall be coated with 4-6 mil of a two part hi-built epoxy
suitable for sewerage service. The exterior of the flanged valves shall be
prime coated with a universal base primer. The exterior of the
mechanical joint valves are to be coated with asphalt varnish.
5.3.26 Air-Release, Air/Vacuum and Combination Air Valves
5.3.26.1 General
The Contractor shall install at each location in the force main shown on
the Drawings the valve assemblies as detailed.
This section cover ½ in (13mm) through 16 in. (400mm) air release,

air/vacuum, and combination air valves having grey cast-iron bodies and
cover with threaded or flanged connections for use in systems with
water at temperature of 125oF (52oC) or less and maximum working
pressures or 300 psig (2070kPa [gauge]).
5.3.26.2 Definitions
For the purpose of this construct, the valves shall be defined as follows:
(a) Air-Release Valve
A hydromechanical device designed to automatically release to

the atmosphere small pockets of air as they accumulate at local
high points along a pipeline when the pipeline or piping system is
full and operating under pressure.
S5-57
(b) Air/Vacuum Valve
A direct-acting, float-operated, hydromechanical device designed

to automatically release or admit large volumes of air during the
filling or draining of a pipeline or piping system. This valve will
open to relieve negative pressures and will remain closed when
the system is full and under pressure.
(c) Combination Air Valve
A device having the features of both an air-release valve and

air/vacuum valve.
5.3.26.3 Data to be Supplied
The Contractor shall submit to the S.O. the following information before
provision of the valves:
(a) Catalog Data
The catalog data shall include illustrations, valve performance

data, a parts schedule that identifies the materials used for
various parts, and a statement of total net assembled weight for
each valve size. The contents shall be sufficiently detailed to
guide in the assembly and disassembly of the valve and for the
ordering of parts.
(b) Certified Drawings
A set of certified drawings shall include principal dimensions,

construction details, and materials used for all parts of the valve.
(c) Operating Manual
An operating manual shall include manufacturer’s installation and

operating instructions, a recommended list of spare parts, and
maintenance procedures.
S5-58
5.3.26.4 Valve Design Requirements
(a) Allowable Stress
The allowable stress at valve design pressure shall not exceed

one third of the yield strength or one fifth of the ultimate strength
of materials used.
(b) Venting
Air-release valves and the air-release mechanism of combination

air valves shall be designed to open positively and vent air to the
atmosphere at system pressures up to the maximum working
pressure as required by the venting orifice size.
(c) Body and Cover
Material of construction. Bodies and covers shall be of grey cast

iron (ASTM A126, Class B, or ASTM 48, Class 35) or ductile iron
(ASTM A536, Grade 65-45-12), and shall have threaded or
flanged connections as required by the S.O..
Inlet and outlet ports. The body inlet port and the cover outlet
port for air/vacuum valves and combination air valves shall be
sized such that the minimum flow area of each port shall be
equal to or greater than the flow area of circle of diameter equal
to the nominal valve size.
(d) Valve Connections
Valve connections shall conform to the following specifications:
Flanged ends. Unless otherwise required by the S.O., flange

dimension and drilling shall conform to
ANSI/ASME B16.1, Class 125 or Class 250.
S5-59
Threaded ends. Threaded connections shall conform to the

specifications for tapered pipe threads for
general use. National Pipe Threads (NPT) per
ANSI/ASME B1.20.1.
(e) Floats
For valves with inlet size less than 4 in. (100mm), the float shall
be capable of withstanding a collapse pressure of 1000 psig
(6900kPa [gauge]). For inlet sizes 4 in (100mm) and larger, the
float shall be capable of withstanding collapse pressures of 750
psig (5180kPa [gauge]).
(f) Gaskets
Gaskets shall be used on all flanged joints and shall be made of

rubber composition or paper that is free of asbestos or corrosive
ingredients. O-rings or other suitable elastometric seals may be
used for gasket.
(g) Orifices
Air/vacuum valve orifice The orifice shall be suitably sized,

using manufacturer’s sizing data, to
permit the required air flow rate to be
discharged and/or admitted.
Air-release valve orifice The orifice shall be suitable for the

volume of air expected to accumulate
in the system at the maximum working
pressure. The orifice size is specific to
the system application.
(h) Cover Bolting
Bolting materials shall equal or exceed the minimum physical

strength requirements of ASTM A307.
S5-60
(i) Seat
Valve seats made of elastomeric materials shall be designed of

material with a hardness selected for watertight shutoff (zero
leakage) and long-term service at a minimum pressure of 20 psig
(138 kPa [gauge]). Valve seat design shall permit easy removal
and replacement in the field.
(j) Special Fittings
Drain port All valves with a 1 in. (25mm) diameter or larger

inlet shall have a ¼ in. (6mm) NPT minimum
plugged drain port located near the bottom of the
valve body and a plugged test port near the top of
the valve.
Others An air-release valve and an air/vacuum valve

assembled with interconnecting piping shall have
pipe and fittings of sufficient size to prevent clogging
and entrapment of foreign materials. The piping
between the air/vacuum valve and the air-release
valve shall be arranged to allow air to rise to the air-
release inlet. When required, a shutoff valve
isolating the two valves shall be provided.
(k) Valve Trim Materials
Valve trim material shall be to inherently corrosion resistant and

shall be made to the manufacturer’s recommendation.
(l) Valve Outlet
Valve outlets shall be threaded, flanged, or hooded (or protected

with another shielding device that is positively anchored to the
valve cover).
S5-61
5.3.27 Scour Valve Assembly
At each low point in the force main the Contractor shall install a scour
valve assembly as detailed on the Drawings. Valves and fittings shall
equal or exceed the pressure rating of the pipe to which they are
attached.
5.3.28 Penstocks
5.3.28.1 General
Penstocks shall be of heavy duty, suitable for sewage use and be of

flush bottom seal. They shall be water tight when closed against the
specified head.
5.3.28.2 Frame and Gate
These shall be of the frame type of robust one piece construction in

close grained heavy duty grey cast iron to BS 1452 Grade 220 with
substantial integrally-cast vertical and horizontal ribbing for resistance to
deflection. The frame back can be flat or cast with a spigot for extending
into concrete especially where unseating pressures are encountered.
Frames and guide strips shall be of close grained cast iron to BS 1452.
Guide channels shall extend to a sufficient height to ensure that the gate
is supported over not less than two third of its depths when at maximum
lift.
5.3.28.3 Faces
These shall be of bronze seating strips of heavy rectangular sections

pinned to machined surfaces on body and gate which are then ground in
together to a watertight bearing. Bronze strips shall also be fitted in the
guides.
5.3.28.4 Spindles
All spindles shall be of the inside screw non-rising type suitably size for
the intended duty and shall be of stainless steel with gun metal nuts on
top.
S5-62
5.3.28.5 Headstock and Handwheel
Headstock and handwheels with gun metal index and pointer shall be
provided for operation of the penstock. This shall be manual or electric
driver as specified or as shown on the Drawings.
5.3.28.6 Extension Stems
They shall be of stainless steel. Long extension stems shall be properly

supported and be supplemented by the use of stem guide and adapter.
All necessary wall brackets, stem brackets, muff coupling, universal
joints shall be provided.
5.3.28.7 Hydraulically Operated Penstock
(a) General
A hydraulic operated penstock shall include an adequate

reservoir with an oil gauge. The hydraulic pump and system shall
be robust and of adequate capacity to smoothly lower and seat
the penstock completely in 2 minutes. The hydraulic pump will be
driven by an electric motor and in addition a hand operated drive
or pump shall be provided so that the hydraulic penstock may be
manually lifted, should the need rise.
The actual penstock shall generally confirm to the specification

and shall in addition be fitted with sufficient cast iron weights
attached to the gate by phosphor bronze bolts etc. to ensure the
drop light closing of the gate in the event of power failure. The
penstock gate shall be opened and maintained open by an oil
pressurised cylinder. It shall completely close under its own
weight from any position and be weighted to overcome off-
seating pressure of not less than 10m water unless otherwise
specified.
S5-63
(b) Penstock Control
A remote manual control panel with isolating switch shall also be

provided to raise / lower the penstock using start and stop push
button.
Limit switches shall be provided to give indication of penstock

fully closed/open. The time required for the penstock to be fully
open or fully close shall not exceed 6 minutes. The normal
operation of the penstock shall be under remote mode whereby
the opening/closing of the penstock shall be controlled
automatically by the RTU/PLC based on signals from the level
electrodes and ultrasonic level sensor in the wet well. In the
unlikely failure of one of these sensors, the automatic control of
the penstock shall continue to function.
The Local mode shall be used by the operator during

maintenance to open or close the penstock using the push button
on the panel.
5.3.29 Sluice Gates
The Contractor shall provide all tools, equipment, materials, and

supplies and shall perform all labour required to complete the gates and
operational as indicated on the Drawings and specified herein.
5.3.29.1 Submittals
The Contractor shall submit to the S.O. for approval complete

fabrication, assembly, foundation, and installation drawings, together
with detailed specifications and data covering material used, parts,
devices, and other accessories forming a part of the equipment
furnished. Data and specifications for the equipment shall include but
shall not be limited to, the following:
S5-64
(a) Anchor Bolt placement in the concrete structure. Anchor bolt

details including projections from concrete.
(b) Gate Size, model numbers, opening sizes, elevations, locations,

and materials of construction.
(c) Stem Sizes including details of connections, thread directions,

stops, etc.
(d) Stem Guide details and locations.
(e) Hoist Guide details and locations.
(f) Operator Details including connections furnished for each type of

hoist.
Submittals shall be made in accordance with the requirements of these

Specifications, including the provision of the Mechanical Equipment
Section.
5.3.29.2 Materials, Products and Equipment
Each item of equipment shall be furnished and installed complete with

all supports, anchor bolts, stem guides, hoisting equipment, and
appurtenances ready for operation. All mechanisms or parts shall be
amply proportioned for the stresses which may occur during operation or
for any other stresses which may occur during fabrication and erection.
Individual parts furnished which are alike in all units shall be alike in
workmanship, design, and materials and shall be interchangeable.
(a) Acceptable Equipment Manufacturers
Equipment to be furnished under this Section of these

Specifications shall be manufactured by Passavant, Armco Steel
Corp., or an approved equal. Units to be furnished shall be of a
design and manufacture that have been used in at least five
applications in similar environments for a period of at least 5
S5-65
years as proof of ability to perform, in accordance with the

requirements of these Specifications.
(b) Anchor Bolts
All anchor bolts, nuts and washers, including anchor bolts used
in the installation and assembly of the equipment shall be
stainless steel, Type 316, (unless specified otherwise herein) and
of ample size and strength for the purpose intended. All bolt
heads and nuts shall be hexagonal. Anchor bolts shall be
furnished with 2 nuts to facilitate installation and alignment.
(c) Protective Coatings
Exposed machined or bearing surfaces shall be coated with a

sewage resistant rust preventive compound. All assembled units
shall be shop coated in accordance with the manufacturer's
standard practice. Stainless parts will not require coating.
Application and material shall conform to the requirements of

these Specifications.
5.3.29.3 Heavy Duty Gates
(a) Gate Frames and Guides
Gate frames and guides shall be cast in one piece and shall be
flat back. The back of the frame shall be machined to a plane
and drilled to mate the thimble. The guides shall be extended for
full gate opening. Guide grooves shall be accurately machined to
provide free movement of the slide tongues and to insure proper
engagement of the wedging devices. Frames and guides shall be
cast-iron, ASTM Designation A 126-66 (Class B or C) or
equivalent BS Code.
S5-66
(b) Gate Slides
The gate slides shall be cast in one piece with vertical and
horizontal ribs, pads for attaching wedging devices, a stem block
pocket and a reinforced section around the perimeter to provide
for mounting of the seating faces. The casting shall be of ample
section to safely withstand 6 metres unseating head. A stem
block shall be provided to attach the gate slide to the stem. It
shall be threaded and provided with a means of locking it to the
rising stem after it is installed. Pads for mounting wedging
devices shall be machined and drilled. A groove shall be cut in
each pad to receive the mounting tongue on the side wedge.
Slides shall be cast-iron, ASTM Designation A 126-66 (Class B
or C) or equivalent BS Code.
(c) Seating Faces
A full-width dovetail slot shall be machined around the waterway

opening of the frame and along the frame guide extensions to a
minimum height equal to one-half of the vertical gate opening.
The perimeter of the slide shall be machined with the same
dovetail. Corrosion-resistant full width dovetail faces shall be
securely mounted and held in position without the use of screws
or other fasteners. Seating faces shall be machined to a plane
with a minimum 0.0016mm finish. With the slide in the fully
closed and wedged position in the frame, the clearance between
faces shall not exceed 0.10mm. Seating faces shall be nickel-
copper alloy conforming to the requirements of ASTM
Designation B 164-70, Class A or B or equivalent BS Code.
(d) Wedging Devices
Each gate shall be provided with sufficient wedging devices to

provide a practical degree of water-tightness. Wedging devices
shall be designed to wedge the seating faces of the slide against
those on the frame when gate is fully closed. Wedging devices
shall be adjustable and provided with positive means of locking.
Individual parts of each wedging device shall be removable and
S5-67
replaceable without complete disassembly of the gate or guide.

All gates shall be equipped with side wedging devices. Side
wedges shall be keyed and attached to the slide with corrosion-
resistant fasteners. Each side wedge block shall be provided with
corrosion-resistant wedging contact face and attached to the
frame with two corrosion-resistant fasteners. Gates with a
waterway opening width of 600mm or more shall be furnished
with top and bottom wedging devices. Each wedge shall be
attached to the frame and each adjustable wedge block shall be
attached to slide with 2 corrosion-resistant fasteners. Wedging
devices shall be nickel-copper alloy conforming to the
requirements of ASTM Designation B 164-70, Class A or B or
equivalent BS Code.
(e) Flush Bottom Seal
The gates shall be provided with flush bottom seals. Therefore,

the dovetail facing along the bottom edge of the slide and frame
shall be omitted. A solid, square-cornered, resilient rubber shall
replace the bottom dovetail facing and wedging devices. The
seal shall be securely fastened to the bottom cross member of
the frame on a stop plate, with a retainer bar and corrosion-
resistant fasteners. The top surface of the seal shall be flush with
the invert of the gate-opening. The full length of the bottom edge
of the slide shall be accurately machined to make contact with
the seal when the slide is closed. The seal shall be replaceable
without removal of the gate slide. Flush bottom seals shall be
rubber, conforming to the requirements of ASTM Designation
D735, Grade B 625 or equivalent BS Code.
(f) Fasteners
All anchor bolts, assembly bolts, screws and nuts shall be of

ample section to safely withstand the forces created by operation
of the gate while subjected to the heads described above.
Quantity and size of the fasteners shall be recommended by the
manufacturer. Anchor bolts shall be furnished with 2 nuts to
S5-68
facilitate installation. All fasteners shall be nickel-copper alloy,

conforming to the requirements of ASTM Designation B 164- 70
(Class A or B) or equivalent BS Code.
(g) Wall Thimbles
Wall thimbles shall be heavy one-piece castings of the "F" type.

Minimum length of thimbles shall be 300 mm. The front flange
shall be machined to a plane and shall be drilled and holes
tapped to mate the drilling of the gate frame. The vertical center
line shall be clearly shown by permanent marks at the top and
bottom of the machined face. The word "top" shall be marked
near the top center line of the thimble opening. The surfaces to
be cast into the concrete shall be free from plant, oil and grease.
Corrosion-resistant studs and nuts shall be provided for attaching
the gate. Mastic shall be provided to form a seal between the
front of the thimble and the back of the gate frame. Wall thimbles
shall be cast-iron conforming to the requirements of ASTM
Designation A 126-66 (Class B or C) or equivalent BS Code.
(h) Stems
Stems shall be one continuous piece and manufactured from

round bar stock. Stem diameter shall be adequate to safely
withstand forces created during gate operation under an
unbalanced head of 6 meters. Stems shall be furnished with
right-hand, 29 degree modified Acme single lead threads of
proper length to provide for complete opening of the gate. The
bottom end of the stem shall be threaded to connect to the stem
block. Stems shall be stainless steel, conforming to the
requirements of ASTM Designation A 582-70 Type 303 or
equivalent BS Code.
(i) Stem covers
Stem covers shall be standard weight, galvanised steel pipe

threaded on both ends and of sufficient length to totally enclose
the stem when the gate is fully open. The top shall be closed with
S5-69
a standard galvanised pipe cap, and the bottom shall screw into
a cast-iron housing mounted on top of the gate operator. The
inside of this housing shall be bored to the exact diameter of the
stem cover to assure accurate alignment of the cover.
(j) Wall Brackets
Wall brackets shall be provided and shall be capable of taking

the thrust encountered for operating under the unbalanced head
and wedging discussed above. The brackets shall be of cast-iron
with heavy reinforcing ribs and located in accordance with the
manufacturer's recommendations.
5.3.29.4 Operators
The manual lift mechanism shall be the crank operated type with either a
single or double gear ratio, depending upon the lift load. Each type shall
have a cast bronze lift nut threaded to fit the operating stem. Ball thrust
bearings shall be provided, above and below the flange on the lift nut to
take the load developed in opening and closing the gate. Gears shall be
of cast iron or steel, accurately machined with cut teeth and smooth
running with suitable shafts running in bronze sleeve bearings or rollers
bearings of ample size. All geared lifts shall be suitable for auxiliary
motor operation. All gears and bearings shall be enclosed in a cast iron
housing. Fittings shall be provided so that all gears and bearings can be
periodically lubricated. The removable cast iron crank shall be fitted with
a rotating handle. The lift mechanism shall be supplied with a cast iron
pedestal, machined and drilled to receive the gear housing and suitable
for bolting to the operating floor. The design of the lift mechanism shall
be such that the slide can be operated with a 11.4Kg effort on the crank.
The maximum crank radius shall be 38cm. The direction of rotation to
open the gate shall be indicated on the lift mechanism. A cast iron stop
nut shall be provided for each lift. All exposed cast iron surfaces shall be
painted in accordance with these specifications. Each rising stems unit
shall be provided with a position indicator to show the position of the
gate at all times.
S5-70
5.3.29.5 Installation
The Contractor shall arrange to have the manufacturer or supplier of the

equipment, furnished under this Section, furnish the services of
competent factory-trained personnel to supervise the installation, initial
operation, and testing. All allowance of 15 actual man-working days
shall be included in the price of the equipment. The Contractor shall
obtain necessary installation drawings from the manufacturer. It shall be
the Contractor's responsibility to handle, store and install the wall
thimbles, gates and accessories and operators in strict accordance with
the manufacturer's drawings and recommendations. Care shall be taken
during mounting of the gates to avoid warping the gate frames and to
maintain clearance between seating faces.
5.3.30 Equipment Testing
(a) Shop Testing
The Contractor shall require the manufacturer of the equipment

furnished under this Section of the Specifications to shop test all
sluice gates for a seat clearance check in accordance with the
applicable provisions of the latest edition of AWWA
Specifications C501 or equivalent BS Code. Prior to shipment of
the gates the Contractor shall submit certified copies of the test
report in triplicate to the S.O. for review. All cost of shop testing
shall be included in the price of the equipment.
(b) In-Place-Testing
Following completion of the installation of the sluice gates, the

Contractor shall provide the services of the authorised
representative of the manufacturer to adjust and operate the
gates. Adjustment shall be made so that the gates operate
smoothly, seat properly, and are installed to the tolerances
recommended by the manufacturer. After the equipment has
been operated and adjusted, the Contractor shall perform a field
S5-71
leakage test on each gate in the presence of the S.O. in

accordance with the applicable provisions of the latest edition of
AWWA Specification C501 or equivalent BS Code. Both seating
and unseating heads shall be tested as applicable. In the event
any of the equipment fails to meet the above test, it shall be
modified as required and retested in accordance with these
Specifications, until the maximum allowable leakage is not
exceeded. Any modifications or adjustments required to meet the
test shall not impair the smooth operation of the equipment.
5.3.31 Tidal Flap Valves
The frame and flap shall be cast iron to BS 1452 and seating faces shall
be bronze or stainless steel. It shall operate efficiently under the
designed hydraulic head.
5.3.32 Fittings
All flanges, fittings, couplings, valves, and appurtenances shall be rated

for the indicated line pressure, except as note on plans.
5.3.32.1 Cast or Ductile Iron Fittings
Cast iron fittings shall be of a strength equal or greater than the pipe to
be joined. Exterior surfaces shall be coated with coal tar pitch varnish.
5.3.33 Cast Iron Specials
Cast iron specials shall comply with BS 78 or BS 2035. Flanges shall be

to BS 10 or the metric equivalent. Jointing flanges shall be truly parallel
to each other so that bolts are used only to make joints tight and not to
pull flanges not in true alignment. All bolts and nuts shall be of bright
steel and be of hexagon head.
S5-72
5.3.34 Valve Operating Tee Wrenches
Valve operating tee wrenches shall have a socket for a 50mm square
operating wrench. One wrench for each type of valve shall be supplied
to a height where it may be operated at waist level.
5.3.35 Protective Coatings
Valve bodies, surface boxes, fittings and all other castings shall be
coated in accordance with BS 4164 for tropical conditions. Where it is
not applicable, they shall be thoroughly cleaned and be given two coats
of coal tar epoxy with a resin base. Machined surfaces shall be covered
by a suitable rust inhibitor, such as a high melting point grease of
approved quality.
All submerged moving parts, or the pins, spindles and faces, etc in
contact with them, shall be of non-corrodile materials. Any parts that
show signs of corrosion or wear during the Defects Liability Period shall
be replaced with non-corrodible materials or special quality for the
purpose at no extra cost. Care shall be exercised in the choice of metals
for use in the valves to reduce the effects of bi-metallic corrosion to a
minimum. The foregoing shall apply also to the moving parts exposed to
the weather.
All flange bolts and nuts shall be lubricated and coated with protective
coating. Exposed ferrous metal surfaces in contact with the earth such
as valves, flanges, butt straps, and couplings shall be field coated in
accordance with the manufacturer's recommendations. Surface shall be
thoroughly cleaned prior to coating.
5.3.35.1 Shop Painting
All exposed ferrous metal surfaces except where galvanised, mortar

coated, or to be cast in concrete, shall be shop painted as follow:
S5-73
(a) All rust, loose scale, and foreign matter shall be removed from
surfaces to be coated by wire brushing or sandblasting. Oil and
grease shall be removed with cleaning solvent, and surfaces
shall be dry.
(b) Surfaces which will be in contact with the earth and are to
receive a field applied coal-tar coating as specified elsewhere,
shall be shop painted as per specification Section 10.
(c) Other exposed surfaces above ground level shall be shop

painted as per specification Section 10.
5.3.36 Floor, Wall Collars
Where pipes pass through concrete floor or other walls, suitable puddle
flange or collar shall be provided.
5.3.37 Hose Bibbs
Hose valves shall be 20mm bronze with composition disc and with
screwed end installed 0.5mm above grade or attached to wall.
S5-74
Appendix 5.1
SIXTH SCHEDULE
ENVIRONMENTAL QUALITY ACT 1974
ENVIRONMENTAL QUALITY (SEWERAGE AND INDUSTRIAL EFFLUENTS)

REGULATIONS 1978
[Regulation 11 (5) (b)]
PARAMETER LIMITS OF EFFLUENT OTHER THAN OF STANDARD A OR B
Parameter Units Limit

o
(i) Temperature c 45
(ii) pH Value - 5.0-9.0
(iii) BOD5 at 20 oC mg/1 400
(iv) COD mg/1 1000
(v) Suspended Solids mg/1 400
(vi) Mercury mg/1 0.10
(vii) Cadmium mg/1 1.0
(viii) Chromium, Hexavalant) mg/1 2.0
(ix) Arsenic mg/1 2.0
(x) Cyanide mg/1 2.0
(xi) Lead mg/1 2.0
(xii) Chromium, Trivalent mg/1 10
(xiii) Copper mg/1 10
(xiv) Manganese mg/1 10
(xv) Nickel mg/1 10
(xvi) Tin mg/1 10
(xvii) Zinc mg/1 10
(xviii) Iron (Fe) mg/1 50
(xix) Phenol mg/1 5.0
(xx) Sulphide mg/1 2.0
(xxi) Oil and Grease mg/1 100
S5-75

S05 Sewerage

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S05 Sewerage

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EDTP GEMAS-JOHOR BAHRU TECH. SPEC. FOR ARCH.

, C&S AND MEP

SECTION 5: SEWERAGE WORKS

5.1 Introduction ......................................................................................... S5-1

5.2.6.7 Testing, Commissioning And Acceptance Tests ... S5-13

5.3.12 Testing of Sewers .................................................................. S5-24

5.3.19.1 General ................................................................ S5-46

5.3.28.6 Extension Stems .................................................. S5-63

5.1 Sixth Schedule: Environmental Quality Act 1974 S5-75

SECTION 5: SEWERAGE WORKS

The wastewater generated from each of the Proposed Station shall be

The wastewater shall be collected by a network of sewers and convey by

The proposed package Wastewater Treatment Plant (WTP) will be under

5.1.1 General Description Of Works

(b) The proposed WTP shall be capable of treating all waste

(c) This treatment system covers the treatment of effluent discharges

These facilities are:

ii Canteen, Surau, Store

iii Offices and Administration Buildings

iv Depot, Maintenance Workshops and etc.

(d) The proposed scope of works including the submission, obtaining

(j) The Contractor shall engaged the Malaysian Engineering

5.2 Wastewater Treatment Plants

5.2.2 Process Description

The proposed treatment process shall have a proven treatment record

5.2.3 Design And Construction Requirement

5.2.3.1 General Requirement

In the design and implementation of the Waste Treatment Plant the

The Contractor shall, prior to development of the design, submit a

(a) Design Parameters.

(b) Design Guidelines.

(c) Treatment process.

Proposed design, product and installation should be tested and accepted

5.2.3.1.1 Design Requirement

(a) Minimum free board of 600mm

5.2.3.1.2 Civil and Structural Requirement

(a) Concrete for all tanks shall of grade 35A.

(b) All internal surfaces of tanks or structures in contact with wastes

(c) All metal in contact with wastewater or in wastewater enclosure

5.2.3.1.3 Mechanical Requirement

(a) Materials for all equipment shall be corrosion resistance to the

(b) Piping materials shall be robust and resistance to any chemical

(c) All pumps shall be seal shall be of mechanical seal

5.2.3.1.4 Electrical and Instrumentation Requirement

(a) Motors shall be weather proof to IP55.

(b) Electric motors and equipment installed shall be explosion proof in

(c) MIMIC Flow Diagram shall be provided with

5.2.3.2 Standard And Regulation

(a) Suruhanjaya Tenaga

(b) Tenaga Nasional Berhad ( TNB )

(c) Standards and Industrial Research Institute of Malaysia ( SIRIM )

(d) British Standard Institution ( BSI ) – British Standard ( BS )

(e) The Institution of Electrical Engineers ( IEE ) – Latest IEE Wiring

(f) International Electrotechnical Commission (IEC)

(g) International Commission on Illumination CIE 115 – 1995

(h) Illumination Engineers Society (IES)

(i) Keratapi Tanah Melayu (KTM)

5.2.4 Electrical Services

5.2.4.1 Power Supply Reticulation

Power supply to this project shall be sourced by the Contractor including

5.2.4.2 Motor Control Center (MCC)

(a) Voltmeter for incomer only

(b) Ammeter comes with maximum demand for incomer only.

(c) Ammeter for motor circuit