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SPECIFICATION FOR PIPEWORKS

SPECIFICATION SAJH WS / PW / 001 (Rev.1.0 / 06.2007)

QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BHD.

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

CONTENTS
PAGE NO. 1.0 GENERAL 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 Order for Pipes and Specials Approvals Hauling and Handling Records of Pipes Supplied Prospecting Pipe Alignment and Cover Pipelaying in Grounds with High Water Table Dangers of Flotation Temporary Cessation of Trench Excavation Examination of Pipes and Fittings Laying Pipes and Fittings Specials Testing Pipelines 1.13.1 General 1 1 1 1 2 2 3 4 4 4 4 5 5 5 5

2.0

MILD STEEL PIPES AND SPECIALS 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 2.26 2.27 2.28 2.29 2.30 General Scope Definition Standards and Codes of Practice Submissions Pipes and Specials Steel Pipes Material, Workmanship and Welding Standards Pipe Ends Bends, Tees, Tapers, Etc. Flanged Joints Mechanical Couplings, Flange Adaptors and Expansion Joints Pipes for Closing Lengths Collars Retaining Rings Physical Testing Works Hydraulic Testing Ring Girders Protection Cleaning and Priming External Coating Wrapping Inspection of External Pipe Coating Painting Unwrapped Pipes and Specials Spun Concrete Lining at Factory Internal Protection at Pipe Ends Pipework for Laying above Ground End Protection Examination of Steel Pipes Low Friction Coating 7 7 7 7 8 9 9 11 12 13 13 14 15 15 15 15 15 16 16 16 16 17 17 17 17 19 19 20 20 20

SPECIFICATION FOR PIPEWORKS i SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

PAGE NO. 2.31 2.32 2.33 2.34 2.35 2.36 2.37 2.38 2.39 2.40 2.41 2.42 2.43 2.44 2.45 3.0 Handling Repair of Lining and Sheathing of MS Pipes Laying MS Pipe Welding MS Pipe Making Welded MS Pipe Joints Air Testing of Welded MS Pipe Joints Completion of Sheathing at Welded MS Pipe Joints Completion of Internal Lining at Welded MS Pipe Joints Testing MS Pipeline 2.39.1 Test Pressure 2.39.2 Leakage Testing Protection in Transit Notice of Deliveries Pipe Dumps and Storage Yards Inspection Marking of Pipes and Specials Measurement of Steel Pipes and Specials 20 21 22 23 23 24 24 25 25 25 25 25 26 26 26 27 27

DUCTILE IRON PIPES AND FITTINGS 3.1 3.2 3.3 3.4 3.5 3.6 3.7 General Compliance with Standards Process of Manufacture Thickness and Diameters Length of Straight Pipes Tolerance on Dimensions External Zinc Coating 3.7.1 General 3.7.2 Zinc Coating 3.7.3 Coating Characteristics 3.7.4 Verification Process 3.7.5 Repairs 3.7.6 Finishing Layer External Coating of Pipes and Fittings Internal Lining of Pipes and Fittings Flexible Joints Flanged Joints Factory Hydrostatic Test Connection to Pipes of Different Type Cutting of Pipes Packing Polyethylene Sheathing Handling Laying DI Pipes Protection Against Damage in Transit Jointing Ductile Iron Pipe Testing DI Pipelines 3.21.1 Test Pressure 3.21.2 Leakage Testing Marking of Pipes and Fittings 28 28 28 28 28 29 29 29 29 30 30 30 31 31 31 32 32 33 34 34 34 34 35 35 36 36 39 39 39 39

3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22

SPECIFICATION FOR PIPEWORKS ii SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

12.2 Handling and Transportation 4.10.9 5.14 4. BHD.12 4.3 Factory Hydrostatic Test on uPVC Pipes 5.11.7 5.2 5.14 5.10.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .4 Precautions Electrofusion Couplers and Tapping Tees PE Compression Fittings Examination of Pipes and Fittings Laying PE Pipes Welding PE Pipes Payment for PE Pipe Joints Testing PE Pipelines Markings 40 40 40 41 41 41 42 43 43 44 44 44 45 45 45 47 47 47 48 52 52 53 4.1.12.5 4.16 5.11.11.1 General 4.11 General Materials used in Manufacture Colour Classification Thickness and Diameter Tolerance and Dimensions Length Appearance Joints Pipe Seal Test Requirements 5.10 5.8 5.13 5. 4.1 Heat Reversion Tests on uPVC Pipes 5.4 5.12 5.4 Sampling Routine Tests 5.7 4.3 4.17 SPECIFICATION FOR PIPEWORKS iii SAJH WS/PW/001 (Rev.9 4.6 4.10. Transportation and Storage 4.15 4.0/06.12.18 5.6 5.15 5.1 5.12.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.2 Resistance to Acetone Test on uPVC Pipes 5.13 4.8 4.1 4.3 5.3 Type Tests 5.10.4 4.2 4.17 4.3 Storage 4.2 Routine Tests 5.0 uPVC PIPES AND FITTINGS 5.11 4.16 4.4 Impact Strength Test at 20 degrees C on uPVC Pipes Compliance Method of Rejection Marking of Pipes and Fittings Test Certificates Delivery 54 54 54 55 55 55 57 57 57 58 58 58 58 58 59 60 60 60 60 60 61 61 61 62 62 5.11.5 5.0 POLYETHYLENE (PE) PIPES AND FITTINGS 4.1 Obligations 5.10 General Scope Interpretation Manufacturing Process Polyethylene Materials Dimensions Flanged Connections Works Tests Packing Handling. PAGE NO.

1 8.11 8.14 6.12 Definitions Levels to be Recorded Explosives and Blasting Disposal of Materials Excess Excavation to be Made Good Site Clearance Trees Stumps Measurement of Site Clearance Stripping Topsoil General Excavation Trench Excavation 78 78 78 79 80 80 80 80 80 80 81 81 SPECIFICATION FOR PIPEWORKS iv SAJH WS/PW/001 (Rev.9 8.20 7.7 8.1 6.9 7.10 7.2 8.7 7.2 6.13 6.4 8.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .3 7.1.5 6.10 6.8 6. Cast Iron.12 6.2 7.0 EARTHWORKS 8. PAGE NO.11 6. 6.4 6. Steel.1 7. etc.0 Closing Lengths Pipe Cutting Welding Personnel Making Joints with Mechanical Couplings and Flange Adaptors Making Flanged Joints Measurement of DI.0 PIPELAYING 6. PE Pipes and Fittings Concrete Protection to Pipes Thrust and Anchor Blocks Valve Chambers Crossing Over Streams.3 8. Fields.8 7.5 7.10 8.4 7.18 6. BHD.6 6.6 8.19 6.15 6.5 8.6 7. Culvert and Rivers Payment for Pressure Testing Pipelines and Specials Sterilising and Flushing Pipelines Payment for Sterilising and Flushing Pipelines Payment for Road Restoration Clearing Up Indicator Posts Painting Pipework and Valves in Chambers Painting Pipework Above Ground Disposal of Surplus Goods Payment of Fees to Authorities 63 63 63 64 64 65 65 65 66 66 66 67 67 67 68 68 68 68 69 69 PIPE JACKING 7.3 6.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.11 General Tender Submission Surface Reinstatement in Road Verges. Prospecting Performance Requirements Approval of Owner Jacking Operation Safety Design of the Jacking Pipes Laying and Connections of Pipeline in Jacked Reinforced Concrete Pipes Sleeve Alternative Method of Pipe Jacking 70 70 71 72 72 72 73 74 75 76 77 8.9 6.7 6.8 8.0/06.16 6.17 6.

2.37 8.3 Curing.16 8. PAGE NO. Measurement of General Excavation Measurement of Trench Excavation Measurement of Filling for Embankment Payment for Trench Excavation and Restoration Top Soiling Turfing Measurement of Top Soiling and Turfing Payment for Turfing Payment of Fees to Authorities 82 83 83 83 84 84 84 85 85 87 87 87 88 88 89 89 90 90 91 92 92 92 93 95 95 95 95 96 96 96 PILING 9.2.14 8. 8. etc.2.1.19 8.38 8.5 Pitching and Driving 98 98 98 99 99 100 101 101 101 102 102 102 102 103 103 103 9.1.1. Road Shoulders and Footpaths Trench Excavation in Fields.39 8.1.17 8.1.9 Piling Records Precast Reinforced Concrete Piles 9.22 8.20 8.34 8.1 General 9.2 Pile Casting 9.33 8. Fields.2 Setting Out 9. Works in Roads and Road Reserves Surface Reinstatement in Roads and Footpaths Payment for Road Restoration Other Structures in the Pipeline Land Drains Care of Existing Services Hedges.5 Pile driving 9.0 Trench Excavation in Roads.23 8. Stripping and Stacking 9.30 8. etc.1.31 8. etc.2.32 8.4 Programme 9.3 Piling Equipment 9.1.8 Piling Personnel 9.2 SPECIFICATION FOR PIPEWORKS v SAJH WS/PW/001 (Rev.24 8. Fences and Walls Crossing Watercourses.35 8.18 8.29 8.7 Load Tests 9.2.41 8.1.0/06.26 8.4 Handling Storage and Transport of Piles 9.36 8.1 General 9.13 8.1 Ground Conditions 9.27 8. Rock and Other Materials in Excavations Supporting Excavation Trimming Excavations Inspection of Excavation Filling to Embankments and Backfilling to General Excavation Trenches Not to be Left Open Refilling Trench Excavation Soft Refill Material – Special Measures Temporary Spoil Tips on the Site Treatment of Material from Excavation Surface Reinstatement in Road Verges.28 8.1.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .6 Preliminary and Working Test Piles 9.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.42 9.25 8.40 8. BHD.15 8.21 8.

3.17 10.4.4.6 10.7 10.8 10.10 10.16 10.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .5 Procedure of Testing 9.6 Records of Test 9.13 10.5 10.1 General Cutback Bitumen Bitumen Emulsion Storage.6 9.2.4.3.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.5 Load Tests Pile Testing 9.1 10.8 9.2. Binder and Composition Mixing Transport Sampling and Testing Bitumen Macadam Layer Thickness and Tolerance 112 112 112 113 113 114 114 115 115 117 117 118 118 118 118 118 119 119 119 120 120 120 122 123 123 123 SPECIFICATION FOR PIPEWORKS vi SAJH WS/PW/001 (Rev. PAGE NO.2 Test Load and Kentledge 9.14 10.26 Preparation of Formation to Receive Road Earth Subgrade Subgrade of Rock Pavement Thickness Sub-base Materials Alternative Sub-base Compaction of Sub-base Road-base Materials Laying and Compaction of Roadbase Finished Surface Definition and Requirements Associated with Table 10.7 Interpretation of Test Results Measurement of Piles and Piling 9.3 Settlement Measurement 9.24 10.4 Equipment and Personnel for Load Test 9.19 10.18 10.2.3 Delivery and Stacking of Piles 9.1 General 9.3.0 ROADWORKS 10.1.7 9.21 10.22 10.2.20 10.11 10.4.4 9.4 10.25 10.3 10.3.2 Treatment of Piles 9.2 10.4.4 Pile Driving and Jointing 9. Handling and Heating-of Bitumen Depot Tray Test Material Surface Preparation Application of Prime Coat Spraying Procedure Protection of Prime Coat Aggregate.3. 9.10 9.5 10.12 10.0/06.2.23 10.4.3 Plant for Pile Driving Measuring Pile Set Extending Piles Preparation of Pile Heads Load Tests 104 104 105 105 105 106 106 106 106 107 107 108 108 108 108 109 109 110 110 110 Treated Timber Piles 9.9 9.9 10.1 General 9. BHD.4.15 10.

6 12.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.40.9 12.5 12.0/06.28 10.38 10.1 11.10 Structural Steel Work Bolts and Nuts Steel Chequered Plate Handrailing Ladder Step Irons Fencing Aluminium Structures and Sections Galvanised Metals Dissimilar Metals 142 142 142 143 143 143 143 144 144 145 SPECIFICATION FOR PIPEWORKS vii SAJH WS/PW/001 (Rev.8 11.1 12.30 10.3 Spreading and Laying the Laterite Pavement 10.40.1 Geotextile Filter Membrane Storage of Geotextile Filter Membrane Laying and Spreading Over the Geotextile Filter Membrane Laterite Pavement 10.11 11.27 10.10 11.1.36 10.40.12 11. BHD.8 12.3 11.0 BRICKLAYER 11.34 10.15 Bricks Cement Sand for Mortar Water Mortar Mixing Mortar Brick Laying Half-Brick Walls Facing Brickwork Damp Proof Course Lintels Building In Scaffolding Valve Chambers and Manholes Payment for Brickwork 138 138 138 139 139 139 139 140 140 140 140 140 141 141 141 12.29 10. PAGE NO.2 12.5 11.2 Pavement Material 10.2 11.0 STEEL AND METAL WORKS 12.35 10.4 12.4 Compaction 10.33 10.31 10.1 Preparation of Formation to Receive Road Pavement 10.9 11.7 11.14 11.3 12.40.40 Laying of Bitumen Macadam Bituminous Tack Coat Joints Laying Around Manhole Covers Compaction Road Shoulders Shoulder Base Selected Fill Grading Lateral Shoulder Sub-drains Refilling of Excavated Pipe Trenches for Roadways Notes Relating to Table 10. 10.32 10.37 10.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .7 12.4 11.40.13 11.39 10.6 11.5 Rectification of Surface 124 124 124 125 125 125 126 126 126 126 128 129 129 135 135 135 136 136 137 11.

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

PAGE NO. 12.11 Rain Water Pipes 12.12 Open Mesh Flooring 12.13 Manhole Covers, Surface Boxes, etc. 145 145 145

SPECIFICATION FOR PIPEWORKS viii SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

SECTION 1.0 GENERAL

QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BHD.

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

1.0

GENERAL The Contractor shall supply all the pipes and specials required unless otherwise specified and construct and complete the pipeline and all associated works as specified and included herein under the Contract. All welding materials, welding equipment, butt and electro fusion equipments, clamps, steel moulds, priming solution, bitumen compound and approved bitumen wrapping tapes or similar material for completing the pipelaying works shall be deemed to be included in the rates of pipelaying unless specific items are provided in the Bill of Quantities.

1.1

Order for Pipes and Specials The quantities of the items in the Bill of Quantities are only approximate and shall be ascertained by the Contractor after the pipeline profiles are determined by a survey carried out in accordance with Clause 8.2 of earthworks. Where a pipe special is to be used for connection to existing works, the Contractor shall purchase the special after he has ascertained the existing pipe diameter, flange and other details at the exact location where it is to be laid. Excess order of pipes and fittings shall be the responsibility of the Contractor and shall be at his own cost.

1.2

Approvals All pipes/valves/joints/fittings/couplings/adaptors shall undergo for SAJH approval procedure by the QA Department and shall have either ISO Quality Standards Approval, SIRIM/IKRAM or other recognized standard approving authority.

1.3

Hauling and Handling Great care shall be exercised to ensure that the pipes and specials are not subject to any kind of shock or sudden load during hauling and handling. Attention is drawn to the Contractor that thin wall pipes, defined as pipes with a diameter/plate thickness ratio greater than 125, shall be so handled, stored and transported as to prevent distortion or damage to the pipes and shall not be moved in any manner involving rotation of the pipe about the longitudinal pipe axis. Thin wall pipes during delivery and when in transit around the Site shall be supported on three rubber covered saddles shaped to give at least 90o circumferential support and shall be firmly held in position at each saddles by straps tightened by turnbuckles in such a manner that the external coating is not damaged. One saddle shall be at the centre of the pipe length and the other two shall each be positioned at a distance one-fifth of the pipe length from each end of the pipe.

1 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

O. and shall have them available for inspection by the S. shall instruct further prospecting if he is not satisfied with the sufficiency of the Contractor's prospecting. The S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . taken over and transported to site (ii) Declared to be defective (iii) Used in the Works (iv) Cut. BHD.5 Prospecting The Contractor shall prospect for the position of buried or otherwise hidden obstructions such as existing services. The Contractor shall be deemed to have allowed the cost of providing the above necessary measures in the Contract Rates for hauling and laying. 1. broken or removed from Site The Contractor shall keep such records continuously up to date. drains.4 Records of Pipes Supplied The Contractor shall keep full and detailed records including item numbers. cables.0/06. The pipes shall be lifted by two reinforced canvas slings at least 300 mm wide suspended from a lifting beam so that the slings are positioned approximately one-fifth of the pipe length from each end of the pipe. size of each. etc. Thin wall pipes in temporary storage or strung out along the pipeline reservoir routes shall be supported on hessian bags filled with fine sawdust straw or similar and shaped so as to give continuous support under at least 40-50 o of the circumference. The positions of supports shall be the same as that for pipes during transit. Any damage to or loss of materials shall be made good. On no account shall the pipes and specials be dropped or let fall onto the ground and under no circumstances shall the pipes or pipe specials be lifted by means of hooks to the ends of pipes and pipe specials. drains. pipes. and these shall not be removed until reinstatements has been completed. The underside of the pipes shall be kept clear of the ground by at least 300 mm. Approved marker posts shall be erected to mark the position of all located services.O. etc. in places where they are known or thought to be and elsewhere and these shall be backfilled with approved materials immediately and in any case not exceeding 24 hours and subsequently reinstated. Trial holes and exploration trenches to ascertain the exact positions of these shall be sunk.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. well ahead of pipelaying and excavation. by the Contractor at his own expense and if approved by the S.O. 1. All pipes and pipe specials shall be lifted by means of reinforced canvas slings. damaged materials shall be returned to the manufacturer for repair as directed by the S. or the damaged or lost materials replaced. culverts.1. and location of all pipes and specials which are: (i) Inspected. at any reasonable time. 2 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O.

BHD. Before commencing excavation the route of the pipeline shall be pegged accurately. drains. Attention is drawn to Clauses concerning the responsibility of the Contractor for the security of existing services.0/06.O. Pipes shall be laid in straight lines on plan but curves of long radius shall be obtained by deflecting MS pipes up to a maximum of 5° for spherical type and 2° for hemispherical type at welded slip joints and using short pipe lengths if necessary. to the approval of the S. Pipes shall be laid to a minimum gradient of 1 on 500 unless otherwise ordered by the S.1.300 Allowable angle of deflection 5º 4º Generally. where the gradient of a pipeline is 1 on 20 or steeper. For pipework of diameter 1000 mm and above. for pipework of diameter below 1000 mm. On these rails shall be marked the centre line and the level to which the pipe is to be laid. pipes are as follows: Nominal Diameter (mm) 80 . Allowable angles of deflection for D.200 250 . Where necessary the Contractor shall make arrangements prior to trench excavation proper for the temporary or permanent support or diversion of services. and the authority concerned. The Contractor shall be deemed to have allowed for the unavoidable delay of the Works due to any obstruction he may encounter with the existing services and no claim for any extra costs on account of this will be allowed.I. pipes shall be laid on an ascending gradient starting from washout (low point) and finishing at the air valve (high point). 3 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. and at as many intermediate points not more than 35 metre apart as may be necessary. For PE pipes the limitation for deflection does not apply.O. the minimum cover to the top of pipes shall be 1000 mm and at road crossings the minimum cover shall be 1500 mm unless otherwise specified. etc. Unless otherwise approved by the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .6 Pipe Alignment and Cover The routes of the pipelines shall be as shown on the Drawings or as directed by the S. Strong sight rails shall be fixed and maintained at each change of direction and gradient.O.O. The full cost of prospecting shall be deemed to be included in the Contract Rates for pilot excavation. 1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the minimum cover to the top of pipes shall be 1500 mm unless otherwise shown on the Drawing.

O. Any damage caused by flotation of pipes. 1. the Contractor shall make all necessary provision to avoid the flotation of any pipe during the construction stage. specials or fittings in unrefilled trenches shall be made good to the satisfaction of the S.7 Pipelaying in Grounds with High Water Table The Contractor shall note that some parts of the pipelines will be laid in grounds with high water table.O. especially in areas adjacent to the streams river crossings and ponds in the vicinity. who will give instructions regarding remedial work or otherwise.O. The Contractor shall.10 Examination of Pipes and Fittings All pipes and specials shall be thoroughly cleaned and carefully examined for cracks and flaws both internally and externally immediately prior to laying. jointed and approved by the S. there is undue delay in :(i) (ii) (iii) (iv) (v) (vi) Refilling pipe trenches Jointing of PE pipes above ground to form string ready for laying.8 Dangers of Flotation Although flotation of pipes in completely refilled trenches or of the completed works will not occur. refill and compact excavated material to at least two thirds of the length of the pipe trench leaving only sufficient space unrefilled to allow for the completion of the external joint or fittings.1. at the Contractor's own expense. Notwithstanding this.O. 1. Materials found to be damaged in any way shall be shown to the S.O. Laying and testing the pipelines Removing surplus material General tidying up of areas where pipes have been laid Partial restoration or maintenance of surface the S. the Contractor's attention is particularly drawn to the danger of flotation of pipes laid in trenches left unrefilled and allowed to be flooded with water in the partially completed works.0/06. immediately after pipes have been laid. 1. BHD..9 Temporary Cessation of Trench Excavation If in the opinion of the S. may order that no further trench excavation shall be opened until the outstanding work has been carried out to his satisfaction and the Contractor shall have no ground for a claim against the Employer on this account.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 4 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. 1. All costs for dewatering and keeping all the excavations and trenches dry for the whole pipelaying work and in a safe manner during construction shall be deemed to be included in the Contract Rates except where specific provision is made in the Bill of Quantities.

The fill and test position shall be located at the lowest point of the pipeline profile to encourage the expulsion of air as the pipe is being filled.0/06. to ensure that the line is cleaned from stones. care shall be taken to ensure that all weight. All valves shall be checked before the test to ensure that they are in working order.O. plastic paper or any other matter that may have entered after laying of pipework. 5 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Testing shall not be carried out until the backfilling of the pipe trenches except at the joints.12 Specials The approximate positions of all specials are shown on the Drawings. have been completed.13 1. Prior to filling the line with clean water for water testing. 1.O.O.1 Testing Pipelines General After a length of the pipeline has been completed it shall be tested as a whole against stop ends. BHD. The water for filling and testing the pipeline shall be obtained from an approved source. Before any length of pipeline is subjected to test pressure. contamination and pollution. Temporary marker posts shall be installed immediately after testing at all junctions between tested lengths. regulate the feed slowly to allow minimum or bubbles into the pipeline. 1. the line shall be thoroughly inspected jointly with the S. Testing shall be carried out over lengths of approximately (2) two kilometre where possible or the full replacement length between washout or overcrossings but not against adjacent valves. dirt. When using high pressure pumps for water feeding. The Contractor shall make all arrangements necessary for conveying the water to the point of filling.11 Laying Pipes and Fittings All pipes and fittings shall be laid to the lines and levels shown on the Drawings or as otherwise directed by the S. Backfilling at flexible joints shall be left uncompleted to facilitate inspection of these joints during testing. The stop ends shall be supplied and fixed by the Contractor and shall be properly strutted to ensure that no movement can take place and they shall be of sufficient strength to withstand the full test pressure which is to be applied.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The test ends shall be tapped for suitable size test connection.13.1. All air-valve positions and the end of the test section shall be vented during the filling of water to bleed out all trapped air which may affect the test. debris. thrust and anchor blocks intended to prevent vertical and lateral displacement of pipes or specials have been properly completed. It shall be free from silt. The exact positions shall be determined on Site by the Contractor to the approval of the S. 1.

QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. pumps. The performance of washout pipework shall. The flowmeter shall have an accuracy of not more than 2% at transition flowrate of the meter as specified in BS5728.1 bar.1.0/06. has issued a certificate to the Contractor to this effect. The Contractor shall supply all necessary apparatus including pipework. A pressure test on washout pipework shall not be required. will attend all tests and all apparatus and methods shall be to his approval.O. may direct.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . flowmeters and pressure charts/recorders and carry out all work necessary to test the pipeline. 6 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Each scour valve in turn shall be opened fully under the normal working head in the pipeline for sufficient time to allow proper flushing of the pipeline and to check the watertightness of the washout pipework.O. The S. Substantial completion will not be certified before the mains have been successfully water tested. be observed during flushing of the pipelines after testing. The flowmeter shall have an integral totaliser display built-in. BHD. the requirements of permissible loss are complied with.O. The Contractor shall carry out any necessary remedial work to pipework as directed by the S. The flowmeter to measure the quantity of flow pumped shall be suitable for the flowrate of the pumps supplied by the Contractor. supply necessary materials and make necessary repairs or remake any joints. and restore the ground at no extra cost to the Contract until. The Contractor shall take all necessary steps to locate any leakage. No length of pipeline shall be deemed to have passed its pressure test until the S. The gauges and recorders are to be checked against a guaranteed standard unit before use and at other times as the S.1 bar. The pressure recorders shall have the ability to record pressures down to 0. on retest. All water used for testing purposes shall be recorded.O. however. Pressure gauges are to have a dial at least 200 mm in diameter and shall have unit graduations on the gauges of not more than 0.

.SECTION 2. BHD.0 – MILD STEEL PIPES AND SPECIALS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

1 MILD STEEL PIPES AND SPECIALS General All pipes. mechanical joints.4 Standards and Codes of Practice The following Standards and Codes of Practice are referred to in this section of the Specification. tapers. steel and other ferrous metals Specification for ordinary and rapid hardening Portland cement Specification for carbon steel pipes and tubes with specified room temperature properties for pressure purposes Hot dip galvanised coatings on iron and steel articles Steel pipes. gas and sewage 7 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. 2.3 Definition The following terms shall have the meanings hereby assigned to them except where the context clearly renders these meanings inapplicable. expansion joints. whether whole or in cut lengths. collars. fittings and specials for water.1.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 2.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. flange adapters. "Pipes" means straight pipes. 2. The Standards or Codes shall be the latest edition current at the time of its preparation unless otherwise specified for particular application:API 5L API 5LS API 1104 BS Handbook 19 BS 12 BS 3601 BS 729 BS 534 : : : : : : : : Line pipe Spiral-weld line pipe Standard for welding pipe lines and related facilities Methods for sampling and analyses of iron. ring girders and similar accessories. specials and fittings must be from SAJH approved sources and be to SAJH specifications (SAJH PS/MS/001). bends. 2. BHD.0 2.2 Scope This section of the Specification covers the requirements for the manufacture and testing of welded steel pipes together with specials complete with internal and external protection systems. "Pipe specials or specials" means tees. blank flanges.0/06.

BS 903 BS 1154 BS 2494 : : : Methods of testing vulcanised rubber Specification for natural rubber compounds (high quality) Materials for elastomeric joint rings for pipework and pipeline Sprayed metal coatings Hot applied bitumen based coatings for ferrous products Surface finish of blast-cleaned steel for painting Weldable structural steels Flanges and bolting for pipes. 8 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. iii) For welding procedure : Details of plant. ii) For joints : Drawings for spigot and socket joints showing allowable tolerances and arrangements to permit air testing of completed joints on Site.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . number of runs and current strength for each type of weld. methods.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. valves and fittings Part I: Ferrous Welding of steel pipelines on land and offshore. materials.5 Submissions The Contractor shall provide drawings. Process of arc welding of carbon and carbon manganese steels. Jointing materials and compounds Unfired fusion welded pressure vessels Steel pipe design and installation BS 2569 BS 4147 BS 4232 BS 4360:1986 BS 4504 BS 4515 BS 5135 BS 5292 BS 5500 AWWA Mll : : : : : : : : : : 2. BHD.0/06.1. calculations and data in respect of the following:i) For pipes and specials : Drawings with descriptions to show the method of forming pipes and fittings in standard lengths from steel sheets or strip. make and size of electrodes.

1.0/06. The pipes shall be formed by the automatic submerged arc process.e. Material for pipes shall be made from carbon steel plate to Grade 43A of BS 4360:1986 or better with a minimum lower yield stress of 275 N/mm2 supplied in plate or strip form as of appropriate for the method of pipe manufacture. except where stated otherwise hereunder. iv) For internal lining: Full details of method of lining and curing including details and sieve analyses of materials to be used and type of cement. 19. the relevant standard will then apply i. BS 534 The Contractor shall provide a ladle analysis of the steel used for the pipes in accordance with Clause 7. the methods of chemical analysis shall be in accordance with BS Handbook No. BHD. Check analyses of the finished pipe shall be taken in accordance with Clause 7.6 Pipes and Specials All pipes and specials shall be provided by the Contractor and delivered to the Site. 2. in accordance with BS 534. 9 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1 of BS 4360:1986. v) For external coating: Full details of coating process to be used.7 Steel Pipes Steel pipes shall be manufactured. including details of the bitumen and the inner and outer wrappings or equivalent subject to the approval of the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . In case of dispute. with either a longitudinal seam or a spiral seam at the option of the Contractor. With the method of manufacture decided upon.2 of BS 4360:1986.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 2. Each item supplied shall be suitably marked to permit identification with items in the Bill of Quantities.

2 6 3 6.1 244.3 193.9 355.8 25 6 307 1600 10.1 150 3.0 10 4.5 26.5 13 6 39.5 31.1 19 6 177 1200 8.0 13 6 62.3 19 6 102 700 6.6 6 3 12.0 10 4.3 19 6 117 800 7.0 10 4.1.3 13 6 85.0 19 6 239 1400 8.2 225 4.1 19 6 141 850 7.7 200 4. Unless otherwise specified.1 19 6 159 1000 7.0 25 6 493 2000 12. thickness of the steel pipe shells and the finished internal diameters of the pipes shall be as shown in the following table :Outside Diameter (O.O.7 250 4.2 25 6 778 The above finished minimum steel shell thickness shall not be to any negative tolerance for acceptance purpose.D) (mm) 88.4 457 508 559 610 660 711 762 813 864 914 1016 1219 1422 1626 1829 2032 2235 * Mass per length (plain end) 80.9 114.9 600 6.0 13 6 55. BHD.7 500 5.7 168.0 10 4.83 125 3. Nominal Diameter (ND) (mm) Minimum Nominal Thickness (mm) Concrete Lining Thickness (mm) Bitumen Enamel Wrapping (mm) Hydraulic Test Pressure (Steel430) 70 70 70 70 70 70 70 64 54 56 49 48 43 50 45 42 39 36 38 36 34 31 29 27 27 26 27 28 subject The thickness of pipes used for branch pipework off the main pipelines or for use in forming specials shall be the greatest of the following:(a) (b) The thickness necessary to provide the same outside diameter to wall thickness ratio specified for straight pipes. standard length straight pipes shall be manufactured with not more than three circumferential joints and with an effective length as shown in the table below:- 10 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.5 23.6 406.3 139.3 13 6 93.0 400 4. Unless otherwise approved by the S.0 25 6 399 1800 11.5 300 4.0/06.3 19 6 109 750 6.5 18. The thickness determined to be necessary in the design of specials as shown on the Drawings.5 273 323.6 175 4.0 550 6.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .5 13 6 44.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.7 219.1 19 6 150 900 7.0 3.6 350 4.5 21.0 10 4.9 650 6.6 6 3 9.76 100 3.6 6 3 14..5 25 6 623 2200 14.6 450 5.

checking of thickness and visual inspection of edges for lamination. If defects in welds are found in a length of pipe or specials.O. The cost of such radiographs of repaired welds shall be included in the Contract Rates and shall not form part of the 3% of all welded length specified in the first paragraph of this Clause.O. lack of complete penetration. 11 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. All standard and half length pipes shall have ends formed as specified below for joints capable of angular rotation. manufacturer. the welds of the pipes and specials immediately before and after the defective pipe or specials in the production line shall be radiographed until the S.5 mm in depth. Truly circular standard straight pipes required for cutting purposes shall be truly circular throughout the length.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Lengths of pipe containing defects in welds after repair will be liable to be rejected. is satisfied that all the welds are considered satisfactory. Finished Internal Diameter (mm) 450 and above Below 450 As per SAJH PS/MS/001 Standard Length (m) 9 6 The allowable tolerance on standard length pipes shall be + 150 mm. In addition a number of straight pipes of half the standard length pipes and truly circular standard straight pipes shall be supplied. All pipes whether manufactured with a longitudinal or spiral seam shall be subjected to non-destructive testing of seam welds and skelp. As a control on weld quality the Contractor shall be required to take and submit radiographs for 3% of all welded length.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . BHD. and undercutting or reduction in pipe wall thickness adjacent to a weld exceeding 0. Weld defects shall include cracks. This shall include determination of country of origin. will either reject the length of pipe containing such defects or will permit the Contractor to carry out repairs and to submit radiographs of such repairs for clearance. Workmanship and Welding Standards Material inspection before rolling shall be carried out to check against Mill Certificates submitted for conformity with the BS 4360. lack of complete fusion. 2. Slag inclusions and gas pockets or voids considered to be minor imperfections may be accepted if the maximum size and distributions does not exceed the limits.1. physical inspection. Where radiographic examination reveals defects in the welds the S. The acceptance of these radiographs shall be in accordance with BS 534 or equivalent as directed by the S.0/06.8 Material.

The joint design shall provide for the contact surface of the spigot end and the sleeve end to be formed to the same spherical radius which shall be more than 50% of the outside diameter of the barrel of the pipe for the spherical type and shall not be less than 50% of the outside diameter of the barrel of the pipe for the hemispherical type. Spigot and socket joints shall be of the spherical or hemispherical sleeve type with a minimum penetration of the formed ends. the angular deflections shall be up to 2 degrees. They shall be of not less than 6 mm diameter and shall be provided with matching plugs to facilitate the air pressure testing of field welds.3 of Std 5L or Table 6. 2. The joint engagement tolerance in any position shall not exceed an average of 1.60 mm with maximum isolated gaps of 2. 12 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. All sockets shall have two tapped holes spaced at 90 degrees apart on the circumference. mechanical couplings or flange adaptors.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The external surface of the plain ended pipes shall be similarly prepared.0/06. The minimum penetration of the spigot into the socket shall not be less than four times the pipe thickness and this overlap shall be obtained at the maximum deflection of 5 or 2 degrees excluding pipe lining.00 mm adjacent to the weld seams.1. BHD.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.2 of Std 5LS. These tapped holes shall be located within the end 30 mm of the sockets and shall be cleared of welding runs. Ends prepared for butt welding shall be subject to manufacturing tolerances in accordance with Table 6. At zero deflection the minimum overlap shall be the minimum penetration as above increased by such allowance as is necessary to ensure contact between the spigot and socket over the specified maximum amount of joint movement. Plain ends for use with welded collars. The spigot and socket joints for the spherical type shall be designed to take angular deflections of up to 5 degrees from the axial to accommodate changes of pipe gradient and/or direction at individual joints. For hemispherical type. The internal surface of the socket and the external surface of the spigot shall be ground smooth along the shop fusion welds for a distance of 150 mm from pipe ends measured along the pipe axis. Pipe ends of the spherical or hemispherical type shall be formed by hydraulic pressing using a full circle die or expanding former capable of forming ends consistently to a constant spherical contact surface throughout the pipe production run.9 Pipe Ends Ends of pipes to be jointed shall generally be as follows :(a) (b) Spigots and sockets for jointing in trench or above ground.

They shall be of the raised face type and shall be truly faced over their whole width.10 Bends. Each bolt shall be supplied and installed with a nut and two washers and each bolt shall be of sufficient length to show two threads past the nut when so installed. truly in line end to end with the longitudinal axis. All flanges shall be adequate to withstand test pressures for the fittings to which they are attached and shall be in accordance with BS 4504. Tapers. bolts. The finish on flange joint surfaces shall be in accordance with Clause 4. washers and joint gaskets shall be supplied by the Contractor. The coating and lining on the straight pipes shall be cut back from the ends to be welded or cut for a sufficient distance to ensure that no material which is intended to remain part of the coating/lining is damaged or affected by the welding or cutting process. tees.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. welded to the pipe by the electric arc process or other approved method. The ends of plain ended specials shall be truly circular and shall conform to the tolerances required for the fitting of mechanical couplings and flange adaptors. Fillet welds shall be subjected to air tests where appropriate and/or magnetic particle testing. Lifting eyes or handles and air release cocks shall be provided as necessary. shall be formed from completely lined pipes as specified by suitable insertion of rubber spacers during lining operation. Tees. Joint gaskets shall be contained within the bolt pitch circle and shall be made from 4.5 mm thick rubber to BS 1154 Class Y3 reinforced with two layers of fabric in accordance with BS 5292. Compensation plates and gusset plates shall be in accordance with BS 5500. 13 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The outside diameter of specials shall conform to the outside diameters of the standard straight pipes.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Plain ends for use with mechanical joints or flange adaptor joints shall be truly circular with a diameter tolerance of + 1 mm over a distance of 225 mm from the pipe ends. Bolt holes shall be drilled off centre lines. 2.11 Flanged Joints All flanges shall be of steel. etc. They shall conform in all respects with the requirements of BS 4504 unless otherwise specified. Special items such as bends. Test certificates for the flange material shall be supplied. Etc.0/06.4 of BS 4504. tapers. BHD. Blank flanges shall be designed and supplied by the Contractor for an end loading equivalent to the rating pressure of the flange. All flanges shall be rated as 16 bar and confirm to table 11 of BS 4504 unless otherwise stated. Welding shall be of a standard equal to that of straight pipes and each butt weld shall be subjected to a 100% radiographs test. All materials required for use in the making of flanged joints including nuts. Pipe specials shall be designed to withstand the full specified factory test pressures. 2.1.

All necessary couplers. The central collar shall be at least 1. nut and washer shall be hot-dip galvanised in accordance with BS 729. 14 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . All bolts.8 mm and an angular deflection of not less than one and a half degrees. All welding protrusion shall be machined finished.1. BHD. Flange adaptors 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 4. nuts. The pressure rating shall be clearly stamped on all couplings and adaptors. They shall be supplied complete with all accessories. bolts and washers. 2. The enamel shall be taint free. 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.12 Mechanical Couplings. etc. Mechanical couplings and flange adaptors shall be hydraulic tested at the place of manufacture one in every five for each size of coupling and adaptor. flange adaptor 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. All flanges shall be drilled in accordance with BS 4504 and details derived from flange design computation based on 16 bar pressure rating by the Contractor. Flange Adaptors 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 9.5 mm and with up to 3 degrees angular deflection between the longitudinal axis of the pipes. Couplings shall be supplied with or without a central register or locating plugs as required. All metallic parts are to be descaled to first quality standard in BS 4232 and protected with two coats of approved two-pack epoxy based enamel unless otherwise stated. Every coupling. Test certificate shall be provided by manufacturer. required for completing joints shall be supplied by the Contractor. non-toxic and chlorine resistant.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.0/06. joint rings. Every expansion joint shall be hydraulic tested at the place of manufacture prior to delivery.5 mm thicker than the equivalent standard pipe thickness. Thrust flanges shall be designed to withstand a longitudinal force equal to the loading applied to a blank flange of equivalent diameter. Expansion joints shall be provided to conform with details as shown on the drawing.

Collars shall make close contact around the circumferences of both pipes connected and the gap between the ends of a split collar after tightening shall not exceed 3 mm. Collars may be provided as single split collars with temporary bolts and lugs.17 Works Hydraulic Testing All pipes shall be hydraulically tested at the place of manufacture in accordance with BS 3601. Full test pressures shall be maintained for at least 3 minutes during testing at the factory and automatic pressure recorders must be installed on hydraulic testing machines.1. The ring shall be protected with two coats of approved two-pack epoxy based enamel if it is too thick to be effectively covered by the concrete lining. 2. 15 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The tolerances of the collar shall be such that nowhere shall the gap between the inside surface of the collar and the outside surface of the pipe at fillet weld locations exceed the tolerances permitted for spigot and socket joints. The overlap on each pipe shall not be less than 75 mm. BHD. one each side of the collar clear of the welding runs and approximately 25 mm from the edge of the collar.13 Pipes for Closing Lengths Pipes to be used for closing lengths shall be correctly sized over their full length so that accurate alignment for split collar joints can be obtained.15 Retaining Rings All flanged pipe ends.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Collars shall have two tapped and plugged holes of not less than 6 mm diameter to permit air pressure testing of the joints after field welding. All such pipes shall be clearly marked. 2.16 Physical Testing Unless otherwise specified physical testing of the pipes shall also be in accordance with Section 4 of Std 5L/S. flanged branches and plain ends for use with mechanical couplings or flange adaptors shall have a 6 mm steel retaining ring welded into the bore of the pipe flush with the end of the pipe after which the ring shall be zinc phosphate coated as specified followed by two coats of bituminous paint. Collar joints shall not be required to take any deflection. 2. Minimum lengths of collars shall be 250 mm. The collar shall be 1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.14 Collars Collars shall be provided for jointing cut pipes or closure pieces by means of internal and external fillet welding. 2. The radial thickness of the rings shall be similar to the thickness of the concrete lining and shall not be less than 6 mm.0/06.5 mm thicker than the equivalent standard straight pipe thickness. 2. Split collar ends shall be prepared for butt welding in the same manner as plain ends of pipes prepared for butt welding in accordance with Std 5LS.

The bitumen shall be Type 2 of BS 4147 16 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Otherwise pipes shall be primed both internally and externally. 2.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 2. Where bitumen wrapping is to be applied at another location. Metallic parts are to be descaled to first quality standard in BS 7079 and painted with two pack polyamide cured epoxy zinc phosphate primer with 75 microns minimum dry film thickness. 2. cleaning and priming shall immediately follow hydraulic testing. BHD.19 Protection All pipes shall be protected both internally and externally against corrosion. Internal and external protection at joints shall be completed on Site after acceptance of joint weld tests. all pipes shall be thoroughly descaled by shot blasting internally and externally to BS 4232 second quality. They shall be supplied complete with all accessories.8 mm for pipes over 324 mm od. If the spun concrete lining is to be applied at the place of pipe manufacture.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 2. Both types of protection shall be applied under factory conditions but not necessarily at the place of manufacture of the pipes.0/06.20 Cleaning and Priming Where bitumen wrapping is to be applied at the place of pipe manufacture. The ends of such pipes shall be coated with an approved priming paint and/or rust inhibitor both internally and externally. The above priming shall stop short of the ends of pipes intended for field welding.21 External Coating The pipes shall be coated with bitumen generally in accordance with Clauses 29 of BS 534 except that the protection shall have a minimum thickness of 4. This shall be suitable for providing a temporary protection from rusting prior to field welding those areas of pipe not given the full factory applied permanent protection and shall not affect the weldability of the metal.1. The pipes shall be protected externally with a double reinforced bitumen enamel wrapping followed by internal protection with spun concrete lining. then the pipes shall be coated with a suitable corrosion inhibitor before despatch from their place of manufacture. Immediately prior to priming. internal priming of the pipe barrel may be omitted. Any pipe which fails to withstand the hydraulic test pressure or which exhibits signs of porosity shall be deemed not to comply with this Specification and shall be rejected unless otherwise decided.18 Ring Girders Ring girders shall be provided to conform with details shown on the Drawings.

Each wrap shall be from 150-225 mm wide and the edges shall overlap by 12-25 mm. poorly applied shall be cleaned to bare metal and re-coated.1. Any lengths on which the coating is. 2. The edge of the wrapping shall be chamfered at 25 degrees. The coating shall be stopped short as shown on the Drawing for ends of all spigot and socket pipes. The inner wrap shall be a glass fibre resin-bonded tissue reinforced in the longitudinal direction with parallel glass threads spaced 10 mm apart. and there shall be not less than 2 mm of bitumen between the inner and outer wraps. 2.5 mm and the minimum weight shall 0. BHD. The nominal thickness shall be 0. 2.0/06.23 Inspection of External Pipe Coating All coated pipes and specials shall be rigidly inspected for defects.75 mm. Care shall be taken to ensure that the inner wrap does not come into contact with the pipe metal or with the outer wrap. It shall be impregnated with a material fully compatible with the bitumen coating to give a finished thickness of 0.25 mm apart.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 2. The whole coated surface area of all pipes and specials shall be tested for pinholes or other invisible defects in the coating using an approved holiday detector at a potential of 14. Aggregate shall be well-graded clean fine 17 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. The internal lining will be similar to the requirement of wrapped pipes. and between the pipe and the inner wrap.25 Spun Concrete Lining at Factory All pipes and specials shall be lined with concrete.24 Painting Unwrapped Pipes and Specials All unwrapped pipes and specials shall be given two layers of primer coat of Red Lead Oxide and two layer of final coat of light green zinc chromate. continuity with a holiday detector and coating quality by cutting out 75 mm square samples at the rate of one sample per 5 lengths of pipe manufactured. in the opinion of the S.22 Wrapping The wrapping materials shall be spirally wound onto the pipes and specials simultaneously with the bitumen coating. The outer wrap shall be of glass fibre resin-bonded tissue reinforced in the longitudinal direction with parallel glass threads spaced 10.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Minor defects may be repaired by touching up.046 kg/m2. Thickness shall be determined by a pit gauge.000 volts. Cement for lining shall be ordinary Portland cement to BS 12. and 250 mm from the ends of all plain ended pipes for use with mechanical couplings or flange adaptors. All repairs shall be checked for thickness and continuity.

The rotational drive shall be capable of close control and provide smooth acceleration and deceleration when working up to and down from the compaction spinning stage. rust. The entire quantity of concrete required for the lining shall be applied without interruption. Tolerance on the thickness of lining shall be as follows :(i) (ii) +3 mm to -2 mm for 25mm and above +2 mm to -1 mm for 19 mm and below Temporary or semi-permanent end restraints shall be fixed to the pipe ends on completion of lining and before removal of the pipe from the lining machine. all surplus water has been removed and the greatest possible density of concrete has been obtained. whichever is the greater. Tests shall be carried out during the lining of pipes to demonstrate that the concrete lining has a strength equal to or greater than the minimum figures stated in Clause 33. the pipe bore shall be cleaned of all loose scale. The pipe shall not be rotated about its longitudinal axis after the fixing of the restraints when being handled and transported to the storage yard and subsequently to the Site.0/06. The testing of concrete cubes shall be conducted at the factory of manufacture and certificate for testing shall be provided.1. Immediately before lining commences. oil. Unless otherwise approved. The support or holding device for the pipe shall be such as to avoid damage to the pipe coating during the spinning operation.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . whichever is the lesser. aggregate and the maximum particle size shall not exceed 8 mm or one third the thickness of the lining. the minimum cement content shall be 330 kg/m3 and the water cement ratio of the mix loaded into the pipe shall not exceed 0. and spinning shall continue until the specified thickness is evenly distributed over the inside of the pipe. If the pipe is rotated by direct contact drive from the machine it shall be supported over at least 90 degrees of its circumference and driven by non-metallic surfaced belts of sufficient width to avoid coating damage. grease or any other foreign matter likely to contaminate or harm the concrete. The speed of rotation of the pipe during the lining compaction stage shall be such as to provide a radial acceleration of at least 250 m/s2. All straight pipes shall be concrete lined by the use of a lining machine designed and built for the purpose of rotating the pipe and centrifugally applying the lining at sufficient speeds to meet the requirements set out below. Pipe specials shall be concrete lined at the factory in such a manner that the lining shall be of the specified thickness and comparable in density and smoothness to the spun lining in straight pipes and generally applied in 18 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. durable and dense concrete lining is obtained that satisfies the tests laid down in Clause 33 of BS 534. BHD. All materials used in concrete for lining shall comply with the requirements for concrete. Areas where an approved priming coat has bonded to the pipe such that wire brushing does not cause areas to flake off will be acceptable as a base for applying the lining. The final aggregate grading and concrete mix proportions shall be such that a hard.5 of BS 534.42. The frequency of these tests shall be at least once every 250 m length of pipe lined or during each working shift.

These cracks shall be cut back to full depth and sealed with an approval epoxy resin filler. Remedial lining operations may be carried out by a method that has been approved in writing in advance by the S. b) Plain Ends For butt straps or collar joints. etc. The edge of the lining shall be angled back at 3mm. For mechanical coupling and flange adaptor joints. accordance with Clause 33. 2. The edge of the lining shall be angled back at 3mm to the pipe axis in order to provide a positive key for in-situ joint protection.0/06. all rebound material.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN..O. shall be removed so that the lining is applied in a homogeneous mass to a clean surface. dribbles. During the lining process. the lining shall be brought right against the retaining rings. Pipes shall not be removed from the factory until at least 14 days have elapsed from the date of lining. the lining shall terminate 90mm back from the pipe end.1. Inspection of the lining shall be carried out at any time prior to and after installation of the pipes.O. BHD. Any pipe with lining that is broken. They shall then be protected from sunlight and kept damp by spraying with water or other means approved by the S.26 Internal Protection at Pipe Ends Concrete shall be omitted at the following locations :a) Spigot & Socket Ends The lining shall terminate as shown on the Drawing.2 of BS 534. for a further period of 7 days. defective or otherwise not in accordance with the Specification may be rejected. Linings shall be kept moist by continuous water spraying for a period of at least 3 days. Linings applied to pipes shall be cured in such a manner as will enable concrete to obtain and subsequently retain optimum strength. 2. The standard of the remedial lining shall satisfy the requirements of this Specification. Surface crazing of the lining will be acceptable unless cracks are severe enough that they can be penetrated to a depth of 2 mm by a 250 microns feeler gauge at 10 points or more over a length of 300 mm when measured with the lining in a saturated condition. 19 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. density and durability.27 Pipework for Laying above Ground Uncoated steel pipes and specials required for installation above ground shall be cleaned to BS 4232 second quality and protected with two layers of primer coat of Red Lead Oxide and two layer of final coat of approved zinc chromate primer.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

The tape shall be removed immediately prior to installation of the pipe or specials so coated. after blast cleaning to BS 4232 first quality. After curing but before removal from the factory the coating shall be wrapped with tape suitable for protecting the coating from damage in transit to and on the Site.28 End Protection The concrete lining and the external coating of pipes and specials to be jointed by welding shall be omitted for a sufficient distance from the ends to prevent damage to the protection during site welding. Coated pipes shall be stacked in one layer only and in such a manner that the coating is not damaged.O. an approved system of low friction vinyl-based protective coating. the external surfaces of the pipe ends for use with mechanical couplings and flange adaptors shall be given.O. 2. The ends of MS pipes and specials shall be cleaned by power brushed to a minimum of 75mm from the pipe end both internally and externally.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .30 Low Friction Coating Where necessary.29 Examination of Steel Pipes Where MS pipe ends to be jointed by welding are coated with ensis oil at the place of manufacture the ends shall be thoroughly cleaned with the ensis oil removed. is "Amercoat 23" system manufactured by Ameron. 2.0/06. Coated pipes must be kept clear of the ground and rested on padded sleepers or supports. The length of pipe barrel to be so protected by the low friction coating shall be 300 mm unless directed otherwise. The unlined surfaces shall be protected with a suitably approved ensis oil or similar material during manufacture so that extensive cleaning of the surface is not required before and after jointing on site. Protective Coatings Division. 20 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. chains and hooks shall not be permitted to come in contact with the coating.1. 2. No pipe shall be moved by rolling.31 Handling Coated pipes shall be lifted and moved only by wide non-abrasive slings or by other means acceptable to the S. they shall overlap the low friction coating by 25 mm. California 92621. stacking in two layers may be considered by the S. A coating. BHD. The coating shall be applied in accordance with the manufacturer's instructions. Wire ropes. Where zinc or bituminous coatings adjoin the low friction coating. Adequate packing between pipes for this purpose must be supplied by the Contractor. 2. which conforms to the above requirements. Brea. Unless under exceptional situation with adequate provision for pipe protection and handling.

Attention is drawn to the Contractor that thin wall pipes.32 Repair of Lining and Sheathing of MS pipes Only specially competent and skilled men shall be employed to carry out repair work to damaged linings and sheathing. On no account shall the pipes and specials be dropped or let fall onto the ground and under no circumstances shall the pipes and specials be lifted by means of hooks to the ends of pipes and specials. One saddles shall be in the centre of the pipe length and the other two shall each be positioned at a distance one-fifth of the pipe length each end of the pipe. Thin wall pipes in temporary storage or strung out along the pipeline reservoir routes shall be supported on hessian bags filled with the sawdust straw or similar and shaped so as to give continuos support under at least 40-50° of the circumference. The Contractor shall be deemed to have allowed the cost of providing the above necessary measures in the Contract Rates for hauling and laying.O. Thin wall pipes during delivery and when in transit around the Site shall be supported on three rubber covered saddles shaped to give at least 90° circumferential support and shall be firmly held in position at each saddles by straps tightened of turnbuckles in such a manner that the external coating is not damaged.'s approval to prevent distortion during handling and delivery.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. or the damaged or lost materials inforced. The pipes shall be so handled. The underside of the pipes shall be kept clear of the ground by at least 300 mm. stored and transported as to prevent distortion or damage to the pipes and shall not be moved in any manner involving rotation of the pipe about the longitudinal pipe axis. with the prior approval of the S. Such struts shall be left in position when thin wall pipes of 1400 mm and above are delivered to the storage areas. The Contractor shall provide suitable timber end struts and sufficient intermediate struts to strengthen the pipes to the S.O.dry mortar (proportion 1 part cement to 2 parts coarse sand) well tamped into the groove. and if they are accessible. stored and transported as to prevent undue distortion and shall not be moved in any manner involving rotation of the pipe about the longitudinal pipe axis. Any damage to or loss of materials shall be made good. Such cracks may be repaired by cutting out a 9 mm x 9 mm dovetailed key and making good with a semi. 2. be repaired on Site. shall be so handled.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Small cracks and flaws in the internal mortar lining of steel pipes and specials may.O. BHD. damaged materials shall be returned to the manufacturer for repair as directed by the S. by the Contractor at his own expense and if approved in by the S. and cured 21 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The positions of supports shall be the same as that for pipes during transit.O. The pipes shall be lifted by means of two reinforced canvas slings at least 300 mm wide suspended from a lifting beam so that the slings are positioned at a distance of one-fifth of the pipe length from each end of the pipe. defined as pipes with a diameter/plate thickness ratio greater than 125.

the pipes shall be slung with slings passed around the outside as specified in Clause 2. all pipes and specials shall be placed on a solid and even foundation for their full length. by keeping it damp for 7 days. Care should be taken not to drop the pipes particularly at fabricated fitting junctures. Joint holes for shall be formed in the excavation as necessary for the convenient and proper making of the welded joints. small cracks may be caulked with an epoxy resin filler.g. which may cause damage to the sheathing of MS pipes. The compound used for repairing sheathings shall be compatible with the sheathing material and shall be approved by the S. shall be picked out and the coating refettled by heating locally with a blow lamp and smoothing over with a fettling knife. it shall be cleaned and re-examined for cracks and flaws whilst hanging in the sling. a coat of approved special quick drying primer applied before re-fettling. BHD.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Small stones. 2. A recess shall be formed in the trench foundation beneath to permit each sling to be withdrawn without damage to the pipe coating or sheathing.O. Pipes and specials shall be placed in position singly and the order of laying pipes shall be subject to the approval of the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . when damage or cracking is extensive and/or inaccessible.O. Where the steel has been exposed all rust and dirt shall be removed carefully by wire brushing or otherwise. The Contractor shall be responsible in either case for all costs involved in this respect and for any delays to construction work thereby caused. All struts at the ends of the pipes and pipe specials shall not be removed until they are ready for engagement. the pipes or specials in question shall be either returned to the factory for repairing properly or replaced completely. All defects to linings and sheathings shall be made good to the entire satisfaction of the S.1. The external sheathing of steel pipes and specials shall be made good wherever the steel has been exposed or the thickness of the coating seriously reduced by damage. 22 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. The trench bottom shall be free from all rock. The trench shall be bedded as shown on the drawings. or where the coating does not adhere tightly to the steel. which may have become embedded in the sheathing.31. e.33 Laying MS Pipe No pipes shall be rolled into place for lowering into the trench. Where in his opinion the damage is such that satisfactory repairs on Site will not be practicable. If a crane is used for handling the pipes into the trench. Additional external jointing material shall be added wherever necessary. and when perfectly clean and dry.0/06. boulders. If the pipes are undamaged and the trench bottom bedded properly the pipes shall be placed in position ready for jointing. Before any pipe or special is lowered into the trench. stones or hard particles. and each pipe or specials shall be individually set for line and level using boning rods. Except for pipework to be embedded in concrete. Alternatively.

's approval.1. After laying. The joints shall be tested in the presence of the S. The collar shall be clamped 23 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. These pipes shall be supplied by the Contractor. The collar shall then be placed on the ends of the pipes so that the space between the pipe ends shall be about 25 mm from the centre line of the collar.34 Welding MS Pipe All electric arc welding equipment shall be to the approval of the S.O.5 mm. to prevent the entry of dirt. Pipes and specials to be embedded in concrete shall be held firmly in position and protected from damage while the concrete is being placed. and change from one procedure to another will not be permitted without submitting the new procedure for re-testing.O. Except when work is actually proceeding. type and gauge of electrodes (ii) Size. dirt. Only procedures approved in writing by the S. for each procedure proposed in accordance with the requirements of BS 4515. 2. the longitudinal welds on adjacent pipes shall be at least 15o out of line. Details shall include: (i) Make. Where pipes are to be jointed by a steel split collar. Before placing the pipes together the portion of the sockets and spigots to be welded shall be cleaned to a bright metallic finish. but such stopper shall allow the entry of water.35 Making Welded MS Pipe Joints Where the steel pipes are to be jointed by welding it shall be by means of an internal and an external circumferential electric arc weld at each joint. Should any pipe become either partially or wholly clogged before final acceptance of the work. the interior of pipes or specials shall be carefully cleaned again to remove any debris.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 2.O. all open ends of pipes and specials in the trench shall be kept closed by means of a fine wire gauge wooden stoppers or other approved means. Details of the socket and spigot welded joint are shown on the Drawings. The Contractor shall submit details of the welding procedure which he proposes to adopt for the S. it shall be cleaned out or replaced by the Contractor at his own expense. stones or other matter that may have entered during laying. shape and number of runs in welded joint (iii) Direction of welding (iv) Current strength (v) Welder competency certificate The Contractor shall make test specimens on pipes of the same size and thicknesses as the pipelines to be welded.O.0/06. For longitudinally welded pipes. stones and the like. BHD. the pipe ends and the collar shall be cleaned to a bright metallic finish. the spigot end shall then be placed in the socket and forced inside so that the spherical surfaces are in contact and that the gap between the pipes at the end of the spigot is nowhere greater than 1.. shall be adopted in the welding of the pipelines.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

BHD. All welds shall be subject to inspection by the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Each time the arc is started it shall be manipulated to obtain complete fusion of the weld metal with the pipe metal and any previously deposited weld metal.0/06. fusion penetration and soundness. At least 2 strips each for internal and external welds shall be sampled for quality check for a slip joint.O. the welds will have to be gouged out and made good.37 Completion of Sheathing at Welded MS Pipe Joints After the S. Welded joints for large diameter pipes of 1000 mm dia and above shall be radiographed at random as directed by the S.O. If the weld does not meet the requirements of the Specification. for the air testing. 2. Before welding over any previously deposited weld metal all slag shall be completely removed and the weld metal and the adjacent pipe metal shall be cleaned by wire brushing. The Contractor shall make all the necessary arrangement apparatus and equipment and a specialist to carry out the test. the lugs shall be removed and the longitudinal weld completed. The repaired welds shall be radiographed again at no extra cost to the client.7 MPa. 24 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. etc.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The bitumen shall be Type 2 of BS 4147. after each joint has been welded it shall be air tested in the presence of the S.. The weld shall be of the convex full fillet type for lap welded joints made manually by the metal arc process using approved types of electrodes.O. The Contractor shall provide all necessary gauges.36 Air Testing of Welded MS Pipe Joints For MS pipes of finished internal diameter larger than 628mm. As soon as the primer has set the sheathing shall be completed by running hot bitumen into a metal mould placed over the joint and overlapping the sheathing by 75 mm on either side of the joint.O. 2. Any defective welding shall be treated as directed by the S. pumps. The primer shall be applied cold by brush. The tap holes shall be then sealed off with welding after each joint has been satisfactorily tested. and shall comply with the requirements of BS 5135 for freedom from undercutting. The analytical report in duplicate shall be submitted to the S.1. the welds shall be examined carefully for leakage. After completion of the internal and external circumferential welds. has advised the Contractor in writing that a welded joint has passed the air test the external sheathing shall be completed to ensure continuity of protection along the pipeline. The annular space between the two welds shall be air tested to a pressure of 1.O.O. Bare metal shall be thoroughly cleaned to a bright metallic finish and it shall be immediately coated with a primer solution. tightly onto the pipes using the lugs and welded longitudinally. While this pressure is maintained for a minimum period of ten minutes. three days after the test.

38 Completion of Internal Lining at Welded MS Pipe Joints For MS pipe larger than 628mm finished internal diameter.39.1. shall be the measure of the rate of loss. 2.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 2. together with the adjacent lining shall be thoroughly cleaned and wire brushed. pumping shall be resumed and the quantity required to be pumped. The Contractor shall also supply all necessary boilers to heat the bitumen to the application temperature recommended by the manufacturer. All other ends of pipes and fittings shall be protected against impact damage and entry of foreign matter.O. The length of main under test shall be deemed to have passed the test if the leakage does not exceed 0. The adjacent lining shall be wetted with thick cement slurry but no accumulations of water in the gap shall be allowed. The internal lining shall then be made from one volume of cement to two volumes of fine aggregate to ensure a smooth continuous lining throughout the pipeline. divided by the time. Where necessary wire mesh may be introduced for ease of completing thick concrete lining particularly those of spherical type joints. the pressure shall be raised by pumping to the specified test pressure. Pumping shall then cease at 10 bar and after a period of 24 hours.39 2. in order to restore the test pressure. 2. The use of method other than the above shall subject to the approval of the S. BHD.1 litre per mm of internal diameter per 24 hour per kilometre of pipeline per 30m of water pressure.0/06..40 Protection in Transit All pipes and specials shall be protected prior to despatch from the manufacturer's works. the main shall be filled with clean water and properly vented to remove trapped air. Priming and sheathing material for the purpose shall be provided by the Contractor including the supply of all the necessary mould boxes and funnels required to form the protective mould and whiting for use in lining the mould boxes prior to each pour.2 Leakage Testing In testing.1 Testing MS Pipeline Test Pressure The test pressure to be applied shall be 15 bar at the lowest point. After a period of 24 hours. the steel exposed by the gap in the internal lining. All flanges shall have wooden discs bolted on.39. on completion of the external sheathing. 25 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The protection shall take into account the end use intended for the pipes and whether or not the final protection has been completed. 2.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

O.O. electricity supply. the materials and workmanship of the pipes and specials. fuel.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . labour.O.O. materials. advance notices and obtain the S. The areas shall be clear or vegetation and leveled off and the Contractor shall construct an unmetalled access track including bridges and over water courses from the main metalled road to the storage yards. The Contractor shall maintain the storage yards in a condition satisfactory to the S.42 Pipe Dumps and Storage Yards The pipes reserve wherever available may be used as pipe dumps or storage reserves for pipe and specials as shown on the Drawings. The Contractor shall prepare the areas shown on the Drawing allocated as the storage yards at which the pipes and fittings shall be delivered. examine and test on the Contractor’s premises or at the places of manufacture if manufactured at other premises. Pipes and specials shall be wrapped or cushioned so that no load is taken directly on the external coating. Every consignment shall be accompanied by a detailed delivery note with the item number of each pipe or specials itemised in the Bill of Quantities. Where no storage dumps are available the Contractor shall have to make his own arrangement to store the pipes and fittings. till the expiry of the Contract.O.O. BHD.43 Inspection All pipes and specials to be supplied under the Contract shall be inspected by the S. 2. stores. 26 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Such inspection.0/06. The Contractor shall provide such office facilities.41 Notice of Deliveries The Contractor shall send to the S. or the Inspector shall be entitled at all times during manufacture to inspect. 2. examination or testing including the inspection by the S. or Inspector shall not relieve the Contractor from any of his obligations under the Contract.'s approval of all consignments. or an Inspector appointed by the Employer at the Contractor’s premises or at the places of manufacture if manufactured at other premises.1. ultrasonic thickness indicators and high voltage holiday detectors as may be necessary to allow a thorough and extensive inspection to be carried out.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The Contractor shall provide at no extra cost to the Employer timber pieces to keep the stored pipes clear of the ground. 2. The S. assistance. apparatus and instruments including X-ray or gama ray equipment.

The cost of all works. 2. etc. 2. wrapping. spigot and socket ended pipes shall be measured and paid in effective length. The item number and diameter of branch in the case of tees and the angle in degrees in case of bends shall similarly be repeated on the lining. i.e.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . All pipes and specials shall only be measured for payment after they have been laid and incorporated into the Works. 27 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.44 Marking of Pipes and Specials All pipes and specials supplied shall have at least the following information:(i) (ii) (iii) (iv) (v) (vi) Outside diameter (in mm) The weight in Kilogram Length of the pipe (in M) ‘SAJH’ lettering Manufacturer’s distinguishing mark and date of manufacture Pipe series / Batch Number The diameter and its consecutive number of standard length pipes shall be repeated on the lining just inside on both ends of the pipes.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The effective length shall mean the net length of the pipe as laid. testing and all other requirements of the Specification including lining. coating. after deduction of the length of overlap at any spigot and socket joint to be made with the pipe. limiting and correct quantities of the pipes and specials to be supplied by the Contractor in fulfilment of his obligations under the Contract.45 Measurement of Steel Pipes and Specials The quantities set out in the Bill of Quantities are provisional only and they are not to be taken as the actual. BHD. For the purpose of this clause. involved in the manufacture and delivery of the steel pipes shall be deemed to be included in the Contract Rates.0/06. Any excess pipes and specials supplied to the site shall not be measured for payment.

.0 – DUCTILE IRON PIPES AND FITTINGS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.SECTION 3. BHD.

2% proof stress of 300 N/sq. fittings and accessories may be subjected. the ductile iron pipes and fittings to be supplied under this Contract shall conform with the requirements of BS EN 545:2002. Fittings and accessories shall also be cast in metal or sand mould.1.2 Compliance With Standards Subject to the specified requirements of this Section.3 Process of Manufacture The manufacturing method for ductile iron pipes and fittings shall comply with BS EN 545:2002.1.0/06.mm and 0. 3. 28 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Where fittings are required to dimensions other than those specified in BS EN 545:2002. 3. Pipes.0 3.5 Length of Straight Pipes The effective lengths of all straights pipes shall be as defined in BS EN 545:2002 and shall be 6 metres. specials and fittings must be from SAJH approved sources and be to SAJH specifications (SAJH PS/DI/001). the requirements shall be stated in the Bills of Quantities and the dimensions shall be as given in the Drawings.mm. Pipes shall be cast centrifugally in metal or sand mould.4 Thickness and Diameters The diameters and shell thickness of standard pipes shall be as shown in Table 3.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 3. to suitable heat treatment in order to given them the required mechanical characteristics. 3. 3. The metal used shall be such that the pipes and fittings are of ductile iron with minimum strength of 420 N/sq.1 DUCTILE IRON PIPES AND FITTINGS General All pipes.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . if necessary. BHD.

0 9.2 10.1 8. 29 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2 14.9% by mass.0 7. length.0 5.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.7 Pipes With Cast-on Flanges Class K12 7.8 - 3.4 15.3 6.8 11.8 6.2 Zinc Coating The pipe surface shall be dry.8 7.8 8.0 6. BHD.4 5.7. it may be applied on a blast cleaned pipe surface.0 9.9 10.0 13.7 8.6 9.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .7.7 3.8 11. at the manufacturer's option.6 100 150 200 250 300 350 400 450 500 600 700 800 118 170 222 274 326 378 429 480 532 635 738 842 4.Thickness and Diameter of Standard Pipes Pipe Diameter (mm) Nominal Diameter Outside Diameter Pipe Shell Thickness (mm) Pipes with Flexible Joint and Welded-on Flanges Class 40 Class K9 6. Table 3. diameter and standard mass of pipes and fittings shall be in accordance with BS EN 545:2002.4 12. 3.6 10.1 External Zinc Coating General All centrifugally cast pipes shall be given an external coating of metallic zinc with a zinc content of at least 99. 3.2 7.0/06.1.8 5.4 9.0 6.2 7.6 Tolerance On Dimensions The tolerance on wall thickness.2 7.1 . free from rust and non-adhering particles or any oil or grease. The zinc is normally applied on the pipe with oxide skin out.

3 (b).1) shall be carried out in accordance with appendix G of BS EN 545:2002.5 Repairs The manufacturer shall carry out repairs to damaged areas of coating.7. a coating of zinc rich paint shall be applied to the spigot joint area in accordance with 3. At the manufacturer's option the socket face and spigot joint area may not be coated with metallic zinc.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .3 Coating Characteristics (a) Appearance The zinc coating shall cover the external surface of the pipe and the mass of coating shall comply with 3.m of pipe surface shall not need repair. The coating shall adhere to the pipe surface and shall not display bare patches.7. (c) Uniformity of Coating The uniformity of coating shall be such that the mass of zinc coating of any 25mm x 25mm area shall not be less than 100 g/sq.8. Greater areas of damage shall be repaired in accordance with 3.7. BHD.0/06.5.7. 3. e.4 (b). (b) Determination of Mean Zinc Coating Mass The manufacturer shall carry out measurements to ensure the mean mass per unit area zinc coatings complies with 3. provided that minor dimension of the damaged area does not exceed 5 mm. 3.7.m. (b) Zinc Coating Mass The mean mass per unit area of sprayed metallic zinc. the area left uncoated as result of applying 30 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.7.g. Where the spigot joint area is not coated with metallic zinc.m. see 3.1.3(a). where damage is defined as the removal of the zinc coating. or uncoated areas.7.3 (b).7.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.7. shall not be less than 130 g/sq.cm/sq.4 Verification Process (a) Visual Inspection The manufacturer shall visually inspect every pipe for quality and uniformity of zinc coating. Pipes having `damaged' areas of coating of up to a maximum of 5 sq.7. The determination of the mean zinc coating mass applied to pipes (see 3. A spiralled appearance is permissible provided the uniformity of the coating complies with 3. as measured in accordance with 3.3 (c).5 (b). 3.

The cement mortar mix shall be one part by mass of cement to 2. the token in accordance with Appendix G of BS EN 545:2002.1977 if pipes are locally manufactured or to BS 12:1978 if imported.6 Finishing Layer After zinc coating. all pipes and fittings shall be coated externally with either. by use either L:(a) Metallic zinc spray complying with the requirements of 3.7.0/06.8 External Coating of Pipes and Fittings Unless otherwise specified. brush.2.5 parts by mass of sand.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. (a) Coat-tar epoxy (epoxy content approximately 12 percent and the minimum dry thickness of the coating shall be 80 microns). The lining thickness shall be as shown in Table 3. sockets and bellmouths shall be lined with cement mortar in accordance to BS EN 545:2002.m and the mass of paint on any 25mm x 25mm area shall be not less than 110 g/sq. BHD.8.7.m.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 3. or (c) Standard coating materials as specified in BS 3416:1976 type II Coating may be applied by dipping. 3.3(b) or (b) Zinc rich paint containing more than 90% zinc by mass in the dried film. 3. the pipe shall be coated with a finishing layer as specified in Clause 3. the mean mass per unit area of this plant shall not be less than 150 g/sq.9 Internal Lining of Pipes and Fittings The internal surfaces of pipes and fittings except blank flanges.1. or (b) Standard coating materials as specified in BS 4147:1980 type I. The cement shall be ordinary Portland Cement to MS 522. spray or roller. 31 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.

Unless otherwise specified. Flexible joints shall be supplied complete with bolts. washers.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .8 4.5 -3 The internal cement mortar lining of straight pipes shall be applied centrifugally in an approved plant and shall adhere firmly to the internal surface the pipe as specified in BS EN 545:2002.8 mm.10 Flexible Joints Flexible joints either of the ‘push-on type’ or of the `mechanical type' shall be in accordance with the manufacturer's standard dimensions and tolerance.5 0. rubber gaskets and other accessories necessary for making water-tight flexible connection between spigot and socket ended pipes and fittings. bolts. 3. The gasket for the joint shall be in accordance with BS EN 545:2002 and BS 2494. Table 3.2 .0 6. The surface shall be substantially free from laitance and any sand segregation present shall be minimal. BHD. Isolated shrinkage cracks shall be acceptable provided their width does not exceed 0. nuts.0/06. The pressure ratings of the flanges shall be PN 16 or PN 25 as specified in the Bills of Quantities.4 0.0 5. Damaged linings shall be made good by means and materials approved by the S.O.Standard Lining Thickness Standard Lining Thickness (mm) Nominal T Diameter (DN) h e i n t 40 to 300 e 350 to 600 r 700 to 1200 n 1400 to 2000 a l Nominal Limit Deviation Maximum crack width and radial displacement 0. pipes of DN 80 to DN 1600 inclusive and fittings of DN 80 to DN 600 inclusive shall be supplied with `push-on' type joints. The surface of the lining shall be substantially smooth but the fine crazing associated with cement rich surface shall be permitted.0 9. 32 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Joint gaskets shall be in accordance with BS 4865 : Part I.6 0.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. washers and joint gaskets.0 -1. glands. Each set of flange joints shall be supplied complete with nuts.11 Flanged Joints Standard flanges shall be drilled in accordance with BS EN 545:2002 and dimensionally compatible with the corresponding flanges that are in accordance with BS 4504:1989. Pipes and fittings of other diameters shall be supplied with `mechanical' type joints.5 -2 -2.1. 3.

1. BHD.3 . Table 3. Bolts and nuts shall be mild steel.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . sweating of other failure of any kind.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.3 without showing signs of leakage.Factory Hydrostatic Test Pressures Nominal Size DN Factory Hydrostatic Test Pressures Pipes with Flexible Joints Pipes with Welded-On Flanges PN 16 Flanges bar (gauge) bar (gauge) 25 25 25 25 25 PN 25 Flanges bar (gauge) 32 32 32 25 25 Factory hydrostatic leak-tightness test pressures for pipes and fittings with cast-on flanges bar (gauge) 25 16 10 10 2* 80 to 300 350 to 600 700 to 800 900 to 1200 1400 to 1600 * 50 40 32 32 25 Additionally tested with air at a pressure of 1 bar 33 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.12 Factory Hydrostatic Test All pipes and fittings shall be subjected to hydraulic pressure test before being lined or coated. The pipes and fittings shall withstand the factory hydrostatic test pressure as indicated in Table 3.0/06. hexagonal and shall be in accordance with BS 916. 3.

14 Cutting of Pipes Pipes which are to be cut to enable fittings to be accurately positioned or to form closing pieces in any portion of the pipeline.0 metre longer than the corresponding pipe and supplied complete with adhesive tape. to terminate in manholes or other parts of the work shall be cut neatly by skilled workers using pipe cutters appropriate for the type and diameter of the pipe. The sheath shall be seamless longitudinally. 3. flanges.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . BHD. To prevent ingress of water and dirt between the pipe and sheath. free from pinholes and tears and no regenerated material shall be used in the process of manufacture. 3. the sheath shall be secured with adhesive tapes at folds. 34 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. stepped collars. Care shall be taken to ensure that the sleeve is rolled towards the socket end without causing tear to the sheath. sufficient slack in the sheath shall be provided to prevent damage during backfilling. bolts and nuts. polyethylene sheath of 200 microns thick with a tolerance of ±25 microns shall be supplied as specified in the Bills of Quantities. 3. The cut ends of pipes shall be smoothed and bevelled to ensure proper positioning at the joint without damage to the jointing rings.16 Polyethylene Sheathing Where sheathing of the pipeline is required due to corrosive soil. Damage to internal lining shall be repaired by touching up with cement mortar of the same composition as the original lining.0/06. Pipes can also be jointed by flanges.1. The strength.13 Connection to Pipes of Different Type Where different types of pipe-work material are to be jointed together. class and design of all such fittings. when drilling dimensions is identical. Each length of sheath shall be at least 1. stepped couplings or changed spigots are to be used. The polyethylene sheath shall be placed over the pipe starting from the spigot end. At joint and fittings. rubber rings and gaskets shall be packed in weatherproof crates with the identification of SAJH and content labelled. collars and couplings shall be in accordance with provisions of this specification for pipes and fittings.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 3. open ends and other parts of the pipe as required. damage to external coating shall be repaired by applying the original coating material by brush.15 Packing Loose parts such as couplings. After cutting. special fittings.

Pipes and specials shall be placed in position singly and the order of laying pipes shall be subject to the approval of the S. the pipes shall be slung with slings passed around the outside as specified in Clause 3.0/06. The trench bottom shall be free from all rock. All struts at the ends of the pipes and pipe specials shall not be removed until they are ready for engagement. all pipes and specials shall be placed on a solid and even foundation for their full length. If the pipes are undamaged and the trench bottom bedded properly the pipes shall be placed in position ready for jointing. and each pipe or specials shall be individually set for line and level using boning rods. stones or hard particles. but such stopper shall allow the entry of water. Except for pipework to be embedded in concrete. boulders.17 Handling Pipes and specials shall be lifted and moved only by wide non-abrasive slings or by other means acceptable to the Engineer. Pipes and specials to be embedded in concrete shall be held firmly in position and protected from damage while the concrete is being placed.18 Laying DI Pipes No pipes shall be rolled into place for lowering into the trench. 35 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 3. Before any pipe or special is lowered into the trench. all open ends of pipes and specials in the trench shall be kept closed by means of a fine wire gauge wooden stoppers or other approved means. stones or other matter that may have entered during laying. Should any pipe become either partially or wholly clogged before final acceptance of the work. chain and hooks shall not be permitted to come in contact with external coatings or internal linings. it shall be cleaned out or replaced by the Contractor at his own expense.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .15. Wire ropes. Care should be taken not to drop the pipes particularly at fabricated fitting junctures. the interior of pipes or specials shall be carefully cleaned again to remove any debris. to prevent the entry of dirt. stones and the like. After laying. The trench shall be bedded as shown on the drawings. BHD. dirt. A recess shall be formed in the trench foundation beneath to permit each sling to be withdrawn without damage to the pipe coating or sheathing. 3. If a crane is used for handling the pipes into the trench. Except when work is actually proceeding.1. Joint holes for shall be formed in the excavation as necessary for the convenient and proper making of the welded joints. it shall be cleaned and re-examined for cracks and flaws whilst hanging in the sling. which may cause damage to the sheathing of DI pipes.

a) With “Push-In” Type Joint Jointing works shall proceed in the following order : i) ii) Lower pipes into the trench without damaging them Remove all foreign material such as sand. 3.0/06. 2) 36 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The gasket shall not warp at any point. and insert the lower portion of the gasket into the groove of the socket. dirt and paint flakes.20 Jointing Ductile Iron Pipe The jointing work for “push-in” or “mechanical” type of joint shall follow the following procedures unless otherwise approved by the Engineer. The gasket shall not warp at any point. 3.1. iii) 2) 3) For Diameter Greater Than 600mm 1) Align the white marks of the rubber gasket with the marks on the face of the socket end and insert the gasket into the socket in the form of a clover-leaf. BHD.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . gravel. Pipes and specials shall be suitably supported so that no loads is taken directly on the external coating. All flanges shall have wooden discs temporary bolted on. Insert the remainder of the gasket into the Socket Groove making sure that the projection on the inside of the sockets fits into the groove of the rubber gasket.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.19 Protection Against Damage in Transit The ends of all pipes and specials shall be suitably covered. Clean the rubber gasket and insert it into the socket in the following manner : For Diameter Under 600mm 1) Form the gasket into a heart-shape. Confirm that the gasket is seated correctly. and protected against damage during transit with straw contained in hessian secured to the pipe ends. mud. Make sure that the projection on the inside of the socket fits into the groove of the rubber gasket.

the jointing is finished. Align the spigot with the gasket and attach the jointing tools as follows: For Diameter Under 150mm 1) 2) Attach the wire rope and set the fork into position Insert the spigot into the socket by pulling on the fork v) vi) For Diameter From 200mm – 600mm 1) Set the lever-block into the position. BHD. Ensure that the lubricant covers the entire end to the first white line of the spigot.0/06. iv) Apply lubricant to the internal surface of the gasket. 3) Confirm that the gasket is seated correctly under the socket. Insert the spigot into the socket by pulling on the lever block 2) For Diameter From 700mm – 1200mm 1) Set the lever-block into position.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . One (1) lever block shall be sufficient. Two (2) lever block shall be sufficient. 37 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Clean the external surface of the spigot end and apply lubricant to the external surface of the spigot. The type of lubricant used shall be of that approved by the Engineer. Insert the spigot into the socket by pulling on the lever block 2) vii) When first of the two white lines marked around the spigot disappears into the socket.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.1.

The gasket shall be placed about 200mm from the end of the spigot. align the bolt holes and insert the bolts at the top and bottom then left and right side.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Apply lubricant to the external surface of the spigot and the gasket and to the internal surface of the socket. Insert the remaining bolts into the bolts holes and gradually tighten them. Centre the gland.600 M20 M24 M30 38 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. tighten the bolts slightly. BHD. Check tightness of all bolts and nuts with the use of a torque wrench. Clean the external surface of the spigot Clean the gland and set the gland on the spigot Clean the rubber gasket and place it on the spigot.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . b) With “Mechanical” Type Joint Jointing works shall proceed in the following order : i) Make a bell hole the pipe socket and spigot to provide additional space for tightening bolts and nuts. Ensure that the lubricant covers the entire end to the first white line of the spigot. Correct torque for bolts and nuts is specified in the following table :Tightening Torque of Bolts & Nuts for Mechanical Joint Recommended Average Handle Length (mm) 250 350 450 ii) iii) iv) v) vi) vii) viii) ix) x) Bolt Size Torque (kgm) 10 14 20 Diameter of Pipe (mm) 100 – 600 700 – 800 900 – 2.0/06. Align the socket with the spigot and push the gasket into the clearance between the spigot and the socket. Clean the internal surface of the socket and remove all foreign materials.

socket penetration lines (two white painted lines) shall be painted on the spigot end of the pipes and fittings. The length of main under test shall be deemed to have passed the test if the leakage does not exceed 0. pumping shall be resumed and the quantity required to be pumped.21.1 litre per mm of internal diameter per 24 hour per kilometre of pipeline per 30m of water pressure.21 3. BHD. the main shall be filled with clean water and properly vented to remove trapped air. divided by the time. the pressure shall be raised by pumping to the specified test pressure. shall be the measure of the rate of loss.).2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .2 Leakage Testing In testing.0/06. After a period of 24 hours. For pipes and fittings having a spigot end for use with a `push-on' type joint. K9 or K12) The serial number Standard reference Initial SAJH in capital letter In the case of fittings. the angle of bend in degrees. 39 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. 3. 3.22 Marking of Pipes and Fittings The following cast on or cold stamped marks shall appear on the socket end of each pipe :(a) (b) (c) (d) (e) (f) (g) (h) The indicator that the pipe is of ductile iron DI.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Pumping shall then cease at 10 bar and after a period of 24 hours.1 Testing DI Pipelines Test Pressure The test pressure to be applied shall be 15 bar at the lowest point. 3. the pressure rating of the flange etc. these marks shall be placed on the body of each fitting along with its main characteristics (ie. in order to restore the test pressure. The year manufacture (the last two digits) The manufacturer's identification mark The nominal diameter (ND) The class designation ( 40.21.1.

BHD. .SECTION 4.0 – POLYETHYLENE (PE) PIPES AND FITTINGS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

BHD. March 1995 : Issue 1. references to " polyethylene or PE" shall infer both high density polyethylene (HDPE). PE pipes to be supplied under this Contract shall conform with MS 1058 : 1994.3 Interpretation In compliance with existing standard nomenclature. dimensions. tapping tees and fittings shall conform generally with UK Water Industry Specification 4-32-06.Specification for PE pipes for water supply (c) Water Industry Specification 4-32-06 . Manufacturers shall preferably operate a quality system in compliance with BS 5750 : Part 2 ( EN 29002 )( ISO 9002 ).Pipe joint assemblies and fittings for types 1 and 2 high density PE pressure pipes.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.2 Scope This Specification covers the supply of polyethylene (PE) pipes and electrofusion couplers. All plain ended fittings for butt welding shall be made from pipes of the same pressure rating.Specification for production and installation 1994. (e) DIN 16963 : 1980 Part 1 to 14 . 40 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. specials and fittings must be of SAJH approved source and be to SAJH specifications (SAJH PS/PE/001) and (SAJH PS/PE/002). 4.0/06. SEPT 1989: Issue 1 (d) Water Industry Specification 4-32-15 . (g) SAJH refer to JKR 20200-0053-99 – JKR Tender Specification for PE Systems for Water Supply. shape and performance. 4.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .1.Specification for PE 80 and PE 100 spigot fittings and drawn bends for nominal sizes up to and including 1000mm. (f) British Standard BS 5750 : Part 2 (EN 29002)(ISO 9002) .0 4.Specification for Polyethylene electro fusion couplers and fittings for cold potable water supply for nominal sizes up to and including 180. (b) MS 1058 : 1994 . and shall comply with DIN 16963 : 1980. tapping tees and fittings complying to the following Specifications : (a) SAJH/PS/PE/001 – Polyethylene (PE) Pipes for Water Supply System.1 POLYETHYLENE ( PE ) PIPES AND FITTINGS General All pipes. 4. Electro fusion couplers.

4.6 Dimensions The nominal outside diameter and wall thickness of the PE pipe corresponding to the rated nominal pressures (PN) and the maximum working pressures shall be as shown in Table 4. 4. The pipes shall be manufactured by an extrusion process using polyethylene material compounded by the material supplier.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 4. The tolerances on wall thickness and diameter of pipes shall be in accordance with MS 1058 :1994. Plain ended segmental fittings shall be made by fabrication with the same PE pipes.1. The dimension of electrofusion couplers shall conform generally with WIS4-32-14.5 Polyethylene Materials The pipes and fittings shall be manufactured from polyethylene containing only those anti-oxidants. The material used for fittings shall be compatible with material used in the PE pipe system.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . UV stabilizers and carbon black necessary for the manufacture of the pipes and fittings to this Specification and to its end use including weldability. BHD.3 :The dimensions of fittings for butt welding shall be in accordance with DIN 16963 : 1980. Fittings not made of polyethylene shall be capable of withstanding the same service requirements as the PE pipes. PE pipes of outside diameter up to 125mm are allowed to be coiled. The standard length of coils shall be 100m for pipes below 125mm dia.2 and Table 4. Electrofusion couplers.1 unless otherwise specified.4 Manufacturing Process All PE pipes and fittings shall be manufactured by manufacturers whose product are certified by SIRIM or other approved institutions. The materials shall be of type PE 80. tapping tees and fittings shall be moulded with the heating elements wires embedded in the bores of the fittings. No reworked material shall be used in the manufacture of pipes and fittings including segmental fittings. They shall have adequate quality assurance systems related to the production of PE pipes. The standard lengths of straight pipes shall be 9m for pipes above 125mm dia.0/06. The internal diameter of the coils should not be less than 25 times the nominal pipe outer diameter.The tolerances on length and standard weight of pipes shall be as shown in Table 4. 41 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The material shall be compounded by the material supplier. The classification and compliance of the material to the requirements of MS 1058 : 1994 shall be certified by an independent and approved testing institution. Mixing of master batch by pipe manufacturers is not permitted.

4 4.1 28.3 24.6 7.1 12.4 11.9 31. Table 4.6 32.5 Min 2.7 50.4 73.5 5.3 40.4 14.4 25.7 15.8 51.9 30.6 90 102.2 39.4 515.3 2.1 12.0 2. nuts and bolts shall be protected with not less than 200 microns thick coating of Fusion Bonded Epoxy Powder.2 20.7 16.3 Max 2.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.1 6.4 368.1 PN 16 14 15.8 49.2 11.2 130.3 3.2 409.7 25.4 28.3 35.7 3.2 6.4 61.8 6.6 229.3 2.7 3. Washers shall be hot dipped galvanised.4 50.6 9.0 11. 42 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.6 38.8 290.3 13.7 25.7 Internal Diameter (mm) PN 12.6 16.1 Wall Thickness for PE 80 Pipes Wall Thickness (mm) PN 16 Min 2.4 18.4 10.6 4.2 163. The flange.6 310.8 155.3 3.8 48.6 40.0/06.2 18.4 19 24.6 Outside Diameter (mm) 16 20 25 32 40 50 63 75 90 110 125 160 180 200 225 250 280 315 355 400 450 500 560 630 Flanged Connections All flanges shall be to PN16 pressure rating and dimensionally similar to BS 4504 : : 1989 Table 11.2 27.2 139.8 57.0 3.2 174.1 22.4 244.8 147.2 217.2 PN 12.1 31.6 327. The fittings to be jointed by electrofusion couplers shall have sufficient insertion length to reach the center of the couplers.9 45.1 56.2 69.3 55.1 5.6 40.1 8.5 16 20.1 50.2 257.2 36.8 34.6 349.6 35.0 9.7 44.2 458.0 3.6 275.6 194.0 17.8 58.8 8.6 19.0 63.7 4.5 Max 2.8 31 38.6 5.2 20.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .1 45.2 10. nuts.2 5.5 7.3 8.5 22.4 26 32. Each set of flange connection shall be supplied complete with gaskets.1. BHD.8 22.4 97 124.6 184 204. bolts and washers.8 85.3 14.0 2.2 22.9 20.4 - Nominal Diameter for PE Pipes (mm) 16 20 25 32 40 50 63 75 90 110 125 160 180 200 225 250 280 315 355 400 450 500 560 630 4.8 27.4 4.9 43.

43 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. bolts and nuts. 80° C (iv) Thermal stability (v) Longitudinal reversion 4.9 Packing Loose parts such as couplings. 5% by wt. flanges. all in accordance to MS 1058 : 1994 (i) Dimensions (ii) Surface finish and marking (iii) Pressure test 165h.0/06.3 Permissible Variation For Weights Permissible Variation For an individual pipe For a batch of 100 pipes For coil bundles 8% by wt. rubber rings and gaskets shall be packed in weather proof crates with the identification of the Consignee and the contents labelled. BHD.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 4.0mm Straight Length of above 6m +20mm .2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Unwound Length +1% .0% Straight Length up to and Including 6m +10mm .8 Works Tests The following tests on the pipe samples shall be conducted.2 Permissible Variations for Pipe Lengths Permissible Variation Coiled Bundles. Table 4. 5% by wt.1.0mm Table 4.

rope or canvas slings shall be used for straight pipes. They shall not be dropped or dragged or subjected to rough handling particularly during loading and unloading operations. The pipes shall not be coiled to less than 25 times the outside diameter of the pipes. free from nails or other hard projections which may cause damage. 4. Either slings or a forklift with suitably protected boom attachments shall be used to unload them. If PE pipes are handled with mechanical lifting devices. BHD.10 4. careful handling is always required. Straight pipes shall be fully supported and bound together with non-metallic ropes. The pipes and fittings shall not be transported or stored together with diesel oil or sharp edged equipment in order to avoid contamination or damage. pipes of lower pressure class shall be stacked above others of higher class. 4.1 Handling. 44 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Transportation and Storage General Polyethylene is a tough resilient material which is relatively light and easy to handle. it is prone to damage by scoring with sharp objects. Coils shall be stored horizontally. Any scoring on the pipe surface that are more than 10% of the wall thickness shall cause the pipe to be rejected or else the section shall be cut out. However. If high sided lorries are used. If the pipes are transported one inside another.0/06.2 Handling and Transportation For transportation bulk loads. When transporting the pipes of different classes. particularly pipes with couplers. When lifting by crane.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. If transported together. the smaller pipes shall be removed first and laid out.10. Coiled pipes whether strapped or on pallets are easily handled by forklift.1. Care shall be taken to avoid positioning pipes and fittings near or adjacent to exhaust pipes or other heat sources. Damage to pipes and pipe ends shall be avoided during lifting. special care shall be taken to prevent slippage or excessive bowing of the pipe.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Therefore. coiled pipes shall be placed on top of straight pipes. All sharp edges shall be adequately padded up. the pipes shall be suitably protected to prevent scoring. Pipes shall NOT be rolled off the edge of loading platforms or trailers. The pipes shall not rest on the sockets of other pipes or pipes fitted with couplers.10. A depth gauge shall be used for measurement. Uncoiling shall be done so that the pipe leaves the coil tangentially (in the direction of the pipe coils) to avoid kinking and twisting of the pipe. the vehicle used shall be provided with a clean flat bed.

11 Electrofusion Couplers and Tapping tees The fittings shall be free from cracks. solvents and other aggressive chemicals. particularly during warm weather. Pipes cut and squared for butt fusion shall be handled with the utmost care to keep the pipe ends from damage. For each size and type of fitting. the pipes shall be properly covered up. At all times pipes and fittings shall be stored away from exhaust outlets and all other high temperature sources. Such stacks shall therefore be not greater than one metre high.0/06. deformation may occur to the pipes in the lower layers.4 Precautions Sharp sections which could cause indentation or scoring to the pipes shall not be allowed to bear against the pipes.10. Adequate space shall be allowed for lifting machinery to manoeuvre around the pipe stacks without causing accidental damage to the pipes. inclusions or other defects likely to impair their performance. Where storage facilities necessitate the material to be exposed externally. Care shall be taken to avoid contact with lubricating or hydraulic oils. 4. During coiling and uncoiling care should be taken to maintain the coil diameter to the specified minimum of 25 times the outside diameter to prevent kinking. 4.1. The pipe storage areas shall be provided with adequate access for construction vehicles and/or lifting equipments. Pipes pre-assembled with fittings or flanges shall be stacked or supported so that the ends are free from loading and protected from damage. dents. the fusion time inclusive of cooling time at a 45 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Straight pipes stacked for storage or transportation shall be supported continuously and evenly to minimise distortions. distortion. flat surface and to a maximum height of two metres to prevent distortion to the bottom convolutions.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Socketed or coupled pipes shall be stacked with the sockets at alternate ends and with the sockets protruding to avoid uneven stacking which may permanently distort the pipes. Padded supports of at least 75mm bearing width at spacing not greater than one metre centres may be placed beneath to support the pipes. blisters.3 Storage Coiled pipes shall be stored on a firm.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. particularly during transportation. voids.10. 4. BHD. gasoline. Coils shall be tied at intermittent points and as a complete coil to prevent slippage and distortion within the coil. Where individual pipes are laid out and stacked to a triangular form.

2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . i.The means shall not prevent use of the couplers with longitudinally restrained pipes in repair situation i. trimming and getting pipe ends and surfaces prepared. For Reducing couplers there shall be no sudden step changes of internal diameter and incorporate a mean of preventing pipe penetration beyond the smaller socket. The design of the tapping tees shall include provision for pressure testing of the connected service pipes and the fusion interfaces between the pipes and fittings without removal of the cutter prior to tapping the main.e. the fittings shall incorporate a female internally threaded brass/stainless steel socket on one end for connection to existing threaded GI meter standpipes. The nominal resistance of the heating elements and production tolerances for each type of fittings shall be declared by the fitting manufacturers. The fusion sealing width. Tapping tees shall have built-in cutting device to cut through pressurized PE pipes without allowing uncontrolled leakage of water to occur. The manufacturer shall declare the allowable operating torques to be applied for the cutting device. This include scraping. They shall be capable of passing all hydraulic testing required of the fittings without additional fastenings or constraints to the cap. Tapping Tees shall be capable of installation by using an underclamp. All fittings shall have mechanically shrouded male electrical terminals. For In-line tees and associated spigots. All electrofusion fittings shall not be removed from its packing until fusion jointing is ready to be conducted. The maximum power requirement and voltage range for all the fittings shall be to the fittings manufacturer's Specification. A permanent and obvious means of indicating that the joint has been subjected to the fusion cycle shall be provided on the external surface of the fitting. Straight couplers and Elbows shall incorporate a means of preventing pipe penetration beyond the socket. given voltage shall be specified by the fitting manufacturer. the distance between the inner and outer turns. it shall be possible to slide the coupler onto one pipe far enough to allow the pipe ends to be aligned and the movement of the coupler reversed until it overlaps both pipe ends in position to be joined. 46 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. It shall be the same for all pipes to be joined to that fitting irrespective of the pipe SDR and material. the fitting shall incorporate means of controlling pipe penetration with the socket such as to prevent obstruction of the tee outlet. For Transition Coupler and Elbow. The cutting device shall have a socket key recess to be operated by a suitable key with no thread follower.1. at any point shall not be less than 15mm.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.e. The fittings integral heating element shall be clear of the path of the cutter.0/06. The tapping tees design shall be easy to removed and replaced from an above ground position. eg fusion or melt indicator. BHD.

O. or his representatives for deep cuts or scratches.13.O. it shall be excluded from the work until repairs have been carried out to the satisfaction of the S. All PE pipes with deep cuts to the pipe wall. The fittings and the manufacturers shall be approved by the S. or his representatives by the Contractor. All fusion joints shall be inspected and assessed with joint record printouts from the automatic butt or electro fusion machine. which are deeper than 10% of the pipe wall thickness. of more than 10% of the pipe wall thickness shall not be laid until that damaged section of the pipe has been satisfactorily cut out on the Contractor's own expense unless the damages have been recorded during take over at Central store. or his representatives before the Contractor is allowed to proceed with pipelaying 47 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1. All damaged or flawed section of pipes shall be cut out and removed to the satisfaction of the S. 4. 4. BHD.12 PE Compression Fittings The compression fittings shall be suitable for quick jointing of PE pipes system.14 Laying PE Pipes The pipes or specials shall be inspected by the S. measured by a depth gauge of suitable accuracy approved by the S.O. The depth shall be measured with approved depth gauges of suitable accuracy supplied for the sole use of the S. before jointing according to Clause 4.O. Pressure rating for fittings of 16mm to 110mm NOD shall be up to 16 bar. before ordering.. Three standard lengths of pipe on each side of the fusion machine shall have a minimum of two (2) roller supports per length of pipe.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .O. Dimensions shall generally be in accordance with DIN 8076 and BS 5114 1975.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.0/06. All PE pipes and fittings outer diameter and roundness shall be measured by approved `PI' ruler supplied by the Contractor. All joints shall be approved by the S. Should any pipe or special are found to be damaged.13 Examination of Pipes and Fittings The ends of PE pipes and specials shall be cleaned by water and any damaged portion cut-off and removed before butt or electrofusion can be allowed to proceed.O. 4. if damage to the internal and/or external protection has not been satisfactorily repaired. Electrofusion fittings shall not be removed from their packing before use.O. The whole fittings shall be manufactured from resistant thermoplastic resins of polypropylene type.O. In general no MS pipe shall be laid if an end has suffered distortion from the circular and a mechanical coupling or socket cannot be fitted or. The pipes and specials shall be jointed by automatic butt or electro fusion welding to form a string above ground and shall be supported by smooth rollers support of a design approved by the S.

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

works. The maximum pulling length of fusion jointed PE pipes into position alongside or directly into pipe trench after fusion jointing shall not exceed 300m or length limited by the hydraulic actuator of the automatic butt fusion machine. Dragging on ground surface is strictly prohibited. All jointing of specials, tees closing lengths etc to be conducted in the trench shall be by automatic electrofusion couplers or other electrofusion fittings. The trench bottom shall be free from all rocks, boulders, stones or hard particles which may damage the pipe walls. Before any pipes or specials are lowered into the trench, the pipes and specials are to be rechecked for deep cut and scratches described above and the fusion joints cooled sufficiently (specified cooling time for the last joint has elapsed) before stress is imposed upon any premade joints. When lowering pipe into trenches, care should be taken to avoid scoring of the pipe by contact with the sides and bottom of the trench. Special care shall be needed when passing under/around obstruction or other utilities. Pipe roller supports for the first four lengths of pipes from the pipe end to be lowered into the trench shall be provided. Cut section of rejected or damaged PE pipes, planks and rope shall be used for protecting the remaining pipes where appropriate but wire ropes or chains shall not be used. The trench bottom shall be bedded with well graded free flowing granular sand that is free from stones or hard particles larger than 6mm diameter. Gradual changes in direction can be accommodated by pipe deflection but the pipe shall not be cold bent to a radius smaller than twenty-five(25) times the outer diameter of the pipe. Under no circumtances shall hot bending in any form be allowed on site. A minimum distance of 300mm from obstruction and other services shall always be maintained. The pipe shall be kept as central as possible within the trench to enable correct side-fill compaction but some snaking to compensate for thermal expansion of the pipe will be allowed. Pipes and specials to be embedded in concrete shall be firmly held in position and protected from damage during pouring or compaction by a heavy duty polyethylene sheet. Should any pipe or specials become either partially or wholly clogged before final acceptance of work, it shall be cleaned out or replaced by the Contractor at his own expense. After laying the interior of pipes or specials shall be carefully cleaned to remove any debris, dirt, stones or other matter that may have entered during laying. Except when work is proceeding, all open ends of pipes and specials in the trench shall be kept closed by means of a fine wire gauge, wooden stopper or other approved means to prevent the entry of dirt, soil, stones and the like, but shall allow the entry of water. 4.15 Welding PE Pipes All PE pipes shall be jointed by fully automatic butt fusion welding equipment. All PE pipes specials and tapping saddles shall be jointed by fully automatic electrofusion equipment. All automatic fusion equipments shall have joints data retrieval facility allowing joint records to be retrieved 48 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

and printed. A printer for each fusion machine used on site shall be supplied to the S.O. for his sole use. An electronic data transfer unit suitable for use with the Butt and Electrofusion machines to transfer all joints data to a computer shall also be provided by the Contractor for the sole use of the S.O.. The full set of Automatic Butt Fusion welding machine shall comprise the following : (a) Chassis and Clamps which are sufficiently robust to accurately align the pipe to be jointed and have insert rings to fit different pipe diameters up to 315mm nominal outer diameter. (b) Hydraulic/Pneumatic Unit capable of actuating the clamp unit to provide adequate force and speed of operation for pipes diameter up to 315mm nominal outer diameter. The pressure required shall be automatically set and calculated by the control box. (c) Trimming/Planning Tool capable of being mounted securely within the frame of the jointing machine, to prevent twist during trimming and planning to produce accurately matched planed surface. (d) Electrically operated heating plate with temperature controller for a uniform temperature range of between 200 to 220 deg. C. The plate shall be uniformly coated with teflon having adequate release properties and fitted with an accurate temperature probe using a digital thermometer. (e) Control Box designed to carry out the operations automatically for pipes diameter up to 315 nominal outer diameter with the following facilities : (1) Automatic interlock of the entire joint cycle with correct heater temperature; (2) Ambient temperature compensation at bead-up; nominal dwell time less than two seconds; constant monitoring of pipe slippage; (3) Automatic monitoring of cooling cycle; (4) Identification of real time; date; job and operator for every joint; (5) Pipe selection programme specific to material type; diameter and SDR rating; (6) Automatic recognition of dual pressure welding conditions for thick wall pipes;

49 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

(7) Complete data retrieval facility for all joints via a data printer or electronic transfer to comply with BS 5750:Part 1 4.9.2 on special processes; (8) Audible alarm to alert operator at critical stages. (f) Portable Generators of brushless alternator construction complete with voltage stability consistent with TIN-12 specification: alternator to be capable of providing a 10% overload facility. Generators to be rated to the appropriate fusion application and the equipment as specified by the manufacturer The Butt Fusion jointing procedure shall be as follows :(1) Cleaning of the trimming tool and the Heater plate. The trimming tool shall be cleaned with water and lint free materials. The heater plate shall be cold when cleaned with soap and water and lint free materials. The heater plate shall be cleaned at the start of each working day by making a dummy joint. The joint shall be cut-off before actual jointing work is conducted. Trimming of pipe ends. Before trimming, the pipe ends shall be wiped clean on both the inner and outer surfaces to remove mud or dust with a damp cloth. The pipe ends shall then be cut square to remove any embedded hard particles or stones using a universal or other approved PE pipe cutter. The pipe shall be dry prior to proceeding. The pipes shall then be positioned in the clamps with pipe makings aligned. This will assist in obtaining best match in diameter. The pipes clamps are then tightened to grip and reround the pipes. The pipe ends shall then be trimmed and planed with the trimming tool mounted onto the machine until continuous shavings are produced from each pipe end. Bevel and clean outer and inner edges of loose shavings and check the pipe end for alignment. The pipe ends trimmed surface shall not be touched or handed to prevent contamination of the clean surfaces before fusion. The pipe ends shall not have any visible gap when the ends are brought together. The maximum outside diameter mismatch of the pipe ends, measured by a depth gauge, shall not be more than 10% of the pipe wall thickness when the pipe ends are brought together for pipes up to 315 NOD. If the mismatch is greater, the pipe shall be realigned and replanned until permitted tolerance is obtained. (3) Automatic jointing The operator shall check that the machine is levelled with appropriate levelling apparatus, input operator code, identify pipe materials and diameter and after inspecting trimming start 50

(2)

SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

The full set of Automatic Electrofusion machine shall include the following. The prepared area shall then be cleaned with acetone or other approved solvent. The tool shall remove a layer 0. There shall be a complete data retrieval facility for all joints to be undertaken via a data printer or a data transfer unit.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The generator shall be rated to the appropriate electrofusion application as specified by the manufacturers of the fittings. The prepared pipe surface shall not be handled or contaminated prior to welding.O. (2) Potable Generator as specified for the automatic butt fusion machine. (4) Alignment and restraint underclamp bottom-loaded saddle kits and Gclamps for pipe sizes up to 315mm nominal outer diameter.0/06. Clean pipe ends and prepare pipe ends with universal scraper or approved surface preparation tool capable of removing the oxidised surface of the pipe ends for length in excess of insertion depth.1. If the pipes are found to be too oval to fit into couplers. All joints shall be assigned a number and shall be marked on the pipe by suitable marker approved by the S. The Electrofusion jointing procedure shall be as follows:(1) Trimming of pipe ends square axis and any burrs removed.O. and also recorded on drawings. (3) Universal main alignment and restraint clamps units with insert rings for pipe sizes up to 315mm nominal outer diameter. (1) Automatic Electrofusion Control Box capable of operating in a fully automatic mode compatible with the integral heating elements of all electrofusion fittings for pipes up to 315mm nominal outer diameter used in this Contract.4mm thick from the outer surface preferably as a continuous strip of swarf over that length and round the pipe or for the full area of saddle base. or his representatives.O. elbows and tees. BHD. Hand scrapers of the Harris type’ or equivalent are allowed for tapping tees and saddles. the automatic fusion cycle. multifunctional for couplers.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . the pipes shall be rerounded by on approved mechanical pipe rerounding tool or a straight length of suitable round pipe be fused onto the end before jointing. For tapping tees and saddles the general area in excess of the saddle base area shall be cleaned to the satisfaction of the S.2 – 0. A log book recording joints data shall be kept by the Contractor on site for the inspection of the S. Check pipes and fittings for correct fit into couplers. (2) 51 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.

2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . apparatus of all types and everything necessary for air testing. the joint shall be cut out and a new joint be made. equipment. to axially align the pipes centrally in the fittings. (4) (5) On completion. the melt indicators of the fusion fittings should appear. materials of all kinds. fuels.O.O. if required.16 Payment for PE Pipe Joints The Contract Rates for making internally and externally welded slip and collar joints. the main shall be filled with clean water at a steady rate to enable all high points to be properly vented to remove trapped air to the approval of the S. operating and maintaining all services. The alignment and gaps between the pipes and fittings shall be checked by depth gauges. BHD. The fittings shall be adjusted with suitable wedges. If this initial analysis indicate that significant volumes of air is still trapped in the system. The total gaps between the pipe outer diameter and fittings shall not exceed 2% of the pipes nominal outer diameter. The main shall not be tap with the integral built-in cutter until the joints or saddles have been approved by the S.O. repair to PE pipes and all as specified. The pressure rise response during this pressurisation phase shall be approximately linear indicating acceptable amounts of air in the system. protecting pipe ends and completing external protection of the welded joints . PE Butt and Electro Fusion joints shall cover the cost of providing. The joint shall be left in the clamps for the cooling time specified for the fittings or tapping tees. The insertion depth is than marked by suitable marker by inserting the couplers/fittings up to the center stop.. 4.1. The pressure rise with respect to time and volume pumped shall be recorded and monitored. In testing. Electrofusion shall then only be allowed to proceed after complying with the above checks. Using correct sized pipe clamps or saddle clamps. The pressure shall then be raised to the specified test pressure by pumping continuously at a constant rate.17 Testing PE Pipelines The test pressure to be applied shall be 1. (6) (7) 4. the test shall be terminated and 52 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. (3) The electrofusion fittings or tapping tees shall be removed from packaging and degreased with acetone or other approved solvent prior to insertion to pipe ends or clamp onto pipe.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.5 times the rated pressure with details shown in drawings or as directed by the S. The filled pipeline shall then be stood for a minimum of 12 hours before water is added to replace collected air.0/06. plant. secure the pipe fittings. making good and/or completion of internal lining and external coating. If there is no apparent movement of the melt indicators.

When the specified test pressure has been attained. 53 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. early morning or late evening.1.3 times the rated pressure and the pressure is then pumped up again to 1. testing shall be arranged to be conducted in the cooler hours of the day. The pressure at the end of the one hour period is noted and the pressure is then reduced to 1. BHD. To avoid high ambient temperatures and sudden cooling of pipeline during test causing fluctuation in pressures. air bleeding at all high points and the end of the test section shall be reconducted prior to the continuation of the test.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The markings shall be made only on those pipes and fittings that have satisfied all tests and other requirements of this Specification.18 Markings All pipes and fittings supplied shall have at least the following information:(a) (b) (c) (d) (e) (f) (h) (i) Manufacturer's identification Dimensions ( nominal outer diameter ) Material supplier and material class (PE 80) Nominal pressure class (PN) in bar Production period (date or code) Number of this Specification ( MS 1058 ) ‘SAJH’ lettering Batch production number In addition all segmented butt welded fittings shall bear the diameter of the branch. The length of pipelines under test shall be deemed to have passed the test if no visible leakage occurs at all exposed welds and joints and the average rate of pressure drop at any stage during the two (2) hours test period or longer does not exceed 10 per cent of the specified test pressure per hour.0/06. and the angle. 4. the test length shall be allowed to stand without make-up pressure and the pressure is allowed to decay over time for one hour. in case of bends and any angled branches on the outside of the pipes and fittings.5 times rated pressure. in the case of tees. the pump shall be stopped and pressure recorded at 10 mins interval for two (2) hours or until the entire tested length of the pipeline and joints has been inspected whichever is longer. After the specified test pressure has been reached.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

BHD.SECTION 5.0 – uPVC PIPES AND FITTINGS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. .

BHD. The dispersion of all ingredients in the material composition shall be informed. 5.1 uPVC PIPES AND FITTINGS General All pipes. mechanical strength and capacity. 54 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. joints and fittings shall consist substantially of polyvinyl chloride. joints and fittings in particular long term mechanical strength and impact strength. The pipes shall conform to the standards as stated unless specifically or otherwise stated in this specification. and the production of finish. the deformation temperature of the material under load shall not lower than 75 degrees Centigrade. specials and fittings must be from SAJH approved sources and be to SAJH specifications (SAJH PS/PV/001)and (SAJH PS/PV/002). or to impair the fabrication or welding properties of the pipes. No other rework material shall be used. None of these additives shall be used separately or together in quantities sufficient to constitute a toxic hazard. with one ended bellmouthed and one plain ended shall be manufactured in accordance to MS 628:1982 and BS 4346 Part 2:1970. joints and fittings complying with this specification is permissible.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 5. The bellmouthed pipes. to which may be added only those additives that are needed to facilitate the manufacture of the polymers.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. uPVC joints and fittings shall be manufactured in accordance to BS 4346 Part 1:1969 and BS 4346 Part 2:1970. The addition of the manufacturer’s own rework material produced during the manufacture and works testing of pipes.3 Colour The colour of the pipes shall be blue. The uPVC pipes and fittings to be supplied shall be of classes C. The bellmouthed socket shall be manufactured in accordance to MS 923 Part 3 or BS 4346 Part II. If tin stabilizers are used for joints and fittings. When tested by method 120B of BS 2782 (Methods of Testing Plastics). these shall be only dialkyl tin C4 and higher homologues. the plain ended pipes shall be manufactured in accordance to MS 628:1982.2 Materials used in Manufacture The material used in the manufacture pipes. 5. D or E as specified in the Bill of Quantities and shall be of SAJH approved as in Specification Subject to the specified requirements of this Section.0 5.0/06.

55 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. C C D E 9 bar 12 bar 15 bar At 30 deg. joints and fittings shall be classified in accordance to the Maximum Permissible Working Pressure as in Table 5.0/06.6 bar 12. An out of roundness tolerance of + / .1 – Classification of uPVC Pipe Maximum Permissible Working Pressure At 20 deg.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. C 7.0.0 bar Class of pipe 5.2 bar 9. Table 5.5 Thickness and Diameter The pipes shall be designated by the nominal size and shall conform to the outside diameters and wall thickness given in table A.1. BHD. A tolerance of +3mm –10mm shall be allowed on the length of an individual pipe but the total length of pipe supplied shall be not less than the total length ordered.1.6 Tolerance and Dimensions Mean tolerances on outside diameters shall conform to the requirements of Table A.4 Classification The pipes. 5.55 percent on mid mean outside diameter is permitted.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 5.

7 2.1 60.6 33.9 33.3 8.9 2.1 48.9 8.3 89.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.5 357.1 1.7 11.5 140. Attachment Table A Nom.0 219.4 244.4 168.1 272.9 4.5 459.3 6.4 114.4 324.3 21.5 max 5.5 89.9 13.1 23.0 168.8 244.3 356.0 169.5 194.5 5.9 max 17.0 7.4 113.3 454.6 PN 15 Individual Value min max 1.4 192.0 74.3 14.2 26.6 6.6 21.7 4.1 2. Size (mm) Mean Outside Diameter (mm) Out of Roundness (Ovality) (mm) Ave.6 323.0 21.0 60.9 2.0 405.7 min 17.9 24.6 12.4 5.8 3.0 21.6 33.0 88.0 21.5 75.4 10.0 48.1.0/06.2 26.2 353.4 48.8 8.5 26.7 42. min 17.7 3.1 3.7 114.5 19.0 193.4 355.6 322.5 2.7 75.0 243.5 12.3 9.2 11.8 17.2 245.3 408.4 11.9 11.8 42.3 6.9 14.5 26.1 194.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .8 273.5 2.7 max 17.7 4.7 404.9 457.9 141.9 33.4 60.5 10 15 20 25 32 40 50 65 80 100 125 155 175 200 225 250 300 350 375 400 - 56 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2 75.8 88.7 19.3 11.1 140.7 247.3 42.1 114.8 Wall Thickness (mm) PN 12 Individual Value min max 4.2 271. BHD.0 406.9 456.2 3.5 Average max 1.5 48.5 5.5 218.4 167.0 18.7 3.3 21.8 15.2 16.3 17.7 220.8 218.4 325.4 42.9 1.2 2.5 60.2 21.1 10.7 139.7 2.8 10.5 1.2 3.

smooth and reasonably free from grooves. The rubber ring shall have the retaining capabilities to hold itself in the housing without causing displacement during handling. The ends of the shortened pipes shall be cut and turned to the correct dimension for jointing. BHD. The rubber ring shall be of type: a) The type which employ compression sealing system b) The type which employ a combination of lip compression sealing system The uPVC coupler joints shall be suitable for use with plain ended uPVC pipes. The plain end of the pipes shall be chamfered to facilitate insertion during jointing.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The rubber rings shall be manufactured of natural rubber complying with the requirements of Type 1 of BS 2494 Part 1 (1976).QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.7 Length The standard length of pipes shall be 6 metres.0/06. The contractor shall supply free of charge the extra joints required due to the supply of non-standard pipes. storage and installation of the pipe. 5. Each coupler joint shall consist of a uPVC sleeve suitable for jointing two rubber rings set in plain grooved ends. 5. Rubber ring shall be factory fitted in the ring housing of the pipe by the manufacturer in the correct way as to specification unless otherwise stated. heat marks and other defects that would impair their performance in service. blisters. provided than the minimum length of any pipe shall be not less than 3.4 metres. The completed joint shall be watertight when the pipes are deflected at angles up to 5 degrees and subjected to (3.1) times the Maximum Permissible Working Pressure specified. 5. The manufacturer may supply not more than 10 percent of the order in lengths decreasing by multiples of 150mm. wrinkles.0. dents. joints and fittings shall be homogenous throughout and the internal and external surface shall be clean.8 Appearance The wall of pipes. 57 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.6 +/.9 Joints The pipes to be supplied shall have an integral bell-mouth socket formed on one end for mechanical rubber ring joint conforming to the relevant sections of BS 4346 Part 2. A witness mark should be put in on the cut end of the pipe.1.

11.1 Obligations The supplier shall give the S. 5.O shall attend the appointed place within the said fourteen days or the test may proceed in his absence.O or his representatives shall have access at all reasonable times for inspection and testing of the pipes being ordered by SAJH. the S. All tests shall be done prior to delivery. The S.O fourteen (14) days notice in writing of date on which any of the samples will be ready for testing or inspection at the place of manufacture or at an approved laboratory. The manufacturer at his own expense.0/06. BHD. The material is approved for contact with cold potable water as in BS 6920 Part 1. Depending on the request of the client.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 58 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Each seal shall be marked with pipe dimension.5 IRHD hardness and meets the requirement of ASTM F-477 and EN 681-1.11.O within seven days three certified copies of the test readings. appliances and supply labour for test specified. The supplier shall in any case submit to the S. and a reinforcing plastic element bonded to the rubber element to hold the seal firmly. seals can be supplied either fitted in the pipe groove or separately in a proper sealed packaging boxes to retain the quality of the seals over a long period.11 Test Requirements 5. 5. manufacturing period and relevant standards used in the manufacturing.1.10 Pipe Seal The seal shall consists of flexible of rubber element of effectively seal against the spigot and socket.3 Type Tests The supplier shall either provide the necessary facilities and a qualified chemists to carry out their test at the factory or retain the services of an independent testing authority approved by the client.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .11. The seal material shall be EPDM rubber in 60 +/. The rubber ring shall have the retaining capabilities minimum of 5 kgf for ND 100mm and below and 9 kgf for sizes ND 155mm. prepare the necessary test pieces. supply and maintain in proper condition all necessary dimensional gauges. 5.2 Routine Tests For routine tests. 5.

3 – Testing Proportion Tests Routine Test Heat reversion Resistance to Acetone Short-term Hydraulic Impact Strength @ 20° C Type Test Resistance to Sulphuric Acid Impact Strength of 0 deg.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The proportions described are as Table 5. C Opacity Effect on Water Long-term Hydraulic One complete test each once a year for each Formulation used. Table 5.4 Sampling The number of sample to be tested by the Supplier at his own expense shall be selected in proportion to the number of pipes each size and class of production within the same day of 24 hours. Not less than 1 sample per 50 pipes from production within same day 24 hours -Ditto-Ditto-DittoProportion 59 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.11. The costs of such additional tests shall be borne by the Supplier.O for inspection. Test shall be carried out not earlier than 15 hours after the pipes have been extruded. All expenses incurred in carrying the Type Tests at the factory or by an independent testing authority shall be borne by the Supplier. BHD. 5. The S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.0/06. or whenever a change is made in the formulation or method of manufacture of the pipes whichever is move often.O reserves the right to collect test samples from the factory forward to an independent testing authority for test.3. Copies or Type Test Certificates shall be submitted to the S.1.

Flattening and/or swelling of the sample shall not be deemed to constitute failure.3 Factory Hydrostatic Test on uPVC Pipes When tested by the method described in Appendix ‘G’ to MS 628:1982 the pipes shall withstand the appropriate Factory Hydrostatic Test pressure for at least 1 hour without failure as shown in Table 5. If of the initial 14 60 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The change in the length of the sample between the scribed mark shall nor exceed 5.12 Routine Tests 5. BHD.1.4 Impact Strength Test at 20 degrees C on uPVC Pipes.2 54. 1 hr interval Factory Hydrostatic Test Pressure (bar) 32. If no specimen fails (defined as fracturing or cracking through its complete wall thickness). no further test specimens need to be taken. 5.12. Impact Strength Test at 20 degrees C shall be carried out as described in Appendix ‘F’ to MS 628:1982.12.1 Heat Reversion Test on uPVC Pipes Heat Reversion Test shall carried out as described in Appendix ‘A’ to MS 628:1982.0 C D E All sizes All sizes All sizes One specimen shall be taken at random from each machine at least once every 8 hours running or once in every 300 metres run.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.4 43.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . and shall meet the requirement specified.0/06. Initially. A specimen shall be taken from each machine at least once in every 8 hours running and shall meet the requirements.4. sufficient specimens shall be taken at random from each machine so that at least one is taken per shift and at least 14 strikes made per extrusion run. A specimen shall be taken from each machine at least once in every 8 hours running. whichever is the greater quantity of pipe and shall meet the requirement. 5. The sample shall show no declamination or disintegration.0 percent and the sample after testing shall show no faults such as cracks.4 – Factory Hydrostatic Test Pressure Class Nominal size of pipes Min.12. cavities or blisters. Table 5.2 Resistance to Acetone Test on uPVC Pipes Resistance to Acetone Test shall be carried out as described in Appendix ‘B’ to MS 628:1982. 5. 5.12.

more than four specimens fail the test shall be discontinued. If the first 14 strikes cause four or more failure the pipes represented by the specimens shall be deemed not to comply with the specification. If the first 14 strikes cause no failure fracturing or cracking the pipes represented by the specimen shall be deemed to comply with the specification. A batch is defined as a continuous extrusion run of one size and class of pipe from one extrusion compound up to a maximum of 8 hours duration. further specimens shall be taken at random and tested to ensure a total of at least 42 strikes. 5. two or three failure.12.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .0/06. The colour of markings shall be dark blue. If during the test. 5. the pipes represented by the specimens shall be deemed not to comply with this specification if out of the 42 strikes five or more failures occur. If because of one. If series of pipes numbered from A 0001 to A 1800 the test on sample pipes of serial number between A 0201 to A 0250 inclusive fail to comply with tests specified in this specification then all the pipes bearing serial number between A 0201 and A 0250 inclusive shall be rejected. BHD. 61 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. 5.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.12.1. two or three specimens fail.14 Method of Rejection All pipes shall be serially numbered and have its serial number indelibly marked on the barrel so that pipes of any batch of fifty or part of it. then the whole batch of 50 pipes represented by the sample shall deemed not to comply with this specification and shall be rejected.13 Compliance Should the first cycle of any Routine Tests specified in clause 5.15 Marking of Pipes and Fittings All pipes and specials supplied shall have at least the following information:a) b) c) d) e) f) The manufacturer’s distinguishing mark The nominal size and class The letters SAJH (at least 75mm high) The date or the last two digits of the year of manufacture The serial number of pipe Standard reference Adhesive labels will not be accepted.1 to 5. strikes. manufactured within the same 24 hours which do not comply with this specification can easily identified and rejected. it is found necessary to increase the number of strikes to 42. one.4 of this specification fail to satisfy the requirement specified.

O copies of all test results. these should be stacked in alternate layers so that the sockets do not carry any load. 5.1.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 5. Pipes should be loaded on a vehicle in such a way that the overhang is not more than 1 metre.0/06. which have been performed on pipes to be supplied.16 Test Certificates The supplier shall submit the Test Certificate to the S. When loading socket and spigot pipes.17 Delivery Pipes made of this material are light and very easily damaged if it is not handled with care. 62 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. BHD.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

BHD. .0 – PIPELAYING QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.SECTION 6.

63 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. BHD.2 Pipe Cutting Where it is necessary to cut pipes to provide closing lengths or for laying pipe specials or in the repair of damaged or chipped pipes. Each welder will be assigned an operator reference number and only these welders will be allowed to weld the pipe joints. 6.O.O. setting up. The Contractor shall be responsible for the preparation.O.O. 6. These steel 'sized' pipes manufactured truly circular along their full length shall be marked by two longitudinal bends in paint along each pipe. PE pipes shall be measured and cut to suit site and temperature condition before being fusion jointed to the approval of the S. Only trained PE welders shall carry out butt or electrofusion welding.0 6. PE pipes shall only be cut by a universal pipe cutter or equivalent to the approval of the S. However. will advise the Contractor in writing which welders pass the performance qualification test. or his representatives. the cutting shall be neatly and accurately performed by skilled personnel so as to leave the end of the pipe truly normal to the axis of the pipe.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Closing length required to be jointed in trenches shall be jointed by electrofusion couplers.3 Welding Personnel Only the most highly skilled welders shall be employed on the Works. The welders are required to do a welding test on site to demonstrate their expertise. shall be at liberty to withdraw his approval to any welder responsible for making joints which fail to meet the required standard.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Every MS pipe welder before commencing any joint welding shall prepare specimens for testing in accordance with BS 4515 for each welding procedure proposed by the Contractor. provision of specimen. 6. all necessary equipment and materials for the testing of welding personnel.1 PIPELAYING Closing Lengths The use of closing lengths for pipes shall be avoided by laying the pipes in a continuous length. The S. The S. Closing lengths shall be located as near to access openings as possible so as to enable internal and external welding at joints to be carried out. The Contractor is required to show proof of the competency of their PE welders in form of certificates from pipe manufacturers or Gas Malaysia Sdn Bhd in using the specified automatic machines for butt and electrofusion jointing. where this proves impossible the Contractor shall use the special 'sized' pipes for cutting to the exact lengths required. Every welder shall be tested in accordance to BS 4515.1.0/06.

For PE pipe systems. For precise tightening. The bolts shall be tightened in regular sequence starting from opposite sides of the bolt circle and then going round in this way until every bolt is tight. Before jointing. or stuck to the flange with rubber solution. the MS flanges and bare metal on MS pipes shall be protected by anticorrosion paint as specified but no petroleum or bituminous based paint shall come into contact with PE stub ends. The use of jointing paste will not be permitted.1. 64 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Mechanical couplings and flange adapters located in chambers shall be painted with two coats of bituminous paint. preset torque wrench shall be used. The Contract Rates for making coupling and adapter joints shall cover all costs in complying fully with the requirements of this Clause.4 Making Joints with Mechanical Couplings and Flange Adaptors Mechanical couplings and flange adaptors joints shall be installed in strict accordance with the instructions given by the manufacturer and to the S. The ends shall then be recoated with a quick drying solution of bitumen so as to produce a smooth coat of uniform thickness. The Contract Rates for making flanged joints shall cover all costs in complying fully with the requirements of this Clause. Excessive tightening of flanged joints shall be avoided. BHD.5 Making Flanged Joints When making flanged joints care shall be taken to see that the rings remain in position undistorted while the bolts are tightened and the ring may be fastened to the bolts with cotton thread. the ends of each pipe shall be free of any debris and any protuberances which may have been caused by rubbing of the packing material and also be removed all rust at exposed places due to stripping of the bitumastic coating. The primer and sheathing material compatible to the sheathing material on the pipes and the mould boxes and funnels required to form the protective mould and whiting used for lining the mould boxes prior to each pour shall be supplied by the Contractor.'s approval. On completion of the joint the surfaces of the coupling and adapter shall be painted with a quick drying primer and an external sheathing mould formed to enclose the coupling and ends of the adjoining pipes. This work shall be carried out by specially competent and skilled men in strict accordance with the instructions given by the manufacturer.0/06. The exposed metal and welds on flanges on MS pipes which will be subsequently buried in trench and not encased in concrete shall be carefully wrapped with Denso' tape according to manufacturer's recommendation. 6.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O. 6. All MS flanges shall be protected with minimum 200 microns thick fusion bonded epoxy coating. The exposed part and welds and the flanges on MS pipes shall be painted with two coats of epoxy paint for flange located in chambers. who shall also supply the necessary boilers to heat the sheathing material to the application temperature.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

flexible joints shall not in general be partially or completely cased with concrete. PE Pipes and Fittings Spigot and socket ended MS and Ductile Iron and PE straight pipes shall be measured in linear metre. tees and other points where horizontal thrust will occur shall be supported with concrete blocks. PE pipes and specials shall include for the full cost of storage at Site. 6. Where concreting is required a sufficient amount is to be placed and left to set in position before the joints are made to prevent any subsequent movement of the pipes when further concrete is placed. tapers. Ductile Iron.O. pipe specials. Concrete bedding and haunching or surround shall be omitted for a distance of 150 mm from the face of flexible joints except as may be otherwise directed by the S. hauling and handling. valves and fittings shall be measured separately and by number... Steel.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . In general pipes shall be bedded on or protected by concrete in the following circumstances:(i) A 150 mm bed and partial haunch where the pipe is in rock. after deduction of the length of overlap at any spigot and socket joint to be made with the pipe.7 Concrete Protection to Pipes Pipes shall be bedded and haunched or fully surrounded in concrete where shown on the Drawings or as directed by the S. The Contract Rates for laying steel pipes.O. replacing damaged pipes where necessary and laying in position in the Works ready for jointing and/or building in together with other costs incurred in complying with the requirements of the Specification for which no separate items are included in the Bill of Quantities. 6.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.8 Thrust and Anchor Blocks Bends. Joints. 6. (ii) A 150 mm surround where the pipeline is under streams and ditches. repairing lining and sheathing. In order to allow relative movement between pipes. BHD.0/06. Cast Iron. Where pipes are laid at gradient steeper than 1 in 12 anchor blocks in concrete shall be provided at the middle of pipes as follows: - 65 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Flanges and flexible joints should not be cast in the concrete blocks. their lengths being defined as their effective lengths as laid measured along the centre line of the pipe.1. The cover between the side of the pipe and the excavated face of the ground which will subsequently take the thrust shall in no circumstances be less than 150 mm. The effective length shall mean the net length of the pipe as laid.6 Measurement of Ductile Iron.

Gradient Exceeding 1 in 12 1 in 8 1 in 3 Anchor Blocks Every third pipe Every second pipe Every pipe Details of thrust and anchor blocks are given on the Drawings. The Drawings shows pipe specials which are required for each crossing. The same care shall be taken as for thrust blocks to ensure that concrete transmitting thrust abuts against undisturbed ground. having regard to the likely thrust developed under test pressure and the actual nature of the ground. after examination of the ground prior to concreting.O.11 Payment for Pressure Testing Pipelines and Specials The cost for testing pipelines and specials shall include for the supply of clean water and all necessary testing apparatus.O. care shall be taken to ensure that additional cover over the pipes is allowed in order that the same passive resistance may be developed as would be the case in level ground. For thrust and anchor blocks to fulfill their purpose they must abut against undisturbed ground. 6. Where timbering has been used in the excavation it shall be withdrawn as the concrete is being placed. pumps.13.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. For horizontal bends in cross-fall ground. 6. however. Drainage from valve chambers to suitable outfalls shall be provided as directed by the S. The lines.O. BHD. and levels of the pipework shall be as shown on the Drawings or as directed by the S.9 Valve Chambers Valve chambers shall be constructed in accordance with the details shown on the Drawings or as directed by the S. if necessary and all other work. the exact requirements relating to the construction of each chamber. the cost of supervision and labour in testing and re-testing. materials and equipment in complying with the requirements of Clause 1.O. on site. pressure gauges. The Contractor shall first obtain from the S.. 66 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. 6.O. flowmeters and pipework. be amended by the S.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Additional anchor blocks may also be needed. The dimensions shown may.10 Crossing Over Streams. Culvert and Rivers Typical details of pipework and support arrangements of over-crossings at streams and rivers are shown on the Drawings.

2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . the cost of all apparatus. measurement shall be in accordance to the Bill of Quantities provided. and any necessary adjustments made to ensure correct operation. The operation of all valves including scour and air valves shall be checked and inspected jointly by the Contractor and S. The main shall be deemed to have been sterilised if the samples of water taken from various tappings on the main show minimum chlorine residual of 0. 6. dosing pump and other necessary accessories for the solution to be injected into the lines when treated water will be introduced gradually. Where the restoration is to be carried out by the Authorities. 6.2 ppm. The Contractor shall have to adopt a dosing system to sterilise the lines effectively. 6.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The system shall be provided with a set up of temporary equipment.O. The section of the treated water main to be sterilised shall be filled with water mixed with a solution of chloride of lime containing about 20 milligrams per litre of chlorine. supplying. chemical mixing tank mixer.12. it shall be flushed with clean water. After the main has been filled with chlorinated water.O.12 Sterilising and Flushing Pipelines When the final connections have been made and the pipelines have been tested to the satisfaction of the S. BHD. The Contractor shall be paid in accordance to the appropriate 67 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Water for sterilisation and flushing shall be obtained by the Contractor at his cost with a formal application and approval from SAJH.O. the Contractor shall comply fully with all regulations and requirements as stipulated by the Authority and such restoration shall be deemed to have been restored by the Contractor.14 Payment for Road Restoration Items in the Bill of Quantities for restoration of metalled roads except where expressly stated otherwise shall apply to road reinstatement. mixing and dosing chemicals. materials and equipment in complying with the requirements of Clause 6. The charges if any imposed by the Authorities for work carried out on metalled roads shall be deemed to be included in the relevant items in the Bill of Quantities. the cost of supervision and labour and all other work.O.13 Payment for Sterilising and Flushing Pipelines The rate for flushing and/or sterilising the pipeline shall include for the full cost of supplying and pumping water. it shall be closed and left for a minimum of 24 hours. Where the restoration is to be carried out by the Contractor. All necessary equipment (inclusive of approved flow meter) for the transfer of water is deemed to be included in the Contract Rates.0/06. After the main has been sterilised to the satisfaction of the S. the pipelines shall be again jointly inspected that they are cleaned before they are thoroughly sterilised and flushed by the Contractor. Consumer connections shall not be connected and commissioned before the pipelines has been sterilised and flushed to the satisfaction of the S.

rubbish and surplus spoil which may have been left on the ground or in and about the Works or lands temporarily occupied by the Contractor and he shall leave in a clean and slightly condition all and any lands occupied by him.0/06.17 Painting Pipework and Valves in Chambers After installation the exposed surfaces of all pipework. valves and fittings in chambers shall be properly cleaned. damaged areas and welded areas shall be power brush cleaned and painted with the same primer of same thickness. Then the whole of the exposed pipe shall be painted with 100 microns dry film thickness of two-pack high build amine-adduct cured epoxy paint followed by 50 microns dry film thickness of two-pack aliphatic polyurethane finish paint. plant.16 Indicator Posts The Contractor shall provide and fix precast concrete indicator posts. materials. washout. After installation. 68 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. excavation and backfilling.18 Painting Pipework Above Ground Steel pipework for installation above ground including stream and river overcrossings shall be painted with two pack polyamide cured epoxy zinc phosphate primer of minimum 75 microns dry film thickness at the place of manufacture. Indicator post shall be measured by number. details of which are shown on the Drawings on the centreline of the pipes at bends.O. Clearing up of the Site as herein specified shall follow closely on the refilling of the trench. air valves and other points as directed by the S. The rate for the supplying and fixing complete the posts shall include for all necessary concrete. Name and number plates fabricated from 16 gauge aluminium sheets with embossed lettering shall be fixed to the post with stainless steel screw and fibre glass washers.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . litter. Temporary reinstatement prior to final restoration shall be measured separately in addition to permanent restoration. Brand and colour of paints are to the approval of the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 6. rates in the Bill of Quantities.O. primed and painted thoroughly with approved paint.O. valves. BHD. The cost of supplying primer and paint and painting pipework and valves shall be included in the rates for laying pipes and the installation of valves. 6. The post shall be set in concrete firmly into the ground to the depths shown on the Drawings and the backfilling well rammed in and around. The paint required for these purposes shall be supplied by the Contractor and approved by the S. 6.1.15 Clearing Up During the progress of pipelaying work the Contractor shall clear up the Site and remove from the surface of the ground all temporary buildings. 6.

O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . If after due notice to the Contractor calling his attention to the necessity for the payment of fees and/or charges to the Authorities the Contractor has failed to make payment. BHD. 6. 6. The cost of all fees and charges payable by the Contractor shall be deemed to be included in the Contract Rates unless otherwise expressly provided for in the Bill of Quantities. Employer shall be entitled to pay such fees and/or charges direct to the Authorities concerned out of any moneys at any time due to the Contractor under the Contract and such payment shall be deemed to be payment made to the Contractor under and by virtue of the Contract. fees and charges required to be paid in relation to the execution of the Works or to any Temporary Works. and if necessary protected.0/06.20 Payment of Fees to Authorities The Contractor shall pay to all authorities all deposits. all materials and plant provided by SAJH and taken over by the Contractor but which have not been used in the Works. 69 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. These shall be placed and arranged.O.1. as directed by the S.19 Disposal of Surplus Goods On completion of the Works the Contractor shall deliver to the SAJH’s store as directed by the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

.SECTION 7. BHD.0 – PIPE JACKING QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

Alternatively.O.O.O.O. If movement or settlement occurs which in the opinion of the S. 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. may cause damage.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Plans and details of the equipment. reliability and soundness of the method employed in completing the work in a satisfactory manner. 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. for his approval.. shall not relieve the Contractor of his sole responsibility for the efficacy. Approval by the S. 7. No monetary or other claims made by the Contractor on the grounds of want of knowledge will be entertained. before commencing these operations. materials and the method of construction to perform and complete the work shall be submitted by the Contractor and must be approved by the S.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the Contractor shall take immediate action to prevent further movement. The Contractor's proposal must be submitted to the S. 7.0/06.1. settlement or damage. 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.1 PIPE JACKING General Pipe jacking shall be the process of installing precast reinforced concrete pipes below a surface obstruction by driving them successively through the in-situ soil from one pit (driving pit) to another (the receiving pit) such that the finished pipe forms a watertight continuous conduit between the pits on the desired alignment for the laying of MS pipeline.O. The Contractor shall satisfy himself as to the soil conditions along the pipe jacking route and if he judges it to be necessary. unstable ground ahead of the jacking face may be stabilised by the injection of suitable chemicals. he shall carry out further soil investigations at his own cost. utilities and pavement shall be monitored by the Contractor during the jacking operation and reported to the S. The omission of any details shall not relieve the Contractor of full responsibility for the satisfactory installation of the work in its entirety. Movement or settlement of structures.0 7.2 Tender Submission The tenderer shall submit with his tender the following particulars relevant to his design and proposal for pipe jacking :- 70 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. nor will methods which may lead to significant ground loss. Methods which require dewatering of the ground will not be accepted. BHD. He shall repair at his own cost any damage and restore structures or pavements to the satisfaction of the S.

7. fields and grassed areas. the Contractor shall replace all topsoil previously removed and it shall be evenly distributed and levelled over the full extent of the stripped area. the Contractor shall jointly with the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The Contractor shall restore all surfaces in a condition not inferior to that which existed prior to commencement of works.1. Road verges shall be restored to their original width and to a minimum fall of 1 in 24 away from the road and towards the ditch (if any). After refilling excavation as specified. Four (4) sets of drawings showing in sufficient detail his design and proposal. Restoration of the dip shall be carried out unless the fact that no dip existed prior to pipelaying has been recorded in writing and agreed to by the S. close turfed and maintained until the new grass is properly established at the Contractor’s expense.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .O. (I) (II) (III) Four (4) copies of a detailed specification giving full particulars of the jacking pipe. The tenderer's design and proposal shall be based on the general arrangements shown on the tender drawings which accompany the tender document as far as possible to suit the tenderer's proposed system.O. For the purpose of determining the required extent of reinstatements described above. Fields. etc.O. Where excavation is in road verges.0/06. pipe joint and construction method proposed.3 Surface Reinstatement in Road Verges. Other areas not originally covered with grass shall be restored to their former state. make assessment of the existing Conditions at each work site before the work commences. The Contractor shall produce two sets of photographs and other records of the existing situation on site and they shall be jointly signed. Four (4) sets of calculations of his design and proposal. 71 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Any damage to the metalled road due to pipejacking work alongside road verges or shoulders shall be reinstated to the satisfaction of the authority concerned at no extra cost to Employer. One set shall be kept by the Contractor and one set shall be submitted to the S. the turf previously removed will suffice for surface reinstatement providing that the grass has not been killed during stacking and that the surface is free from all loose stones. The working space occupied by the Contractor which was originally covered with grass if destroyed during the course of construction shall be covered with 50mm of topsoil. BHD.

and these shall not be removed until reinstatements has been completed. imposed by the Owner shall be deemed to be included in the Contract Rates. rains. Unless otherwise stated. well ahead of pipejacking and excavation. Approved marker posts shall be erected to mark the position of all located services. utilities or pavements shall be permitted.1. drains. etc. etc. 7. expenses. pipes. all costs.O. upheaval or settlement of soil which in the opinion of the S. No movement. The S. rental. in places where they are known or thought to be and elsewhere and these shall be backfilled with approved materials immediately and in any case not exceeding 24 hours and subsequently reinstated. drains.0/06. The pipeline laid in the jacked pipe sleeves shall pass the watertightness test specified for the pipelines in trench.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. shall instruct further prospecting if he is not satisfied with the sufficiency of the Contractor’s prospecting. may cause damage to structures. 72 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Attention is drawn to clauses concerning the responsibility of the Contractor for the security of existing services.O.6 Approval of Owner Before commencing preparations for pipe jacking the Contractor shall obtain the written consent to his proposed procedures of the Owner or Owners of the land.O. Trial holes and exploration trenches to ascertain the exact positions of these shall be sunk. charges. to the approval of the S. services and structures below which (or close to which) the jacked pipeline will pass. culverts. 7.. Where necessary the Contractor shall make arrangements prior to excavation of jacking and receiving pits and pipejacking proper for the temporary or permanent support or diversion of services. The Contractor shall be deemed to have allowed for the unavoidable delay of the Works due to any obstruction he may encounter with the existing services and no claim for any extra costs on account of this will be allowed. etc.4 Prospecting The Contractor shall prospect for the position of buried or otherwise hidden obstructions such as existing services. compensation etc. cables.5 Performance Requirements The centre-line of the fully jacked pipes forming a continuous sleeve shall at all points along its length be within 75mm of the required alignment in the horizontal plane and 25mm in the vertical plane.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The full cost of prospecting shall be deemed to be included in the relevant Contract Rates. and the authority concerned. BHD. 7.

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. for approval. Where a mechanical shield is used. The Contractor shall be required to furnish and install and remove to the extent required. sheeting. for approval.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The maximum tolerance allowable in the displacement of the centreline of the jacked pipe from the design centreline is 75mm in the horizontal plane and 25mm in the vertical plane but there shall be no backfall at any point.O. and he shall remove the excavated spoil to the jacking pit by conveyor to minimise traffic on the invert.O. a detailed schedule of the entire jacking operation. and for the efficient execution of the 73 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.7 Jacking Operation The Contractor shall be fully responsible for the materials. The crew for the operation of the shield must be specialist. BHD. thrust blocks or whatever provisions that may be required for backing up the jacks employed in jacking the pipe forward. Approval of such schedule shall not relieve the Contractor of his responsibility to provide a fully satisfactory installation.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 7.O. The pipes shall be jacked into place true to line and level. the Contractor shall submit to the S. During jacking and excavation. etc. This continuous work where required shall not be construed as overtime work. 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. The Contractor shall be fully responsible for the design and construction of the jacking and receiving pits.. with experience in the use of that particular type of machine. the Contractor must provide proof that the particular model of shield has been used successfully in soils similar to that on the site. Details of how the pipes are to be lowered into the pit and jointed shall be submitted to the S. The pipe ends shall be jointed by MS thrust collars/sleeves before the pipeline is jacked. The Contractor shall include with his submission evidence that he has successfully completed a jacking installation using procedures similar to those proposed. thrusting wall. Other method may be used subject to the approval of the S. The pipes for the jacking operation shall not exceed 4m long.. Where chemical stabilisation of soil is used. equipment and facilities required in conjunction with jacking the pipes. the Contractor shall constantly ensure that the internal lining of the jacking pipes is not damaged. installation of jacking equipment. Before starting work. a chemical grout shall be pressure injected into the soil over and ahead of the pipe jacking to stabilise the soil. After the jacking operations has begun. bracing. the Contractor shall work continuously and expeditiously in accordance to programme until the complete length of jacked pipes is installed.

hydraulic pressure testing of the pipelines and after the connections at the extreme ends of the MS pipeline have been made. Daily site records of thrusting pressures. 7. Grouting shall be undertaken through holes as specified herein. A ladder shall be fixed permanently in the receiving pit. 74 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. railway or structures along the pipeline route. Pits shall be securely fenced to prevent unauthorised persons from entering in. jointing of the length of jacked pipes.0/06.O. At the beginning of each shift and after any break for refreshment or other reason. operating procedures. shield machine. shall be submitted to the S. including plant.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . one on each side of the pipe jacking line.. He shall also backfill the pits with well compacted suitable approved materials. and shall leave the pits for meal breaks.1. rests and the like.O. These ladders shall be kept clear of obstructions to allow rapid exit in an emergency. the line and level measurements of the jacking pipes and any movement or settlement of existing structures shall be properly maintained and shall be submitted to the S.8 Safety The minimum of plant shall be used in the pits. the Contractor shall pressure grout the jacked pipes to fill all the voids existing outside the pipe. All costs associated with the provision of safety equipment and measures shall be deemed included in the Contract Rates. jointing and installing of the MS pipeline.. 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. BHD. For the sections of the pipeline crossing under roads. the Contractor shall provide and use an approved instrument to check for noxious gases before anyone re-enters either pit. Two ladders shall be permanently fixed on opposite sides of the driving pit. All persons entering the pits shall wear safety helmets constantly. Then. the Contractor shall be required to incorporate in his tunnelling method measures to arrest settlement or upheaval of the soil so as to safeguard the integrity of the structures and other property. and shall be fully satisfactory to him before construction. equipment. jacking operation. review of the plans shall not relieve the Contractor from his responsibility to provide a safe and satisfactory jacking pit. rate of thrusting. However. jacking pit and intermediate jacking stations etc. The Contractor shall ensure that the traffic flows along railway lines and roads are not affected in any way by his work. On successful completion of the jacking operation. Excavated materials and plant other than small tools shall not be passed via the ladder but shall be handled by crane.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Full details of the proposals. the Contractor shall remove complete 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.

All pipes shall be manufactured with two sets of grout holes. reinforcement and joint details. calculations.9 Design of the Jacking Pipes The Contractor shall design the pipes to be jacked and the pipe joints in accordance with the jacking procedure and operation proposed by the Contractor.0/06. The thrust collar shall be fitted onto the pipes with rubber rings to prevent the ingress of water into the pipe from outside. spalling or distortion. The nominal diameter of the jacking pipe shall be as shown in the Drawings for laying of the specified pipe. The length of each pipe shall not exceed 4m and the pipe ends shall have an external rebate suitable to accommodate a MS joint/thrust collar. (2) (3) (4) (5) (6) The jacked pipes shall be designed to withstand. Overburden load as shown on the Drawings. The precast reinforced concrete pipes shall be sufficiently reinforced with steel to withstand all stresses induced by handling. The collar shall be designed to take the jacking load applied and transfer the load to the next pipe. jacking. in conjunction with the jacking load applied.O. 75 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The proposal shall be endorsed by a Professional S.O. The design shall be submitted with full detailed calculations to the S. name and address of proposed manufacturer and the manufacturing processes to the S. the following external loads: (i) (ii) Highway loading of 45 units of Type HB loading in accordance with BS 5400.1.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 7.O. for approval. the maximum crack width developed on the pipe shall not exceed 0. The pipes shall be of at least strength Class ‘2Z’.25mm.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. When subject to the design load in such a test. Each set shall consist of three grout holes spaced at 120 degrees on centres circumferentially located at quarter points from either end of the pipe. for pipe jacking under JKR roads. for approval before construction commences.5 times shall be used in the calculations to determine the strength of the pipes required. The details of the jacking pipes are shown on the Drawings and the design shall take into account the following requirements: (1) The pipes for jacking operation shall be precast concrete pipes manufactured by centrifugal or other equivalent process to be approved by the S. BHD. The Contractor shall submit full details of his proposal for the pipes giving detailed drawings showing sizes. A load factor of not larger than 1. earth and water pressure and all working loads at the depth at which they are to be used without cracking.O. The strength of the pipes shall be tested by the three edge bearing test. All such tests shall be carried out at the expense of the Contractor.

0/06. The size. The end of the jacked reinforced pipe sleeve shall be grouted after the full length of MS pipe has been jacked/pushed through. supply ultrasonic examination equipment and other apparatus as may necessary to allow a thorough and extensive independent examination to be carried out.O. The walls of the pits shall only be removed when the backfill of the pits are completed.O. the MS pipe shall be jacked or pushed through the sleeve. Care shall be taken to ensure that the internal concrete linings are not damaged during the operation. materials. reserves the right to carry out any independent ultrasonic examination of the welded joints as he may deem fit.17. When the Contractor has completed the connections of the pipelines and has completed the protection of these connections with sand or concrete surround. The Contractor shall submit his proposals to the S. 76 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. or his representatives. The Contractor shall provide such assistance. Such independent ultrasonic examination shall be carried out by an Inspector appointed by S. of this Contract.O.O. for site ultrasonic examination. or his representatives. and paid through items in the Bill of Quantities. BHD. The Contractor shall maintain and keep these pits intact and in a safe condition to facilitate the connections.. 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 connections at the two ends of the jacked pipeline will be made at the jacking or receiving pits. After each section is jointed by welding and approved by the S.10 Laying and Connections of Pipeline in Jacked Reinforced Concrete Pipes Sleeve The laying of the MS pipeline shall only commence after the full completion of the jacking of the reinforced concrete pipes to the approval of the S. The S.14.1.'s instructions given as a result of the examination of ultrasonic results shall be final. The MS pipes shall be in length of 4 metres or less and to be jointed by welded split collars as specified in Clause 2. labour. he shall then backfill the pits with well compacted suitable approved materials. The bottom of the MS pipes shall be suitably supported on rollers or other means to prevent scouring of the MS pipe external surfaces. of this Contract.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. number and make of ultrasonic equipment proposed shall be stated. The pipe ends shall be properly braced to prevent damage. In addition all welded joints shall be tested by ultrasonic examination in accordance with BS 3923 in the presence of the S. electricity.O.O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 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. 7. Connections at the extreme ends of the MS pipeline shall be made only upon successful completion of the hydraulic pressure test of the pipeline as specified in Clause 2. The S. The Contractor shall provide adequate equipment and qualified and experienced personnel to conduct the ultrasonic examination.

0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 7.O.1.11 Alternative Method of Pipe Jacking Methods of pipe jacking other than described above may be proposed by the Contractor and subject to the approval of the S. 77 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. BHD.

.SECTION 8.0 – EARTHWORKS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BHD.

suitable for use in soiling areas to be grassed or cultivated. BHD.O. Trench. means excavation of trenches into which pipes or cables are to be laid to levels and limits specified on the Drawings or otherwise directed by the S. including turf.O. if excavated by hand. Such permission shall not absolve the Contractor from any of his obligations or liabilities under the 78 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. means excavation below or outside the limits of Bulk Excavation and Trench Excavation. 8. for Bulk. in his presence and such levels when agreed with him shall form the basis for measurement. means excavation in open cut (excluding Trench excavation and Incidental Excavation) down to levels specified on the Drawings or otherwise as being the general levels after completion of excavation. would normally have to be loosened either by blasting or by the use of pneumatic tools (excluding clay spades worked on an air compressor) or by other rock quarrying methods or.O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . means excavation outside the limits specified or shown on the Drawings or directed by the S.0 8.O.3 Explosives and Blasting The S. in the manner specified or as agreed with the S. Incidental and Excess Excavation(s) except where clearly stated to the contrary. 8. (iii) Bulk Excavation : (iv) Trench Excavation Incidental Excavation Excess Excavation : (v) (vi) : : All reference to "excavation" or "excavations" shall apply to Bulk.15 cubic metre in volume. restrict or prohibit blasting if in his opinion it is necessary to do so for the safety of persons or property or to safeguard the Works. No blasting shall be carried out in any part of the Works without the permission in writing of the S.O. means material which in the opinion of the S.1 EARTHWORKS Definitions The following terms shall have the meanings hereby assigned to them :(i) (ii) Topsoil Rock : : means any surface material. shall have power to regulate.0/06.2 Levels to be Recorded Before the surface of any part of the Site is disturbed or the works thereon are begun the Contractor shall take and record levels of any such part.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. An isolated solid boulder or detached piece of rock shall qualify as Rock only if it exceeds 0.1. 8. by the use of wedge and sledge hammers. Trench or Incidental Excavation.O.

O. sewer or other services. strength. Y and Z planes and record measurements digitally. storage. etc. Contract and he shall take all necessary precautions including the use of blasting nets to avoid damage. positions of charges. detonation delays.O. may direct. depths.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . water main. of any existing structure. all excavations into rock by blasting to prepare foundations for any proposed reservoir next to existing reservoir shall be carried out with extreme care. of concrete placed in the Works. Notwithstanding the above. due to the close vicinity of the existing reservoir. The Contractor shall provide vibration measuring instruments to monitor the magnitude of vibration caused by the proposed arrangements with respect to explosive charges. Approval of the Contractor's proposal shall not absolve him from responsibilities in the event that the existing structures are damaged as a result of the blasting method used. 79 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. spacings. fully informed at all times when blasting is proposed to be carried out and of any details that may be required concerning strength of charges and their positions. electric cable.4 Disposal of Materials All requirements herein for the disposal by the Contractor of materials arising from site clearance or from excavations are subject to the provisions of the Specification. BHD. or such greater or lesser distances as the S. the Contractor shall submit to the S. loss or injury to persons and to public or private property. transport and handling of explosives and shall provide a store or stores suitable for explosives in accordance with local regulations.O.O. All details regarding the type of explosives or chemicals.1. Pilot tests to assess the effectiveness of the controlled blasting shall be conducted at an approved location within the site before the method is approved. Explosives shall not be used within 15 metre. The instrument shall be able to measure resultant peak particle velocities from measurement in X. a detailed controlled blasting plan. The Contractor shall obtain the necessary permits and licences for the use. Sensors shall be mounted at different positions on the existing structures as instructed by the S. Before any rock blasting commences. spacings. The cost of providing such vibration measuring instrument shall be deemed to be included in the rates for rock excavation in the Bill of Quantities. The Contractor shall keep the S. pipelines and structures. The instrument shall be a triaxial vibration recorder or similar and shall be capable of measuring velocities in the range of 50-70 mm/sec.0/06. The purpose of the control of blasting operations is to eliminate any possibilities of damage to the existing reservoir.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 8. detonation delays used and the method of monitoring the magnitude of vibration generated shall be supplied to the S.

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

8.5

Excess Excavation to be made good The Contractor shall at his own expense be required to fill the Excess Excavation with such kind of suitable fill material or in such class of concrete as may be reasonably required by the S.O. having regard to the circumstances. Any surplus unused or unsuitable material resulting from Excess Excavation shall be removed from the Site by the Contractor at his own expense.

8.6

Site Clearance All areas of the Site marked on the Drawings or specified for clearance or from which material is to be excavated or upon which filling is to be deposited shall be cleared to the extent required by the S.O. of all buildings, walls, gates, fences and other structures and obstructions and of all bushes, hedges, trees, stumps, roots and other vegetation except for trees marked for preservation. Material so cleared shall be disposed off the sites to dumpsites approved by the local authority or as may be reasonably directed by the S.O. Open burning of cleared materials is strictly prohibited.

8.7

Trees Trees shall be uprooted or cut down as near to ground level as possible. Branches and foliage shall be removed and burnt to ash or disposed of off the Site. Useful timber within Reserved Land of the Government or Authorities shall remain the property of the Government and shall be cut into suitable length and stacked properly.

8.8

Stumps Stumps and roots whether existing or remaining after tree felling shall where directed by the S.O. be grubbed up and disposed of off the Site. The resulting hole shall be filled with approved material and properly compacted to the same dry density as the adjoining soil.

8.9

Measurement of Site Clearance Items in the Bill of Quantities for site clearance shall include for clearing the Site all as specified including all fallen trees and their stumps. Site clearance shall be measured as the area so cleared on plan to the S.O.'s requirements and instructions.

8.10

Stripping Topsoil Where ordered by the S.O. topsoil shall be stripped, to such depths and over such areas as he may direct, as a separate operation prior to any further excavation which may be required.

80 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

8.11

General Excavation General excavation means excavation, whether Bulk or Incidental, required for structures and shall not include Trench Excavation. The ground shall be excavated by such methods and to such dimensions and depths as shall allow for the proper construction of the Works. Where nominal 'payment' limits of excavation are not shown on the Drawings or otherwise specified they shall be deemed to be the minimum net limits which would allow the outline of the completed structure to be lowered vertically from ground level into its final position. The Contractor shall make his own allowance for any working space required, and any excavation outside the aforesaid limits which has not been ordered by the S.O. whether it be excavated to suit the Contractor's method of working or unavoidable overbreak or due to his carelessness or error, shall be held to be Excess Excavation.

8.12

Trench Excavation The line and level of trenches shall be as shown on the Drawings or as directed by the S.O. Before commencing Trench Excavation, the route of the trench shall be pegged out accurately and the existing ground levels shall be agreed with the S.O. Strong sight rails shall then be fixed and maintained at each change of gradient, and at as many intermediate points as may be necessary. On these rails shall be marked the centre line and the level to which the excavation is to be carried out, such rails being not more than 35 metre apart. Trench Excavation shall be carried out by such methods and to such lines dimensions and depths as shall allow for the proper construction of the Works, provided always that, unless the S.O. permits otherwise and subject to any specific requirements of the Specification no Trench Excavation shall be less than the widths stated below :D Clear Width of Trench for Backfill With Excavated Material MS/DI PE Pipes Pipes NA D + 450mm D + 600mm Clear Width of Trench for Trench for Backfill With Sand MS/DI PE Pipes Pipes NA D+ 450mm D + 600 mm 300mm D+300m m -

Communication pipes up to 63mm OD Not exceeding 500mm Exceeding 500mm but not exceeding 750mm

Where D in mm is the external diameter of the MS and DI pipe including any sheathing. Where D in mm is the nominal external diameter of the PE pipes. 81 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

Notwithstanding the foregoing, any rock in trench excavation shall be so excavated that the clearance between the pipe when laid and the rock sides and bottom of the trench is kept to the minimum limits necessary to provide for the specified thickness of bedding haunching and surround to the pipe. Any excavations outside these limits whether for working space or due to overbreak shall be held to be Excess Excavation. The sides of Trench Excavation shall be vertical as far as possible. However, the Contractor shall be responsible to take the necessary precaution and safety measure to ensure such Trench Excavation is safe for working. Stones shall be removed from the trench invert and holes so formed shall be filled with well compacted selected soft material. Where mechanical excavators are used, the last 150 mm of the excavation shall be removed with care to the required depth, and the trench invert carefully trimmed true to level. Any widening or deepening of Trench Excavations necessary to accommodate curves, joints or bends in the pipe or to provide extra working space for the construction thereof shall be held to be Excess Excavation. Trench Excavation shall wherever practicable be carried out in such a way that every part of the excavation is at least 600 mm clear of the existing edge of the carriageway. In any event the Contractor shall take special precautions, which shall include the continuous support of the sides of the excavation, from the time when excavation is begun until the refilling of the trench is placed, to ensure that there is no disturbance of the adjacent road or road foundation. For the purpose of measuring certain work in connection with Trench Excavation "nominal limits" of Trench Excavation are stated above and any excavation outside these limits, which have not been ordered by the S.O. shall be held to be Excess Excavation. 8.13 Trench Excavation in Roads, Road Shoulders and Footpaths All Trench Excavation and other work carried out within the limits of any road reserve shall be completed as rapidly as possible and not more than half of the width of the carriageway shall be obstructed at one time unless a full diversion has been provided and approved by the Authorities. A minimum width of 4 m wide of traffic lanes shall have to be kept clear for flow of traffic and where necessary the shoulder should be strengthened to the satisfaction of relevant Authorities at the Contractor's own cost. Road drains and grids shall be kept free from obstruction. Where trenches are excavated in public roads, road shoulders and footpaths of congested areas necessitating carting spoil to distant tips, the Contractor shall employ suitable plant to ensure that the passage of traffic past the Works is not impeded by the loading and unloading of spoil. Excavated materials shall not be left standing on road pavement. All trenches on metalled roads shall not be left open for more than one day and all trenches on road verges shall not be left open for more than three days. Tarmacadam and similar road surfaces shall be broken out neatly along the trench line using a diamond disc road cutter to keep the edges straight and vertical. 82 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

8. The quantities of Rock or material alleged to be Rock excavated from within the nominal limits of excavation shall be recorded by the S. Any extra excavation necessary to provide space for such support or other working space shall be held to be Excess Excavation. plantations. for any reason. Overbreak (that is excavation outside the nominal limits of excavation) shall be kept to a minimum and shall be held to be Excess Excavation. any portion of the bottoms. padi.0/06. These materials shall only be classified as 'Rock' when.O.1 shall be notified to the S. The Contractor shall also provide barricades to fence off the works and approved road sign boards placing at regular intervals to ensure safety of the public and vehicles.15 Rock and other Materials in Excavations Any material in the excavations which the Contractor considers may be classified as Rock as defined in Clause 8. etc.16 Supporting Excavation The Contractor shall well and effectively support the sides and ends of all excavations to prevent any fall or run from any portion of the ground outside the excavation and to prevent settlement or damage to structures adjacent to the excavation. to perform excavations with sloping faces (other than sloping excavations shown on the Drawings or required as permanent features of the Works) and without 83 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. sides or ends of any excavations shall give way the Contractor shall at his own expense take all necessary remedial measures including the excavation and removal of all the ground thereby disturbed both within and without the nominal limits of excavation and such extra excavation shall be held to be Excess Excavation. including the continuous support of the sides of the excavation from the time excavation is begun until refilling of the trench is completed to ensure that there is no disturbance of the adjacent road or road foundation. in the opinion of the S. may require.14 Trench Excavation in Fields. Where the Contractor elects and is permitted by the S. Bulk excavation of these materials shall include the use of an efficient parallelogram type ripper having a single shank in sound working condition for attachment to a track machine also in sound working conditions with a minimum weight of 24 tonnes and a nett power rating of not less than 240 hp. These materials are tough and may exceed conventional methods of excavation.1. If. and the Contractor each day or at such shorter intervals as the S.1.O. Materials like shale and weathered sandstone strata may not be classified as 'Rock' within the meaning of Clause 8. recorded and signed shall qualify for additional payment as Rock..O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The Contractor shall take special precautions. The Contractor shall have particular regard to the safety of livestock in fields or which may be introduced to the fields. they cannot be ripped efficiently as described above. grass verges and the like. The term "fields" includes fields. 8.O. and shall ensure that all excavations.O. 8. BHD.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. before excavation of the material is begun. Only such proportion of material so notified. access routes and steep or loose slopes arising from the Contractor's operations in these fields are adequately protected.

O. soft or loose during the progress of the Works.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O.0/06. Should the material forming the bottom of any excavation. shoring.O. at the time of his inspection. Such further excavation shall be held to be Excess Excavation. subsequently become unacceptable to him due to exposure to weather conditions or due to flooding or have become puddled. Before commencement of any constructional work all shattered and loose material shall be removed from the excavations by hand so as to ensure that the work rests on a solid and perfectly clean foundation or abuts against solid ground.. BHD. 8. selected excavated materials or selected imported material as directed by the S. where required by the S.18 Inspection of Excavation When the specified levels or limits of excavation are reached the S. the Contractor shall remove such damaged. Should the Contractor have excavated to within 150 mm above these specified levels or to within 150 mm of these specified limits before he is ready or able to commence the constructional work he shall.17 Trimming Excavations When excavating to specified levels for the foundation of any structure or pipes or to specified limits for the faces of any structure required to abut against undisturbed ground the Contractor shall not excavate the last 150 mm until immediately before commencing the constructional work. shall permit otherwise. but shall not be held to be Excess Excavation. softened or loosened material and excavate further by hand. while acceptable to the S. 8.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .19 Filling to Embankments and Backfilling to General Excavation Excavated material including imported material used as filling or backfilling to excavations or completed structures or as fillings to embankments or to raise the ground level shall be free from clods and lumps and shall be approved by the S.O. except where the S. excavate further so as to remove not less than 150 mm of material immediately before commencing the constructional work and such further excavation shall be held to be Excess Excavation.O.1. The approved material shall be placed in layers not exceeding 225 mm depth before compaction and shall be compacted to a dry density not less than 90% of the maximum dry density obtained in Test 11 of BS 1377 except for the top 3m of the embankment filling and filling under structures where the minimum dry density shall be 95% of the maximum 84 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. will inspect the ground exposed.O. Such further excavation shall be refilled to the specified levels or limits with concrete. the excavated faces shall be to stable slopes and heights and the resulting extra excavation shall be held to be Excess Excavation. and if he considers that any part of the ground is by its nature unsuitable he may direct the Contractor to excavate further. 8.

dry density. due to exposure to weather conditions or due to flooding or have become puddled. 8. the Contractor shall at his own expense remove such damaged. Should the material being placed as filling or backfilling. the Contractor shall at the end of the Defects Liability Period remove any excess material or make up any deficiency of backfilling or filling to the specified levels. Trench Excavation shall be carried out expeditiously and. After such drying out or adding of water. The excavated material shall be soft material free from stones of all kinds shall be deposited in 150 mm layers and thoroughly rammed under and around the pipe with suitably shaped rammers working alternately on either side of the pipe (particular care being taken to avoid damage to the pipe and any sheathing) until the trench has been refilled up to the swell of the pipe. Joint holes may be left unrefilled until the joints have been air tested and moulded or protected. BHD.O.O. Where necessary the Contractor shall adjust the moisture content of the fill or backfill material either by drying out or adding of water. Where necessary. Pipelaying shall follow closely upon the progress of Trench Excavation.20 Trenches Not to be Left Open No length of trench excavation shall be started until the pipes to be laid in that length are available on Site.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The Contractor shall take precautions to prevent flotation of pipes in locations where Trench Excavations may be flooded and these precautions may include the partial refilling of the trench leaving pipe joints exposed while awaiting tests of the joints. If the S. 8.21 Refilling Trench Excavation Trench Excavation shall normally be refilled using suitable materials selected from excavations carried out within two hundred metres of the length to be refilled. considers that the Contractor is not complying with any of the foregoing requirements he may prohibit further Trench Excavation until he is satisfied with the progress of laying and refilling of Trench Excavation. The Contractor shall when placing the filling or backfilling make due allowance for any settlement that may occur before the end of the Defects Liability Period . softened or segregated material and replace it with fresh approved material. and thereafter until the soft filling has been carried up at least 300 mm above the top of the pipe. 85 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. or imported fill materials. and the Contractor shall not permit the carrying out of Trench Excavation in unreasonably excessive lengths until pipelaying matches up with the progress of Trench Excavation.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . become unacceptable to the S. soft or segregated during the progress of the Works. the fill shall be thoroughly mixed until the moisture content is suitable. while acceptable at the time of selection.0/06. subject to any specific requirements of the Contract.1. the refilling and surface reinstatement of Trench Excavation shall be commenced and completed as soon as reasonably practicable after the pipes have been laid and jointed.

Where necessary the Contractor shall adjust the moisture content of the refill material either by drying out or by adding water to assist the compaction of the material. will leave the finished work sufficiently "proud" to allow for future settlement to the original ground level. Quarry dust shall not be considered for use as filling material. The reinstated surface shall be rolled with a two-tonne roller when the material is dried. The topping of the refilling shall be in accordance with the remainder of the refilling for trench excavation as described above for backfill with excavated material. the Contractor shall not use such material for refilling trenches and shall only use fresh approved material. become unacceptable to the S. BHD. The sand material shall be deposited in 150 mm layers on both sides of the pipe simultaneously and thoroughly compacted and around the pipe working alternately on either side of the pipe until the trench has been filled up to 150 mm above the top of the pipe except for pipes laid in roads where the sand backfill shall be brought up to the base course formation level..QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.1.0/06. while acceptable at the time when approved. Sand filling such as mining sand or river sand filling within the grading limit will be accepted for use. Sand backfilling to trench excavation shall be provided as shown in drawing or as directed by the S. 86 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Should the material to be placed as refilling.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .O. sufficiently dense to prevent material from the superimposed layers being washed into the voids in such refill. The sand filling material shall be compacted either by a suitable mechanical vibrator and/or by an approved system of water jet. in the opinion of the S.O. The remainder of the refilling may consist of coarse material free from boulders and clods of earth larger than 150 mm in size provided that the compacted refill is. soft or segregated during the progress of the Works.O. Trench Excavations shall be refilled with concrete to the heights and limits as shown on the Drawings and where directed by the S.O. Any part of the reinstated surface that settled beyond the adjacent original ground level the Contractor shall have to make good of the settlement to avoid formation of drains or gulleys within the refilled trenches. The coarse filling is to be carried up to the level at which surface reinstatement is to commence or to such level at which the surface reinstatement of the whole of the topsoil. This coarse material shall be spread in layers of depth not greater than 225 mm and be thoroughly rammed by an approved mechanical rammer or pan vibrator. due to exposure to weather conditions or due to flood or have become puddled.

24 Treatment of Material from Excavation Subject to any specific requirements of the Contract.O. (c) And the Contractor shall do any or all these things as directed.22 Soft Refill Material .1. stumps.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . BHD. To excavate soft material from suitable borrow areas and transport it to the length of trench to be refilled.Special Measures Where in the opinion of the S. topsoil being placed in separate spoil tips where so ordered.23 Temporary Spoil Tips on the Site Temporary spoil tips may be used to store excavated material as required and shall be arranged by the Contractor subject to the S. namely. The Contractor shall ensure that no excavated material which is suitable and is required for re-use in the Works is disposed off outside Site.O. 8. No tree trunks. soft material. and the Contractor shall do any or all these things as directed. sufficient supply of the aforesaid soft material for trench refilling cannot reasonably be obtained from Trench Excavations within two hundred metres of the length of trench to be refilled without resorting to sieving or other special means then the S.O.'s approval having regard to any particular requirements of the Contract. and backfilling to general excavation including any necessary double handling. 8. may direct of any of the various grades of material hereinafter specified for the refilling and surface reinstatement of excavations. hard material and topsoil. Where the nature of the excavated material is suitable the Contractor's temporary storage as aforesaid shall include for the separate storage as the S. the Contractor shall make his own arrangements for the temporary storage of any excavated material which is required for use in refilling Trench Excavation. shall be placed in the temporary spoil tips. roots. Temporary spoil tips shall be so shaped as to maintain stability and good drainage at all times.O. 8.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. branches or rubbish of any kind shall be placed in spoil tips.O. To transport suitable soft material from Trench Excavations at distances greater than two hundred metre from the length to be refilled ("overhaul"). In this connection the Contractor shall have regard to the working areas available to him for the construction of the Works. shall order the Contractor:(a) (b) To carry out such work as may be necessary to sieve out stones.0/06. 87 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Any temporary tips alongside the excavations shall be to stable slopes and heights. coarse material. Only material which is approved by the S.

fields and grassed areas. After refilling Trench Excavation as specified. Fields. Any damage to the metalled road due to pipelaying work alongside road verges or shoulders shall be reinstated to the satisfaction of the authority concerned at no extra cost to the Employer.1.26 Works in Roads and Road Reserves Where work is carried out within road reserve. fees. close turfed and maintained until the new grass is properly established at the Contractor's expense. The working space occupied by the Contractor which was originally covered with grass if destroyed during the course of construction shall be covered with 75 mm of topsoil.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . BHD. etc.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Where Trench Excavation is in road verges.25 Surface Reinstatement in Road Verges. Restoration of the dip shall be carried out unless the fact that no dip existed prior to pipelaying has been recorded in writing and agreed to by the S. the turf previously removed will suffice for surface reinstatement providing that the grass has not been killed during stacking and that the surface is free from all loose stones. The Authorities may impose charges for works carried out on road verges and metalled roads and the Contractor shall pay the Authorities and recover the cost under the appropriate items in the Bill of Quantities. Other areas not originally covered with grass shall be restored to their former state. Any excavated material not required or not suitable for use in the Works shall become the liability of the Contractor and he shall be entirely responsible for its removal from the Site and for its ultimate disposal. Road verges shall be restored to their original width and to a minimum fall of 1 in 24 away from the road and towards the ditch (if any). etc. the Contractor shall comply fully with all regulations and requirements in force in that place by all relevant local and public authorities (hereinafter referred to as Authorities).O. 8. The times of working allowed by the Authorities may or may not fall within day light hours or within the normal working hours of the Authorities. 88 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The Contractor shall restore all surfaces in a condition not inferior to that which existed prior to commencement of works. which may be imposed by the relevant Authorities. 8.0/06. the Contractor shall replace all topsoil previously removed and it shall be evenly distributed and levelled over the full extent of the stripped area. The Contractor shall comply with all the regulations for the disposal of surplus excavated materials off the site including the payment of royalties.

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

8.27

Surface Reinstatement in Roads and Footpaths Surface reinstatement of roads and footpaths shall be restored to the approval of the S.O. and to the requirements of the Authorities concerned or the owner or tenant. Any settlement or defects prior to final surface reinstatement shall be made good by the Contractor to the satisfaction of the S.O. Where the pipe trench crosses or is along tarmacadam roads and footpaths belonging to private owners or Authorities, the pipe shall be surrounded with sand and topped up with 375 mm thick of crusher run material followed by 100 mm thick of dense bituminous mix comprising 60 mm thick binder course and 40 mm thick wearing course. The crusher run and binder course surfaces shall receive a layer of tack coat before the application of binder course material and wearing course materials. All fill materials shall be compacted by approved means. The consolidated surface shall be brought up to the same level or the adjoining road. Any subsidence shall be filled in by the Contractor using the same materials. The road shall be kept continuously at its proper level to the satisfaction of the S.O. and the Authorities from the date of filling in the trench until the surface is finally restored. All materials for this reinstatement and subsequent maintenance shall be supplied by the Contractor. When any section has been reinstated as specified the Contractor shall notify the S.O. who in the presence of the Contractor shall inspect the length of reinstated trench. The S.O. shall at this inspection indicate any further reinstatement required and the Contractor shall complete this work to the satisfaction of the S.O. and the authority concerned within fourteen days of the inspection. Acceptance of reinstatement by the S.O. or the Authorities at this inspection shall not relieve the Contractor of his responsibility for the maintenance of surfaces as specified above.

8.28

Payment for Road Restoration Items in the Bill of Quantities for Restoration of Metalled Roads except where expressly stated otherwise shall apply to road reinstatement. The charges if any imposed by the Authorities for work carried out on metalled roads shall be deemed to be included in the relevant items in the Bill of Quantities under Restoration of Metalled Roads. Where the restoration is to be carried out by the Contractor, measurement shall be in accordance to the Bill of Quantities provided. Where the restoration is to be carried out by the Authorities, the Contractor shall comply fully with all regulations and requirements as stipulated by the Authorities and such restoration shall be deemed to have been restored by the Contractor. The Contractor shall be paid in accordance to the appropriate rates in the Bill of Quantities. Temporary reinstatement prior to final restoration shall be measured separately in addition to permanent restoration.

89 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

If after due notice to the Contractor calling his attention to the necessity for further reinstatement of any trenches across roads and footpaths, he has failed to make good the reinstatement, the Government or the appropriate Authorities may proceed with such repairs and the cost of such reinstatement shall be deducted by the Government from any payments due to the Contractor. Towards the end of the Defects Liability Period the S.O. will inspect the pipeline route in the presence of the Contractor. In the event that final road reinstatement is to be carried out by the Authorities concerned, the Contractor shall carry out temporary reinstatement for the vehicles to pass over it. The temporary reinstatement includes the trench to be refilled with sand, topped with 375 mm thick of crusher run material and followed by a layer of tack coat and 40 mm thick of dense bituminous mix wearing course. All filled materials shall be compacted by approved means. The Contractor shall carry out final reinstatement of public roads and footpaths only if he is instructed by the S.O. Otherwise final reinstatement of these roads will be carried out by the Authorities as and when agreed between the Authorities, the S.O. and the Contractor. The Contractor shall pay the Authorities and shall recover the cost under the appropriate items in the Bill of Quantities. No quantities of final reinstatement beyond the limits of Trench Excavation specified or reinstatement due to Excess Excavation, settlements adjacent to Trench Excavations or damage to road surfaces in the course of pipelaying shall be measured for payment. 8.29 Other Structures in the Pipeline The Contractor shall carry out further excavation as may be necessary to accommodate structures such as thrust blocks and valve chambers. Such excavation shall include for disposal of surplus material and, where appropriate, for backfilling round the structures. 8.30 Land Drains Where land drains, mole drains or field drains are severed by Trench Excavation they shall be kept in effective temporary operation during construction of the pipeline. The Contractor shall submit to the S.O. for approval a temporary drainage arrangement to ensure the water course is not hindered during the construction. The drain on either side of the Trench Excavation shall be cut-back for at least 300 mm and temporary pipes of suitable length and diameter shall be jointed to the existing drain and laid resting with the ends on solid ground with suitable stopping to prevent the subsequent run of land drainage water into the pipe trench. During trench re-filling, the refill material shall be carefully placed and thoroughly compacted under the temporary pipes to give them adequate support. Should any existing sub-soil or field drains be uncovered during general excavation, the Contractor shall either carefully replace them when 90 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

QUALITY ASSURANCE DEPARTMENT

SAJ HOLDINGS SDN. BHD.

backfilling, or if this is impracticable shall divert them to new drains or ditches, or otherwise relay them as the S.O. may direct. At the appropriate stage of refilling the Trench Excavation the drains shall be permanently restored to the satisfaction of the S.O. 8.31 Care of Existing Services Information relating to the positions of all existing mains, cables, culverts, pipes, drains or services of any kind shall be ascertained by the Contractor. Notwithstanding any information which may be furnished by the S.O., the Contractor shall be responsible for ascertaining from his own inspection of the Site and from the respective supply authorities and other public authorities the positions of all mains, pipes and cables whether underground or overhead, within or near the Site. Where services are shown on the drawings or where there is evidence of services in the ground, the Contractor shall also determine their exact positions. In addition the Contractor shall watch for and determine the position of any service which may not have been marked. Where Trench Excavation is carried out close to or across the line of sewers, pipes, cables and other services the Contractor shall provide temporary adequate supports to secure the services and where such sewer, pipe, cable or other service is temporarily displaced or disturbed it shall be restored to its original state. If restoration of any service to its original state cannot be achieved then it shall be replaced and made good. The cost of excavating around any service which crosses the trench, and of temporarily supporting it while pipelaying is undertaken, shall be deemed to be included in the rates for excavation. All damage to services shall be made good to the satisfaction of the S.O. and the authorities concerned. The cost of making good any damage shall be deemed to be included in the rates for excavation. In the event that any damaged service shall only be repaired by the authority concerned, all costs whatsoever relating to the repairing of the damaged service undertaken by the authority shall be at the Contractor's expense. Where damage to a service had already existed prior to excavation or other work, repair of the damaged service shall be undertaken by the Contractor, if so ordered by the S.O. and the Contractor shall be paid on Daywork for repairing such service. Where in the opinion of the S.O., construction of the pipeline cannot reasonably be carried out unless the sewer, pipe, cable or other service is permanently severed or permanently diverted or permanently supported the Contractor shall undertake such work if so ordered by the S.O. Any such work if carried out shall be to the satisfaction of the S.O. and of the authority concerned and shall be paid for at Daywork where necessary and at the appropriate Contract Rates. Where pipes are laid under culverts they shall, subject to other provisions in the Contract and to the S.O.'s instructions, be given a concrete surround extending for 600 mm clear on each side of the culvert, and a concrete half haunch to the culvert shall be provided over the width of the trench cast directly on top of the concrete surround. The cost of all work in removing any piles and concrete bed under culverts and of temporarily supporting the 91 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD

the means of disposal being the Contractor's responsibility. double handling. items for Rock. filling. temporary fencing. During the Defects Liability Period all hedges replanted in the above manner shall be inspected and any dead plant replaced by the Contractor.34 Measurement of General Excavation Items in the Bill of Quantities for "excavation" except where expressly indicated otherwise shall apply to excavation where Bulk. BHD. 8.O.1. shall include for any allowance the Contractor considers necessary to cover overbreak and the making good thereof.O. 8. provide temporary fencing for any parts of such barriers as have had to be removed.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Etc Where the pipeline crosses underneath rivers. In the case of a hedge the section removed shall be replaced by new plants of the appropriate variety and where ordered by the S. Incidental or Trench in any material and shall not only include for all work in connection with excavation but shall also include for all loading and transportation. culverts and other watercourses the Contractor shall be deemed to have allowed for all the additional measures necessary for the proper construction of the pipeline including maintaining the full flow of water. the plants shall be protected from livestock on both sides by an adequate post and barbed wire fence. may order for permanent restoration of such barriers.O. Incidental Excavation for removal of unsuitable material shall (unless it is held to be Excess Excavation) be measured as the volume ordered by the 92 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. Items for "Excavation in Rock" measured Extra Over (E.33 Crossing Watercourses. After trenches have been refilled and surfaces reinstated. All work in connection with excavation and subsequent disposal of excavated material as specified shall be valued by measurement of such items as are set forth in the Bill of Quantities for "excavation" and where appropriate of the further E. No separate payment shall be made in respect of Excess Excavation or the backfilling thereof. All such measurements unless otherwise specified shall be the net volume of the voids to be formed by the removal of material excavated to the specified levels and limits described herein or shown on the Drawings. as a temporary measure during construction of the pipeline. backfilling and for disposal of surplus materials. culvert during pipelaying shall be deemed to be covered by the rates for the items in the Bill of Quantities for pipe crossing under culverts.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the Contractor shall carry out work as the S.0/06. fences and walls the Contractor shall. Fences and Walls Where the Trench Excavation passes under barriers such as hedges.32 Hedges. 8.) other excavation items. no allowance being made for bulking.

O. S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . for temporary fencing and.) excavation and filling for payment.O. BHD.0/06.35 Measurement of Trench Excavation Items for Trench Excavation shall apply to excavation in any material and shall include not only for all work in connection with excavation but also for refilling of trenches spreading and compacting excavated material over pipeline reserve as directed and for disposal of surplus material.O. Items in the Bill of Quantities for excavation and filling shall be measured as the volume after compaction of the fill material placed to the limits and depths shown on the Drawings or as directed by the S. The Contractor shall be deemed to have made his own allowance for compaction and for any "loss" of material into the ground below the embankment.O. The net volume of voids ordered to be refilled within the normal width of trench excavation shall be measured for payment. (as defined as aforementioned) shall be measured as extra over (E. chambers. Excavation in borrow areas for refilling of trenches shall include for loading and transporting the excavated material from borrow areas which are not more than two hundred metres from the length of trench to be refilled. 8. Where such distance is in excess of two hundred metre ("Overhaul distance").O. for the stripping and subsequent reinstatement of the top surface all as specified.1. to accommodate joints and bends in the pipeline and to provide working space. thrust blocks and the like. to be excavated beyond the nominal dimensions of general excavation and shall include for the disposal of the excavated material off the Site and for refilling the excavation with approved material emanating from excavation elsewhere or refilling with the grades of concrete as may be reasonably ordered by the S.) excavation for payment.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The length of Trench Excavation shall be measured through and including any space occupied by manholes. Trench Excavation shall be measured by length along the centre line of the pipeline at the various depths stated in the Bill of Quantities and the Contractor shall be deemed to have made his own assessment (subject to any specific requirements of the Contract) of the widths of Trench Excavations necessary for the proper construction of the Works including all allowances to provide support for the excavations. shall include for loading and transporting the excavated materials from borrow areas which are not more than two hundred metres from the locations to be filled.O. Where the distance as aforementioned is in excess of two hundred metres ("overhaul distance") the product of the overhaul distance and the volume after compaction of the fill material placed to the limits and depths shown on the Drawings or as directed by the S. in fields. The depth of Trench Excavation for pipes shall be measured normal to the profile of the ground along the centre line of the trench from the original 93 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. the product of the overhaul distance and the net volume of voids to be refilled within the normal width of the trench excavated shall be measured as extra over (E. No extra payment shall be made for trenches which are curved in plan or elevation. Excavation in borrow areas for filling to embankments for pipelines or for raising the ground level along the pipeline routes as directed by the S.O.

BHD.0/06. Crossing rivers culverts and other watercourses shall include for all additional measures necessary to make the crossings as specified.1. Trench Excavation) for additional payment.O. ground level or where appropriate from the ground level remaining after the completion of any general excavation down to the specified invert level of the pipe plus the thickness of the pipe barrel and plus.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Incidental Excavation items it shall be measured as for those items. When measured E. Trench Excavation) as the area calculated by multiplying the length of trench so excavated by its nominal width. Trench Excavation and all work in connection therewith as specified shall be valued by the measurement only of such items as are set forth in the Bill of Quantities. except where expressly provided for otherwise by the inclusion in the Bill of Quantities of any of the following further items:Incidental Excavation for structures situated in the pipeline shall be measured only to the extent that the net excavation required to accommodate the structures falls outside the nominal dimensions of the Trench Excavation. The stripping of the top surface and the surface reinstatement of Trench Excavation in fields shall be included in Trench Excavation and shall not be separately measured. Trench Excavation items. The sides of Trench Excavation shall be deemed to be vertical in all materials and the nominal widths defined in Clause 8. Excess Excavation and the backfilling thereof shall not be measured for payment.O. to be excavated beyond the nominal dimensions of Trench Excavation and shall include for the disposal of the excavated material off the Site and for backfilling the excavation with approved material emanating from Trench Excavation elsewhere or for backfilling the excavation with the grades of concrete ordered by the S. fences and walls shall include for all temporary measures for dealing with such barriers as specified and shall be measured as the length of such barriers so dealt with within the nominal width of Trench Excavation. Trench Excavations in roads and in footpaths as specified shall be measured (E. Only such crossings as may be itemised in the Bill of Quantities will be measured (E.O. Incidental Excavation for removal of unsuitable material shall (unless it is held to be Excess Excavation) be measured as the volume ordered by the S. Any permanent measures required by the S. shall be measured as the volume of Rock within the nominal limits of Trench Excavation in Rock. where appropriate. the specified thickness of bedding for the pipe. measured E. Rock. shall be ordered by him as additional work.O. The length to be measured for payment for crossing natural watercourses shall be defined as the width of 94 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.12 shall apply to any depth of trench and whether or not bedding or surround to the pipe is specified.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O. Crossing hedges.O.

The Contractor shall be deemed to have made his own allowance for compaction and for any "loss" of material into the ground below the embankment. All clods and lumps shall be broken up and any rubbish. measured normal to the surface. The depth after spreading and trimming shall be 75 mm unless otherwise directed. for raising the ground level of the Site or for filling under structures shall include for the supply. spreading.O. will be due on completion of restoration of the final surface. etc.0/06.37 Payment for Trench Excavation and Restoration Payment for trench excavation shall be made in two stages. stones. will be made at the same time as the second stage payment for excavation. thrust blocks. 8. as follows :(a) (b) 75% of the total amount due will be paid on completion of pipelaying.38 Top Soiling Topsoil shall be evenly spread and trimmed over embankments and other areas to the slopes and levels shown on the Drawings or ordered by the S.O.O. Each turf shall be approximately 200 mm by 200 mm by 50 mm thick. etc. compacting and shaping all as specified. Overhaul of refill or excavated materials (E. including reinstatement of all surface damage. footpaths. 95 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. roots and weeds shall be removed. Filling for embankment shall be measured as the volume after compaction of the fill material placed to the limits and depth shown on the Drawings or ordered by the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.36 Measurement of Filling for Embankment Items in the Bill of Quantities for "forming embankment" for roadworks.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Trench Excavation or Excavation in borrow areas) shall apply in cases where the S. 8. Payment for the separate items in roads. BHD. the waterway along the pipeline at the time of construction of the crossing (except flash floods and floods).O.39 Turfing The Contractor shall establish grass by continuous or spot turfing as directed. orders material to be transported from locations of excavation which are more than two hundred metres from the areas to be filled. 8. 8. Turf shall be laid immediately after delivery to Site.O. completion of chambers. Payment for the second stage shall be due only after restoration of any length has been inspected and approved by the S.1. The remaining 25% for any length.

Turfing will be paid for in two parts:(a) (b) At fifty percent of the Contract Rate when the turfing has been carried out. Items where included for turfing shall include for all work in connection with turfing as specified. Topsoiling shall be measured as the areas so treated. All turfed areas shall be lightly rolled with an approved roller or punned immediately after laying. or from an approved source off the Site.41 Payment for Turfing Payment for continuous turfing shall be the area covered by the turves provided. and except where expressly indicated otherwise items shall apply to sloping as well as to horizontal surfaces. and for cutting and trimming and weeding at least once two months until the end of the Contract Period.42 Payment of Fees to Authorities The Contractor shall pay to all Authorities all deposits. At fifty percent of the Contract Rate when the S. Where turf is laid on slopes steeper than 1 on 3. hauling and spreading all as specified. Topsoiling and turfing of re-filled trenches shall be included in items for Trench Excavation and shall not be separately measured for payment. the Contractor shall turf the relevant area again at no extra cost to the Government.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . fees and charges required to be paid in relation to the execution of the Works or to any Temporary Works. 8. Where spot turfing is required the distance between the centre lines of divots in the form of a triangular pattern shall not exceed 500 mm and the percentage of the area covered shall be agreed and payment made on the total area spot turfed multiplied by the percentage. 96 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. each turf shall be securely pegged down with two cleft wooden pegs 150 mm long.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.0. 8. BHD.40 Measurement of Top Soiling and Turfing Items where included in the Bill of Quantities for spreading topsoil shall include for obtaining topsoil from spoil tips on the Site.1.0/06. is satisfied that the grass has established itself. Where grass fails to establish itself. and shall be watered regularly until the grass has been established. 8. Grass areas affected by trench excavation shall be restored as specified above.

The cost of all fees and charges payable by the Contractor shall be deemed to be included in the Contract Rates unless otherwise expressly provided for in the Bill of Quantities. BHD.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. If after due notice to the Contractor calling his attention to the necessity for the payment of fees and/or charges to the Authorities the Contractor has failed to make payment. the Government shall be entitled to pay such fees and/or charges direct to the Authorities concerned out of any moneys at any time due to the Contractor under the Contract and such payment shall be deemed to be payment made to the Contractor under and by virtue of the Contract.1.0/06. 97 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

SECTION 9. BHD. ..0 – PILING QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

maintained and undisturbed.O.O.1. For a pile cut-off at or above ground level the maximum permitted deviation of the pile centre from the centre point shown on the Drawings shall not exceed 75mm in any direction.1 PILING General Unless otherwise specified.2 Setting Out The pile layout and the number of piles shown on the Drawings are provisional only. 98 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The Contractor shall set out the piles from the main grid lines of the proposed structure or such base lines as shall be agreed with the S.'s prior approval in writing.O. The Contractor shall. The type of pile to be used at each structure. 9. BHD.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . not less than 24 hours prior to commencing work on the piles concerned. The Contractor's attention is. For a pile cut off below ground level an increase in the verticality tolerance is permitted up to 1 in 75 from the finished pile. 9. shall be supplied free of charge with two (2) copies of the results of all such investigation by the Contractor. The main setting out for piles shall be completed prior to commencement of piling. shall be as indicated on the Drawings or as directed by the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.1. lines.1 Ground Conditions It shall be the Contractor's responsibility to carry out further sub-surface investigation if he has any doubt about the available information or if he considers further information necessary or desirable.0 9. Such investigation by the Contractor shall be entirely at his own expense and shall have the S. any circumstances which indicate that the ground conditions differ from those expected by the Contractor from his interpretation of the results of soil investigation carried out by SAJH and which affect adversely the bearing capacity of the pile.0/06. The S. 9.O.O. All main setting points. In addition to submitting the records required. before commencing any part of the piling work ascertain from the S.O. Secondary or individual pile setting out shall be completed and agreed with the S. all piling shall conform in all respects to the Civil Engineering Code of Practice CP 2004 `Foundations' issued by the `British Standards Institution. where piling is required. stations and the like shall be suitably protected. the layout of the piles required.O.1. London'. drawn to the fact that suitable founding strata may be encountered at depths which require the actual installation of different lengths of pile and which may give rise to considerable variation within any particular site or pile groups. however. the Contractor shall report immediately to the S.

1.4 Programme The Contractor shall submit to the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . his proposed programme for the execution of the piling work at least seven days before commencement of the work. supported on an adjustable base. prior to implementation of said revisions.O. Before any piling work is commenced. lengths and safe working loads. Such information shall include a full description of the piling frame. the Contractor shall inform the S.O.O. 99 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The type of piling equipment shall be suitable for the type of piles to be driven and shall be that of a system which produces the minimum noise during driving. The Contractor shall provide sufficient number of units to ensure completion of piling work according to programme.O.O. All plant being used shall be maintained in a satisfactory condition and any items suffering wastage or damage shall be promptly replaced or repaired. full details of the pile driving equipment and the method of carrying out the work which he intends to use. 9. and the weight of the hammer shall be at least half that of the pile or otherwise specified. In general. helmet and packing and of a method of handling and pitching piles and supporting them during driving.1. sizes. appear desirable. 9. hammer.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the Contractor shall submit to the S. and the Contractor shall submit all of his proposals at least three weeks before the date on which he intends to use the plant on the Site. The piling frame shall be of sturdy construction.1. Single or double acting diesel or air operated hammers may also be employed. in the light of ensuing experience. In addition. BHD. shall also be submitted for the approval of the S.O. No piling shall be carried out without the approval in writing of the S. The type and weight of hammer shall be to the approval of the S. a heavy hammer with a short drop should be used in preference to a light hammer with a longer drop. securely guyed and with ample toggle connections to leaders so that the pile is firmly held at all times. of the equipment and method of working and any revisions to these as described above. if this has already been approved by the S.O.3 Piling equipment The piling equipment shall be capable of speedily and efficiently installing piles of the specified types.0/06. The Contractor shall submit confirmation of hammer energy per blow to the satisfaction of the S. Any revisions to these proposals which. and of the proposed driving procedure set to give penetration to the required level and of the proposed set for the working load on the pile and the method of calculating it.O. daily of the programme of piling for the following working day and shall give adequate notice of his intention to work outside normal hours.

1. Piles shall be pitched accurately in the positions as shown on the Drawings. A set shall be taken only in the presence of the S. all exposed piles shall be adequately supported and restrained by means of leaders.O. BHD. It may be used for driving frictional piles with prior approval of the S. e) The temporary compression of the pile shall be record if required. if required.O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Where required by the S. 9. The contractor shall inform the S.1.0/06. The Contractor shall provide all facilities to enable the S. unless otherwise approved. However. temporary support or other guide arrangements to maintain position and alignment and to prevent buckling and damage to the piles. pile driving shall be as specified hereunder. When a final set is being measured. The driving equipment to be used shall be of such type and capacity to the approval of the S. The final set of a pile other than a friction pile.O. 100 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. b) The dolly packing shall be in sound condition. shall be carried out in accordance with an approved procedure. without damage or distortion. At all stages during driving and until the pile has set or driven to the required length.O. trestles. shall be recorded either as the penetration in millimetres per 10 blows or as the number of blows required to produce a penetration of 25mm.O. to check driving resistances. may permit the suspension of driving if he is satisfied that the rate of penetration prior to the cessation of driving will be substantially re-established on its resumption or if he is satisfied that the suspension of driving is beyond the control of the Contractor. A follower (long dolly) shall not be used for driving end bearing piles.O. Each pile shall be driven continuously until the specified set and/or depth has been reached. it shall be of a free fall type and the weight of the hammer shall be as specified in CP 2004. Retrieve checks. set shall be taken at approved intervals during the driving to establish the behaviour of the piles. c) The hammer blow shall be in line with the pile axis and the impact surfaces shall be flat and at right angle to the pile and hammer axis. The log shall record the number of blows for every 300mm of pile penetration. If drop hammer is used.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the following requirements shall be met:a) The exposed part of the pile shall be in good condition. A detailed record of the driving resistance over the full length of each pile shall be kept.5 Pile driving Unless otherwise specified. d) The hammer shall be in good condition and operating correctly. without delay if an unexpected change in driving characteristics is encounted.O. the S.

7 Load tests The Contractor shall submit to the S.8 Piling Personnel Piling work shall be carried out under the direction of a competent supervisor experienced in the particular system of piling to be used. before 101 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. The S. All loading tests shall be carried out and comply with the conditions as described in Section 9. dimensions and bearing capacity. levels and measurements shall be taken to determine the movement of the ground or any pile resulting from the driving process. The S. will direct the lengths of piles to be supplied or manufactured. to the depths required by the S. After testing of trial piles the S. He shall be employed full time for the duration of the piling operations and his appointment shall be subject to the approval. 9.6 Preliminary and Working Test Piles A preliminary test pile is a pile installed at the Site before the commencement of the main piling work for the purpose of establishing the driving criteria for subsequent working piles and for confirming the adequacy of the pile design. Preliminary test piles shall be of the same materials and driven or formed with the same plant and in the same manner as the working piles.O.4 of the Specification on pile testing. the Contractor shall submit to the S.1.O. A working test pile is a pile which is installed as part of the permanent foundation works.O. The S. If any pile rise occurs as a result of adjacent piles being driven.O. The remaining piling at the Site shall not proceed until the testing of the advance working pile has been completed to the satisfaction of the S. and meets the requirements for acceptance specified herein. will also instruct the testing of further piles during the course of the piling work. 9. his proposals for correcting this and to avoid the same in subsequent work. with the same equipment as proposed for the main piling work. Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground. No work on working test piles shall proceed until the testing of the preliminary test pile has been completed to the satisfaction of the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . will select the location of the preliminary test piles and the working piles to be load tested. Piles selected for this purpose shall be constructed or driven.1.0/06. 9. He will also direct the lengths of any extension piles to be supplied or manufactured.1.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O. and may select for testing one or more working piles which the Contractor shall drive in advance of the remaining piles at the Site.O.O.1. When required.O. BHD. for approval complete details of the testing equipment he intends to use for testing piles.O. of the S. will decide upon the necessity for testing working piles. in writing.

Pile shoes shall consist of "chilled hardened" cast iron points and mild steel straps cast into the points and be in accordance with the Drawings or otherwise approved by the S.2 9. accompanied by Drawings and programme. The Contractor shall also submit to the S.'s Representative two (2) sets of a complete drawings showing details of all piles driven at the Site. the Contractor shall submit to the S. Notwithstanding any approval of the Contractor's proposals by the S.9 Piling Records The Contractor shall keep a record of all piles driven at the Site. the Contractor shall prepare and submit to the S. the Contractor shall be and remain solely responsible for the successful installation of the piles. All pile test records shall be considered as confidential and shall not be disclosed by the Contractor to any third party without the express permission in writing of the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Pile units shall be cast in one continuous operation on a horizontal platform in steel or wooden moulds and no interruption shall be permitted.2.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O.O. Where required load tests shall be carried out to assess bearing capacity.O. 9. The record shall contain such details as specified or otherwise as required by the S. The length of each pile unit cast shall be as detailed on the Drawings.1. Main reinforcing bars shall be supplied in one complete length.0/06.O. of the methods he proposes to adopt for handling and driving piles.. Spacer forks shall be of cast iron.2 Pile Casting Before any reinforced concrete pile is cast.O. should this prove impracticable separate lengths shall be effectively coupled mechanically or lapped as specified.O.2.O. the commencement of piling work.1 Precast Reinforced Concrete Piles General Precast reinforced concrete piles shall conform to the details shown on the Drawings. BHD.O. 9. Concrete reinforcement and formwork shall be in accordance with the appropriate section of the Specification. 9. Pile extensions shall be cast in suitable lengths to suit Site conditions.1. The 102 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. On completion of all piling work at each site. for approval a description. mild steel or other material or type and shape approved by the S. giving full particulars of all plant and equipment to be employed.'s Representative within 24 hours a copy of the field record of the piling work done each day. The Contractor shall also employ at each site a specially qualified foreman together with the necessary gang of trained personnel and labour experienced in the installation of the piles.

O. moulds shall be thoroughly cleaned before casting. before it is used in the Works. Each pile shall be clearly marked with the date of casting and all stacks shall be arranged to facilitate the removal of piles for driving in their correct order of age. Stripping and Stacking Piles made with ordinary Portland cement shall be kept damp for a period of 14 days after casting. These plates shall be aligned with great care to ensure that they are truly perpendicular to the axis of the pile. Piles shall be stored on adequate bearers so arranged that they may be picked up for transport without damage. in the position and in according with the details shown on the Drawings.5 Pitching and Driving Piles shall be pitched accurately in the positions and driven to the appropriate lines and levels shown on the Drawings.O.O. before use. 9.3 Curing. lifted using only the proper lifting holes and supported in the manner as approved by the S. provided the piles are kept supported on level blocks spaced at not more than 1. BHD. Any pile showing signs of honeycombing or other defects on removal of the formwork shall be repaired to the satisfaction of the S. Lifting holes shall be formed. and the assembled reinforcement lowered into the mould and held in position from the top.O.4 Handling Storage and Transport of Piles Piles shall be handled with great care. Failure by the Contractor to observe this requirement may result in rejection of the pile concerned. After casting the piles.8m centres. For piles made with Rapid Hardening cement the above periods shall be modified as directed by the S. during casting. Any pile or pile extension cast with an end plate not truly perpendicular to the axis of the pile shall immediately be rejected. After 21 days piles may be lifted and removed to a suitable stacking area but they may not be driven until they are at least 4 weeks old. Any departure from the approved method of lifting the piles shall be approved by the S. Any piles cracked or damaged during handling shall not be used in the Works and shall be replaced by the Contractor at no extra cost to the Government.1. The mild steel end plates for jointing piles and pile extensions shall be placed in the ends of the moulds before placing concrete.2.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 9. During and after completion of piling the pile head shall not be more than 75mm off centre in any one direction from its required position. 9. Side forms may be stripped 4 days and bottom boards 12 days after casting.O.O. Handling and delivery of the piles shall be done in a manner which avoids excessive bending stresses. Piles shall be suitably constrained to maintain their correct position by means of guys or guides.2.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .2. formwork shall be removed in the presence of the S.0/06. Care shall be taken to ensure that bearers are level transversely so that piles are not subjected to undue stress. The method of transport shall be subject to the approval of the S. 103 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.

QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 9. the net energy per blow. Immediately after a pile has been completely driven.5m and at no time during driving shall the centre of the hammer be more than 38mm off pile centre. Where piles are driven below the level of the bottom of the leads of the pile frame. BHD. Every hammer shall bear an identification mark and the Contractor shall furnish a weight bridge certificate of its actual weight. covering the head of the pile. to whom the records shall be submitted on request. Piles damaged during driving shall be removed and replaced by the Contractor without extra cost to the Government unless the S. may require that a heavier hammer is used.O.1. If. The hammer drop shall not exceed 1. 25mm thick. shall be contained within the helmet and separate the helmet from the head of the pile.2.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . The top of the helmet shall be recessed and fitted with a timber stub dolly 300mm long. the S. however. The use of a follower or dolly will not be permitted except with the written approval of the S.O. conditions at the Site show that this is insufficient. All piles shall be driven to such final set or depth as may be approved by the S. The type of helmet specified above may be modified at the discretion of the S. 9.O. If a single acting power operated hammer is used. During driving the heads of the piles shall be protected by a helmet of cast steel or mild steel fitting closely around the pile.O.0/06. Should any pile heave upwards it shall be redriven to its original level or. The packing and stub dolly shall be renewed as often as necessary to prevent damage to the piles. multiplied by the efficiency of the blow shall be at least 25 kilojoules.2. No piles which have been deflected from the permitted tolerance shall be forcibly brought back to correct alignment. the limitations on hammer weight specified above for gravity operated hammer shall apply to the moving weight of a single acting power operated hammer. until its specified set is again obtained. 104 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. extension leads shall be fitted. If a double acting power operated hammer is used.O.6 Plant for Pile Driving If a gravity operated hammer is used the weight of the hammer shall be at least 3 tonnes or 75% of the weight of pile. a record shall be made of the reduced level of the pile head and further checks shall be made on the level of the head after the driving of adjacent piles. is satisfied that effective repairs can be made in-situ. A packing of coiled hemp rope or asbestos fibre.7 Measuring Pile Set The Contractor shall provide suitable means of measuring and recording the pile set under each hammer blow. The Contractor shall maintain a record of the driving of all piles giving sets and other details required by the S. if necessary.

and.'s Representative will instruct the Contractor which length of pile extension to use for extending the piles.2.1. aligned and plumbed.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . After the slag has been chipped from the weld and the weld wire brushed and cleaned.8 Extending Piles Piles shall be extended as directed by the S.O. If the pile has suffered no damage. The end plate of the pile extension shall be similarly cleaned and the extension pitched.4.'s Representative and the cost of all such repairs shall be borne by the Contractor.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O. it shall be inspected by the S.O.'s Representative. The end plates shall then be joined by a fillet electric arc weld extending completely round all four sides as shown on the Drawings.2. it shall be painted with 2 coats of coal tar epoxy of an approved type. Where the length of pile left above the required level exceeds the length of pile cap reinforcement required. the top of each pile shall be cut down to the correct level.O.10 Load Tests The Contractor shall carry out load tests on precast concrete piles by the Maintained Load Method as detailed in Section 9. 105 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. and running a pencil along the straight edge at the moment of impact to record on the paper the elastic and plastic sets resulting from the blow.9 Preparation of Pile Heads After pile driving and load tests (if required) have been completed to the satisfaction of the S. free from rust and scale. the excess length of pile may first be cut at the level which provides the required length of reinforcement. 9. The S. placed carefully on top of the pile head. Tests shall be carried out on preliminary piles and working piles.O. This may be achieved by using a fixed straight edge held against a sheet of paper affixed to the pile. The straight edge shall be attached to a fixed frame of heavy timber standing close to the pile.2. and filed down to expose bare metal.1. as defined in Section 9. 9.7 and as directed by the S. BHD. Pile driving shall continue when the paint has dried. If the pile head has suffered damage it shall be repaired by the Contractor to the satisfaction of the S. and shall be carried out as described below. 9. When the pile shall have been driven to within one metre of the pile head above ground level.O. the end plate shall be thoroughly cleaned. and the steel reinforcement exposed and bent into the required positions. if pronounced satisfactory. the dolly and packing shall be removed and the head of the pile examined for damage. prior to construction of the pile cap.0/06.

1.O. 9.2 Treatment of Piles The method of treatment shall be full-cell process as described in MS 3. 9. The dimensions of sawn timber piles shall be within the rate of 2mm less and 6mm greater than their specified cross-sectional dimensions. of the delivery of timber piles to the Site and provide the necessary facilities to enable the S. The S.3 Delivery and Stacking of Piles The Contractor shall notify the S.3 9. The treated timber pile shall be permanently marked with identifications which indicate that it complies with the Specification.3.O. Piles shall be supplied in one single length of 6 metres. the Contractor shall notify the S. BHD. The timber shall be free from rot.38. change number and date of treatment. may require inspection of the treatment plant to observe and ensure that the manufacturing process and control testings of the piles are carried out in accordance with the Specification. the name of the supplier and manufacturer for approval.3.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . and the Contractor shall furnish such records for the piles supplied when requested by the S.0/06.3. to inspect the piles 106 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.cu. The depth of penetration of preservation when determined by the method described in Appendix H of MS 3. The net dry salt retention in the treated part of the timber as determined by the method described in appendix `K’ of MS 3. unless otherwise approved.38 shall be a minimum of 16 kg. The centroid of any cross-section of a sawn timber piles shall not deviate by more than 25mm from the straight line connecting the centroids of the end faces of the standard length of pile. fungal or pest attack and any other defects not permitted for its grade.O. Records for the actual treatment schedule shall be kept during the treatment process.O. Before commencement of any work.O. The composition for preservative shall be Type 2 of MS 3.38 shall be a minimum of 25mm. 9. and the length of the pile. manufacturer trade mark. Where applicable the standard of workmanship shall conform to CP 112.m.38.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.1 Treated Timber Piles General Timber used for the piles shall not be of a lesser quality than the selected Structural Grades specified in Section J (Stress Gading) of Part III of the Malayan Grading Rules for Sawn Hardwood Timber. Before the treated timber pile is accepted for the Works the Contractor shall obtain from the manufacturer of the treated piles a warranty on approved form which provides that for a ten year period the treated piles shall be free from such fungus and insect attack which may render the supported structures unsound.

2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . If during driving the head of the pile becomes excessively broomed or otherwise damaged. which in the opinion of the S. the damaged part shall be cut off. the pile shall be rejected and replaced at the Contractor’s expense. In the case of hard driving.3.0/06. The top of the pile shall first be trimmed to fit closely into the recess of the underside of the helmet. The piles shall be separated by sticks or blocks placed vertically one above the other and closely spaced horizontally to avoid sagging of the piles. a packing piece shall be used above the helmet. and take random sampling for determination of depth of penetration of preservation and the net dry salt retention.O. The pile head shall be fitted with toothed metal plates as approved by the S.5 Load Tests If so directed by the S. A hardwood dolly and if necessary.O.4 Pile Driving and Jointing The pile head shall be adequately protected during driving. so that the necessary strength and stiffness are developed at the joint. Any pile driven to the required set at a depth of 6. If jointing is required. When a pile has been driven to the required set or depth. a metal helmet shall be fitted to the top of the pile. Each piece of pile shall be stacked clear of the ground and have an air space around it. will affect its strength. so that “brooming” does not occur. the Contractor shall carry out load tests on treated timber piles shall be carried out by subjecting a group of the piles to a 107 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. When fissures appear in a pile during driving. unless otherwise approved by the S. pile joints shall be made by using galvanised mild steel welded boxes 460mm long fabricated from 5mm thick plates unless otherwise shown on the Drawings. 9.O.O. BHD. for protection against “brooming" and splitting during normal driving. the head of the piles shall be cut off square to sound wood and treated with an approved preservative and a waterproof coating to the approval of the S. The joint and the ends of the piles to be jointed shall be constructed.1. Accepted piles shall be marked and stacked in lengths on paving of drained hard ground. The pile head shall be embedded for a depth of not less than 150mm in the concrete cap which shall be at least 150mm thick round the pile. The internal dimensions of the box shall be 3mm undersized of the pile cross-sectional dimensions.O.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. and the helmet refitted. All rejected piles shall be removed from the Site promptly. be in one continuous length. 9.0m or less shall.3.

The load test shall be performed before commencing to drive the remaining piles. Certificates of calibration for all measuring devices shall be provided at the S. 2 rows of 2 nos. 9. supported centrally over the test pile on suitably constructed temporary staging or by means of anchor piles. with a minimum of 25mm travel. At least 48 hours notice of the commencement of each test shall be given to the S. The entire measuring assembly shall be properly protected 108 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2 Test Load and Kentledge The test load shall be applied by means of an hydraulic jack of adequate capacity fitted with measuring devices capable of registering loads in increments not exceeding 2 tons.O. The gauges shall be erected on stiff steel beams. graduated in 0. until actual failure of the group takes places. 9. The hydraulic jack and measuring devices shall be approved by the S. may direct to vary the number of the piles required. vertical test load. From the results of the test (s).025mm divisions.O.4. these piles shall not be closer to the test pile centre to centre than 1. The kentledge shall be provided by a heavy mass of dead load.4 9.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.). The piles tested may after wards form parts the foundation of the structure.5 metres or 5 pile diameters or equivalent whichever is the larger.8 metres from the test pile. the ends of which shall rest on or be fixed to reliable supports. the load test shall only commence after the piles have been driven and left in position for a period of not less than 7 days. and shall be rigidly fixed to the ground to a depth of not less than one metre of concrete surround. pile tests shall be carried out as described in this Section of the Specification.O. If anchor piles are used to provide reaction for the jack.O.4.'s request. shall be appropriately re-driven to the required set or level as directed by the S. the elevation of the supports shall be checked frequently with reference to a fixed benchmark.4.O.1 Pile Testing General Unless otherwise specified.3 Settlement Measurement Vertical movements of the test pile shall be measured by at least two dial gauges. The pile shall be tested to failure by the Maintained Load Method as specified in Section 9.1.O. exceeding the maximum test load required. Such supports shall be located not closer than 1. which later form part of the piled foundation to the structure. and shall be driven at location of the site as selected by the S. The group of piles shall consist of at least four (4) piles (ie . Anchor piles. all to his full satisfaction. the S.4.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 9.0/06. before use. In addition. BHD.

O. 9. direct sunlight and other disturbances that might affect its reliability.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 9. A settlement-time graph shall be plotted to indicate when the rate of settlement of 0. supports. The Contractor shall provide all other labour required for the proper execution of the test. Both settlement and time readings shall be recorded every minute. Settlement readings and time observations shall be taken before and after each new load increment. The maximum test load shall than be maintained for a minimum of 24 hours. against rain.0/06.05mm in 15 minutes is reached. b) Constant rate of penetration test The load shall be applied at a constant rate of penetration of a value varying between 0. Each increment of load shall be applied as smoothly and as expeditiously as possible.4. anchor piles. may at his discretion decide to carry out the CONSTANT RATE OF PENETRATION method of testing on completion of the Maintained Load Test. the rate to be so chosen as to suit the available pumping equipment. The S. Further loading shall 109 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. will supervise and direct the whole process of the test and provide skilled staff to assist in taking and recording all readings. who shall also provide all necessary facilities to enable the S. The S. Temperature readings shall be taken when requested by the S. including the construction and dismantling of the load staging and handling of the kentledge materials on and off the load stage.5mm per minute. equipment. to check all readings during the progress of the test. all to the full satisfaction of the S.5 Procedure of Testing The MAINTAINED LOAD method of testing shall be carried out on the test pile. shelter. The test load shall then be decreased in four equal stages and timesettlement readings taken as described aforesaid until the movement ceases.75mm per minute to 1.O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .O. At least 60 minute intervals shall be allowed between the unloading decrements.1. BHD. and the like required for the load test shall be provided by the Contractor. A further increment of load shall be applied when this rate of settlement is achieved or until a minimum time of 2 hours elapsed.4 Equipment and Personnel for Load Test All kentledge staging. and the like and for the continuous and competent watching of the whole assembly.4. whichever is later. The process is repeated until the maximum test load is reached. a) Maintained load test The load shall be applied in increments of 25% of the working load until a maximum test load of twice the working load is reached.O. and time-settlement readings shall be taken in regular intervals as for the other load stages.O.

b) Haul. pitch to position ready for driving pile and extension pile. joints. BHD. as appropriate and approved by the S.5 Measurement of Piles and Piling Piles and piling and all works in connection therewith shall be valued by measurement of only such items as are provided in the Bills of Quantities.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. No distinction shall be made between the driving of a standard length of pile and the driving of an extended pile.0/06. handle. c) The total settlement under twice the Design Load exceeds 38mm.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .O. etc.1.4. 110 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. a) Mild steel end plates and splicing bars to be welded to end plates. The supply and delivery of precast reinforced concrete.4. on completion of each test. be discounted when the loading varies directly as the penetration in the case of end-bearing piles in sand or gravel or when the rate of penetration is constant without further increase in the load in the case of friction piles in clay.'s interpretation and conclusions arrived at on the test results shall be final. Loading shall then be released gradually and rebound readings taken. 9. When the pile test as prescribed has been carried out. Pile driving shall be measured by the total length of penetration obtained below formation.O. river or stream bed level.7 Interpretation of Test Results The S. transporting and pitching of extension piles shall be in accordance with the total number of pile lengths handled whether they be full length piles or cut lengths from standard pile lengths. Payment of the following items shall be measured once only for each pile location irrespective of the actual numbers of items eg. c) Jointing pile and pile extension including painting with coal tar epoxy. The site handling. b) The total settlement under Design Load exceeds 13mm. 9. 9. and pretensioned spun concrete piles shall be measured in accordance with the total length of piles incorporated in the permanent works. Piles delivered to the Site and cut piles not incorporated in the Works shall on completion of piling be removed from the Site and no payment of any kind shall be due to the Contractor for such piles. end-plates. the pile so tested shall be deemed to have failed if:a) The residual settlement after removal of the test load exceeds 6mm. not including the original copy.6 Records of Test The Contractor shall submit two copies of all records of results. together with load-settlement and load-time graphs to the S.O.

idle time. shoes for steel pipe and timber piles. all in compliance with the requirements of the Specification. The Contract Rates for piles and piling shall include for the full cost of providing temporary staging and all equipment. 111 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. Steel sheet pile items shall be measured on the basis of the overall plane area and the shape of the sheet piles will not be considered in measurement. labour and materials necessary for transporting. handling. measuring and recording pile set and keeping field records. Bakau piles and timber piles shall be measured only by the total length of piles supplied. The respective lengths of any pile subsequently withdrawn and remedial work executed to correct defective piles shall not be measured for payment. raking piles. delivered and driven below the foundations to the level of the pile cutoffs.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BHD. driving.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .0/06. jointing of piles and cutting of pile heads after driving. removing or re-driving (if incorrectly driven or damaged). pitching. Separate items are provided for load tests.

SECTION 10.0 – ROADWORKS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BHD. .

Test No.1 ROADWORKS Preparation of Formation to Receive Road The preparation of formation shall be carried out only after completion of all sub-grade drainage. The formation shall then be checked and the final trimmed surface shall be rolled by one pass of a smooth-wheeled roller of not less than 5 tonnes or an equivalent vibratory roller prior to the laying of the sub-base or base-course.1. Test No. 10. SPECIFICATION FOR PIPEWORKS 112 SAJH WS/PW/001 (Rev. Other layer of sub base and shoulder shall be compacted to a dry density equal to at least 90% of the maximum dry density as determined by BS 1377:1975. and such preparation shall be carried out immediately prior to the laying of the sub-base or the road-base where no sub-base is required. If the Contractor allows the moisture content of the completed formation to reach a value above the permitted maximum for the compacted material.O. The formation shall be so constructed to drain surface water to the side ditches or other drainage system.. unless otherwise agreed by the S. the Contractor shall reshape and re-compact the formation to the required density before the sub-base or base is placed. cross-section surface tolerance and compaction specified but in no case shall a tolerance of + 25mm from the levels shown on the Drawing be permitted. "Plant and Method Specification for Compaction of Earthworks and Subgrades". grades and typical cross sections shown on the Drawings. the Contractor shall remove all loose rock and replace it with suitable approved material. camber. if directed by the S. they shall be removed and backfilled with approved stable material and compacted according to the Specification in Table 10. services and ducts or any other drainage work that might affect the works.O. Where ruts or other objectionable irregularities occur as a result of construction traffic or other causes. make good at his own expense the surface by recompaction before laying the sub-base or base.13.O..0/06.3 Subgrade of Rock Where the surface of an excavation in rock has deteriorated and is no longer acceptable as subgrade. 10. Notwithstanding the above the top 300mm of the finished embankment shall be compacted to a dry density equal to at least 95% of the maximum dry density as determined by BS 1377:1975. piped drains.13.1. It shall be trimmed to conform to the lines. The surface shall be constructed to sufficient accuracy to permit the construction of subsequent layers of material to the thickness.0 10.2 Earth Subgrade Where soft spots and unsuitable material occur. the Contractor shall allow the materials to revert to an acceptable moisture content and. The surface of the formation shall be substantially uniform in density throughout its entire width and shall conform to the density requirements for compaction. BHD.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 10.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. or as directed by the S.

90 45 . may order variations in the thickness of the various layers of the pavement as shown in the typical cross-section Drawings as a result of the above tests.80 10 .2 mm 300 microns 150 microns Percentage By Weight Passing 100 95 .O.30 2 .2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . clay balls and any other deleterious substances.75 35 . soaked or unsoaked tests as described in BS 1377 on the prepared subgrade to determine the strength of the subgrade.30 0.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.R.10 SPECIFICATION FOR PIPEWORKS 113 SAJH WS/PW/001 (Rev.5 Sub-base Materials The sub-base material shall be hard.). 10. 10.4 Pavement Thickness The thickness of the various layers of the pavement shall be as shown on the Drawings. durable and clean. The laterite or crushed rock or gravel shall conform to one of the following gradings :Percentage By Weight Passing (A) (B) 100 75 . may carry out or direct the Contractor to carry out California Bearing Ratio (C. However before the construction of the pavement the S.100 45 .100 60 .50 10 .75 30 .60 20 . Any such changes shall be treated as a variation to the Contract.B.50 15 .100 58 . BHD.65 25 . It shall be granular material such as laterite or gravel or crushed rock or sand and shall be free from organic material.1.2 100 70 .4 mm 420 microns 75 microns The sand shall conform to the gradings given below :BS Sieve Size 10 mm 5 mm 1.2 BS Sieve Size 40 mm 25 mm 20 mm 10 mm 5 mm 2.30 0.0/06.O. The S.

The Contractor shall ensure that the subgrade is not disturbed by the operations carried out to adjust the moisture content of the sub-bases material. scarifying. Sub-base sandy material shall be compacted by use of vibrating equipment.25 The portion passing the No.O. At the time of laying and compaction of sub-base.70 20 .4 mm 420 microns 75 microns 100 80 . The material shall be free from vegetable matter. The proposed sub-base material shall have a laboratory controlled unsoaked CBR value not less than 30% when compacted to 95% of maximum dry density as determined by the BS 1377:1975 Test No 13 or modified AASHO compaction test.30 5 . typing.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Test No. soft particles or clay lumps and shall conform to one of the following gradings:BS Sieve Size Percentage By Weight Passing (A) 40 mm 20 mm 10 mm 5 mm 2. the formation shall be dry.6 Alternative Sub-base Alternative suitable material may be accepted subject to the prior approval of the S. BHD. Rolling operations shall begin from the outer edge towards the centre gradually in a longitudinal direction except on superelevated curves where rolling shall begin at the low side and progress towards the high side.55 12 . have a liquid limit not greater than 35 and a plasticity index not greater than 11.20 (B) 100 80 .70 12 .100 55 . Each layer shall be compacted to at least 95% of the maximum dry density as determined by BS 1377:1975.36 sieve shall. Sub-base material containing excess moisture shall be dried by harrowing. 13.7 Compaction of Sub-base The sub-base material shall be laid in layers not exceeding 225 mm in thickness. SPECIFICATION FOR PIPEWORKS 114 SAJH WS/PW/001 (Rev. If necessary the Contractor shall add water to the sub-base material to achieve the required moisture content.40 8 .O.0/06.1. if it is plastic.100 55 . 10. 10.90 40 .2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Compaction of sub-base shall be carried out by adequate compaction equipment approved by the S.90 40 . ripping or mixing prior to or during compaction.

O. It shall be laid to give a total compacted thickness. All material shall be placed and spread evenly to the full width of the roadbase. It shall be from a quarry approved by the S. The roadbase shall be constructed to the full compacted thickness as shown on the Drawing.9 Laying and Compaction of Roadbase All work on the portion of the subgrade or sub-base on which the roadbase is to be laid shall be properly shaped and compacted in accordance with the requirements of the Specification before the placing of the roadbase material on that portion. The maximum compacted thickness of any one layer shall not exceed 150mm.100 60 .22 0. 2. The material shall be crushed rock of hard durable particles or rock crushed to the correct size.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . SPECIFICATION FOR PIPEWORKS 115 SAJH WS/PW/001 (Rev. width. The material passing No. well graded and lie within the following grading limits: BS Sieve Size 50 mm 40 mm 20 mm 10 mm 5 mm 2.1.60 25 .4 mm 600 microns 75 microns Percentage By Weight Passing 100 95 .QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.8 Note: 1. grade and levels as shown on the Drawings or as directed by the S. objectionable coatings or other foreign matter. or as directed by the S.O. The thickness of the finished sub-base shall be on average not less than the required thickness.O. It shall have a CBR value of not less than 80 when compacted to 95% of the maximum dry density as determined by BS 1377:1975 Test No. The finished sub-base shall not vary more than + 20 mm from the grade or level shown on the Drawing. The preparation of the subgrade or sub-base shall be completed at least 200 metres ahead of the placing of the roadbase material. The flakiness index of the coarse aggregate shall be less than 35 per cent. organic matter. The particle size shall be determined in accordance with the requirements of BS 1377.36 BS Sieve when tested in accordance with BS1377 shall be non-plastic. 10.30 8 .40 15 . BHD.13. 10.0/06.80 40 .8 Road-base Materials The crushed rock road base to be placed on top of the sub-base shall consist of sound durable material free from clay lumps.

Tipping of aggregate and laterally spreading by dozer or motor grader can cause segregation between the coarse and fine particles. The material shall be spread by a motor grader or any other approved mechanical plant. not less than 300mm wide. ridges or cracks are eliminated. Rolling operations shall begin along the edges and progress towards the centre gradually in a longitudinal direction. Each layer shall be thoroughly compacted with suitable compaction equipment to the requirement specified in Table 10. cracks or loose material. at the Contractor's own expense. The rolling operation for each layer shall continue until all rolling marks. which results in hungry patches during compaction. the rolling shall begin at the low side and progress towards the high side. all such areas shall be scarified and additional fines added before recompaction.1. On completion of compaction the surface of any layer of material shall be well knitted. All loose segregated or otherwise defective areas shall be made good by being removed and replaced with properly graded material. extreme care shall be exercised so as not to damage the kerbs or gutters.0/06. SPECIFICATION FOR PIPEWORKS 116 SAJH WS/PW/001 (Rev. segregation or loose material which may develop in the surface during or after construction shall be corrected or removed and the defective areas made good to the full thickness of layer and recompacted. Any irregularities. Care shall be taken to prevent segregation of the material into the coarse and fine fractions.2. BHD. Any damaged kerbs or gutters shall be removed and replaced at the Contractor's own expense. shall be constructed to the top of each uncompacted layer of the base to act as a haunch to support the edges of the roadbase during rolling. Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse joints. the base shall be constructed in two or more layers of approximately equal thickness.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . When the specified compacted thickness of roadbase exceeds 150mm. Should this occur. Compaction shall be completed as soon as possible after each layer has been spread and shaped satisfactorily. Each layer shall be compacted to the required density before the next layer is placed. "Compaction Procedure for Unbound Sub-base and Roadbase Materials and for Soil-Cement and Cement-bound Granular Roadbase" and to a compacted density of at least 98% of the maximum dry density as determined in accordance with BS 1377:1975. On superelevated curves. When a roadbase is spread adjacent to concrete kerbs or gutter sections. Segregated surface areas of a base constructed or base material contaminated to such an extent that it no longer complies with the Specification shall be removed and replaced with well graded and satisfactory material at the expense of the Contractor.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Before the laying of each layer of roadbase material a partial width of the shoulder. ridges. free from movement under compaction plant and from compaction planes.

2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Vibratory rollers shall only be operated with their vibration mechanism operating at the frequency of vibrating recommended by the manufacturers. Wheel load is the weight of the roller divided by the number of wheels. adding or removing material.5 km per hour for a towed machine. When the spacing exceeds 288mm the effective widths shall be taken as the sum of the widths of the individual wheeltracks only. 10.10 Finished Surface The finished roadbase surface shall be even. provided that each spacing does not exceed 288mm.0/06.11 Definition and Requirements Associated with Table 10. 10. loose material or fines and true to cross. reshaping and recompacting.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Moisture content control of the roadbase material shall be accomplished by sprinkling with water or drying as required. at the Contractor's own expense. free from hungry patches. If higher gears or speeds are used. BHD.1.5 . The roadbase material shall be maintained at the correct moisture content as necessary for proper compaction. Vibratory rollers operating without their vibration mechanism in use will be classified as smooth wheeled rollers.section. (i) The requirements of vibratory rollers are based on the use of the lowest gear on a self propelled machine and a towing speed of 1. The load per 10cm width is the total weight on the roller divided by the total roller width. shall be corrected by loosening. Vibratory rollers are self propelled or towed rollers having means of applying mechanical vibration to one or more rolls. irregularities. (ii) (iii) SPECIFICATION FOR PIPEWORKS 117 SAJH WS/PW/001 (Rev.2. lines and level. The finished surface level of the roadbase shall not vary from the level shown in the Drawing by more than 12 mm. Any irregularities on the finished roadbase surface of more than 12mm when measured with a straight edge 3 metres long laid either parallel to the centre line of the road or laid transversely. All such rollers shall be equipped with a device automatically indicating the frequency at which the mechanism is operating. The effective width of a pneumatic tyred roller for this purpose is the sum of the widths of the individual wheeltracks together with the sum of the spacing between the wheeltracks. Where a smooth-wheeled roller has more than one axle the machine will be assessed on the basis of the axle giving the highest value of load per 10cm width. The surface of the aggregate roadbase shall be well drained at all times. an increased number of passes shall be provided in proportion to the increase in speed of travel.1 Number of passes is the number of times that each point on the surface of the layer being compacted has been traversed by the compaction plant.

of the bitumen distributor in accordance with BS 1707. SPECIFICATION FOR PIPEWORKS 118 SAJH WS/PW/001 (Rev. handling. Petroleum Bitumen shall comply with the requirements (for the appropriate grade) given in BS 3690. 10. Handling and Heating-of Bitumen Bituminous materials shall be handled and stored with due regard for safety and in such a way that at the time of use in the work the material conforms to the Specification.O. Overheated bitumen shall.14 Bitumen Emulsion Bitumen Emulsion shall be of the anionic and or cationic type and shall comply with the requirements (for the appropriate grade) given in BS 434. if the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. so direct.13 Cutback Bitumen Cutback bitumen shall be of the rapid curing type or the medium curing type and shall comply with the requirements (for the appropriate grade of cut back bitumen) given in BS 3690.0/06. 10. In particular.100 pen).16 Depot Tray Test The Contractor shall provide a set of 50mm wide trough as described in Appendix "A" of BS 1707 and shall carry out Depot Tray Test A in the presence of the S.O. heating and the procedure to be used for testing the efficiency of the spraying equipment. Bitumen shall be heated in an approved type of bitumen heater having a capacity commensurate with the output required. be disposed off at the Contractor's expense.2.15 Storage. BHD. Combination of different types of plant will be permitted in which case the number of passes for each type shall follow such proportion of the appropriate number in Table 10.12 General This section specifies the methods of storage.2 as will together produce the same total compactive effort as any type operated singly in accordance with Table 10. 10. The heater shall be fitted with a thermometer accurately registering the temperature of the bitumen and so situated as to be readily accessible. Bitumen emulsion showing signs of separation shall not be used. 10.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . or by its penetration value (as for example 80 . Great care must be ensured that the bitumen be heated to a temperature within the range specified for its grade. "Penetration grade bitumen". 10. Petroleum Bitumen shall be intended when material is referred to as "Asphalt Cement" "Straight-run Bitumen". bitumen emulsion shall be handled with care and not subjected to mechanical shocks or extremes of temperature likely to cause separation of bitumen.1.

18 Surface Preparation Immediately before the application of the prime coat the surface of the road base shall be brushed clean and free from all dust. dirt.O.17 Material The prime coat shall be a medium curing cut-back bitumen of grade M. Should the quantity of bitumen in any trough or troughs be found to lie outside the prescribed tolerance from the average.O. or M.0/06.O.19 Application of Prime Coat The prime coat shall be applied uniformly over the full width of the prepared road base by means of an approved pressure load mobile distributor complying with the requirement of BS 1707.O. The jets shall be so arranged in the spray bar that they are effectively preheated in the same SPECIFICATION FOR PIPEWORKS 119 SAJH WS/PW/001 (Rev. the surface shall be restored or reprepared to the satisfaction of the S.O. including the replacement of any faulty jets. regarding its grading.35mm (1/4in.O. sharp and free from organic matter and with not more than 45% of material passing No. 10. dried or wet mud. BHD. Material for blinding shall be clean.O.I. or. This test shall be carried out prior to using the distributor for the first time on the Contract and at such intervals thereafter as may be required by the S.) BS Sieve. Should any part or parts of the prepared surface become contaminated or unsuitable for the application of the prime coat. Moisture control of the road base shall be carried out by the Contractor using a wetting agent and method approved by the S. the Contractor shall carry out such adjustments to the distributor. and to a level of dampness to the satisfaction of the S. the pressure feed mobile distributor shall be fitted with a spray bar through which the hot bitumen can be circulated while the distributor is not spraying. Alternatively. the surface of the road base shall be slightly damped before the application of the prime coat. The actual grade to be used shall determine the penetration of each grade.O.. Not more than 5% of material used for blinding shall be retained on the 6. as may be necessary to achieve compliance with the test requirements. grit arising from the crushing of rock may be used.1. subject to the approval of the S. organic matter or any other loose material to the satisfaction of the S. In addition to the Special Requirements detailed in Section 3 of BS 1707.25 BS Sieve.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 10.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 10. Preparation of the surface as above shall not precede the application of bitumen by more than 450m.C. due to lack of care on the Contractor's part to protect the surface or due to prolonged exposure. If considered necessary by the S.C.

durable SPECIFICATION FOR PIPEWORKS 120 SAJH WS/PW/001 (Rev. Coarse Aggregate The coarse aggregate shall be natural aggregate sub-stantially free from the material passing a BS 3. 10. Binder and Composition This is a general specification for bitumen macadam road pavement surfacing.35mm (1/8in) Sieve.20 Spraying Procedure Immediately before any spraying run is begun the spray bar shall be tested by allowing all the jets to discharge simultaneously for about half a minute with a slotted metal tray placed beneath the spray bar whilst a visual inspection is made. 100 .2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . may direct. After testing the spray bar the distributor shall proceed with the spraying run without delay.135 135 . after carrying out Site tests. The base course and wearing course shall have thickness as shown on the Drawings and laid in accordance with BS 4987 : 1973 after construction of road base and bitumen prime coat or tack coat. The blinding shall be rolled with not more than two passes of an approved roller.I. or when rain is imminent. Any jet which is seen not delivering a uniform spray cone shall be cleaned or replaced. temperature as the circulating bitumen. Any areas insufficiently covered shall be resprayed by spray lance to the satisfaction of the S. SPRAYING TEMPERATURE FOR BITUMEN PRIME COAT TEMPERATION OF APPLICATION GRADE OF BITUMEN F DEGREES M. The bitumen shall be applied at a temperature in accordance with the table below and at the rate of spray as directed by or agreed with the S.21 Protection of Prime Coat After laying the prime coat.22 Aggregate.O. or immediately after rain until the road base has dried.O. After spraying the surface shall be left for a minimum period of three (3) hours before blinding. but not to be less than 440ml/sq. M.O. It shall be hard.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. clean. barriers shall be erected to keep the area surfaced free from traffic for such period as the S. BHD.0/06.70 10. No spraying of bitumen shall be carried out during.C.m. Blinding shall be applied so as to obtain a uniform covering without evidence of bare or fat patches of bitumen.60 60 .C.O. 10.160 C DEGREES 40 .1.

substantially all of which shall pass a 3.0 .35mm (1/8 in.200) BS Sieve. between 80 and 100. or other material approved by the S.30 0 .80 10 .100 50 . Composition of Mixtures The composition of freshly mixed material for the bitumen macadam shall comply on analysis with the following requirements: a) Base Course Passing BS Sieve (mm) 63 50 40 25 13 3 Binder Content as found by analysis 1 ½" (38mm) Nominal Size Aggregate % By Weight 100 90 .3.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. ii) Binder The binder shall be straight run bitumen. the content of silt. BHD.8 SPECIFICATION FOR PIPEWORKS 121 SAJH WS/PW/001 (Rev. Only granite shall be used for the wearing course.0/06.O.10 3. Portland cement.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . If sand is used. it shall consist of crushed rock.1. method A or B. crushed rock of the granite or limestone group or of any other rock group as may be approved by the S. Fine Aggregate i) The fine aggregate shall consist of crushed rock or of clean sand. At least 75 per cent of it shall pass a 75 um (No. loam and clay shall not exceed 3 per cent by weight of the fine aggregate.) BS Sieve. determined in accordance with BS812. If added filler is used in the bitumen macadam. which shall have a penetration at 25 deg C.O. hydrated lime.

and excessively high temperatures of the aggregate at the time of mixing.40 14 .O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .148 deg C Binder 130 . b) Wearing Course 3/4" (20mm) Nominal Size Aggregate 100 95 . SPECIFICATION FOR PIPEWORKS 122 SAJH WS/PW/001 (Rev.162 deg C It is particularly important to avoid excessive heating of the binder.4 .1.0/06.30 3-6 4. as these will adversely affect the quality of the resultant macadam. and the aggregate and binder separately heated to the following temperatures before entering the mixer: Aggregate 120 . the material passing 75 micron BS test sieve shall include portland cement or hydrated lime to the amount of 2% by mass of the total aggregate.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. including any added filler.4 Passing BS Sieve (mm) 25 20 13 10 6 3 1.075 Binder Content as found by analysis Note: a) When gravel other than limestone gravel is the aggregate. shall be weighed or measured in a mechanical mixer and thoroughly mixed in such a manner that all particles of the aggregates are completely and uniformly coated. The materials.23 Mixing The aggregate shall be surface dried. The exact bitumen content depending on density. BHD. shape and grading of the aggregate will be determined by the S.2 0. The mixing plant shall have a capacity sufficient to supply the paver on the road continuously when spreading the mix at normal speed and required thickness. b) 10.100 70 .75 40 .60 25 .90 55 .5.

1. Test methods for bitumen. using a correctly shaped template instead of a straightedge.24 Transport The bitumen macadam shall be transported from the manufacturing plant to the Site in clean vehicles and shall be protected against adverse weather conditions by means of tarpaulins. The temperature of the Bitumen Macadam. The use of coated dust.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Sampling and examination of bituminous mixtures for roads and buildings. during delivery to laying site. oil or water on the interior of vehicles to facilities discharge of the bitumen macadam may be permitted. placed in any position on the road surface parallel to the centre line. sand and fillers. the gap at any place between the points at which the straightedge is in contact with the road shall not exceed the following limits:Base course Wearing course : : 10mm 6mm The transverse profile shall conform to a similar standard of accuracy.0/06. 10.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . shall be protected to minimise loss of heat during transit so that all material is delivered in a condition suitable for spreading and compacting. 10. It is particularly important that bitumen macadam. shall be between 104oC and 132oC and at the time of rolling not less than 79oC. but the amount shall be kept to a minimum and any excess shall be removed by tipping or brushing. 10.25 Sampling and Testing Sampling and testing of the aggregate and mixed materials carried out shall be in accordance with the following British Standards as appropriate: a) b) c) BS 812 BS 598 BS 3235 Methods for the sampling and testing of mineral aggregates. BHD. SPECIFICATION FOR PIPEWORKS 123 SAJH WS/PW/001 (Rev. which is to be laid warm.26 Bitumen Macadam Layer Thickness and Tolerance The base course and wearing course shall be laid by machine in single course each and the compacted thickness of the individual courses shall be:Base course Wearing course : : 65mm 35mm The accuracy of finish in the longitudinal direction shall be determined by measuring the gap under a 3m straightedge.

BHD. dragging of the bitumen macadam. and at temperatures within the range required. tempers and screeds.. The bitumen macadam shall be supplied continuously to the machine. smooth and compact surface to the required widths. but not to be less than 270 ml/sq. conveying and spreading mechanisms. The machine shall be used only when it is in a serviceable condition. shall be cleaned off at the end of each working day. The bituminous material shall be applied by means of distributor at the rates directed by the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Works shall not proceed under unsuitable weather conditions. the edge shall be cut back and painted as above. as far as possible. The machine shall be of a type preferably self-propelled and capable of laying bitumen macadam continuously so as to produce automatically an even.m.27 Laying of Bitumen Macadam The bitumen macadam shall be laid by machine.28 Bituminous Tack Coat The surface of the dense bitumen macadam base course shall be cleaned immediately prior to the application of the tack coat. 10. Bituminous material remaining in the hoppers.1. Accumulations of material not of the specified quality shall be removed from the Site. The machine shall be operated to avoid. SPECIFICATION FOR PIPEWORKS 124 SAJH WS/PW/001 (Rev. On no account shall cleaning solvent be allowed to come into contact with any road surfacing material. 10.O. the material shall be cut back to a vertical face of the full depth of the course being laid and painted with bitumen or bitumen emulsion before any new material is laid. 10.29 Joints When a transverse construction joint is to be made. A fully trained and experienced operator shall be in direct charge of the machine. On longitudinal joints a complete bond of the two strips after compaction shall be ensured. On carriageways. thickness and cross-falls without segregation of the bitumen macadam.0/06.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Material supplied to the machine shall be laid as soon as possible after delivery. Continuous inspection of the finished surface as it is laid shall be carried out and any defects immediately rectified before any rolling takes place. narrow strips remaining alongside machine work shall be as far as possible hand laid and rolled at the same time as the machine laid work and allowance shall be made for extra compaction of hand laid strips. If this is not possible.

The bitumen macadam shall be tamped so that after final compaction.O. The layers shall be compacted to 95% of maximum dry density as determined in accordance with BS 1377:1975. levels. The material for shoulder construction shall be of well-graded laterite. BHD. SPECIFICATION FOR PIPEWORKS 125 SAJH WS/PW/001 (Rev. and conforms to the requirements of sub-base material and the following additional requirements: Minimum Plasticity Index Maximum Plasticity Index (Above for material passing 425 per sieve) Minimum CBR at 95% maximum dry density : : : 10 30 20 Shoulders shall be placed and compacted in layers not exceeding 200mm thickness before compaction. overlapping on successive passes by at least one half of the width of the rear roll.0m.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Compaction shall be carried out with a roller or rollers of weight not less than 6 tons nor exceed 10 tons. The shoulder shall be constructed on a previously prepared sub-base or subgrade finished as required in the Specification.32 Road Shoulders Road shoulders shall be constructed to the lines.30 Laying Around Manhole Covers When laying around manhole covers and similar fittings. dimensions and cross sections shown on the Drawings and as directed by the S. the finished surface is level with. the bitumen macadam shall be uniformly compacted by rolling to a density of not less than 98 percent of the Marshall Density of the mix. those parts against which the bitumen macadam is to abut shall be cleaned and painted with bitumen or bitumen emulsion prior to laying operations. gravel mining ballast or other suitable local material approved by the S. 10.0/06. The roller shall be fitted with a quick reverse and smooth acting clutch. The bitumen macadam shall be rolled in a longitudinal direction. such fittings. Traffic shall not be allowed to pass over the surface until the bitumen macadam has been completed and is adequately set.31 Compaction As soon as rolling can be effected without causing undue displacement. grades. 10. 10.1.O. and the width of a roller shall not be less than 1. Rollers shall not be allowed to stand on newly laid macadam while there is a risk that the surface will be deformed thereby. working from the sides to the centre of the carriageway. The work shall be carried out in conformity with the requirements for simultaneous construction of sub-base or base where required and as approved by the S. or slightly proud of.O.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

BHD.33 Shoulder Base Selected Fill Grading The selected fill material is to be used as shoulder base material over the compacted subgrade at the edge of the pavement and the verge and any other areas shown on the Drawings or as directed by the S. Such lateral shoulder sub-drains shall be constructed of graded selected fill to provide free drainage outlet from the pavement sub-base and shall be constructed to the dimensions and material as shown on the Drawing or as directed by the S. hard.4 600 microns 75 microns % Passing By Weight 100 80 .30 12 .O. SPECIFICATION FOR PIPEWORKS 126 SAJH WS/PW/001 (Rev.1 and 10. It shall comprise of clean.1.34 Lateral Shoulder Sub-drains Shoulder sub-drains shall be constructed along the road shoulders as shown on the Drawings or as directed by the S.36 Notes Relating to Table 10. 10.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. considers mechanical compaction is required. 10.100 45 .O.1 The notes given in this Clause and Tables 10.50 15 . or used as directed by the S. As soon as the compaction of sub-base is completed the roadbase will be laid and compacted.O.2 are for guidance only and shall not relieve the Contractor from his basic obligation to produce work to the required standard of the Specification.O.70 25 . Any depressions found shall be made up with material of the same kind as that of the original surface all at the Contractor's own expense.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 10.12 2 -8 Alternative suitably graded material may be accepted by the S.O.0/06. before proceeding with the laying of the premix. well-graded sandy gravels obtained from crushed rock and shall be free from any organic matter or deleterious material.35 Refilling of Excavated Pipe Trenches for Roadways In roads and in all other places where the S. The grading of the material shall fall within the following limits: BS Sieve (mm) 50 40 20 10 5 2.O. durable.2.20 6 . 10. the suitable material above the pipe shall be spread in layers of not greater than 150 mm and thoroughly consolidated by mechanical means as listed out in Table 10.

For pneumatic tyred rollers. a) The requirement for vibratory rollers are based on the use of the lowest gear on a self-propelled machine and a towed machine. Where a smooth-wheeled roller has more than one axle the machine will be assessed on the basis of the axle giving the highest value of force per 100mm width.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . All such rollers shall be equipped with a device automatically indicating the frequency at which the mechanism is operating. a) The static pressure under the plate of a vibrating-plate compactor is calculated by dividing the total weight of the machine in working order by the area in contact with compacted soil. Vibratory rollers shall be operated with their vibration mechanism operating only at the frequency of vibration recommended by the manufacturers. BHD. wheel load is the total weight of the roller divided by the number of wheels. Vibratory rollers are self-propelled or towed having means of applying mechanical vibration to one or more rolls. i) ii) The depth of compacted layer is the height by which an embankment is raised by each successive compacted layer. b) SPECIFICATION FOR PIPEWORKS 127 SAJH WS/PW/001 (Rev.1. Vibratory rollers operating without their vibration mechanism in use will be classified as smooth-wheeled rollers. Vibrating-plate compactors shall be operated at the frequency of vibration recommended by the manufacturers. The effective width shall be the sum of the widths of the individual wheel tracks when the spacing exceeds 225mm. If higher gears or speeds are used an increased number of passes shall be provided in proportion to the increase in speed of travel.0/06.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. Number of passes is the number of times that each point on the surface of the layer being compacted has been traversed by the item of compaction plant. In assessing the number of passes of pneumatic tyred rollers to meet the requirements of Table 10. The forces per 100mm width is the total force (weight) on the roll divided by the total roll width. iii) iv) v) b) c) vi) Vibrating-plate compactors are machines having a base-plate to which is attached a source of vibration consisting of one or two eccentrically-weighted shafts.1 the effective width shall be the sum of the widths of the individual wheel tracks together with the sum of spacing between the wheel tracks provided each spacing does not exceed 225mm. They shall normally be operated at travelling speeds of less than 15 m/min but if higher speeds are necessary the number of passes shall be increased in proportion to the increase in speed of travel.

p.p.) II) Roadwork Minimum Value 20 kN/m 3.) pH>=2 pH<=13 10% (max.3 kN 50 l.0/06.7 kN/m 0.1. However.68 kN 1.37 Geotextile Filter Membrane The geotextile to be used.3 kN 13 l. for the rock filled gabion/mattresses and road sub-base/formation interface shall conform to the following specifications: Criteria Tensile strength Maximum force sustained in grab tension with 45% elongation (200 mm strip) CBR puncture resistance Minimum flow through geotextile under 100 mm head of water Maximum pore size Acid resistance Basic (alkali) resistance Coefficient of variation I) Gabion/Mattresses Minimum Value 7. Power rammers are machines. In the case of power rammers one pass will be considered as made when the compacting shoe has made one strike on the area in question. vii) Vibro-tampers are machines in which an engine-driven recipro. BHD. and b) the number of passes shall be that for the type of plant requiring the greatest number of passes. Self-propelled rollers are unsuitable. Where combinations of different types or categories of plant are used.s.cating mechanism acts on a spring system./sq. where the Contractor uses a lighter type of plant to provide some preliminary compaction only these requirements to assess the effective compaction could be disregarded.metre 145 µm (max.s. 10.) pH>=2 pH<=13 10% (max.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the compaction requirements shall be: a) the depth of layer shall be that for the type of plant requiring the least depth of layer. where specified or shown on the Drawings. which are actuated by explosions in an internal combustion cylinder. each explosion being controlled manually by the operator.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . viii) ix) x) For items marked with an asterisk the rollers shall be towed by track-laying tractors. through which oscillations are set up in a base-plate./sq metre 160 µm (max.) SPECIFICATION FOR PIPEWORKS 128 SAJH WS/PW/001 (Rev.

O. cut back bitumen.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . or as directed by the S. BHD.0/06. or compacted embankment bench level. oil.38 Storage of Geotextile Filter Membrane The geotextile material shall be stored according to the manufacturer's recommendation out of sunlight.39 Laying and spreading over the Geotextile Filter Membrane The geotextile shall be laid on trimmed formation. petrol.O. to the satisfaction of the S. The thickness of the layer immediately on top of the geotextile shall not be less than 250 mm and not greater than 400 mm. to be in damaged or deteriorated condition shall be replaced by the Contractor at his own cost. may reject all such material left exposed to sunlight for more than six hours on the grounds of deterioration due to over-exposure to sunlight. Any geotextile material deemed by the S. the geotextile material shall not deteriorate significantly in strength due to exposure to sunlight. Additionally. petroleum bitumen.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. the sub-base or drainage blanket material shall be uniformly tipped onto the geotextile filter membrane.000 Langley's isolator radiation. puncture or damage to the geotextile shall be made good by patching with 500 mm minimum overlap. The opaque wrapping/packaging around the geotextile shall not be removed until immediately before use. The as laid geotextile material shall not be left uncovered and exposed to sunlight for a period greater than six hours. The geotextile material shall be resistant to general chemical attack. The geotextile material shall retain at least 80% of its original strength after an exposure to 10. The S. The geotextile for road sub-base formation shall be woven type material. Any tear. fungi and the like. bacteria. 10. by the Contractor at this own cost. Following this.1. prior to laying of the sub-base or drainage blanket material.O. SPECIFICATION FOR PIPEWORKS 129 SAJH WS/PW/001 (Rev. The geotextile for rock filled gabion/mattresses can be non-woven type. 10.O.

5 4 225 3.76 . BHD.21 .3 4 175 2.0.71 .2.8 more than 7.2.5.70 12 100 0.0.2 more than 5.6 2.51 . 75 75 125 150 150 175 200 225 250 16 12 12 8 4 4 4 4 4 150 150 150 200 225 250 275 300 300 16 12 6 10* 12* 10* 8* 8* 6* SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.81 .2 5.25 8 125 1.1.3 .5.25 .4.1.2 125 125 150 8 6 4 125 125 150 10 8 8 125 125 Unsuitable 10* 8* Unsuitable Grid Roller Force Per 100mm Width (kN) 2.9 * These rollers shall be towed.45 Unsuitable Unsuitable 0.2 4 250 4.26 .1.46 .2.61 . Self-propelled rollers are unsuitable.1 PLANT AND METHOD SPECIFICATION FOR COMPACTION OF EARTHWORKS AND SUB-GRADES Well-Graded Granular & Dry Cohesive Soil Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Cohesive Soil TYPE OF COMPACTION PLANT CATEGORY Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Uniformly-Graded Materials Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Smooth-Wheeled Roller Force Per 100mm Width (kN) 2.8 4 200 2. TABLE 10.8 Force Per 100mm Width (kN) 150 150 150 10 8 4 Unsuitable 125 150 Unsuitable 12 12 150 Unsuitable Unsuitable 10 Unsuitable Unsuitable Vibratory Roller Unsuitable Unsuitable 0.4.3.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD 130 .6 .1 .31 .7.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.75 4 150 1.0/06.

10.0 .1. Self-propelled rollers are unsuitable.6 .2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD 131 .3 .75 5 more than 75 100 (4) 150 (6) 200 (8) 3 3 3 100 (4) 125 (5) 150 (6) 3 3 3 150 (6) 200 (8) 225 (9) 3 3 3 * These rollers shall be towed.0 .8 .2 17.4.2 .2.5 1.3 10.12.2.0 .5 .0 more than 12 125 150 175 225 300 350 400 450 6 5 4 4 4 4 4 4 Unsuitable Unsuitable 125 125 125 150 150 175 Unsuitable Unsuitable 12 10 10 8 8 6 150 Unsuitable Unsuitable Unsuitable Unsuitable Unsuitable Unsuitable Unsuitable 10* Unsuitable Unsuitable Unsuitable Unsuitable Unsuitable Unsuitable Unsuitable Vibrating-plate Compactor Static Pressure under Base Plate (kN/m2) 8.0/06.1 . SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.0 2.0 6. Table 10.65 65 .13.1 12.0 .20.5 .) Cohesive Soil TYPE OF COMPACTION PLANT CATEGORY Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Well-Graded Granular & Dry Cohesive Soil Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Uniformly-Graded Materials Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Pneumatic-tyred Roller Wheel Load (Tonnes) 1.0 .8.0 4.6.17.1.5 2.1 (contd.8 13.0 8.7 more than 20.12.7 Unsuitable Unsuitable Unsuitable 100 (4) 150 (6) 200 (8) Unsuitable Unsuitable Unsuitable 6 6 6 Unsuitable 75 (3) 75 (3) 125 (5) 150 (6) 200 (8) Unsuitable 10 6 6 5 5 75 (3) 100 (4) 150 (6) 150 (6) 200 (8) 250 (10) 6 6 6 4 4 4 Vibro-tamper Mass (kg) 50 . BHD.

1. (contd.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD 132 . Table 10.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.) Well-Graded Granular & Dry Cohesive Soil Minimum Number Of Passes Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Cohesive Soil TYPE OF COMPACTION PLANT CATEGORY Maximum Depth Of Compacted Layer (mm) Uniformly-Graded Materials Maximum Depth Of Compacted Layer (mm) Minimum Number Of Passes Power Rammer Mass (kg) 100 more than 500 150 (6) 275 (11) 4 8 150 (6) 275 (11) 6 12 Unsuitable Unsuitable Unsuitable Unsuitable SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.1.0/06. BHD.

31 .1.3 2.2 COMPACTION PROCEDURE FOR UNBOUND SUB-BASE AND ROAD BASE MATERIALS AND FOR SOIL-CEMENT AND CEMENT-BOUND GRANULAR ROAD BASE TYPE OF COMPACTION PLANT Smooth-wheeled Roller MINIMUM NUMBER OF PASSES CATEGORY Force Per 100 mm Width (kN) 2.1.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.2 17.2 4.75 1.25 1.12 > 12 Vibratory Roller Static Force Per 100mm Width (kN) 0.5. TABLE 10.17.2 .2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD 133 .7 > 20.71 .7 16 6 4 3 3 3 2 Unsuitable 16 6 5 5 4 4 Unsuitable Unsuitable 10 9 8 7 6 12 12 10 8 Unsuitable Unsuitable 16 12 Unsuitable Unsuitable Unsuitable Unsuitable 16 8 Unsuitable 16 Unsuitable Unsuitable < 110mm LAYER < 150mm LAYER < 225mm LAYER 8 5 3 Unsuitable 8 6 Unsuitable Unsuitable 10 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.8 2.51 .2 Pneumatic-tyred Roller Wheel Load (Tonnes) 4-6 6-8 8 .26 .0/06.4.4.2.8 .21 .6 .81 .20.2 > 5. BHD.3.76 .5 3.2.1.9 Vibrating-plate Compactor Static Force Under Base Plate (kN/m2) 13.

2 (contd.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD 134 . BHD.1.0/06.75 > 75 < 110mm LAYER 4 3 2 < 150mm LAYER 8 6 4 < 225mm LAYER Unsuitable 10 8 Power Rammer on Dropping Weight Compactor Mass (kg) 100 .) TYPE OF COMPACTION PLANT Vibro-tamper MINIMUM NUMBER OF PASSES CATEGORY Mass (kg) 50 .60 65 . Table 10.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.500 > 500 5 5 8 8 Unsuitable 12 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.

BHD. fax or royalty to the relevant Authorities for the use of laterite from the borrow area and is deemed to be included in the Contract Rate. A rough compensation maximum deviation of ± 25mm will be permitted of the surface on the final completed formation. The laterite supplied for incorporation in the works shall be from the same borrow area from which the approved sample was obtained.O. The material shall be free from vegetable matter. services and ducts or any other drainage work that might affect the work unless otherwise agreed by the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. The Contractor shall submit sample of laterite for testing from his borrow area and approval obtained from the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . soft particles.O. 10. The S.2 Pavement Material Laterite pavement shall be constructed and installed true to line. The pavement shall consist of laterite. The cost and expense to remove any rejected material is deemed to be included in the Contract Rate. The surface of the formation shall be substantially uniform in density throughout the entire width and shall confirm to the density requirements for compaction. may reject any laterite for incorporation in the Works if in his opinion the material does not conform to the approved sample or unsuitable for the Works.40. The Contractor shall pay all necessary fees.O. clay lumps. Notwithstanding the laterite from the approved borrow area. 10.’s decision is final and not subject to arbitration. grades and typical cross-section as shown in the Drawings or as directed by the S. before construction of the laterite pavement. or other suitable local material approved by S.O.O. It shall be trimmed to confirm to the lines. grade and crossfall as shown on the Drawings or as directed by the S.1 LATERITE PAVEMENT Preparation of Formation to Receive Road Pavement The preparation of formation shall be carried out only after completion of all subgrade.0/06.O. and such preparation of formation shall be carried out immediately prior to the laying of the laterite pavement. any organic matter or other deleterious substance and shall conform to one of the grading given below: 135 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.O. The Works Contractor shall ensure that till is compacted with a slight outward slope to ensure good run-off surface water.O.40. and compacted to a minimum thickness of 150mm or as directed by the S. chambers. drainage.1. the S.40 10. pipe drains.

have a liquid limit not greater than 35 and plasticity index not greater than 11.0/06.O. ridges. Before construction of the laterite pavement. extreme care shall be exercise as not to damage any existing physical feature and any damaged shall be made good or replaced at the Contractor ‘s own expenses. Any rolling marks.S. Compaction and rolling operations shall begin along the edges and progress gradually towards the centre in a longitudinal direction. B.O. California Bearing Ratio (CBR) Soaked Test as described in B. On super-elevated curves.4 mm 420 micron 75 micron 100 80-100 55-90 40-70 30-55 12-30 5-20 The portion passing No. the compaction and rolling shall begin at the low side and progress gradually towards the high side.O. When the pavement is spread adjacent to any structures. The finished level shall not vary more than ± 20 mm from the grade or level shown on the Drawings.40. existing building or any physical features. or directed by the S. Sieve Percentage by Weight Passing A B 100 80-100 55-90 40-70 20-40 8-25 40mm 20 mm 10 mm 5 mm 2. Compaction shall be completed as soon as possible by suitable compaction equipment and as directed by the S. BHD.O. 10. The material shall be spread and graded evenly over the width by motor grader or such other approved mechanical plant as directed by the S.S. 136 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. 1377:1975 may be carried out on samples of the laterite materials and on the prepared laterite pavement by the S.4 Compaction Compaction shall be a minimum soaked CBR of 20% when compacted to 95% of the maximum dry density determined in BS 1377 Compaction Test (4.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.3 Spreading and Laying the Laterite Pavement The material shall be laid in one layer and compacted to thickness as specified with suitable and adequate compaction equipment approved by S.5 kg.5 kg rammer method) and soaked for 4 days under a surcharge of 4.1. if it is plastic. 10.S.O.40. 36 – B. The Contractor shall provide the attendance to carry out the test and the cost and expenses arising therefrom is deemed to be included in the Contract Rate. cracks or irregularities which may developed during or after construction shall be corrected and the defective areas made good to the full thickness and recompacted. Sieve shall.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .

137 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.O. The material removed from any high spot shall be run to waste and removed from the site at the Contractor’s own expense. The area treated shall be not less than 15m long and 2 metre wide or such lengths to be determined by the S. BHD.1. necessary to obtain compliance with the Specification. agrees.3 unless the S. Any reasonable compaction requirement or directed by the S.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . is deemed to be included in the Contract Rate. laid and compacted to Specification.40.5 Rectification of Surface The surface of the prepared formation and the laterite pavement where it is not in compliance with the tolerance set out in Clause 10.O.40. 10. shall be rectified by the Contractor.O. The defective area shall be scarified to a depth of 80 mm and corrected either by removal of material from high spots or by importation of further similar material to low spots.0/06. All low spots shall be made up with approved fresh material as specified.

BHD. .SECTION 11.0 – BRICKLAYER QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.

0 11.20 mm 70-100 600 µm 40-100 300 µm 5-70 150 µm 0-15 Sands for general purpose mortar Sands for reinforced brickwork mortar 100 90-100 70-100 40-80 5-40 0-10 138 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. and free from all defects. for approval and all deliveries of bricks shall be up to the standard of the samples approved and kept on the site. The grading of the sand when determined as described in B.'s decision as to the suitability of any sand shall be final.O.1 BRICKLAYER Bricks All bricks used in the Works.0/06.O.40 mm 90-100 1.S.3 Sand for Mortar Sand for mortar shall be natural sand obtained from rivers or approved pits and shall be hard durable clean and free adherent coats such as clay and from clay pellets.S. shall be hard.76 mm 100 2. Sieve B.I. 12.1. 11. unless otherwise described.B. SIEVE 4. The S. Facing bricks shall be of the colour selected by the S.S. standard size and from approved sources. undamaged.S. All rejected bricks shall be removed from the site forthwith at the Contractor's own expenses.O. with good faces and clean arises. before any bricks are ordered samples shall be submitted to the S. BHD. 11.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. It shall not contain harmful organic impurities or harmful materials such as iron pyrites salt coal mica shale laminated or flaky or elongated particles in such a form or in sufficient quantities to affect adversely the hardening strength or durability of the mortar or as might attack the reinforcement in reinforced brickwork. They shall be regular in size and shape. well burnt.2 Cement The cement. shall be ordinary Portland cement complying with B.A.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 11. machine made wire out clay bricks of R. 812 shall be within the following limits : % By Weight Passing B. unless otherwise shown in the Drawings.

P.S.4 Water Water shall be fresh. The mixture shall be thoroughly mixed dry after which only sufficient water shall be added with fine rose and the mass thoroughly mixed again to produce a uniform material of good consistency.6 Mixing Mortar The ingredients for the mortars shall be measured in proper gauging boxes and a boarded platform shall be used for mixing. All work found out to comply strictly with this requirement shall be taken down and rebuilt at the Contractor's expense. 11. level shall be composed of one part of cement and six parts of sand with the addition of an approved mortar plasticiser used strictly in accordance with the manufacturer's instruction. BHD. 11. level.7 Brick Laying Bricks shall be carefully handled from carts or lorries and stacked and all broken bricks shall be removed from the site without delay. 139 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. piers and bearing wall shall consist of one part of cement to three parts of sand by volume and shall be made in as small quantities as is required and shall be used within half an hour of mixing. 11. Mortar for brickwork above D.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.1. No re-making up of partially set mortar shall be permitted. clean of potable quality. The tops of all walls where work has stopped shall be made thoroughly wet immediately before further work is commenced.C. Bed and vertical joints of brickwork shall be filled solid with mortar and no vertical joint shall be allowed to be flushed up from the top each joint must be filled up as the bricks are laid.C.5 Mortar Mortar for brickwork below D.0/06. free of vegetation and other deleterious matters and shall comply with B. 3146. All bricks shall be soaked in water for at least half an hour immediately before being laid and shall then be kept wet until they are set in the structure.P. New brickwork shall be protected from the sun and kept moist for at least one day after it has been built. All brickwork shall be constructed in English bond unless otherwise specified and shall be carried out perfectly true and plumb through successive courses so that no part of the work is more than 900mm above any adjacent brickwork. 11.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . No overhang work will be permitted and scaffolding shall be carried up as the work proceeds.

11. commencing two courses above floor level. complying with B. etc.P. The ties shall be adequately secured to the main reinforcement in the concrete. Cramps shall be embedded in concrete and built in as the brickwork proceeds.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . doors.9 Facing Brickwork All facing brickwork shall be executed in first quality approved racing bricks in Stretcher or Flemish bond as shown. On end of the cramp shall be turned up and screwed to the frame and the other end shall be split and fish-tailed for building in. It shall be lapped at least 75mm at angles and joints and shall be laid on 20mm thick bed of cement/sand (1:1) mortar coated with bitumen on the upper surface.S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. frames and precast units where shown and wherever required. finished with a neat struck weathered joint. 11.11 Lintels Unless otherwise shown all brickwork over openings shall be supported on precast concrete lintels in accordance with the dimension shown on the drawing or as directed by the S. No broken bricks shall be used except when bricks cut to the correct size and shape are used to form the bond. properly bonded into any backing walls. 11.O. Wrot-iron cramps shall be 38mm x 6mm x 225mm long for fixing wooden frames. plasters and other brickwork shall be properly bonded together in the best approved manner. 140 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. cramps for metal windows. 11. etc. 11.12 Building In Build in cramps. All wall angles piers. Joints shall not be more than 6mm in thickness and all joints shall be raked out to a depth of 12mm to form a key for plastering as the work proceeds.8 Half-Brick Walls Half-brick walls shall be built in stretcher bond and shall be reinforced at every fourth course with "Exmet" or other approved brick reinforcement. BHD.C.8 kilogram per square metre. piers.1. 743 and weighing not less than 3.10 Damp Proof Course Provide and lay where shown on drawings bituminuos sheet damp-proof course composed of "Plurex" or other approved hessian-based bituminous D. Joints shall be raked out to a depth of 13mm and pointed up in coloured cement mortar to approved tints. All brickwork adjacent to reinforced concrete shall be bonded to the concrete structure with approved ties set at every fourth course.0/06.

all cutting and fitting to reinforced concrete. and for all other specified work in connection with bricks and bricklaying for which no separate items are provided in the Bill of Quantities.15 Payment for Brickwork Brickwork shall be measured in square metres for the net quantity erected.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. 11. Chambers and manholes shall be of 225mm brickworks set in cement mortar. the bottom of all manholes shall be benched up with Grade 20 concrete to an average thickness of 200mm and requisite half round channels shall be formed. The Contract Rates shall include the cost of providing the bricks and mortar. 11. b) The pipes. to accommodate cables and instrumentation.14 Valve Chambers and Manholes a) Valve chambers and manholes where necessary shall be provided and constructed. reveals. BHD. for the supply and fixing of all galvanised steel expanded metal lath. specials and valves in the valve chambers shall be set in Grade 20 concrete blocks to exact line and level prior to the construction of the chamber walls and all parts of the pipes and specials which are to be encased in concrete shall be brushed clean of their respective coatings. plumbing quoins and angles. No scaffolding bearers supported on the walls of the building under construction. Unless approved by the S. 141 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.13 Scaffolding All scaffolding must be self supporting and independent of the building.O.1. and no allowances shall be made for cutting and wastage. as instructed by the S. The internal sides and the bottom of all manholes shall be rendered with 1:3 cement sand mortar 12mm thick. the Contract Rates for such work shall include cutting recesses for switches. Where chases shall be cut.0/06. notches and rebates and all openings. 11. raking out joints for keying and subsequent pointing up for flashings and damp proof course. forming sill.O.

0 – STEEL AND METAL WORKS QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. .. BHD. SECTION 12.

12.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Where it is not practicable to provide individual frames to each plate. BHD.0/06. ragbolts. Steelwork shall be thoroughly descaled to BS 4232 second quality and shall be painted with two coats of two pack epoxy based red lead primer before leaving the manufacturer's works. The plate panel sizes shall be such that they can be lifted by two men easily and each panel shall be provided with suitable sized lifting holes. ragbolts. 12. Chequer plates used elsewhere shall be painted on the lower (hidden) upper (exposed) surfaces with one undercoat.0 12.1 STEEL AND METAL WORKS Structural Steel Work Structural steel work shall conform to the requirements of BS 449. After installation on Site chequer plates sued in valve chambers shall be painted with a further two coats of two pack coal tar epoxy paint. Chequer plates for use in valve chambers or manholes shall be hinged to one side of the frames unless otherwise specified.3 Steel Chequered Plate Chequer plating shall be mild steel and shall have a non-slip pattern on its upper face. two coats of semi-gloss high finishing paint of approved quality and colour. Each bolt shall be provided with two washers and bolts shall be long enough to show a full thread through the nut after fixing. 12. The edges of all chequer plates shall be finished straight or to the outline of obstructions and shall be free of burn marks or irregularities. All bolts. 142 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.2 Bolts and Nuts Bolts. BS 968 whichever is appropriate and steel tubes for structural purposes shall comply with BS 1775 and shall be obtained from a manufacturer to the prior approval of the S.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. BS 548. Chequer plating which has been cut with a torch shall afterwards be ground to present a straight edge. Chequer plating shall be thoroughly wire brushed and painted with two coats of two pack epoxy based red lead primer before delivery. Chequer plates shall be securely bolted with countersunk screw studs to frames set in the edges of and spanning the ducts or opening. Any damage to this coating shall be repainted before erection. nuts and washers shall be hot-dip galvanised in accordance with BS 729. steel shall comply with BS 15.1. nuts and washers shall conform to BS 15 as regards material and BS 916 as regards dimensions. the plates shall be stiffened by welding steel angles on their underside to eliminate discernible deflection.O. The sizes of chequer plates shall be such that no discernible deflection occurs under the weights of a man standing upon it.

Step irons shall be measured by number and the Contract Rates for step irons shall include for the supply and all necessary fixing work galvanising and painting with 2 coats of approved two pack coal tar epoxy paint.1.5 Ladder Mild steel ladders shall be hot-dip galvanised in accordance with BS 729. BHD. 12.6 Step Irons Steel irons for use in chambers shall unless otherwise specified be bent from 25mm diameter mild steel bars to the shape and dimensions shown on the Drawings and shall be hot-dip galvanised after bending.7mm wire of 50mm square mesh reinforced with 3 nos. bolts. The steel ladders shall be galvanised before leaving the manufacturers' works and the Contract Rates for supplying and fixing steel ladders shall include for painting as specified. and for all nuts. Each length of chain shall be fitted with a shackle at one end and a nap fastening at the other. Unless detailed on the Drawings. an undercoat and a further 2 coats of an approved gloss paint after installation.0/06. smooth welded chains in accordance with BS 4942 Part 2. After cleaning with lithoform it shall be painted with two coats of approved two pack coal tar epoxy paint which shall be obtained from an approved manufacturer. the Contractor shall submit to the S. The rates for handrailing shall include for painting and formation and subsequent grouting up of pockets in the concrete for stanchions. Intermediate support between the ends of the ladder shall be by means of stays securely fixed to the nearest part of the structure. it shall be painted with two coats of two pack epoxy red lead primer.1 mm 143 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev. they are to be galvanised mild steel 10mm nominal size. Where safety chains are required. After cleaning with lithoform. 12. detailed drawings of the ladder for approval before placing any orders.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.7 Fencing Fencing shall be as detailed on the Drawings. 12. Steel ladders shall be 450mm wide. stays and other things necessary for fixing the ladders securely in place.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . 12. 4. Expansion units shall be provided where the handrailings are more than 15 metre long.O. Chain link for fencing shall be PVC coated and consist of hot dipped galvanised 3. of welded construction and shall not have an unsupported length of more than 2 metre. short links.4 Handrailing Handrailing shall be made from hot-dip galvanised mild steel hollow sections and flats.

This gate shall be complete with lock gears and a 75mm lock of approved brand. Suitable gate as shown in the drawings shall be provided to match the fencing.0 metre intervals with straining posts at all corners and at intervals of 15 metre.0/06. All galvanised metal parts shall be protected from damage due to electrolytic action. Where aluminium members are in contact with other non-aluminium structures the contact faces shall be protected by insulating pads of neoprene bitumen alloy. smooth and as free from spangle as possible. Fence posts shall be of 64mm x 64mm x 9. 12. excavation.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN. white rust and abrasion during delivery.1. screw tapping. nuts and washers shall be completely galvanised including the threads but galvanising removed in the course of nut fixing may be replaced with an approved zinc rich paint. and filled in with Grade 20 concrete to be flushed with ground level. All mild steel angles shall be galvanised and painted in accordance with BS 5493.5mm black vinyl glued on. All hollow boxed and pressed sections shall be extruded from fully heat treated aluminium alloy and etched and anodised in bronze colour to BS 1615.O. BHD. in the opinion of the S. Bolts.00 grams per square metre of area covered and be not less than 0. All galvanising shall be done by the hot-dip process with spilter. The galvanising shall be uniform. concrete support and dwarf walls.8 Aluminium Structures and Sections Aluminium structures shall be constructed in alloy NE8M to BS 1474. not less than 98% of which shall be pure zinc. The Contract Rates for fencing and gate shall include for the supply of all materials. erection of the fencing complete painting with 2 coats of approved paint. galvanising. stays corner posts. Four (4) keys shall be provided for the locks. Recesses on internal faces of boxed sections shall be finished with a strip of 13mm x 6. cutting. hot dipped galvanised line wires.3mm hot dipped galvanised mild steel angles raked at 45o.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD . Barbed wires shall be galvanised two ply 2. 144 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.9 Galvanised Metals All metals to be galvanised shall be of the full dimensions shown or specified and all punching. drilling.64 mm with 4 point barbs spaced at 75 mm interval. the damage to the galvanising is too severe or extensive the part shall be removed and be re-galvanised. All fence posts and struts shall be sunk into post holes 300mm x 300mm x 750mm deep. Stays for straining posts shall be 51mm x 51mm x 6.1mm thick. welding and the removal of burrs shall be completed before the galvanising process commences. It shall weigh not less than 6. storage and erection. clean. Minor damage shall be touched up with an approved zinc chromate or other approved metallic compound but if. fence posts. Cold working shall be avoided. Payment will be made for the net length of fencing and number of gate erected. 12.4mm hot dipped galvanised mild steel angles spaced at 3.

Steel rain water pipes and fittings shall be of hot dipped galvanised no. BHD. ground for pavement. Access covers and surface boxes exposed to the weather shall incorporate a waterproof seal. providing and erecting support brackets for holding the pipe in position. Four sets of each type of lifting key shall be supplied by the Contractor. Frames shall be firmly bedded in 1:3 cement/sand mortar and the tops of all covers and gratings shall be flush with the finished surface of the surrounding floor. They shall be formed into required lengths by an approved method of soldering and properly secured with 50mm x 0.0/06. Panels shall be fixed to angle kerbing or supporting steelwork with adequate clips so that movement is prevented. surface boxes. square. gulley grating and frames shall be obtained from an approved manufacturer and shall comply generally with BS 497. They shall be formed into required lengths where necessary by an approved method recommended by the suppliers.QUALITY ASSURANCE DEPARTMENT SAJ HOLDINGS SDN.13 Manhole Covers. Cut-outs for plant items shall be trimmed with curved or straight edge trimmings as appropriate. etc. Ductile iron manhole and access covers.10 Dissimilar Metals The Contractor shall not use fixtures and fittings for metalwork including pipework in which dissimilar metals likely to lead to galvanic action are placed in permanent contact with each other. Panels shall be trimmed across the ends of load bearing bars by flats of the same cross-section welded to each load bearing bar. jointing and building into concrete. 12. Items not covered by this standard shall be of a quality equal to the first grade available in the country. Surface Boxes. After erection all exposed surfaces shall be cleaned down with lithoform and painted with one flat undercoat and two high gloss finishing coats of paint of approved quality. Rain water pipes shall be measured as the net length erected in place and shall include for all works in forming bends where required. 16 SWG pressed steel sheets and rectangular in cross-section. cutting. 145 SPECIFICATION FOR PIPEWORKS SAJH WS/PW/001 (Rev.12 Open Mesh Flooring Open mesh flooring shall be fabricated from mild steel load bearing bars of flat section bared with round. or twisted square bars perpendicular to and welded to each load bearing bar.1.11 Rain Water Pipes uPVC rain water down pipes and fittings shall be obtained from an approved manufacturer. 12.2007) NO CHANGES ALLOWED WITHOUT THE PERMISSION OF QUALITY ASSURANCE DEPARTMENT OF SAJ HOLDINGS SDN BHD .8mm galvanised sheet iron straps spaced at approximately 1800mm centre. 12. 12.