BOOK III

PART 4.4 Civil Works

4.4.1 General

PART 4.4 CIVIL WORKS

4.4.1. GENERAL CIVIL AND ARCHITECTURAL DESIGN REQUIREMENT

4.4.1.1 BUILDING AND STRUCTURAL DESCRIPTIONS

The Bidder shall provide all necessary permanent civil works for overall
scope of works. For clarification, additional notes about certain of the civil
buildings and structures are given below.

The Bidder shall propose the architectural views of the buildings in the bid
proposal.

4.4.1.1.1 STEAM TURBINE BUILDING

The size and arrangement of this building shall be designed to house of

steam turbine and all associated mechanical and electrical equipment
specified in the applicable mechanical and electrical technical specifications
and shall be considered space for maintenance.

The Steam Turbine Building composes of Turbine Hall, Deaerator Bay and
Coal Bunker. The Steam Turbine Building shall be a structural steel framing,
enclosed with double skin insulated metal sidings and slope double skin
insulated metal roofing.

The ground floor shall be a reinforced concrete slab finished with floor
hardener. The elevated floors shall be reinforced concrete and galvanized
steel grating shall be provided for any floor openings as approved by the
Owner. All opening shall be completed with galvanize hand rail. Galvanized
metal decking shall be used for forming the elevated concrete floors.

Windows and louvers shall be provided for ventilation purposes, and smoke
heat vents shall be provided at the roof purposed for air circulation.

The Steam Turbine shall be mounted on a turbine table monolithic

reinforced concrete foundation supported by pre-stress concrete hollow
spun piles separate with building foundation.

The Steam Turbine Building foundation shall comprise of reinforced

concrete monolithic slab supported on pre-stress concrete hollow spun
piles.

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4.4.1.1.2 BOILER HOUSE AND AUXILIARY

The size and arrangement of this structure shall be designed for boiler and
all associated mechanical and electrical equipment specified for in the
applicable mechanical and electrical technical specification and also shall
be considered and ample space for maintenance requirement.

The Boiler House shall be a structural steel framing enclosed with insulated
metal roofing.

The floor shall be a reinforced concrete slab finished with floor hardener
conform to ASTM D 1308. Steel grating shall be provided for any floor
openings as approved by the Owner. All side opening shall be completed
with galvanize hand rail. Galvanized metal decking shall be used for forming
the elevated concrete floors.

The Boiler House shall be mounted on a monolithic slab/mat reinforced

concrete foundation supported by pre-stress concrete hollow spun piles

4.4.1.1.3 CENTRAL CONTROL ROOM

The Central Control Room shall be designed as a steel framing structure

integrated to Steam Turbine Building.

The structure shall consist of ground, cable spreading and main floors for
housing control board, computers, electrical equipment, cable, batteries,
laboratory equipment and AC machine.

Windows and louvers shall be provided for ventilation purposes,

Sunscreens made of aluminum plate shall be provided in front of glazed
windows. An air conditioning system will be provided in the majority of room
in the Central Control Room such as control room, computer room, office
room, conference room and others as approved by the Owner. The control
room, computer room and etc. shall be installed with raised floor and
louvered ceiling grid system.

4.4.1.1.4 ADMINISTRATION BUILDING

The Administration Building shall be designed as reinforced concrete

structure founded by reinforced mat supported by on pre-stress concrete
hollow spun piles.

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Plastered finish brick wall shall be used for the siding and an acoustic
suspended ceiling system shall be provided for all areas except for kitchen
and toilet room, shall used moisture resistant ceiling. An Air Conditioning
system and fire protection system shall be provided.

4.4.1.1.5 CHIMNEY

The Chimney arrangement drawings shall be included in the bidder

proposal to show an intended arrangement of the Chimney for this project.

The Chimney windshield with 2 (two) barrel of inner flues foundation shall
be of reinforced concrete.

The flues shall be connected with frame steel girder and beams for
platforms located approximately every 40 m in height. Sliding hinges and fix
hinges shall be provided for connection between flues and the girder
against force induced. Lateral support for chimney flues near the top and at
each platform shall be provided. The portion of flues at and above roof shall
be connected of stainless steel.

Insulation to cover flues and all projecting element shall be provided so that
the surface temperature of the insulation surface shall no exceed 500 C.

The flues liner shall be reinforced using external stiffeners to avoid

excessive vibration under all operating condition. The spacing of the
stiffener shall not exceed 1.5 times the diameter of the liner or 8 m
whichever is smaller.

The minimum thickness of liner plat shall be 10 mm and allowable of 1.6

mm thickness shall be added to the computed thickness of liner for
corrosion.

The Bidder shall propose the height of inner steel flues liners of 100 m. The
actual height shall be based on plume dispersion calculation and as a
minimum shall comply with Environmental Regulation & Standard.

Steel liner furnished shall be new and un-damaged and shall conform to
pertinent AISC and ASTM standard specifications, i.e. liner and breeching
plates, bars to ASTM A36/A36M-90. Top 10 meters (min) of liner plates,
bars, angels, flashing and stiffeners to ASTM A167-90 type 3161. Liner and
breeching insulation conform to ASTM C612-83 class 3 mineral fiber board,
50 mm thickness, designed for 455 0C maximum temperature, and with K-

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factor of 0.30 per 25 mm of thickness at 93 0C temperature and minimum

density of 48 kg/m3 etc.

All exterior surfaces of the liner and portion of the breeching within the
exterior of circumstance of the concrete shall be insulated, including the
exterior of the breeching access door. Insulation shall conform to ASCE
1975.

One millimeter galvanized 25 mm hexagonal wire netting shall be wrapped

over the insulation.

The exterior surface of the concrete shell shall be printed with international
orange and white. Coating of top 20 m and painting of remaining shall be
provided. The color and wide arrangement shall be proposed for Owner
approval.

To ensure that minimum maintenance over the operational life of the power
plant, the chimney shall include low viscosity corrosion inhibitor protection
which accept chloride testing in accordance to ASTM 1152 lower than 0.007

The Chimney shall stand on reinforced concrete mat foundation and shall
be supported by pre-stress concrete hollow spun piles.

4.4.1.1.6 ACCES ROAD AND BRIDGES

New access road shall be provided to connect the province road to power
plant. The new access road will cross Parit Baru river, hence a proper
bridge is required. Other bridge shall be provided in discharge outfall as an
access to sea guardhouse. Bridges shall be made of reinforced concrete
structure supported by concrete piles.

4.4.1.1.7 COOLING WATER INTAKE AND DISCHARGE

Cooling water for the Turbine Condensers and Power Station Auxiliary Plant
shall be drawn from and discharged to the river.

The Bidder shall indicate layout drawing shows locations of river water
intake line and discharge outfall positions in his bid proposal.

Optimization of the CW system and associated intake and outfall positions

shall be the responsibility of the Bidder.

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River cooling water will be flowed by gravity to CW Intake Pump House.

From CW pump station, cooling water will be circulated to Condenser by
using underground pipe (conduits). From condenser, cooling water will be
discharged through buried pipe ended in seal pit as indicated in the Bid
Drawing and will continue by using discharged canal as indicated in the Bid
Drawing.

The capacity of Intake line, river water settling pond, seal pit and discharge
canal shall cover for ultimate capacity i.e. for four (4) units.

The Bidder shall undertake survey works to provide sufficient hydrographic

data (e.g. currents, bathymetry, tidal levels, sea water temperatures, etc) for
mathematical modeling of tidal, currents and thermal dispersion to verify the
location of intake and outfall structures and sedimentation study.

The cooling water discharged canal shall be reinforced concrete structure,

reinforced concrete sheet pile, reinforced concrete panel or any other
approved slope protection material.

4.4.1.1.8 CW INTAKE PUMP STRUCTURE

CW Pump Structure shall be reinforced concrete outdoor structure founded

on pre-stress concrete hollow spun piles. This structure shall be provided
with auxiliary facilities such as stop log, stationary bar screen, traveling
screen, gantry crane rail beam.

4.4.1.1.9 PRE TREATMENT WATER FACILITIES

The river water shall be treated trough clarifier, sludge thickener, treated
river water basin and filter pressed house. Treated river water basin shall
have the capacity minimum of 2 x 2100 m3. Clarifier, Sludge Thickener and
treated river water basin shall be made of reinforced concrete structure
sitting on piles foundation.

4.4.1.1.10 CHLORINATION BUILDING

Chlorination Building shall consist of steel structure and reinforced concrete

mat supported by pre-stress concrete hollow spun piles. The inside surface
of concrete wall and floor shall be protected from acid and alkali by the
chemical resistant proof coating.

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4.4.1.1.11 WASTE WATER TREATMENT FACILITIES BUILDING

The Waste Water Treatment facilities building shall be steel frame indoor
structure founded in reinforced concrete mat supported on pre-stress
concrete hollow spun pile.

4.4.1.1.12 REVERSE OSMOSIS STRUCTURE

Reverse Osmosis structure shall be steel frame indoor structure founded in

reinforced concrete mat supported on pre-stress concrete hollow spun pile.

4.4.1.1.13 FUEL OIL TANK FARM FOUNDATION AND BUNDWALL

Foundations are designed and provided to support fuel oil tank, surrounded
by concrete wall dike.

These fuel oil storage tanks foundations are reinforced concrete slab
founded on pre-stress concrete hollow spun piles.

Drainage system shall be provided. Storm and oily water drainage inside
dike are collected in concrete ditch and pits and then discharged to outside
dike through underground pipes and pits and then routed to oil separator.

4.4.1.1.14 PIPE WORK SUPPORT STRUCTURES

The design and construction shall take into account the anticipated
movement, static, dynamic and seismic force where applicable and the
need to restrict differential settlements and movements between pipe
supports and adjacent plant and buildings.

Pipe work support structures shall sit on reinforced concrete sleeper

supported on pre-stress concrete hollow spun piles if required.

4.4.1.1.15 COAL STORAGE AND COAL HANDLING FACILITIES STRUCTURE

The Coal Storage facilities shall consist of transfer tower, coal stockyard,
coal shed, coal water settling pond, transfer house, coal crusher house,
underground reclaim hopper coal conveying gantry. All structures shall be
supported on pre-stress concrete hollow spun piles.

Coal handling facilities including Coal Control Building and Coal Shed shall
be supported on pre-stress concrete hollow spun piles.

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4.4.1.1.16 TREATMENT OF COAL STORAGE AREA

The contract includes for ground treatment/stabilization of the area to be

designated as the coal stockyard. This will be in order to ensure that the
surcharge weight of the coal does not result in slip failure or earth fracture
of the underlying or reclaimed material or of the reclamation embankment.

Preliminary proposals for treatment of the coal stockyard area shall be

submitted in the bid proposal.

4.4.1.1.17 ASH POND & ASH HANDLING FACILITIES AND BOTTOM & FLY ASH SILO

The ash pond shall be used to dispose of the station surplus ash by
products. It is envisaged that the pond will be used for disposal of furnace
bottom ash (FBA) and pulverized fly ash (PFA).

Leachates from ash dispose of in the ash pond must be controlled and
prevented from contaminating to aqueous environment.

The Bidder shall design and construct a line ash–pond/lagoon system

(including creation of bunds) sufficient for handling and disposal of FBA and
PFA ash by – products.

The Bidder shall design and construct a suitable ash pond and associated
waste water treatment system as may be required to meet the discharge
criteria.

To avoid contamination of ash to ground water, HDPE conform to ASTM

D1693, 1004 and 4833 for layer protection shall be provided.

Preliminary design for treatment of the ash yard area including bottom and
fly ash silo shall be submitted in the bid proposal for Owner approval.

4.4.1.1.18 CABLE DUCTS

Cable ducts shall consist of box culverts reinforced concrete structure

completed with drainage system including submerged pump and pump pit
facilities, and supported on pre-stress concrete hollow spun piles (if
necessary, based on soil condition).

4.4.1.1.19 UNDERGROUND CABLE DUCT AND TRENCH

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The underground cable duct shall consist of reinforced concrete around

cable pipes. Concrete of cable duct shall be placed so as not to damage the
pipes and the spaces between each pipe shall be completely filled with
concrete.

The cable trench shall consist of reinforced concrete, covered with

removable trench covers and shall be drained.

Cable duct and cable trench shall be founded on pre-stress concrete hollow
spun piles if necessary.

4.4.1.1.20 SUBSTATION BUILDING OF 150 KV SWITCHYARD

All strain structures towers and equipment support shall be of galvanized

steel material. The structures supporting conductors shall include facilities
for ready access to all insulator sets. These shall be permanently attached
climbing devices with guardrails.

The foundations for the structures shall be either footings of reinforced

concrete slab or reinforced concrete slab supported on pre-stress concrete
hollow spun piles based on the geotechnical condition of the substation site
and shall be approved by the Owner.

4.4.1.1.21 JETTY AND ACCESS TRESTLE STRUCTURES

The Bidder shall provide permanent jetty and access trestle including
associated harbor facilities, for the purpose of unloading coal from barge.
The Bidder shall propose design of jetty and access trestle structure
including plan arrangement and shall include in his bid proposal.

The Bidder shall be responsible to conduct performance test and to get all
necessary permit (operational permit, etc) from appropriate authority.

A permanent Jetty structure shall be provided for unloading coal from barge
of minimum 5.000 DWT either coal handling structure attached to Jetty. The
proposed jetty shall consider space for crane traveling, coal conveyor, cable
duct, vehicle access and piping route, etc.

Permanent Jetty and access trestle structures shall be designed for a 30

years life times. Jetty structure and access trestle shall be reinforced
concrete structure supported on steel piles.

4.4.1.1.22 DREDGING

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The Bidder shall be responsible to conduct dredging in order to provide

permanent jetty and access trestle. The necessity of dredging work shall be
based on Bathymetry data of survey as subject for approval of the Owner.

4.4.1.1.23 AUXILIARY/MISCELLANEOUS BUILDINGS AND STRUCTURE

The other following auxiliary/miscellaneous building and structure shall

include but not limited to:
 BOP plant and facilities
 Emergency diesel generator building
 Water treatment building
 Waste water treatment building
 laboratory
 Acid and alkali storage
 Industrial and portable and fire fighting pump house including foam fire
fighting station
 Air compressor house
 Dry ash air compressor house
 Sand storage and limestone storage
 Auxiliary island electrical building
 Transformer foundation and facilities
 Garage for loader, dozer, service room and staffs room
 Material storage and maintenance building
 Workshop
 Warehouse
 Gate house and elevated gate house (reinforced concrete structure)
 Mosque
The Bidder shall propose overall size room arrangement of mosque
building.
 Plastered finish brick wall shall be used for the siding and an acoustic
suspended ceiling system shall be provided for all areas except for toilet
room, shall used moisture resistant ceiling. An Air Conditioning system
shall be provided.
 Park Shelter
The Bidder shall propose overall size of car park shelter and shall be
design as steel structure founded on pre-stress concrete hollow spun
piles ( if necessary ), floor shall be made of reinforced concrete with
floor hardener.
 Other building and structure as required by Owner.
The foundation of auxiliary/miscellaneous building and structures shall be
either reinforced concrete footing or reinforced concrete slab supporting on
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pre-stress concrete hollow spun piles and shall be approved by the Owner
based on geotechnical condition of the Site.

4.4.1.1.24 SITE DRAINAGE

The Power Station complex shall be provided with an integrated and

comprehensive drains system which minimizes the influence of total site
discharges on the environment and that complies with the local authority’s
requirements.

The drainage material shall be either pre-cast or cast in-situ reinforced

concrete. Drainage crossing to road shall be designed as concrete box/pipe
culvert.

4.4.1.1.25 ROAD WORK

The Bidder shall be responsible to design and construct 8 meter width of

main road and 6 meter secondary and 4 meter width tertiary road,
guardrails, reinforced concrete bridges supported on pre-stress concrete
hollow spun piles, including parking area and also associated road marking
and sign, road lighting. All roads shall be provided with 1.5 meter width of
pedestrian on each side.
All of roads arrangement shall be shown on the Bidder drawing proposal
and subject to Owner approval.

4.4.1.1.26 FENCE WORK

The Bidder shall be responsible to provide perimeter and security fencing

and gates.

Perimeter fencing shall be barbed wire and shall be galvanized steel bar
panel. The height of perimeter fencing shall be 3 m.

The perimeter wall shall have three stands of barbed wire mounted on 45º
extension arms.

Security fencing shall be galvanized steel bar panel. The height of security
fencing shall be 2.1 m.

All of fencing and gates arrangement shall be shown on the Bidder drawing
proposal and subject to Owner approval.

4.4.1.2 SITE DEVELOPMENT

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The Bidder shall be responsible to design and construct all site

development works in the power plant area.

The works shall consist of but not limited to clearing, grubbing, stripping,
excavation of unsuitable material, disposed unused material, backfilling and
compacting under building and heavy structure, soil improvement, river
protection ( PC corrugated sheet piles ) also filling and compacting to grade
level including demolition any substructure founded on the project area.

The Bidder shall provide vertical band shaped drain to accelerate

consolidation time at site caused by piling works.

The Bidder shall describe the material and arrangement of this soil
improvement method in his proposal. All material and arrangement shall be
subject to approval of the Owner.

4.4.1.3 TEMPORARY SITE FACILITIES

The Bidder shall be responsible for providing temporary site construction

facilities i.e. site office and fully furnish facilities including furniture’s and
facilities such as water, electricity, telephone, air conditioning system,
sewage treatment, sewerage, car park shelter for both Owner and Bidder.

4.4.1.4 SITE INVESTIGATION

A limited site geotechnical data is provided by the Owner for reference only
to the Bidder relating to ground conditions and other site specific data are
purely factual descriptions of findings at discrete locations around the
project site. The Owner shall not accept any responsibility for the integrity of
the data nor any interpretation placed upon it. Accordingly the Bidder should
satisfy himself of the ground conditions and other site specific issues in
preparing his bid proposal. Except otherwise noted in the bid document, no
subsequent cost extensions will be entertained.

The Bidder shall undertake site investigations and site survey prior to
design/construction of the civil work at his cost. The Site investigation
required by Bidder and proposed after contract signing will be the Bidder’s
responsibility and no additional cost to the Owner.

Any hazards of constraints to construction likely to be encountered shall be

identified and addressed in the report.

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All geo-technical reports and information shall be submitted to the Owner

prior to design work.

4.4.1.5 EXISTING SERVICES

The Bidder shall satisfy himself of the nature and location of any services
that may affect, or be affected by, the design, construction or operation of
the permanent and temporary works and shall make due allowance of the
protection or diversion of such services required for and during the
construction of the works.

All costs arising out of disruption of existing services by the Bidder shall be
borne by the Bidder.

The Owner accepts no liability for additional costs or delays which may be
incurred due to the discovery, disruption or damage to any existing services
occurring during the construction of the works.

4.4.1.6 GROUND RISK

The Bidder is required to make due allowances for and include in his bid
proposal for ground risk (unforeseen condition) appertaining to existing sub-
surface conditions and those pertaining to the completed (handed over)
site.

4.4.1.7 PROVISION OF INFORMATION

The Bidder shall provide full and detail architect's and structure’s drawings
of all buildings and structures including structure and foundation calculation
to the Owner for approval. The Bidder shall not proceed with working
drawings/construction without such approval from Owner.

4.4.1.8 FIRE, SAFE MEANS OF ESCAPE

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Plant and buildings provided by the Bidder constituting "the Works" shall
comply with the applicable fire authority requirements regarding safe means
of escape in the event of fire or other emergency hazard.

The buildings shall be designed and constructed so that there are safe
means of escape from fire to a place of safety at all the time.

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