Technical Specifications Guide For Projects in Iraq PDF

TECHNICAL
SPECIFICATIONS
GUIDE FOR
PROJECTS IN
2013
IRAQ
Second edition
GENERAL REQUIREMENTS – SITEWORK – CONCRETE - PILES - SPECIFICATION
STEEL STRUCTURE - THERMAL AND MOISTURE PROTECTION -
FINISHING OF MATERIALS,
WORKMANSHIP
Prepared By: Ahmed. A. Elshaibani OF CIVIL
ENGINEERING
WORKS
In the name of Allah, the Beneficent, the Merciful
TECHNICAL SPECIFICATIONS GUIDE FOR PROJECTS IN IRAQ
Copyright © 2010, 2013
All Rights Reserved
No part of the contents of this book may be reproduced or transmitted in any form or by any
means without the written permission of the publisher.
Editor: Ahmed A. Elshaibani

Typesetting: by the editor
Cover design: by the editor
Second published 2013
Copyright © 2010, 2013 by Dar Al-Rowad for Printing, Publishing & Distribution
۲۰۱۰ ‫ ﻟﺴﻨﺔ‬۱۸۸۱ ‫ﺭﻗﻢ ﺍﻻﻳﺪﺍﻉ ﻓﻲ ﺩﺍﺭ ﺍﻟﻜﺘﺐ ﻭ ﺍﻟﻮﺛﺎﺋﻖ ﺑﺒﻐﺪﺍﺩ‬
This book contains information obtained from authentic and highly regarded sources.
Reprinted material is quoted with permission, and sources are indicated. A wide variety of
references are listed. Reasonable efforts have been made to publish reliable data and
information, but the author and the publisher cannot assume responsibility for the validity of
all materials or for the consequences of their use.
No part of this book may be reprinted, reproduced, transmitted, or utilized in any form by
any electronic, mechanical, or other means, now known or hereafter invented, including
photocopying, microfilming, and recording, or in any information storage or retrieval system,
without written permission from the publishers.
Bagdad Library Cataloguing in Publication Data

A catalogue record for this book is available from the Bagdad Library
Printed and bound in Iraq
E-mail (for comments and suggestions): ahmedelshaibani@yahoo.com
1
SPECIFICATION OF MATERIALS WORKMANSHIP
OF CIVIL ENGINEERING WORKS
This book is dedicated to
Whom I owe my life and knowledge
Teacher, Mentor and Friend
2
Contents
• SECTION 1 SCOPE OF WORKS 7
Part 1 General Information 7
Part 2 - SUMMARY OF WORK 8
• SECTION 2 SPECIFICATION 10
• DIVISION 1 GENERAL REQUIREMENTS 10
SECTION 1.1 STRUCTURAL DESIGN CRITERIA 11
SECTION 1.2 MECHANICAL AND ELECTRICAL WORK COORDINATOR 19
SECTION 1.3 QUALETY CONTROL & SUBMITTALS 20

PART 1 - GENERAL 20
PART 2 – PRODUCTS 24
PART 3 – EXECUTION 25
SECTION 1.4 PROGRESS SCHEDULES 26

PART 1 – GENERAL 26
PART 3 - EXECUTION 31
• DIVISION 2 SITEWORK 34
SECTION 2.1 – GENERAL FOR EARTHWORK AND SITE PREPARTION 35
SECTION 2.2 – STRUCTURE EXCAVECATION AND BACKFILL 40
SECTION 2.3 – DEWATERING 44
SECTION 2.4 - SERVICE ROADS, PARKING AREAS AND FOOTPATHS 46

PART 1 - GENERAL 46
PART 2 - PRODUCTS 53
• DIVISION 3 CONCRETE 107
SECTION 3.1 GENERAL 108
SECTION 3.2 FORMWORK AND CONCRETING PRACTICE 114

PART 1- FORMWORK 114
PART 2 – CAST-IN-PLACE CONCRETE 117
PART 3 - CONCRETE REINFORCMENTE 133
SECTION 3.3 CONCRETE BATCHING AND DELIVERY 135

PART 1 - GENERAL REQUIREMENTS & SUBMITTALS 135
PART 2 - PRODUCTS, STORAGE AND HANDLING 138
PART 3 – CONCRETE TYPES, MIX DESIGN AND QUALITY CONTROL 146
SECTION 3.4 CONCRETE REPAIR 160

PART 1 - GENERAL 160
3
SECTION 3.5 TESTING OF WATER RETAINING STRUCTURES 171
PART 3 – EXECUTION 172
• DIVISION 4 PILES 175

PART 2 - MEASUREMENT AND PAYMENT 176
• DIVISION 5 STEEL STRUCTURE 194
SECTION 5.1 STRUCTURAL STEEL 195

SECTION 5.2 METAL FABRICATIONS 215

SECTION 5.3 FIRE PROTECTION FOR STEEL STRUCTURE 222

PART 1 - REQUIREMENTS 222
PART 2 - MATERIALS 224
PART 3 - APPLICATION AND USE 225
• DIVISION 6 THERMAL AND MOISTURE PROTECTION 232

PART 2 PRODUCTS, STORGE AND INSTLATION 233
• DIVISION 7 FINSHING 244

PART 1 – BRICK 245
PART 2 – CONCRETE BLOCKS 246
PART 3 – ORDINARY AND TERRAZZO TILES 246
PART 4 – CONCRETE FLAGS 246
PART 5 – JUSS 247
PART 6 – TIMBER 247
PART 7 – WINDOWS 248
PART 8 – DOORS 249
PART 9 – PAINT 251
PART 10 – GLASS AND GLAZING 253
PART 11 – MISCELLANEOUS MATERIALS 254
• DIVISION 8 MECHANICAL 260
• DIVISION 9 ELECTRICAL 262
• REFERENCES 264
4
Preface
In the name of God
These specifications include general instructions and

description of using materials in construction of general buildings
and roads carrying out methods and measuring of different
demanded activities to perform the project.
The Iraqi Standard Specification was the basic subject of this

booklet because of its obligatory application in the country followed
by international specifications as second degree like the British
Standard (BS) and the American (ASTM & AASHTO) when an
Iraqi specification is not available or included occasionally as an
appendix to the Iraqi one.
The Iraqi standard issued by Central system of standardization and

quality controlling (c. s. s. q. c), and National Center for
Construction Laboratories & Researches (NCCLR) materials
Specification & Construction Works, Concerning of methods of
carrying out emphasis on local experience in the practical side.
This Specification represents the guide of one set of the contract

documents for projects of Ministry & institution of Iraq, and This
Specification is intended to applying the requirements of the
Contract and nothing therein relieve the Contractor of any of his
obligations under the said Conditions.
Finally, I hope that this booklet will serve as a useful guide for
working parties in the execution of construction projects and to
know the specifications of materials used in the fields for roads &
building to achieve optimal quality level... and success is a gift of
God.
Eng. Ahmed A. Elshaibani
5
PROJECT NAME
CONTRACT No. / /
This Section is one of a set of SBD for Procurement of Works

Summary
PART 1 – BIDDING PROCEDURES
Section I. Instructions to Bidders (ITB)

This Section provides relevant information to help Bidders prepare their bids.
Information is also provided on the submission, opening, and evaluation of bids and
on the award of Contracts. Section I contains provisions that are to be used
without modification.
Section II. Bid Data Sheet (BDS)
This Section consists of provisions that are specific to each procurement and that
supplement the information or requirements included in Section I, Instructions to
Bidders.
Section III. Evaluation and Qualification Criteria (alternative Section III to be used when
Prequalification has not taken place before bidding)
This Section contains the criteria to determine the lowest evaluated bid and the
qualifications of the Bidder to perform the contract.
Section IV. Bidding Forms
This Section contains the forms which are to be completed by the Bidder and
submitted as part of his Bid.
Section V. Eligible Countries
This Section contains information regarding eligible countries.
PART 2 – WORKS REQUIREMENTS
Section VI. Works Requirements

This Section contains the Scope of Works, the Specifications, the Drawings, the Bill
of quantities, and supplementary information that describe the Works to be procured.
PART 3 – CONDITIONS OF CONTRACT AND CONTRACT FORMS
Section VII. General Conditions (GC)

This Section contains the general clauses to be applied in all contracts. The text of
the clauses in this Section shall not be modified.
Section VIII. Particular Conditions (PC)
This Section consists of Part A, Contract Data, which contains data, and Part B,
Specific Provisions, which contains clauses specific to each contract. The contents of
this Section supplement the General Conditions and shall be prepared by the
Employer.
Section IX: Annex to the Particular Conditions - Contract Forms
This Section contains forms which, once completed, will form part of the Contract.
The forms for Performance Security and Advance Payment Security, when required,
shall only be completed by the successful Bidder after contract awaed.
6
SECTION 1 SCOPE OF WORKS
Part 1 General Information

1.01. OBJECTIVE
The objective of this proposal is seeking an economic and efficient bid from the
PC employer for the following purposes regarding to the General Technical
Specification:
a. ...........……………………………. .
b. ...…………………………………. .
c. ..………………………………….. .
d. .…………………………………… .
e. ....………………………………… .
f. ..………………………………….. .
Client’s requirements are summarized as follows:
• Steel structures and related works which will be noted in general Specification.
• Roofing-claddings
• Windows
• Doors
• Electrical Equipment
• Mechanical/HVAC system
• …………………………………………
1.02 DEFINITIONS
For the purposes of this tender, the following definitions shall apply:
 Main Project ……………………
 SBD : Standard Bidding Documents
 PC : shall mean : Procurement, Construction
 Client : Ministry of ……………………… of Iraq - …………………………………… .
 PC Employer: A person / party who will be responsible for fabrication and supplies
material, transportation, installation and commissioning based on drawing. Also
employer shall apply the required modification and finalizing the detail design based
on existing condition of each building /site.
 Sub Employer: Third Party – Who will be responsible for construction/Design as
the potential of PC employer.
 Tender : Shall mean this tender for PC works
 Bidder : Shall mean the legal entity receiving the tender document
 Bid Proposal : Shall mean the totality of the completed tender documents and
other documents that are submitted to client by the bidder before closing date of
tender.
1.03. Location
The project is located in …………………………………………………….. .
1.04. TYPE OF CONTRACT
Contract is on …………… basis due to the BOQ’s.

7
1.05 CLIENT PROJECT ORGANIZATION
Client elects a person to act as his representative; Client Representative is authorized to

act on behalf of the Client in all matters related to the execution of the project.
Employer staff may be in contact with relevant disciplines of Client staff. However, formal
communications will be through Client Representative, and/or his designees, and
Employer Project Manager, and/or his designees.
1.06 CLIENT's PROJECT COORDINATOR
CLIENT’s project coordinator is the staff of the Ministry of ………………

………………………………………………….
1.07 OFFICIAL ADDRESSES
a) Correspondence to Client Representative shall be addressed to:
Client Representative:
Postal address…
Dept. of Contracts
Email: ……………….@................
1.08 CLOSING DATE OF TENDER
Closing date of tender will be: / / 20
Part 2 - SUMMARY OF WORK

2.01. INTRODUCTION
The following is the Tenderer’s scope of work.
2.02 GENERAL
The Client, Ministry of …………….. Intends to further develop ……………….. In

………………. seeking for the PC employer who has the ability for the rapid installation.
The Project is to be implemented by awarding the EPC Package for civil- building works.
This document defines the scope of work for the EPC Package for the integrated
Development project.
EMPLOYER intends to appoint specialized Sub-contractors to endorse the Basic Engineering

documents, perform the detailed engineering, procurement and construction of the
………………….
2.03 SCOPE OF WORK
Unless specifically stated otherwise in the Contract, the Scope of Work that is issued in the
"General Technical Specification" by CLIENT shall include the performance of all activities,
and the provision of all personnel (including project management and supervision), materials,
facilities (including temporary materials and facilities), plant, consumables, services,
documentation, insurance and other items detailed, required or reasonably implied, to safety
and efficiently execute the following:
8
Endorsement of the basic engineering detailed, procurement, fabrication, transportation,
installation, of the permanent new extension facilities based on the noted specification.
2.04 INFORMATION TO BE SUPPLIED BY CLIENT
Client will provide the following data to Employer –

• Geophysical and soil investigation Reports.
• Surveying layout
• Site layouts, Location and accesses.
• Details of life line resources (Required electricity, water supply, sewerage system at
the battery limit of the project from the public administrations).
• Visa or any other contact/visit permissions for the project.
9
SECTION 2
SPECIFICATION
DIVISION 1
GENERAL
REQUIREMENTS
10
SECTION 1.1 STRUCTURAL DESIGN CRITERIA
1. General
Process structures will be water containing hydraulic structures constructed of cast-in-place
reinforced concrete. Generally, the structures will be above grade with the foundation and
lower portion below grade. Design loading and basic design criteria for structural components
of buildings, channels, water containing structures and miscellaneous structures shall be as
presented herein. These criteria are minimum standards and more conservative approaches
may be used based on the judgment of the designer.
2. Loads and Load Combinations
2.1 Dead Loads

The loads resulting from the weight of all permanent loads, equipment, fixtures, etc., such as
walls, partitions, floors, roofs, equipment bases, earth for buried structures, and all permanent
non-removable stationary construction are dead loads.
Where permanent partitions are indicated, their actual weights are included in the dead load
acting at the given partition location. Where the use of other partitions is envisaged, an
additional imposed load should be specified for the floor area. This may be taken as a
uniformly distributed load of not less than one third of the load per meter run of the finished
partitions. For floors of offices, this additional uniformly distributed partition load should not be
less than 1.0 kN/m2.
The weights of tanks and other receptacles, and of their contents, are considered as dead
loads.
2.2 Live Loads

Live loads consist of all loads (other than dead loads) that must be considered in the design
to satisfy applicable codes and specific project requirements. Design criteria for live loads
shall be as presented in Table 7-1.
2.3 Wind Loads

Wind load shall be in accordance with the “Seismic and Wind Speed Design for Iraq
Infrastructure Reconstruction Project Phase 2”. The following wind speed shall be used in
design:
• Basic Wind Speed: 35 meter per second (80 mph) with 3-second gust speed of 45
meter per second (100 mph or 162 km per hour).
2.4 Seismic Design Load

Loading, application, and design methods shall conform to the IBC – International
Building Code 2006. The following values shall be used for seismic load design criteria:
- Mapped short-period spectral response acceleration:
• Mapped MCE for 0.2s spectral response acceleration Ss =1.24, 0.31 for Baghdad, Basra
• Mapped MCE for 1.0s spectral response acceleration S1 =0.56, 0.14 for Baghdad, Basra
Note:"The probabilistic MCE [Maximum Considered Earthquake] spectral response accelerations
shall be taken as the spectral response accelerations represented by a 5 percent damped
acceleration response spectrum having a 2 percent probability of exceedance within a 50-yr.
period."
- Response modification factor, R = 5
- Long-Period transition period in seconds, TL = 4
11
Table 1 - Live Load Design Criteria
Condition Criteria
Floor (general) 4.8 kPa
Heavy Storage 12.0 kPa
Light Storage 6.0 kPa
Catwalks 4.8 kPa
Personnel Assembly Areas 4.8 kPa
Kitchens, laundries, laboratories, 3.0 kPa
Classroom
Corridors, hallways, aisles, etc., subject 5.0 kPa
to wheeled vehicles, trolleys etc.
Factories, workshops and similar 5.0 kPa
buildings (general industrial)
Pump Stations, Process Buildings, and 9.6 kPa
Process Slabs
Unrestricted Vehicular Areas AASHTO HS 20
Partitions (Present or Future) 1.0 kPa
Sidewalks and Driveways 12.0 kPa may have concentrated loads also
Sluice Gate Operator Supports As determined for individual operator, assuming 28 N
minimum forces acting on the operator handle.
Assume force acts in both directions.
Fixed Stairways 4.8 kPa and 4.5 kN concentrated
Roof 1.0 kPa
Gratings, Checkered Plates, and Minimum of 4.8 kPa and 1.33 kN concentrated, but
Hatches not less than loading for adjacent floor area (but not
less than 8.6 kPa for grating). The maximum
deflection under this loading shall be limited to L/240.
Buried Structures Use AASHTO guidelines for structures for structures
in potential traffic areas.
2.5 Impact Loads

Impact loads shall be based on AASHTO Standard Specification for highway bridges due to
moving vehicular wheel loads.
Crane support girders and monorails - for horizontal and vertical impact forces, see AISC
requirements.
Light machinery supports - 20 percent minimum or manufacturer’s recommendation.
2.6 Liquid Loads

Liquid holding basin walls shall be designed for maximum liquid levels with the following
conditions:
• Full of liquid, no backfill.
• Backfill and ground water with tank empty.
• Any tank cell empty or full in any combination.
• Hydrodynamic loads due to seismic forces.
• Static earth pressure plus surcharge with tank empty.
• Dynamic earth pressure with tank empty.
12
2.7 Lateral Earth Pressure
Lateral earth pressure values shall be as established by the site geotechnical investigation.
The following values may be used as a minimum:
•
2
Active pressures - 1.7 kN/m
•
2
At-rest pressures - 2.8 kN/m
•
2
Passive pressures - 12.0 kN/m
• Surcharge pressures - Use a minimum of 0.6 meter of earth for walls where vehicular
loads can come within H/2 of the wall.
• Lateral loads due to earthquakes on retaining walls - 20% of total earth pressure
forces plus 20% of the wall weight acting horizontally at 2/3 the fill height above the
base of wall.
2.8 Weight of Soil

Lateral earth pressure values will be established by the site geotechnical investigation.
2.9 Bearing Pressure, Settlement, and Sliding Friction.

Lateral earth pressure values will be established by the site geotechnical investigation.
2.10 Combination of Loads

The most severe distribution, concentration, and combination of design loads and forces shall
be used in the design. The referenced codes permit stress increases for some load
combinations.
3. Foundation Design
Foundation designs shall be per recommendation the site geotechnical investigation.
4. Concrete Design
4.1 Design Strengths
• Concrete Strength C16/20 - for lean concrete and pipe encasement

C25/30, C28/35, C32/40 - for all reinforced concrete
C28/35 Foundations in sulphate conditions
C32/40FR - for unreinforced concrete structures and
benching
Cements shall be “Ordinary Portland Cement”, Type
I, II, or V
• Reinforcing Plain round mild steel bars, symbol “R”, Fy = 250
2
N/mm
Deformed high yield bars, symbol “T”, Fy = 420
2
N/mm
• Welded Steel Wire Fabric Conform to BS 4483
4.2 Design Methods

The design for reinforced concrete structures shall be considered for two different types of
structures:
13
• The concrete, above-grade components of architectural non-water holding type
buildings, where the concrete is protected from moisture, shall be designed using
Strength Design Method.
• All liquid-holding concrete structures, concrete components exposed to outside
weather and backfill material, and concrete surfaces exposed to wash down or humid
process conditions shall be designed per ACI 350R and BS 8007 Codes.
4.3 Deflection limits

The total deflection due to vertical loads does not exceed span/250, and this should
normally ensure that the part of the deflection occurring after construction of finishes and
partitions will be limited to span/500 or 20 mm, whichever is the lesser.
Relative lateral deflection response to wind loads in any one storey under the
characteristic wind load should not exceed H/500, where H is the storey height.
As a guide the calculated maximum crack width should not exceed 0.3 mm
4.4 Load Combinations

Basic Load Combinations for Structures:
a. Strength Design Method
• U = 1.4(D + F )
• U = 1.2(D + F + T) + 1.6(L + H) + 0.5(Lr or R)
• U = 1.2D + 1.6(Lr or R) + (1.0L or 0.8W)
• U = 1.2D + 1.6W + 1.0L + 0.5(Lr or R)
• U = 1.2D + 1.0E + 1.0L
• U = 0.9D + 1.6W + 1.6H
• U = 0.9D + 1.0E + 1.6H
b. ALLOWABLE STRESS DESIGN
• D
• D+L
• D + (Lr or S or R)
• D + 0.75L + 0.75(Lr or S or R)
• D + (0.6W or 0.7E)
• a. D + 0.75L + 0.75(0.6W) + 0.75(Lr or S or R)
• b. D + 0.75L + 0.75(0.7E) + 0.75S
• 0.6D + 0.6W
• 0.6D + 0.7E
Where: D = Dead Load, Lr = Roof live load, R = Rain load, H = Soil Loads, F = Fluid
Loads, W = Wind loads , E = Seismic Soil Load or Hydrodynamic Load
Check structures for maximum possible (hydraulic overflow) water level condition.
4.5 Concrete Retaining Walls

Use recognized design methods:
• Minimum safety factor against overturning = 1.5
• Minimum safety factor against sliding = 2.0
5. Structural Metalwork Design
5.1 Codes and Design References

For uniformity of design and detailed requirements, the following codes shall be used:
14
• Structural Steel - Refer to the Manual of Steel Construction, Specification for
Structural Steel Buildings ASD or LRFD in AISC, using ASTM A36 steel.
• Aluminum - Uniform Building Code, 1997 Edition and Aluminum Construction Manual,
1986 Edition.
Use the following references regarding applications for bolts.
• High strength - use ASTM A325-SC (slip critical type) for basic design for bolting
structural steel and fabricated steel where indicated on design drawings.
• Use ASTM A307 or acceptable equivalent as basis for design of all bolts that are not
in contact with water including anchor bolts, unless noted otherwise.
• Bolts for aluminum - use stainless steel bolts
• Stainless steel bolts - use Type 304 or 316 bolts for basic design for construction in
potentially corrosive environments.
Refer to appropriate ASTM specifications for design information.
5.2 Miscellaneous Metals

Material for miscellaneous metals – handrail, grating, checker plate, ladders, stairs, etc. –
shall be as shown on the Drawings.
5.3 Deflection limits

When checking the deflections of a structure, the cost adverse realistic combination and
arrangement of unfactored loads shall be assumed.
The deflection of a building or part of a building shall be limited so as not to impair the
strength or efficiency of the building or of its contents, nor be unsightly or cause damage
to the finish or inconvenience to the occupants.
Deflection of members listed in the table below shall not exceed the tabulated limits,
unless the Employer can demonstrate to the Engineer's satisfaction that greater values
would not be detrimental to the performance of the structure.
TABLE 2 - Deflection limit

A. Beams Deflection due to imposed
loads
Cantilevers: length/180
Beams carrying plaster finish: span/360
Roof beams not carrying plaster finish: span/200
Purlins and sheeting rails: to suit the characteristics of the
sheeting
B. Columns Horizontal deflection
Each storey, top of column, brick or plaster height/300
cladding:
Single storey portal framed structures, with metal height/90
cladding:
C. Crane girders Deflection at point of maximum
span moment
Vertical deflection due to static wheel loads: span/700
Horizontal deflection (calculated on properties of span/500
top or bottom flange alone as applicable):
15
The relative lateral deflection of adjacent frames (including the end frames) of sheeting
clad structures shall be limited generally to frame centers /250, unless greater values can be
shown to have no detrimental effect on the structural performance of the sheeting.
6. Buildings
All buildings will be designed in accordance with the 1997 edition of the Uniform Building
Code. Design loads will be as outlined in this section and as recommended by the Uniform
Building Code.
6.1 Design Loads

Dead loads shall include the weight of all permanent construction including structure and
enclosure, roofs, walls, floors, partitions, interior finishes, fixed equipment, equipment
bases, pipes, HVAC, electrical, lighting, and any permanent non-removable stationary
construction. Unless otherwise noted, all equipment will be mounted on 150mm
concrete bases.
Unless otherwise noted the following minimum uniform dead loads shall apply:
• HVAC ductwork 0.24 kPa
• Lighting 0.14 kPa
• Piping less than 300 mm in diameter 0.24 kPa
Loads from piping greater than 300 mm in diameter shall be calculated and located
during detailed design. Pipe supports shall be designed assuming the pipe is full of
water. Pressure pipelines shall be designed with considerations for thrust where
required.
Live loads shall be as follows:
• Minimum floor loading 4.8 kPa unless otherwise noted
• Stairs and landings 4.8 kPa
• Roof load 1.0 kPa without reduction
Wind Loads Refer to C.2.3.
Seismic Loads Refer to Section C.2.4
Impact Loads crane and hoist supports will be designed for impact loads without a 1/3
increase in allowable stress.
• Cranes and hoists 25% of the lifted load
• Horizontal crane load 20% of the lifted load and trolley
weight
Combination of Loads The most severe distribution, concentration, and combination of
design loads and forces as shown on the IBC 2006 shall be used in the design.
6.2 Casts-in-Place Concrete

Design Strengths Refer to Section C.4.
Concrete Retaining Walls The stability of retaining walls is governed by UBC Section
1611.6.
• Minimum safety factor against overturning = 1.5
• Minimum safety factor against sliding = 2.0
6.3 Masonry
Concrete masonry will be designed in accordance with IBC Chapter 21. All masonry shall
be designed as reinforced masonry with maximum vertical reinforcement spaced at 1200
mm on centers, using Type S mortar, medium weight block and Grade 60 reinforcing bars.
16
Steel wire horizontal joint reinforcement shall be ASTM A82, Grade 80. A specified
compressive masonry strength (f'm) of 10,000 kPa shall be used in the design of masonry
walls.
Seismic, wind, and minimum interior pressure loading shall be considered. Amplified wind
loads at parapets shall also be evaluated.
6.4 Structural Steel

Use A36 steel as the basis of design. Combined stress ratios shall be limited to 0.90.
Allowable beam and column stresses shall be increased 1/3 for load cases including
wind or seismic. Connections shall be designed without the 1/3 increase in allowable
stress.
6.5 Gypsum board panel sheathing
A. Cold-formed steel framed wall systems, sheathed with gyp sum board, are permit ted
to resist horizontal forces produced by wind or seismic loads subject to the following:
1. Nominal shear values, used to establish the allowable shear value or design shear
value, are given in Table 3.
TABL 3
2. The shear values listed in Table 3 shall not be cumulative with the shear values of
other materials applied to the same wall unless otherwise permitted herein.
3. The nominal shear values shown are for gypsum board that is applied to both sides
of the wall.
4. Where gypsum board is only applied to one side of the wall, the nominal shear
values shall be taken as one-half of the value shown.
5. Where gypsum board is applied perpendicular to studs, end joints of adjacent

courses of gypsum board sheets shall not occur over the same stud.
6. Screws used to attach gypsum board shall be a minimum No. 6 in accordance with
ASTM C 954.
7. Walls resisting seismic loads shall be subject to the limitations in Section 4.2-2.4
7. SURFACE DRAINAGE SYSTEM
7.1 The roof drainage system shall be based mainly on catch basins and gutters in
accordance to general technical Specification, or the surface drainage system
shall be based mainly on open drainage ditches, and when required catch basins,
storm drains and culvert be utilized.
17
7.2. The surface storm water runoff shall be determined by rational method from the
following equation.
Q = 2.778 C.I.A
Where :
Q = Rate of runoff (liters/sec)
C = Runoff coefficient
I = Design rainfall intensity (mm/hr)
A = Area of the drained surface (hectares)
The design rainfall intensity I shall be specified in the site conditions.
The runoff coefficient C shall be taken as follows:
• Roof c = 1.0
7.3. The open drainage ditches shall be designed using the Manning’s formula. The
Manning’s formula when employed in metric system is as follows:
2/3 1/2
Q = 1/n A.R . S
2/3 1/2
V = 1/n. .R . S
Where:
Q = Rate of flow (m³/sec)
A = Cross- sectional area of the water in the drainage ditch (m²)
R = Hydraulic radius (m) where R = A/p
P = Cross- section Wet Perimeter (m)
S = Hydraulic gradient (meters per meter)
V = Velocity of the flow (m/sec)
N = Roughness coefficient
The roughness coefficient "n″ shall be taken as follows:
a. Lined drainage ditches:
• Dressed ashlar surface 0.0143
b. Free boards. or additional wall heights, shall be added above the calculated water
surface level of the drainage ditches as follows:
i. 0.10 m (minimum) for all types of ditches.
ii. The minimum velocity of flow in drainage ditches shall be 0.60 to 0.90 m/sec.
8. Codes and Standards

Refer to specifications for the complete list of codes and standards. A partial list is as follows:
• ASCE/SEI 7-10 Minimum Design Loads for Buildings and Other Structures
•
th
AISC Manual of Steel Construction -ASD, 9 ed
•
rd
AISC Manual of Steel Construction -LRFD, 3 ed
• ACI 318M-11 “BUILDING REQUIREMENTS FOR STRUCTURAL CONCRETE."
• ASTM Material Standards
• IBC – International Building Code 2006

• IMC – International Mechanical Code 2006
• IEC – International Electrical Code 2006

• ACI 315 " DETAILS AND DETAILING OF CONCRETE REINFORCEMENT "
• BS 8110 – Structure Use Of Concrete
• BS 8500 – Concrete Complementary British Standard to BS EN 206-1

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SECTION 1.2 MECHANICAL AND ELECTRICAL WORK COORDINATOR
1.01 SUMMARY
A. This Section specifies the responsibilities of the Contractor’s Coordination

Engineer.
1.02 MECHANICAL AND ELECTRICAL WORK COORDINATOR
A. For the duration of the Work, the Contractor shall employ a Coordination Engineer
who is technically qualified and administratively experienced in field coordination of
mechanical and electrical work required for this Project.
1.03 COORDINATION RESPONSIBILITIES
A. The Coordination Engineer shall be responsible for coordination of all mechanical and
electrical activities with that of other Sections, and shall review the effect of changes
on work of other Sections.
B. The Coordination Engineer shall coordinate progress schedules, including dates for
submittals and delivery of products. The Coordination Engineer shall:
1. Conduct meetings between parties concerned with the Work to establish and
maintain coordination, update progress schedules, and resolve coordination
matters.
2. Provide minutes of meetings and reports to all concerned parties.
3. Participate in progress meetings.
4. Report on progress of the Work and any required changes in schedules.
5. Follow-up submittals and the procurement process.
6. Review Shop Drawings, Product Data, and Samples for compliance with the
Contract Documents.
C. The Coordination Engineer shall observe the Work for compliance with the Contract
Documents. The Coordination Engineer shall check the following:
1. Field dimensions, clearances, and relationships to available space and anchors.

2. Compatibility with equipment and Work of other sections, electrical
characteristics, and operational control requirements.
3. Motor voltages related with starting mode and control characteristics.
4. Utility connections.
4. Controls, interlocks, wiring of push button switches, and relays.
5. Wiring and control diagrams.
6. Operability of equipment in advance of start-up.
D. The Coordination Engineer shall verify information and coordinate preparation of the
Record Documents.
E. The Coordination Engineer shall coordinate proposed substitutions and modifications,

including proposals and requests from Lower Tier Contractors, and shall verify
compliance with the Contract Documents.
F. The Coordination Engineer shall observe start-up, adjustments, and test runs, The
Coordination Engineer shall observe and maintain a record of tests. The record shall
include the following information:
1. Specification section number, Product, and name of Lower Tier

Contractor/Supplier.
2. Name of testing agency and name of inspector.
3. Name of manufacturer's representative present.
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4. Date, time, and duration of tests.
5. Type of test, and results.
6. Retesting required.
G. The Coordination Engineer shall assemble background documentation for dispute

and claim settlement and shall submit copies of documentation to the Employer upon
request.
H. The Coordination Engineer shall liaise with the representatives of the electric utility to
determine the power supply required and all other pertinent information as required
by BS 7671 Chapter 31, and shall make all necessary arrangements for connection,
inspection, and testing. The Coordination Engineer shall schedule in advance
required utility service interruptions and such interruptions shall be approved by the
Employer.
I. The Coordination Engineer shall observe equipment demonstrations, record times,

and additional information required for operation and maintenance manuals.
SECTION 1.3 QUALETY CONTROL & SUBMITTALS
PART 1 - GENERAL
1.01 SUMMARY
A. This Section specifies the Quality Assurance/Quality Control (QA/QC) activities that
the Contractor shall perform during all phases of the Contract, including:
1. GENERAL QUALITY REQUIREMENTS.

2. SUBMITTAL PROCEDURES
1.02 GENERAL QUALITY REQUIREMENTS
A. The Contractor shall be responsible for all QA/QC Activities with the exception of
those additional inspections, tests, and/or audits which may be conducted by the
Employer.
B. The Contractor shall develop, implement, and maintain a Quality Plan consistent with
the requirements of this Section, that ensures all materials, equipment, installation
and performance criteria comply with the Contract Documents.
C. The Contractor’s Quality Plan shall be subject to review by the Employer. No

construction shall begin and no requests for payments shall be processed until the
Contractor’s Quality Plan is approved.
D. The Employer will reject non-conforming materials or equipment, whether in place or

not. The Contractor will be notified in writing to correct or remove the defective
material or equipment from the Work. If the Contractor fails to respond, the Employer
may order correction, removal, and/or replacement of defective materials or
equipment by others. The Contractor shall bear all costs for such work.
E. The Employer may sample, inspect, and test materials accepted on the basis of a
Certificate of Compliance at any time. The fact that the materials were accepted on
the basis of certificate shall not relieve the Contractor of its responsibility to use
materials which comply with the contract document.
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F. If the Contractor fails to perform any or all of the provisions of this Section, the
Employer reserves the right to have the Employer perform such activities and charge
the Contractor for the actual cost of such work.
G. The Contractor shall provide equipment, instruments, qualified personnel and suitable
transport acceptable to the Employer as needed to inspect the Work and perform the
tests required by the Contract Documents.
H. The Contractor shall notify the Employer in advance to provide sufficient time to
inspect various areas or aspects of the Work while still visible. Such notification shall
be given by a written “Inspection Request” in a format acceptable to the Employer,
each and every time various areas of the Work are to be covered up so as to prevent
subsequent inspection. These activities shall be identified as Hold Points in the
Contractor’s Inspection and Test Plans and shall be allocated as directed by the
Employer.
1. If the Contractor does not notify the Employer in sufficient time to allow for
inspection before covering up installations governed by a Hold Point, the
Contractor shall remove all such materials/equipment the Employer deems
necessary to verify compliance of the Work.
2. Any delays, additional work, or additional costs attributed to the above shall be at
the Contractor’s expense.
I. The Contractor shall construct, equip, and maintain a site laboratory capable of
conducting various tests as specified herein, unless otherwise approved by the
Employer. Other tests may be conducted at manufacturer’s laboratories, government
laboratories, or independent commercial laboratories approved by the Employer.
1. The laboratory shall be constructed near the Employer’s office.

2. As a minimum, the site laboratory shall be capable of conducting the following
tests.
a. Temperature of fresh concrete.

b. Slump of fresh concrete.
c. Unit weight, yield and air content (gravimetric) of concrete.
d. Bleeding of concrete.
e. Curing on concrete specimens.
f. Soil compaction tests.
g. Insitu density test for soils.
h. Moisture content of soils.
i. Sieve analysis.
J. Coating thickness and adhesion.
1.03 SUBMITTAL PROCEDURES
A. SUMMARY
Section includes procedures for preparing and transmitting submittals required by

specification sections for a product, material, or construction method:
Shop drawings.
Product data.
Manufacturer's certificates.
Design data and calculations.
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Manufacturer's instructions.
Manufacturer's field service reports.
Samples.
Operation and maintenance manuals (timing, quantity, content and form).
B. SUBMITTALS
Schedule submittals to expedite Work. Unless otherwise indicated in this Section,

submittals shall be submitted within 30 days of date of Notice to Proceed.
Preparation:
Provide separate submittal for each specification section requiring submittals. Where
multiple sections relate to the same system or element and are being provided from
the same source, a single combined submittal is acceptable.
Coordinate submission of related items. Group submittals of related products in a

single transmission.
Include all submittal material requested for that section.
Identify variations from requirements of Contract Documents. State product and

system limitations which may adversely affect Work.
Mark or show dimensions and values in same units as specified.
Contractor responsibilities:
Coordinate submittals to avoid conflicts between various items of work.
Submittal transmittal form:
Include with each submittal a transmittal form. Sample copy of an acceptable form is
at Attachment A. Contractor's standard submittal form may be used provided it
contains essentially the same information as sample.
Identify Project, Employer, Contractor, supplier, manufacturer, pertinent drawing

sheet and detail numbers, and associated Specification Section numbers.
Sequentially number transmittal forms. Re-submittals shall have original number with
a suffix. Acceptable form of number is SSSSS-NN-T where:
SSSSS indicates 5 digit specification section number.
NN indicates different submittals for that specification section.
T indicates the number of times that submittal has been made.
Failure of Contractor to review submittals prior to transmittal shall be cause for

rejection.
Incomplete, improperly packaged, and submittals from sources other than Contractor
will not be accepted.
Review: will review and return submittals with comments.
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Do not fabricate products or begin work which requires submittals until return of
acceptance.
On return, promptly distribute reviewed submittals to concerned parties. Instruct

parties to promptly report any inability to comply with provisions.
Resubmission:
Revise and resubmit submittals as required within 15 days of return from Make re-
submittals under procedures specified for initial submittals.
Identify all changes made since previous submittal.
C. QUALITY ASSURANCE
Where required by Specification Sections, provide quality assurance submittals:
Qualification data: Written information demonstrating capabilities and experience of

firm or person. Include lists of complete projects with names contact information for
references.
Manufacturer's certificates: Submit reference data, affidavits, and certifications on

manufacturer's letterhead certifying that products conform to or exceed specified
requirements. Certificates may be based on recent or previous test results .
Installer approval: Certification on manufacturer's letterhead that installer complies

with requirements and is approved for installing manufacturer's products.
Welding certificates: Written certification that welding procedures and personnel

comply with requirements. submit record of Welding Procedure Specifications (WPS)
and Procedure Qualification Record (PQR) on American Welding Society (AWS)
forms. Include names of firms and personnel certified.
Field test reports: Written reports qualified testing agency indicating and interpreting
results of field tests performed either during or after installation for compliance with
specified requirements.
D. SUBMITTAL REVIEW
Will review submittals for sole purpose of verifying general conformance with design
and general compliance with Contract Documents. Approval of submittal by A/E does
not relieve Contractor of responsibility for correcting errors which may exist in
submittal or from meeting requirements of Contract Documents.
Review time Initial review within 14 days of receipt. reserves right to withhold action
on a submittal requiring review of related submittals until related submittal is received.
Additional time will be required if processing must be delayed to permit review of
related subsequent submittals. A/E will review re-submittals within 14 days.
Review actions: After review, will return submittals marked as follows to indicate
action taken:
Part of work covered by submittal may proceed provided it complies with

requirements of Contract Documents. Final acceptance will depend upon that
compliance. The term "approved" shall only indicate that there is no exception taken
to the submittal. Approved except as noted: Part of work covered by submittal may
proceed provided it complies with notations and corrections on submittal and
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requirements of Contract documents. Final acceptance will depend upon that
compliance.
Not approved, revise and resubmit: Do not proceed with part of work covered by
submittal including purchasing, fabricating, and delivering. Revise or prepare new
submittal in accordance with notations and resubmit.
PART 2 – PRODUCTS
2.01 QUALITY CONTROL PROCEDURES
A. The Contractor shall develop and implement Quality Control Procedures, in a format
acceptable to the Employer, in an effort to prevent non-compliances from being
incorporated into the Work. Quality Control Procedures shall also be developed to
identify and document those non-compliances which do occur and track them until
corrective action is taken and preventive action is implemented. As a minimum,
Quality Control Procedures shall be submitted to govern the following activities:
1. Submittal review, submission and tracking.

2. Material receivable, inspection and storage.
3. Field testing on site.
4. Non-conformances.
5. Document control.
2.02 METHOD STATEMENT (WORK INSTRUCTIONS)
A. The Contractor shall submit method statements, in a format acceptable to the

Employer, for all major activities such as, surveying, dewatering, excavating,
trenching, pipe laying, backfilling, concrete work, coating application, membrane
application and others as designated under the subtitle “Submittals” in various
sections of this specification.
B. In addition to providing a step by step description of the work (in sequential order),
method statements shall also clarify the following:
1. Scope of work covered.

2. References (other MS, procedures or standards).
3. Lower Tier Contractors utilized.
4. Products required.
5. Tools and equipment required.
6. Prior activities to be completed.
7. Personnel required and designated responsibilities.
8. Safety Hazards and Precautions to be taken.
9. Quality Control Measures (if not governed by a Quality Control Procedure).
10. Procedure (step by step sequence of work).
2.03 INSPECTION AND TEST PLANS
A. The Contractor shall develop and submit Inspection and Test Plans, in a format
acceptable to the Employer, for all major activities encountered during the course of
the work such as, pipe laying and testing, construction of manholes or chambers,
equipment installation, and commissioning and other as necessary to assure that all
inspections and tests are conducted to confirm compliance with the Contract
Documents. The Inspection and Test Plans shall be developed to monitor activities
on a step-by-step basis in sufficient detail and to indicate the following:
1. Type of Inspection required (surveillance, witness, hold point, etc).
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2. Type and frequency of test required.
3. Acceptance or rejection criteria.
4. Reference to records which document compliance.
5. Mechanism to identify which inspections/tests will be verified by the Employer or
independent inspection agency.
PART 3 – EXECUTION
3.01 GENERAL
A. The Employer may perform additional inspections and test at the place of the
manufacture or the shipping point to verify compliance with applicable Specification
requirements. Inspections and tests performed by the Employer shall not be
considered a guarantee that materials delivered at a later time will be acceptable. All
costs associated with unacceptable materials being delivered to the Site shall be
borne by the Contractor.
B. Inspections and tests conducted by persons or agencies other than the Contractor
shall no way relieve the Contractor of its responsibility and obligation to meet all
Specifications and referenced standards.
3.02 MATERIAL/EQUIPMENT RECEIVAL INSPECTION AND STORAGE
A. The Contractor shall develop and implement written control procedures to assure that
all materials and equipment are inspected upon arrival to confirm compliance with the
Contract Documents and that all materials and equipment are properly handled and
stored according to the contract requirements and/or the manufacturer’s
recommendations.
B. The Contractor shall be responsible for handling, storing and preserving equipment
and material from the time of receipt to the time of acceptance by the Employer.
C. The Contractor’s storage and handling procedures shall be designed to prevent

damage, deterioration, distortion of shape or dimension, loss, degradation, loss of
identification, or substitution.
D. The Contractor shall identify equipment and material requiring special handling or
storage. The Contractor shall provide a cold store for any materials which may be
damaged by excessive heat.
E. The Contractor shall identify all materials and equipment so that they are traceable
throughout all inspections, test activities, and records. For stored items, the
identification method shall be consistent with the expected duration and type of
storage.
F. The Contractor shall develop and maintain a receiving/inspection log containing at

least the following information:
1. Purchase order number.

2. Item number (if applicable).
3. Suppliers name.
4. Quantity.
5. Item description.
6. Reference to applicable contract requirements.
7. Date received.
8. Heat number, serial number or other identification, as applicable.
9. Verification of receipt of all required supporting documentation.
10. QC acceptance sign-off and date.
11. Non-conformance number, if applicable.
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SECTION 1.4 PROGRESS SCHEDULES
PART 1 – GENERAL
1.01 SUMMARY
A. This Section specifies the scheduling activities to be performed by the contractor and
includes, but is not limited to, the following:
1. Final Design Schedule.

2. Construction Schedule.
3. Updates and Revisions.
4. Payment Applications.
5. Requested Time Adjustment Schedule.
6. Schedule of Off-Site Activities.
B. The approved construction schedule shall be the baseline schedule against which all
progress is measured.
1.02 DEFINITIONS
A. Critical Path Method (CPM): A method of planning and scheduling a construction

project where activities are arranged based on activity relationships and network
calculations determine when activities can be performed and the critical path of the
Project.
B. The Project Construction Schedule (PCS), covers the overall Time for completion as
specified in Document I. The Contractor shall be required to plan, perform and
coordinate his works to meet the time requirements of the project, including making
due allowances for the work of other package Contractors.
C. Construction Schedule(s): The Contractor's developed schedule(s) for execution of

the Contract that meets the contract requirements for the performance of this contract
and the requirements of the Construction Program.
D. Contractor's cost load Construction Schedule: The Contractor's approved CPM

schedule with assigned cost values based on the priced Bill of Quantities that total
the Contract lump sum price and to be used as the basis for calculating interim
payments.
E. Critical Path: The longest continuous chain of activities through the network schedule
that establishes the minimum overall project duration.
F. Network Diagram: A graphic diagram of a network schedule, showing the activities

and activity relationship.
G. Activity: A discrete part of a project that can be identified for planning, scheduling,
monitoring, and controlling the construction project. Activities included in a
construction schedule consume time and resources.
1. Critical activities are activities on the critical path.

2. Predecessor activity is an activity that must be completed before a given activity
can be started.
H. Event: An event is the starting or ending point of an activity.
I. Milestone: A key or critical point in time for reference or measurement.
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J. Float is the measure of leeway in activity performance. Accumulative float time
belongs to the Owner.
1. Free float is the amount of time an activity can be delayed without adversely
affecting the early start of the following activity.
2. Total float is the measure of leeway in starting or completing an activity without
adversely affecting the planned project completion date.
1.03 GENERAL SCHEDULING REQUIREMENTS
A. Work Breakdown Structure (WBS) in CSI Format (Traditional Construction)
The Contractor shall prepare and submit for approval a WBS in the Construction
Standard Institute (CSI) Master Format for traditional construction activities. The
WBS shall be used in conjunction with the Integrated Master Schedule (IMS) to
report, verify, analyze, and monitor construction cost and schedule status. All tasks
required under this TO shall be included in the WBS, in sufficient level of detail to
provide a basis for analysis and field verification. At the Conceptual Work Plan
(CWP) stage, the WBS will contain a minimum of two levels of detail. At the
Implementation Work Plan (IWP) stage, the WBS will contain a minimum of three
levels of detail.
B. The contractor shall provide a Planning Engineer familiar with Critical Path Methods
(CPM) with suitable qualifications and experience in construction projects of
comparable complexity.
C. The contractor shall provide its staff with all necessary computer equipment and
software to create and update all specified schedules and reports.
1.04 SUBMITTALS
A. The contractor shall submit the credentials of its Planning Engineer for the Employer
approval.
B. The contractor shall develop and update all schedules and reports as specified within
this Section. The contractor shall provide sub-schedules for each stage of work. In
addition to the required number of color prints, the contractor shall provide all the data
and the schedules on a computer diskette for review by the Employer.
C. The contractor shall submit design and construction schedules (Work Programmer)
within two weeks (14 days) of signing the Employer Agreement. The schedules shall
include proposed network diagrams, bar charts, resource histograms, progress S-
curves, mathematical analyses, etc. along with written certification that relevant
Lower Tier contractor have reviewed and accepted the proposed schedule.
D. The contractor shall review all schedules and network diagrams jointly with the
Contractor. After review, the Contractor shall revise the schedules as required by the
Contractor and shall re-submit the schedules within one week for approval.
E. Following the Employer’s approval of the schedule, the contractor shall distribute
copies of updated schedules to Lower Tier contractors, suppliers, and other
concerned parties. The contractor shall request Lower Tier contractors, suppliers, and
other concerned parties to promptly report in writing all problems anticipated by
projections shown in schedules.
F. Neither the Employer’s approval of the schedule nor any changes to the schedule
shall affect the contractor’s obligation to complete the Work within the specified time.
Neither the Employer’s approval of the schedule nor any changes to the schedule
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shall affect the contractor’s obligation to use safe and efficient methods of
construction with suitable equipment to obtain high quality work compliant with the
Contract Documents.
PART 2 – PRODUCTS
2.01 DESIGN AND CONSTRUCTION SCHEDULES
A. General Requirements
1. The contractor shall prepare network analysis diagrams and supporting

mathematical analyses using the Critical Path Method.
2. The schedules shall illustrate order and interdependence of activities and
sequence of work; how the start of a given activity depends on completion of
preceding activities, and how completion of the activity may restrain start of
subsequent activities.
3. The schedules shall illustrate the complete sequence of construction by activity,
identifying work of separate stages. The schedules shall include dates for
submittals and return of submittals; dates for procurement and delivery of critical
products; and dates for installation and provision for testing. The contractor shall
provide a legend for symbols and abbreviations used.
4. Milestones if any in the Contract Documents shall be identified and linked to the
delay penalties.
B. Integrated Master Schedule (IMS)
The Contractor shall prepare and submit an IMS for approval. The IMS shall detail the
project schedule and status through the use of Gantt charts and Critical Path Method
(CPM) analysis. The project shall be monitored, and progress/status shall be reported
bi-weekly against the baseline IMS. The baseline for the IMS shall be adjusted at each
modification to the TO that has an appreciable (>5%) impact to either the cost or the
schedule. The IMS shall be used in conjunction with the WBS to report, verify, analyze,
and monitor construction cost and schedule status and progress. All tasks required
under this TO shall be included in the IMS, with sufficient level of detail to provide a
basis for analysis and field verification of progress utilizing the Earned Value
Measurement System. Construction Progress reporting will be based on the accrued
value of measured and verified physical completion of WBS tasks. The IMS shall be
prepared utilizing the CSI Master Format 2004 for identification of Definable Features
of Work. At the CWP stage, the IMS will contain a minimum of two levels of detail. At
the IWP stage, the IMS will contain a minimum of three levels of detail, be resource
loaded, provide sufficient detail to adequately monitor and analyze the progress of the
project. The Contractor will submit for approval and maintain the IMS with current
progress data utilizing Primavera or compatible software. The reports shall be provided
in native file format readable by Primavera or compatible software.
C. Design and construction schedules shall conform to the following requirements:
1. Presented in bar chart form and supporting critical path diagram.

2. Using Primavera or other approved computer software.
3. Including a Sequence of Listings showing the chronological order of the start of
each item or work.
4. Provide space on the schedules for notation and revisions.
5. Paper size shall meet the approval of the Employer.
6. Off-site activities shall be included.
7. Provide a histogram showing manpower and equipment resources.
8. Provide a construction progress S-curve.
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D. Details
1. The contractor shall provide sufficient details to enable the Contractor to evaluate
the contractor’s planned schedule and to monitor progress on a day to day basis
throughout the project.
2. The activities shall be selected such that the duration is generally less than 21
calendar days.
3. The schedule shall represent an accurate, efficient, reasonable and feasible plan
for accomplishing the work.
E. COST LOADING
1. Within Seven (7) days of obtaining approval of the Construction Schedule, the
Contractor shall submit for the Engineer's approval a cost loaded Construction
Schedule with a fully detailed schedule of values and all necessary supporting
details of all activities in the cost loaded Construction Schedule based upon the
priced Bills of Quantities, and the total shall equal the Contract Price.
2. The approved cost loaded Construction Schedule shall be the basis for calculating
progress payments pro-rata to the work performed.
3. Revision to the Construction Schedule may require re-allocation of costs. Revised
activity cost data shall be submitted with the updated Construction Schedule.
4. Cost allocation per activity shall be spread throughout the duration of the activity
on a direct linear relationship.
5. Cost allocation for specific activities shall be approved by the Engineer's
Representative.
6. Cost/Schedule Status Report (C/SSR) as follow
a. The Contractor shall prepare C/SSRs, which summarize performance
information for program management purposes as specified in each individual
cost reimbursement TO. The C/SSR contains contract data, including original
and current contract values and management estimate at completion,
performance data, and narrative explanations which present information on
significant cost, schedule variances, contractual problems, or other areas of
interest. The C/SSRs will be submitted with the biweekly invoices for this TO.
b. The Contractor shall develop Earned Value charts as part of the Cost/Schedule
reporting requirements. In addition, the Contractor shall populate tracking web
sites as specified by the COR.
F. The contractor shall prepare the following schedules:
1. Overall schedule
2. Detailed bi-monthly schedule
3. Handing over schedule
G. The contractor shall tabulate each activity in the detailed network diagrams using
calendar dates and shall identify the following for each activity:
1. Activity number
2. Activity description
3. Duration of activity in work days
4. Earliest start date
5. Earliest finish date
6. Actual start date
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7. Actual finish date
8. Latest start date
9. Latest finish date
10. Total and free float
11. Monetary value of activity
12. Manpower and plant usage for each activity.
13. Percentage of activity completed
14. Responsibility
15. Work area code.
H. The analysis program shall be capable of compiling monetary value of completed and
partially completed activities, of accepting revised completion dates, and
recompilations of all dates and float.
I. Required Sorts
1. By preceding work item or event number from lowest to highest.

2. By amount of float, then in order of early start.
3. By responsibility in order of earliest possible start date.
4. In order of latest allowable start dates.
5. In order of latest allowable finish dates.
6. Listing of basic input data which generates the report.
7. Listing of activities on the critical path.
2.03 SCHEDULE OF OFF-SITE ACTIVITIES
A. The contractor shall include all procurement related activities for long lead items in
the Construction Schedule.
1. These activities may be submitted as a separate “Off Site Activities” Schedule
upon written approval by the Contractor.
2. Off site activities shall be properly correlated and interrelated to the Construction
Schedule.
3. Show all restraints and dependent activities which may affect the Construction
Schedule.
4. Long lead items shall be considered as equipment or materials which require
more than one month between the time an order is placed and the time the item
is delivered to the project site.
B. The “Off Site Activities Schedule” shall include but not necessarily be limited to:
1. Activities for submitting, ordering, manufacturing, fabricating and delivering long
lead items to the project site.
2. Significant construction related activities performed by the contractor away from
the project site, including material and equipment purchase and delivery.
3. contractor’s drawings and submittals for long lead items.
4. Required off site inspection activities by the Client or the Employer.
C. contractor shall be solely responsible for expediting material and equipment deliveries
to ensure the latest approved Construction Schedule is maintained.
D. Notify the Employer in writing whenever it is anticipated that the delivery date of any
material or equipment will be later than shown on the latest approved Construction
Schedule.
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PART 3 - EXECUTION
3.01 UPDATES AND REVISIONS
A. Progress Schedule
1. The contractor shall develop the monthly Progress Schedule by updating the
Design and Construction Schedule every month to reflect the actual progress of
the works against the baseline schedule.
2. The contractor shall submit two copies of the preceding month’s Progress
Schedule marked with the proposed updates and revisions.
3. The contractor shall Indicate the following in the mathematical analysis, which
accompanies the updated schedule:
a. Activities in progress or to be performed in the future,

b. Percent complete for each activity,
c. The critical path for the project based on the latest update data,
d. The earned value for each activity.
B. Progress Reports
1. The Contractor shall maintain daily recording of actual start and actual finish
dates of each activity, enter these data to the construction programmer in the
computer, enter the percentage of completion (or remaining duration) to each
activity, run time analysis by the computer.
2. The contractor shall submit a report two days before each progress meeting
which summarizes progress.
3. The format of the report shall be acceptable to the Employer.
4. The required information shall include, but not necessarily be limited to, the
following:
a. Generate Planned and Actual “S” curves to monitor the progress of various
elements of the Employer as instructed by the Employer. Weight factors for
these curves should be approved by the Employer. Percentage of actual
progress achieved against planned shall be submitted on a weekly basis.
b. Work progress whether in the mills, shops or in the field,
c. Existing status of all Works, rate of progress, estimated time of completion
and cause of any delay (if any),
d. Description of Work accomplished since submission of previous progress
schedule,
e. Comparison of actual work status against the contractor’s previous Progress
Schedule.
f. Status of equipment and material deliveries.
g. Details of project work for the next week/month.
h. Summary of all testing and results.
i. Information regarding any design changes.
j. Information regarding any variations.
k. Summary details of inspections and approvals to proceed with work.
l. Records of manpower, plant etc. compared to programmed requirements.
m. Information required by the Client.
n. Weather records.
o. Records of delays and stoppages with reason therefore
p. Value of work done.
q. Cash flow forecast.
r. Progress photographs.
s. Changes or additions to Contractor’s supervisory personnel since the
proceeding progress report.
t. Causes of any delays.
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u. Changes in logic, construction sequence and activity duration, including an
explanation of why the changes are necessary.
v. Proposed actions by the Contractor to restore the schedule to the contractual
Time for Completion, including what is being done or what is planned to be
done in each problem area.
w. Identify anticipated problems or changes and present plan to deal with them
so as to minimize or prevent delays.
5. Updates and revisions to required schedules and reports shall not modify or limit,
in any way, the contractor’s obligations under this Contract; including but not
limited to the Contract Time, Contract Completion Dates, Contract Milestone
Dates, etc.
6. Recovery Schedule: If at any time, as a result of updating the programmed, it
should appear to the Engineer that the project is delayed by more than 10%, the
Engineer may request the Contractor to submit a recovery schedule which shows
the planned corrective measures to complete the project on time. This schedule
shall be used for Progress Monitoring only while the approved programmed shall
remain the contract programmed for assessment of all contractual issues.
3.02 RECOVERY SCHEDULE
A. If as a result of updating the Construction Schedule, as required in Clause 3.01

above, a delay to the Contract completion of more than 10% is shown, which
delay may be attributed to the Contractor, the Engineer’s Representative may
require and the Contractor shall submit a Recovery Schedule, based on fully
detailed and supported corrective measures, to allow Contract completion to be
achieved on schedule.
B. Recovery Schedule is for planning and monitoring purposes only.
3.03 PAYMENT APPLICATIONS
A. Contractor shall submit to the Employer at the end of each calendar month or as
otherwise agreed a valuation of the total work done with all items set out in full in
accordance with of the Conditions of Contract.
B. The Employer shall be under no obligation to process the contractor’s payment

application until contractor meets the requirements of this specification Section.
Certification may be withheld until compliance is achieved.
3.04 REQUESTED TIME ADJUSTMENT SCHEDULE
A. The contractor shall provide with each change, an activity diagram showing the revised
activities and the changes affecting their interdependence.
B. Any request for an extension of the contract completion date by the contractor shall be
supported by all documentation deemed necessary by the Employer.
C. The contractor shall submit proof based on a revised activity diagram for each extension
in order for the Employer to consider its acceptance.
D. The schedule must clearly display that the activities in the schedule have used all of the
available float time in the request.
E. Activities which do not affect the contract completion date will not be considered for a time
extension request.
End of Section
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DIVISION 2
SITEWORK
34
SECTION 2.1 – GENERAL FOR EARTHWORK AND SITE PREPARTION
1.01 DEMOLITION AND REMOVAL
A. SUMMARY
A. This Section specifies general requirements for earthworks and site preparation and
including:
1. Complete demolition of designated existing buildings and/or structures including

foundations.
2. Removal of existing underground tanks, manholes, and pipes.
3. Sealing existing pipelines which are not to be removed.
4. Cutting into existing structures to make connections to new and existing work.
5. Removal of existing protective coatings from concrete surfaces to permit
resurfacing, patching and recoating of surfaces.
6. Arrangement with relevant utility owners for renewal and/or relocation of their
existing services.
7. Removal or salvage of designated mechanical, electrical or other equipment.
8. Removal from site and disposal of trash, debris, demolished materials and
salvable materials.
9. Handling all flows, protection of existing and new work from damage.
10. Removal and disposal of any hazardous material relating to or associated with
demolition or new work.
B. GENERAL REQUIREMENTS
A. Demolition shall include removal of all below grade structures foundations, piles and
pipes cables, etc., and restoration to original conditions unless otherwise approved by
the Employer.
B. The Drawings are based on existing record drawings and may not show all items to
be removed. The Contractor shall examine the site as necessary before bidding to
review conditions and determine the actual extent of demolition required.
C. The use of explosives will not be permitted.
D. The Contractor shall obtain required permits from the governing authorities and pay
for all associated licenses, permits and inspections required by these authorities.
E. The Contractor shall conform to applicable procedures when discovering hazardous

or contaminated materials.
1.02 SITE PREPARTION
A. The Contractor shall provide interior and exterior shoring, bracing and support as
necessary to prevent movement, settlement or collapse of both, facilities to be
demolished and adjacent facilities which are designated to remain.
B. The Contractor shall maintain and protect utilities which are to remain against
damage during demolition.
C. The contractor shall cover and protect equipment, fixtures, surface finishes and floors
remaining in the demolition area to prevent soiling or damage.
D. The contractor shall remove protective measures when work is completed
35
E. The contractor shall maintain and protect utilities which are to remain against damage
during demolition.
F. The contractor shall provide bypass connections where necessary to serve occupied
portions of facilities.
1,03 Site Clearance
The contractor shall clear, from all areas planned for the work, all buildings, materials,
debris, etc, prior to the cutting and filling work taking all necessary precautions to
prevent damage to the existing road structures and buildings or other facilities, in the
area, which shall not be demolished.
1.04 EARTHWORK
A. GENERAL REQUIREMENTS
Earthwork shall comply with the following requirements unless approved by the
Employer.
1. No trees or shrubs shall be disturbed unless approved by the Employer in writing.
3. All excavation and backfilling shall be performed in dry conditions and shall be
maintained in accordance with Part 2.
4. Earthwork shall be constructed to the lines, grades, elevations, slopes, and cross
sections indicated on the Drawings. Allowance shall be made as required for the
thickness of any pavement, blinding concrete, lining, and riprap.
5. All excavations shall be stepped back at a safe and stable slope no steeper than
1 vertical to 1 horizontal.
6 Slopes shall be smooth and uniform upon completion of the work.
7. Excavated materials shall be used for the construction of embankment, shoulders

and other such places as directed by the Employer, unless the material is found
to be unsuitable.
a. If not immediately re-used, the excavated material shall be stockpiled in an

area designated by the Employer.
b. Before excavating any material the Contractor shall test to existing material to
determine if it is suitable to the requirements of fill or sub grade material as
specified.
c. Suitable and unsuitable materials shall be stockpiled separately.
8. Trial holes shall be carried out as necessary to confirm existing soil conditions
and determine exact location of utilities or other obstructions.
9. Line and level of structures shall be as shown on the Drawings, unless otherwise
approved by the Employer. The Contractor shall not deviate from the specified
lines or levels without the written approval of the Employer. Unless approved by
the Employer, any deviation in line or levels, along with any additional
excavation, dewatering, backfilling, thrust blocks, valves, air and vacuum
assemblies, blow off assemblies, extra pipe lengths, manholes or other
appurtenances which may be required, shall be at the Contractor’s expense.
36
10. Before starting excavation, the Contractor shall accurately peg out the limits of
the excavation and the Contractor shall survey and record the existing ground
level as agreed with the Employer. Adequate working space shall be provided in
all excavations for safe operating procedures. Unless otherwise accepted by the
Employer, structure excavations shall extend at least 1.5 m beyond the
horizontal limits of the foundation or structure.
11. When the work is carried out adjacent to or across the line of existing services,
the Contractor shall maintain all services and utilities.
12. The bottom of the excavations shall be properly trimmed off and compacted to
provide a firm and uniform bearing at formation level.
1.05 SITE INVESTIGATION
A. Soil investigation reports or soil boring logs may be provided by the Employer. Such
documents are for information purposes only. The Employer does not warrant the
correctness of the information provided, nor does it guarantee any statements,
opinions, or conclusions contained in the documents. The provision of such
documents does not relieve the contractor of its obligation to conduct a thorough
investigation of the Site and the sub-soil conditions therein, nor does it relieve the
contractor of its obligations and responsibilities under this Contract. Boring logs and
related information made available to the contractor depict subsurface conditions only
at the specific locations and at the particular time designated on the logs. Soil
conditions at other locations may differ from conditions occurring at the boring
locations, and the passage of time may result in a change of the subsurface
conditions or water levels at the boring locations. The Employer will not be liable for
any loss sustained by the contractor if conditions encountered during progress of the
work differ from the borings, samples, tests, and/or reports provided. Information
made available to the contractor, either in these documents or in any other source,
will not relieve the contractor of its responsibility to establish the exact nature and
extent of the Work. The contractor shall assume all responsibility for:
1. Deductions and conclusions regarding the nature of the materials to be

excavated.
2. Difficulties involved.
3. Dewatering requirements.
4. Maintaining the required excavations.
5. Performing work affected by the subsurface conditions at the Site.
6 Conducting investigations to satisfy itself of the validity of above data.
B. Contractor's Responsibilities
1. The contractor shall be deemed to have visited the Site before submitting its
Tender, to have conducted all necessary inspections and investigations, and to
have allowed for the following conditions in its Tender:
a. Means of access to the Site and working space.

b. Nature of the ground and sub-soils.
c. Presence of existing foundations or other hidden obstructions.
d. Level of the water table.
e. Extent of rock.
f. Support to neighboring properties and structures.
g. All factors affecting the Work.
2. The contractor shall be deemed to have contacted the relevant authorities to

establish the existence of any existing, live, or redundant services adjacent to or
passing through the Site and shall be deemed to have allowed in its Tender for
their location, diversion, demolition or removal.
37
1.06 SURVEY
Prior to commencement of the work, the contractor shall check the existing bench
marks and reference points located on or out of the site as indicated. The contractor
shall establish newly standard bench marks and points for the works within the site
with the agreement of the Engineer.
a. Traversing
Prior to execution of the works the contractor shall check the existing reference
points, and the results shall be submitted to the Engineer for approval.
b. Principal points
Principal points shall be established taking advantage of the existing reference points.
Individual principal point posts shall be of wood, 15cm x 15 cm size, with an indicating
nail on the top, the surface of the post above the ground shall be painted white.
c. Bench marks
When establishing bench marks within the site, a minimum of one (1). back and forth
leveling operation shall be carried out. Establishment of temporary bench marks shall
be determined and performed by the contractor. Temporary bench mark posts shall
be of wood, 12cm x 12cm x 100cm in size, with an indicating nail on the top, the
surface of the post above ground shall be painted.
d. Other survey
Setting out for survey shall be done with the agreement of the Engineer.
The Engineer may issue instructions or orders for surveys to supplement those listed
above or for different surveys with which the contractor shall promptly comply and
carry at this own expense.
1.07 FILL MATERIAL
A. Suitable fill material shall consist of excavated or borrow material free from rubbish,
vegetation, perishable matter, tree and plant stumps, and other objectionable matter.
B. Suitable fill material shall comply with the requirements in Table 1, unless otherwise
approved by the Employer.
1. Load bearing material shall be used below all foundations.

2. Non-load bearing materials shall be used in open areas and around structures.
3. Dune sand or uniformly graded sand meeting AASHTO T-180 classification A-3
with low binding properties may only be used in areas approved by the Employer.
C. When sufficient quantities of suitable fill materials cannot be obtained from site
excavations, additional material meeting the requirements of Table 1, shall be
obtained from approved borrow areas. The Contractor shall be responsible for the
arrangement and payments for all borrow material.
TABLE 1
SUITABLE FILL MATERIAL
LOAD NON-LOAD
TEST STANDARD BEARING BEARING
MATERIAL MATERIAL
Maximum particle
- 75 mm 150mm
size (rocks)
Passing 0.075mm BS 1377: Part 2: Method 9.2 25% maximum -
Liquid limit BS 1377: Part 2: Method 4.5 35% maximum 40% maximum
Plasticity index BS 1377: Part 4: Method 5 10% maximum 10% maximum
1
CBR BS 1377: Part 4: Method 5 15% minimum -
Water Soluble Salts BS 1377: Part 3: Methods 5 & 7 5% maximum -
1. Compacted to 95% MDD and soaked for 96 hours.
38
1.08 PLACEMENT OF FILL MATERIAL
A. Placement of fill materials shall comply with the following requirements:
1. Distribution of materials throughout each layer shall be essentially uniform.

2. Fill shall be free from lenses, pockets, streaks, or layers of material differing
substantially in texture or gradation from the surrounding material.
3. If the surface of any layer becomes too hard and/or smooth for proper bond with
the succeeding layer, it shall be scarified parallel to the axis of the fill to a depth
not less than 75 mm before the next layer is placed.
4. Top surface of each layer of fill shall be approximately level during construction.
The final surface of fill shall be finished with a 2% crown or cross-slope as
suitable for site drainage, unless shown otherwise on the Drawings.
B. Field Compaction
1. Fill material in landscaped or open areas shall be compacted in loose lifts up to

250 mm thick to at least than 90% MDD.
2. Fill material below structures and paved areas shall be compacted to at least
95% MDD in 200 mm maximum loose lifts, unless otherwise directed by the
Employer.
3. Around pilecaps and strap beams backfill and compact to 85 percent.
4. All fill shall be moistened or aerated to control the moisture content to within a
range of ± 3% of the optimum moisture content when compacted.
5. Uniform moisture distribution shall be obtained by discing, blading or other
approved methods before the compaction of the layer.
6. If the top surface of the preceding layer of compacted fill or foundation becomes
too dry or wet to permit suitable bond, it shall be scarified and moistened by
sprinkling or aerated to acceptable moisture content before the placement of the
next layer.
7. See Quality Control for testing.
1.09 GEOTEXTILES
A. Geotextiles for general earthworks shall comply with the requirements of Section 2.4.
B. The handling, placement, and installation of geotextiles shall be carried out strictly in
accordance with the manufacturer’s recommendations.
C. Where used as base stabilisation for embankments, the type of construction

equipment used for spreading and compacting initial fill layers shall be suitable so as
to avoid damage to the geotextile. The initial layer of fill placed on the geotextile shall
be free from sharp angular or pointed material that may puncture the geotextile.
D. Trucks shall not be permitted to drive over the geotextile. The placement of
geotextiles shall be coordinated to ensure that trucks do not cause damage to the
material.
END OF SECTION
39
SECTION 2.2 – STRUCTURE EXCAVECATION AND BACKFILL
2.01 SUMMARY
A. This Section specifies requirements for excavation and backfilling for structures
and anti-termite treatment.
2.02 REFERENCES
A. Product manufacture, testing and installation shall comply with the following
references, unless otherwise approved by the Contractor.
1. BS 1377 - Methods of test for soils for civil engineering purposes.
2.03 DEFINITIONS
A. The following definitions shall pertain to words or phrases as used in this Section.
1. “Structure excavation” means excavation in all materials of whatever nature

encountered for the construction of buildings, tanks, footings or other structures.
2. “Formation level” means the bottom of the excavation.
3. “MDD” means maximum dry density of a soil.
4. “OMC” means optimum moisture content of a soil.
2.04 QUALITY CONTROL
A. “Inspection Requests” shall be submitted to the Employer during construction before

proceeding with at least the following activities. Minimum notification time shall be 24
hours.
1. Start of excavation (at new location).

2. Placement of blinding concrete.
3. Start of backfilling (at new location).
4. Sampling and testing.
B. Testing Laboratory
1. Testing of all materials shall be carried out by a suitably equipped site laboratory
or in an independent laboratory as described in Section 4.4.
2. During the course of the work, tests shall be carried out under the supervision of
the Employer, to:
a. Identify fill materials, and determine suitability.

b. Determine compaction characteristics of fill materials.
c. Determine moisture content, and field density.
d. The allowable soil bearing load shall be verified by dynamic cone penetration
test or as directed by the Employer.
e. Determine compaction fraction and grading for granular pipe surround.
f. Concrete tests as specified in Part 6.
3. The Contractor shall maintain a daily log of all tests carried out for the Employer’s
review.
C. Test Methods
1. Compaction tests to establish maximum dry density for all soils shall be
determined by BS 1377: Part 4: Method 3.5/3.6.
2. In situ density of compacted soils shall be determined by BS 1377: Part 9 Method
2.1 or 2.2 (as appropriate).
3. Cone penetration test TRL Method or BS 1377.
40
D. Testing
1. Density tests shall be made before removal of dewatering systems.

2. The Contractor shall adjust his operations so as to permit time to make tests and
shall excavate and fill such holes as may be required for sampling and testing.
3. A subsequent layer cannot be placed until the density of the proceeding layer has
been tested and approved.
4. At least two field density test shall be conducted for each layer at each structure
2
(or every 2000 m ), unless otherwise directed by the Employer.
5. At least one compaction test (MDD/OMC) shall be conducted for every 30 field
density tests conducted or as directed by the Employer due to changes in the
soil.
3
6. At least one complete soil analysis shall be carried out every 1500 m or as
directed by the Employer due to changes in the soil.
2.05 DELIVERY, STORAGE AND HANDLING
A. Delivery, storage and handling shall be according to the method statement along with
the following provisions:
1. Transportation, handling and stockpiling of fill material shall at all times be

performed in a manner to avoid segregation and contamination.
2. Stockpile materials at least 1.0 m away from edge of excavation.
2.06 EXCAVATION SUPPORT AND STABILITY
A. All excavations shall be stepped back at a safe and stable slope no steeper than
1 vertical to 1.5 horizontal, unless otherwise approved by the Employer.
1. Maximum step height shall be 1.5 m.

2. Minimum bench width shall be 1.0 m
3. Stability investigations and reports shall be provided by a qualified
geotechnical Contractor for any stepped excavations exceeding a 1 to 1
slope.
4. Additional excavation may be directed by the Employer at the contractor
expense to reduce slopes on any unstable excavations.
B. Trench boxes, caissons, sheet piling or other means of soil support may only be
used in areas of limited access and only with the Employer consent.
1. Before using any soil support systems, the contractor shall furnish, a method
statement and drawings showing all details of the soil support system he
proposes to use, together with all relevant calculations prepared by a qualified
structural engineer. No excavation work shall start until the Employer consent
is obtained. Such consent shall in no way relieve the contractor from its
contractual obligations and responsibilities to provide a safe, dry, and stable
excavation.
2. All components of any soil support systems shall be removed, unless
otherwise approved by the Employer. Removal shall be conducted in a
manner to prevent damage to pipe or structures. Any voids left behind shall
be carefully filled and compacted. Every precaution shall be taken by the
contractor to prevent slips and falls of earth and other materials in
excavations.
3. If in the opinion of the Employer, the support provided by the contractor is not
satisfactory, the contractor shall provide support as directed by the Employer.
The absence of the Employer direction or action by the contractor in
accordance with the direction of the Employer shall not relieve the contractor
of its obligations under the Employer.
41
4. Underpinning, shoring, or other protective measures required for buildings,
structures, and apparatus or adjoining excavations shall be provided by the
contractor as approved by the Employer.
5. If for any reason, any portion of the excavation gives way, the contractor shall
at its own expense take all necessary remedial measures, including the
excavation and removal of all soil thereby disturbed.
2.07 DISPOSAL OF MATERIALS FROM EXCAVATIONS
A. Subject to any other specific requirements of the Employer, the contractor

shall make its own arrangements for the temporary storage of any excavated
material which is required for use in refilling trench or structure excavations,
including any necessary double handling.
B. The height and slope of any temporary tips alongside the trench excavation
shall be stabilized at all times.
C. Where the nature of the material permits, the contractor’s temporary storage
facilities shall allow for separate storage for various grade materials.
D. Any excavated material that is not required or is found to be unsuitable for re-
use, shall be removed from site, and disposed in a legal manner by the
Subcontractor.
2.08 FORMATION LEVEL
A. The bottom of the excavation shall be properly trimmed off and compacted to
provide a firm and uniform bearing at formation level.
1. Minimum compaction shall be 95% MDD.

a. Compaction shall be verified by field density tests conducted to BS
1377 Part 9.
b. At least one filed density test shall be conducted for every structure.
B. If loose or unsuitable soil is encountered at formation level, such material

shall be removed as directed by the Employer and replaced with C17
concrete or approved granular material.
C. When excavating to designated formation levels or to specified limits, the

contractor shall not excavate the last 150 mm until immediately before
commencing construction work. If, the contractor excavates the last 150 mm
before he is ready or able to start the work, he may be required to remove
and replace additional material as directed by the Employer. Any such further
excavation and replacement of additional foundation material ordered by the
Employer shall be at the cost of the contractor.
D. Should the excavation bottom while acceptable to the Employer at the time of
his inspection, subsequently become puddled, soft or loose due to exposure
or flooding during the progress of the works, the contractor shall remove such
damaged softened or loosened material and replace it with approved material
as directed by the Employer. Any such further excavation and replacement of
additional foundation material ordered by the Employer shall be at the cost of
the contractor.
E. Any stones or flints greater than 50 mm in size shall be picked out of the
excavation bottom. Any holes so formed shall be filled in with suitable
material and trimmed to the correct level.
F. All shattered and loose materials shall be removed from the bottom of the
trench excavations so that the pipe surround rests on a solid and clean
foundation.
42
2.09 EXCESS EXCAVATION TO BE RESTORED
A. Care shall be taken to prevent excavation below the designated formation level.
1. If the Contractor excavates below the formation level, he shall restore the same
with Grade 17 concrete, unless otherwise instructed by the Employer.
2. Excess excavation required due to deterioration of soils shall be restored with
Grade 17 concrete, unless otherwise instructed by the Employer.
3. Overburden removed during excavation which extended under neat lines of slabs
at changes in elevation shall be restored with Grade 17 concrete.
4. The Contractor, at its own expense, shall remove from the Site all material
resulting from excess excavation below that required for the foundation.
B. All voids or changes in elevation below slabs shall be restored up to neat lines with
Grade 17 concrete, unless otherwise approved by the Employer.
2.10 BACKFILLING
A. Placement of backfill shall conform to the following requirements, unless otherwise

1. Backfill shall not be placed until the required foundation coating or membrane has
been completed and the foundation and/or structure to be backfilled has been
inspected and approved by the Employer.
2. Only suitable fill materials as defined in Part 2 shall be used as backfill.
3. All backfill shall have a uniform moisture content within the range of ± 3% of
optimum moisture content (OMC).
4. Backfill material shall be placed in loose layers not exceeding 200 mm thickness.
5. Backfill adjacent to structures shall be placed and compacted in a manner which
will prevent damage to the structures or protective membranes. Maximum
particle size adjacent membranes or coatings shall be 75 mm.
6. Height of the backfill adjacent to structures shall be increased at approximately
the same level on all sides of the structure to allow structures to assume the
loads from the backfill gradually and uniformly. Backfilling shall not start until the
concrete in the structure has obtained at least 70% of the designated
compressive strength.
7. Compaction equipment shall produce the specified compaction, as designated
herein.
a. Heavy equipment shall not be operated within 4 m of any structure.

b. Vibratory rollers shall not be used within 1.5 m of any structure.
c. Vibratory rollers weighing in excess of 4 tonnes (gross) shall not be used
around structures, unless approved by the Employer.
B. Compaction shall be carried out as follows, unless otherwise approved by the

Employer.
1. Each layer of backfill shall be compacted to 95% in paved areas.

2. Each layer of backfill shall be compacted to 90% MDD in unpaved areas.
C. Finished surfaces shall be + 25 mm from specified level, unless otherwise approved

by the Employer.
2.11 VAPOR BARRIER
A. A vapor barrier (polythane sheet at least 100 microns thick) shall be placed below all
floor slabs, unless noted otherwise.
B. Sheeting joints shall be lapped at least 300 mm and taped together.
END OF SECTION
43
SECTION 2.3 – DEWATERING
3.01 SUMMARY
A. This Section specifies general requirements for control of groundwater.
3.02 GENERAL REQUIREMENTS
A. Dewatering operations shall comply with the following requirements, unless otherwise
1. The Contractor shall furnish, install, operate, and maintain all equipment and
appliances necessary to keep excavations free from water during construction at
all times.
2. All dewatering shall be performed by well-point systems unless otherwise

approved by the Employer. Sump pumps may only be used with the Employer’s
permission where rocky or dense strata are encountered.
3. The Contractor shall ensure that the static water level will be drawn down to a
depth of at least 300 mm below the bottom of the excavation as required to keep
the bottom of the excavation dry.
4. The Contractor shall maintain dewatering at all times during construction so that
no groundwater comes into contact with the pipe, exposed reinforcement, or
unprotected concrete surfaces. Failure to comply with the above shall entitle the
Employer to condemn the affected section of Work and demand complete
removal and replacement at the Contractor’s expense.
5. If the Contractor fails to maintain the excavations in dry conditions acceptable to
the Employer, the Employer reserves the right to employ a professional
dewatering employer on the Contractor’s behalf. All costs attributed to the above
shall be at the Contractor’s expense.
3.03 WELL-POINT SYSTEMS
A. All well-point systems shall conform to the following requirements, unless otherwise
1. The well-point system shall be placed on both sides of a trench or completely

around isolated excavations.
2. Maximum allowable drawdown for a single stage system shall be 4.0 m.
a. Multi-stage well-point systems shall be used for excavations requiring a

drawdown of more than 4 m.
b. Well-points at all levels of multi-stage systems shall be installed on both sides
of a trench or completely around isolated excavations.
3. Maximum spacing of well-points shall be 1.0 m.

4. All well points shall be place in bored holes and backfilled with coarse filter sand
5. Vacuum pumps of suitable size and quantity shall be used to maintain the
system.
6. The number of well points serviced by one pump shall not exceed 40.
7. If necessary, dual well points at 1.0 m on center or well points placed at 0.5 m on
center shall be used with rotary vacuum pumps servicing no more than 30 well
points to achieve maximum performance.
44
3.04 SUMP PUMPING
A. Sump pumps may only be used with the Employer’s permission where rocky or very
dense strata are encountered.
B. If approved, sump pumping shall comply with the following requirements, unless
otherwise approved by the Employer.
1. At least two sumps shall be placed in each excavation (preferably in opposite

corners). For long trenches sumps shall be placed on each side of the trench.
Each sump shall be provided with a separate pump, suction hose and discharge
line.
2. Sumps shall be big enough to hold sufficient water for priming, pumping and
maintaining the excavation floor relatively dry.
3. All sumps shall be fitted with a suitably sized cage for graded filter material.
4. Drains leading to the sump shall be so arranged as to allow drainage of the entire
excavation and given sufficient fall to prevent silting up, unless steps are taken to
keep them cleared out.
5. Ditches shall be sufficiently wide to allow a water velocity low enough to prevent
erosion.
6. Elevation of the sump shall be at least 0.5 m below formation level.
7. Maximum draw down for suction pumps shall be 5 m. For greater draw downs,
use pumps at lower levels or use suspended submersible pumps.
C. If excavation faces become unstable, the sump shall be abandoned and other
methods of dewatering shall be used.
3.05 REMOVAL OF DEWATERING SYSTEMS
A. No dewatering system shall be removed without the approval of the Employer.
B. Release of groundwater back to its static level shall be performed in a manner to

prevent disturbance of natural foundation soils, compacted fill or backfill, and to
prevent flotation or movement of structures, pipelines and sewers.
C. Equipment shall only be removed when no longer required. Monitoring and

settlement measurement systems shall be maintained in operation as required by the
Employer.
D. If approved by the Employer, well-points and like items may be abandoned in place.
Any such approvals shall be in writing.
END OF SECTION
45
SECTION 2.4 - SERVICE ROADS, PARKING AREAS AND FOOTPATHS
PART 1 - GENERAL
1.01 SUMMARY
A. This Section specifies requirements for all road works and footpaths.
1.02 RELATED SECTIONS
A. Section 4.4 - Quality Control & Submittals.

D. Section 5.1 - General Earthwork and Site Preparation.
E. Section 3.3 - CONCRETE BATCHING AND DELIVERY.
1.03 REFERENCES
references, unless otherwise specified or unless otherwise approved by the
Contractor.
1. BS 381C Colors for identification, coding and special purposes

2. BS 812 Testing aggregates
3. BS 873 Road traffic signs and internally illuminated bollards.
4. BS 882 Aggregate from natural sources for concrete.
5. BS 1377 Methods of test for soil for civil engineer purposes.
6. BS 1474 Wrought aluminum and aluminum alloy for general
engineering
7. BS 1490 Aluminum and aluminum alloys Ingots and casting for
general engineering purposes.
8. BS 1851 Titanium dioxide pigments
9. BS 3262 Hot applied thermoplastic road marking materials
10. BS 6088 Solid glass beads for use with road marking compounds and
for other Industrial uses.
11. BS 6717 Pre-cast concrete paving blocks
12. BS 7263 Pre-cast concrete flags, curbs, channels edgings and
quadrants
13. BS EN485 Aluminum and aluminum alloys
14. ASTM C40 Test Method for Organic Impurities in Fine Aggregates for
Concrete
15. ASTM C88 Test Method for Soundness of Aggregates by use of Sodium
Sulphate and Magnesium Sulphate
16. ASTM C117 Test Method for Material Finer than 75µm (No. 200) Sieve in
Mineral Aggregate by Washing.
17. ASTM C127 Test Method for Specific Gravity and Absorption of Coarse
Aggregate.
18. ASTM C128 Test Method for Specific Gravity and Absorption of Fine
Aggregates.
19. ASTM C131 Test Method for Resistance to Degradation of Small-size
Coarse Aggregate by Abrasion and Impact in the Los
Angeles Machine.
20. ASTM C136 Test Method for Sieve Analysis of Fine and Coarse
Aggregates
21. ASTM C936 Specification for Solid Concrete Interlocking Paving Units
22. ASTM D242 Specification for Mineral Filler for Bituminous Paving
Mixtures
23. ASTM D751 Test Methods for Coated Fabrics.
24. ASTM D977 Specification for Emulsified Asphalt
25. ASTM D979 Practice for Sampling Bituminous Paving Mixtures.
46
26. ASTM D995 Specification for Mixing Plants for Hot-Mixed, Hot Laid
Bituminous Paving Mixtures.
27. ASTM D1117 Method of Testing Non-Woven Fabrics.
28. ASTM D1559 Test method for Resistance to Plastic Flow of Bituminous
Mixtures using Marshall Apparatus
29. ASTM D1682 Test Methods for Breaking Load and Elongation of Textile
Fabric.
30. ASTM D1910 Methods of Test for Construction Characteristics of Woven
Fabrics.
31. ASTM D2027 Specification for Cutback Asphalt (medium-curing)
32. ASTM D2041 Test Method for Theoretical Maximum Specific Gravity and
Density of Bituminous Paving Mixtures
33. ASTM D2172 Test Methods for Quantitative Extraction of Bitumen from
Bituminous Paving Mixtures
34. ASTM D2726 Test Method for Bulk Specific Gravity and Density of
Compacted Bituminous Mixtures using Saturated Surface –
Dry Specimens
35. ASTM D2950 Standard Test Method for Density of Bituminous Concrete in
Place by Nuclear Methods
36. ASTM D2995 Practice for Determining Application Rate of Bituminous
Distributors
37. ASTM D3549 Test method for Thickness or Height of Compacted
Bituminous Paving Mixture Specimens
38. ASTM 3786 Test Methods for Hydraulic Bursting Strength of Knitted
Goods and Non-Woven Fabrics: Diaphragm Bursting
Strength Test Method.
39. AI-MS-2 Mix Design Methods for Asphalt Concrete and Other Hot Mix
types
40. AASHTO M20 Penetration Graded Asphalt Cement
41. AASHTO T-168 Sampling Bituminous Paving Mixtures
1.04 DEFINITIONS
A. The following definitions shall pertain to words or phrases as used in this Section:
1. “Cut” shall mean any void resulting from excavation.

2. “Embankment” shall mean any fill placed above the existing ground or cut.
3. “Fill” shall mean suitable material used to raise an embankment up to the
bottom of sub grade.
4. “Subgrade” shall mean the compacted top surface (150 to 300 mm) of the
existing ground (or in some cases fill) below the formation level.
5. “Formation level” shall mean top of subgrade after final compaction.
6. “Formation” shall mean the top surface of the subgrade after preparation for
subsequent layers of material.
7. “Sub-base” shall mean one or more layers of granular material situated
between the subgrade and road base or wet mix.
8. “Road-base” shall mean one or more layers of granular material situated
between the sub-base and asphaltic base course.
9. “Wet-mix Macadam” shall mean a road base material consisting of graded
crushed rock pre-mixed in a plant with a controlled amount of water sufficient
for adequate compaction.
10. “Base course” shall mean one or more layers of asphaltic concrete situated
above just above sub base, road base or wet mix.
11. “Wearing course” shall mean the top layer of asphaltic concrete directly
supporting the traffic.
12. “Asphaltic concrete” shall mean a hot mixture of asphalt cement and well
graded, high quality aggregate, thoroughly compacted into a uniform dense
mass.
47
13. “Borrow material” shall mean suitable fill material taken from an approved
source.
14. “Ruts” shall mean grooves cut into any road surface by vehicular traffic.
15. “OMC” shall mean optimum moisture content.
16. “MDD” shall mean maximum dry density.
17. “CBR” shall mean California bearing ratio.
18. “Prime Coat” shall mean a thin film of liquid asphalt applied on a previously
prepared untreated soil.
19. “Tack Coat” shall mean a thin film of liquid asphalt applied on a previously
prepared bituminous course or to an existing bituminous surface.
20. “Foot Path” shall mean a passage paved by interlocking blocks for pedestrian
traffic.
21. “Coarse aggregate” shall mean that material retained on a 4.75 mm sieve.
22. “Fine aggregate” shall mean that material passing a 4.75 mm sieve.
A. Product manufacturer, testing and installation shall comply with the following
requirements, unless otherwise approved by the Contractor.
1. Paving shall conform to the lines and levels on the drawings unless otherwise
approved by the Contractor.
2. All materials for use in construction shall be obtained only from sources
3. The specific source of materials shall not be changed without prior written
approval of the Contractor.
4. If the grading and quality of material delivered to the site does not conform to
the grading and quality as previously inspected and tested or does not
comply with the specifications, the Contractor may reject such material at the
site of the work.
5. Sufficient materials shall be stored in stockpiles to allow for testing and
approval of such materials before use in works.
1.06 SUBMITTALS
A. Product Approval
1. The Contractor shall submit sufficient information to the Contractor, before
purchase, according to Section 1.3. Such information shall include at least
the following, unless otherwise required by the Contractor.
a. Manufacturer’s name.
b. Supplier’s name.
c. Product name (if applicable).
d. Product description.
e. Manufacturer’s technical data.
f. Storage instructions.
g. Relevant test results of all materials specified.
h. Application or installation instructions.
i. Mix design (if applicable).
j. Details of asphalt plant, location and calibration results
k. Aggregate report.
l. Borrow pipe location.
B. Samples
1. Samples (applied) shall be supplied for at least the following products or as

requested by the Contractor.
a. Geotextile Fabric: 200 mm x 200 mm sample of each proposed fabric.

48
b. Pre-cast Concrete Kerbs: If requested, three sample of each size.
c. Concrete Paving Blocks: 15 samples of each size and color and as
required for testing.
d. Aggregates: 100 kg of each size and type.
e. Fill Material: 100 kg from each source.
f. Existing Material: 100 kg from each source.
g. Free Draining Material: 50 kg from each source.
h. Stabilizing Material: 50 kg from each source for crushed aggregates, and
400 kg from each source for stabilizing rock fill.
i. Subgrade Material: 100 kg from each source.
j. Rock Fill Material: 500 kg from each source.
k. Granular Sub-base Material: 100 kg from each source.
l. Road Base Material: 100 kg from each source.
m. Wet-mix Macadam: 100 kg from each source.
n. Bedding Sand: 25 kg from each source.
o. Jointing Sand: 25 kg from each source.
p. Bituminous Mixes: 50 kg from each source.
q. Prime Coat: 3 liters from each source.
r. Tack Coat: 3 liters from each source.
s. Bitumen: 3 liters from each source.
t. Road Marking Materials: Applied samples and or as requested by the
Employer.
u. Signs: Prepared samples as requested by the Employer.
2. All sampling will be witnessed by the Employer, unless agreed otherwise.
C. The Contractor shall provide separate method statements meeting the

requirements of Section 1.3, for at least the following activities or as requested by
the Employer.
1. Site clearing and earthwork.

2. Dewatering activities (if necessary).
3. Method of mixing and laying for sub-base, road base and wet-mix.
4. Method of surface preparations and application of prime and tack coat.
5. Method of mixing, laying and compaction of bitumen mixtures.
6. Asphalt plant calibration.
D. The contractor shall submit shop drawings according to Section 1.3 for at least
proposed roadway Sections.
E. The Contractor shall prepare a mock-up meeting the requirements of Section 1.3
for at least the following installations or as requested by the Employer:
1. Concrete Paving Blocks
a. Provide mockup of paving layout where directed by the Employer.

2
b. Size: 15 to 20 m .
c. Laying of bedding course, installation of paving blocks and accessories to
indicated pattern shall be included.
d. Show range of shades, color, and texture of pavers.
e. Accepted mockup may become part of the work.
2. Rock Fill
a. Provide mock-up of laying trial as directed by the Employer.

b. Length 100 m, width 4 m.
49
3. Sub-Base

4. Road Base

5. Wet-Mix

6. Asphaltic Base Course
a. Provide laying trial as directed by the Employer.

7. Binder Course

8. Asphaltic Wearing Course
a. Provide laying trial as directed by the Employer.

A. Before dispatch from the factory, the Contractor shall notify the Employer, in
sufficient time to allow the Employer or his representatives to inspect and test the
products, if so desired.
1. All notifications shall be made by written “Inspection Requests” in accordance

with Section 4.4. An advance copy may be faxed to the Employer’s office,
but the original shall arrive before the scheduled day of inspection.
2. Minimum notification times shall be as follows:
1. 24 hours on site.
2. 48 hours within Baghdad city and surrounding areas.
3. 72 hours for other areas within Iraq.
4. 2 weeks outside of Iraq.
B. “Inspection Requests” shall be submitted to the Employer during the on site

installation work before proceeding with at least the following activities. Minimum
notification time shall be 24 hours.
1. Start of excavation
2. Start of backfilling
3. Start of free draining material
4. Start of stabilizing material
5. Start of rockfill
6. Start of subgrade
7. Start of sub-base and road base and wet mix mixing and laying.
8. Start of prime coat and tack coat application.
9. Start of bituminous paving mixtures.
10. Sampling and testing.
50
C. Testing Laboratory
1. Testing of all materials shall be carried out by a suitably equipped site

laboratory or in an independent laboratory as described in Section 4.4.
a. Routine materials testing and site testing shall always be conducted in

the site laboratory, unless otherwise agreed by the Employer.
b. All sampling shall be witnessed by the Employer, unless otherwise
directed by the Employer.
2. During the course of the work, all required tests shall be carried out under the
supervision of the Employer, to ascertain the suitability of materials according
to this speciation.
3. The Contractor shall maintain a daily log of all tests carried out for the
Employer’s review.
D. Test Methods
1. Compaction tests to establish maximum dry density for all soils shall be
determined by BS 1377: Part 4: Method 3.5/3.6 as appropriate.
2. In situ density of compacted soils shall be determined by BS 1377: Part 9
Method 2.1 or 2.2 (as appropriate).
3. Cone penetration test: TRL Method or BS 1377 as directed by the Employer.
E. Testing
1. Density tests shall be made before removal of dewatering systems.

2. Contractor shall adjust his operations so as to permit time to make tests and
shall excavate and fill such holes as may be required for sampling and
testing.
3. A subsequent layer cannot be placed until the density of the proceeding layer
has been tested and the area approved.
4. At least one field density test shall be conducted for each layer at each
2
structure (or every 200 m ), unless otherwise directed by the Employer.
5. At least one compaction test (MDD/OMC) shall be conducted for every 30
field density tests conducted or as directed by the Employer due to changes
in the soil.
6. At least one complete soil analysis shall be carried on each type of material
as specified in relevant Clauses or as directed by the Employer due to
changes in the soil.
B. Delivery, storage and handling shall be according to the manufacturer’s

recommendations along with the following provisions:
1. Transportation, handling and storage shall at all times be performed in a

manner to avoid product damage.
2. Only nylon slings shall be allowed for lifting products. Steel chains, clamps or
cables shall not be allowed for lifting purposes, unless approved by the
Employer. Steel chains or cables may be allowed for securing products
during transport or storage provided protective padding or timber blocking is
used.
3. Do not store products directly on ground, unless approved by the Employer.
Ensure adequate timber blocking is used to provide sufficient support.
4. Where product manufacturer recommends storage under controlled
temperatures, the Contractor shall provide an enclosed, insulated, cool store
maintained at the proper temperature 24 hours per day.
51
5. If stored outside, cover products to prevent ultraviolet degradation as
recommended by the manufacturer.
6. The Contractor shall visually inspect all products upon delivery and report any
damage to the Employer.
a. Any products damaged during delivery, storage or installation shall be

marked by the Contractor and set aside.
b. Proposals for repair of any damaged products shall be submitted in
writing to the Employer for approval.
c. No repairs to damaged products shall be attempted without the
Employer’s approval.
d. Any damaged products deemed unsuitable for repair by the Employer
shall be removed from site and replaced at the Contractors expense.
B. Delivery
1. Deliver materials and products in factory labeled packages indicating name,

brand, type, size, color, production date and expiry date where applicable.
2. Sequence deliveries to avoid project delays and to permit proper co-
ordination of the work.
C. Storage
1. Protect geotextile fabric against direct sunlight and completely off form the
ground and as recommended by the manufacturer.
2. Edges of pre-cast concrete kerbs/concrete paving blocks shall be protected
to prevent staining, chipping or spillage of concrete.
3. Equipment and methods used for stockpiling aggregates and for removing
aggregates from the stockpiles shall be approved by the Employer.
a. No segregation of the aggregate shall result and no foreign material shall

contaminate the aggregate.
b. Centre of the storage area shall be elevated and sloped to the sides in
order to provide proper drainage of excess moisture. Material shall be
stored in such a way to prevent segregation and to allow proper control of
moisture. Stockpiles shall be built up in layers not exceeding 1 m.
Height of each stockpile shall be limited to a maximum of 5 m. Stock
piles shall not be constructed in a conical shape. Sufficient material shall
be stored in stockpiles to allow for testing and approval of such materials
before use in the works. Minimum quantity of aggregates stock piled
shall be sufficient for one week’s production.
4. Bitumen
a. The temperature shall be kept as low as possible.

0
b. Shall not be stored above 60 C approximately above the softening point.
c. All boilers, pre-heating pits, tolls and plant and surrounding area shall be
kept clean.
52
PART 2 - PRODUCTS
2.01 FREE DRAINING MATERIAL
A. Free draining material, for placement in wet conditions, shall conform to the
following requirements.
1. Sieve analysis according to BS 812: Part 103 meeting the following

requirements:
TABLE 1
Sieve Size (mm) Percent Passing
37.5 100
10.0 30 to 100
5.0 0 to 50
0.600 0 to 30
0.075 0 to 5
2. The grading shall not vary from the maximum to the minimum limits of
adjacent sieves.
3. Ten percent fines value (BS 812: Part III): 50 kN minimum.
2.02 STABILISING MATERIAL (CRUSHED)
A. Stabilizing material, for unstable conditions, shall comply with the following
requirements as approved by the Employer.
1. Crushed Aggregates
a. Sieve analysis according to BS 812: Part 103 meeting the following

requirements:
TABLE 2
Sieve Size (mm) Percent Passing
50.0 100
28.0 80 to 100
14.0 60 to 85
5.0 40 to 70
2.0 20 to 50
0.850 5 to 25
0.425 0 to 10
0.180 0 to 2
b. Los Angeles Abrasion (ASTM C131): 30 maximum

c. Bulk Specific Gravity (BS 812): 2.65 minimum
d. Water absorption (BS 812): 2.0 maximum
2. Stabilizing Rock Fill
a. Non-friable sound crushed rock.

b. Size of rock shall be 300 to 100 mm meeting the above properties.
2.03 EXISTING MATERIAL
A. Existing material shall conform to the requirements of Section 5.1.
53
2.04 FILL MATERIAL
A. Suitable fill material shall conform to the requirements of Section 5.1. All fill
material for road works shall be of load bearing quality.
2.05 SUBGRADE
A. Suitable subgrade materials shall conform to the requirements of Table 3, unless
TABLE 3
Test Standard Criterion
Organic impurities BS 1377: Part 3: Method 3 2% Maximum
Acid soluble sulphate content BS 1377: Part 3: Method 5 2% Maximum
Acid soluble chloride content BS 1377: Part 3: Method 7 2% Maximum
CBR at 95% of the MDD (96 hrs soaked) BS 1377: Part 4: Method 7 30 Minimum
Fines passing through No 200 sieve BS 1377: Part 2:Cl. 9.2 (Wet) 25% Maximum
Liquid limit BS 1377: Part 2: Method 4.5 35% Maximum
Plasticity Index BS 1377: Part 2: Method 5 6% Maximum
Maximum Particle Size - 63 mm
Notes:
a. Higher sulphate content maybe acceptable when carbonate content is in
the range of 30% to 40% in accordance with BS 1377: Part 3: Method 6.
b. Higher chloride content may be tolerated provided that the ratio of
(carbonate plus sulphate) to chloride content is maintained at
approximately 15:1.
c. Dry density / moisture content test shall be carried out to BS 1377: Part
4. Method 3.5/36 as appropriate.
B. Minimum Test Frequency

1. One sample shall be tested to confirm the above properties for every 1500 m³
(or part there of) placed or compacted.
2
2. Two insitu density tests shall be made every 2000 m of subgrade laid.
2.06 GEOTEXTILE FABRIC

A. The geotextiles may be woven or non-woven fabric, having a stable network of
filaments or yarns that retain their relative position when used in the proposed
manner and shall meet the following requirements, unless otherwise approved by
the Employer.
1. Geotextile shall contain an ultraviolet light inhibitor.
2. Geotextile shall be inert to commonly encountered chemicals, acids, alkalis,
sea water etc., found in soils.
3. Geotextiles for general road works shall comply with Table 4.
TABLE 4 - GEOTEXTILE FABRIC

Minimum Physical
Test
Characteristics
Protected Unprotected
Description Method Units
Type 1 Type 2
Fabric Weight EN965 g/m² 100 125
Tensile Strength EN-ISO-10319 KN/m 5.0 9.0
Elongation EN-ISO-10319 % 30 30
Puncture Strength EN-ISO-12236 N 1000 1400
Opening Size EN-ISO-12956 um 90 90
Flow Rate (normal to plane) EN-ISO-11058 L/m²s 90 90
4. Geotextiles for placement below stabilizing material shall comply with Table
4A.
54
TABLE 4A - GEOTEXTILE FABRIC FOR STABILISING MATERIAL
Description Test Method Minimum Physical Characteristics
2
Weight EN965 125 g/m
Thickness under load (700
EN964-1 0.7 mm
kPa)
Tensile strength EN-ISO-10319 12 KN/m
Puncture resistance EN-ISO-12236 2000N
2
Flow rate EN-ISO-11058 80L/m s
2.07 BEDDING SAND
A. Sand to be laid over geotextile shall be crushed black sand from a source
approved by the Employer and the sieve analysis shall performed in accordance
with BS 812: Part 103.
TABLE 5
Sieve Size (mm) Percent Passing by Wet Sieving
5.0 100
2.0 65 – 90
0.425 30 – 50
0.150 10 – 30
0.075 2 – 10
2.08 ROCKFILL
A. Rockfill shall be 100% hard durable crushed rock of suitable size, free from
organic matter, shale and other deleterious material. Rockfill shall bind readily to
form a stable mass with sound, smooth, well-knit upper surface free from loose
material. Rockfill material shall conform to the requirements in Table 6, unless
TABLE 6
Sieve Size (mm) Layer 1 Layer 2 Layer 3
175 100 - -
125 25 to 60 100 -
63.0 5 to 40 25 to 60 -
37.5 - 0 to 15
28.0 0 to 10 -
20.0 0 to 5
10.0 100
5.00 85 to 100
2.36 60 to 80
0.425 40 to 60
0.150 20 to 30
0.075 10 to 20
Physical Requirements (applicable to all layers)
Soundness (MgSO4 ), after 5 cycles 10% Maximum
Los Angles Abrasion 40% Maximum
Thin and elongated pieces by weight (thickness less than 1/5 of 5% Maximum
length)
Clay lumps and friable particles 0.25% Maximum
Specific gravity (apparent) 2.6 Minimum
Soluble Salts (layer 3) 5% Maximum
Note: 1. All layers of rock fill material shall be of the same kind of rock in nature and color.
2. If approved by the Employer, other suitable grading may be used.
55
2.09 CONCRETE KERBS
A. Pre-cast concrete kerbs shall be manufactured by a company specializing in

kerbstone manufacturing with at least three year’s experience, unless otherwise
agreed by the Employer.
B. Pre-cast kerbs shall conform to BS 7263: Part 1: 1994 except as modified in this
Section.
C. This Section covers non-mountable kerbs, dropped kerbs, heel kerbs, quadrants,
flush kerbs, kerb ramps, noses, channel blocks and edgings.
D. Materials for precast kerbs
1. Cement
a. Portland cement, conforming to BS 4027 or ASTM C 150, Type V.

3
b. Minimum cement content shall be 380 kg/m .
2. Aggregates
a. As specified in Section 3.2 for grade C30, unless otherwise approved by

the Employer.
b. Combined gradation shall be as follows, unless otherwise agreed by the
Employer. Sieve analysis shall be according to BS 812: Part 103.
1Cl.7.2.
TABLE 7
ASTM Sieve Size (mm) % By Weight Passing
20.0 95 to 100
14.0 80 to 100
10.0 60 to 85
5.0 40 to 65
2.36 22 to 42
1.18 12 to 32
0.600 7 to 23
0.300 4 to 15
0.150 2 to 10
0.075 0 to 2
3. Water/Admixtures: As specified in Section 3.2 or to be determined by pre-

cast manufacturer as appropriate to design requirements.
E. Manufacturer
1. Pre-cast kerb stones shall be hydraulically pressed precast products

manufactured in a fully automatic batching plant and complying with the
requirements of BS 7263: Part 1 except as modified hereunder.
a. They shall be uniform in color free from cracks, flaws of other defects and
shall have well defined arises.
b. If required by the Employer 100 mm diameter cores shall be taken from
the pre-cast elements to ascertain that the concrete strength is not less
than specified value.
i. Cores shall be tested to BS 1881: Part 120

ii. A sample of 3 products shall be taken from a consignment of not
more than 1000 products.
56
iii. Two cores shall be cut from each of three samples.
iv. Mean compression strength of two cores shall reported as the
compressive strength of that product.
v Average compressive strength of 3 products shall not be less than
35.0 MPa.
vi. Mean water absorption of specimens when tested in accordance with
B7263: Part 1 shall not be greater than 3.0%.
2. Fabricate units using steel or other approved molds in compliance with the
approved manufacturing and testing procedures.
3. Quality control recommendations and dimensional tolerance in accordance
with BS 7263: Part 1: 1994.
4. Elements shall be manufactured to the designated dimensions as shown on
the Contract Drawings, unless otherwise directed by the Employer.
5. Precast kerbs shall be formed by elements 900 mm long where required to
be laid in straight lines, unless otherwise approved by the Employer. May be
reduced to 200 mm long where required to be laid to curves depending on
the radii of the curves.
6. Cure units by either:
a. Low pressure steam;
b. Steam vapor;
c. Radiant heat and moisture;
d. Other similar process as approved by the Employer.
F. Finishes
1. Ensure exposed-to-view finish surfaces of pre-cast concrete members are fair

faced, uniform in color and appearance.
2. Cure members under identical conditions to develop required quality.
Minimize appearance blemishes such as non-uniformity, staining, or surface
cracking.
3. Small surfaces holes, normal form joint marks, minor chips, and spalls are
acceptable, if approved by the Employer.
a. Major or unsightly imperfections, honeycombs, or structural defects are

not acceptable.
b. Repair or replace as directed by Employer.
4. Tolerances of manufacture shall be 3 mm in any one dimension and end

faces shall be truly perpendicular to the base.
5. Testing frequency shall be as directed by the Employer.
2.10 IN-SITU CONCRETE KERBS
A. Cast in-situ kerbs (if allowed by the Employer) shall comply with the following
except as modified by the Employer.
1. Grade C40 concrete compliant with Section 3.2.

2. Cement used shall conform BS4027 or ASTM C150 Type V.
3. Compressible joint filler board 10 mm thick compliant with Section 3.2 shall
be placed at joints
2.11 INTERLOCKING PAVING BLOCKS
A. Concrete paving blocks shall be manufactured by a company specializing in

exterior concrete paving block manufacturing with 3 year’s experience unless
otherwise agreed by the Employer. The installer shall be a company specializing
in installing exterior pavers with 3 year’s experience, unless otherwise agreed by
the Employer.
57
B. Aggregates shall conform to the requirements of Section 3.2 except as follows.
1. Nominal size aggregate of coarse aggregate shall be 10 mm. Maximum

aggregate size shall not exceed 14 m. Grading of the aggregate need not
necessarily comply.
2. Portland cement conforming to BS 4027 (SRC) or ASTM, C150 Type V.
3. Pigment (inorganic) shall comply with BS 1014. Minimum pigment content
shall be 5% by weight of cement, unless otherwise approved by the
Employer.
4. Thickness shall be 60 mm on footpaths and 80 mm on plant internal roads
and parking areas, unless otherwise shown on the Drawings or instructed by
the Employer.
5. Color and pattern of the blocks shall be as noted on the drawings or as
6. Shall be locally manufactured.
7. Shall comply with BS 6717: Part 1 in all aspects, unless otherwise modified in
this section.
8. Compressive Strength.
a. Average strength of 10 blocks tested in accordance with BS 6717: Part

1and shall not be less than 49 MPa.
b. Strength of any individual block shall be not less than 40 MPa.
9. Water Absorption
a. Average of 3 specimens tested in accordance with ASTM C140 shall not

be greater than 5%.
b. No individual result shall be greater than 7%.
10. Sulphate and Chlorides
a. The total sulphate content shall not be more than 4.0% by weight of the
cement in the mix.
b. The total chloride content (as NaCl) shall not be more than 0.15% weight
of mix.
C. Bedding Sand
1. Shall consist of non-plastic, black crushed sand meeting the following
properties, unless otherwise approved by the Employer.
TABLE 8
10 100
5.0 95 – 100
2.36 80 – 100
1.18 50 – 85
0.300 10 – 30
0.150 5 – 15
0.075 0–3
Test Standard Limit
Clay, silt and dust content (Wet sieve) BS 812: Part 103.1 3.0% Maximum
Sulphates (SO4) BSI 377: Part 3 Method 5 0.3% Maximum
Chlorides (Cl) BSI 3777: Part 3 Method 7 0.5% Maximum
2. Shall be obtained from a single source.

3. Allowed to drain before use.
4. Shall be covered with suitable sheeting to minimize moisture changes.
58
D. Jointing sand shall consist of non-plastic sand meeting the following
requirements, unless otherwise approved by the Employer.
TABLE 9
2.36 100
1.18 90 to 100
0.300 15 to 50
0.075 0 to 3
E. Kerb stones compliant with Section 2.09 shall be provided for edge restraint,
unless otherwise agreed by the Employer.
2.12 GRANULAR SUB BASE
A. Hard, durable gravel and/or crushed gravel or crushed stone with sand and silt.
B. Free of clay balls or other deleterious substances.
C. If required approved binding material shall be added to the coarse gravel to

improve the binding property of sub-base material but in no case the percentage
of binding material added shall not be more than 20% of the sub-base.
D. Grading shall be as follows when tested in accordance table 10
TABLE 10
Percentage By Weight Passing
Sieve Size (mm)
Type A Type B Type C Type D
75 100 - - -
50 95-100 100 - -
25 - 75-95 100 100
9 30-65 40-75 50-85 60-100
4.75 25-55 30-60 35-65 50-85
2.36 16-42 21-47 26-52 42-72
0.3 7-18 14-28 14-28 23-42
0.075 2-8 5-15 5-15 5-20
CBR at 95% MDD (96
45% 35 30 20
hour soaked) (Minimum)
1. Materials shall conform to the following requirements:
59
TABLE 11
Test Standard Limit
BS 1377: Part 2 : Method
Liquid Limit Maximum 25%
4.5
Plasticity Index BS 1377 : Part 2 : Method 5 Maximum 6%
Organic Material BS 1377 : Part 3 : Method 3 Maximum 2%
SO3 Content BS 812 : Part 118 Maximum 5%
Acid Soluble Chloride (by weight of
BS 812: Part 117 Maximum 1%
aggregate)
Gypsum Content CaSo4 2H2O SO3 Content * 2.15 Maximum 10.75%
Total dissolved solids BS 1377 : Part 3 : Method 8 Maximum 10%
Flakiness Index BS 812: Part 105.1 Maximum 35%
Elongation Index BS 812: Part 105.2 Maximum 15%
Ten Percent Fines Value BS 812: Part III Minimum 50 KN
Los Angeles Abrasion ASTM C131/C535 Maximum 45%
Soundness (MgSO4), after 5 cycles ASTM C88 Maximum 12%
Linear Shrinkage BS 1377: Part 2: Method 6.5 Maximum 3%
Compaction Test (MDD) BS 1377: Part 4: Method 3.6 Minimum 2.1 Mg/m
Sand equivalent value ASTM D2419 Minimum 30%
Notes: 1. Samples are to be collected as described in ASTM D75.
2. If no road base is used minimum in-situ density shall be 98% MDD and the CBR
shall be increased to 80 at 100% MDD.
E. Minimum Test Frequency
1. One sample every 1500 m³ shall be tested for complete analysis unless
2. One in-situ density tests shall be made every 1000 m² of granular sub base
laid, unless otherwise approved by the Employer.
3. One in-situ density shall be carried out for every 200 liner meter of shoulder
or foot path, unless otherwise approved the Employer.
2.13 AGGREGATE ROAD BASE
A. Hard, durable crushed gravel or crushed stone.
1. The amount of crushing shall be such that at least 75% (by weight) of the
pieces retained on 4.75 mm sieve shall have at least one mechanically
fractured face.
2. Material shall consist of uniform mixtures of gravel and or crushed gravel with
sand, silt and clay conforming to the following gradation limits.
B. Free of organic matter or other deleterious substances.
C. Grading shall be as follows when tested in accordance with AASHTO T27-74.
60
TABLE 12
Sieve Size (mm) % by Weight Passing
37.5 100
25 80-100
12.5 50-80
4.75 30-60
0.425 10-30
0.075 5-15
D. Material shall conform to the following requirements:
TABLE 13
Test Standard Limit
Liquid Limit BS 1377: Part 2: Method 4.5 Maximum 25%

Plasticity Index BS 1377: Part 2: Method 5 Maximum 4%
Organic Impurities BS 1377: Part 3: Method 3 Maximum 0.2%
SO3 Content BS 812: Part 118 Maximum 5%
Acid Soluble Chloride (by weight of BS 812: Part 117 Maximum 1%
aggregate)
Flakiness Index BS 812: Part 105.1 Maximum 35%
Elongation Index BS 812: Part 105.2 Maximum 15%
Sand Equivalent Valve ASTM D2419 Minimum 40%
Los Angeles Abrasion ASTM C131/C535 Maximum 45%
Soundness (MgSO4), after 5 cycles ASTM C88 Maximum 18%
Linear Shrinkage BS 1377: Part 2 : Method Maximum 3%
6.5
Compaction Test (MDD) BS 1377: Part 4: Method 3.6 Minimum 2.2 Mg/m
In-situ Density Test BS 1377: Part 9: Method 2.2 Minimum 98% MDD
CBR at 95% MDD (96 hours soaked) BS 1377: Part 4: Method 7 Minimum 80%
E. Minimum Test Frequency

3
1. One sample every 1500 m shall be tested.
2
2. Two in-situ density tests shall be made every 500 m of aggregate road base
laid.
2.14 WET-MIX MACADAM ROAD BASE
A. Coarse aggregate shall be crushed rock or crushed gravel.
B. Fine aggregate shall be crushed rock or crushed gravel.
C. Combined grading shall be as follows when tested in accordance with BS 1377:

Part 2: Method 9.2 or 9.3.
1. The combined grading shall be subject to the approval of the Employer.
61
TABLE 14
Sieve Size
Present Passing
(mm)
50.0 100
37.5 95 to 100
20.0 60 to 80
10.0 40 to 60
5.0 25 to 40
2.36 15 to 30
0.600 8 to 22
0.063 2 to 8
2. Materials shall conform to the following requirements.
TABLE 15
Test Standard Limit
Liquid limit BS 1377: Part 2: Test 4.5 25% Maximum

Linear shrinkage BS 1377: Part 2: Method 6.5 3% Maximum
Plasticity index BS 1377: Part 2: Test 5 4% Maximum
Aggregate crushing value BS 812: Part 110 25% Maximum
Water absorption ASTM C128/C127 2% Maximum
Flakiness index BS 812: Sect. 105.1 30% Maximum
Elongation index BS 812: Sect. 105.2 30% Maximum
CBR at 100% MDD (96 hrs BS 1377: Part 4: Test 7 80% Minimum
soaked)
Los Angeles abrasion ASTM C131/C535 45% Maximum
Soundness (MgS04), 5 cycles ASTM C88 18% Maximum
Organic impurities BS 1377: Part 3: Method 3 0.2% Maximum
Chloride content Acid soluble BS 812: Part 117 1% Maximum
Sulphate content Acid soluble BS 812: Part 118 0.5% Maximum
Juss Content BS 1377 5% Maximum
Sand equivalent valve ASTM D2419 45% Minimum
Crushed face (coarse aggregate Non-Standard Each particle shall
only) have a minimum of
one crushed face
Note: 1. Samples shall be collected to ASTM D75.
D. Minimum Test Frequency

3
1. One sample every 1500 m shall be tested for complete analysis unless
2
2. Three in situ density shall be made every 1000 m of carriageway, unless
3. Three in situ density shall be made every 500 linear meter of shoulder or as
2.15 MATERIALS FOR ASPHALTIC CONCRETE
A. Mineral aggregates for bituminous paving course shall consist of coarse

aggregates, fine aggregates and filler material all complying with the following
requirements.
B. Before the production of aggregates or delivery of aggregates the Contractor

shall notify the Employer of the source of aggregates for inspection of the borrow
or quarry area. All sources of aggregates shall be approved by the Employer
before the processing of material.
62
C. The properties of aggregates specified in this section shall be for aggregates from
individual sources or individual stock piles.
D. If the grading and other specified properties of the material delivered to the site
does not conform to the same properties of originally approved samples or does
not comply with the specification, the Employer reserves the right to reject such
materials at the site of the work. If required by the Employer the Contractor shall
submit to the Employer the original invoices for any delivery of mineral
aggregates including filler.
E. Coarse Aggregates (those retained on a 4.75 mm sieve). Mineralogical tests

shall be carried out on the aggregates, if requested by the Employer.
1. Shall consist of crushed rock or crushed gravel.

2. Shall be clean, hard, tough, durable and sound.
3. Shall be of uniform quality and free from decomposed stone, shale, clay
lumps and other deleterious substances.
4. Crushed gravel consists of products obtained by crushing material that has
first been screened in such a manner that not less than 90% of the material to
be crushed is retained on an ASTM 9.5 mm sieve.
5. 100% (by weight) of each stockpile of aggregate retained on 2.36 mm sieve
shall have at least one crushed face.
6. At least 85% (by weight) of each separate stockpile of aggregate retained on
2.36 m sieve shall have all faces crushed, unless otherwise approved by the
Employer.
7. Procedure for crushed face determination shall be as described in the
following Section.
8. Bulk specific gravities between any two size fractions shall not vary by more
than 0.4.
9. Coarse aggregate in each individual stock pile shall have properties which
comply with the following values:
TABLE 16
Base Course/ Wearing
Test Standard
Binder Course Course
Los Angeles Abrasion ASTM C131/C535 Maximum 40-35% Maximum 30%
Aggregate Crushing Value BS 812: Part 110 Maximum 25% Maximum 20%
Soundness (MgSo4), after
ASTM C88 Maximum 18% Maximum 18%
5 cycles
Flakiness Index BS 812: Part 105.1 Maximum 25% Maximum 25%
Elongation Index BS 812: Part 105.2 Maximum 15% Maximum 15%
Water Absorption ASTM C128/127 Maximum 2% Maximum 2%
Acid Soluble Chlorides (by
BS 812: Part 117 Maximum 0.1% Maximum 0.1%
weight of aggregate)
Acid Soluble Sulphate (by
BS 812: Part 118 Maximum 0.5% Maximum 0.5%
weight of aggregate)
BS 1377: Part 3
Organic Impurities Maximum 0.05% Maximum 0.05%
Method 3
Note: 1. Samples shall be collected according to ASTM D75.

3
2. One sample every 1500 m shall be tested for complete analysis, unless
63
F. Determination of Crushed, or Uncrushed Face Of Aggregates
1. General
a. This method covers the determination of the percentage of fully crushed,

partially crushed or uncrushed aggregates retained on 2.36 mm sieve.
b. This test is applicable only on coarse aggregates.
2. Definition
a. The crushed face of an aggregate is defined as the face of the aggregate

particle which is 100% mechanically crushed by suitable crushing plant.
The aggregate shall have rough texture and sharp edges and shall be
clear from any organic impurities, clay deposits or oxidation discoloring.
b. A fully crushed aggregate is defined as an aggregate having all its faces
crushed mechanically by a suitable plant.
c. A partially crushed aggregate is defined as one or more of its faces
crushed mechanically by a suitable plant.
d. An uncrushed aggregate is defined as an aggregate having none of its
faces crushed.
3. Apparatus required
a. A balance of suitable capacity accurate and readable to 0.1% of the

sample mass.
b. Sieve, 2.36 mm, conforming to the requirements of ASTM E11.
c. Oven capable of maintaining a temperature of 110 ±5 C.
0
4. Collect a representative sample of aggregate from each individual stockpile

as described in BS 812: Part 102.
5. Obtain a test portion having the minimum following weights.
TABLE 17
Maximum Nominal Size (mm) Minimum Mass (kg)
37.5 15
25.0 10
20.0 5
12.5 2
10.0 1
6. Wash the sample thoroughly through a 2.36 mm sieve and dry it in an oven
until a constant mass is achieved. If approved by the Employer a hot plate
may be used in lieu of oven.
7. Cool the sample to room temperature and sieve it again through the 2.36 mm
sieve.
8. Weigh the sample retained on 2.36 mm sieve and record the mass to the
nearest 1 gm (M1). Discard the material passing 2.36 mm, if any.
9. Spread the sample on a clean surface and visually examine each individual
particle for the number of crushed faces and sort out as follows:
a. Separate all uncrushed particles and record the mass (uncrushed

particles) to nearest 1gm (M2)
b. Separate all aggregate particles having all its faces mechanically crushed
(fully crushed particles), and record the mass to the nearest 1gm (M3).
c. Separate all aggregates having one or more faces crushed and record
the mass to the nearest 1gm, (M4).
64
10. Calculate the percentage of aggregates which have the same number of
uncrushed or partially crushed or fully crushed as follows and report the
values to the nearest 1%.
M2
Uncrushed Particles% (UCP) = X 100
M1
M3
Fully Crushed Particles% (FCP) = X 100
M1
M4
Partially Crushed Particles (PCP) = X 100
M1
11. Fine Aggregates (Those passing a 4.75 mm sieve). Shall not be flaky or
elongated and shall be clean and free from organic matters, clay or any other
detrimental material.
G. Fine aggregate shall be obtained from 100% crushed gravel or crushed rock,
unless otherwise approved by the Employer.
1. If approved by the Employer, a maximum of 25% (by weight) of fine

aggregate may be uncrushed provided that it is separately fed into the plant.
2. Use of dune sand shall not be permitted.
3. Fine aggregates shall have properties which comply with the following values:
TABLE 18
Test Standard Limit
Soundness (MgSo4), after 5 cycles ASTM C88 Maximum 5%
Plasticity Index BS 1377: Part 2: Non-Plastic
Method 5
Acid Soluble Chlorides (by weight BS 812: Part 117 Maximum 0.1%
of aggregate)
Acid Soluble Sulphates (by weight BS 812: Part 118 Maximum 0.5%
of aggregate)
Organic Impurities ASTM C40 Color of supernatant liquid shall be
lighter than standard color solution
Water absorption ASTM C128 2.0% Maximum
Note : 1. Samples shall be collected according to ASTM D75
3
2. One sample every 1500 m shall be tested for complete analysis.
3. Frequency and tests on hot bin aggregates shall be as directed by the Employer.
H. Filler Material
1. When the combined grading of the coarse and fine aggregates is deficient in
material passing the ASTM No. 200 sieve, external mineral filler shall be
added as approved by the Employer at the Contractor’s expense.
2. Mineral filler shall consist of finely ground particles of limestone or cement in
accordance with ASTM D242.
3. Mineral filler shall be thoroughly dry and free from organic substances and
clay.
4. At the time of use it shall be sufficient dry to flow freely and essentially free
from agglomerations.
I. Test frequency shall be as directed by the Employer.
65
J. Bitumen Binder
1. Shall be penetration grade 40/50 or 60/70 as directed by the Employer.

2. Bitumen shall be prepared by refining crude petroleum.
3. Shall be homogeneous and free from water.
4. Shall not foam when heated to 175°C.
5. Shall conform to the following requirements, unless otherwise accepted by
the Employer.
0
6. Bitumen heated 10 C above the maximum temperature obtained from
viscosity – temperature relationship shall be considered over-heated and
shall be removed from site and disposed of by the Contractor at his own
expense. Bitumen shall be heated only in approved boilers or bulk storage
containers equipped with adequate and accurate thermometers.
7. When filling the bitumen from distributor boilers or bulk containers, the
bitumen shall be passed through a filter of fine wire gauge.
8. The Contractor shall take every reasonable precautions to avoid fire or health
hazards.
9. A sample of bitumen that the Contractor propose to use in the work together
with a statement as to its source and properties shall be submitted to and
approved by the Employer at least 45 days before Construction begins.
10. The properties of bitumen shall be as follows, unless otherwise approved by
the Employer.
TABLE 19
Grade 40/50 GRADE 60/70
AASHTO
Test Min- Max- Min- Max-
Method
imum imum imum imum
Penetration at 25°C 100g, 5 sec. D5 40 50 60 70
Flash Point, Cleveland Open Cup, °C D92 232 - 232 -
Ductility at 25°C, 5 cm per minimum, cm D113 100 - 100 -
Solubility trichloroethylene, % D2042 99 - 99 -
Thin film oven test
D1754 - 0.80 - 0.8
3.2 mm, 163°C, 5 hr Loss on heating, %
Penetration of residue % of original D5 52 - 55 -
Ductility D113 - - 50 -
0
Kinematic viscosity (centistokes) at 135 C D2170 280 - 240 -
Softening points (Ring and ball app.) D36 51 55 48 52
11. Only the bitumen represented by the approved sample shall be used by the
Contractor.
12. Blending of bitumen from different refineries will not be permitted.
13. One full analysis shall be carried out on a sample from every 80 ton
2.16 ASPHALTIC CONCRETE
A. When tested according to ASTM C117 and ASTM C136, the combined
aggregates shall conform to the following grading having a smooth curve to the
appropriate limits and shall not vary from the low limit on one sieve to the high
limit on the adjacent or vice-versa.
66
TABLE 20
% by Weight Passing
ASTM Sieve
Wearing Course
Size (mm) Base Course Binder Course
Type A Type B
37.5 100 - -
25.0 90 - 100 100 -
19.0 76 - 90 90 - 100 100
12.5 56 - 80 70 - 90 90 - 100 100
9.5 48 - 74 56 - 80 76 - 90 90 – 100
4.75 29 - 59 35 - 65 44 - 74 55 - 85
2.36 19 - 45 23 - 49 28 - 58 32 - 67
0.300 5 - 17 5 - 19 5 - 21 7 - 23
0.075 2-8 3-9 4 - 10 4 - 10
B. Combined mineral aggregate shall meet the following requirements:
1. Sand Equivalent Value (ASTM D2419): min 65

(determine after all processing except for addition of asphalt binder)
2. Plasticity Index BS 1377: Part 2: Method 5: Non-plastic
3. Bulk specific gravity: 2.70 minimum
C. Grading given in the above table represent the extreme limits.
1. Combined aggregate as finally selected for use in the work shall have a
grading within the limits designated in the Table 20 and shall be acceptable to
the Employer.
2. Base course limit may vary from the low limit on one sieve to the high limit on
the adjacent or vice-versa with the Employer’s approval.
3. Wearing course shall be continuously graded from coarse to fine.
D. Coarse aggregate, shall show no detrimental amount of stripping when tested in

accordance with ASTM D 1664. The area coated shall be evaluated not only at
25°C but also after the aggregate has been soaked in water at 40°C and 60°C.
1. Minimum value of non-stripped area shall be 95%.

2. If stripping occurs, the aggregate shall be rejected unless:
a. An approved method of treatment shall be carried out as specified to

change the material from a hydrophilic to a hydrophobic state.
b. Only approved additives shall be used with the bituminous binder.
E. When necessary to change the hydrophilic character of aggregates to

hydrophobic, additives of approved type will be added to the bituminous material
in such percentage as required to obtain satisfactory results from the test
performed in accordance with ASTM D1664. Approved additive will be used in
accordance with Technical Specifications issued by the manufacturer and
approved by the Employer after appropriate testing.
F. No extra payment will be made for required anti-stripping additives.
G. Design Criteria
As showed in table 21
67
TABLE 21
Base Binder Wearing
Properties
Course Course Course
Bitumen Content (% of total mix) Marshall
3 to 5.5 4 to 6 4 to 6
Specimens
Immersion – Compression (ASTM D 1075)
Minimum 70 Minimum 70 Minimum 70
Index of Retained Strength (%)
Air voids in total mix (VIM %) 3 to 6 3 to 5 3 to 5
Voids in mineral aggregate (VMA %) Minimum 12 Minimum 13 Minimum 14
Voids filled with Bitumen (VFB %) 55 to 75 60 to 80 65 to 85
Stability (KN) Minimum 5 Minimum 7 Minimum 8
Flow (mm) 2 to 4 2 to 4 2 to 4
Minimum Minimum
Stiffness (kg/mm) Minimum 500
450 500
Loss of Marshall Stability by submerging
specimens in water at 60° C for 24 hours Maximum Maximum Maximum
compared to stability measured after 25% 25% 25%
submersion in water 60° C for 30 minutes.
Filler/Bitumen Ratio 0.9 to 1.4 0.9 to 1.4 0.9 to 1.4
VIM after compaction to refusal Minimum
2%
Note: 1. The exact percentage of bitumen to be used shall be fixed by the Employer on
the basis of the laboratory mix and full scale plant trial mix results.
H. Job mix for Bituminous Paving Courses
1. Mix approved for use in the works shall be designed using Marshall tests.
2. Field trials with the following recommendations shall be taken into account.
a. For base course, the Marshall tests shall be modified by substituting all
aggregate sizes over 25 mm with an equal weight of aggregate sizes in
the next lower grading size.
b. Combined aggregate gradation should be adjusted within the allowable
limits to achieve maximum stability whilst not going below the minimum
requirement for void content.
c. Minimum bitumen binder content should be used according to the results
of the Marshall Method of Mix Design, provided that it will still satisfy all
the specified requirements.
d. Before final approval, the proposed job mix, but with a bituminous content
at the upper percentage limit shall be compacted to refusal (400 to 600
blows). Resulting voids in the mix shall be not less than 2%.
e. Final job mix shall display all characteristics as specified for Asphaltic
Concrete mixes.
f. Mix formula shall take into consideration the absorption of bitumen into
the aggregates
i. For calculations of voids in the mix (VIM), Theoretical Maximum

Specific Gravity as per ASTM D2041 and bulk specific gravity as
prescribed by ASTM D2726 are to be used.
ii. For calculation of voids in the mineral aggregate (VMA) the equations
as mentioned in Asphalt Institute Manual MS-2 shall be used.
iii. Voids Filled with Bitumen (VFB) shall be calculated using the
following equation:
(VMA – VIM)
VFB = X 100
VMA
68
iv. After receiving approval of the aggregates and bitumen from the
Employer, the Contractor shall make a written request for the
approval of the job-mix formula from the Employer at least thirty, (30)
days before the date he intends to begin production of plant-mix
“Bituminous Paving Course” Mixes. Formula will be prepared by the
Contractor under the supervision of the Employer in the Laboratory.
v. The laboratory job mix formula shall define: percentage of aggregate
passing each required sieve size, percentage of bitumen binder to be
added to the aggregate, temperature at which the mix is to be
emptied from the mixer, and temperature at which the mix is to be
delivered to the works site.
vi. Laboratory job mix formula shall be used for the basis of approval of
the job standard mixture.
vii. Before the start of the permanent work, “mock-ups” or trial areas
having lengths of at least 30 m shall be laid to the specified layer
thickness outside the area of the permanent work for the Employer’s
approval.
a. Materials used in the trials shall be those approved for use in the
bituminous paving courses.
b. Equipment used shall be that according to the Contractor’s
approved method statement and the program of work.
c. The object of these trials is to determine:
1. Adequacy of the Contractor’s equipment.

2. Loose depth measurements necessary to result in the
specified compacted layer depths.
3. Relationship between the number of compaction passes and
the resulting density of the material.
d. Additionally at least two samples of non-compacted material and

two cores of specified diameter shall be taken from the trial area
in accordance with AASHTO T-168 and analyzed in the presence
of the Employer to determine:
1. Aggregate grading
2. Binder content
3. Stability
4. Flow
5. Marshall Density
4. Voids
5. Road density
6. Stiffness
7. Filler/Bitumen ratio
8. Voids filled with bitumen
e. Results shall be submitted to the Employer for approval before

further mixing and laying are carried out.
viii. If the laboratory job mix formula fails to produce a satisfactory trial,
the mix proportions may be modified by agreement with the
Employer, within the applicable specification requirements to produce
a mix of satisfactory workability and acceptable surface finish.
a. After approval of the “mock-up” (trial area) by the Employer, the

mix shall be designated as the ‘Job Standard Mix’ and shall
thereafter be the approved mix.
b. From the successful production trial, 4 Marshall specimens are to
be made at the correct temperature as described 2.16K. The
69
temperature of the mix on arrival shall be within 10°C of the
mixing temperature. The resultant density will be referred as the
“Job Standard Density”.
c. Additional Marshall samples of the successful plant mix shall be
compacted to refusal to ensure that the minimum VIM is still
within the acceptable limit. If this value has changed significantly
from that obtained in the laboratory, then the whole mix design
shall be reconsidered.
ix. All mixes produced shall conform to the properties of Job Standard
Mix approved by the Employer, within the ranges of tolerance
specified in Table 22.
x. Should a change in a material be encountered or should a change in
a source of material be made, a new Job-Standard Mix shall be
submitted by the Contractor and approved by the Employer before
the mix containing the new materials is delivered. Job materials will
be rejected if they do not possess the same characteristics of the
approved Job Standard Mix.
I. Job Mix Tolerance

TABLE 22
Aggregate retained on 4.75 mm sieve or larger + 6%
Aggregate passing 4.75 mm sieve and retained on 0.850 mm sieve + 4%
Aggregate passing 0.850 mm sieve and retained on 0.075 mm sieve + 2%
Aggregate passing 0.075 mm sieve + 2%
Bitumen Binder + 0.3%
Temperature for mixing and placing ± 15°C
J. Samples of bituminous paving course mixes shall be taken from the mixing plant
and/or behind the paver before compaction, as decided by the Employer, to
check compliance with the approved job mix requirements.
K. Density of the compacted mixes shall be related to the job standard density or the
daily Marshall Density at the option of the Employer, which shall be determined
by making four Standard Marshall specimens from samples of the mix taken from
the mixing plant or paver.
1. Density of each sample shall be determined and compared with the mean
value.
2. Any individual result, which varies from the mean by more than 0.015 g/cc,
shall be rejected.
3. Marshall tests shall be repeated on a daily basis to establish the daily
Marshal Density for that particular day’s production.
4. Daily Marshall Density shall not vary from the Job Mix Design Density by
more than + 1%.
L. Assistance of the Employer in the preparation of the job standard mix shall in no
way relieve the Contractor of his responsibility for producing a bituminous mix
meeting the requirements of the Specifications.
M. Temperature of the bitumen binder for mixing and compacting shall be in

accordance with ASTM D1559. The Contractor shall submit a temperature /
viscosity chart for each grade of bitumen to be used.
N. Preparation of Mineral Aggregate for Bituminous Mix
1. Coarse and fine aggregate shall be stored at the asphalt plant in such a
manner that separate stockpiles will not become intermixed.
70
a. Stockpiles shall be of sufficient size to provide a minimum quantity of one
week’s continuous production of asphalt mix.
b. Aggregates brought to the asphalt plant to supplement stocks should be
tested and approved before placing in the existing approved stockpiles.
2. Cold bins shall be calibrated with the materials to be used and the settings
shall be such as to produce a combined gradation in accordance with the job
mix formula.
a. Proportioning shall be such that surpluses and shortages in the hot bins
will not occur.
b. Neither the dryer nor the screens shall be overloaded.
c. All the above shall be as approved by the Employer.
3. Materials shall be thoroughly dried and heated so that their temperature is

within 8°C of the temperature needed to satisfy the viscosity requirements of
the asphalt cement.
a. Moisture content of the heated and dried materials shall not exceed
0.5%.
b. Quantity of materials fed through the drier shall in all cases be held to an
amount, which can be thoroughly dried and heated within the limits
specified.
4. Immediately after heating, the aggregates shall be screened into at least five
sizes and conveyed into separate bins ready for batching and mixing with
bituminous materials. When the aggregates supplied are of such size and
grading that separating into five bins is impractical, the number of required
separations may be reduced to four or to three with the approval of the
Employer.
5. Efficiency of the screening operations shall be sufficient to produce (at plant
operating capacity) gradations (in all sizes of heated and dried aggregates)
which are reasonably uniform and result in the production of a mix complying
with the limits specified for the aggregate gradation.
O. Preparation of Bituminous Mix
1. Asphaltic concrete shall be prepared in a central mixing plant conforming to

the requirements of ASTM D995.
a. The plant shall be equipped with an efficient mechanical dust extraction

system and storage silos.
b. Its design shall be provided for the controlled return of some of the filler
to the mix, when necessary, by means of filler weighing bin discharging in
to the pugmill.
c. The dust collection system shall be powerful enough to keep the mineral
filler contents the in hot sand bin below 2%.
d. The plant settings once established shall not be changed without the
approval of the Employer.
e. The minimum mixing time shall not be less than that recommended by
the manufacturer. The mixing time may be increased by the Employer if
additional time is necessary to obtain a homogeneous mix and
satisfactory coating.
f. Bitumen binder shall be introduced into the mix in the proportion specified
by the job-mix formula.
2. Initial mixing time will be designated by the Employer. Mixing time may be
increased by the Employer if additional time is necessary to obtain a
homogeneous mix and satisfactory coating.
71
3. Timing at the batch plant for mixing shall begin at the start of the introduction
of the bitumen into the pugmill.
4. Length of mixing time for continuous plants will be determined by the
following formula or other approved methods:
Pugmill dead load capacity in

Mixing time in seconds = kg
Pugmill output in kg/second
5. Temperature of the aggregate immediately before mixing shall be within + 8°

C of the temperature of the bitumen binder.
a. Temperature of the aggregate and asphalt before mixing shall be

approximately that of the completed mix as defined in the job mix formula
b. Mix temperature shall be within the limits set out in the job mix formula
when emptied from the mixer.
P. Minimum test requirements for bituminous courses
1. Bitumen material
a. One sample shall be tested for penetration and Ring ball test for every 80
tones or part thereof, unless otherwise agreed by the Employer.
2. Aggregate
a. One sample for each stockpile or every 1500 m³ or part thereof.

b. Perform all the required tests.
3. Bituminous mix
a. One sample of mix shall be obtained from at least every 200 tones or part
thereof.
b. Test Method
Bitumen content ASTM D2172
Grading ASTM C117 & C136
Density ASTM D2726 or by nuclear ASTM D2950
Stability and flow ASTM D1559
Void contents MS - 2
c. Loss of Marshall stability shall be tested for at least every 7,000 tones
and shall be as specified in the previous section.
2.17 PRIME COAT
A Prime coat shall be a medium curing cut back asphalt (MC-70) conforming to
AASHTO M82/75 or ASTM D2027 except as modified in Table 23 or as accepted
by the Employer.
72
TABLE 23
Limits
Test Standard Min- Max-
imum imum
0
Saybolt Frugal viscosity at 50 C (60 to 120 sec.) ASTM D88 70 120
Flash Point, Tag open Cup, 100°C ASTM D3143 38 -
Distillation : ASTM D402
Distillate (% of total distillation to 360°C.)
To 225° C - 20
To 260° C 20 60
To 315° C 65 90
Residue from distillation to 360° C, % by volume ASTM D402 55 -
difference
Tests on residue from distillation:
Penetration at 25° C, 100g 5 sec. ASTM D5 120 250
Ductility at 25° C, cm ASTM D113 100 -
Solubility in trichloroethylene, % ASTM D2042 99 -
Water content, % volume ASTM D95 - 0.2
B. Sampling shall be in accordance with ASTM D140.
C. Frequency of the testing shall be as directed by the Employer.
2.18 TACK COAT
A. Tack coat shall be slow setting emulsified asphalt, grade SS-1h (anionic) or CSS-
1h (cationic) conforming to AASTO M208/72 or ASTM D977 as shown in the
Table 24 below or as accepted by the Employer.
TABLE 24
Limits
Test Standard
Minimum Maximum
Saybolt Furol Viscosity at 25° C, seconds ASTM D88 20 100
Storage Stability Test, 24 hrs, % - 1
Residue by distillation ASTM D402 57 -
Tests on residue from distillation:
Penetration 25° C, 100g 5 sec. ASTM D5 40 90
Ductility 25°, 5 cm/min.cm ASTM D113 40 -
Solubility in trichloroethylene, % ASTM D2042 97.5 -
B. Sampling shall be in accordance with ASTM D140.
C. Depending on the possibilities of obtaining Bituminous materials, the Employer

may modify the type and gradation of the materials for the prime coat and tack
coat.
D. Frequency of the testing shall be as required by the Employer.
2.19 ROAD MARKING MATERIALS
A. Thermoplastic materials shall comply with BS3262 (super imposed type) hot-
applied thermoplastic road marking materials and shall be suitable for road
surface temperature of up to 80°C, unless otherwise approved by the Employer.
Proportions, testing requirements and type of materials used shall be as
mentioned in the Contractors approved method statement.
73
B. Road marking paint shall be either chlorinated rubber, one pack epoxy or alkyd
based or equivalent specifically made for road painting and as approved by the
Employer. Shall be suitable for applying by brush or mechanical means to
cement concrete or bituminous pavement to give a chemically stable film of
uniform thickness.
C. Yellow paint shall be standard color BS 381C No. 355, except where an
alternative shade has been specified in the Contract. Contain not less than 6%
by mass of a suitable yellow pigment.
D. White paint shall contain no less than 6 percent by mass or titanium dioxide as a
pigment conforming the type A (anatase) type R (rutile) specified in BS 1851 or
E. Ballotini shall comply with the requirements of BS6088.
2.20 TRAFFIC SIGNS
A. Permanent traffic signs shall be refectories and shall comply with the following
requirements except as modified here under or as directed by the Employer.
1. The relevant local authority requirements.

2. BS 873 in respect of quality.
3. The traffic sign regulation and General Directions; 1975 and traffic signs
manual published by HMSO:UK, with the addition of Arabic lettering where
appropriate.
B. Sign plates shall be manufactured either from:
1. Sheet aluminum to BS EN485, SIC-1/2H, NS3-3/4N, NS-1/2H or HS 30-WP

with a minimum thickness of 3 mm, unless otherwise approved by the
Employer.
2. Extruded aluminum hollow plank sections to BS 1474, HE 9 TE and HE 30
TF or as approved by the Employer.
C. Information on signs shall be constructed in extruded aluminum plank sections,

which will either be self-locking or rear fixing, and the aluminum shall be BS EN
485, or BS 1490 or other approved equivalent International Standard.
D. All sign plates shall have clean, smooth edges cut to the required shape of the
sign and shall be etched and degreased to the sign sheeting manufacturer’s
specifications before application of the sheeting.
E. Sign shall be covered with “High Intensity” reflective sheeting.
1. Sheeting shall have the manufacturer’s guarantee for a period of not less
than 5 years for “Engineering Grade” and 7 years for “High Intensity”.
2. Rear faces shall be non-reflective grey and should give a similar life span to
the sign face.
3. Reflective sheeting shall be fixed to the sign plate either with a heat activated
adhesive using vacuum applicator or with a pressure sensitive adhesive
using a pressure roller in accordance with the sheeting manufacturer’s
instructions.
4. Sign faces shall be formed from a single piece of reflective sheeting, but if for
any reason the sign face shall be fabricated from more than one piece of
material all joints in the material shall be over lapped by not less than 6 mm
and where sheeting is applied to extruded sections it shall extend over the
top and bottom edges of the sections by not less than 3 mm. No butt joints
shall be permitted and in horizontal joints the overlap shall be from the top.
74
5. Sheeting, after application to the sign base, will not come off at the edges nor
shall it peel off or warp.
a. Surface shall be smooth, flat and free from any bubbles, pimples, edge
chipping or edge shattering.
b. Surface shall be washable and weatherproof.
6. Corners of all direction signs shall be rounded to a radius of 75 mm.
F. Stiffening and Framing
1. All stiffening and framing shall be of hot dipped galvanized steel.

2. Signs constructed of aluminum sheet shall, when recommended by the
Traffic Sign Manual, be framed on all edges using hot dipped galvanized
steel angle.
3. Stiffening to signs constructed of aluminum sheet, having an area exceeding
0.10 square meter shall be confined to horizontal lengths at the top and
bottom edges of the sign plate.
G. All rivets or other devices fixing sign plates to their framework shall be of non-
staining steel or other materials approved by the Employer and shall have a
sufficient cross sectional area to prevent failure from thermal stresses or wind-
pressure or such other stresses as may be specified.
1. All rivet and bolt holes shall be edge-sealed with clear lacquer after the
application of the plastics sheeting.
2. Rivets shall be spaced at not more than 150 mm apart, around the outside
edge of the sign plate and on cross braces the spacing shall be not more
than 300 mm.
3. Any rivet brought through the sign face shall be colored to match the sign
face.
4. Any rivet or other device fixing sign plates to their framework shall have
protective washer of nylon or other approved insulating material inserted
where they would be in contact.
H. All materials shall be supplied in new and unused condition except in so far as
they have been tested in the course of manufacture.
2.21 SIGN FOUNDATION
A. Shall be as stated in the Contractors approved method statement.
2.22 BEDDING MORTAR FOR KERBS
A. 1 part cement to 3 parts sand.
2.23 JOINTING GROUT FOR KERBS
A. 1 part cement to 1 part sand with 1/5 part hydrated lime with sufficient water to be
plastic.
2.24 BEDDING AND BACKING CONCRETE FOR KERBS
A. Shall conform to Grade C20 of Section 3.2.
75
PART 3 - EXECUTION
3.01 GENERAL
A. All operations shall be performed in accordance with the specification, and in

conformity with the lines, grades, thickness and typical cross Section shown on
the plans or established by the Employer. Only approved material shall be used
in the construction. The embankment and subgrade in fill shall be constructed
using only suitable material obtained from roadway excavation or imported fill
material from sources previously approved by the competent authority.
3.02 SITE PREPARATION AND CLEARING
A. Site preparation and clearing shall comply with Section 5.1, unless otherwise
3.03 DEWATERING
A. A. Dewatering shall comply with Section 2.3.
3.04 PLACEMENT OF FILL
A. Before the placement of any fill materials, the Contractor shall conduct trial
compaction tests as directed by the Employer.
1. Fill material used in the trials shall be with the proposed borrow or excavated
material.
2. Compaction equipment to be used shall be that specified and acceptable to
the Employer.
3. The object of these trials shall be to determine the optimum moisture content
and the relationship between the number of compaction equipment passes
and density for the proposed borrow materials.
B. Compaction of fills shall be carried out at the moisture content determined by the
trials.
1. Fill material which does not contain sufficient moisture to obtain the required
compaction shall have additional water incorporated therein by the use of
approved sprinklers and mixing.
2. Material containing an excess of the amount of moisture required to obtain
the necessary compaction shall not, without written approval of the Employer,
be incorporated in the fill until it has been allowed to dry before compaction.
Drying of wet material may be expedited by disking or other approved
methods.
3. During construction of the roadway the road bed shall be maintained in such
a condition that it will be well drained at all times.
4. The Contractor shall make allowances in the height and width of the work for
any swelling or shrinkage.
C. Fill materials shall be placed in horizontal layers of uniform thickness.
1. Work shall be carried out to adhere to the designated slopes, levels and
depths.
2. After adjustment of the moisture content to that required to attain maximum
density, the loose material shall be compacted to obtain the specified density.
3. Maximum layer thickness shall be 150 mm, unless otherwise agreed by the
Employer.
76
D. Placement of fill materials at points inaccessible to normal compaction equipment
shall be made in horizontal layers of loose material not exceeding 100 mm in
depth and thoroughly compacted by the use of mechanical tampers.
E. When fill materials are to be placed and compacted on slopes steeper than 3 to 1
the following shall apply, unless otherwise approved by the Employer. If the
embankment shall be benched in steps or prepared as directed by the Employer.
The width of the benching shall be enough to permit the operations of placing
equipment.
F. If the original surface upon which the embankment is to be placed is an old road
bed, the surface shall be ploughed, scraped and broken up regardless of the
height of the embankment and compacted as directed by the Employer.
G. If backfill is to be placed below standing water, only approved granular material

meeting the requirements of “free draining material” shall be deposited. Placing of
aggregates may be with or without the associated use of compaction plant.
H. If the foundation on which the embankment or the subgrade materials are to be

laid is unstable, crushed aggregate or stabilizing rock fill meeting the
requirements of “stabilizing material” shall be placed and compacted as directed
by the Employer.
1. Stabilizing material (crushed aggregate) shall always be laid on geotextile

fabric covering the area to be stabilized as determined by the Employer.
2. The surface to receive the geotextile shall be prepared to a relatively smooth
condition free of obstructions, depressions and debris.
3. Geotextile shall be installed as described herein.
4. Crushed material shall be laid in 150 mm thick layers and compacted to the
satisfaction of the Employer.
5. Total thickness shall not be less than 300 mm.
6. The rock fill shall be end tipped into the area to the stabilized and rolled with
a bulldozer (D8) in layers not exceeding 600 mm (compacted thickness) until
the area is stabilized to the satisfaction of the Employer.
a. The top 100 mm above this surface shall be blinded with the crushed
stabilizing material and compacted with 10 Ton vibrating roller for at least
6 passes to create a dense well bonded surface.
b. Stabilizing rock fill shall be used only if the area cannot be stabilized with
other suitable materials.
c. The thickness of stabilizing rock fill material shall be as directed by the
Employer.
I. Density to which suitable fill layers shall be compacted is 95% MDD, unless
J. When an embankment or filled area has achieved settlement and requires

additional material to bring it up to the required formation level, the top of the
borrow or fill shall be thoroughly scarified before the placement of additional
material.
3.05 SUBGRADE PREPARATION
A. After site clearing the upper portion (300 mm below formation level) of the
existing subgrade (cut area) shall be sampled and tested to confirm suitability of
the material.
1. If the upper portion of the subgrade is found to be unsuitable, such subgrade

material shall be removed and replaced with suitable subgrade material as
77
directed by the Employer. The ground after cutting shall be treated and
prepared as existing ground.
2. When the existing ground in the cut (within 300 mm of the formation level) is
found to be suitable, the subgrade surface shall be completely broken up by
ploughing or scarifying, watered and mixed to achieve a uniform moisture
content between ±2% of the OMC for the full depth of 150 mm.
3. The top 300 mm below formation level in fill area shall be constructed with
approved sub grade material and each layer shall be compacted to 95% of
the MDD. The moisture content shall be within ±2%of the OMC.
B. After the foregoing work has been accomplished, the entire subgrade shall be
shaped to a smooth uniform surface. Excess material which cannot be disposed
of by normal drifting to the low spots during blading and shaping operations shall
be removed and placed in other areas deficient in materials or disposed of in an
approved manner.
C. Once prepared, the subgrade shall be maintained in the finished condition until
the first succeeding course of subbase or base material has been placed.
1. Contractor shall take all precautions necessary to protect subgrade from

damage.
2. Hauling over finished subgrade shall be limited to that which is essential for
construction purposes.
3. Contractor shall protect the prepared subgrade from both his own and public
traffic.
4. Contractor shall maintain the subgrade by blading and rolling as frequently as
may be necessary to preserve the subgrade in a completely satisfactory
condition.
5. The Contractor shall be responsible for reinstatement (to the satisfaction of
the Employer) of any layer damaged or disturbed after the compaction and
approval, before placing the next layer.
6. Finished surface of the formation level shall not vary at any point by more
than 10 mm above or 30 mm below the grade shown on the drawing or
established by the Employer.
7. An inspection request shall be sent to the Employer before proceeding to the
next operation.
3.06 COMPACTION
A. Contractor shall carry out the compaction of fills as specified after grading and
leveling the surface to be compacted.
1. In areas to be filled, compaction shall include adding necessary fill, water,

and other materials as required, and compacting the first layer in addition to
subsequent layers up to the proposed levels.
2. In areas already excavated down to the required level, compaction shall
include adding the necessary water, etc., and compacting the surface, in
accordance with the procedure outlined hereinafter.
3. Procedure outlined below shall not relieve the Contractor of his duties to
determine the most suitable procedure for compaction. All such procedures
shall be subject to the approval of the Employer.
B. After carrying out the grading, leveling, scarifying, pulverizing, and other work as
required, the Contractor shall add the necessary amount of water (within 3% of
the MDD) to obtain a suitable moisture content for compaction. Fill shall be
thoroughly turned over after adding each lot of water so as to achieve a
homogeneous moisture content throughout the whole thickness of the layer.
78
C. Before compacting, samples from the pulverized fill will be taken and tested
according to standard procedures in order to establish the moisture content.
1. Field testing using "Speedy Moisture Device" or similar instrument giving

direct readings for the field moisture content may be used for guidance only.
2. In the event that moisture is more than Optimum Moisture Content, the area
represented by the sample shall be scarified and aerated until the moisture
content is within 3% of the optimum moisture content.
3. The fill shall then be leveled for compaction.
D. After primary leveling, compaction shall be started by means of approved rollers

depending on the type of material being compacted in order to obtain the required
dry density.
1. Placement and compaction of materials shall be in layers not exceeding 150

mm compacted thickness, unless otherwise approved by the Employer.
2. Each layer of fill material shall be compacted to 95% of the MDD, unless the
layer is 1.0 meter below formation level where compaction to only 90% MDD
is required.
E. Rolling shall be carried out in the direction of the road axis until the fill reaches
the required density.
1. In crowned sections, rolling shall start from both edges of the road in the
direction of the axis.
2. If the road is super elevated, rolling shall start from the lower side and
continue to the higher side.
3. In order to compensate for the amount of water lost in evaporation in the
course of compaction, additional quantities of water shall be added as
required.
F. The surface shall thereafter be leveled longitudinally and transversely by motor

graders and finally rolled to achieve uniform compaction, free from undulations,
soft spots and depressions.
G. No layer shall be covered by the next layer until it has been tested, inspected and
H. Saline water for earthworks shall only be permitted if the percentage of water
soluble salts in the compacted fill does not exceed 3% by weight of dry soil.
3.07 GEOTEXTILE FABRIC INSTALLATION
A. The Contractor shall furnish and place geotextile fabric as shown on the
drawings.
1. The surface to receive geotextile fabric shall be prepared to a relatively

smooth condition free of obstructions, depressions, and debris and shall be
installed to the correct lines and grades or as directed by the Employer.
2. Geotextile fabric shall not be laid in a stretched condition, but shall be laid
loosely with the long dimension parallel to the centerline of the pavement and
to the direction of traffic with no wrinkles or folds.
a. Void space shall not be left between the geotextile and the ground
surface.
b. If the geotextile is damaged during installation a geotextile patch shall be
placed over the damaged area extending beyond the damaged area a
minimum of 500 mm.
79
3. In the event the width of the proposed area for fabric requires more than one
panel width of fabric, the panels shall be overlapped a minimum of 300 mm
on firm ground and 1.0 m on soft uneven ground.
a. Longitudinal joints in the fabric shall have an overlap of at least 500 mm.
b. To prevent slippage of the overlapping fabric, the areas of overlap shall
be stabilized as approved by the Employer with anchor blocks, or
aggregate piles etc.
c. On curves the geotextile may be folded or cut to conform to the curves.
4. In the event construction machinery is used to place the fabric, the working
platform for the machinery shall be the soil subgrade and not the previously
laid fabric.
5. After placement of the geotextile fabric, the Contractor shall spread a 50 mm
thick layer of crushed black sand over the geotextile fabric.
6. Subsequent layers of material shall not be dumped directly on the fabric, nor
shall the haul trucks run on the fabric.
a. Material shall be spread by a bull dozer or front end loader.

b. Blade or bucket shall be kept sufficiently high so that the aggregate is not
being pulled over the fabric, but being dropped at a minimum height to
the satisfaction of the Employer.
7. Fabric damaged or displaced before or during installation or during placement

of overlying aggregate material shall be replaced or repaired at the
Contractor's expense and to the satisfaction of the Employer.
8. An inspection request shall be sent to the Employer before the installation of
geotextile.
3.08 EXECUTION PLACEMENT AND COMPACTION OF ROCK FILL
A. If shown on the drawings, rock fill for each layer shall be laid and compacted in
the following manner, unless otherwise indicated on the drawing or agreed by the
Employer.
st
1. The thickness of 1 layer shall be180 mm.
nd
2. The thickness of 2 layer shall be 120 mm
rd
3. The thickness of 3 layer shall be 50 mm.
B. An Inspection request shall be sent to the Employer before the placement and
after completion of each layer.
1. Subsequent operations shall not be carried out until each layer of rock fill has
been approved by the Employer.
st
C. Geotextile shall be provided before the placement of 1 layer.
1. It shall be woven or non-woven as specified in Clause 2.06.

2. A layer 50 mm of crushed sand complying with the requirement of Cl. 2.07
st
shall be placed on the top of the geotextile before the placement of 1 layer
for the protection of the geotextile.
D. A trial area shall be prepared by the Contractor and the materials shall be spread
and compacted in an approved manner. Samples shall be collected and tested in
the presence of the Employer to check the compaction and penetration of fines.
E. The rock fill shall be spread and compacted on site using the approved
equipment and procedures as developed from the trials. Variation from the
80
approved methods or the use of plant not included previously will be permitted
only if the Contractor can demonstrate to the Employer that the required
compaction can be achieved by the alternative method.
F. Each layer shall be spread over the full width of the embankment.
G. Compaction shall proceed from outer edge progressing gradually towards the
centre.
1. Each succeeding pass shall uniformly overlap the previous pass.

2. Continue rolling until the entire thickness of each layer is thoroughly and
uniformly compacted to the specification requirements.
3. Each layer of rockfill shall be compacted by a vibrating roller with a minimum
of 6 passes.
H. The surface of the second layer shall be prepared in a manner approved by the
Employer. Ensure a smooth surface free from ruts, ridge is obtained according to
the proper cross section
nd
I. The whole surface of the 2 layer shall be carefully filled and compacted with
rd
sand from the 3 layer in order to fill all voids. The finished surface shall be hard,
smooth, free from lean patches, and be suitable for the operation of paving
equipment.
J. The average thickness of each individual layer shall not be less than the specified
thickness.
1. At any point the thickness shall not be less than 90% of the specified
thickness.
2. The finished surface of the rock fill at any point chosen by the Employer shall
be within ±20 mm.
K. The variation between two points on testing with a 3 mm straight edge shall be
within ±20 mm.
L. Sampling and testing shall be carried out at one location in each layer for every
750 m or part thereof, unless otherwise agreed by the Employer.
3.09 INSTALLATION OF PRECAST CONCRETE KERBS
A. Precast kerbs shall be set to the lines and grades as shown on the Drawings,
unless otherwise agreed with the Employer.
1. Under no circumstances will it be permitted for levels to be set by direct

measurement from pavement layers.
2. Any excavated surface for the concrete bedding shall be watered and
compacted to a minimum of 95% MDD.
3. Unless otherwise indicated, elements shall be laid either directly onto a wet
concrete base or on to a cement/sand (1:3) mortar bedding, 25 mm thick
placed on a previously laid concrete base on approved sub-grade.
4. Dimensions of the base and backing shall be as shown on the Drawings.
5. Concrete base shall be constructed with Grade 20 Concrete.
6. Unless otherwise indicated, after kerb units have been laid a continuous
backing of Grade 20 Concrete shall be poured for the elements using steel
forms.
7. No pavement layers shall be laid against kerbing until such time as the
backing is complete, back filled and approved by the Employer.
81
8. Joints between radius kerbs, shall have a width not greater than 4 mm and be
filled with a cement/sand (1:3 ratio) grout with 1/5 part hydrated lime and
sufficient water to make the mixture plastic and easily smoothed.
9. Bull noses and curved faces shall be of constant radius with the smooth
change from radius to plain face.
10. A grooving tool shall be used to produce a smooth, circular section groove
not more than 3 mm deep in all joints.
11. Grouted joints shall be cured by an approved method to the Employer’s
satisfaction.
12. Joints between straight kerbs shall have a width of 4 mm and be filled with
the above specified grout, unless otherwise directed by the Employer.
13. Immediately after any concrete is in place and for 7 days thereafter the kerbs,
base backing and mortared joints shall be fully cured and protected from
drying out and against the harmful effects of weather, including rain and rapid
temperature changes.
14. Method of protection shall be subject to the Employer’s approval.
15. Use of colored curing membranes will not be permitted.
16. Concrete not properly cured and protected will be rejected and shall be
removed from the works.
17. Expansion joints shall be placed as shown on the Drawings, unless otherwise
18. Every 9 meters (or as directed by the Employer) the joint between kerbs shall
be filled with an approved joint filler 10 mm thick. The filler shall extent
through the kerbs, bed, backing and channel and shall be trimmed to the
finished slope of the kerb and channel.
19. At access points the kerbs (including the bed backing) shall be dropped to
shown a face of 75 mm or as shown on the drawing.
20. At the end of any kerb run, the end element shall be sloped down to ground
level and angled away from the road at 30 degrees.
21. All kerbs shall be painted with approved materials to the satisfaction of the
Employer, unless otherwise agreed by the Employer. The pattern of the
painting and the Lower Tier Contractors (if any) shall be approved by the
Employer.
22. Krebs shall be level within a tolerance of ±3 mm at each end of the element,
to the designated lines and grades.
3.10 IN-SITU CONCRETE KERB LAYING
A. In-situ kerbs shall be laid to the lines and grades as shown on the drawings.
1. In-situ kerbs shall be laid by an approved automatic kerbing machine, unless

2. The kerbs shall be dense with regular sides, arises and chamfers and
finished to a fine surface free from blow holes.
3. The concrete used for the kerbs shall be grade C40 as shown in Section 3.2,
except as modified by the Employer.
4. Requirements of Section 3.2 for cast-in-place concrete shall be applied for
cast in-situ kerbs, unless otherwise approved by the Employer.
5. Kerbs shall be cut to form expansion and contraction joints as shown on the
drawings or as directed by the Employer.
6. The joints shall be filled with suitable compressible board or other suitable
material as approved by the Employer.
7. The maximum deviation of the top of the kerb under a straight edge shall be
not greater than 3 mm in 3 m.
8. The vertical alignment of the finished kerb shall not depart from the true level
more than ±6 mm at any point.
9. The horizontal alignment shall not depart from that shown on the drawing by
more than ±13 mm nor deviate from the straight by more than 3 mm in 3 m.
82
3.11 GRANULAR SUB-BASE
A. After the formation has been inspected and accepted by the Employer, granular
sub-base shall be placed, as shown on the drawings.
1. Material shall be delivered to the roadbed as a uniform mixture.

2. Shall be spread in layers.
3. Segregation shall be avoided.
4. Shall be free from pockets of coarse or fine materials.
5. Spread by finisher, or grader or other approved mechanical methods as
6. Watered, shaped to a compacted thickness not exceeding 150 mm and
compacted to the required grade and cross-section.
7. Compaction procedure and plant shall be to the satisfaction of the Employer.
a. At the time of compaction the moisture content of the laid material shall
not vary by more than + 2% of the optimum moisture content.
b. The grading of the placed materials shall be checked by taking samples
from an area 0.5 m x 0.5 m from the full depth of the layer for every 1000
3
m of material laid.
8. No road mixing of subbase shall be permitted.

9. Before using in the works subbase material shall be stockpiled in a manner to
prevent segregation.
B. Sub-base shall be compacted to not less than 98% of the maximum dry density
as determined in accordance with BS 1377: Part 4 : Method 3.6, unless otherwise
1. The surface on completion of compaction shall be well-closed, free from

movement under compaction plant and free from ridges cracks or loose
material.
2. Finished surfaces of the road sub-base shall not vary at any point more than
10 mm above or below the grade established by the drawings.
3. The surface shall be maintained in a condition satisfactory to receive any
subsequent base or surfacing material.
4. Any sub-base, which does not conform to the specified requirements shall be
reshaped, removed or reworked, watered and thoroughly re-compacted to
conform to the specified requirements.
5. At any stage in the mixing, transportation, spreading or compaction process
the Employer may instruct specified tests to be carried out.
6. An inspection request shall be sent to the Employer before proceeding with
the next operation.
3.12 AGGREGATE ROAD-BASE
A. Compaction Trials
1. If directed by the Employer, before the start of the aggregate road base
operations, the Contractor shall construct trial lengths as directed by the
Employer.
a. Materials used in the trials shall be those approved for use as aggregate
road-base.
b. Equipment and plant used shall be that according to the Contractor’s
approved detailed program of work
2. Trial lengths may not form part of the permanent works but may be permitted
in the construction of temporary detours of sufficient length.
83
3. Object of these trials is to determine:
a. Adequacy of the Contractor’s equipment.

b. Loose depth measurements necessary to determine suitable compacted
layers depths.
c. Field moisture content.
d. Relationship between the number of compaction passes and the resulting
density of the material.
4. Contractor may proceed with the aggregate road-base work only after the
methods and procedures established in the compaction trials have been
B. After the previous work has been inspected and accepted by the Employer,
approved road-base material shall be placed as shown on the drawings.
1. Road-base material shall be delivered to the road as a uniform mixture

complying with the specific requirements.
2. Method of mixing and laying of road base material shall be subject to the
approval of the Employer.
3. Layers shall not exceed 150 mm in compacted thickness.
4. Material shall be handled in a manner, which avoids segregation.
5. Segregated materials shall be remixed until uniformity is obtained.
6. Suitable precautions shall be taken to prevent rutting during the spreading.
7. No hauling or placement of material will be permitted when, in the judgment
of the Employer, the weather or road conditions are such that the hauling
operations will cause rutting or contamination of granular road-base material.
8. Road-base, which has been placed without approval of the Employer shall be
removed at the Contractor’s expense.
9. Moisture content of the aggregate road-base material shall be adjusted by
watering with approved sprinkler trucks or by drying out, to be within ±2% of
the OMC before compaction.
10. Road base shall be compacted to not less than 100% MDD by means of
approved compaction equipment progressing gradually from the outside of
the road towards the centre with each succeeding pass uniformly overlapping
the previous pass.
a. Rolling shall continue until entire thickness of each layer is thoroughly

and uniformly compacted to the specified density.
b. Rolling shall be accompanied by sufficient blading in a manner approved
by the Employer, to ensure a smooth surface free from ruts or ridges is
obtained with the proper section and crown.
11. Surface of the material shall on completion of compaction:
a. Be well closed.
b. Free from movement under the compaction plant.
c. Free from compaction planes, ridges, cracks, or loose material.
12. Any areas inaccessible to normal compaction equipment shall be compacted

by means of mechanical tampers, until satisfactory compaction is obtained.
13. The gradation of the placed material shall be checked by taking samples from
3
an area 0.5 m by 0.5 m from the full depth of the layer of every 1000 m of
laid material.
14. Contractor shall program his operations to avoid the drying out of the sub-
base during construction.
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a. At any stage in the mixing, transportation, spreading or compaction
process the Employer may instruct the Contractor to carry out the
specified tests.
b. If any layer of aggregate road-base material, or part thereof, is permitted
to dry out after compaction, or does not conform to the specified
requirements or finish, the Contractor shall, at his own expense, remove
water, rework or re-compact the material, as directed by the Employer,
before the next layer of aggregate road-base or subsequent pavement
layers are placed.
C. Finishing
1. Before the start of each activity, an inspection request shall be sent to the
Employer for inspection and tests.
2. Surface of the finished aggregate road base will be tested with a 3 m
straightedge by the Employer at selected locations.
a. Variations of the surface from the testing edge of the straight edge
between any two contacts with the surface shall at no point exceed 10
mm when placed on or parallel or perpendicular to the centerline of the
roadway.
b. Cross section as shown on the Drawings shall not vary by more than 10
mm from the required elevation.
a. All humps and depressions and thickness deficiencies exceeding the
specified tolerance shall be corrected by removing the defective work or
by adding new material as directed by the Employer.
b. Any work necessary to reshape the surface shall be at the Contractor’s
expense.
3.13 WET-MIX MACADAM
A. Compaction Trial.
1. Before the start of laying, a compaction trial shall be conducted with the
approved wet mix as directed by the Employer.
2. The objective of the trial is to determine:
a. Adequacy of Contractors equipment.

b. Loose depth measurements to necessary to obtain the specified
compacted layer thickness.
c. Field moisture content.
d. Relationship between the number of passes and the resulting density of
the material.
3. The Contractor may proceed with the wet-mix macadam work only after the
methods and procedures established in the compaction trials have been
B. After previous work has been inspected and accepted by the Employer, approved
wet-mix material shall be placed as shown on the drawings.
1. Wet-mix shall be mixed in a plant approved by the Employer.

2. Wet-mix material shall be delivered to the roadbed as a uniform mixture
complying the specification requirements.
a. The material shall be placed and spread evenly using a paving machine
or spreader box operated with a mechanism which levels off the material
at an even depth and without delay.
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b. The material shall be laid and compacted to a maximum thickness of 150
mm, unless otherwise agreed by the Employer.
c. Wet-mix material, which has been placed without the approval of the
Employer, shall be removed at the Contractors expense.
3. Material when mixed shall be removed at once from the mixer and
transported directly to the point where it is to be laid. Mixed material shall be
protected during transit and while awaiting tipping.
4. The moisture content of the wet-mix macadam at the time of laying shall be
within 1% of the optimum. Moisture content shall be determined according to
BS 1377: Part 2: Test 3.2
5. Compaction shall be completed as soon as possible after the material has
been spread.
6. Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints. Rolling shall continue until the entire
thickness of each layer is thoroughly and uniformly compacted to the
specified density.
7. The surface of any layers after compaction shall be:
a. Well closed
b. Free from movement under compaction plant
c. Free from compaction planes, ridges cracks or loose materials.
8. All defective areas shall be made good to the full thickness of the layer and
compacted to the specified density, unless otherwise approved by the
Employer.
9. If directed by the Employer, sieve analysis shall be carried out on the material
recovered from 5 consecutive field density tests or material collected from an
area 0.5 mm by 0.5 mm from the full depth of the layer as instructed by the
Employer.
10. If the results are not acceptable to the Employer the area shall be removed
and the source of material rejected until further notice. An oversize content of
up to 10% may be accepted by the Employer.
11. Immediately before placing the first layer of the next pavement course on the
wet-mix macadam the final layer of wet-mix macadam shall be at the
specified density and to the required grade and section.
12. The surface of the wet-mix macadam will be tested with a 3 m straight edge
by the Employer at selected locations.
a. The variations of the surface from the testing edge shall not exceed 10
mm at any point when placed on the centre line or perpendicular to
centre the line of the roadway.
b. The compacted thickness and cross sections shall be as shown on the
drawings and shall not vary by more than 10 mm from the required
elevation.
13. All defective work shall be repaired as directed by the Employer.

14. At any stage in the mixing, transportation or compaction process, the
Employer may instruct the Contractor to carry out the specified tests.
15. An inspection request shall be sent to the Employer before each subsequent
work.
16. The material shall be compacted to a field density equal to or greater than
100% of the MDD obtained when tested according to BS 1377: Part 4: Test 7.
In situ density shall be determined in accordance with BS 1377: Part 9: Test
2.2.
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3.14 PLACEMENT OF ASPHALTIC PAVING COURSE
A. Equipment
1. Method statement and equipment list shall be according to the type and
number outlined in the Contractor’s detailed Programmed of Work, as
approved by the Employer. The Contractor shall furnish to the Employer the
manufacturer’s technical data for each equipment and no equipment shall be
used without the approval of the Employer.
2. Trucks used for hauling bituminous mix shall have tight, clean, smooth metal
beds which have been coated with a minimal amount of paraffin oil, lime
solution, or other approved material to prevent the mix from adhering to the
beds. Excess release agent shall be drained from the bed before loading
bituminous materials.
3 Each vehicle shall be equipped with a canvas cover or other suitable material
of such size as to protect the mix from the weather and the trucks shall be
clearly numbered for easy identification.
4. The pavers shall be self propelled and equipped with hoppers and distributing
screws of the reversing type to place the mixture uniformly in front of the
electronic controlled screeds.
5. If during construction it is found that the spreading and finishing equipment in
operation leaves surface tracks in the pavement or indented areas or other
objectionable irregularities that are not satisfactorily corrected by scheduled
operations, the use of such equipment shall be discontinued and other
satisfactory spreading and finishing equipment shall be provided by the
Contractor.
6. Rolling equipment shall be self-propelled.
a. Wheels on the rollers shall be equipped with adjustable scrapers.

b. Rollers shall have water tanks and sprinkling apparatus, which shall be
used to keep the wheel wet and prevent the surface material from
sticking.
c. Rollers shall be of steel-wheel and pneumatic tyre type and shall be in
good condition.
d. Rollers shall be capable of reversing without backlash.
e. Rollers shall be operated at speeds slow enough to avoid displacement
of the bituminous mix.
f. Number and weight of rollers shall be sufficient to compact the mix to the
required density while it is still in a workable condition.
g. Use of equipment, which results in excessive crushing of the aggregate,
will not be permitted.
h. A minimum of three rollers, two steel-wheel and one pneumatic-tyre type,
shall be used with each spreading operation for each lane.
7. Contractor shall provide adequate back-up equipment for use in the event of
mechanical failure, all to the satisfaction of the Employer.
8. The Employer reserves the right to stop the use of any equipment or plant
deemed to be detrimental to the work required and instruct its removal and
replacement with suitable equipment.
9. The Contractor shall not be allowed to use any plant without the permission
of the Employer.
10. The Employer shall have the right to expel any operators, mechanics or labor
and to instruct suitable replacement thereof at any time he deems such action
is necessary.
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B. Surface Preparation
1. When the Bituminous Mix is placed on a prepared area, (whether or not a

prime coat is designated on the Drawings) the area shall be even and firm
and within the construction tolerances specified.
2. When the paving layer is constructed on an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust.
a. Any loose, broken or shattered bituminous material along the edges of

the existing surface shall be removed.
b. Any exposed sub-grade or shoulder adjacent to the edge of the existing
surface to receive the new bituminous mix shall be shaped, bladed,
compacted and broomed and primed to provide a uniform firm sub-grade
for the new surface course.
3. Existing bituminous surface, base, or sub-grade shall be removed if broken,

shattered, or unstable. Areas shall be excavated to a depth as directed by
the Employer, and refilled with the Bituminous Mix.
4. Before the placing of the mix, when designated on the Drawings or directed
by the Employer, a prime coat or tack coat shall be applied to the surface in
accordance with the Specification for Prime Coat or Tack Coat.
C. Placing of the mix
1. All bituminous mixes shall be introduced to the paver at a temperature not

less than 120°C for binder course and 130°C for surface course and not more
than 163° C. Mixes outside this temperature range shall be discarded.
2. Bituminous mix shall be spread and finished to crown and grade by
automatically controlled bituminous paves unless otherwise approved by the
Employer.
a. Bituminous mix may be spread and finished by hand methods only where
machine methods are impractical as determined by the Employer.
b. Paver shall lay the bituminous mix without tearing the surface and shall
strike a finish that is smooth, true to cross section, uniform in density and
texture and free from hollows, transverse corrugations or other
irregularities.
c. Paver shall be operated at a speed which will give the best results for the
type of paver being used and which co-ordinates satisfactorily with the
rate of delivery of the mix to the paver, to provide a uniform rate of
placement without intermittent operations of the paver.
3. Mix shall be delivered to the paver in time to permit completion of spreading,

finishing and compaction of the mix during daylight hours.
4. Longitudinal joints in successive layers shall be offset not less than 300 mm.
Width of surface or top course placements shall conform to traffic lane edges
as shown on the Drawings.
5. Leading half of half roadway paving shall not get ahead of the trailing half of
the pavement by more than one average full-day of paving.
a. In no case, shall the leading half be more than 500 m ahead of the
trailing half without the written permission of the Employer.
b. If the Contractor fails to comply with this requirement, the Employer may
suspend paving on the leading half until such time, as the Contractor
shall pave the trailing half to a point approximately even with the leading
half.
6. Unless otherwise directed by the Employer, where successive layers are to

be placed, the surface of the existing layer shall be swept clean with a power
88
broom, or by other means as approved by the Employer, and a tack coat
applied. Tack coat may not be required where:
a. Delay between laying subsequent courses is less than 48 hours.

b. Surface is fresh and clean at the discretion of the Employer.
7. Asphaltic concrete mixes (except leveling courses) shall be laid at an un-

compacted thickness such that after rolling, the thickness of the compacted
layer shall be:
a. Minimum 2.0 times the maximum aggregate particle size.

b. Maximum 4.0 times the maximum aggregate particle size.
8. Maximum thickness for layers may be increased slightly when such increase
is more adaptable to total pavement thickness and when in the opinion of the
Employer it is not detrimental to placement and rolling conditions.
9. Contractor shall erect and maintain an approved reference string line and
operate the paver to conform to the reference string line for the initial layer
and/or any other layers as directed.
a. Elevation control point stakes for the first layer of bituminous paving
course shall be set at a maximum spacing of 20 m.
b. For subsequent layers, control points shall be set at 10 m maximum
spacing.
D. Compaction of Bituminous Layers
1. After spreading and strike off, and as soon as the mix conditions permit the
rolling shall be performed without excessive shoving or tearing.
0
a. If the temperature of the joint falls below 120 C the material shall be
removed by approved methods to ensure the required compaction at the
joint.
b. Rolling procedure for each new job shall consider the following criteria.
1. Amplitude setting
2. Number of passes
3. Rolling speed
4. Rolling pattern
c. Each mixture shall be thoroughly and uniformly compacted.
2. Rolling will not be prolonged to an extent that cracks appear.
3. When rolling a thin lift use the following sequence.
a. Transverse joints.
b. Outside edge
c. Initial or breakdown rolling, beginning on the low side and progressing
towards the high side.
d. Intermediate rolling (as above)
e. Finish rolling.
f. When paving in echelon or abutting a previously placed lane or other
lateral restraint the mix should be rolled in the following sequence.
1. Transverse joint
2. Longitudinal points
3. Outside edge
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4. Initial or breakdown rolling, beginning on the low side and
progressing toward the high side.
5. Intermediate rolling (as above)
6. Finish rolling
4. When placing a thick lift, roll the mix in the following sequence.
a. Transverse joints
b. Initial or breakdown rolling, beginning edge 300-380 mm from the lower
unsupported edge and progressing toward the other edge.
c. When within 300 mm of an unsupported edge, the roller should advance
toward the edge in approximately 100 mm increments in successive
passes.
d. Intermediate rolling, beginning on the low side and progressing toward
the high side.
e. Finish rolling.
f. When placing thick lifts in echelon, when abutting a previously placed
lane or other lateral restraint, roll the mix in the following sequence.
1. Transverse joint
2. Longitudinal joint
3. Initial or breakdown rolling beginning at the longitudinal joint and
progressing towards the outside edge.
g. When within 300 mm of an unsupported edge, the roller should advance

toward the edge in approximately 100 mm increments in successive
passes.
5. When the transverse joint is made next to an adjoining lane.
a. Make the first pass with a static wheeled roller moving along the
longitudinal joint for a few feet.
b. Straighten the surface and make corrections if necessary.
c. Roll the joint transversely with all except about 150 mm of wheel width on
the previously laid material.
d. Repeat the above with successive passes each covering an additional
150 to 200 mm of the new mix until the entire width of a drive wheel is on
the new mix.
e. Unless precautions are taken, transverse rolling shall stop 150 to 200
mm short of the outside edge and the edge shall be compacted later
during the longitudinal rolling.
6. When the longitudinal joints are rolled with steel-wheeled or pneumatic tired
rollers.
a. Only 100 to 150 mm of the roller width should ride on the newly-placed
lane on the first pass.
b. The bulk of the width should ride on the previously compacted side of the
joint.
c. In subsequent passes, allow more and more roller width onto the fresh
material until the entire width is on the new mixture.
7. When longitudinal joints are rolled with vibratory rollers.
a. Extend the drums only 100 to 150 mm onto the previously compacted
lane with the rest of the drum width on the newly placed mixture.
b. Allow the roller to continue to move along this line until a thoroughly
compacted next joint is obtained.
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8. In echelon paving, the second paver and roller should keep as close as
possible to the first paver to ensure that uniform density is obtained across
the joint.
9. Except in echelon and thick paving, the edges of the pavement should be
rolled concurrently with the longitudinal joint and the roller wheel should
extent 50 to 100 mm beyond the pavement edge provided that lateral
displacement of the mix is not excessive.
10 Initial or breakdown rolling shall be done by means of either a tandem power

steel roller or three-wheel roller followed by a pneumatic-type roller or as
a. Rolling shall begin as soon as the mix will bear without undue
displacement.
b. Rolling shall be longitudinal, beginning at the low side of the spread of
material and proceeding toward the high side, overlapping on successive
passes by at least one half the width of the near wheels.
c. Alternate passes of the roller shall be of slightly different lengths.
d. On adjoining lanes the same rolling procedure should be followed after
compaction of the longitudinal joints.
11. Motion of the roller shall at all times be slow enough to avoid displacement of
the mix.
a. To prevent adhesion of the mix to the rollers, the wheels of the rollers
shall be kept properly moistened with water, an excess of water will not
be permitted.
b. Under no circumstances shall the use of diesel fuel or any other asphalt
stripping agent be used for preventing adhesion of the asphalt to the
roller wheels.
12. Intermediate rolling should follow breakdown rolling as closely as possible

while the mix is still above the minimum temperature at which compaction
can be achieved.
a. Intermediate rolling shall be continued until all the mix placed has been
compacted thoroughly.
b. Regardless of the type of rollers used, the rolling pattern shall be as
developed in the same manner as for breakdown rolling.
13. Finish rolling shall be accomplished with steel wheeled, static-weight

tandems or vibratory tandems without vibration while the material is still warm
enough to remove the roller marks. Follow the selected rolling procedure as
long as the surface appearance is good and the compaction results are
approved.
14. Determine the rolling speed and pattern as follows:

a. The normal speed is 5 to 7 km/h
b. On thin, hot layers the speed may be increased to 10 km/h
c. On thick and harsh mixes the speed may be reduced to 3 to 5 km/h.
d. Start by compacting the joints.
e. First transversal joints and then the longitudinal joints.
f. Roll the lowest edge before the highest.
g. Follow paver as closely as possible.
h. Run towards and backwards in the same rolling lane.
i. Change rolling lane only on compacted areas.
j. Run the second rolling lane parallel with the first lane up to the paver and
back till the entire paving width is rolled.
k. Reverse at another section than the adjacent rolling lanes.
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l. Turn off vibrations before reversing.
m. Change speed smoothly.
o
n. Never park the roller on the hot mix (more than 70 C).
o. Use a slow rolling speed and avoid making sharp turns in curves.
p. On steep grades rolling procedure may be changed as follows:
i. Reverse the roller so that the tiller wheel is in the direction of paving.
ii. Do not use pneumatic-tired rollers for initial breakdown.
iii. Operate static mode for initial rolling until stability is developed in the
mix to permit low amplitude vibration.
15. Initial or breakdown rolling shall be done by means of either a tandem power
steel roller or three-wheel roller followed by a pneumatic-type roller or as
16. Rollers shall be operated by competent and experienced roller men and shall
be kept in operation continuously if necessary, so that all parts of the
pavement will receive substantially equal compaction at the time desired.
The Employer will order the mixing plant to cease operation at any time
proper rolling is not being performed.
17. Any mix that becomes loose, broken, mixed with foreign material, or which is
in any way defective in finish or density, or which does not comply in other
respects with the requirements of the Specification shall be removed.
Replace with new materials, and finish in accordance with the Specifications.
18. When the asphalt mix is laid in inaccessible areas to rollers, compaction shall
be done with small hand operated plate vibrators.
19. Road Density requirements when compacted in Marshall moulds with 75

blows on each face:
a. Base course - Minimum 96%

b. Binder course - Minimum 96%
c. Wearing course - Minimum 97%, 98% for expressways, bridge
with their approaches for a distance of 200 m on each side, and all grade
intersections
d. Densities in excess of 101.5% shall not be permitted.
20. Compaction sampling and testing of bituminous courses
a. Density of the mix as placed and compacted on the road shall be

determined from cores cut from the compacted courses on the road at
locations specified by the Employer.
b. Samples shall be obtained in accordance with ASTM D979 in sets of two
from the same location on the road. Samples shall be obtained within 24
to 48 hrs after the time of laying, unless otherwise approved by the
Employer.
c. Frequency of testing shall be a minimum one set of samples per traffic
lane per 300 m per layer or minimum of one set per day for shorter
lengths.
d. Contractor shall cut the samples with an approved core drill in the
presence of the Employer.
e. Equipment shall be capable of cutting the material without shattering the
edges of the specimen.
f. Diameter of samples shall be:
1. Base course - 150 mm
2. Binder course - 100 mm
3. Wearing course - 100 mm
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g. All test holes shall be filled and made good with approved material by the
Contractor at his expense and to the satisfaction of the Employer.
h. Additional tests shall be taken as necessary to determine limits of areas
deficient in density, or for re-check.
i. The mean density of twin cores will be referred to as “Road Density”.
j. If the compacted asphalt yields in-situ air voids below 5% for more than
10 percent of the samples, this will be considered as an early indication
of a possible failure in the mix on deformation.
1. If this occurs, the mix shall be redesigned or rolling pattern modified

as directed by the Employer.
2. In-situ voids shall be calculated form the core specimen obtained to
determine the compaction.
E. Should any bituminous course fail to achieve the specified density, re-rolling may
be allowed by the Employer, subject to the following conditions:
1. Densification to be achieved shall be 1% or less.

2. Only PTRs to be used weighing no greater than 18 tons.
3. Re-rolling to take place within 72 hours from the time of the initial rolling of
the asphalt.
4. Re-rolling to take place at the time of the day when the asphalt has attained
its maximum natural temperature.
5. Re-rolling to be applied for a maximum of two hours.
6. Re-rolling to be carried out in the presence of the Employer’s representative.
7. Section of the works in question shall be cored for density determination
immediately after the completion of re-rolling and in the presence of the
Employer.
8. If after re-testing, the density achieved is 0.5% below the specified density,
the asphaltic material will be accepted in the works subject to a 20%
reduction to the billed rates. If, the density is greater than 0.5% below the
specified density, the asphaltic material shall be removed and new material
shall be laid at the Contractor’s cost.
F. Contact surfaces between the bituminous paving and of kerbing, gutters,

manholes, and other appurtenances shall be coated with a thin uniform tack coat.
G. Joints in bituminous paving
1. Joints between old and new pavement or between successive day’s work
shall be made, to ensure thorough and continuous bonding between the two.
2. All construction joints in previously laid material shall be constructed by
cutting the material back vertically for its full depth to expose a fresh surface.
3. Before placing the fresh mix against a cut joint or against old pavement, the
contact surface shall be sprayed or painted with a thin uniform tack coat.
4. Where a finishing machine is used, the longitudinal joint shall be made by
overlapping the screed on the previously laid material by at least 30 mm with
a sufficient amount of mix so that the joint formed will be smooth and tight.
5. Transverse joints in succeeding layers shall be off set a least 2.0 m.
H. Protection of compacted layer
1. Contractor shall protect all sections of newly compacted pavement from traffic
until they have hardened sufficiently to the approval of the Employer.
2. On heavily trafficked roads during the summer months a minimum period of 7
days shall elapse before the newly compacted pavement is trafficked.
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I. The Employer shall test the profile of the surface for each course of the various
asphalt paving courses to determine compliance.
1. If directed by the Employer, after completion of final rolling, the finished

surface shall be tested by the use of the rolling straight edge similar to the
type designed by the transport and road research laboratory. Testing shall
be along any line or lines parallel to the centre line on sections selected by
the Employer for compliance with the criteria of the following table.
TABLE 25
MAXIMUM PERMITTED NUMBER OF IRREGULARITIES
Surface of Carriage Ways
Irregularity (mm)
4 7
Test length (m) 300 75 300 75
Major Roads 20 9 2 1
Minor Roads 40 18 4 2
No irregularity exceeding 10 mm will be permitted.
2. When the total length of the pavement is less than 300 m, the measurements
shall be taken on 75 m lengths.
3. Pavements shall also be measured transversely for irregularities at points
directed by the Employer with a 4 m long straight-edge placed at right angles
to the centre line of the road. The maximum allowable difference between
the pavement surface and the straight edge shall be 3 mm.
4. A 4 m long straight edge will be used to test longitudinal surface regularity if.
a. The length is less than 75 m.
b. The use of traveling beam device is impracticable.
5. The maximum allowable difference between the pavement surface below the
straight edge 4 m long placed parallel with or at right angles to the centerline
of the road shall be:
a. For base course: 6 mm
b. Binder course: 6 mm
c. Wearing course: 3 mm
6. The surface levels of pavement courses shall be determined from the true
pavement surface which shall be the surface of the surface course or
calculated from the carriageway vertical profile and crossfalls as shown on
the Drawings. The vertical depth below the true pavement surface of any
point on the constructed surface of the formation or pavement courses shall
be within the appropriate tolerances stated in Table 26.
TABLE 26
Pavement Course Tolerance
Road Surface ±4 mm
Binder Course ±6 mm
Road base +8 mm –20 mm
Sub-base +10 mm –20 mm
J. Core Samples
1. Depth of each bituminous paving course shall be measured by cored

samples.
2. Contractor shall furnish and operate an approved core drill for cutting
samples from the compacted mix on the road.
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3. Cores extracted for thickness measurement may be used for density
determination. Density samples may be used for thickness measurements.
K. Tolerance in bituminous paving thickness
1. Thickness of the bituminous paving courses shall be determined in

accordance with ASTM D3549.
2. For the purpose of establishing an adjusted unit rate for bituminous paving
courses, units to be considered separately are defined as 300 m in each
traffic lane.
a. Last unit in each lane shall be 300 m plus the fractional part of 300 m
remaining.
b. Take at least three cores at random from each unit being sampled.
3. Other areas such as intersections, entrances, crossovers, ramps, etc. will be

considered as one unit.
a. Thickness of each unit shall be determined separately.

b. Small irregular unit areas may be included as part of another unit.
c. At such point as the Employer may select in each unit, one core shall be
taken for each 750 m² of bituminous paving course.
4. If the core so taken is deficient from the specified thickness by not more than
3 mm, then full payment will be made. If the core so taken is deficient from
the specified thickness by more than 3 mm, then two additional cores from
the area represented shall be taken. If deficient by more than 3 mm but less
than 10 mm or 15%, whichever is less, then the adjusted unit price as
provided in the Bill of Quantities will be made.
5. In calculating the average thickness of each bituminous paving course:
a. Measurements which are in excess of the specified thickness by more

than 3 mm will be considered as the specified thickness plus 3 mm.
b. Measurement which are less than specified thickness by 10 mm or 15%
(whichever is less), will not be included in the average.
6. If the core thickness is less than specified thickness by more than 10 mm or

15% whichever is less, determine actual thickness by taking additional cores
at not less than 3 m intervals parallel to the centre line in each direction from
the affected location until in each direction, a core is found which is not
deficient by more than 10 mm or 15% whichever is less.
7. Exploratory cores for deficient thickness may be used in average for adjusted
unit price.
L Where tolerances in this specification are exceeded the Contractor shall

determine the full extent of the areas which are out of tolerance and shall restore
the surface of the pavement.
1. If the surface of the formation level is too high, it shall be retimed and re-
compacted as specified. If the surface is too low, the deficiency shall be
corrected by the addition of suitable material of the same classification and
moisture content or other approved material laid and compacted to the
specification.
2. For sub-base, road bases or wet-mix at least the top 75 mm shall be
scarified, reshaped with the materials added or removed as necessary and
re-compacted all to this specification. The area treated shall be not less than
30 m long and 2 m wide or as determined by the Employer.
95
3. For base course, binder course and wearing courses the full depth of the
layer shall be removed and replaced with fresh material laid and compacted
to the specification as follows.
4. Where the number of surface irregularities exceeds the specified limits, the
area to be rectified shall be 300 m or 75 m long as appropriate and the full
width of the lanes affected or such lesser areas as determined by the
Employer.
5. When the base course, binder course or wearing course, is deficient in
thickness by more than 10 mm or 15% whichever is less the area to be
rectified shall be the full width of the paving lane or the full width of the area
affected in one operation and at least 5 m long for base course and binder
course or 15 m for wearing course, unless otherwise approved by the
Employer.
6. Testing of wearing course for compliance shall be carried out as soon as
practicable after completion of the surfacing and remedial works completed
before the road in opened for traffic.
M. Weather Limitations for Bituminous Paving Operations
1. Hot bituminous mix shall only be placed when:

2. The air temperature is 8° C or above.
3. The weather is not dusty, foggy or rainy.
4. The existing surface is free from moisture.
5. Bituminous mix shall not be placed during sand storms.
6. No paving operations shall be started if rain is imminent.
N. Application of Prime coat
1. Applied at a rate of not less than 0.7 liters/m² and not more than 1.5 liters/m²
or 0.8 to 1.2 kg/m2 Exact rate of application, which may be varied to suit field
conditions, will be determined by the Employer following trials to be carried
out by the Contractor.
2. Surface to be prime coated shall be uniformly smooth, slightly damp and firm
and true to the grades and cross sections shown on the Drawings within the
specified tolerances.
3. Prime coat shall not be placed on a soft, uneven base.
4. Any holes, depressions or irregularities shall be repaired by the removal of
loose and unsuitable material to the satisfaction of the Employer.
5. Replace with suitable material compacted to produce a dense, even surface
of uniform texture.
6. When required, the surface to be primed shall be lightly bladed and
compacted.
7. The Employer may instruct a light application of water to facilitate penetration.
8. Priming will not be permitted when the surface is excessively damp or
containing free water.
9. After cleaning operation and before the application of prime coat an
inspection request for the area to be coated shall be sent to the Employer.
10. If the surface contains loose material, dirt, clay or other objectionable matter,
such materials shall be removed from the surface with power broom, or
blower supplemented with hand brooms as directed by the Employer.
11. During application adjacent kerbs or other structures which are liable to be
disfigured by splashing of bitumen shall be protected as directed by the
Employer.
12. Items accidentally marred by prime coat shall be cleaned to the satisfaction of
the Employer.
13. No traffic shall be allowed to run over the primed surface until its curing
period is over.
14. An inspection request shall be forwarded to the Employer before the
application of the prime coat.
96
15. Prime coat shall not be applied:
a. When the ambient temperature is less than 13° C.
b. During rain, fog, dust storms or other unsuitable weather.
16. Application temperature for MC-70 liquid asphalt shall be between 50° C and
80° C as approved by the Employer.
17. Prime coat application:
a. Shall be applied to one lane of the carriageway width at a time.
b. When applied in two or more lanes there shall be a slight overlap along
adjoining edges.
c. Overlapping will not be permitted at transverse joints.
d. Thick paper shall be used to protect the previous application.
18. Traffic shall be kept off the prime coat until it has penetrated to a depth of 10
mm into the sub grade, road base or wet-mix and is fully cured.
19. Prime coat shall be left undistributed for a period at least 24 hours or as
otherwise directed by the Employer.
20. Contractor shall furnish and spread at his cost sufficient clean fine sand, of an
approved quality, to blot up areas, which show an excess of prime coat.
Excess sand shall be swept away before the placement of Bituminous
mixtures.
21. Primed surface shall be maintained in a good, clean condition at all times
until the next course is placed.
22. Any surface irregularities or holes in the primed surface, however caused,
shall be repaired and corrected to the Employer’s satisfaction.
23. If the prime coat becomes contaminated or losses its tacking properties, a
second coat of prime coat shall be applied at the Contractors expense if
24. If required by the Employer, the Contractor shall prepare a trial section by
applying prime coat on an approved area, to check the rate of application, as
O. Application of Tack Coat
1. Applied in quantities of not less than 0.25 liters/m² and not more than 0.40
liters/m².
2. Immediately before applying the tack coat, all loose material, dirt, clay or
other objectionable material, shall be removed from the surface with a power
broom or blower supplemented with hand brooms, as directed by the
Employer.
3. After the cleaning operation, and before the application of the tack coat, an
inspection of the area to be coated will be made by the Employer.
4. Application temperature for the tack shall be between 20° C and 60° C as
5. Tack coat shall not be applied when:
a. Ambient temperature is less than 13° C or during rain, fog, dust storms or
other unsuitable weather.
6. After application, the surface shall be allowed to dry to the proper condition of
tackiness to receive the following pavement course.
7. The tack coat shall be applied a short distance and not more than two hours
8. Tack coat shall be applied only so far in advance to pavement courses to
obtain the proper condition of tackiness.
9. Contractor shall protect the tack coat from damage during this period.
10. If the completed tack coat is damaged by rain or dust, it shall be allowed to
dry and shall be cleaned by power broom or blower.
11. If required by the Employer, an additional light application of tack coat shall
be applied.
12. No additional payment shall be made for this work.
13. Where, in the opinion of the Employer, a tack coat is not necessary, the
Contractor shall clear, at his expense the existing surface free of dust and
other deleterious material.
97
P. Application and heating equipment for liquid asphalt
1. A self-powered pressure distributor should be used for applying asphalt

mixture.
2. Distributor shall have pneumatic tyres of such width and number that the load
produced on the base surface shall not exceed 110 kg/cm of tyre width. Shall
be so designed and equipped as to distribute the bituminous material
uniformly at even heat on variable width of surface at readily determined and
controlled rates from 0.2 to 5.0 liters/m² with a pressure range of 1.25 to 5.2
2
kg/m .
3. The allowable variation from any specified rate shall not exceed 5%.
a. For normal use the spray bar of the distributor should be adjusted so that
the vertical axes of the nozzles are perpendicular to the roadway.
b. Nozzles should be set at an angle of 15 to 30 degrees of the horizontal
axis of the spray-bar.
c. Each nozzle should be set at the same angle.
d. The spray bar should be set high enough above the road way for the
surface to receive double coverage.
e. Allowable variation from any specified rate shall not exceed.
i. Transverse spread not more than 15%.

ii. Longitudinal spread not more than 10%.
f. Distributors and booster tanks shall be so maintained at all times that no

dripping of bituminous material will occur from any part of the equipment.
Q. Distribution equipment shall include:
1. Independently operated bitumen pump.

2. Pressure gauges and tachometer reading speed in m/minute.
3. Volume measuring devices.
4. Thermometer for reading the temperature of tank contents.
5. Hose attachment for applying bituminous material to spots unavoidably
missed by the distributor.
a. Distributor shall be equipped for circulation and agitation of the

bituminous material during the heating process.
b. Equipment for heating shall consist of steam coils and equipment for
producing steam, so designated that steam will not be introduced into the
material. In the event of storage tanks being used, an armored
thermometer with a range of 10 to 150°C shall be fixed to the tank so that
the temperature of the bituminous material may be determined at all
times.
c. Other heating facilities may be used subject to the approval of the
Employer.
R. Protection of adjacent structure from bitumen splashing.
1. When bituminous materials are being applied, the surface of all structures,
wheel guards, guard rail, kerbs and gutter, and other roadway appurtenances
shall be protected in an approved manner to prevent them from being
splattered with bituminous material or marred by equipment operation.
2. In the event that any appurtenances become splattered or marred, the
Contractor shall at his own expense, remove all traces of bituminous
materials. Repair all damage, and leave the appurtenances in an approved
condition.
98
3.15 APPLICATION OF ROAD MARKING MATERIALS
A. Road marking materials shall consist of the materials mentioned in Clause 2.18
as approved by the Employer. Application proceeding and testing requirements
shall be as mentioned in the Contractors approved method statement. Application
shall be by mobile sprayer either hand-propelled or self propelled.
B. The markings shall be white or yellow continuous or intermittent lines, letters,

figures arrows or symbols laid to the dimensions and as shown on the drawings
or as directed by the Employer.
C. Markings shall only be applied to surfaces, which are clean and dry free from
deleterious substances.
D. Where owing to the action of traffic or otherwise the pavement has become
polished before the application of road markings.
E. Markings shall be free from raggedness at their edges and shall be uniform and
free from streaks.
F. Carriage way lane and edge lines shall be laid by approved mechanical means to
a regular alignment.
G. Where markings are to be reflectorized with balloting it shall be screed or spray

applied uniformly on to the wet paint film at a rate of 400 to 500 g/m².
H. The Contractor shall control the traffic in such a manner as to protect the freshly
marked surface from damage.
I. The traffic control shall be so arranged as to give.

1. Minimum interference to the traveling public.
2. Signs, barricades, flagmen and control devices shall be supplied by the
Contractor.
3. A system of spaced warning flags or blocks shall be used to protect the fresh
marking until it has dried if so required.
J. Any lines, stripes or markings, which became blurred or smeared by the traffic
shall be corrected by the Contractor at his own expense.
K. If Thermoplastic material is used

1. The Contractor shall state the maximum safe heating temperature.
2. The temperature range of apparatus.
3. The method of laying to be used.
4. A tack coat compatible with the marking material shall be applied in
accordance with the manufacturer’s instructions before the application of the
material unless otherwise directed by the Employer.
5. The thickness shall be minimum 1.5 mm ±0.3 mm or as agreed by the
Employer.
L. If Road Marking paint is used.

1. It shall be applied by brush or mechanical means in areas as approved by the
Employer.
2. The paint shall be supplied fresh and ready for use in sealed manufacture’s
containers.
3. The paint shall be applied without the use of thinners or other additives
unless otherwise stated by the manufacturer.
4. The coverage rate shall be as recommended by the manufacturer and as
99
3.16 ERECTION OF SIGNS
A. Sign shall be erected in accordance with the recommendation in the Traffic Signs
Manual, Chapter 13.
1. All foundations, framing and fixing for traffic signs shall be suitable for local
conditions.
2. Calculations showing the design and erection procedures shall be submitted
to the Employer for approval.
3. The design wind speed shall be taken as 120 km/hour with gusts up to 160
km/hour.
B. Approximate position and mounting height of each sign shall be as indicated on

the Drawings.
C. The exact sign position and mounting heights shall be determined on site and as
D. In order to avoid secular reflections from the sign plates, signs which are
approached along a straight length of road or a right hand bend shall be set at an
angle of:
0
1. 85 measured clock wise from the near side edge of the carriage way.
0
2. 95 measured anti-clock wise from the near side edge of the carriage way.
E. Signs sited on lift hand bends shall be set at 90 degrees to the tangent at that
point.
F. The reference number of the sign and date of manufacture shall be indicated by
self-adhesive numbers on the reverse side of the sign in the bottom left hand
corner and in a consistent and readily visible position on all posts and fittings.
1. The manufactures name and trademark shall not be permitted on the face of
the sign.
2. Sizes and color of the markings shall be as approved by the Employer.
3. All signs shall be capable of giving a service life of at least 10 years.
3.17 FOOTPATHS
A. Footpaths shall be constructed as shown on the drawings, unless otherwise

B. The subgrade material shall conform to the requirements of this Section and shall
be compacted to 90% of the MDD.
C. The sub-base shall comply with the requirements of this Section and shall have a
CBR value of not less than 65% and shall be compacted to 95% of the MDD
before the placing of bedding sand.
D. The interlocking blocks shall be 60 mm thick, unless noted otherwise. The choice
of color and pattern shall be as directed by the Employer.
E. The kerbstones or edging to the areas to be paved shall be laid in advance of

paving operations.
F. Paving blocks shall be placed as specified in this Section.
100
3.18 INSTALLATION OF CONCRETE PAVING BLOCKS
A. Before starting work, lay out lines marking the blocks area be paved and
establish grade elevation and slope of finished pavement surface.
B. The area to receive laying course shall be free from foreign materials, cut or soft
spots and the level shall be correct. Any defects shall be corrected by replacing
unsuitable material or as necessary.
C. Edge restraint shall be fixed as shown on the drawings before laying operations.
D. Interlocking paving blocks shall be laid on a sand bedding (laying course) of 50

mm thickness (after compaction) in such manner as not to disturb the blocks
already laid.
1. The manner of laying shall ensure that the blocks avoid to disturbing the sand
cushion until the unit is in correct position.
2. Under no circumstance shall the sand cushion be compacted or walked upon
after it has been screeded.
3. Each block shall be placed firmly against its neighbor so that they fit closely
together.
4. Joints between blocks shall be between 2 to 4 mm.
5. Laying of the concrete paving blocks shall start at right angles to the main
pavement axis starting at one end of the area.
6. Paving blocks shall be laid in a herringbone pattern at 45° to the main
pavement axis, unless otherwise shown on the Drawings or otherwise
instructed by the Employer.
E. Where gaps are less than 40 mm dimension, they shall be filled with a 1:3
cement sand mortar or other suitable material acceptable to the Employer.
F. Where blocks do not fit the edge restraints or other obstructions such as
manholes or up-stands the gaps shall be filled using cut blocks.
G. Blocks shall be cut using only a mechanical block splitter.
H. Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall

be checked after laying the first three rows of blocks and thereafter at regular
intervals. If joints begin to open, the blocks shall be knocked together using a
rubber or wooden mallet.
2
I. After each 15-20 m area has been laid, the blocks shall be vibrated with a plate
vibrator having a frequency of 75-100Hz.
1. For 60 mm thick blocks the vibrator shall have a centrifugal force of 7 to 16

2
kN and a plate area of 0.2 to 0.4 m
2. For 80 mm thick blocks the vibrator shall have centrifugal force of 16 to 20 kN
2
and a plate area of 0.35 to 0.5 m
J. A minimum of two passes of the plate vibrator shall be made in each direction,
i.e. at 90 degrees to each other.
1. Vibration shall continue until no further compaction of the sand layer is

apparent.
2. Laying course shall have a compacted thickness of 50 m.
3. After block surfacing has been compacted dry jointing sand shall be spread
over the surface and brushed into the joints.
101
4. If necessary the joint sand shall be filled again and further passes of the plate
vibrator shall be made in each direction, until the sand is no longer absorbed
into the joints.
5. The plate vibrator shall not pass closer than 1 m to a temporarily unrestrained
edge during laying.
6. No paving shall be left in an un-compacted condition overnight, except for the
1 m strip at the temporarily unrestrained edge.
K. On completion, the finished surface level, shall be within 5 mm of the design

level.
1. Maximum deviation within the compacted surface, measured by a 3 m

straight edge shall not exceed 3 mm.
2. Level of any two adjacent blocks shall not differ by more than 1 mm.
3. Any areas of paving which do not comply with these tolerances shall be
removed and replaced. Adjust the sand laying course and re-lay the paving
blocks to the correct levels.
L. After all the joints are filled surplus sand shall be swept away.
3.19 LIFTING AND RELAYING CONCRETE BLOCK PAVING
A. This clause covers the lifting, removal, temporary storage and reinstatement of
concrete block paving for work on buried services or other reasons.
1. The minimum necessary area of block to be removed shall be agreed with

the Employer before beginning work.
2. The Contractor shall carefully remove the concrete blocks, clean (chisel off
any mortar or hardened sand) the exposed faces, protect, load, transport and
unload the sound and unbroken blocks at locations designated by the
Employer.
3. The Contractor shall remove the concrete blocks by hand so as to preserve
the blocks. Any damaged blocks shall be replaced by the Contractor.
4. The Contractor shall cart away and dispose of the remainder of the blocks to
a location designated by the Employer.
5. The Contractor shall break and remove the mortar or any concrete base laid
below the blocks as directed by the Employer. The Contractor shall cart
away to the designated location mortar or any concrete base laid below the
blocks.
6. Before beginning relaying of blocks, the Contractor shall agree with the
Employer the location where any new blocks are to be placed to minimize
negative aesthetic impacts due to color difference.
7. Additional or substitute pattern, if needed, can be used for laying blocks only
after a written approval from the Employer is obtained.
8. The reinstatement of the blocks shall be in accordance with Clause 3.18.
9. Blocks re-laid against existing blocks shall be placed slightly higher to
accommodate any consolidation or settlement. This level difference shall be
agreed with the Employer after initial laying trials.
10. The Contractor shall supply new bedding sand for the laying of the blocks.
The use of the old bedding sand will only be permitted if approved by the
Employer and only after the Contractor has carried out tests as per the
requirements of this Specification.
102
3.20 TRENCH EXCAVATION AND REINSTATEMENT IN ROADS
A. This Section covers the reinstatement of pavement cut and removed for laying
pipes.
B. The area to be rectified shall be the full width of the paving laid or the full width of
the areas affected in one operation and at least 5 m long for base and binder
course, 15 m for wearing course or 15 m for base binder and wearing course
C. Where open excavation is allowed, all trench excavation and other work carried
out within the limits of any existing road, highway or paved parking area shall be
completed as rapidly as possible, subject to approval of the Employer.
1. If the roads are capable of carrying two or more lanes of traffic, not more than
half of the width of the carriage way shall be obstructed at any one time.
2. In single-lane roads, the Contractor shall program his work in such a manner
that minimum inconvenience is caused to those persons who have
reasonable grounds for using the road and in the case of private or restricted
roads, who have authority to use them.
3. Contractor will not be permitted to excavate trenches in more than one
location in any one road at a given time without the Employer's permission.
D. If in the opinion of the Employer, the amount of traffic using a road which is to be
completely or partially obstructed by the works is sufficiently great, the Contractor
shall provide a suitable system of traffic control to be approved by the Employer.
1. Any such system of control shall require appropriate warning signs, lights and
barricades at the approaches to sections of the road in which, or adjacent to
which, work is being executed. These signs shall be removed immediately
upon removal of the dangers for which they provide a warning against.
2. If the Contractor wishes to completely obstruct any road for any significant
period of time, he shall apply to the Employer for permission to do so.
Obstruction of the road shall not begin until the Contractor receives the
Employer's permission in writing. Such permission will not, in general, be
granted for roads which have more than one traffic lane or for those sections
of roads for which satisfactory alternative routes exist.
3. Costs incurred by the Contractor in respect to all aspects of work in roads,
including maintaining access past the works, the provision of a traffic control
system and warning signs and the like shall be included in the rates for
excavation and pipe laying.
4. If permission to close any road to traffic cannot be obtained the Employer will
not be liable to pay any compensation to the Contractor.
E. Trench excavation parallel to roads will normally be located in the service

reserves adjacent to the road, rather than in the carriage way itself.
1. Trench excavation shall wherever practicable be carried out in such a way

that every part of the excavation is at least 1 m clear of the existing edge of
the carriageway.
2. 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 completed, to ensure
that there is no disturbance of the adjacent road or road foundation.
F. The Employer may direct the trench excavation to be realigned from that shown
on the Drawings in order to avoid interference with existing utilities and structures
or to facilitate smooth traffic flow.
103
G. Where trench excavation or any other part of the works obstructs any footpath or
right-of-way, the Contractor shall provide, at his own cost, a temporary footpath
around the obstruction to the satisfaction of the Employer. Where necessary, the
temporary footpath shall include bridges of wooden planks or other approved
construction.
H. Where excavated material has temporarily been deposited on a landscaped area,

the area shall on completion of backfill be restored entirely to its original condition
and left free from loose stones.
I. Road drains and channels shall be kept free from obstruction at all times.
J. All material placed in the trench within paved roadways and parking areas shall
be approved wadi gravel or road base material enclosed in geotextile compliant
with Section 2.4 and as approved by the Employer.
K. The road surface shall be reinstated to its original condition by the Contractor.
L. Excavation, backfilling and paving shall be as follows:
1. Where trenches are open cut in asphalt or concrete roads, the roads shall be
saw cut along the edges of the trench, before excavation.
a. Care shall be taken to avoid disturbing underlying layers of materials and

any damage shall be restored to the satisfaction of the Employer.
b. If in the opinion of the Employer, any material is unsuitable, the material shall be
removed to such a depth and over such area as the Employer shall direct. The
material shall be disposed by the Contractor. All voids resulting from such
excavation and removal shall be replaced with suitable material and compacted
as specified herein.
c. The final surface reinstated from an open cut shall be completed true to line,
level and to the required density as specified herein.
2. Cut the pavement to solid material with pneumatic asphalt cutting tools.
a. Make the cut square or rectangular with faces straight and vertical.
b. One pair of faces shall be cut at right angles to the direction of traffic.
c. Vertical faces may be stepped if allowed by the Employer.
3. Remove the cut pavement and excavate the under lying layer to a depth of
minimum 300 mm or as required. Cart away and dispose all pavement and
excavated soil at a location designated by the Employer.
4. Thoroughly compact the sub soil with mechanical compactor to 98% of the
MDD.
5. Pipes below roads shall be surrounded in concrete, unless otherwise directed
by the Employer.
6. Fill the excavation with approved wadi gravel compliant with the requirements
for sub-base or road-base material as approved by the Employer.
a. The material shall be premixed to the optimum moisture content before

placement.
b. Loose layer thickness shall not be greater than 150 mm.
c. Compact each layer to minimum 98% of the MDD in accordance with the
Standard procedures as described herein.
7. In some cases road base material may be required above the wadi gravel
and shall be compacted to 100% MDD.
8. Clean the edges of the pavement with a wire brush and apply tack coat.
104
9. Apply a light coat of prime coat on the surface of the wadi gravel or road base
material as directed by the Employer.
10. Place and compact approved base, course binder or wearing course as
applicable in 50 mm layers to the same level as the adjacent surface.
11. Compact the lower layers with a vibratory compactor.
a. Compact the top layer with a steel wheel roller by first compacting the
hot-mix bituminous layer 150 mm from the two traffic edges and then by
rolling in the direction of traffic.
b. The drive wheel of the roller shall be in a forward position.
c. Use of asphalt pavement finisher shall depend on the area to be repaired
and shall be used if directed by the Employer.
12. Check levels of the repair with a straight edge and correct as required.
M. All material placed in the trench within paved roadways and parking areas shall
be approved wadi gravel or road base material enclosed in geotextile compliant
with Section 2.4 and as approved by the Employer.
N. The road surface shall be reinstated to its original condition by the Contractor.
O. If the pavement has depressed but the asphalt has not fractured repair the
pavement as follows, unless otherwise agreed by the Employer.
1. Cold plane and remove the upper 50 mm of the pavement starting just back
form the depression.
2. Cart away and dispose the removed pavement at a location designated by
the Employer.
3. Clean the surface with a wire broom and apply a light tack coat
2
(approximately 0.2 l/m ) on the surface and the cut faces.
4. Fill the cut with approved base, binder or wearing course as applicable.
5. Initially compact the hot bituminous mix by a steel wheeled roller 150 mm
form two traffic edges and then by rolling in the direction of traffic. The drive
wheel of the roller shall be in the forward position.
6. Check the level of the repair with a straight edge and correct as necessary.
P. Minimum Test Frequency

3
1. One sample every 750 m shall be tested.
2. Two in-situ density tests shall be taken from each trench on each layer.
END OF SECTION
105
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106
DIVISION 3
CONCRETE
107
SECTION 3.1 GENERAL
1.01 SUMMARY
A. Section Includes: Cast-in-place concrete, including formwork, reinforcing, mix

design, placement procedures, and finishes.
B. Related Sections: Refer to the following sections for related work:
1. Part 5, “Earthwork.”
2. Part 7, “Structural Steel.”
3. Part 9, “Joint Sealants.”
1.02 REFERENCES
Product manufacture, testing and installation shall comply with the following
references unless otherwise stated otherwise approved by the Employer.
The initials IQS followed by a number refers to the Iraqi Organization Standard of that
number. Where IQS exists, it shall be given priority in application. Tests not covered
by IQS shall be carried out according to BS or ASTM.
The initials B.S. followed by a number refers to the British Standard of that number.
The initials A.A.S.H.T.O. followed by a number refers to the American Association of

State Highways and Transportation Officials publication of that number.
The initials A.C.I followed by a number refers to the American Concrete Institute
publication of that number.
The initials A.S.T.M. followed by a number refers to the American Society for Testing
and Materials publication of that number.
1. IQS 5 Specification for Ordinary Portland Cement

2. IQS 6 Specification for Sulphate Resisting Cement
3. IQS 45 Specification for Aggregates from Natural Source for Concrete
4. IQS 1703 Specification for Water used in Concrete
5. ASTM A615 Specification for Deformed and Plain Billet-Steel Bars for concrete
Reinforcement
6. ASTM C31 Standard Practice for Making and Curing Concrete Test Specimens
in the Field
7. ASTM C33 Specification for concrete Aggregates
8. ASTM C39 Standard Test Method for Compressive Strength of Cylindrical
Concrete Specimens
9. ASTM C40 Test Method for Organic Impurities in Fine Aggregates for Concrete
10. ASTM C42 Obtaining and Testing Drilled Cores and Sawed Beams of Concrete
11. ASTM C88 Test Method for Soundness of Aggregates by Use of Sodium
Sulphate or Magnesium Sulphate
12. ASTM C94 Specification for Ready-Mixed Concrete
13. ASTM C109 Test method for Compressive Strength of Hydraulic Cement
Mortars (Using 2inch or 50 mm specimen specimens)
14. ASTM C123 Test Method for Lightweight Pieces in Aggregate
15. ASTM C127 Test Method for Specific Gravity and Absorption of Coarse
Aggregate
16. ASTM C128 Test Method for Specific Gravity and Absorption of Fine Aggregate
17. ASTM C131 Test Method for Resistance to Degradation of Small Size Coarse
108
Aggregate by Abrasion and impact in the Los Angeles Machine
18. ASTM C138 Test Method for Unit Weight, Yield and Air Content (Gravimetric) of
Concrete
19. ASTM C142 Test Method for Clay Lumps and Friable Particles in Aggregates
20. ASTM C143 Test Method for Slump of Hydraulic Cement Concrete
21. ASTM C150 Specification for Portland Cement
22. ASTM C157 Test method for Length Change of Hardened Hydraulic – Cement
Mortar and Concrete
23. ASTM C171 Specification for Sheet Materials for Curing Concrete.
24. ASTM C172 Practice for Sampling Freshly Mixed Concrete
25. ASTM C191 Test Method for Time of Setting of Hydraulic Cement by Vicat
Needle
26. ASTM C192 Practice for Making and Curing Concrete Test Specimens in the
Laboratory
27. ASTM C227 Test Method for Potential Alkali Reactivity of Cement-Aggregate
Combinations (Mortar-Bar Method).
28. ASTM C232 Test Methods for Bleeding of Concrete
29. ASTM C260 Specification for Air-Entraining Admixtures for Concrete
30. ASTM C289 Test Method for Potential Alkali-Silica Reactivity of Aggregates
(Chemical Method)
31. ASTM C309 Specification for Liquid Membrane-Forming Compounds for Curing
Concrete
32. ASTM C330 Specification for Lightweight Aggregates for Structural Concrete
33. ASTM C494 Specification for Chemical Admixtures for Concrete
34. ASTM C495 Test Method for Compressive Strength of Lightweight Insulating
Concrete
35. ASTM C511 Specification for Moist Cabinets, Moist Rooms and Water Storage
Tanks Used in the Testing of Hydraulic Cements and Concretes
36. ASTM C513 Test Method for Obtaining and Testing Specimens of Hardened
Lightweight Insulating Concrete for Compressive Strength
37. ASTM C535 Test Method for Resistance Degradation of large- Size Aggregates
by Abrasion and Impact in the Los Angles Machine.
38. ASTM C796 Test Method for Foaming Agents for Use in Producing Cellular
Concrete Using Preformed Foam
39. ASTM C869 Terminology Relating to Clay Products
40. ASTM C1017 Specification for Chemical Admixtures for Use in Producing Flowing
Concrete
41. ASTM C1064 Test Method for Temperature of Freshly Mixed Portland Cement
Concrete
42. ASTM C1202 Test Method For Electrical Indication of Concrete’s Ability to Resist
Chloride Ion Penetration
43. ASTM C1240 Specification for Silica Fume for use in Hydraulic – Cement
Concrete and Mortar
44. ASTM D512 Test Methods for Chloride in Water
45. ASTM D513 Test Methods for Total and Dissolved Carbon Dioxide in Water
46. ASTM D516 Test Method for Sulphate Ion in Water
47. ASTM D1888 Test Method for Particulate and dissolved Matter, Solids, or
Residue in Water
48. ASTM D2419 Test Method for Sand Equivalent Value of Soils and Fine
Aggregate.
49. ACI 224.3 Joints in Concrete Construction
50. ACI 302 Guide for Concrete Floor and Slab Construction
51. ACI 305 Hot Weather Concreting
52. ACI 3042-2R Placing Concrete by Pumping Methods
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53. ACI 308 Standard Practice for Curing Concrete
54. ACI 318 Building Code Requirements for Structural Concrete
55. ACI 350.1 Tightness Testing of Environmental Engineering Concrete
Structures
56. BS 12 Portland cement
57. BS 812 Testing aggregates
58. BS 882 Aggregates from natural sources for concrete
59. BS 1881 Methods of testing concrete
60. BS 3148 Water for making concrete (including notes on the suitability of the
water)
61. BS 4027 Sulphate-resisting Portland cement
62. BS 4408 Recommendations for non-destructive methods of test for concrete
63. BS 4449 Specification for Carbon Steel Bars for the Reinforcement for
Concrete
64. BS 4466 Specification for Bending Dimension and Scheduling and
Reinforcement for Concrete
65. BS 4482 Cold reduced steel wire for the reinforcement of concrete
66. BS 4550 Methods of testing cement
67. BS 5075 Concrete admixtures
68. BS 5080 Methods of Test for Structural Typing in Concrete and Masonry.
69. BS 5328 Part 1 Guide to specifying concrete
70. BS 5328 Part 2 Methods for specifying concrete mixers
71. BS 5328 Part 3 Specification for the procedures to be used in producing and
transporting concrete
72. BS 5328 Part 4 Specification for the procedures to be used in sampling, testing and
assessing compliance of concrete
73. BS 206-1 Specification, performance, production and conformity
74. BS 5606 Accuracy in building
75. BS 5975 Code of practice for false work
76. BS 6089 Assessment of concrete strength in existing structures
77. BS 6093 Design of joints and jointing in building construction
78. BS 6100 Glossary of building and Civil Engineering terms
79. BS 6699 Ground Granulated Blast furnace Slag
80. BS 7542 Method of test for curing compounds for concrete
81. BS 8007 Design of concrete structures for retaining aqueous liquids
82. BS 8110 Structural use of concrete
83. BS 8500 Concrete complementary British Standard to BS EN 206-1
84. BS 12350 Testing fresh concrete
85. BS 12390 Testing hardened concrete
86. CSTR No.11 Concrete Society Technical Report No. 11
87. DIN 1048 Test methods for concrete
88. ISO 9000 Quality management and quality assurance standards
89. EFNARC Specification and Guidelines for Self-Compacting Concrete.
November 2001
1.03 DEFINITIONS
1. “Cementitious Materials” shall mean cement or cement plus GGBS or a blend

of cement, GGBS and MS.
2. “Water/Cement Ratio” shall mean the ratio between the total weight of water
in the concrete (less the water absorbed by the aggregate) and the weight of
cement (or cementitious materials), expressed as a decimal fraction.
110
3. “Admixtures” shall mean a material other than water, aggregate, cementitious
materials or fiber reinforcement, used as an ingredient of concrete or mortar.
0
4. “Hot Weather” shall mean when the shade temperature is above 40 C on a
0
rising thermometer or 43 C on a falling thermometer.
5. “Coarse Aggregate” shall be considered as that size passing a 28mm sieve
and predominately retained on a 5 mm sieve.
6. “Fine Aggregate” shall be considered as that size predominately passing a 5
mm sieve and predominately retained on a 0.075 mm size.
7. “OPC” shall mean ordinary Portland cement.
8. “SRC” shall mean sulphate resisting Portland cement.
9. “MSRC” shall mean moderate sulphate resisting Portland cement.
10. “GGBS” or “GBS” shall mean ground granulated blastfurnace slag.
11. “MS” shall mean Micro-Silica.
12. “GMS” shall mean a blend of GGBS and MS.
13. “Gap-graded aggregate” shall mean graded aggregate without one or more of
the intermediate sizes.
14. “Single-size aggregate” shall mean aggregates containing a major proportion
of particles of one size.
15. “Characteristic Strength” shall mean that value of strength below which no
more than 5% of the strength measurements are expected to fall.
16. “Target Mean Strength” shall mean the specified strength plus the margin.
17. “Margin” shall mean the difference between the specified strength and the
target mean strength.
18. “Acceptable or Accepted” shall mean acceptable or accepted by the
Employer.
19. “Approval or Approved” shall mean approval from the Contractor or approved
by the Employer.
20. “All-in” aggregate shall mean the materials composed of a mixture of coarse
aggregate and fine aggregate.
21. “Compressive Strength Test Results” shall mean the average of 3 specimens
sampled from the same load and tested at the designated day.
22. “Grade” shall mean numerical value of 28 days characteristic compressive
strength.
23. “Ready Mixed Concrete” shall mean concrete mixed in a stationary mixer and
supplied in the fresh condition to the purchaser either at the site or in the
purchaser’s vehicle.
24. “Self Compacting Concrete” (SCC) shall mean fresh concrete, which is able
to flow under its own weight (without the need of any vibration) and
completely fill the formwork even in the presence of congested reinforcement
whilst maintaining homogeneity.
25. “Annulus Grout” shall mean concrete made with or without aggregate
additions to Portland cement, water and air entraining agents to create a free
flowing grout used for filling the annulus of casing pipes in tunneling works.
26. “Batch” shall mean the quantity of concrete mixed in one cycle of operation in
a stationary batch mixer.
27. “Load” shall mean one or more batches discharged into a truck.
28. “Time of Loading” shall mean the time of first contact between cement and
aggregates or, when the aggregates are surface dry, between cement and
added water.
1.04 SUBMMETALS
A. General: Submit the following items in accordance with the Conditions of

Contract and Part 4.4, “Submittal Procedures.”
B. Product Data: Submit product data for the following materials and items.
1. Reinforcement
2. Forming Accessories
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3. Admixtures
4. Patching Compounds
5. Hardener
6. Joint Systems
7. Curing Compounds
8. Sealants
C. Shop Drawings: Submit detailed shop drawings for fabrication, bending and
placement of concrete reinforcement.
1. Show bar schedules, stirrup spacing, diagrams of bent bars and

arrangement of reinforcement including bar overlap.
2. Include special reinforcement required for openings through concrete
structures.
D. Laboratory Test Reports: Submit concrete materials test reports and mix
design reports certifying that each material or item complies with or exceeds
the specified requirements.
1.05 FIELD QUALITY CONTROL
A. Testing and Inspecting: The Contractor must submit their Company’s Quality
Control Plan for the approval by Engineer. Alternatively an approved qualified
testing and inspecting agency shall be appointed by the contractor to perform
field tests and inspections and prepare test reports.
B. Testing and Inspecting: Engage a qualified testing and inspecting agency to

perform tests and inspections and to submit reports.
C. Inspections:
1. Steel reinforcement placement.

2. Steel reinforcement welding (If applicable).
3. Headed bolts and studs.
4. Verification of use of required design mixture.
5. Concrete placement, including conveying and depositing.
6. Curing procedures and maintenance of curing temperature.
7. Verification of concrete strength before removal of shores and forms from
beams and slabs.
D. Concrete Tests: Testing shall be in accordance with requirements of BS 12350

& BS 12390.
1. Slump: ASTM C143; one test for each concrete load at point of discharge
and one for each set of compressive strength test specimens.
2. Air Content: ASTM C231; pressure method; one for each set of
compressive strength specimens.
3. Concrete Temperature: ASTM C 1064/C 1064M; one test hourly when air
temperature is 40 deg F (4.4 deg C) and below and when 80 deg F (27 deg
C) and above, and one test for each composite sample.
4. Unit Weight: ASTM C 567, fresh unit weight of structural lightweight
concrete; one test for each composite sample, but not less than one test for
each day's pour of each Concrete Mix.
5. Compression Test Specimens: BS 12350.
a. Cast and laboratory cure two sets of three standard cube specimens
for each composite sample.
b. Cast and field cure two sets of three standard cube specimens for each
composite sample.
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6. Compressive Strength Tests: BS 12390-3:2002 test one set of three
laboratory-cured specimens at 7 days and one set of two specimens at 28
days.
a. Test one set of three field-cured specimens at 7 days and one set of
three specimens at 28 days.
b. A compressive strength test shall be the average compressive strength
from a set of three specimens obtained from same composite sample
and tested at age indicated.
7. When strength of field-cured cylinders or cubes is less than 85 percent of

companion laboratory-cured cylinders or cubes. Contractor shall evaluate
operations and provide corrective procedures for protecting and curing in-
place concrete.
8. Strength of each Concrete Mix will be satisfactory if every average of any

three consecutive compressive-strength tests equals or exceeds specified
compressive strength and no compressive-strength test value falls below
specified compressive strength by more than 500 psi (3.4 MPa).
9. Test results shall be reported in writing to Engineer, concrete manufacturer,

and Contractor within 48 hours of testing. Reports of compressive-strength
tests shall contain Project identification name and number, date of concrete
placement, name of concrete testing and inspecting agency, location of
concrete batch in Work, design compressive strength at 28 days, Concrete
Mix proportions and materials, compressive breaking strength, and type of
break for both 7- and 28-day tests.
10. Nondestructive Testing: Impact hammer, sonoscope, or other

nondestructive device may be permitted by Engineer but will not be used as
sole basis for approval or rejection of concrete.
11. Additional Tests: Testing and inspecting agency shall make additional tests
of concrete when test results indicate that slump, air entrainment,
compressive strengths, or other requirements have not been met, as
directed by Engineer. Testing and inspecting agency may conduct tests to
determine adequacy of concrete by cored cylinders complying with ASTM C
42/C 42M or by other methods as directed by Engineer.
12. Additional testing and inspecting, at Contractor's expense, will be performed

to determine compliance of replaced or additional work with specified
requirements.
13. Correct deficiencies in the Work that test reports and inspections indicate
dos not comply with the Contract Documents.
E. Measure floor and slab flatness and levelness according to ASTM E 1155
(ASTM E 1155M) within 48 hours of finishing.
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SECTION 3.2 FORMWORK AND CONCRETING PRACTICE
PART 1- FORMWORK
1.01 MATERIALS
A. Formwork materials shall include the following items:
1. 19 mm form face plywood.

2. Sheet steel.
3. GRP.
4. Other as approved by the Employer.
1.02 EXECUTION
A. Design, erect, shore, brace, and maintain formwork, according to ACI 301/BS
8110, to support vertical, lateral, static, and dynamic loads, and construction
loads that might be applied, until structure can support such loads.
B. Construct formwork so concrete members and structures are of size, shape,

alignment, elevation, and position indicated, within tolerance limits of ACI 117/BS
EN 206-1.
C. Limit concrete surface irregularities, designated by ACI 347R as abrupt or

gradual, as follows:
1. Class A, 1/8 inch (3.2 mm) for smooth-formed finished surfaces.

2. Class B, 1/4 inch (6 mm) for rough-formed finished surfaces.
D. Construct forms tight enough to prevent loss of concrete mortar.
E. Fabricate forms for easy removal without hammering or prying against concrete
surfaces. Provide crush or wrecking plates where stripping may damage cast
concrete surfaces. Provide top forms for inclined surfaces steeper than 1.5
horizontal to 1 vertical.
1. Install keyways, reglets, recesses, and the like, for easy removal.
2. Do not use rust-stained steel form-facing material.
F. Set edge forms, bulkheads, and intermediate screed strips for slabs to achieve
required elevations and slopes in finished concrete surfaces. Provide and secure
units to support screed strips; use strike-off templates or compacting-type
screeds.
G. Provide temporary openings for cleanouts and inspection ports where interior
area of formwork is inaccessible. Close openings with panels tightly fitted to
forms and securely braced to prevent loss of concrete mortar. Locate temporary
openings in forms at inconspicuous locations. The Engineer must approve
locations and details of all temporary openings.
H. Chamfer exterior comers and edges of permanently exposed concrete.
I. Form openings, chases, offsets, sinkages, keyways, reglets, blocking, screeds,

and bulkheads required in the Work. Determine sizes and locations from trades
providing such items.
J. Clean forms and adjacent surfaces to receive concrete. Remove chips, wood,
sawdust, dirt, and other debris just before placing concrete.
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K. Retighten forms and bracing before placing concrete, as required, to prevent
mortar leaks and maintain proper alignment.
L. Coat contact surfaces of forms with form-release agent, this Form shall be
colourless, not stain concrete, and not absorb moisture. according to
manufacturer's written instructions, before placing reinforcement.
M. In the absence of any specified camber, the soffit of all beams more than five (5)
meters in span shall be laid to a camber where:
2
CAMBER = (SPAN)
7200 X DEPTH
1.03 FORM TIES
A. Form ties shall have the following features:
1. Factor of safety of not less than 1.5.

2. Factory-fabricated.
3. Adjustable-length.
4. Removable or snap-off type.
5. Cone ends if required by the Drawings.
6. Designed to prevent formwork deflection and to prevent slipping concrete
surfaces on removal.
7. Allows no metal to be left embedded closer than the cover required for concrete.
8. Leaves a hole smaller than 10 mm diameter in the concrete surface when using
snap ties.
1.04 JOINTS
A. Construction Joints: Provide construction joints conforming to the requirements of

Section 2.03 that are placed as shown in the approved shop drawings.
B. Movement Joints: Provide movement joints conforming to the requirements of

Section 2.03 that are placed as shown in the approved shop drawings
1.05 REMOVAL OF FORMWORK
A. The Employer shall be notified before the removal of any formwork.

General: Do not remove forms for any portion of the structure until concrete is strong
enough not to be damaged when forms are removed.
1. Remove forms without damage to concrete.
2. Do not use bars or heavy tools against concrete in form removal.
3. Promptly repair concrete found defective after form removal.
B. Strip formwork carefully to avoid sudden shocks from removal of wedges or vibration
which might damage concrete.
C. Where finished surfaces have re-entrant angles, remove formwork as early as

possible to avoid shrinkage cracks.
D. Concrete shall be thoroughly wetted as soon as forms are first loosened and shall be
kept wet during the removal operations and until curing media is applied.
E. Potable water supply with hoses having fine fog spray attachments shall be ready at
each removal location before operations are commenced.
F. At the time of stripping any formwork, the concrete shall be of sufficient age and
strength to withstand any adverse effects of striking, including any stresses resulting
115
from thermal shock or any adverse effects which may cause the loss of surface
durability upon premature exposure.
G. Formwork for sides of beams, walls, columns, and similar parts of the Work that does
not support weight of concrete may be removed after cumulatively curing at not less
than 50 deg F (10 deg C) for 12 hours after placing concrete, if concrete is hard
enough to not be damaged by form-removal operations and curing and protection
operations are maintained.
1. Leave formwork for beam soffits, joists, slabs, and other structural elements that
supports weight of concrete in place until concrete has achieved at least 70
percent of its 28-day design compressive strength.
2. Remove forms only if shores have been arranged to permit removal of forms
without loosening or disturbing shores.
3. Unless specified otherwise, the following minimum periods shall apply to the
removal of formwork.
Cold Weather Normal Weather

Removal of Form work from
(Below 60°F or 16°C) (Over 60° F or 16° C)
Slab soffit forms (props left 14 days 7 days

d )(props left
Beams soffit forms 14 days 7 days
Props todslab) 18 days 11 days
Props to Beams 21 days 14 days
Note: Times are exclusive of the day of concrete placement.

The above periods may be reduced if the specimen tests of the relevant elements
show 75% of the concrete design strength.
H. Stripping of formwork within the time limits listed above does not relieve the
Contractor from successfully crushing specimens that have been kept adjacent to the
structure and cured by the same methods used for the structure and achieving
specified compressive strength results.
I. If the 7-day test results meet or exceed the specified 28 days strength, the Employer
may, upon its discretion, reduce the minimum stripping times specified in Table 1.
J. Notwithstanding the foregoing, the Contractor shall be held responsible for any
damage arising from removal of formwork before the structure is capable of carrying
its own weight and any other incidental loading.
K. Sidewalk Forms: Do not remove side forms for twelve (12) hours after completion of
finishing.
L. Curb and Gutter Forms: Remove forms of curb front not less than two (2) hours nor
more than six (6) hours after placement of concrete.
1. Forms of curb back shall remain in place until face and top of curb have been
finished as specified for concrete finishing.
2. Do not remove gutter forms while concrete is sufficiently plastic to slump in any
direction.
1.06 EARTH FORMS
A. Earth forms will not be permitted unless otherwise approved by the Employer.
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1.07 SHORES AND RESTORES
A. Comply with BS 8110/AC1 318 (AC1 318 M) and AC1 301 for design,
installation, and removal of shoring and re-shoring.
1. Do not remove shoring or re-shoring until measurement of slab

tolerances is complete.
B. In multistory construction, extend shoring or reshoring over a sufficient

number of stories to distribute loads in such a manner that no floor or
member will be excessively loaded or will induce tensile stress in concrete
members without sufficient steel reinforcement and Comply with AC1 347.2 .
C. Plan sequence of removal of shores and reshore to avoid damage to

concrete. Locate and provide adequate reshoring to support construction
without excessive stress or deflection.
PART 2 – CAST-IN-PLACE CONCRETE
2.01 PLACING CONCRETE
A. Responsibility: None of the requirements of this Section shall relieve the

Contractor of its responsibility to place in the Work only sound, well-compacted
concrete free from defects.
B. Blinding: Before placing blinding concrete the formation shall be compacted and
tested as specified in Sections 2.2 at DIVISION 2.
1. Before placing blinding, a 100-micron thick polyethylene sheet shall be

placed over the formation.
2. The blinding concrete shall be grade C17/20 concrete.
3. Unless otherwise shown on the drawing or agreed by the Employer the
thickness of blinding shall be 75 mm.
4. Blinding shall be tamped into the formwork and given a class U2 wood float
finish.
5. Immediately after finishing, the concrete shall be completely covered with
100-micron thick polyethylene sheet for at least 1 day.
C. Screed
1. After the application of water proofing membrane onto a blinding slab, a

screed of 50 mm shall be placed on top of the water proofing membrane.
2. Screed shall comply with the requirements in Section 3.
3. Screed shall be tamped into the formwork and given a class U2 wood float
finish.
4. The top of the screed must be at the correct level.
5. Immediately after finishing, the screed shall be completely covered with a
polyethylene sheet for at least 1 day.
6. For bonded levelling screed an ASTM C 881 Type V bonding agent, or ASTM
C 1059 mortar tested by ASTM C 1042 methods. In all cases, the base slab
must be thoroughly cleaned of debris and laitence that would prevent bond.
The topping construction joints should be in the same location as the base
slab joints.
117
D. Preparation for Concreting
1. Before placing concrete, the Contractor shall remove from the forms or from
the surface of previously cast concrete any oil, laitance, loose fragments,
sand, earth, mud, timber and other debris.
2. Forms and reinforcing shall be washed down with sweet water and exposed
concrete shall be thoroughly saturated, but standing water shall be blow out
or removed.
3. Adequate curing materials including ample water shall be available before
casting.
4. For night concreting operations the Contractor shall arrange adequate
suitable lighting to the satisfaction of the Employer.
5. The Contractor shall provide safe secure access for all personnel on
concreting operations.
E. Inspection by the Employer
1. No concrete shall be placed until the Employer has inspected and approved
the surfaces upon which the concrete is to be placed, the formwork, the
reinforcing steel and accessories.
2. Contractor shall give the Employer an “Inspection Request: as described in
Section 4.4 not less than 24 hours before casting to enable his inspection to
be carried out.
3. If concrete is not placed within 24 hours of approval being given, approval
shall be obtained again before concreting.
F. Supervision and Personnel
1. Contractor's Staff approved to supervise concrete work shall be on site

whenever such work is executed.
2. During the placing of all reinforced concrete, a competent steel fixer shall be
in attendance on each concreting gang.
3. The steel fixer shall ensure that the reinforcement and embedded fittings are
kept in position as work proceeds.
G. Placement
1. Field Inspection: Do not place concrete until forms and reinforcing steel have
been inspected and approved.
1. Place Ready-Mix concrete within specified time after batching.

Below 40 degrees F (4 degrees C) See Cold Weather Placing
40 - 85 degrees F (4 - 29 degrees C) 90 minutes
86 - 90 degrees F (30 - 32 degrees C) 75 minutes
Above 90 degrees F (32 degrees C) 60 minutes
Concrete exceeding delivery time may be rejected by the Employer.
2. Adding Water: Do not add water after initial introduction of mixing water
for batch except when slump of concrete is less than that specified upon
arrival at job site, and maximum water/cement ratio for mix has not been
exceeded.
a. Notify Employer before adding any water.
b. Add water to bring slump within specified limits. Turn drum at least 30
additional revolutions at mixing speed. Do not add water to batch at
any later time.
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c. Insure that concrete strength meets specified requirements, and water
does not exceed maximum amount specified in CONCRETE MIX
DESIGN.
3. The concrete shall be deposited as close as practicable to its final position to

avoid rehandling or moving the concrete horizontally by vibration.
a. All concrete shall be placed by pump, unless otherwise approved by the

Employer
b. If other methods are allowed by the Employer, the concrete must be
transferred from the transit mixer to its place in the work as rapidly as
possible by methods, which will minimise segregation and drying-out.
c. The Contractor must provide suitable access roads for the above
equipment.
4. Ensure that concrete is of the required workability at the point and time of
placing.
5. Concrete unplaced after 1.5 hours from the time of loading, shall not be used,
unless the slump and temperature are checked and found to be satisfactory.
6. If segregation has nevertheless occurred in any instance, the materials shall

be remixed to the satisfaction of the Employer or discarded.
7. Concrete shall be placed and compacted before initial set has occurred.
a. If cold a joint occurs it shall be treated as construction joint, unless

b. If construction joints are not shown on the drawings or in case of
emergency construction joints shall be placed as directed by the
Employer.
8. Concreting shall be carried out continuously up to the construction joints.

The timetable for the depositing of concrete shall be so arranged that no face
of concrete is left exposed for more than 20 minutes before fresh concrete is
deposited against it in order to avoid cold joints. If the interruption of
concreting exceeds 20 minutes the joint shall be treated as a construction
joint, unless otherwise directed by the Employer.
9. When dropped into place, concrete shall be dropped vertically into the
formwork through suitable means to avoid segregation.
a. It shall not strike the formwork between the point of its discharge and its
final place in the Work.
b. Concrete shall not be dropped freely through a height greater than 1.5 m.
c. Chutes and conveyor belts, when allowed, shall be designed so that
there is no segregation or loss of mortar and shall be provided with a
vertical tapered down pipe or other device to ensure that concrete is
discharged vertically into final position.
10. Concrete shall be carefully placed in horizontal layers 300 to 500 mm thick
that shall be kept at an even height throughout the Work.
a. Concrete shall not be allowed to slide or flow down sloping surfaces to its
final position, but shall be placed in its final position from the pump.
b. Concrete shall not be placed in standing water in the formwork.
119
11. Concrete shall be placed to prevent segregation. The concrete shall not be
permitted to strike against forms and ricochet on bars and form faces.
Concrete shall not be permitted to drop freely more than five feet (1.5) m.
12 Where concrete abuts against earth or any other material, which may become
loose and fall, care shall be taken by suitable means to avoid fall of materials
on to the surface of the wet concrete.
13. Before placing concrete on soil the bottom shall be thoroughly compacted to a
neat horizontal plane or such profile as shown on the drawing.
14. Before placing concrete on rock foundation the surface shall be thoroughly
wetted and cleaned by application of water or of water and air under pressure
from a hose. Faults or seams in the rock shall be cleaned or repaired as
15. Concrete Toppings: Place on top of structural slabs where indicated on the
Drawings. All toppings shall have a steel trowelled finished unless otherwise
agreed with the Employer.
16. Continuity of Concrete Work: Whenever instructed by the Employer, the

Contractor shall carry out the work in such a manner that the placing of the
concrete in any particular section of the structure shall be executed without
any interruption whatsoever from the beginning to the end of the operation.
17. Care shall be taken to prevent men engaged in placing concrete from
introducing foreign matter into the concrete from their boots or other means.
Where concrete, is placed directly against the surface of excavations any
softened material shall first be removed.
2.02 COMPACTING CONCRETE
A. Except for slabs less than 100 mm thick, all concrete placed insitu shall be
compacted with power-driven internal type vibrators having a frequency of not
less than 10,000 cycles per minute, supplemented by hand spading and tamping
1. The intensity of the vibration shall be such as to visibly affect a mass of

concrete of 25 mm slumps over a radius of at least 450 mm.
2. Unless otherwise agreed by the Employer, slabs less than 100 mm thick shall
be compacted by approved vibrating screeds.
3. The type of vibrators shall be subject to the approval of the Employer.
B. Internal type vibrators shall be inserted into the uncompacted concrete vertically
and at regular intervals.
1. Where the uncompacted concrete is in a layer above freshly compacted

concrete the vibrator shall penetrate vertically for about 150 mm into the
previous layer.
2. Vibrators shall not come into contact with the reinforcement or the formwork.
3. Vibrators shall be drawn back slowly (approximately at a rate of 100
mm/second) from the concrete so as to leave no voids.
4. Internal type vibrators shall not be placed in the concrete in a haphazard
manner nor shall concrete be moved from one part of the work to another by
means of the vibrators.
5. Vibrators shall at all times be adequate in numbers, amplitude and power to
compact the concrete properly and quickly throughout the whole of the
volume being compacted to the satisfaction of the Employer.
120
6. Spare vibrators in operable condition must be readily on hand in case of
breakdown.
C. Compaction shall start as soon as there is sufficient concrete to immerse the

vibrator and shall continue during the placing operations so that at no times shall
there be a large volume of uncompacted concrete in the formwork.
D. Vibrators shall be manipulated in order to thoroughly compact concrete in all

corners and around the reinforcement and any embedded fixtures.
E. Duration of vibration shall be limited to that required to produce satisfactory

compaction without causing segregation. Vibration shall not be continued after
water or excess grout has appeared on the surface.
F. External Vibrators
1. External vibrator shall be rigidly clamped to the formwork resting on an elastic

support so that both the form and the concrete are vibrated.
2. The formwork shall be strong and tight to prevent distortion and leakage of
grout.
3. Concrete shall be placed in thin layers and the position of the vibrator may
have to be changed as concreting progresses.
4. If approved by the Employer portable non-clamped vibrators may be used at
sections not otherwise accessible.
5. The frequency of the vibrator shall have at least 8,000 cycles per minute
G. Operators shall be trained in the use of vibrators. The foremen shall have a
minimum of 5 years experience in the supervision of placing concrete.
2.03 JOINTS
A. Intervals During Concreting: Concreting shall be carried out continuously up to

the construction joints. The timetable for the depositing of concrete should be so
arranged that no face of concrete should be left for more than 20 minutes before
fresh concrete is deposited against it.
B. Construction Joints
1. Comply with ACI 224.3 except as modified herein.

2. If the Contractor’s method of forming construction joints are not proving
effective the Employer may order the Contractor to execute at the
Contractors expense such preventive measures as the Employer may
consider necessary to ensure the water tightness of the construction joints.
In water retaining and/or excluding structures, all construction joints shall
require the use of an approved type of PVC water stop, self-swelling water
bar, and hose injection system or joint sealant.
3. Submit detailed proposals not less than three weeks before the start of
concreting to include the following:
a. Sequence of placing concrete.

b. Sizes of concrete pours.
c. Positions of all vertical and horizontal construction joints.
d. Height of lifts.
4. No concreting shall be started until the Employer has approved the detailed
proposals.
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5. Construction joints shall be so located as not to impair the strength of the
structure.
a. Positions of construction joint and size of formwork panels shall be so co-

ordinated that where possible the line of any construction joints coincides
with the line of a formwork joint and that in any case all construction joint
lines and formwork joint lines appear as a regular and uniform series.
b. For all exposed horizontal joints and purposely inclined joints, a uniform
joint shall be formed with a batten of approved dimension to give a
straight and neat joint line.
6. Concrete which forms the face of a construction joint shall have all laitance
removed and the aggregate exposed before the placing of fresh concrete.
a. Laitance shall wherever practicable be removed to expose the

aggregates by spraying the concrete surface with water under pressure
and brushing whilst it is still green.
b. Where the laitance cannot be removed whilst the concrete is still green,
the whole of the concrete surface forming part of the joint shall have the
aggregate exposed by means of a proprietary power driven
scrabbling/bush hammer as approved by the Employer. Powerful
hammers shall not be used. Hacking, chipping, chiselling, etc. will not be
permitted.
c. All loose matter shall be removed and the exposed surface thoroughly
cleaned by wire brushing, air blasting or washing and the surface to
which fresh concrete is applied shall be clean and saturated with suitable
water.
d. If in the opinion of the Employer any deleterious materials have come in
contact with the concrete at the construction joint, the concrete shall be
cut back to such a depth as the Employer shall order and the required
surface shall be thoroughly cleaned with compressed air and water jet or
other approved means and brushed and watered immediately before
depositing fresh concrete.
e. Immediately after the discontinuance of placing concrete all accumulated
mortar splashed on the rebar’s and the surface of the forms shall be
carefully removed.
7. Keys and joints shall be located as follows, unless otherwise approved by the
Employer.
a. Suspended Slabs: In the middle third of span in slabs, beams or girders.
b. Unless otherwise shown, maximum distances between construction joints

are:
Walls: 12 M
Slabs on grade 7 M, or 20 M with saw-cut joints at 5 M centers.
Suspended slabs, superstructure beams and girders: 25 M.
c. Place beams, girders, brackets, column capitals, haunches and drop

panels with slabs.
d. Locate near middle of spans of slabs, beams and griders unless a beam
intersects a girder at this point, in which case the girder joint shall be offset
twice the beam width and additional shear reinforcement provided to the
acceptance of the Engineer.
e. Provide a stop end at all construction joints except for slabs on grade. Add
dowels, if necessary to make total steel passing through stop end at least
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the equivalent of 10mm at 400 mm centers each face. Embed dowels at
least 500 mm on each side of joint.
f. Before placing new concrete, remove all dirt, loose aggregate and laitance
from face of existing concrete. Coat face of joint across beans with epoxy
adhesive. Saturate other surfaces with water and leave damp.
g. Ground Slabs
1. Shall be cast in panels designed by movement subject to the 5 m

panel limits.
2. Where no movement joints are specified or where the distance
between movement joints exceeds 5 m in any direction for ground
slabs and exceeds 5 m in length for wall slabs (except as described
above under walls).
i. Shall be sub-divided by properly formed construction joints into

panels of dimensions not exceeding 5 m.
ii. Panels shall be separately concreted. No panel shall be
concreted until the concrete in adjacent panel is at least 3 days
old on adjacent panels restrained on two or less sides, or at least 7
days old for in-fill panels restrained on three or more sides.
3. Above requirement will generally be met by casting in alternate bays.

4. If long and short bays are proposed, the long bays shall be concreted
first.
5. It is desirable that reinforcing bars extending across in-fill bays are
not continuous (i.e. a splice is provided within the in-fill bay).
6. If the Contractor adopts the above or other approved method to
accommodate shrinkage, the Employer may agree to a reduction in
the 7 day’s time for in-fill panels.
7. The peripheral ring beam in the floor of a circular tank shall not be
concreted in advance of its integral floor slab.
8. The periods referred to above do not apply to successive lifts in
walls.
9. Proposed sequence of casting panels as called for in this subsection
shall be submitted for Employer’s approval before the start of
concreting.
C. Contraction (Control) Joints
1. Contraction Joints in Slabs-on-Grade: Construct contraction joints in slabs-

on-grade to form panels of patterns as shown. Use saw cuts 1/8 inch (3.18
mm) wide by one-fourth of slab depth, or inserts 1/4 inch (6.32 mm) wide by
one-fourth of slab depth, and shall be no less than one (1) inch total depth.
unless otherwise indicated
.
a. Saw-cut joints in slabs on grade should generally occur on column lines and
on intermediate lines which result in panels of approximately square
sections. Sections shall not exceed 5 mm in length or width.
b. Make saw-cuts 5 mm wide x 25 mm deep as soon as the concrete can be

cleanly cut and before shrinkage cracks can form. Fill all saw-cuts with
polysulphide joint filler, not less than 21 days after casting. Joints shall be
clean and dry when fitted.
c. Form contraction joints by inserting premolded plastic, hardboard, or

fiberboard strip into fresh concrete until top surface of strip is flush with slab
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surface. Tool slab edges round on each side of insert. Remove inserts and
clean groove of loose debris after concrete has cured.
d. Form contraction joints in unexposed floor slabs by saw cuts as soon as

possible after slab finishing as may be safely done without dislodging
aggregate. Contraction joints formed by soft-cut saw shall be made no
greater than eight hours after placement of concrete.
e. If joint pattern is not indicated in Contract Drawings, provide joints at intervals

not exceeding 30 times the slab thickness in either direction, and located to
conform to bay spacing wherever possible (at column centerlines, half bays,
third bays).
2. Sidewalks: Construct joints to divide surface into rectangular areas.
a. Space transverse contraction joints at distance equal to sidewalk width or 5

feet (1.5 m) on center, whichever is less, and continuous across slab.
b. Construct longitudinal contraction joints along centerline of sidewalks 10 feet

(3 m) .
c. Form contraction joints in fresh concrete by cutting groove in top portion of

slab to depth of at least one-fourth of sidewalk slab thickness.
(1) Use jointer to cut groove, or saw groove in hardened concrete with
power-driven saw, unless otherwise approved.
(2) Construct sawed joints by sawing groove in concrete with 1/8 inch (3.18
mm) blade to the depth indicated on Contract Documents.
3. Curb and Gutter: Construct joints at right angles to line of curb and gutter.
a. Construct contraction joints directly opposite contraction joints in abutting

Portland cement concrete pavements.
b. Space joints so that monolithic sections between curb returns will not be less
than 5 feet (1.5 m) nor greater than 15 feet (4.5 m) in length.
c. Form contraction joints with 1/8 inch (3.18 mm) thick separators, with section
conforming to curb and gutter cross section.
d. Remove separators as soon as practicable after concrete has set sufficiently

to preserve width and shape of joint and prior to finishing.
D. Expansion Joints
1. Reinforcement or other embedded metal items bonded to the concrete

(except dowels in floors bonded on only one side of joints) shall not extend
continuously through any expansion joint.
2. Do not seal joints until adjacent concrete is at least 28 days old.
3. Prepare and apply joint sealant in accordance with PART 7 and

manufacturer's instructions.
4.
5. Slabs-on-Ground: Expansion joint material shall be placed around utility
access openings within the slab, including clean outs and utility valves, and
between new concrete slab and adjacent masonry.
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a. Provide premolded, asphalt impregnated joint material 1/2 inch (12.7 mm)
thick .
b. Extend joint material to full depth of concrete.
6. Sidewalks: Place joints in sidewalks at point of tangency (PT) and point of

curvature (PC) of sidewalk returns, between sidewalk and building or
structure, in sidewalk returns, between sidewalk and back of curb returns and
around utility poles.
a. Provide joint material 1/2 inch (12.7 mm) thick.
b. Extend joint filler strips to full depth of concrete being placed at PT, PC,
and around utility poles,
c. Provide joint filler strips between sidewalk and curb to full depth of
sidewalk with top of filler strip set flush with top of curb.
d. Provide transverse sidewalk joints at spacing not to exceed 30 feet (9 m).
e. Every one hundred (100) feet in sidewalk curb and gutter when hand-
formed.
f. (8) Every two hundred (200) feet in sidewalk, curb and gutter when placed
slip formed.
7. Curbs and Gutters: Form expansion joints with preformed expansion joint
filler material 1/2 inch (12.7 mm) wide. Cut and shape to curb and gutter
cross section.
a. Provide expansion joints in curb and gutter at end of returns except where
cross gutters are being constructed.
b. Provide expansion joints at ends of cross gutter transitions and along line
of work at regular intervals, not to exceed 36 feet (11 m).
c. Provide joints in gutter continuous with those in adjacent curb.
d. Place prior to the placement of concrete At each end of curb returns.
2.04 CONCRETE FINISHING
A. Requirements for formed surfaces shall comply with Section 1.
B. Unformed finishes shall be as designated on the Drawings and shall comply with
one of the following:
1. Class U1.
2. Class U2.
3. Class U3.
4. “Spaded”.
5. “Bonded”.
6. “Broomed”.
C. Class U1 finish:
1. Class U1 shall be used at the Construction joints only.
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2. Concrete shall be levelled and screeded, to form a uniform plain or ridged
finish, which shall not be disturbed in any way after the initial set. (Unless it is
being converted to Class U2, U3 or bonded concrete).
3. Surplus concrete shall be struck off immediately after compaction.
4. Class U1 is the first stage for Class U2 and U3 finishes and for a bonded
concrete surface.
D. Class U2 finish:
1. Shall be a wood float finish.

2. Floating shall be done after the initial set of the concrete has taken place and
the surface has hardened sufficiently.
3. Concrete shall be worked no more than is necessary to produce a uniform
surface free from screed marks.
E. Class U3 finish:
1. Shall be a hard smooth steel-trowelled finish.

2. Trowelling shall not start until the moisture film has disappeared and the
concrete has hardened sufficiently to prevent excess laitance from being
worked into the surface.
3. Surface shall be trowelled under firm pressure and left free from trowel
marks.
F. Bonded Finish: Where a bonded concrete surface is specified, the laitance shall
be removed from the Class U1 finished surface and the aggregate exposed while
the concrete is still green.
G. Spaded Finish: A spaded finish shall be a surface free from voids and brought to
a reasonably uniform appearance by the use of shovels as it is placed in the
works.
H. Broomed Finish: Where a broom finish is specified, the surface of the concrete
shall first be levelled and screeded and then brushed in one direction with a stiff
broom.
I. All surfaces, which are not to be covered with a further finish will be U3 finish. All
surfaces on which further finishing screeds or treatment are to be applied will be
U2 finish.
2.05 CURING OF CONCRETE
A. Curing water shall be potable and shall comply with the requirements of BS 3148,
B. Curing Sheet Materials
1. White polyethylene sheet with a minimum thickness of 100 microns and a

minimum reflectance of 70%.
2. Hessian or water absorbent material shall be as approved by the Employer.
C. Curing Compounds
1. Conform to ASTM C309 Type I, Class B

2. Curing efficiency > 90%
2
3. Water Retention < 0.55 kg/m
4. Touch drying time Maximum 4 hours
5. Compatible with subsequently applied finishes or coverings.
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6. Not deleterious to bond of cementitious materials to concrete.
D. Review Curing Methods with the Employer:
1. “Wet curing” shall be used for all reinforced concrete, unless otherwise
2. “Moisture retaining” curing shall be used for unreinforced concrete and
blinding.
3. Curing compounds may only be used with special approval of the Employer.
4. If structural members are of considerable depth or bulk or have an unusually
high proportion of cement, special curing methods may be required.
5. Curing shall be in accordance with ACI 308 Chapter 2 and as modified
hereunder.
6. Additional recommendations in ACI 305 shall also be taken into
consideration.
E. Wet Curing
1. Execute by either:
a. Pounding with water.

b. Fine fog water sprays in continuous operations.
c. Appling two layers wetted Hessian or other approved absorptive material
and then covering with white polyethylene sheeting (at least 100 microns
thick) to keep continuously wet.
2. Before placing concrete the Contractor shall store ample amount of water and
curing materials for curing the concrete. The minimum quantity of water in
the tank shall be enough to cure the concrete continuously for at least 3 days
or as approved by the Employer.
3. Wet curing shall be carried out immediately after finishing or form removal for
a continuous period of:
a. At least 7 days for concrete without any mineral additives.

b. At least 10 days for concrete with mineral additives (GGBS or MS).
4. Horizontal Surfaces:
a. To prevent premature drying, polyethylene sheet shall be placed over the

concrete before finishing immediately after placement.
b. After finishing, the polyethylene sheet shall be immediately replaced until
the concrete is in suitable condition to receive the wet Hessian (not more
than 12 hours).
c. Two layers of wet Hessian shall then be applied over the entire concrete
surface and covered with approved polyethylene sheet.
d. When curing is being installed over starter bars (such as around the top
of walls at the construction joint) the starter bar assembly shall be packed
with wet Hessian and covered with polyethylene sheeting as described
above.
e. Large areas of ground slabs may be cured by ponding with water of
specified quality.
i. During the curing period make sure that no salt concentration has
taken place due to the evaporation of water. If necessary, renew the
water regularly.
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ii. After completion of the curing period and before the removal of water,
Hessian shall be placed over the slab in such a manner that all the
area is covered by the Hessian.
iii. When the Hessian has become dry, leave it on the slab for three
days and gradually remove it. The Hessian shall not be wetted
during this period.
5. Curing Formed Surfaces:
a. Formwork shall not be retained in place longer than necessary for the
concrete to gain sufficient strength to enable it to be stripped safely.
b. Except for soffits and other sections that have to be supported, formwork
shall be stripped within 24 hours.
c. When sub-horizontal soffit formwork is struck less than a week after
casting, an approved curing compound shall be applied, unless otherwise
d. During the striking of formwork exposed areas of concrete shall not be
subjected to prolonged exposure without effective curing. If the striking
operation takes longer than two hours, the exposed concrete shall be
continually sprayed with water, until the curing system is installed.
e. Two layers of wet Hessian and polyethylene sheet shall be installed as
quickly as possible on vertical surfaces.
1. Wet Hessian and polyethylene sheet must be in close contact with

the vertical surfaces and secured in place by suitable means.
2. Surplus free water must be present on the concrete surface at all
times during the specified curing period.
6. If any drying out of the wet curing system has occurred, the wet curing shall
be extended for double the period that any part of the system became dry.
7. In certain circumstance as an alternative to the wet curing for the whole of the
curing period, the Employer may allow a short period of wet curing followed
by the application of a curing compound.
8. The Hessian shall be allowed to become dry after the curing period before its
removal from the structure.
F. Moisture Retaining Curing
1. Cover concrete surface with approved polythane sheet or other approved cover.
2. Cover shall be in the widest practicable widths and shall have 200 mm side and
end laps.
3. Seal with waterproofing tape or adhesive.
4. Immediately repair any holes or tears in the cover with cover material and
waterproof tape.
G. Liquid Membrane Curing
1. Approved curing compounds may be applied with the Contractors consent as

follows:
a. After 3 days of full wet curing on concrete made without mineral additives.
b. After 7 days of full wet curing on concrete made with mineral additives.
2. Apply an approved membrane forming curing compound in accordance with

the manufacturer's recommendations immediately after any water sheen,
which may have developed from wet curing, has disappeared from the
surface.
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a. Particular care shall be taken to achieve the required rate of spread.
b. A curing compound suitable as primer for tanking membrane shall be
used, unless otherwise agreed by the Employer.
c. A curing compound shall not be used on surfaces that are to be
subsequently wet cured.
3. Do not use on surfaces against which additional concrete or other material is

to be bonded unless:
a. It is proven that the curing compound will not prevent bond, or

b. Positive measures are taken to remove it completely from those areas,
which are to receive bonded applications.
C. If concrete has not been cured in accordance with the Specification, the
Employer may instruct the Contractor to cut additional cores for RCP
and/or compressive strength test. Tests shall be carried out as directed
by the Employer at the Contractors expense.
I. Thermal Curing
1. The Contractor shall take special precautions as directed by the Employer to

cure any element which has a minimum least dimension greater than 1.0m.
a. Maximum temperature differential between interior and exterior surface

0
shall not exceed 20 C, unless otherwise approved by the Employer.
a. Thermocouples shall be placed and maintained as directed by the
Employer to monitor concrete temperatures within the structure.
b. An automatic logging system shall be used to record all temperatures
every 3 hours.
2. Thermal curing shall typically be accomplished by providing sufficient

insulation boards or blankets (in two layers) on the concrete surface in order
to maintain the temperature differential within allowable limits.
a. Thermal curing shall not be considered as a substitute for wet curing and
must be carried out simultaneously.
b. All insulation shall remain in place at least 14 days after casting, unless
temperature records prove that the temperature differential has reduced
to 75% of the maximum allowable value, at which time half (or one layer
of insulation) may be removed.
c. The remaining insulation (one layer) shall remain in place until the core
0
temperature has cooled to less than 20 above the average ambient
0
temperature and the ambient temperature is within 10 C of the surface
temperature.
3. The Contractor shall provide a detailed method statement describing all

aspects of thermal curing in both the horizontal and vertical positions.
J. Curing Compound
Apply uniformly in continuous operation by power spray or roller according to
manufacturer's written instructions. Recoat areas subjected to heavy rainfall
within three hours after initial application. Maintain continuity of coating and
repair damage during curing period.
a. After curing period has elapsed, remove curing compound without damaging
concrete surfaces by method recommended by curing compound
manufacturer.
K. Curing and Sealing Compound: Apply uniformly to floors and slabs indicated in
a continuous operation by power spray or roller according to manufacturer's
129
written instructions. Recoat areas subjected to heavy rainfall within three hours
after initial application. Repeat process 24 hours later and apply a second coat.
Maintain continuity of coating and repair damage during curing period.
Full-scale site trials shall be conducted as directed by the Employer to verify the performance
of the Contractor’s proposed methods of thermal curing before application on permanent
works.
2.06 FIELD QUALITY CONTROL
A. Testing and Inspecting: The Employer must submit their Company’s Quality
Control Plan for the approval by Engineer. Alternatively an approved qualified
testing and inspecting agency shall be appointed by the employer to perform
field tests and inspections and prepare test reports.
B. Testing and Inspecting: Engage a qualified testing and inspecting agency to

perform tests and inspections and to submit reports.
C. Inspections:
1. Steel reinforcement placement.

2. Steel reinforcement welding (If applicable).
3. Headed bolts and studs.
4. Verification of use of required design mixture.
5. Concrete placement, including conveying and depositing.
6. Curing procedures and maintenance of curing temperature.
7. Verification of concrete strength before removal of shores and forms
from beams and slabs.
2.07 FORM SETTING FOR STRUCTURAL COMPONENTS
A. Design, erect, support, brace and maintain formwork to support vertical and
lateral loads that might be applied until such loads can be supported by
concrete structure.
B. Construct formwork so concrete members and structures are of correct size,

shape, alignment, elevation and position.
C. Provide for openings, keyways, chamfers, inserts and other features required in
work.
D. Maintain formwork construction tolerances, unless otherwise indicated:
1. Variation from Plumb:

a. In the lines and surfaces of columns, piers, walls, and in arrises:
In any 10 feet (3 m) of length ........................................................ 1/4 inch (6.35 mm)
Maximum for the entire length ............................................................. 1 inch (25 mm)
b. For exposed corner columns, control-joint grooves, and other
conspicuous lines:
In any 20 foot (6 m) length ............................................................ 1/4 inch (6.35 mm)
Maximum for the entire length ....................................................... 1/2 inch (12.7 mm)
2. Variation from level or from grades specified in Contract Drawings:

a. In slab soffits, ceilings, beam soffits and in arrises, measured before
removal of supporting shores:
In any 10 feet (3 m) of length ........................................................ 1/4 inch (6.35 mm)
In any bay or in any 20 foot (6 m) length ....................................... 3/8 inch (9.53 mm)
130
b. In exposed lintels, sills, parapets, horizontal grooves, and other
conspicuous lines:
In any bay or in 20 foot (6 m) length.............................................. 1/4 inch (6.35 mm)
3. Variation of the linear building lines from established position in plan and
related position of columns, walls, and partitions:
In any bay ..................................................................................... 1/2 inch (12.7 mm)
In any 20 foot (6 m) of length ........................................................ 1/2 inch (12.7 mm)
Maximum for the entire length ............................................................. 1 inch (25 mm)
4. Variation in the sizes and location of sleeves, floor openings,

and wall openings .............................................................................. 1/4 inch (6.35 mm)
5. Variation in cross-sectional dimensions of columns and beams and in the

thickness of slabs and walls:
Minus ........................................................................................... 1/4 inch (6.35 mm)
Plus ............................................................................................... 1/2 inch (12.7 mm)
6. Footings*:
a. Variations in dimensions in plan:

Minus 1/2 inch (12.7 mm)
Plus ........................................................................................... 2 inches (51 mm)
b. Displacement or eccentricity:
2% of the footing width in direction of displacement
but not more than............................................................................. 2 inches (51 mm)
c. Thickness:
Decrease in specified thickness........... ....................................................... ..........5%
Increase in specified thickness........................................................................No limit
7. Variation in Steps:
a. In a flight of stairs:
Rise ..................................................................................... +1/8 inch (+3.18 mm)
Tread +1/4 inch (+6.35 mm)
b. In consecutive steps:
Rise ................................................................................. +1/16 inch (+1.588 mm)
Tread +1/8 inch (+3.18 mm)
* Tolerances apply to concrete dimensions only.
E. Design and fabricate formwork to be readily removable without impact, shock or

damage to cast-in-place concrete surfaces and adjacent materials.
F. Chamfer all exposed corners and edges to produce uniform smooth lines and
tight edge joints, unless otherwise indicated in the Contract Drawings.
G. Provisions for Other Trades: Provide openings in concrete formwork to

accommodate work of other trades.
1. Determine size and location of openings, recesses and chases from trades
providing such items.
2. Accurately place and securely support items built into forms.
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2.08 FORM SETTING FOR SIDEWALKS, CURBS AND GUTTERS
A. General: Set forms to the indicated alignment, grade and dimensions.
1. Provide minimum of three (3) stakes per form placed at intervals not to
exceed 4 feet (1.2 m) to hold forms rigidly in place.
2. Provide additional stakes and braces for corners, deep sections, and radius
bends, as required.
3. Provide clamps, spreaders, and braces where required to insure rigidity in

forms.
4. Clean and coat forms with form oil each time before concrete is placed.
5. Wood forms may be thoroughly wetted with water before concrete is

placed, except when probable freezing temperatures may occur, oiling is
mandatory.
B. Divide curb, and combined curb and gutter into blocks or stones in lengths not
to exceed 6 feet (2 m) long.
1. Use metal templates not less than 1/16 inch (1.588 mm) thick cut to the
same cross section as the curb or curb and gutter being constructed.
2. Securely attach templates to forms to prevent movement during concrete

placement.
C. Sidewalks, Curbs and Gutters: Set forms for sidewalks, curbs and gutters with
the upper edge true to line and grade with an allowable tolerance of 1/8 inch (3
mm) in any 10 foot (3 m) long section.
1. After forms are set, check grade and alignment with 10-foot (3 m)
straightedge.
2. Provide transverse slope of 1/4 inch per foot (6.35 mm per meter) with low
side adjacent to the roadway.
132
PART 3 - CONCRETE REINFORCMENTE
GENERAL REQUIREMENTS
A. Unless noted otherwise, all reinforcing shall be uncoated deformed high yield bars.
A. Delivery
1. Bars in each lot shall be legibly tagged by the manufacturer.
a. The tag shall show the manufacturer’s test number and lot number, and other
applicable data that will identify the material with the corresponding certificate
issued for that lot of steel.
b. Reinforcing shall be delivered clean and free of rust conforming to BS 7079
Part A1 grade a condition.
2. Offsite commercial fabricators shall furnish three copies of a certification which

shows the heat numbers from which each size of bar in each shipment was
fabricated.
B. Storage and Handling
1. Store reinforcement at all stages on suitable structures a minimum of 200 mm

above the ground surface or as directed by the Employer.
2. All reinforcement shall be covered with suitable canvas tarpaulins. Plastic
sheeting is not allowed.
3. Fabricated reinforcing bars shall be kept clean and shall be free from pitting,
loose rust, mill scale, oil, grease, earth, paint, or any other material, which may
impair the bond between the concrete and the reinforcement.
4. Any reinforcing found in a corroded condition exceeding BS 7079 Part A1 grade
B may be rejected by the Employer and removed from site.
5. Do not rough handle reinforcement, drop it from a height, or subject it to shock
loading or mechanical damage.
6. Storage facilities shall be such as to permit easy access for inspection and
identification.
7. Clearly tag bundles of reinforcement with bar schedule and bar mark reference.
3.02 MATERIALS
A. Reinforcing Steel bar : Conform to ASTM A615M GRADE 60 or According to DIN

488 Bst 500S, reinforcing bars should conforming to ASTM A 706/A 706M for
enhanced weldability, unless otherwise approved by the Employer.
B. Welded Steel Wire Fabric Reinforcement: Conform to BS 4483.
C. Tie Wire: Conform to BS 4482 and provide 1.6 mm black annealed mild steel.
D. Spacers
1. Spacers shall be concrete blocks or cylinders, unless otherwise approved by the

Employer.
2. Concrete spacers shall be manufactured from a pre-bagged micro-concrete.
a. Minimum compressive strength: 60 MPa at 28 days.

b. Maximum aggregate size shall be 5 mm.
133
c. Spacers shall be wet cured for 3 days unless otherwise accepted by the
Employer.
d. Concrete spacers shall be of uniform size and free of honeycombing or
cavities.
e. All spacers shall have an embedded tie wire.
3.03 TESTING OF REINFORCEMENT STEEL
A. The Employer reserves the right to sample and test each size of the reinforcement
steel upon its arrival at the work site.
B. Tests procedure and frequency shall be carried out in accordance with ASTM A615M,
unless otherwise directed by the Employer.
C. The following shall be determined for each delivery of reinforcement, unless

otherwise directed by the Employer.
1. Mass per unit length.

2. Tensile strength (ultimate).
3. Yield stress.
4. Elongation.
5. Bend test.
6. Re-bend test.
D. Test results for each bar size shall be submitted to the Employer three weeks before
concrete work commences on Site, unless otherwise accepted by the Employer.
E. Further tests may be called for when the source of supply of reinforcement changes,
in which case the cost of such extra testing will be borne by the Contractor.
F. When any test results do not conform to the relevant standard, the reinforcement
steel may be removed from the site upon the Employer’s direction and all costs
resulting there from shall be borne by the Contractor.
3.04 INSTALLATION
A. General
1. Detailing of concrete reinforcement according to ACI 315. Cutting and bending of

reinforcement shall be done without the application of heat. Bends shall have a
substantially constant curvature. In case of fabricating errors, do not rebend or
straighten reinforcement in manner that will injure or weaken material.
2. Adjustments and Cleaning
a. Check position of reinforcement prior to and during placing concrete. Pay

particular attention to the position of top reinforcement in cantilever sections.
b. Protect exposed reinforcement from all aggressive elements.
i. Any reinforcement which has been exposed to ground water shall be

removed and replaced with new steel, unless otherwise directed by the
Employer.
ii. Embedded bars which have been exposed to ground water shall be grit
blasted to the satisfaction of the Employer.
c. At the time of concreting, all reinforcement steel must be thoroughly cleaned

and freed from all loose rust, loose mill scale, oil, grease, mud, paint, and
other substances to the satisfaction of the Employer including partially set
134
concrete which may have been deposited thereon during the placing of a
previous lift of concrete.
d. Immediately prior to concrete placing, all reinforcing steel shall be washed
thoroughly with high-pressure potable water jets.
3. Tolerance for d and minimum concrete cover in flexural members, walls, and
compression members shall be as follows:
Tolerance on d Tolerance on minimum

concrete cover
d ≤ 200 mm ±10 mm –10 mm
d > 200 mm ±13 mm –13 mm
Except that tolerance for the clear distance to formed soffits shall be minus 6 mm
and tolerance for cover shall not exceed minus 1/3 the minimum concrete cover
required in the design drawings and specifications.
4. Tolerance for longitudinal location of bends and ends of reinforcement shall be ±

50 mm, except the tolerance shall be ± 13 mm at the discontinuous ends of
brackets and corbels, and ± 25 mm at the discontinuous ends of other members.
SECTION 3.3 CONCRETE BATCHING AND DELIVERY
PART 1 - GENERAL REQUIREMENTS & SUBMITTALS
A. Concrete shall be batched only with approved materials, approved mix designs,
and at approved facilities.
B. The Contractor shall define the method of design of the mix, by reference to a
recognised published design method. The Employer shall approve the design
method.
C. Plant trials shall be carried out for each grade and type of concrete in the
contract, unless approved otherwise by the Employer.
D. Aggregate proportions shall be based on measured and not assumed relative

densities.
E. If requested by the Employer, concrete mix designs, which include an admixture,

shall be prepared and tested both with and without the admixture to give a clear
indication of its effects on the physical characteristics of the mix.
F. Results of the trial mixes must demonstrate that the proposed mix complies with
the strength, workability and durability requirements of this specification.
SUBMITTALS
A. Product Data, test results and other information as required to prove compliance
with the specification shall be submitted for approval according to Part 4.4 on at
least the following products.
135
1. Cement
a. Recent independent test results acceptable to the Employer confirming

compliance with the specified requirements and referenced standards.
b. Manufacturer's certificates shall also be supplied with each consignment of
cement certifying compliance with the relevant standard.
2. GGBS

b. Manufacturer's certificates with all information necessary to verify
compliance with BS 6699 shall also be supplied with each consignment
of GGBS.
3. MS: Recent independent test results acceptable to the Employer confirming

4. Aggregates

b. Full details of the proposed sources of aggregates.
5. Water: Recent independent test results acceptable to the Employer

confirming compliance with the specified requirements and referenced
standards.
6. Admixtures
a. Manufacturer’s technical specifications and recommendations.

b. Recent trial results acceptable to the Employer illustrating the efficiency
of the product for its particular application.
7. Concrete mix design with at least the following information:

a. Type of cement
b. Cement content
c. GGBS content (if applicable)
d. MS content (if applicable)
e. Maximum aggregate size
f. Individual and combined grading curves
g. Test results of all constituent materials
h. Quantities of all individual materials
i. Name of admixture
j. Target slump (at discharge)
k. Details to calculate W/C ratio
l. Compressive strength
m. Hardened density
n. Water permeability
o. RCP
p. Bleeding
q. Water absorption
r. SO3 and Cl contents
s. Slump profile
t. Target unit weight
u. Target temperature
136
B. Samples of the following shall be submitted.
1. Cement
a. Provide cement samples from each consignment delivered to the site as

required by the Contractor for testing.
b. Samples shall be taken in the presence of the Employer’s
Representative.
2. GGBS
a. As requested by the Contractor for independent testing.

b. Samples shall be taken in the presence of the Employer’s Representative.
3. MS
a. As requested by the Contractor for independent testing.

Representative.
4. Aggregates
a. Provide samples of both fine and coarse aggregates for testing at least
three weeks before beginning deliveries to the site and at regular
intervals as required by the Contractor.
Representative.
5. Water
a. Provide samples of water proposed for concreting works.

Representative.
6. Admixture: As proposed by the Contractor and approved by the Contractor.
C. Method Statements: The Contractor shall submit a method statement according

to Part 4.4 for concrete batching and delivery, which shall include at least the
following details:
1. Type of plant proposed.

2. Layout of concrete production facility.
3. Proposed method of organisation of the concrete production facility.
4. Quality control procedures for concrete and concrete materials.
• Batching and Transport of concrete.
137
PART 2 - PRODUCTS, STORAGE AND HANDLING
2.01 CEMENT
A. Ordinary Portland Cement (OPC) used in the mix shall conform to IQS 5 or
ASTM C150 Type I, as approved by the Employer.
B. Sulphate Resisting Portland Cement (SRC) used in the mix shall conform to
IQS5 or ASTM C150 Type V, as approved by the Employer.
C. If required, Moderate Sulphate Resisting Portland Cement (MSRC) shall conform

to ASTM C150 Type II, as approved by the Employer.
D. Any cement, which is, in the opinion of the Employer, unsuitable for use in the
Works shall be rejected and the Contractor shall promptly remove such cement
from the Site.
E. Whenever required by the Employer, representative samples of cement shall be

taken and forwarded in the presence of the Employer to an approved
independent laboratory for analysis to check compliance against the
Specification. The weiof sample taken from the shipment not less than (7) kg so
that the sample is formed (12) mixed equal sub sample which are taken from
deferent places.
Storage of Cement
A. Immediately upon arrival at the Site, cement shall be stored in:
i. Silos designed for this purpose, or

ii. Dry, weather-tight and properly ventilated structures with floors raised
450 mm above ground level with adequate provision to prevent
absorption of moisture.
iii. Each silo shall be labelled to show the type and source of cement.
iv. Separate silo shall be provided for each type of cement.
B. Cement delivered to the Site in drums or bags provided by the supplier or

manufacturer shall be stored in the drums or bags until used in the Works.
i. Any cement in drums or bags which have been opened shall be used
immediately.
ii. In no case shall bagged cement be stored in stacks more than eight
bags high.
iii. A free passage of at least one meter shall be left between the cement
and the sidewalls of the structure.
C. Where site limitations preclude the storage of cement on site, cement shall be
stored at a central location and shall be delivered daily as required to specific job
sites.
D. Different types of cement shall be kept in clearly marked separate storage

facilities.
E. All storage facilities shall be subject to approval by the Employer and shall be
such as to permit easy access for inspection and identification.
F. During transport and storage, the cement shall be fully protected from all adverse
weather elements.
G. Do not use cement more than 4 weeks old for silo stored cement and 6 weeks
for bagged cement unless otherwise approved by the Employer.
138
H. Any consignment of cement not used within two months from the date of
manufacture of cement, which, in the opinion of the Employer, is of doubtful
quality, shall not be used in the work until it has been retested as directed by the
Employer and shown to comply in all respects with the relevant standard of
manufacture.
2.02 MICROSILICA (MS)
A. Microsilica shall comply with ASTM – C1240 in addition to the following

requirements, unless otherwise approved by the Employer.
1. MS shall be from one source. MS supplied or blended from several different

sources shall not be accepted.
2. MS shall be supplied in powder form.
3. Amorphous silica (maximum 5%).
B. Whenever required by the Employer, representative samples of microsilica shall

be taken and forwarded in the presence of the Employer to an approved
independent laboratory for analysis to check compliance against the
Specification. A representative sample of microsilica shall be collected from each
consignment and kept in the store. Samples shall be disposed only with the
permission of the Employer.
Storage of (MS): Upon arrival at site, MS shall be stored in silos designated for this
purpose.
2.03 AGGREGATES
A. Aggregates shall meet the requirements of Table 4 along with the following
general requirements, unless otherwise approved by the Employer.
1. Aggregates shall consist of hard, durable, uncoated particles containing no

harmful material in quantities sufficient to adversely affect the concrete or
reinforcing steel.
2. The aggregates used in the permanent work shall be obtained only from the
sources approved by the Employer.
3. Aggregates shall comply with the requirements of IQS 45, BS 882, except as
modified hereunder and if necessary, shall be washed clean with potable
water, to comply with these requirements.
4. Samples of aggregates will be tested initially and at intervals during

construction of the works.
a. The Contractor shall provide the necessary equipment and labor for all
sampling.
b. If required by the Employer, any or all specified tests shall be carried out
in an approved independent laboratory and the Contractor shall bear all
the expenses.
5. Unless otherwise approved by the Employer, sampling of aggregates shall be

carried out in accordance with IQS 29 and the applicable Sections of BS 812.
139
3
6. Carry out all tests which the Engineer order a sample every 150 m , weighing
of sample at least (25) kilograms for coarse aggregate and weighing at least
(13) kilograms for fine aggregate.
7. Fine aggregate shall be naturally-occurring uncrushed sand, crushed sand, or

a blend of the two.
a. The use of clean dune sand, blended with coarser sand may be permitted
if it meets the applicable specification requirements (except grading).
b. Beach sand shall not be permitted for use in concrete mixes.
c. Combined or individual fine aggregate gradation shall be in accordance
with Zone 1 or Zone 2 of Table 4 of this Section.
d. The fineness modulus of fine aggregate shall be from 2.4 to 3.2.
e. The fineness modules shall not vary by more than ±0.2 from the value of
the representative sample used in the mix design.
8. Coarse aggregates of (single or graded) sized crushed (limestone or Rock).
a. The grading of coarse aggregate shall be in accordance with Table 1 of

this Specification.
b. Nominal sizes to be blended together shall be 20 mm and 10 mm, unless
c. In no case should the maximum size of aggregate be larger than 1/5 the
narrowest dimension between sides of the form, 1/3 of the thickness of
slabs or toppings or larger than 3/4 the minimum clear spacing between
reinforcing bars and is limited to one-third of the smallest inside diameter
of the pump or pipe line.
d. The variation of grading on any sieves between the approved samples and
subsequent consignments of single sized aggregate shall not exceed ±8%
by weight. If for any reason, grading is changed beyond these limits and
cannot be corrected for reasons beyond the control of the Contractor, the
Employer may request a new concrete mix design or modification to the
approved mix proportions.
9. Combined Aggregate
a. Approved coarse aggregate and fine aggregate in each batch shall be

combined in proportions to meet the specified grading in Table 3 of this
Specification.
b. In no case shall materials passing the 0.075 mm sieve exceed 3.0% for
gravel aggregate or 7.0% for crushed rock by weight of the combined
aggregate.
c. Changes from one gradation to another shall not be made during
progress of the work, unless approved by the Employer.
d. Crushed and uncrushed aggregates, except dune sand, shall be mixed
only if approved by the Employer.
e. During production the combined grading (all-in aggregates) shall not vary
on any sieve by more than 3% from the approved grading.
f. Shall be used only for compressive strength classes ≤ C12/15.
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TABLE 1 - SPECIFICATION LIMIT OF COURSE AGGREGATE
Sieve
20 mm to 20 mm 10 mm
Size
5 mm Nominal Size Nominal Size
mm
28.0 100 100 --
20.0 90-100 85 – 100 --
14.0 -- -- 100
10.0 30-60 0 – 25 85 – 100
5.0 0-10 0–5 0 – 25
2.36 -- -- 0-5
TABLE 2 - SPECIFICATION LIMIT OF FINE AGGREGATE

Zone 1 Zone 2
Sieve Size
Overall limits (Percentage by Mass (Percentage by Mass
(mm)
passing BS Sieve) passing BS Sieve)
10.0 100 100 100
5.0 90-100 90 – 100 90 – 100
2.36 60-100 60 – 100 65 – 100
1.18 30-100 30 – 90 45 – 100
0.600 15-80 15 – 54 25 – 80
0.300 5-48 5 – 40 5 – 48
0.150 0-15 0 – 15 0 – 15
TABLE 3 - SPECIFICATION LIMIT OF ALL-IN AGGREGATE

20 mm Nominal Size 10 mm Nominal Size
Sieve Size (Percentage by Mass (Percentage by Mass Screed Mix (Percentage by
(mm) passing BS Sieve) passing BS Sieve) Mass passing BS Sieve)
28.0 100 -- --
20.0 95 – 100 -- --
14.0 -- 100 --
10.0 -- 95 – 100 100
5.0 35 – 55 30 – 65 90 – 100
2.36 -- 20 – 50 60 – 100
1.18 -- 15 – 40 30 – 90
0.600 10 – 35 10 – 30 15 – 54
0.300 5 – 15 5 – 40
0.150 0–8 0–8 0 – 15 
 Increase to 10% for crushed rock fines.
 Increase to 20% for crushed rock.
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TABLE 4 - CONCRETE AGGREGATES
Requirement Test Methods Permissible Limits
BS 812 ASTM Fine Coarse
Grading Table 4 of BS 882 Table 3 of BS 882
Part 103 (wet)
(C & M only)
Material < 0.075 mm :
Natural / Crushed gravel Part 103 (wet) Maximum 5% Maximum 3%
Crushed Rock Maximum 15% Maximum 3%
Sand Equivalent Valve D2419 Minimum 75%
Clay Lumps and
C142 Maximum 1% Maximum 2%
Friable Particles
Light Weight Pieces C123 Maximum 1% Maximum 1%
Organic Impurities Test 8 max.0.05%. NA
of BS1377 Refer note 1
Water Absorption C128/C127 2.3% Maximum 2%
Specific Gravity (app.) C128/C127 Min. 2.6 Min. 2.6
Flakiness Index Part 105.1 NA Maximum 25%
Elongation Index Part 105.2 NA Maximum 25%
Acid Soluble Chlorides Maximum 0.03% Maximum 0.015%
Concrete with : SRC
Part 117,
Other concrete Maximum 0.05% Maximum 0.02%
Appendix C
For pre stressed and
steam cured Concrete max.0.01% max.0.01%
Acid Soluble Sulfates Part 118 Maximum 0.5% Maximum 0.1%
Soundness (MgSO4), after Maximum 15% Maximum 18%
C88
5 Cycles
Impact Value Part 112 NA Maximum 35%
Loss Angeles Abrasion C131,C535 NA Maximum 30%
Aggregate drying shrinkage BS1881: NA Max. 0.075%
Shrinkage Part 120
Potential Reactivity: C289 INNOCUOUS INNOCUOUS
(Refer Note 2) 6 MONTH 6 MONTH
Of Aggregates, Chemical EXPANSION EXPANSION
Method Of Cement- C227 0.10% MAX 0.10% MAX
Aggregate
Combination
Note: 1. Color of supernatant liquid shall be lighter than standard color solution if tested
according to ASTM C40, Use of a fine aggregate failing in the this test is not prohibited,
provided that, when tested for the effect of organic impurities on strength of mortar, the
relative strength at 7 days, calculated in accordance with Test Method C 87, is not less
than 95 %.
2. Potential reactivity and organic impurity tests are not required for RAK aggregates,
unless otherwise directed by the Employer.
3. Aggregates may initially be assessed for its reactivity in accordance with ASTM C289
and if potential reactivity is indicated, then mortar bar tests in accordance with ASTM
C227 shall be carried out.
4. Properties of aggregates specified in Table 7 shall be for aggregates from individual

sources or individual stock piles, unless otherwise directed by the Employer.
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TABLE 5
FREQUENCY OF ROUTINE TESTS ON AGGREGATES
S. No. Kind of requirement - Test method Test frequency rate
1 Grading BS 812 Part 103 Every Two weeks or per 100m3

whichever is more frequent
2 Material finer than 0.075mm BS 812 Part 103 Do
3 Clay lumps and friable particles ASTM C142 Do
4 Organic impurities BS 1377 Test B Each month or per 200m3 whichever is

more frequent
5 Water absorption - ASTM C128 / C12 Do
6 Specific Gravity - ASTM C128 / C127 Do
7 Shell content - BS 812 Part 106 Each two months or per 100m3
whichever is more frequent
8 Particle shape BS 812 Parts 105.1, 105.2 Do
9 Acid soluble chlorides, C1 Qualitative On each delivery to site

BS 812 Part 117 App. A/B Qualitative Each week if result is more than
BS 812 Part 117 App. C 75% of the limit and each month if
result is less than 75% of limit.
10 Acid soluble sulfates, SO3 Each 2 weeks if result is more than
BS 812 Part 118 75% of the limit and each 2 months if
result is less than 75% of the limit.
11 Soundness, MgSo4 (5 cycles) ASTM C88 Each two months
12 Mechanical strength
10% fines of impact value Each three months
BS 812 Parts 111, 112
Los Angles abrasion Do
ASTM C131 / C535
13 Moisture variation in sand by Moisture Meters Twice daily
Note 1: The above tests shall be carried out at the specified frequency at an approved
laboratory at the contractor expense.
Note 2: The above frequencies may be reduced at the Employer discretion.
B. Lightweight Aggregate: ASTM C 330, 10 mm nominal maximum aggregate size.
Storage of Aggregates
a. The Contractor shall provide means of storing the aggregates at each

point where concrete is made such that:
i. Each nominal size of coarse aggregates and fine aggregate shall be

kept separated at all times.
ii. Contamination of the aggregates by the ground or other foreign
matter shall be effectively prevented at all times.
iii. Each heap of aggregate shall be capable of draining freely.
143
iv. Storage shall be such as to minimize segregation.
v. Stockpiles shall be on hard and clean surfaces with not more than
5% slope and shall be shaded from direct sunlight.
vi. Aggregates shall be shaded to avoid direct sunlight.
vii. Each bin shall be labelled displaying the nominal size and source of
aggregate.
b. Coarse aggregates shall be stockpiled in at least two of the following

nominal sizes: 20 mm and 10 mm.
2.04 WATER
A. Water used for concrete-mixes and washing of equipment shall be potable water
and shall comply with the requirements of IQS 1703, unless otherwise stated
herein or in Table 6.
B. The pH of water used in concrete work shall be in the range of 7 to 9.
C. Ice if used, shall be flake ice and shall be the product of frozen water, which
complies with the acceptance criteria of Table 9, unless otherwise accepted by
the Employer.
D. Every effort should be made to protect water pipes and tanks from the sun, by
burying, shading, insulation and/or painting white.
E. Contractor shall make his own arrangements and obtain approval for the supply
of water.
F. Whenever required to do so by the Employer, the Contractor shall take samples

of the water being used for mixing concrete and test them for quality as directed
by the Employer.
G. No source of water shall be used unless approved by the Employer.
TABLE 6 - CHEMICAL LIMITATIONS FOR MIXING WATER

Parameter Test Method Limit (mg/l)
Chloride (as CI) ASTM D512 250
Sulfates ASTM D516 350
Alkali carbonates and bicarbonates ASTM D513 500
Total dissolved ions, including items above ASTM D1888 2000
Storage of Water: Store in clean covered tanks to prevent contamination. The chilled
water storage tank shall be insulated.
2.05 ADMIXTURES
A. General: Admixtures shall:

1. Not be used without the written approval of the Engineer;
2. Be used at the agreed dosage rates in strict accordance with the manufacturer's
recommendations and any Engineer's instructions;
3 Be of fresh stock
144
4. Shall contain no more than 0 05% chloride calculated as calcium chloride by
weight of cement in the concrete
5. Shall not contain more than 1.5% of the air regardless of the mixing time.
B. Pozzolanic Admixtures: Class C fly ash may be used as a cement substitute in the
range of 20%-25% for concrete that will not be exposed to the viewing public. Fly
ash shall meet the requirements of ASTM C 618 with a maximum loss of ignition of
3 percent. Fly ash shall not be used with Type IP (MS) or Type III portland cement.
Class C fly ash shall not be used where sulfate resistant concrete is required.
Where Type V portland cement is specified for sulfate resistance, Type II portland
cement and Class F fly ash may be used. Class F fly ash may be used as an
addition to Type V portland cement.
C. ground granulated blast-furnace slag (ASTM C 989)
D. Air-Entraining Admixture: ASTM C 260.
E. Chemical Admixtures: Provide admixtures certified by manufacturer to be

compatible with other admixtures and that will not contribute water-soluble chloride
ions exceeding those permitted in hardened concrete. Do not use calcium chloride
or admixtures containing calcium chloride.
1. Water-Reducing Admixture: ASTM C 494/C 494M, Type A.
2. Retarding Admixture: ASTM C 494/C 494M, Type B.
3. Water-Reducing and Retarding Admixture: ASTM C 494/C 494M, Type D.
4. High-Range, Water-Reducing Admixture: ASTM C 494/C 494M, Type F.
5. High-Range, Water-Reducing and Retarding Admixture: ASTM C 494, Type G.
6. Plasticizing and Retarding Admixture: ASTM C 1017/C 1017M, Type II.
F. Set-Accelerating Corrosion-Inhibiting Admixture: Commercially formulated, anodic

inhibitor or mixed cathodic and anodic inhibitor; capable of forming a protective
barrier and minimizing chloride reactions with steel reinforcement in concrete
and complying with ASTM C494/C 494M, Type C.
G. Non-Set-Accelerating Corrosion-Inhibiting Admixture: Commercially formulated,

non-set-accelerating, anodic inhibitor or mixed cathodic and anodic inhibitor;
capable of forming a protective barrier and minimizing chloride reactions with steel
reinforcement in concrete.
H. Color Pigment: ASTM C 979, synthetic mineral-oxide pigments or colored water-

reducing admixtures; color stable, non-fading, and resistant to lime and other alkalis.
I. Synthetic Fiber Reinforcement: Synthetic Fiber reinforcement shall be 100% virgin

polypropylene fibers. Fibers shall be added at the batch plant and shall be sized and
proportioned in accordance with manufacturer’s instructions for proper workability
and finishability. Fibers may be used to enhance concrete performance in regard to
plastic shrinkage or settlement crack resistance, abrasion and impact resistance,
and residual strength, but in no case shall fibers be used as a substitute for
structural reinforcement.
Storage of Admixture
a. Store in an enclosed container, recommended by the manufacturer and

protected from extremes of heat by shading.
b. All tanks shall be fitted with a circulating pump, which shall be operated
daily.
c. All tanks shall be indelibly marked for easy identification of its contents.
145
PART 3 – CONCRETE TYPES, MIX DESIGN AND QUALITY CONTROL
3.01 Concrete mixes shall comply with the requirements of Table 7, unless otherwise
3.02 Slump due to water content alone (without the addition of super plasticizer) shall
be as follows:
Allowable Slump Min-Max (inch)

Reinforced foundation walls and footings 1-3 (25-76 mm)
Unreinforced footings, caissons and substructure walls 1-3 (25-76 mm)
Reinforced slabs, beams and walls 1-4 (25-102 mm)
Building columns 2-3 (51-76 mm)
Pavements 1-2 (25-51 mm)
Sidewalls, driveways and slabs-on-ground 2-4 (51-102 mm)
Heavy mass construction 1-2 (25-51 mm)
Sidewalks, curbs and gutters 2-4 (51-102 mm)
Tolerance in Slump: When the specified slump is 3 inches or less, the tolerance shall
be plus or minus 1/2 inch. When the specified slump is greater than 3 inches, the
tolerance shall be plus or minus 1 inch.
After the addition of super plasticizers, slumps may range from 3 to 11 inches (76 mm
to 279 mm) provided that the concrete mix is cohesive and non-segregating, has
controlled time of set and minimal bleed water.
3.03 Design of Concrete Mixes
1. At the start of the Works, the Contractor shall design a mix for each grade of
concrete listed in Table 1 that is required to be built into the Works.
2. Mix designs may be proportioned according to a recognized standard or on a
trial and error basis as approved by the Employer.
3. The target mean strength shall exceed the characteristic strength by a margin
of 1.64 times the standard deviation expected from the concreting plant using
the same materials and supervision.
2
a. No standard deviation less than 3.5 N/mm shall be used as a basis for
designing a mix.
2
b. If previous data is not available a standard deviation of 6.0 N/mm shall
be used as a basis.
c. The Contractor shall propose the standard deviation.
4. Submit full details of the mix designs to the Employer for his approval.
5. Each mix design shall be such that:
a. Combined aggregate grading shall be continuous (not gap graded).

b. Aggregate quantity shall be calculated by weight.
c. Mixes shall be designed to produce a characteristic strength of not less
than that specified in Table 7.
d. The combined grading (all-in) of the aggregate shall comply with Table 3
of this Specification for 20 mm and 10 mm nominal size.
e. All aggregates except dune sand shall be from the same source, unless
f. Cementitious Materials: Limit percentage, by weight, of cementitious
materials other than Portland cement in concrete as follows:
1. Fly Ash: 25 percent.
2. Combined Fly Ash and Pozzolan: 25 percent.
3. Ground Granulated Blast-Furnace Slag: 50 percent.
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TABLE 7 - GENERAL REQUIREMENTS FOR CONCRETE MIXES
Max Type Cementitious Comp. Target Max. Max.

Max. Max. Max. Max. Max. Max.
Concrete Typical Applications Agg. of Min. Min. Min. Str. Slump Unit Wat. Wat.
W/C Temp. Bleed RCP Cl SO3
Grade Size Ceme Total GGBS MS cubes (mm) Wt. Abs. Perm.
Ratio (0C) (%) (Coul.) (%) (%)
(mm) nt (kg/m3) (%) (%) (N/mm2) (kg/m3) (%) (mm)
C16/20 Blinding & Pipe Surround 20 SRC 280 Nil Nil 0.60 20 100±25 N/A N/A N/A N/A N/A N/A N/A 4.0
C20/25 All Reinforced concrete 20 OPC 340 Nil Nil 0.55 25 100±25 30 N/A 1.0 3.5 25 4000 0.10 4.0
C32/40FR Unreinforced Structures 20 OPC 380 Nil Nil 0.42 40 100±25 30 N/A 1.0 N/A N/A N/A N/A 4.0
C32/40GBS As Directed by the Employer 20 OPC 380 65 Nil 0.40 40 150±35 28 ±35 0.5 2.0 20 1200 0.10 4.0
C32/40GMS As Directed by the Employer 20 OPC 400 55 4 0.38 40 150±35 30 ±35 0.5 1.5 10 800 0.10 4.0
C50/60SCC As Directed by the Employer 20 OPC 450 55 4 0.36 60 Table 8 30 ±35 0.5 1.5 10 800 0.10 4.0
Flowable 1.5 See 1900
Soil replacement 5 SRC 80 50 Nil N/A N/A N/A N/A N/A N/A N/A 4.0
Fill (Max.) Note 11 ±300
Protection for Water Proofing 35
Screed Mix - SRC 400 Nil Nil 0.50 125±35 32 ±35 N/A N/A N/A N/A 0.10 4.0
Membrane (Min.)
Annulus 12 See
Filling Pipe annulus 5 SRC 600 Nil Nil 0.45 32 ±50 N/A N/A N/A N/A N/A 4.0
Grout (Min.) Note 11
Notes: 1. Target unit weight shall be established during plant trials and shall not vary more than the tolerances shown in Table 7.
2. Except for flowable fill, screed mix and annulus grout, and values for compressive strength are minimum characteristic strength at 28 days.
3. Values for water permeability, water absorption and RCP are at 28 days.
4. Max. MS content shall be 8%.
5. Max. GGBS content shall be 50%.
6. Except for SCC mixes, cementitious content shall not exceed 450kg/m3.
7. Nominal aggregate size shall be 20 mm, unless otherwise approved by the Employer.
8. Concrete mixes with 10 mm nominal size aggregate may be used in congested areas, if the cementitious content is increased 30 kg.
9. GGBS and MS shall be proportioned by weight of total cementitious material.
10. C40FR shall include up to 1.0 kg/m3 fiber reinforcing (exact rate shall be determined by trials).
11. Consistency of flowable fill and annulus grout shall be as approved by the Employer during plant trials.
12. Additional requirements for Self Compacting Concrete (SCC) shall be as specified in clause 3.03 6.
13. Combined grading for screed mix shall be as shown in Table 3.
14. For minimum mixing times, see clause 3.08-A.4.b.
15. For massive reinforced concrete structures in excess of 1000 mm thick, peak temperature after casting shall not exceed 700C and maximum temperature differential
shall not exceed 200C, unless otherwise approved by the Employer.
147
4. The amount of Ground Granulated Blast Furnace Slag is limited to 50
percent of the total weight of cementitious materials.
5. Silica Fume: 10 percent.
6. Combined Fly Ash, Pozzolans, and Silica Fume: 35 percent with fly
ash or pozzolans not exceeding 25 percent and silica fume not
exceeding 10 percent.
7. Combined Fly Ash or Pozzolans, Ground Granulated Blast-Furnace
Slag, and Silica fume: 50 percent with fly ash or pozzolans not
exceeding 25 percent and silica fume not exceeding 10 percent.
g. Admixtures: Use admixtures according to manufacturer's written

instructions.
1. Use plasticizing admixture in concrete, as required, for placement
and workability.
2. Use water-reducing and retarding admixture when required by high
temperatures, low humidity, or other adverse placement conditions.
3. Use water-reducing admixture in pumped concrete, concrete for
heavy-use industrial slabs and parking structure slabs, concrete
required to be watertight, and concrete with a water cementitious
materials ratio below 0.50.
4. Use corrosion-inhibiting admixture in Concrete Mix where indicated.
h. Color Pigment: Add color pigment to Concrete Mix according to

manufacturer's written instructions and to result in hardened concrete
color consistent with approved mockup.
6. Self-Compacting Concrete (SCC): Self-compacting concrete shall meet all the

requirements of this section, except as modified hereunder or as agreed with
the Contractor.
3
1. Cementitious content shall not exceed 550 kg/m .
2. If necessary, a viscosity enhancer shall be used to prevent segregation.
3. Typical requirements for combined grading are not be applicable to SCC.
4. SCC may be placed with or without a concrete pump.
5. Because of the fluid consistency of the mix, special care shall be taken
for the design and construction of the formwork.
6. The type and quantity of admixtures used in the concrete shall be
subject to the approval of the Contractor.
7. In addition to requirements in Table 7, SCC concrete shall meet the
requirements of Table 8, unless otherwise approved by the Contractor.
The slump flow shall be checked on each truck load of concrete at the
job site. If segregation is noticed, other tests shall also be conducted on
site as directed by the Employer.
TABLE 8
Test Property Test Method Specification Limit
Filling Ability Slump flow 625 – 800 mm (spread)

Filling Ability V-Funnel 5 – 10 seconds
Segregation Resistance V-Funnel +3 seconds
Passing Ability Fill Box 90 to 100%
Passing Ability U - Box 0 to 30 mm
148
3.04 DURABILITY
A. Following are the durability criteria required for various Concrete mixes to be
used in the Project:
Chloride Permeability to AASHTO- T-277
Type of Structure Maximum Charge Pass at 28 Days

(Coulombs)
Superstructure 4,000
Substructure 2,000
Water Permeability to DIN 1048

(Coulombs)
Superstructure 15 mm
Substructure 8 mm
30 Minute Absorption to BS 1881 Part 122

(Coulombs)
Superstructure 3.5%
Substructure
3.05 LABORATORY TRIALS
A. Upon the Employer’s request, preliminary laboratory trials shall be carried out
with the approved materials to determine if the mixes will satisfy the Specification.
1. The mix design process shall be under the control of an experienced mix
design specialist.
2. Samples shall be taken and tests shall be conducted at a laboratory approved
by the Employer to prove conformance with all the requirements in Table 7.
3. If any of the values obtained are unacceptable, the mixes shall be re -
designed.
4. Approval of the laboratory-mix proportions shall in no way relieve the
Contractor of his responsibility to produce concrete, which meets the
requirements of these Specifications.
5. All costs connected with the laboratory trials and the design of the proposed
mixes shall be borne by the Contractor.
6. Whenever a change of brand or source for any of the concrete ingredients
occurs, additional laboratory mixes may be required and the cost of these
trials shall also be borne by the Contractor.
7. Mix proportion shall be adjusted to give a theoretical yield of 0.995 to 1.005
m3 as described in ACI 211.1. The entrapped air content shall be assumed
as 2.0% for 20 mm nominal size aggregate and 3% for 10 mm nominal size
aggregate.
149
3.06 PLANT TRIALS
A. As soon as the Employer has approved the concrete mix proportions from the
laboratory trial, the Contractor shall conduct a plant trial in the presence of the
Employer.
1. All concrete mixes shall require a plant trial, unless waived by the Employer.
2. Before starting full-scale plant trials, all materials and equipment shall be
available for inspection by the Employer and the plant shall be in the full
working order.
3. The plant trials must prove compliance of all criteria set forth in Table 7,
unless otherwise accepted by the Employer.
4. Plant Trials shall be mixed for the same time, by the same means and with
the same equipment, which the Contractor proposes to use in the Works.
5. The proportions of cement, GGBS, MS, aggregate and water shall be
carefully determined by weight to correspond with the Contractor's approved
mix proportions.
6. Contractor shall make three separate truck loads for each concrete mix,
3
a. Each load shall be not less than 3.0 m mixed in at least 2 batches,
unless otherwise accepted by the Employer.
b. Twelve 150 mm test specimens shall be made from each load for C25,
and other mixes. Methods of making and curing specimens shall be in
accordance with BS 1881: Part 108 and Part 111 respectively and as
follows: Specimens shall be stored in insulated boxes until removed
from the moulds.
7. The Contractor shall carryout all tests mentioned in Table 7 at a laboratory

a. Whenever required, initial and final setting time of concrete shall also be
conducted as directed by the Employer.
b. Air content shall be conducted on C40N, C40FR, GBS, and GMS & SCC
mixes.
8. The slump and temperature of each batch during each plant trial shall be
measured and recorded, by the method described in BS 1881, immediately
after mixing and thereafter at 15 minutes intervals up to 90 minutes after
batching or as envisaged for delivery and standing on site. Based on these
trials, the Employer shall identify any adjustments required for acceptable
workability.
9. Three specimens shall be tested at 3, 7, 14 and 28 days for hardened density
and compressive strength as described in BS 1881: Part 114 and Part 116
respectively.
a. If the average value of the strength of three specimens tested at 28 days

is less than the characteristic strength given in Table 7, the mix shall be
rejected and redesigned.
b. If the difference between the greatest and the least strengths at 28 days
is more than 15% of the average strength of that batch or if the range of
the three batch averages exceeds 20% of the overall average of the
batches, the Plant trial shall be repeated.
10. For Water Permeability : 3 specimens shall be tested at 7 and 3 at 28 days.

11. For RCP : 3 specimens shall be tested at 7 and 3 at 28 days.
12. For water absorption : 3 specimens shall be tested at 7 and 3 at 28 days.
150
B. Re-design of the concrete mixes and the making and testing of preliminary and
trial mixes of concrete shall be repeated for each grade of concrete until all
results meet the requirements of Table 7.
C. Trial Panel and Block
1. For C21/25 & grades containing GGBS and/or MS, at least one reinforced
horizontal slab measuring 1.0 m x 2.0 m x 0.30 m and one reinforced wall
section measuring 1.2 m high, 2.0 m long and 0.30 m thick shall be
monolithically cast utilizing the same placement and curing methods as
proposed for the works.
a. Configuration of reinforcement shall be as directed by the Employer.

b. A polythane sheet shall be placed below the slab.
2. Each slab shall be sampled and tested for RCP, water permeability and water
absorption.
a. Each sampling shall consist of three cores of suitable diameter and

length.
i. 100 mm diameter for RCP tests.

ii. 150 mm diameter for water permeability tests.
iii. 75 mm diameter for water absorption tests.
b. The location of the cores shall be as directed by the Employer.

c. A cover meter shall be used to locate and avoid rebar in the core.
3. Additional cores shall also be taken if directed by the Employer.

4. The cores will be given to the Employer for delivery to an independent
laboratory of the Employer’s choice.
5. The cores shall be promptly tested for RCP, water absorption and water
permeability values and the results promptly given to the Employer.
6. The average value from the cores taken from trial slabs at 28 days shall not
exceed the following, unless otherwise approved by the Employer.
C20/25 GBS Mixes GMS & SCC

Maximum RCP values
4000 1200 800
(Coul.)
Maximum W.P. values (mm) 25 20 10
Maximum W.A. values (%) 3.0 2.0 1.5
7. All associated costs for coring and testing shall be borne by the Contractor.
D. The Contractor shall only use the approved mix of each grade of concrete in the
Works. If at any time during the construction of the Works, the source of cement,
GGBS, MS, aggregate, admixture or mix proportions are changed, the concrete
shall be rejected and/or new trial mixes shall be made, tested and approved for
use. If any unapproved mixes or non-compliant concrete is used in the
permanent works, it shall be removed and replaced at the Contractor’s expense,
E. If requested by the Employer, additional specimens may be required and trials

carried out to determine:
1. Stripping times for formwork.

2. Efficiency of curing.
3. To check testing and sampling errors.
151
3.07 ROUTINE CONCRETE TESTING
A. Under the supervision and direction of the Employer, the Contractor shall
perform all tests as shown in Table 9, unless otherwise approved by the
Employer.
TABLE 9 - FREQUENCY OF TESTING FOR FRESH AND HARDENED CONCRETE

Minimum Frequency
Test Higher than C17/20 C40N & GBS, GMS
C17/20
EX. C20/25 & SCC Mixes
Temperature Alternative loads Each load Each load
Concrete Slump Alternative loads Each load Each load
Visual Exam of Each load Each load Each load
Aggregate
(after washing)
Compressive Stress 3 sample per 100 m³ 3 sample (9 3 sample per (50 m³
and Density specimens) for first 50 for raft foundation &
m³ then subsequent to break water) , (20m3
50 m3 of production for all structural
1set/150 m3 or element) or 200 m2
(minimum once a day) (minimum once a day)
Unit Weight (wet) As directed by the As directed by the As directed by the
Employer Employer Employer
Air Content N/A As directed by the As directed by the
Employer Employer
Concrete Bleeding NA Once a month Once a month
Water Absorption NA NA 3 specimens per 100
Water Permeability NA NA m3
3 specimens per 100
m3
Rap. Chl. Pen. (RCP) NA NA 3 specimens per 50 m3
SO3 and Cl Contents As directed by the As directed by the Every 250 m3
Employer Employer
B. Current Margin: Unless otherwise approved by the Employer, the current margin
for compressive strength shall be established for each approved mix design as
follows:
1. The first 35 truckloads shall be sampled.
2. At least three specimens shall be taken for each sampling and crushed at 28
days. Additional specimens (three each) for 7-day strength need only be
taken as required meeting Table 8.
3. The current margin for 28 days compressive strength shall be established as

1.64 times the standard deviation obtained from the above 35 results.
4. The standard deviation is calculated by summing the squares of the

differences of the individual test values from their average, dividing by one
less than the number of test values, and taking the square root of the results,
it is expressed in the same units as the test results themselves.
i.e. Standard Deviation = ( Σ ( X − X1) 2

/ (n − 1) )
Where x is an individual test results
X1 is the average value of test results
n is the total number of tests analyzed
152
C. Routine Test Specimens
1. In addition to the above, test specimens shall be randomly taken from the
concrete which is being used in the work and prepared in accordance to the
relevant standard and the following provisions, unless otherwise approved by
the Employer.
a. All specimens shall be made at the point of delivery and all specimens
for each set must be from the same load (transit mixer truck).
b. Use approved cube moulds of the same type and manufacture for
making all test specimens.
c. Start tests for slump, temperature, and air content within 5 min after
obtaining the final portion of the composite sample. Complete these tests
expeditiously. Start molding specimens for strength tests within 15 min
after fabricating the composite sample. Expeditiously obtain and use the
sample and protect the sample from the sun, wind, and other sources of
rapid evaporation, and from contamination.
d. All specimens shall be kept in closed insulated boxes for initial curing
until removed from the moulds and placed directly in a suitable curing
tank.
e. Six specimens (150 mm) shall be made for density and compressive
strength testing.
f. Three specimens (150 mm) shall be made for water permeability testing.
g. Three specimens (150 mm) shall be made for water absorption testing.
h. Each grade of specimens shall be indelibly numbered consecutively
throughout the work and marked with the date.
i. Make the samples to be used for tests take at least 1.5 times the
quantity estimated as being required for the tests.
2. Compression Test Specimens:
a. Cast and laboratory cure two sets of two standard cylinder

specimens for each composite sample.
b. Cast and field cure two sets of two standard cylinder
specimens for each composite sample.
3. Compressive Strength Tests: test one set of two laboratory-cured specimens

at 7 days and one set of two specimens at 28 days.
a. Test one set of two field-cured specimens at 7 days and one

set of two specimens at 28 days.
b. A compressive strength test shall be the average
compressive strength from a set of three specimens obtained
from same composite sample and tested at age indicated.
4. When strength of field-cured cylinders or cubes is less than 85 percent of

companion laboratory-cured cylinders or cubes. Employer shall evaluate
operations and provide corrective procedures for protecting and curing in-
place concrete.
5. In the sampling and testing plan and the conformity criteria of individual
concrete compositions or concrete families, distinction is made between initial
production and continuous production.
Initial production covers the production until at least 35 test results are
available.
Continuous production is achieved when at least 35 test results are obtained

over a period not exceeding 12 months.
153
6. For compressive strength and density, test three specimens at 7 days and
three at 28 days.
a. The mean of three specimens strength results made from one sample
are tested at the same age shall be taken as a test result. If an individual
specimen result varies by more than 10% from the mean result, that
specimen value shall be discarded and the result will be the average of
the remaining specimens values.
i. Investigations to determine the reason for such high variations shall

be carried out as directed by the Employer.
ii. If an individual specimen test result varies by more than 15% from
the mean, that result shall be deemed invalid and cores shall be
taken from the area in question, unless otherwise directed by the
Employer.
b. The mean of the any four consecutive test result exceeds the specified
2
compressive strength by at least (4 N/mm for initial production or 1.48
times the standard deviation for continues production), and no any
individual test result (average of three specimens) below the specified
2
compressive strength by more than 4 N/mm .
c. Results meeting the following criteria shall be considered as non-

compliant.
i. The average strength determined from any four consecutive test

results does not exceed the specified characteristic strength by 0.5
times the current margin.
ii. Three or more results in any 35 consecutive results are less than the
specified characteristic strength.
iii. One or more results in any 35 consecutive results are less than 85%
of the specified characteristic strength.
iv. Average strength of all 35-test results in each set of 35 are less than
the specified characteristic strength by 1.48 times the current
standard deviation.
d. If the average 7-day strength indicates that the concrete may be

defective; the Contractor shall immediately inform the Employer and stop
all concrete activities until the reason for such low strength is determined
and corrected.
e. At the Contractor’s option, potentially defective concrete may be removed

and replaced without awaiting the 28-day test results.
7. For water permeability, test three specimens at 28 days.
8. For water absorption, test three specimens 28 days.
9. For rapid chloride penetration, test three specimens at 28 days.
10. If the test specimens fail to meet the designated requirements, then the
following action shall be taken by the Contractor.
i. Suspend concreting operations and do not proceed further without

ii. Take test cores in accordance with BS 1881: Part 120, from suspect
concrete and test as directed by the Employer.
iii. Any Re-testing shall be conducted to the Employer’s satisfaction at the
Contractor’s expense.
154
D. Routine Concrete Coring and Testing
3
1. From every 500 m of concrete cast with GBS, GMS or SCC mixes, the
Employer shall designate a structure (or portions of a structure) to be core
sampled and tested for RCP values.
2. Each sampling shall consist of three 100 mm dia. cores of suitable length for
RCP testing.
a. The Contractor shall provide a covermeter to locate the rebars.
b. Core locations shall be marked by the Employer.
c. The cores will be given to the Employer for delivery to an independent
laboratory of the Employer’s choice.
3. The cores shall be promptly tested for RCP values and the results promptly
given to the Employer.
4. The average value at 28 days shall comply with the same requirements as for
trial slabs.
5. All associated costs for coring and testing shall be borne by the Contractor.
6. In addition to the frequency mentioned in Table 8, the Contractor shall collect
dust samples or core specimens for chloride and sulphate contents,
whenever required by the Employer.
a. Samples shall be collected as directed by the Employer and the samples

shall be given to the Employer for sulphate and chloride content tests.
b. The samples will be sent to an approved independent laboratory and the
Contractor shall bear all the costs associated for sampling and testing.
c. The results of each structure in question shall comply with the following
requirements:
TABLE 9 - Limits of Chloride and Sulphate Content on Site Samples

Sulphate
Chloride (Cl)
(SO3) by
by weight of
weight of
Description cement in the
cement in
mix
the mix
(Maximum)
(Maximum)
For reinforced Made with SRC 0.15%
4%
concrete Made with cement other than SRC 0.30%
For unreinforced Made with SRC 0.20%
4%
concrete Made with cement other than SRC 0.65%
E. The Contractor shall keep records of all specimens taken and tests made using a
proforma approved by the Employer.
F. Submit at weekly intervals, test reports giving test results for slump, temperature,
hardened density, strength and any other tests performed during the week. In
addition to the above, the Contractor shall submit a monthly report and statistical
analysis as directed by the Employer.
G. If high variability in slump values or wet unit weight occur, the Employer may
instruct the Contractor to stop concreting operations, until corrective action is
taken.
H. Cost of all sampling and testing shall be borne by the Contractor.
155
3.08 MIXING AND DELIVERY OF CONCRETE
A. All concrete batching shall comply with the following requirements, unless
1. All concrete shall be manufactured in a fully automated; computer controlled
batching plant, approved by the Employer. The plant shall be equipped with
a suitable water chiller along with sufficient insulated storage and flake ice-
making facility with automatic feed to ensure concrete temperatures are
maintained within specified limits. Dry mixing or mixing in the truck drum will not
be allowed.
2. Mixing and transporting of concrete shall be in accordance with the
requirements for ready mixed concrete in BS 5328 or ASTM C94 except as
modified hereunder or as directed by the Employer. Concrete shall be
transported from the mixer to the point of placing as rapidly as practicable in
approved agitators.
3. Concrete shall be mixed in batches with suitable equipment capable of

combining the aggregates, cement, GGBS, MS and water (including
admixtures, if any) into a mixture of uniform colour and consistency and of
discharging the mixture without segregation.
4. Amount of concrete mixed in any one batch shall not exceed the rated
capacity of the mixer.
a. Manufacture’s rated capacity shall be displayed on the mixer in terms of

the volume of mixed concrete.
b. Unless mixer performance tests are conducted to ASTM C94 and
approved by the Employer the following mixing time shall be used.
i. 30 seconds for concrete without mineral addictives.

ii. 45 seconds for concrete with cement and GGBS.
iii. 60 seconds for concrete with cement, GGBS and micro silica.
c. All materials from the previous batch shall be removed before materials
for a fresh batch enter the drum.
d. If work is suspended, including any periods exceeding twenty minutes,
the mixers and all handling plant shall be washed with clean water.
e. All mixing and batching equipments shall be maintained free of set
concrete, cement or any other deleterious materials and shall be clean
before commencing mixing
5. No water shall be added into the concrete after initial mixing at the plant.
B. Transportation, delivery and handling shall be in accordance with BS 5328 or ASTM

C94 except as described hereunder, unless otherwise approved by the Employer.
1. Each truck shall arrive at the job site with its water container full.
a. All trucks used to deliver concrete shall be approved by the Employer.

b. Water tank of each truck shall contain a transparent tube or some other
approved device to check the level of water in the tank.
c. In the event that the water container is not full or field test results are
outside the acceptable limit, the load shall be rejected.
2. Contractor shall be responsible for delivering concrete in such a manner as to

avoid cold joints.
156
C. When the concrete is mixed in a truck loaded to its maximum capacity, the number
of revolutions of the drum or blades at mixing speed shall be not less than 70 nor
more than 100. If the batch is at least one-half (1/2) cubic yard less than the
maximum capacity, the number of revolutions at mixing speed may be reduced too
not less than 50. All revolutions after 100 shall be at agitating speed.
D. When a truck mixer or agitator is used for transporting concrete, the concrete shall
be delivered to the site of the work and discharge shall be completed within 45
minutes or before the drum has been revolved 300 revolutions, whichever comes
first, after the introduction of the mixing water to the cement aggregates. In hot
weather, or under conditions contributing to quick stiffening of the concrete, the time
may be reduced by the Superintendent. When a truck mixer is used for the complete
mixing of the concrete, the mixing operation shall begin within 30 minutes after the
cement has been intermingled with the aggregates only.
E. Frequency of sampling and testing shall be as defined in Section 3.05.
F. Allowable batching tolerances shall be as shown in Table 10, unless otherwise

3
approved by the Employer. When producing small loads, (less than 1.5 m ) or loads
comprised of only 1 or 2 batches, greater cumulative tolerances may be allowed
with the Employer’s permission.
TABLE 10 - ALLOWABLE BATCHING TOLERANCES

Material Individual Batch Cumulative Load
Cement + 2% + 1%
GGBS + 2% + 1%
M.S. + 4% + 1%
Aggregates + 2% + 1%
Water + 1% + 1%
Ice + 1% + 1%
Admixtures + 3% ± 3%
G. If field tests show excessive temperature, non-compliant slump, non-compliant unit

weight, or any other discrepancy the entire load of concrete from which the sample in
question was taken shall be rejected.
1. The slump and temperature tests shall be carried out t the point of discharge
just before placement.
2. Rejected concrete shall be removed from the site at the Contractor's expense
3. Perform slump tests in accordance with BS 1881 at the site of pour for each
load delivered to site, except of grade C20 which shall be at the Employer’s
decision. Concrete placement shall proceed only following satisfactory
verification of slump or other specified field test results.
H. Use mixed concrete without delay. Concrete shall be placed not later than 90
minutes from the time of mixing, unless otherwise approved by the Employer.
I. Concrete must be placed and compacted up to the designated construction joints

before initial set has occurred. The timetable for the depositing of concrete should be
so arranged that no face of concrete shall be left exposed for more than 20 minutes
before fresh concrete is deposited against it in order to avoid cold joints.
157
3.09 HOT WEATHER CONCRETING
A. Follow the recommendations of ACI-305 and the following precautions during hot
weather, unless otherwise directed by the Employer.
1. Cool ingredients before mixing to maintain concrete temperature at time of

placement below 90 degrees F (32 degrees C).
2. Take all precautions necessary to prevent the temperature of concrete rising
0
above 30 C at the time of placement.
3. When air temperature is between 85 and 90 deg F (30 and 32 deg C), reduce
mixing and delivery time from 90 minutes to 75 minutes; when air
temperature is above 90 deg F (32 deg C), reduce mixing and delivery time to
60 minutes.
4. Do not mix or place concrete when the ambient shade temperature is
0 0
above 40 C on a rising thermometer or above 43 on a falling
thermometer. Hours at which concreting will be allowed to take place will be
agreed with the Employer.
5. Cool aggregate with draughts and/or shade from direct sunlight.
6. Cold water to be used in mixing.
7. When ice is used, take into account all ice when computing water/cement
ratios. Ensure that ice is melted before the concrete leaves the mixer.
8. Paint white, provide shade or insulate the rotating mixer drum to prevent
overheating of the metal and excessive heat transfer.
9. Cover reinforcing steel with water-soaked burlap when required to ensure that
steel temperature will not exceed the ambient air temperature immediately
before embedment in concrete.
10. Wet forms thoroughly before placing concrete.
11. Use water-reducing retarding admixture (Type D) when required by high
temperatures, low humidity, or other adverse placing conditions.
12. Record temperature of concrete for each truck as delivered and after placing
in forms. Record air content and slump for each truck.
13. No concrete shall be placed during sandstorms or heavy rains.
3.10 NON-COMPLIANT CONCRETE
A. Concrete shall be considered to be non-compliant if any of the following

conditions are found to exist.
1. Compressive strength results less than those shown in Table 7.

2. Unapproved mix is used.
3. Approved mix proportions or materials have been changed.
4. Sulphate or chloride contents in excess of those shown in Table 9.
5. Water/cement ratio in excess of Table 7.
6. Cementitious content less than those in Table 7.
7. Water permeability, water absorption or RCP values in excess of those
shown in in Table 7.
8. Concrete that fails to meet one or more requirements of the specification.
9. Lines and levels outside allowable tolerances
10. Excessive Honey comb
11. Insufficient rebar cover
12. Exposed reinforcement.
13. Embedded timbers or rocks.
14. Cracks in excess of 0.2 mm
15. Improperly formed or leaking joints.
16. Crazing or cracking caused by insufficient curing.
17. Curing not in accordance with Contract Documents.
18. Concrete members cast in the wrong location.
158
19. Reinforcing size, quantity, strength, and position or splicing at variance with
the Contract Documents.
20. Damaged concrete.
B. Any structures containing non-compliant concrete shall be completely broken

out and removed, unless otherwise accepted by the Employer. If broken out,
the concrete shall be replaced as directed by the Employer and the Contractor
shall bear all costs associated with reconstruction.
C. The Employer’s decision shall be final in all aspects related to non-compliant

concrete.
D. Any additional costs associated with non-compliant concrete shall be at the

Contractor’s expense.
159
SECTION 3.4 CONCRETE REPAIR
PART 1 - GENERAL
1.01 SUMMARY
A. This Section specifies concrete repairs.
1.02 RELATED SECTIONS
A. Section 4.4 - Quality Control & Submittals.

B. Section 3.2 – Formwork AND CONCRETING PRACTICE
C. Section 3.5 - Testing of Water Retaining Structures.
1.03 REFERENCES
A. ASTM C150 Specification for Portland Cement.

B. ASTM C1140 Standard Practice for Preparing and Testing Specimens from
Shortcrete Test Panels.
C. ASTM C1202 Test Method for Electrical Indication of Concrete’s Ability to Resist
Chloride Ion Penetration.
D. BS EN 12504-1 Testing concrete in structures.
E. BS 1881 Methods of testing concrete.
F. BS 4652 Zinc-rich priming paint (organic media)
G. BS 6319 Testing of resin compositions for use in construction.
H. ACI 506 Guide to Shotcrete
I. ACI 506.2 Specification for Shotcrete
J. ACI 506.3 Guide to Certification of Shotcrete Nozzlemen
K. ACI 506.4 Guide for the Evaluation of Shotcrete
L. ACI 548.1 Guide for the use of Polymers in Concrete
M. DIN 1048 Test methods for concrete
1.04 DEFINITIONS
1. “Micro-concrete” is a mixture of Portland cement, water and suitably graded

aggregates proportioned to produce a free flowing concrete without segregation
of the constituents.
2. “Mortars” are cementitious or chemical materials proportioned to produce a
trowelable consistency for vertical and overhead repairs.
3. “Fillers” are cementitious or chemical materials used for repair of small air holes,
pinholes or cavities.
4. “Injection resins” are extremely fluid chemical materials used for crack injection.
A. Products, application, and testing shall comply with the following requirements,
unless otherwise approved by the Contractor.
1. Lower Tier contractors thoroughly specialising in repair techniques shall carry out
the works. The contractor’s staff shall not carry out concrete repair works.
2. Only independent laboratories or Lower Tier bcontractors thoroughly familiar with
testing techniques shall carry out testing procedures.
3. All product manufacturers shall operate under a certified ISO 9000 Quality
System.
160
B. The repair system to be used for a particular area or member will be designated by
the Contractor and will generally be as follows:
1. Cementitious repair mortars shall be used for small surface repairs, generally
2
smaller than 5 m .
2. Micro-concrete shall be used for small, localised repairs, generally smaller than 1
3
m.
2
3. Shotcrete shall be used for large surface repairs, generally larger than 5 m .
3
4. C32/40 concrete shall be used for large repairs, generally larger than 1m .
5. Cracks or construction joints, which are leaking, shall be injected with vinlyester
or polyurethane resins as directed by the Contractor. If leaking is too great for
typical crack injection methods, approved foaming agents or rapid setting mortars
may be used with the Contractor’s permission.
6. Poorly formed construction joints or cold joints shall be repaired as directed by
the Employer.
1.06 SUBMITTALS
A. The Subcontractor shall submit sufficient information, before purchase, according to

Section 4.4 including:
1. Manufacturer’s name.
2. Supplier’s name.
3. Product name (if applicable).
4. Product description.
5. Manufacturer’s technical data.
6. Storage instructions.
7. Application instructions.
8. Mix design (if applicable).
B. Samples (applied) shall be supplied for at least the following products or as requested
by the Employer:
1. Fillers.
2. Mortars.
3. Coatings.
4. Grouts.
5. Sealants.
6. Aggregates.
7. Cement.
8. Water.
9. Fibers.
C. The Contractor shall provide separate method statements meeting the requirements
of Section 4.4, for at least the following activities or as requested by the Contractor.
1. Grit blasting, typical surface preparation, all concrete repair methods including
rebar cleaning and coating.
2. Method of mixing and application of shotcrete.
3. Crack injection.
4. Coating application.
5. Grouting of rebar dowels.
D. The Contractor shall submit renovation drawings including maps for all members
(floors, walls, soffit, beams, columns, exterior roof) showing size, depth and type of all
repairs.
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E. Mock-up
1. The Contractor shall prepare a mock-up meeting the requirements of Section 4.4
for at least the following installations or as requested by the Employer.
a. Typical surface preparation (after grit blasting) and coating application.
(minimum 3 m2).
b. Shotcrete application (minimum 10 m2).
c. Crack injection (minimum 3 m)
d. All concrete repair methods (1m2)
e. Joint sealant replacement (1m)
2. The Contractor shall conduct pull-off tests on all repair and shotcrete applications
as directed by the Contractor, at no additional cost to the Empoyer.
a. The minimum pull-off strength shall be 1.5 MPa when failure occurs at the
interface or within the repair material.
b. If failure occurs in the parent concrete further investigation will be conducted as
directed by the Contractor.
3. Shortcrete panels of 80 cm x 80 cm x 12 cm simulating actual job conditions shall

be cast for each type of shortcrete applications and each shooting position to be
encountered in the structure and cores shall be cut for the following tests.
a. Compressive strength (three cores of 75 mm diameter)
b. Water absorption test (three cores of 75 mm diameter)
c. RCP test (three cores of 100 mm diameter)
d. Water permeability (three cores of 150 mm diameter)
e. Visual inspection (three cores of 100 mm diameter)
4. Cores (except for visual inspection) shall be from a non-reinforced section of the
panel.
5. Cores for visual inspection shall be from a reinforced section of the panel.
6. Cores for all tests shall be cut only 3 days before the testing date.
7. The length and width of the mould may be increased if required.
8. Cores for water absorption, water permeability and RCP shall be cured as
follows:
a. After drilling, wipe the surface clean and allow surface moisture to evaporate.
b. When the surface appears dry, but not later than 1 hour after drilling, place
cores in separate plastic bags to prevent loss of moisture.
c. Transport cores immediately to the testing laboratory and leave it in the
sealed plastic bags until the time of testing.
9. Shortcrete trial panels shall be cured on site in wet hessian and polythene sheet
as stipulated in ASTM C1140.
A. “Inspection Requests” shall be submitted to the Employer during the on site

installation work before proceeding with at least the following activities. Minimum
notification time shall be 24 hours.
1. Coating application
1. Shotcrete application
2. Application of repair Materials
3. Concrete casting
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C. Delivery, storage and handling shall be according to the manufacturer’s

1. Transportation, handling and storage shall at all times be performed in a manner

to avoid product damage.
2. All products shall be delivered in original unopened packages, containers, or
bundles, bearing the manufacturer’s name, product name, date of manufacture,
and date of expiry.
3. Do not store products directly on ground, unless approved by the Contractor.
4. Where product manufacturer recommends storage under controlled
temperatures, the Subcontractor shall provide an enclosed, insulated, cool store
maintained at the proper temperature 24 hours per day.
5. If stored outside, cover products to prevent ultraviolet degradation or moisture
impregnation as recommended by the manufacturer.
damage to the Empoyer.
a. Any products with damaged or previously opened containers found during

delivery, storage or installation shall be removed from site.
b. Any improperly stored or expired materials shall be removed from site.
c. Any damaged products deemed unsuitable for repair by the Employer shall
be removed from site and replaced at the Contractor’s expense.
7. Bulk mixed shotcrete shall be suitably stored on polythene sheets and kept well
covered with additional sheets to provide complete protection as directed by the
Contractor. Bulk mixed shotcrete shall be used within 3 days, unless otherwise
1.09 WARRANTY
A. The manufacturer and the Subcontractor shall jointly guarantee the completed repairs
to be free from defects in workmanship and materials for a minimum period of 10
years from the date of handover to the Contractor.
B. The Subcontractor shall furnish the manufacturer’s guarantee and warranty

certificates for all materials and components used.
C. If the concrete repairs are found to be defective during the warranty period, the
Subcontractor and manufacturer shall replace or repair the concrete without any
additional cost to the Contractor.
PART 2 - PRODUCTS
2.01 CEMENTITIOUS REPAIR MORTARS
A. Cementitious repair mortars shall be special purpose pre-bagged polymer modified

mortars requiring only the addition of water at site.
B. Cementitious repair mortar shall be a single component polymer modified, shrinkage

compensated, and high-build mortar free of chlorides with the following properties:
1. Minimum compressive strength: 35 MPa at 28 days (BS 6319 Pt.7)

2. Water permeability when tested to DIN 1048 shall not exceed 25 mm.
C. If required, bonding agents and ancillary materials shall be as recommended by the

repair material manufacturer, unless otherwise directed by the Employer.
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2.02 RAPID SETTING MORTARS
A. Rapid setting mortars for temporarily plugging leaks in running water shall be special
purpose pre-bagged cementitious mortars requiring only the addition of water at site.
The product shall produce an initial set in approximately 1 minute. A controlled rate
of set shall be provided to minimise risk of thermal cracking. The product shall be
chloride free.
2.03 MICRO-CONCRETE
A. Micro-concrete shall be supplied as a pre-bagged special purpose product requiring

only the addition of a pre-determined volume of water at site to produce a mix of
predictable performance. Micro-concrete shall be a single component, shrinkage
controlled, free flowing concrete with the following properties.
1. Minimum compressive strength 60 MPa at 28 days.

B. If required, bonding agents and ancillary materials shall be as recommended by the

repair material manufacturer, unless otherwise directed by the Contractor.
2.04 CRACK INJECTION RESINS
A. Crack injection resins shall comply with the following:
1. Foaming agents shall be water reactive, solvent free, two-component

polyurethane injection resin.
2. Polyurethane resin shall be two-component system, forming a permanent flexible
compound.
3. Vinlyester resin shall be a multi-part system, which forms a permanent flexible
self-swelling (salt-water grade) compound.
2.05 SHOTCRETE
A. Pre-bagged shotcrete shall be a single component cementitious material suitable for

dry or wet mix applications.
1. Maximum aggregate size: 13 mm

2. Specified compressive strength (average of three cores) shall be 35 MPa at 28
days.
3. Water permeability when tested according to DIN 1048 shall not exceed 25 mm.
4. Maximum RCP value shall not exceed 4000 coulombs.
5. A suitable fiber shall be incorporated to control cracking.
B. Bulk mixed shotcrete compliant with the recommendations of ACI 506.2 may be used
in lieu of pre-bagged shotcrete, if approved by the Contractor.
1. Aggregates shall meet the requirements in Section 3.3 except as modified

hereunder. All aggregates used in the dry mix shall be reasonably dry (no
surface water in the aggregate will be allowed)
2. The combined grading shall be within one of the following limits, unless otherwise
agreed by the Employer. Zone II and III shall be used only if approved by the
Employer.
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Sieve Size Zone I % Passing Zone II % Passing Zone III % Passing
12.5 mm 100 100 100
9.5 mm 90-100 100 100
4.75 mm 70-85 95-100 95-100
2.36 mm 50-70 80-100 70-90
1.18 mm 35-55 50-85 45-75
0.60 mm 20-35 25-60 25-60
0.300 mm 8-20 10-30 15-35
0.150 mm 2-10 2-10 8-16
3. A suitable approved fiber shall be added to the shotcrete to reduce crack

propagation.
a. Fiber shall be monofilament unless otherwise approved by the Contractor.

b. The use of fiber shall be strictly in accordance with the manufacturer’s
instructions and as approved by the Contractor.
c. Before the approval of shotcrete the Subcontractor shall carryout trials mixes
in the presence of the Contractor.
3
4. Minimum cementitious content shall be 415 kg/m and cement shall be ASTM
Type I.
5. Compressive strength shall be 35 MPa at 28 days.
6. Maximum RCP value shall not be more than 4000 coulombs.
0
8. The temperature of the mix shall not be more than 32 C.
9. Shotcrete shall comply with the following ACI Standards except as modified in
this Section:
a. ACI 506 Guide to Shotcrete

b. ACI 506.2 Specification for Shotcrete
c. ACI 506.3 Guide to Certification of Shotcrete Nozzlemen.
d. ACI 506.4 Guide for the Evaluation of Shotcrete.
e. ACI 548.1 Guide for the use of Polymers in Concrete.
10. Except as modified hereunder the mould for casting shotcrete panels shall
comply with the requirements of ASTM C1140.
11. Before the start of the work each nozzle man will be tested and shall obtain a
grade of 2.5 or better in accordance with ACI 506.3.
12. The Contractor shall spray shotcrete into approved moulds for cutting cores as
directed by the Employer for specified tests.
13. As required by the Employer cores shall be cut from the finished structure for the
specified tests and visual inspection. Cores for compressive strength shall be 75
mm diameter.
14. Dry mix delivered shall be well protected as directed by the Employer and shall
be used within 3 days. Dry mix not used within three days will be rejected.
15. The Contractor shall only be allowed to start the works after the Employer has
approved the materials, mix design, nozzlemen and the site procedures.
16. The finished surface shall be smooth, free from voids, cracks, honeycombing,
and suitable for the application of surface coatings or other finishes.
2.06 CONCRETE
A. Requirements for C32/40 concrete with 10 mm aggregate and with typical size
aggregate shall be found in Section 3.3.
2.07 COATING FOR REBAR
A. Coating for repair of rebar shall be a single component zinc epoxy primer meeting the
requirements of BS 4652 Type 2. Minimum zinc content shall be 85% (dry film).
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2.08 REINFORCING STEEL
A. Reinforcing steel shall comply with the requirements of Section 3.2 Part 3.
2.10 WATER
A. Mixing and curing water shall comply with Section 3.3.
PART 3 - EXECUTION
3.01 EXAMINATION OF SURFACE DEFECTS
A. As soon as forms are removed, exposed surfaces shall be carefully examined and
any irregularities shall be immediately rubbed or ground in a satisfactory manner in
order to secure a smooth, uniform, and continuous surface. Plastering or coating of
surfaces to be smoothed will not be permitted. No repairs shall be made until after
inspection by the Employer. In no case will extensive patching of honeycombed
concrete be permitted. Concrete containing minor voids, holes, honeycombing, or
similar depression defects shall have them repaired as specified herein. Concrete
containing extensive voids, holes, honeycombing, or similar depression defects, shall
be completely removed and replaced.
B. Any concrete repairs that the Employer deems necessary shall be promptly executed
by the Contractor at its own expense, using the appropriate repair materials
designated by the Employer.
C. The Employer shall be notified by written “Inspection Request” as described in

Section 4.4 to inspect and approve the surface preparation before filler or coating
applications.
3.02 CONCRETE REMOVAL
A. Concrete shall be chipped out and cut back as directed by the Employer.
B. Defective surfaces to be repaired shall be cut back from trueline a minimum depth of
12 mm over the entire area. Feathered edges will not be permitted. Where chipping
or cutting tools are not required in order to deepen the area properly, the surface shall
be prepared for bonding by the removal of all laitance or soft material, and not less
than 0.8 mm depth of the surface film from all hard portions, by means of an efficient
sandblast.
C. All defective, and/or contaminated concrete shall be chipped out to a depth as

1. If reinforcing is encountered, the concrete shall be cut back at least 20 mm

beyond the rebar, upon the Contractor’s instructions, regardless of the concrete
condition.
2. The weight of jack hammers shall not exceed 10 kg unless otherwise approved
by the Contractor.
3. Edges shall be tapered to eliminate square shoulders at the perimeter of cavities
or at abrupt changes in thickness.
D After cutting and sandblasting, the surface shall be wetted sufficiently in advance of
shooting with shotcrete or with cement mortar so that while the repair material is
being applied, the surfaces under repair will remain moist, but not so wet as to
overcome the suction upon which a good bond depends. For exposed walls, the
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cement shall contain such a proportion of white Portland cement as required to make
the colour of the patch match the colour of the surrounding concrete.
E. Holes left by tie-rod cones shall be reamed with suitable toothed reamers so as to
leave the surfaces of the holes clean and rough. These holes then shall be repaired
in an approved manner with dry-packed cement grout. Holes left by form-tying
devices having a rectangular cross-section, and other imperfections having a depth
greater than their least surface dimension, shall not be reamed but shall be repaired
in an approved manner with dry-packed cement grout.
F. All repairs shall be built up and shaped in such a manner that the completed work will
conform to the requirements of this Section, as applicable, using approved methods
which will not disturb the bond, cause sagging, or cause horizontal fractures.
Surfaces of said repairs shall receive the same kind and amount of curing treatment
as required for the concrete in the repaired section.
G. Before filling any structure with water, all cracks that may have developed shall be
"vee'd" and filled with sealant. This repair method shall be done on the water bearing
face of members. Before backfilling, faces of members in contact with fill, which are
not covered with a waterproofing membrane, shall also have cracks repaired.
3.02 PATCHING HOLES IN CONCRETE
A. Patching Small Holes
1. Holes which are less than 300 mm in their least dimension and extend completely
through concrete members shall be filled as specified herein.
2. Small holes in members which are water-bearing or in contact with soil or other fill
material shall be filled with non-shrink grout. Where a face of the member is
exposed to view, the non-shrink grout shall be held back 50 mm from the finished
surface. The remaining 50 mm shall then be patched in accordance with the
method described above.
3. Small holes through all other concrete members shall be filled with non-shrink
grout, with exposed faces treated as above.
B. Patching Large Holes
1. Holes that are larger than 300 mm in their smallest dimension shall have a
keyway chipped into the edge of the opening all around, unless a formed keyway
exists. The holes shall then be filled with concrete as specified herein.
2. Holes which are larger than 600 mm in their smallest dimension and which do not
have reinforcing steel extending from the existing concrete, shall have reinforcing
steel set in grout in drilled holes. The reinforcing added shall match the
reinforcing in the existing wall unless indicated otherwise.
3. Large holes in members which are water bearing or in contact with soil or other
fill, shall have a bentonite type waterstop material placed around the perimeter of
the hole unless there is an existing waterstop in place.
3.03 CARE AND REPAIR OF CONCRETE
A. The Contractor shall protect all concrete against injury or damage from excessive
heat, lack of moisture, overstress, or any other cause until final acceptance by the
Employer. Particular care shall be taken to prevent the drying of concrete and to
avoid roughening or otherwise damaging the surface. Any concrete found to be
damaged, or which may have been originally defective, or which becomes defective
at any time prior to the final acceptance of the completed work, or which departs from
the established line or grade, or which, for any other reason, does not conform to the
requirements of the Contract Documents, shall be satisfactorily repaired or removed
and replaced with acceptable concrete at the Subcontractor’s expense.
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3.03 REBAR REPAIR AND REPLACEMENT
A. Any exposed rebar encountered during renovation shall be grit blasted to remove all
rust and scale and coated with zinc primer. Zinc primer shall be mixed and applied in
accordance with the manufacturers directions on the same day, as the grit blasting.
B. Heavily corroded rebar, exceeding 10% loss of cross section as determined by the
Employer shall be lapped with new rebar of the same size.
1. All new rebar shall be grit blasted and coated in the same manner as repaired
rebar.
2. Heavily corroded rebar may be removed if sufficient lap is available with
acceptable rebar. If sufficient lap length is not available, the Subcontractor shall
drill and grout rebar dowels as directed by the Contractor.
3. Minimum cover on newly placed rebar shall be 40 mm, unless otherwise
4. Clear distance between newly placed rebar and existing adjoining rebar shall be
35 mm for shotcrete applications.
3.04 APPLICATION OF CEMENTITIOUS REPAIR MORTARS
A. All areas to be repaired shall be saw cut all around and chipped down to remove
defective or contaminated concrete.
B. Rebar shall be repaired or replaced as directed by the Employer.
C. All prepared surfaces shall be thoroughly cleaned by high-pressure air blast just
before mortar application.
D. Mixing shall be according to the manufacturer’s recommendations
E. Primer
1. Concrete surfaces shall typically be soaked with water and blown free of surface
water just before application.
2. Other primers may only be used if approved by the Contractor. Mixing and
application of the primer shall be in strict accordance with manufacturer’s
recommendations.
F. Mortar Application
1. Mortar application shall be according to the manufacturer’s recommendations.

2. All cavities shall be fully filled to the pre-existing surface level and troweled to a
smooth finish.
3. Curing shall be conducted according to the manufacturer’s recommendations.
3.05 APPLICATION OF MICRO-CONCRETE
C. All surfaces thus prepared shall be thoroughly cleaned by high-pressure air blast just
before mortar application.
D. If necessary, formwork shall be erected according to Section 3.2 Part 1. Formwork

shall be watertight.
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E. Mixing shall be according to the manufacturer’s recommendations.
F. Primer
1. Concrete surfaces shall typically be soaked with water and blown free of surface
water just before application.
2. Other primers may only be used if approved by the Contractor. Mixing and
application of the primer shall be in strict accordance with manufacturer’s
recommendations.
G. Placement
1. Micro-concrete shall be placed according to the manufacturer’s

recommendations.
2. All cavities shall be fully filled to the pre-existing surface level and troweled to a
smooth finish.
3. Curing shall be conducted according to the manufacturers recommendations.
3.06 APPLICATION OF SHOTCRETE
C. Areas thus prepared shall be thoroughly cleaned by high-pressure air blast and
soaked with water before the application of shotcrete. Any excess water shall be
removed.
D. Application shall be with dry mix, unless otherwise approved by the Employer.
0
E. Do not place shotcrete when substrate or reinforcing temperature is above 38 C.
F. Spraying shall generally be at right angles to the surface and will generally start at he
bottom and work upwards on vertical surfaces.
1. Screed boards, profile guides or stretched wires shall be used to maintain proper
thickness, and uniform surface profile.
2. Maximum thickness per layer shall be 50 mm.
3. Application of subsequent layers shall be delayed for at least 1 hour.
G. The finish surface shall be lightly trimmed to profile and left rough to receive filler or
mortar.
H. Wet curing, according to Part 2 - Section 3.2, shall commence immediately upon
finishing and shall continue for 7 days.
I. Control joints shall be provided at a maximum spacing of at least 3 meters or as

directed by the Contractor.
3.07 C32/40 CONCRETE

C. Areas thus prepared shall be thoroughly cleaned by high-pressure air blast and
soaked with water before the application of shotcrete. Any excess water shall be
removed.
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D. Placement, compaction, finishing and curing for C32/40 concrete shall conform to the
requirements in Section 3.2 Part 3.
E. The Employer may limit the maximum aggregate size to 10 mm at its discretion.
3.08 CRACK FILLING (SURFACE)
A. Cracks shall be ground out and filled at the surface as directed by the Employer.
1. Grinding shall be in the form of a square notch 5 mm deep by 5 mm wide.

2. The notch shall be blown clean of all dust and filled to the surface with an
approved epoxy filler.
3.09 CRACK INJECTION
A. Crack injection shall be performed with one or more of the following resins as directed
by the Contractor.
1. Foaming agent to stop water leakage.
2. Polyurethane resin.
3. Vinlyester resin.
B. All injection shall be conducted by drilling holes at approximately 45 degrees to the

surface in order to intersect the crack at the center of the member.
C. Crack injection shall typically start at the bottom of vertical surfaces and shall continue
upwards as resin is seen to exit the crack.
D. If necessary, the crack surface may be filled and fitted with indicator holes to prevent
excessive loss of resin.
A. Surface tolerances for all repairs shall comply with Section 3.2 Part 3, unless otherwise
B. Minimum pull-off values for any repairs with any materials shall be 1.5 MPa, when failure
occurs at the interface or within the repair material, unless otherwise approved by the
2
Contractor. One pull-off test shall be conducted for every 100 m of repairs.
C. Samples of shotcrete, micro-concrete and cementitious repair mortar shall be taken as

follows, unless otherwise approved by the Contractor.
1. Shotcrete: two 80 x 80 x 20 mm box for six cores on daily basis.

2. Micro-concrete: six specimens (150 mm) for every 100 bags used.
3. Cementitious mortar: six specimens (150 mm) for every 400 bags used.
D. Testing shall be as follows:
1. Shotcrete:
a. Test three cores for compressive strength at 7 days and three cores at 28 days.
b. Dispose of samples when directed by the Contractor.
th
c. Conduct permeability test on every 15 sample or as directed by the Contractor.
2. Micro-concrete and cementitious mortar. Conduct compressive strength on three

specimens and permeability on three specimens.
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SECTION 3.5 TESTING OF WATER RETAINING STRUCTURES
PART 1 - GENERAL
1.1 RELATED WORK
A. Section 4.4 - Quality Control.

B. Section 3.2 - Cast-In-Place Concrete
C. Section 3.4 - Concrete Repair.
1.2 SECTION INCLUDES
A. The testing, for water tightness of water tanks in basement and reflecting
pool.
1.3 SUBMITTALS
A. The contractor shall submit a method statement according to Section 4.4 to cover
all aspects of testing and repair of water retaining structures.
B. The Contractor shall record and submit to the Engineer within 24 hours the
results of the watertightness test carried out.
C. Technical data on repair materials (if necessary).
A. The Contractor shall test, for water tightness, all structures that are intended and
designed to be watertight. This shall include all structures which contain or
convey liquid or which must resist external infiltration, including but not limited to
the following:
1. Tanks and reservoirs

2. Channels
3. Sumps
4. Underground Chambers or structures subject to ground water infiltration.
B. Testing shall be conducted after application of interior protective coatings, but

before application of exterior coatings or membranes.
C. The cost of obtaining and subsequent disposal of the water shall be borne by the
Contractor at his expense.
PART 2 - PRODUCTS
2.1 WATER
A. All water used for testing shall be potable water as defined in Section 3.2 -
Cast-In-Place Concrete.
2.2 REPAIR MATERIALS
A. Any leaks or damp spots shall be injected with a hydrophilic (water-swelling)

vinlyester based resin according to Section 3.4.
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PART 3 – EXECUTION
3.1 CLEANING
A. All water retaining structures shall on completion, be carefully cleaned to the

complete satisfaction of the Contractor.
B. All structures shall first be pumped dry and cleaned of all debris. The structure
shall then be brushed down (on all internal faces) with a stiff broom while still dry
and swept clean.
C. All associated pipe work shall be cleaned in accordance with the relevant
specification requirements.
3.2 TEST PREPARATION
A. General
1. Testing shall not be undertaken until obtaining written approval from the
Contractor.
2. Filling shall not take place earlier than 28 days after the casting of the final
sections of the structure, unless otherwise agreed by the Contractor.
3. In the case of structures which are subdivided into individual tanks, each
individual tank shall be tested separately, provided that the design of
structure will sustain all imposed loads. In the case of underground or semi-
underground structures, the testing may take place after application of water
proofing membrane, liner material or installation of any perimeter drain,
provided the exterior ground water is allowed to rise to normal levels.
4. All temporary bulk heads, cofferdams, pipe blind flanges, and closed valves
should be checked to see that they form a complete seal at these outlets and,
if possible, these outlets should be observed during the actual test.
5. Backfilling against exterior walls shall not take place until the Contractor has
given his written approval.
6. If possible tests should not be scheduled when a major change in the
average daily temperature is predicted.
3.3 TEST PROCEDURE FOR CONCEALED VESSELS OR STRUCTURES
A. TESTING OF STRUCTURES OTHER THAN STORAGE RESERVOIRS
1. As soon as possible after the completion, the structure shall be filled with
water, to a level and at a rate agreed with the Engineer and left to stand for 3
days, in order to allow for absorption. The structure shall be considered
satisfactory if subsequent to this period there is no visible leakage and no fall
in level over a period of 24 hours, after making due allowance for rainfall and
evaporation, and no visible leaks, Testing shall be completed prior to
backfilling around structures.
2. In the event that any water retaining structure fails to pass the test, the
Contractor shall make good the structure and re-test at his own expense.
The procedure shall be repeated until the structure passes the test.
B. TESTING OF STORAGE RESERVOIRS
1. After completion and cleaning of the structure and all associated pipework (if
any), the Contractor shall fill the structure with potable water or irrigation
water as approved by the Contractor, at uniform rate of not greater than 2 m
in 24 hours. The structure shall then be left filled the reservoir up to the top
level and leave for 7 days. Water shall be added over this period to maintain
the top water level. The Contractor shall ensure that all pipes and specials
are available in ample time ahead of testing.
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2. On the eight day a shallow watertight G.I. evaporation tray of area 0.4 sq.
metres shall be filled with 75mm of water and placed to float in the tank. The
water level in the tank shall be recorded and the test commenced and carried
out over the next 7 days. Re-adding of water levels in the reservoir and tray
shall be made and recorded every 24 hours over this period.
3. If the water level in the tank falls or any other sign of leakage occurs by the
end of the test period then the Contractor shall search and mark all areas of
defect. The tank shall then be emptied and the defects made good by
surface hacking and rendering, cutting out defective or damaged concrete,
and filling with concrete of the same mix as that in the original structure.
4. After completion of remedial measures the tank shall be refilled and the test
repeated. This process shall be repeated until the tank is watertight to the
satisfaction of the Engineer.
C. The acceptance criteria shall be as follows:
1. The allowable leakage rate for unlined or uncoated concrete water

containment structures, should not exceed 0.1% of the water volume in a 24-
hour period.
2. The allowable leakage rate for fully lined or coated concrete water
containment structures should not exceed 0.025% of the water volume in a
24-hour period.
3.4 TEST PROCEDURE FOR EXPOSED VESSELS OR STRUCTURES
A. For exposed structures where visual examination is possible, the following

procedure shall be adopted.
B. After completion and cleaning of the structure and all associated pipework (if
any), the Subcontractor shall fill the structure with potable water or irrigation water
as approved by the Contractor. The structure shall then be left filled for a
stabilising period as directed by the Contractor.
1. The water level shall be filled up to the maximum operational level.

2. Water shall be added during the stabilising period to maintain the afore
mentioned level.
3. Subcontractor shall ensure that all pipes and specials are available in ample
time, before testing.
4. The final water level for the test shall be the top water level or the operational
water level as shown on the mechanical drawings. It may not be the full
internal height of the structure.
5. Hold water at each water level for such time as the Contractor may require.
6. Should any dampness or visible leakage occur at any stage, the
Subcontractor should immediately seal the area by means of crack injection
until the defects are remedied to the satisfaction of the Contractor before
continuation of the test.
7. If emptied for repairs, the structure shall be refilled and checked again after
72 hours.
C. Acceptance Criteria: No visible leaks or damp areas.
END OF SECTION
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DIVISION 4
PILES
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PART 1 - GENERAL
1.1 SCOPE
A. This specification deals with all the general requirements for Cast in Place
(Bored) piles or Continuous Flight Auger (CFA) piles & precast concretes pile
including design, materials, workmanship, testing, etc.
B. This specification shall be read in conjunction with the specifications for

concrete (Part 6 , Section 3.2 “Cast in Place Concrete” and Section 3.3
“CONCRETE BATCHING AND DELIVERY”.
1.2 GENERAL
A. Related standards.
1. For all piling work the conditions stated in BS 8004 shall apply.
Wherever there is a conflict between its conditions and this
specification then this specification shall apply and reference to be
made to BS 5930 and BS 1377.
2. Specialized Sub-Contractor.
All the piling work shall be carried out by a specialized piling
contractor, who is well experienced in the type of piles being
constructed and he shall have properly trained adequate staff and
equipment.
3. Existing services
The Contractor shall obtain all the details regarding locations, depth,
etc. of all the services in area where piling work is to be done and he
shall take due care not to damage any of these services or utilities.
4. Existing structures.
The Contractor shall examine all the adjacent structures for cracks,
settlements and the like and make a record in the form of photographs
and sketches and bring the same to the notice of the Engineer and the
owner of the property in question before commencing the works.
5. Insurance coverage
Piling contractor shall submit insurance guarantee as required by Local
Authorities, before commencing the works.
PART 2 - MEASUREMENT AND PAYMENT
2.1 Piling
The Contractor will be paid at the contract unit price per meter (including test
piles), for "Piling" multiplied by the total length in meters of acceptable piles
actually installed including cutoffs. The Contractor reserves the right to
increase or decrease the total length of piles to be furnished and installed by
changing the foundation pile locations or elevations, requiring the installation
of additional piles, or requiring omission of piles. Payment shall constitute full
compensation for furnishing, delivering, handling, and installing all material,
labor, and equipment necessary to install the foundation piles. The Contractor
will not be allowed payment for broken, or rejected piles.
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2.2 Submittals
Contractor acceptance is required for submittals.

The following shall be submitted:
• Pile Design including calculations, drawings showing reinforcement
details, pickup points details, as well as specifications for all materials to
be used in the manufacture of the precast concrete piles. Approval of
design details is required prior to start of production.
• Concrete ingredients test reports and certificates of compliance (Cement,
Cementitious material, Coarse and Fine aggregates, water, admixtures,
reinforcement, etc.) for all materials proposed for use in the manufacture
of the precast concrete piles. Approval of proposed materials shall be
obtained prior to commencement of pile production.
• Concrete mix design (using the approved ingredients) for approval prior
to start of pile production.
• A procedure describing the entire process of pile manufacture. This
procedure shall include but be limited to reinforcement placement, types
of forms, concrete placement method, curing method, and lifting
procedures.
• A procedure for storing, pickup and delivery of piles to the site for driving.
Concrete strength at the time the pile is lifted from the casting bed shall
be sufficient to resist all handling and storage loading. Piles shall be lifted
and blocked for storage at pre-designated points such that bending
stresses will be within acceptable limits. No precast concrete piles shall
be delivered to the site before the concrete has achieved at least 80% of
its minimum design compressive strength, or at least one week old.
• Certificates that shows the adequacy of the pile driving equipment
(Hammer, driving cap, cushion, etc), the criteria used in the selection of
the equipment, and the procedure to be used to demonstrate its
suitability. Pile driving shall not commence until acceptance is obtained
from the Contractor as to the type and weight of the hammer.
• Description of the pile driving system, including: pile hammer type, ram
weight, ram fall, hammer energy, rated speed, cap details and weight,
cushion type and details, helmet weight and details and any other items
required for predicting the pile driving criteria.
• Pile driving criteria to be used for test piles and description of the pile
driving formula or pile driving analysis computer program used to
determine.
• A schedule for driving the piles in showing the order in which pile driving
is proposed to facilitate the general construction schedule. No driving
shall commence until schedule is approved.
• A complete and accurate record of each driven pile. The record shall
indicate the pile location (as driven), size, length, final elevation of tip and
top, pile weight, number of splices and locations, blows required for each
meter of penetration throughout the entire length of the pile and for the
final 150 mm of penetration, and the total driving time. The record also
shall include the type and size of the hammer used, the rate of operation,
and the type and dimensions of driving helmet and cushion block used.
Any unusual conditions encountered during pile installation shall be
recorded and immediately reported to the Contractor.
• A complete report on the pile test within seven days of completion of
each pile test, including, but not limited to, a description of the pile driving
equipment, driving records for both test piles and reaction piles, complete
test data, analysis of test data, and recommended allowable design loads
based on the pile test results. The report shall be prepared by or under
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the direct supervision of a professional engineer experienced in pile
driving.
• The work shall be performed by a Contractor specializing in the required
foundation system and having a minimum of 5 years experience in the
fabrication and installation of similar foundation system under similar
subsurface conditions.
PART 3 – PRODUCTS
3.1 GENERAL
A. Casings
1. Temporary casings
These casings shall be free from any distortions and of uniform cross
section. They shall have no internal projections or encrusted concrete
on the inside surface which will hinder proper construction of the pile.
2. Permanent casings
Permanent casings shall be made of steel, non-corrodible metal or

concrete. If a permanent casing is made of a series of short lengths, it
shall be designed and placed so as to make a continuous water free
shaft. The quality and dimensions of these casings shall be such that
they can tolerate the stresses caused by handling and installation.
B. Drilling fluid
1. Supply
Drilling fluid, Bentoniete shall be supplied to the site prior to mixing and
it shall comply with Specification Engineering Equipment and Material
Users Association - EEMUA 163 Drilling Fluid Materials or equivalent
accepted standard
The manufacturer of Bentonite shall provide a certificate, giving details
of the properties of each consignment. This shall include the apparent
viscosity range (in centipoises), the gel strength range (in
newtons/sq.m) for solids in water. The Engineer shall have access to
these details as and when required.
2. Mixing
Fresh clean water shall be used to prepare the suspension with

Bentonite powder. The temperature difference between that of the
water, used for making the suspension and that of the suspension
0
when supplied to the bore hole shall not be less than 5 C at places
where ground water is chemically contaminated or is saline,
precautions shall be taken to make the Bentonite suspension suitable
and effective in all respects.
3. Tests
Control tests shall be carried out on the bentonite suspension, using

suitable apparatus. The density of freshly mixed bentonite suspension
shall be measured daily as a check on the quality of suspension being
formed. The measuring device shall be calibrated to read to within
5g/L. Tests to determine viscosity, gel strength, density, sand content,
178
fluid loss and pH value shall be carried out to bentonite supplied to the
pile bore during drilling and from the pile bore immediately prior to
concreting. The results of these tests shall comply with Table 1.
Table 1: Bentonite Tests
Sampled from Pile

Property Supplied to Pile Bore
Method Bore immediately
During Drilling
Prior to concreting
Bentonite
4-5% 5-8% 4% min
Content
Fann
Plastic viscosity 3 - 10 7 - 20 20 max
Viscometer*
10 min gel Fann
2 - 20 10 - 40 7.5 - 40
strength (Pa) Viscometer*
Density (g/ml) Mud balance 1.02 -1.07 1.03 -1.10 1.02-1.10
API sand
API test 3 max 3 max 6 max
content(% vol)
Fluid loss in 30
API Test 40 max 40 max 60 max
min (ml)
pH meter or
pH 8 - 12 8 - 12 8 - 12
indicator strips
*Note: Where the Fann Viscometer is specified, the fluid sample should be screened by a number 52
sieve (300 µm) prior to testing.
C. Pre-cast concretes pile
1. Normally no pre-cast concerts pile shall be driven until it is 28 days old.

2. Driving r records of all piles shall be kept and these shall embody the
following information: number, size and length of pile, date of
manufacture, date and time of driving, type, weight and fall of hammer
and to level on completion of driving. Details of the set or blows per
300mm of pile penetration and the temporary compression of the
ground shall also be recorded from the time at which a marked
increase in resistance to driving occurs until the pile has reached the
final level.
D. Concrete
1. Concrete for piles shall be generally in accordance with Part 6, or

specifications except where it is modified as below.
2. The grade of concrete and type of cement used shall be as per
drawings or as per the directions of the Engineer. The quantity of
3
cement used shall not be less than 380 kg/m recommendations of BS
8500 shall be followed where ground conditions show a high sulfate
content.
3. General guidelines for slump values of concrete used in piling.
a. Water free unlined bore and widely spaced reinforcement 100 ±
25 mm (type A)
b. Closely spaced reinforcement and diameter < 600 mm 150 ±25
mm (type B)
c. Concrete placed by tremire or placed under water or where
drilling fluid is used 175 ± 25 mm (type C)
d. Rammed or compacted concrete 0 to 50 mm max.
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3.2 DESIGN
A. Responsibility
The responsibility of designing and installing a stable, economical and

functional pile or a pile system rests entirely on the Contractor or the
specialist Sub contractor proposed by the Contractor. These piles shall
satisfy the requirements of this specification and shall be capable of
supporting all phases of the structure for which they are being built as shown
in the drawings, Unless otherwise agreed by the Engineer, the safe maximum
working load on any pile shall not be greater than 85 tones when loaded in
compression and 21 tones when loaded in tension. Compression piles shall
also be designed to withstand a horizontal load equal to 10% of the working
vertical load applied at the pile head, in addition to the vertical load
B. Pile Locations
All pile locations shall be as shown on drawings. If for any unsuitable site
condition or for any reason a pile cannot be located exactly at the proposed
locations, then Contractor shall propose a revised suitable layout.
C. Pile Loading
All the structural load including those of wind loads, etc., plus the loads
coming from the ground conditions such as negative friction shall be
considered for the design of the pile. When a group of piles are installed the
behavior of the whole group as well as the individual pile shall be considered
for the design.
D. Factor of Safety
For all pile foundation designs. Shall be designed and be able to develop the
above loads with safety factor, The factor of safety shall be as defined in BS
8004 which is the ratio of ultimate bearing capacity to the working load. This
factor of safety shall not be less than 2.5 and the different settlement in
th
adjacent columns shall not be more than 1/500 of column spacing.
3.3 CONCRETE
A. Strength
The concrete for piles shall have a maximum design stress for working loads
in compression as 25 % of the specified 28 day Characteristic strength. For
the design the nominal cross sectional area of the shaft shall be used.
B. Reinforcement
1. Piles shall be reinforced as shown on the drawings. Cages shall

consist not less than 8 No. evenly spaced high yield steel
reinforcement bars having a total cross- sectional area of not less than
0.8% of the nominal pile cross-sectional area. The concrete cover to
the reinforcement shall be minimum of 75 mm. The method used to
maintain such cover required the Engineer’s approval. In case of
precast concrete shell pipes the dimension shall be measured from the
inner surface of the shell.
The stability of reinforcement cages shall be achieved by means of

continuous helical stirrups, the diameter and pitch of which shall be
subject to the approval of the Engineer. The helical stirrups shall fit
closely around the main bars and be bound to them by approved wire
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the ends of which shall be turned to the interior of the pile. Pot welding
shall require the approval of the Engineer.
2. Where piles are designed to resist uplift forces, the permissible direct
tensile stress in the longitudinal reinforcement shall not exceed 85
2
N/mm . Where piles are designed to resist bending moments the
permissible tensile stress in the longitudinal reinforcement shall not
2
exceed 125 N/mm .
C. Protection
Where and when protection to piles from adverse soil conditions is required it
shall be as described on the drawings.
D. Spacing
Friction piles shall not be placed closer than three diameters centre to centre.
With piles deriving their resistance from end bearing, the spacing centre to
centre should not be less than twice the least diameter of the pile. For piles
having enlarged bases careful consideration shall be made of interaction
effects between the bases.
E. Under Reams
Under reams shall not be provided for piles with a shaft diameter less than
750 mm.
F. Foundation levels.
Piles which carry the majority of their working load in end bearing shall be
founded at a sensibly common level or at a common depth relative to the
founding stratum.
G. Handling and pitching or driven linings or casings
The piles shall be designed such that they or their components, permanent or
temporary, can be loaded, transported, pitched and installed, as applicable,
without any over-stress occurring which might cause damage to the piles
before they are capped.
3.4 Piling Scheme
A. Tender Stage.
The Contractor shall tender on the basis of a piling scheme shown on the
drawings taking full account of the soil investigation’s information available
and his own experience.
The Contractor shall supply with his tender the following information:
1. Type of pile.
2. Methods and type of plant to be used to install piles including, where
applicable, the method of forming under reams.
3. Method of placing and compacting concrete.
4. Method of overcoming ground heaves. Where applicable.
5. Grade of concrete to be used.
6. The cross sectional dimensions and length of pile constructed to carry
the specified loads. Also, as appropriate, the details of the shape and
plan of any under ream.
7. The anticipated proportion of the working load carried in shaft friction
and in end- bearing together with the estimated factors of safety.
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8. Any reduction in pile numbers due to group action.
9. The minimum spacing of piles in groups.
10. The properties and application of “slip” compounds, designed to reduce
the effects of negative skin friction where applicable.
The contractor shall also provide with his tender his proposed program for the
construction of the works. The programme shall be in bar chart form showing
the sequences and duration of each operation.
Any additional soil investigations considered necessary by the Contractor to

enable him to design the piles in accordance with the specification shall be
carried out at the Contractor’s own expense.
PART 4 - EXECUTION
4.1 GENERAL
A. Substandard Work
Any pile which fails to comply with the Specification or the drawings in any
respect, will be condemned by the engineer. When an installed pile is
Condemned, the pile shall be repaired, replaced or its load carrying capacity
down rated as appropriate and the engineer may take such actions which he
considers necessary. In the extreme case the pile cap shall be redesigned
and the foundations modified as necessary.
B. Ground Water
1. Adequate precautions shall be taken at all times to prevent surface

water or ground water entering the shaft, and where the pile passes
through unstable granular or water bearing soils, lining tubes shall be
provided. In cases where it is impossible to prevent the ingress of
ground water or where a pile is bored for its full length in unstable soil
the engineer may approve the boring of length in unstable soil the
engineer may approve the boring of piles under Bentonite. Approval
for boring under Bentonite or water will not be given for raking or under
reamed piles.
2. The level of the Bentonite. Where approved, shall be maintained at a

level not less than 1.0m above the maximum level of external ground
water. Pumping from boreholes shall not be permitted unless a lining
has been placed into s stable stratum and it can be shown to the
satisfaction of the Engineer that pumping will not have a detrimental
effect on the surrounding soil or property.
C. Formation and Inspection of Borings.
1. Written approval of the Engineer shall be obtained before water is used

to assist boring.
2. A minimum length of 1500 mm temporary casing shall be inserted in
every boring which shall protrude a minimum of 500 mm above ground
level. Where piles pass through or are cut off in strata containing
flowing water the Contractor shall be required to take adequate
precautions against washing away of the fine content of concrete. This
may require the provision of permanent linings throughout the strata
concerned.
3. All debris and sediment shall be removed from the boring and
disposed off the site.
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4. Large diameter bored piles having a diameter greater than 800 mm
which are designed to carry any part of their working load in end-
bearing shall be inspected by using remote camera, subject to the
Engineer’s approval.
5. The cross- sectional area of pre-bored holes to facilitate the formation
of piles driven, vibrated or jetted into the ground shall not exceed that
of the pile.
D. Obstruction or Changes in Condition
The Contractor shall inform the Engineer immediately when unforeseen

underground obstructions are encountered and shall not resume wok until
approval to continue has been obtained. If the nature of the strata should
vary significantly from that indicated in the site investigation in report, the
Engineer should be notified immediately.
Where such observations indicate that the piles have been subjected to
heave, the piles in that vicinity shall be re-driven to the penetration resistance
required as determined by the pile driving and load tests at no extra cost to
the Employer.
E. Handling
The Contractor shall take all necessary precautions against damage to piles
or components when manufacturing, unloading, transporting, storing,
handling, pitching, boring of piles and piles damaged or distorted to the extent
that their function is impaired will be rejected.
F. Driving of Linings (or Casings)
1. The type of equipment adopted shall be selected with consideration of

any noise regulations imposed by statutory bodies. Knowledge of such
regulations shall be the responsibility of the Contractor.
2. The written approval of the Engineer shall be obtained before water or
Bentonite is used to assist the driving.
3. The written approval of the Engineer shall be so given or activated not
later than 24 hours after pre boring.
4. Where linings or temporary or permanent casings are installed or
removed by vibrating equipment a certificate of performance shall be
provided for this equipment.
G. Work near existing Buildings
1. The Contractor shall carry out work adjacent to any existing building in
such a manner that a minimum vibration to the ground shall occur.
2. The Contractor shall fix “tell-tales” to the existing building where
directed by the Engineer. These shall be inspected daily and any
cracking shall be immediately reported to the Engineer.
3. If during execution of the work damages is, or is likely to be, caused to
any part of adjacent building including finishes etc., and any equipment
etc. within any adjacent building the Contractor shall submit to the
Engineer, his proposal for avoidance of such damages.
H. Converting
1. Except where otherwise specified in writing the workmanship for

concreting shall be in accordance with Part 6 ‘Concrete specifications.
2. In the case of bored piles, unlined borings or those which have reached
the founding depth shall not be permitted to stand un-concreted over
night. The whole of the concrete in any one pile shall be poured
continuously in any one operation and construction joints will not be
183
permitted to stand. If concreting is interrupted by a plant breakdown or
any other unforeseen circumstances resulting in a delay or more than
one hour between successive batches, the engineer shall be informed
immediately and the Contractor shall make such measure as the
Engineer directs.
3. The placing of concrete shall not commence until approved by the
Engineer and it shall then be completed within 8 hours.
4. Piles shall be bored and concrete shall be placed without such delay as
would lead to significant impairment of the soil strength. No unlined
bores shall be left unconcreted for periods in excess of 24 hours.
5. Excavations left open for more than 12 hours may need to be re-cleaned
and have the bentonite recycled to the satisfaction of the Engineer.
6. The Contractor is fully responsible for ensuring that no “necking” or
narrowing of the pile shaft occurs during concreting and extraction of the
casing. The level of the concrete in the shaft is to be taken after the
placing of each batch as a check that “necking” has not occurred.
7 The Contractor shall take all precautions in the design of the mix and
placing of the concrete to avoid arching of the concrete in the casing. No
spoil, liquid or other foreign matter shall be allowed to contaminate the
concrete.
8. In cases where the Engineer has approved piles bored under water or
drilling mud, or where the concrete has to be placed using a tremie pipe,
the internal diameter of the pipe of the tremie shall not be less than 150
mm for concrete made with 20 mm aggregate and not less than 200 mm
for 40 mm aggregate. The tremie pipe shall be clean, watertight, without
internal or external projections and shall extend to the bottom of the pile
prior to commencement of concreting. Care shall be taken to ensure
that all bentonite slurry or water is expelled from the tube at the start of
concreting. Sufficient embedment of the tube in the concrete shall be
maintained so as to ensure that no-entry of bentonite slurry into the pipe
takes place. Concreting shall continue until sound uncontaminated
concrete is present at ground level.
9. The Contractor shall take all possible precautions to prevent segregation
of the concrete taking place. Concrete in raking piles shall be placed
using a full length chute which is first lubricated with grout.
10. The use of poker vibrators will not be permitted except in special cases
which have been approved by the Engineer prior to the commencement
of work.
11. The level of the finished concrete shall be not less than 150 mm and not
more than 450 mm above the specified cut-off level. In cases where the
final required pile cut-off is below the ground water level, the finished
concrete level for piling operations shall be extended to 300 mm above
the ground water level and the aforementioned tolerance shall apply to
this modified cut-off level.
12. During withdrawal of temporary linings or casings a sufficient head of wet
concrete shall be maintained within them to prevent the inflow of ground
water or collapse of unstable soil. Excavation around the piles to assist
in the extraction of temporary lining tubes will not be permitted.
I. Lengthening of Piles
When lengthening a cast in place pile. The head shall be cut off square to
bind concrete; all loose particles shall be removed by wire brushing, followed
by washing with water.
Welded joints shall not be acceptable. For lap or splice joints sufficient link
bars shall be provided to resist eccentric forces. The methods of lengthening
shall be subject to approval of the Engineer.
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J. Finishing Pile Heads:
1. Set tops of piles to elevations indicated.
2. Where a temporary casing is used, bring up the top of the pile sufficiently
above the required finished level to allow slumping on withdrawal of the
casing and to permit all laitance and weak concrete to be removed.
3. Pay particular attention to the compaction of the concrete in the top
meter of the pile. Cut away any defective concrete in the head of the
completed pile and restore with new concrete well bonded into the old.
4. Extend reinforcement or provide dowels for connection of grade beams.
Expose the reinforcement in the pile for a sufficient distance to permit it
to be adequately bonded to the foundation slab.
5. If, the groundwater level is higher than the required pile head casting
level shown on the Drawings, submit proposals to the Contractor for
acceptance before placing concrete. Do not leave the pile head below
groundwater level, unless accepted precautions are taken.
K. Pile Location Identification
The Contractor shall be responsible for identifying the location of, and
providing safety measure for all partly formed or completed piles. In the
event of the top of the pile being below the surrounding ground surface all
bars protruding above the level of finished surface shall be coated with
cement slurry and then the remaining void shall be back filled with granular
material to ground surface and the location marked by a brightly coloured peg
or other approved system of identification.
L. Tolerance
The maximum tolerance from the plan position shown on the drawing at the
cut-off level of any vertical pile shall be 75 mm or 1/6 of the pile diameter
whichever is the smaller. Vertical piles shall be not more than 1 in 75 out of
the true vertical. The maximum tolerance from the plan position on the
drawing at the cut-off level of any raking pile shall be 150 mm or 1/3 of the
pile diameter whichever is the smaller. The axis of raking piles shall not
deviate more than 1 in 25 from the specified rake and direction thereof.
M. Piling records.
From the commencement of work, the contractor shall record, for each pile
constructed, all data relevant to the pile type. The records shall be maintained
continuously and shall be available to the Engineer at all times.
The Contractor shall supply one copy of the pile record to the engineer within
24 hours of the completion of any pile. A further two copies for each pile shall
be supplied within seven days of the completion of the pile.
4.2 TESTING OF CONCRETE
A. Except where otherwise specified or authorized in writing concrete shall be

tested in accordance with the requirements of the related Specifications
except for frequency of testing which shall be as specified below. The
Contractor shall provide the necessary facilities for making concert test
specimens and carrying out slump tests on site for the duration of the
contract.
B. Test specimens, of sides 150 mm, shall be made at a frequency of two sets
per day or one set per 20 m3 of concrete whichever is the greater frequency.
Each set shall consist of 6 specimens. Two of these specimens shall be
retained and protected in undamaged condition until their disposal is
approved by the Engineer. Slump tests shall be taken at a frequency required
185
by the Engineer, but shall not be less than one test for every three piles. Each
set of test specimens taken shall be supplemented by a slump test on the
same batch of concrete.
C. The Contractor shall conduct all such required tests on the casted piles as
specified herein or as directed by the Engineer by an approved testing
agency to prove their suitability, bearing capacity, integrity, stability… etc.
The testing agency so employed for carrying out the required tests on the
piles shall be completely independent of and shall not be related in any way
to the piling sub-contractor.
Prior to carrying out of any tests on the piles, the testing agency shall submit
for Engineer‘s approval, their pre-qualifications to carry out the said type of
works and shall also submit the other details such as name, qualifications,
previous experience, etc, of all the staff involved in the testing procedures,
for similar approval.
4.3 PILE TESTING
A. The Contractor shall be required to carry out load tests on a certain number of
piles (as specified or as directed) and provide a report to prove to the
satisfaction of the Engineer that the type, size and diameter of the proposed
piles are adequate to carry the specified load. The selection or location of test
piles shall be at the Engineer’s discretion
The load tests shall not commence until the required concrete strength of the
test pile has reached a value such that the pile is not damaged due to the load
is at least twice the stress at maximum test load, and the pile concrete is at
least 7 days old, 4 weeks should elapse after driving before testing for finer
grained soils.
All test procedures shall be in accordance with the guidance given in with BS
8004:1986, ASTM D4945-89) specifications, AASHTO designation: T 298-93 or
as in “Specification for piling” institution of Civil Engineers, TTL-London 1988
for the test loads indicated on Drawings.
The test shall be performed by experienced engineers from an approved
testing agency, using Pile Driving Analyzer (PDA) equipment.
Prior to dynamic testing, the Hammer system and the magnitude of the proof
load shall be studied properly. The pile tops shall be prepared properly to
receive the loading.
Test loads shall be applied to the pile head by jacking against kentledge,
reaction pile or anchorages. The contractor shall state with his tender which
method he proposes to use. Where kentledge is used the Contractor shall
satisfy the Engineer as to the accuracy of the weight which shall be at least
20% more than the maximum load to be applied in the case of vertical piles or
be such that the component of the kentledge measured along the axial load to
be applied. Where reaction piles or anchorages are required they shall not be
less than 3 times the diameter of the test pile or 2000 mm whichever is the
greatest.
The contractor shall perform the load tests in the quantity and at the locations
specified by the Engineer and the time specifically determined by the Engineer,
but not less than two weeks after the driving has been completed.
B. Before commencing any tests the contractor shall submit to the engineer, for
approval, full details of his proposals including the datum beam arrangements
and the location of reaction piles or kentledge supports.
Notwithstanding the Engineer’s approval, the Contractor shall be responsible
for the ability of the test set-up to apply safely the required load and to measure
this load and the resulting settlements to accuracy of + 2% and +0.05 mm
respectively. The Contractor’s arrangements shall include details for protecting
186
all gauges and other testing equipment from weather or other conditions likely
to affect their performance.
C. The load shall be measured by means of a proving ring or other approved

system and also by a pressure gauge included in the hydraulic system. The
contractor shall satisfy the engineer that the measuring services are calibrated
to an accuracy of + 2%.
D. The settlement, shall be measured by extensometer dial gauges mounted on

independent rigid datum frame, which shall be supported at points at least five
diameters from either the test pile or the kentledge perimeter where kentledge
is used. The accuracy of the gauges shall be checked against a master gauge
that shall be supplied by the Contractor for use by the Engineer. The master
gauge should be certified by an approved laboratory and to be accurate to
+05%.
E. During the course of a test, level observations shall be taken on the test pile,
the datum frame and kentledge stack, reaction piles or anchorages.
F. The pile test shall be continuous day and night and the Contractor shall provide
technically qualified supervision throughout its duration and shall ensure that
the jacks maintain the correct pressure.
G. Within 24 hours of the completion of each pile test the Contractor shall submit
to the engineer copies of the following graphs for the complete test including
recovery and allowing for any movement of datum beam:
a. Load - Settlement
b. Load - Time
c. Settlement - Time
H. When the results of test on piles are not, in the opinion of the Engineer,
satisfactory, further tests are to be carried out as directed by the Engineer.
If satisfactory results cannot be obtained from these further tests the contractor
shall agree with the engineer to the modifications which shall be made to the
pile design or to the additional piles which may be required to carry the
specified loads.
4.4 NEGATIVE SKIN FRICTION
A. General
When a component of loading due to negative skin friction has been indicated
by the Engineer, the Contractor shall give full consideration of this in relation
to test loading. In evaluating the necessary reactions to the test pile it shall
be considered that at the time of tests positive friction occurs and this positive
friction shall be equal in magnitude to the negative skin friction. Thus the test
load applied at any multiple of the structural working load, shall be further
increased by a loading equivalent to twice the negative skin friction in order to
negate the positive friction and simulate the long term negative skin friction.
For loads less than the structural working load, the additional load applied for
negative skin friction effects shall be in proportion to the friction of the
structural working load under consideration.
B. Revision of Requirements
A relaxation of the above procedure may be allowed by the Engineer on the
basis of preliminary pile tests. The Engineer will then stipulate the revised
testing loads.
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4.5 PRELIMINARY PILE TEST
When required such tests shall be carried out to verify the design
assumptions and to check the sufficiency on the piling system before any
working piles are constructed. The contractor shall give the Engineer at least
48 hours notice of the commencement of construction of any preliminary
piles, The Contractor shall provide min. of 3 test piles for each different type
of piling and shall submit detailed placing records and other data as directed
by the Engineer.
A. Preliminary pile load tests shall be carried out on specially constructed piles
outside the area of permanent work.
B. These piles shall be tested to at least three times their design load or failure,
the piles shall be constructed in a manner representative of those to be
constructed in the permanent work and at a location to be agreed with the
Engineer.
C. Each preliminary test pile shall be constructed similar to that to be used for
the construction of the working piles, and using similar equipment and
materials. Any variations will only be permitted with prior approval of the
Engineer.
D. A full record of the strata passed through shall be kept for preliminary test
piles.
E. The load shall be applied in increments of 25% of the estimated working

loads plus an allowance for any negative skin friction. The load shall be
maintained at each increment for at least one hour or until settlement has
ceased whichever is the longer before the application of the next increment of
load. Settlement readings shall be taken every 10 minutes each load
increment was held until the rate of settlement was less than 0.05 mm in 10
minutes, the unloading was in similar decrement, each one held for 10
minutes, at zero load the pile was left for one hour to recover.
F. The load shall be maintained at working load for a 6 hour holding or until
recovery has ceased whichever is longer.
G. The load shall be removed in the decrements as the increments of loading.
H. The pile shall remain unloaded for one hour or until recovery has ceased
whichever is the longer.
I. The pile shall then be reloaded in increments equal to 25% of the estimated
working load together with an appropriate allowance for negative skin friction
except that loading shall continue until the load reaches 150% of working
load. The load shall be maintained for a 6 hour holding period at both
working load and 150% of working load or until settlement has ceased to
increase measurably in 1 hour whichever is the longer.
J. The pile shall be loaded for third time except that loading shall continue until
the maximum test load shown on the drawings is reached. The load shall be
maintained for a 6 hours holding period or until settlement has ceased to
increase measurably in 1 hour whichever is the longer at each of working
load, 150% of working load and maximum test load.
K. The final recovery level reading shall be taken at least 12 hours after the pile
is completely unloaded.
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4.6 CONSTANT RATE OF PENETRATION (C.R.P) TEST
A. A preliminary pile test may take the form of a C.R.P. test on a non working
pile installed during the main piling work. In either case the results will be
used to evaluate the safe working load on the piles and the procedures shall
be as follows:-
B. The test rig shall have a load capacity exceeding that required to cause pile
failure and shall be to the Engineer’s approval. The contractor shall submit
calculations demonstrating the probable pile failure load.
C. The rate of settlement of pile fails in one of the following ways:
1. A constant or reducing load has been recorded for an internal of

penetration of 10 mm.
2. A total penetration of the pile base equal to 10% of the base width is
reached.
D. Reading shall be taken at 15 second intervals and a load settlement graph

shall be drawn as the test proceeds.
E. The pile shall then be unloaded in five approximately equal decrements with
penetration readings taken 15 minutes after each decrement and after one
hour at no load.
4.7 ULTIMATE LOAD TEST
A pile test to failure may also be undertaken using the maintained load test. Loading
increments shall be equal to one quarter of the working load, with allowance for
negative skin friction as applicable.
4.8 Safe Design Capacity
The safe design capacity of a test pile as determined from the results of load tests
shall be the lesser of the three values computed according to the following:
1. One-half of that load which causes a net settlement after rebound of neither
more than 0.28 mm per metric ton or 0.01 in / ton of total test load, nor 19 mm
after removal of test load.
2. 50% the final load at which the total displacement equal 10% of the dia of pile.
3. One-half of the load that causes a gross settlement of not more than 25 mm, 1
inch, provided the load settlement curve shows no sign of failure.
4.9 WORKING PILE TEST
A. Such tests will be required on a statistical number of working piles selected

by the Engineer as a test of the uniformity of the ground conditions and of the
workmanship and materials used 1 per 150 working piles minimum 2.
B. Two load cycles shall be applied, the first to the working load and the second
to the proof of load of 1.5 times the figure. The procedure to be followed shall
be as specified in this section. Negative skin friction allowance shall apply.
C. Where working piles have deep cut-off levels. The engineer may require
measure to be taken to eliminate shaft friction over this length shall be
allowed for in the evaluation of the test results.
189
Table 2 Suggested increments of load and minimum holding time
for loads up to 1.5 Design Load
4.10 TEST FAILURE CRITERIA
Any pile which fails before the proof load mentioned on the drawings is reached
shall be condemned by the Engineer.
A pile will be deemed to have failed the test if any of the following criteria is
satisfied.
1. The settlement of the pile at working load, including allowance for negative
skin friction as necessary, exceeds 10 mm. No allowance for elastic
shortening shall be permitted.
2. The residual settlement after the test load is removed is greater than 0.125
mm per ton of the load.
If any preliminary of working pile fails the test, the cost of the additional test shall be
borne by the contractor who shall replace the pile (s) with additional piles at his own
expense. Any piles constructed prior to a failed working pile test shall stand
condemned as unsatisfactory until demonstrated by the Contractor that the quality
and bearing capacity of each individual pile is acceptable.
4.11 FLUCTUATING LOAD TESTS
The engineer may require the load on a test pile to be cycled several times between
the working and proof loads. In the event, the pile shall be unloaded and relocated
between those two loads is less than ten minutes except that shock loads shall not
be allowed. Both loads shall be maintained for one hour until settlement (or
recovery) has ceased.
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4.12 COMPLETION OF A TEST
A. Measuring equipment
On completion of a test all equipment and measuring devices shall be
dismantled checked and either stored so that they are available for use in
further tests or removed from site as specified.
B. Kentledge
Kentledge and its supporting structure shall be removed from the test pile and
stored so that they are available for use in further tests or removed from the
site as specified.
C. Preliminary Pile Test.

The pile cap, if formed in concrete, shall be broken off and the resulting
material disposed off the site. If the pile cap is made of steel it shall be cut off
and stored so that it is available for use in further tests or removed from the
site as specified.
The pile head shall be made good or extended to the cut-off level.
On completion of a preliminary pile test, reaction piles and ground anchors
shall be cut-off below ground level as indicated by the Engineer, removed
from the site and the ground made good with approved material as specified.
D. Working Pile Tests

On completion of a test on a working pile, the test pile cap, if in concrete,
shall be stripped and left in a state ready for incorporation in the permanent
works and the resulting material disposed off the site. If the pile cap is made
of steel it shall be cut-off and stored so that it is available for use in further
tests or removed from the site as specified. On completion of a working pile
test, temporary piles and ground anchors shall be removed, cut-off as
specified earlier or, if approved, incorporated in the permanent works.
E. It should be noted that each site has unique and often unforeseen
characteristics. Hence proper judgements shall be made even during the
testing program by the testing engineer and suitable alternations may have to
be carried out to the standard test procedures to get accurate and reliable
results.
Based on field results, the driving stress, the integrity of the test pile and the
bearing capacity of the pile shall be checked.
4.13 LOW STRAIN INTEGRITY TESTING OF PILES
If required, a low strain integrity testing of piles shall be done to get information
about the physical dimensions, continuity and consistency of materials used in the
piles. (BS 8004: 1986 and “Specification for piling”. : Institution of Civil Engineer,
TTL - London 1988)
The requirements of Low Strain Integrity Testing are as follows:
A. The testing shall be carried by an approved specified firm.
B. The contractor will be required to perform low strain integrity testing on 15%
of the piles.
C. The method to be adopted shall be approved by the Engineer and shall be

one of the following.
1. The sonic method

2. The vibration method
3. The sonic logging method
191
D. In the case of cast-in- situ concrete piles, integrity test shall not be carried out
until after 7 days or more have elapsed after casting. Where the method of
testing requires the positioning of sensing equipment on the pile head, the
head shall be clean, free from water, laitence, loose concrete and be readily
accessible for the purpose of testing.
E. The interpretation of tests shall be carried out by competent persons and the
full test results and findings shall normally be given to the Engineer within 2
days of the completion of each phase of testing.
F. Depending on the ground conditions and on the pile conditions, the Engineer
may require additional special low strain studies on certain number of piles
(5% or more) in order to plot an approximate pile shape profile. This can be
done by signal matching analysis using suitable software on the collected
data.
G. Full details of the ground conditions and the construction method shall be
made available to the specialist firm in order to facilitate the study and to give
accurate results.
H. When the test results of several piles are not, in the opinion of the Engineer,
satisfactory, the contractor shall submit proposal for any remedial work to be
agreed by the Engineer.
END OF SECTION
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DIVISION 5
STEEL
STRUCTURE
194
SECTION 5.1 STRUCTURAL STEEL
PART 1 - GENERAL
1.01 INTRODUCTION
This specification describes the minimum technical requirements for the

fabrication, delivery and erection of all structural steel in accordance with the
design drawings and this specification.
1.02 PURPOSE
This specification is for the fabrication, delivery and erection of all structural
steel.
1.03 REFERENCES
references, unless otherwise approved by the Employer
1. AISC American Institute of Steel Construction

M011 Manual of Steel Construction
S302 Code of Standard Practice for Steel Building and Bridges
S314 1980 Specification for Structural Joints Using ASTM A325 or ASTM
A490 Bolts.
S326 Specification for the Design Fabrication and Erection of Structural Steel
for Buildings
2. ASTM - American Society for Testing And Materials

A6 Standard Specification for General Requirements for Rolled Structural
Steel Bars, Plates, Shapes, and Sheet Piling
A36 Standard Specification for Carbon Structural Steel
A53 Pipe, Steel, Black and Hot-Dipped Zinc-Coated Welded and Seamless
A108 Standard Specification for Steel Bar, Carbon and Alloy, Cold-Finished
A123 Coatings on Iron and Steel Products
A153 Zinc-Coating (Hot Dip) On Iron and Steel Hardware
A242 Standard Specification for High-Strength Low-Alloy Structural Steel
A283 Standard Specification for Low and Intermediate Tensile Strength
Carbon Steel Plates
A307 Carbon Steel Externally Threaded Standard Fastebers
A325 High Strength Bolts for Structural Steel Joints.
A386 Zinc-Coating (Hot Dip) On Assembled Steel Products
A446 Steel Sheet, Zinc-Coated (Galvanized) By The Hot-Dip Process,
Structural (Physical) Quality
A490 Heat-Treated Steel Structural Bolts 150 Ksi Tensile Strength
A500 Cold-Formed Welded and Seamless Carbon Steel Structural Tubing In
Rounds and Shapes
A501 Hot-Formed Welded and Seamless Carbon Steel Structural Tubing,
A525 Steel Sheet, Zinc-Coated (Galvanized). by the Hot-Dip Process,
General Requirements
A529 Structural Steel With 42,000 Psi (290 Mpa) Minimum Yield Point.
A572 High-Strength Low-Alloy Columbium-Vanadium Steels of Structural
Quality
A588 High-Strength Low-Alloy Structural Steel with 50 Ksi (345 Mpa)
Minimum Yield Point to 4 in (100 mm) Thick.
195
A618 Hot-Formed Welded and Seamless High Strength Low-Alloy Structural
Tubing.
A770 Through-Thickness Tension Testing of Steel Plates for Special
Applications
A992 Standard Specification for Structural Steel Shapes
E94 Radiographic Testing
E709 Magnetic Particle Examination
F436 Hardened Steel Washers
3. AWS - American Welding Society
B3.0 Welding Procedure and Performance Qualification.
D1.1 Structural Welding Code Steel
4. ANSI - Amerian National Standards Institute, Inc.:
B18.B.22.1 Plain Washers
SSPC PS 13.01 Epoxy-Polyamide painting System
E. SSPC - Steel Structures Painting Council :
SP 10 Near-White Blast Cleaning
PS 12.00 Guide for Selecting Zinc-Rich Painting Systems
5. B.S. - British Standards

BS 4 Structural Steel Sections
BS 449 The use of structural steel in buildings Part 2: Metric units
BS 639 Covered carbon and carbon-manganese steel electrodes for manual
metal-arc welding (no longer current)
BS 729 Hot Dip Galvanizing Coating on Iron and Steel Articles
BS 1133 Packaging Code Section 6 Temporary protection of metal surfaces
against corrosion (during transport and storage)
BS 1449 Steel plate sheet and strip Part 1: Section 1.12: Tolerances on
dimensions and shape for hot-rolled narrow strip (no longer current)
BS 1474 Wrought aluminium alloys for general engineering purposes
BS 1490 Aluminium allow ingots and castings for general engineering
purposes
BS 1763 Thin PVC Sheeting (calendered, flexible unsupported)
BS 2600 Method for radiographic examination of fusion welded butt joints in
steel. Part 1: 2mm up to and including 50 mm thick, Part 2: Over 50
mm up to and including 200mm thick (no longer current)
BS 2853 The design and testing of steel overhead runway beams
BS 2910 Methods for radiographic examination of fusion welded
circumferential butt joints in steel pipes (no longer current)
BS 2994 Specification for cold rolled steel sections
BS 3643 ISO Metric screw threads
Part 1: Principles and basic data
Part 2: Specification for selected limited of size
BS 3692 ISO Metric precision hexagon bolts, screws and nuts
BS 3923 Methods for ultrasonic examination of welds
Part 1: Manual examination of fusion welds in ferritic steels (no longer current)
Part 2: Automatic examination of fusion welded butt joints in ferritic steels
BS 4165 Electrode wires and fluxes for the submerged arc welding of carbon
steel and medium tensile steel (no longer current)
BS 4190 ISO Metric black hexagon bolts, screws and nuts.
BS 4232 Surface Finish of Blast Cleaned Steel for Painting
BS 4320 Metal washers for general Design Consultanting purposes
BS 4360 Specifications for Weldable Structural Steels
BS 4395 High strength friction grip bolts and associated nuts and washers for
structural Design Consultanting Part 1: General grade
BS 4604 The use of high strength friction grip bolts in structural steelwork
Part 1: General grade
196
BS 4848 Hot rolled structural steel sections Part 2: Hollow sections (no longer
current)
BS 4872 Approval testing of welders when welding procedure approval is not
required Part 1: Fusion welding of steel
BS 4933 ISO Metric black cup and countersunk head bolts and screws with
hexagon nuts (obsolete but remains current)
BS 5135 Arc welding of carbon and carbon-manganese steels (no longer
current)
BS 5289 Visual inspection of fusion welded joints (no longer needed)
BS 5395 Design of stairs, ladders and walkways
BS 5400 Steel, concrete and composite of bridges Part 10: Code of practice
for fatigue
BS 5531 Safety in erecting structural frames
BS 5599 Hard anodic oxidation coatings on aluminium
BS 5950 Structural use of Steelwork in Building (BS EN 10025).
BS 5977 Part 2 Pre-fabricated lintels
BS 5996 Specification for acceptance levels for internal imperfections in steel
plate, strip and wide flats, based on ultrasonic testing (no longer
current)
BS 6161 Methods of test for oxidation coatings on aluminium
BS 6037 Permanently installed suspended access equipment
BS 6072 Method for magnetic particle flaw detection (obsolete)
BS 6363 Welded cold formed steel structural hollow sections (no longer
current)
BS 6443 Method for penetrant flaw detection
BS 6651 Code of Practice for protection of structures against lightning
BS 6722 Recommendations for dimensions of metallic materials
BS 6780 Through thickness reduction of area of steel plates and wide flats
BS 7079 Preparation of steel substrates before application of paints and
related products
BS 7419 Specification for holding down bolts
BS 7668 Weldable structural steels. Hot finished structural hollow sections in
weather resistant steels
BS EN 898-1 Mechanical properties of fasteners made of carbon steel and
alloy steel — Part 1: Bolts, screws and studs
BS EN 287 Approval testing of welders for fusion welding
BS EN 288 Approval of welding procedures for metallic materials
BS EN 449 Welding consumables – covered electrodes for manual metal arc
welding of non alloy and fine grain steels – classification
BS EN 756 Welding consumables – wire electrodes and wire flux
combinations for submerged arc welding of non alloy and fine
grain steels – classification
BS EN 970 Non-destructive examination of fusion welds – visual inspection
BS EN1001 Welding-Recommendation for welding of metallic materials
Part 1: General guidance for arc welding
Part 2: Arc welding of ferretic steels
BS EN 1435 Non-destructive examination of welds – Radiographic
examination of weld joints
BS EN 1708 Part 2: Basic weld joints details in steel - none internal
pressurized components
BS EN 1714 Non-destructive examination of joints – Ultrasonic examination
of welded joints
BS EN10021 General Technical delivery requirements for steel and iron
products
BS EN 10025 Hot rolled products of non-alloy structural steels.
197
BS EN 10029 Tolerances on dimensions, shape and mass for hotrolled steel
plates 3 mm thick or above
BS EN 10034 Structural steel I and H sections - Tolerances on shape and
dimensions
BS EN 10045 Charpy impact test on metallic materials
BS EN 10051 Continuous hot-rolled uncoated plate, sheet and strip of non-
alloy and alloy steels - tolerances on dimensions and shape
BS EN 10056 Structural steel equal and unequal leg angles
BS EN 10067 Hot rolled bulb flats - Dimensions and tolerances on shape,
dimensions and mass.
BS EN 10113 Hot-rolled products in weldable fine grain structural steels
BS EN 10132 Cold rolled narrow steel strip for heat treatment – technical
delivery conditions
BS EN 10137 Plates and wide flats made of high yield strength structural
steels in the quenched and tempered or precipitation hardened
conditions
BS EN 10147 Continuously hot-dip zinc coated plate and strip
BS EN 10155 Structural steels with improved atmospheric corrosion
resistance. Technical delivery conditions
BS EN 10160 Ultrasonic testing of steel flat product of thickness equal or
greater than 6 mm (reflection method)
BS EN 10164 Steel products with improved deformation properties
perpendicular to the surface of the product. Technical delivery
conditions
BS EN 10204 Metallic products. Types of inspection documents
BS EN 10210 Hot finished structural hollow sections in non-alloy and fine
grain structural steels
Part 1: Technical delivery requirements
Part 2: Dimensions, tolerances & sectional properties
BS EN 10219 Cold formed welded structural hollow sections of nonalloy and
fine grain steels.
BS EN 22553 Welded, brazed and soldered joints – symbolic representation
on drawings
BS EN ISO 2566-1 Steel - Conversion of elongation values - Part 1: Carbon
and low alloy steels.
B. Order of Priority in the use of Code and Standards
1. The above mentioned Codes and Standards shall provide complete

guidance to compliance criteria to which the Steelwork Contractor is
expected to confirm.
2. The Steelwork Contractor shall provide full and detailed specification and
clearly state the alternative proposals with a comparison to the specified
materials for consideration by the Engineer.
1.03 SUBMITTALS
A. Product Data: For each type of product indicated.
B. Shop Drawings: Show fabrication of structural-steel components.
C. Welding certificates.
D. Mill test reports.
E. Source quality-control test reports.

198
1.04 QUALIFICATIONS
A. Structural steel fabrication and erection shall be performed by an organization

experienced in structural steel work of equivalent magnitude with a minimum of 5
years documented experience.
1. The Contractor shall verify all measurements and shall take all field
measurements necessary before fabrication.
2. The Contractor shall be responsible for correctness of detailing, fabrication and
for the correct fitting of structural members.
3. Substitution of sections or modification of connection details, or both, will not be
accepted by the Employer.
4. Connections fully designed and detailed on the Drawings shall be furnished as
shown.
5. Members and connections, for any part of the structure, not shown on the
Drawings shall be the Contractor’s responsibility.
a. Such connections shall be considered standard and designed and detailed in

accordance with BS 5950: Part 1 and BS 449: Part 2.
b. Welding shall be in accordance with AWS D1.1.
c. High-strength bolting shall be in accordance with the AISC S329.
1.05 TESTING
A. All steelwork material shall be tested to show compliance with the relevant material
quality standard. The Contractor shall obtain the manufacture’s test certificates and
submit them for approval.
B. The Engineer may from time to time himself select samples of the steel for testing by
an approved Laboratory at the Contractor’s expense. The standard for acceptance of
the results of such tests shall be those laid down in the relevant standards specified
herein
C. The Contractor shall engage, at its own expense, an independent, certified, Testing
Laboratory to inspect high strength bolted connections and welds and to perform all
tests. All costs of testing shall be at the expense of the Contractor. The Testing
Laboratory shall perform its duties in such a way that fabrication and erection of
structural steel are not unnecessarily delayed or impeded. The Contractor shall
coordinate and allow sufficient time for the Testing Laboratory to complete all testing
and inspections before shop painting.
D. The Contractor shall provide the Testing Laboratory with the following:
1. A complete set of accepted shop drawings.

2. Information as to time and place of all rollings and shipments of materials to
shops.
3. Certification of chemical composition with each shipment of bolts and fasteners to
the project site.
4. Representative sample pieces as requested by the Testing Laboratory.
5. Full and ample means and assistance for testing all material.
6. Proper facilities, including scaffolding, temporary work platforms, etc., for
inspection of the work in the mills, shop and field.
7. Cutting lists, order sheets, material bills, shipping bills, and mill test reports
including certified copies of mill test reports for:
a. Bolts, nuts and washers.

b. Names and locations of mills and shops.
c. Analyses of chemical and physical properties.
199
E. Access to places where materials for this Contract are fabricated or produced shall be
provided to the Employer and the Testing Laboratory for the purpose of inspection
and testing. The Employer may inspect structural steel at the plant before shipment.
At any time before final acceptance, the Employer may reject any material which
does not conform to all of the requirements of the Drawings and Specifications.
F. The Testing Laboratory shall inspect bolted connections in accordance with AISC
Specifications for Structural Joints Using ASTM A325-83C, ASTM A325M-83 and
ASTM A490-83A or ASTM A490-82. The Testing Laboratory shall perform testing
and inspection of high strength bolt connections as required by AISC S314.
The installation and tightening of bolted connections shall be observed to determine if
the tightening procedure is working properly and the correct tension has been
achieved. The Engineer will observe and verify the checking of impact wrenches used
for the calibrated wrench method. The Engineer will also observe and verify the
checking of manual torque wrenches used for the torque method.
The Contractor shall provide a tension measuring device, such as a Skidmore-

Wilhelm Calibrator, that has been calibrated within the last year and is accompanied
by a certificate verifying its date of calibration. The wrench shall be calibrated yearly
and accompanied by a certificate indicating the date of calibration.
Before the installation of fasteners in the work, the Engineer shall check the marking,
surface condition and storage of bolts, nuts and washers and the faying (contact)
surfaces of joints for compliance with the Contract requirements.
With the exception of inspecting direct tension indicators and the tension control
assemblies, the Engineer will inspect fasteners after installation by applying the
inspecting wrench to a minimum of 10 percent of the bolts, but not less than two
bolts, selected at random in each connection. The actual torque value of each
inspected bolt will be determined as the head or nut is rotated 5 degrees in the
tightening direction. This value shall be within the minimum and maximum job
inspecting torque values as determined during the calibration of the inspection torque
wrench using the bolt tension values specified in Table A.
Bolts installed using tension control assemblies shall be visually inspected for
consistent “twist-off” and thread stick out.
If any bolt in a connection is found to have a torque value below the minimum or
above the maximum job inspecting torque, all bolts in that connection shall be
inspected. All under-tightened bolts shall be tightened and reinspected. All over-
tightened bolts shall be loosened and the bolt and nut removed for visual inspection
of the bolt and nut threads. If there is visible thread damage or the nut does not spin
freely on the bolt when turned by hand without the aid of a wrench, a new bolt and nut
shall be installed. Undamaged fasteners may be reinstalled with the following
exception: Galvanized bolts, AASHTO M 253M (AASHTO M253) bolts, tension
control assemblies and direct tension indicators shall not be reused. This
specification does not recognize standard torques determined from tables or from
formulas which are assumed to relate torque to tension. Testing using such standard
torques shall not be considered valid. Inspection torques must be determined directly
from calibrations performed at the project site reflecting actual work conditions.
G. The Testing Laboratory shall inspect and test welding during fabrication and erection
of structural steel in accordance with the Structural Welding Code and as follows:
1. The Testing Laboratory shall ensure that all welders working on the project are
certified in accordance with AWS or equal.
2. The Testing Laboratory shall visually inspect all welds.
3. Edges of material to be welded shall be ultrasonically examined for evidence of
laminations, inclusions or other discontinuities. The extent to which such defects
will be permitted and the extent of repair permitted shall be determined by the
200
Testing Laboratory and made in accordance with ASTM A6, Paragraph 9.
Repairs made by welding shall be done in compliance with the requirements of
AWS D1.1 and the accepted welding procedures.
4. Magnetic particle and ultrasonic inspection shall be made of all welds indicated
on the Drawings. Magnetic particle inspection shall be made on the root pass of
all multiple pass welds, on the backside of groove welds made from both sides,
and on finished weld. Magnetic particle inspection shall be in accordance with
ASTM E109. Any type of crack or zone of incomplete fusion or penetration will
not be acceptable. If magnetic particle inspection is not feasible, dye penetration
inspection shall be performed.
5. Ultrasonic inspection shall be performed in accordance with AWS D1.1.
6. Radiographic inspection shall be in accordance with the requirements of AWS
D1.1. A double film technique shall be used.
7. The Testing Laboratory shall be responsible for conducting and interpreting tests,
shall state in each report whether or not the test specimens conform to all
requirements of the Contract Documents, shall identify the types and locations of
all defects found in the work, and shall identify the measures required and
performed to correct such defects. Where inspection reveals defects, the extent
of inspection shall be increased as necessary to ensure that the full extent of the
defects in a joint has been found, and that the same defects are not present in
welds made on similar parts or under similar circumstances. Corrective
measures, including additional and more complete testing, which may result from
these tests shall be the Contractor's responsibility.
8. Shop welds shall be inspected in the shop before the work is painted or approved
for shipment. Work that is not acceptable shall be designated by "Repair" or
"Reject", as applicable.
H. Each bolting crew and welder shall be assigned an identifying symbol or mark. All
shop and field connections shall be so identified so that the inspector can refer back
to the crew or person making the connection.
I. The Testing Laboratory shall perform specified tests and submit reports directly to the
Employer. The Testing Laboratory shall maintain a daily record of the work that was
inspected and its disposition. Reports of welding tests shall be made on the form
prescribed in AWS D1.1. One copy of each of the reports shall be submitted to the
Employer on a weekly basis. One copy of each radiographic film shall be sent to the
Employer, and the Testing Laboratory shall retain a copy.
J. The Testing Laboratory shall prepare test specimens from steel samples cut from
delivered material and shall conduct tension tests in accordance with ASTM.
Contractor shall mill order 1.0 m extra length for the members noted on the Drawings
to provide the steel for testing.
K. Bolts and nuts shall have independent laboratory verifications with samples selected
as follows:
• A minimum of one (1) sample from each mill heat and each manufacturing lot for
each manufacturer.
• A minimum of one (1) sample for each mill heat and each lot for each manufacturer of
bolts 30mm (1-1/4 inches) and larger.
A. Do not handle structural steel until paint has thoroughly dried.

B. Care shall be exercised to avoid abrasions and other damage.
C. Stack material above ground out of mud and dirt and provide for proper drainage.
D. Protect from damage or soiling by adjacent construction operations.
E. Provide suitable separators to avoid individual items from coming into contact.
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F. Do not deliver material to the project site until the proposed method and sequence of
erection has been reviewed by the Employer.
G. Method and sequence shall be planned so as to avoid delay or damage to the work of
other trades.
H. Storage of fabricated steel at the job site shall be the responsibility of the Contract.
PART 2 - PRODUCTS
2.01 STRUCTURAL STEEL
A. All structural steel shall conform to BS 4: Part 1, and BS 4360 Grade 43A, or BS EN
10025 Grade S275JR, or ASTM A36, Grade 36.
B. Steel shapes of structural quality fabricated by the electric-resistance welding process
from coils shall conform to ASTM A769
C. W-Shapes: ASTM A992
D. Channels, Angles: ASTM A 36/A 572, Dual Certificate Grade 50.
E. Plate and Bar: ASTM A36/A36M.
F. Cold-Formed Hollow Structural Sections: ASTM A500, Grade B, structural tubing.
2.02 BOLTS, CONNECTORS, AND ANCHORS
A. Use the following bolt category regarding the application of bolts:
1. Ordinary Bolt Assemblies: Ordinary bolts and nuts (other than H.S.F.G.) shall
comply with BS 3692 or BS 4190 for hexagon headed bolts or BS 4933 for cup
headed or countersunk bolts. Unless otherwise specified bolts shall be of grade
8.8. Ordinary washers shall comply with BS 4320, plain washers shall be made of
steel and taper or other special shaped.
2. HSFG Bolts: High strength friction grip bolts, nuts and washers shall comply with
BS 4395 and BS 4604. Rivets shall comply with BS 4620.
3. High-Strength Bolts, Nuts, and Washers: ASTM A325, Type 1, heavy hex steel
structural bolts; ASTM A563 heavy hex carbon-steel nuts; and ASTM F436
hardened carbon-steel washers.
1. Finish: Plain.
4. Tension-Control, High-Strength Bolt-Nut-Washer Assemblies: ASTM F1852, Type
1, heavy hex head steel structural bolts with splined ends; ASTM A563 heavy hex
carbon-steel nuts; and ASTM F436 hardened carbon-steel washers.
1. Finish: Plain.
5. High strength bolts shall be minimum 20mm (3/4 of an inch) diameter, unless
otherwise specified, and shall conform to ASTM A325 Type 1 for galvanized bolts
and ASTM A325 Type 3 for plain type bolts.
6. Stainless steel bolts shall be Type 304 or 316
7. Provide two washers per each nut and bolt.
8. Shear Connectors: ASTM A 108, Grades 1015 through 1020, headed-stud type,
cold-finished carbon steel; AWS D1.1, Type B.
9. Unheaded Anchor Rods: ASTM F1554, Grade 36.
1. Configuration: Straight.
2. Finish: Plain or Hot-dip zinc coating, ASTM A 153/A 153M, Class C.
10. Headed Anchor Rods: ASTM F 1554, Grade 36, straight.
1. Finish: Plain and Hot-dip zinc coating, ASTM A 153/A 153M, Class C,
Mechanically deposited zinc coating, ASTM B 695, Class 50.
11. Threaded Rods: ASTM A 36/A 36M.
1. Finish: Plain or Hot-dip zinc coating, ASTM A 153/A 153M, Class C,
Mechanically deposited zinc coating, ASTM B 695, Class 50.
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2.03 WELDING ELECTRODES
A. All welding electrodes shall be E70XX and shall comply with the provisions of AWS
Specifications A5.1, A5.5, A5.17, A5.18, A5.20.
B. All welds not specified shall be continuous fillet welds using not less than the
minimum size based on thickness of the thicker part jointed.
Thickness (mm) Minimum Weld Size (mm)

12 4
Over 12 to 20 6
Over 20 to 40 8
Over 40 to 50 10
PART 3 - EXECUTION
3.01 BENCH MARKS
A. The Contractor shall employ the services of a qualified surveyor who shall:
1. Establish permanent benchmarks.
a. Field checks all elevations of concrete on which structural steel is to be

placed.
b. Locations of anchor bolts.
2. Report discrepancies to the Employer.

3. Obtain the Employer's approval before the work proceeds.
3.02 ERECTION
A. The Contractor shall be responsible for the accurate setting and leveling of all bearing
plates or setting plates.
1. Bearing plates or setting plates shall be leveled on steel wedges or shims or as

otherwise detailed.
2. Bearing and setting plates shall be grouted as specified. All shims to have 50 mm
grout coat.
3. Set base and bearing plates for structural members on wedges, shims, or setting
nuts as required.
4. Weld plate washers to top of base plate.
5. Snug-tighten anchor rods after supported members have been positioned and
plumbed. Do not remove wedges or shims but, if protruding, cut off flush with
edge of base or bearing plate before packing with grout.
6. Promptly pack grout solidly between bearing surfaces and base or bearing plates
so no voids remain. Neatly finish exposed surfaces; protect grout and allow to
cure. Comply with manufacturer's written installation instructions for shrinkage-
resistant grouts.
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B. Furnish templates for accurate setting of all anchor bolts. Furnish shim plates or
developed fills where required to obtain proper fit and alignment.
C. Oxygen cutting of structural steel for "fitting-up" purposes shall not be done except
with the prior approval of the Employer. The use of an oxygen-cutting torch for
correcting fabrication errors will not be permitted.
ERECTION TOLERANCE
A. The Contractor shall be responsible for the correct fitting of all structural members
and for the elevation and alignment of the finished structure. Any adjustments
necessary in the steel work because of discrepancies in elevations and alignment
shall be the responsibility of the Contractor.
B. Erected steelwork shall comply with the tolerances as set out below:
 e  1
 〈
• Building inclination  H  500 and e〈 25mm
e 1
 〈
• Building warping  L  2000 and e 〈30mm
• Fitting level of column e < 3 mm
• Deviation of anchor bolts from center line e < 2 mm
• Eccentricity of column center e < 5 mm
• Height of story e < 3mm
e  1 
 〈  
• Inclination of column  L   500 
e  1 
 〈  ande〈5mm
• Horizontal inclination of the beam  L   1000 
e  1 
 〈  
• Bending of beam  L   1000 
Where; E = Eccentricity
L = Length
H = Height
C. All measurements relating to the above shall be on the theoretical centerlines of the
members.
3.04 CONNECTIONS
a. Welding or bolting shall not be performed until all stiffening components of the
structure have been properly aligned.
b. Drift pins shall not be used to enlarge holes in primary members.
1. Holes that must be enlarged to admit bolts shall be reamed.

2. Burning and drifting will not be permitted.
c. When high strength bolts or high strength bearing bolts are used Bolts shall be
tightened to develop a tension not less than 5 percent in excess of the minimum bolt
tension specified in Table A except as noted below. Except as permitted below,
installation shall be assured by the calibrated wrench, turn of the nut, torque, tension
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control assembly (“twist-off”), or direct tension indicator method. Bolts shall not be
tightened to more than the maximum tension specified in Table A.
1. In using manual torque wrenches, the required torque can be read from the
wrench dial.
2. Care should be taken that the wrench is properly calibrated.
3. Nuts shall be in motion when torque is measured.
4. In using power wrenches, the recommendations of the wrench manufacturer shall
be followed.
5. Use hardened washer under bolt head or nut whichever is turned in tightening,
unless the specified standards require hardened washer under both head and
nut.
d. Bolts shall be tensioned by the Contractor in the presence of the Engineer using one
of the following methods:
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1. Calibrated Wrench Method. A random sample of not less than three bolt and nut
assemblies of each diameter, length, grade and type to be used in the work shall
be checked a minimum of each working day in a device capable of indicating bolt
tension..
The test shall be performed on each wrench to be used to determine the working
torque for the wrench. Variations in the number or location of washers will require
separate checks. Additional calibration of the wrenches being used shall be
performed as directed by the Engineer.
All powered wrenches shall be adjusted to stall or cut-out at the specified tension.
Power wrenches without cut-outs will not be permitted.
2. Turn of the Nut Method. All bolts shall be tightened by the applicable amount of
nut or head rotation specified in Table B. During the tightening operation, there
shall be no rotation of the part not turned by the wrench.
A random sample of not less than three bolt and nut assemblies of each diameter,
length, grade and type to be used in the work shall be checked each working day
in a device capable of indicating bolt tension. The test shall demonstrate that the
method of estimating the “snug tight” condition and controlling turns from “snug
tight” to be used by the bolting crew(s) develops a tension of at least 5 percent in
excess of the minimum bolt tension specified in Table A, and not more than the
maximum tension specified in Table A. Separate checks will be required for each
diameter fastener with hardened washers placed under the nut and/or bolt head as
they will be used in the structure. Variations in the number or location of washers
will require separate checks.
3. Torque Method. Manual torque wrenches for installation shall be supplied by the
Contractor, calibrated yearly, and each accompanied by a certificate indicating its
date of calibration. A random sample of not less than three bolt and nut
assemblies of each diameter, length, grade and type to be used in the work shall
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be checked a minimum of each working day in a device capable of indicating bolt
tension. The test shall be performed on each wrench to be used to determine the
working torque for the wrench. Additional calibration of the wrenches shall be
performed as directed by the Engineer. Separate checks will be required for each
diameter fastener with hardened washers placed under the nut and/or bolt head as
they will be used in the structure. Variations in the number or location of washers
will require separate checks.
4. Tension Control Assembly Method. A tension control assembly consists of a

tension control bolt with a spline end and a suitable nut and washer. This method
shall be employed when installing “button” or “dome” headed high strength bolts.
All bolts shall be tightened by the application of torque to the nut and counter-
torque to the spline end of the bolt using an approved spline drive installation tool.
A random sample of not less than three tension control assemblies of each
diameter, length, grade and type to be used in the work shall be checked a
minimum of each working day in a device capable of indicating bolt tension. The
test shall be performed to verify that the spline twist-off develops a tension of at
least 5 percent in excess of the minimum bolt tension specified in Table A, and not
more than the maximum tension specified in Table A . Additional verification of the
tension control assemblies shall be performed as directed by the Engineer.
Separate checks will be required for each diameter fastener with hardened
washers placed under the nut and/or bolt head as they will be used in the
structure. Variations in the number or location of washers will require separate
checks.
5. Direct Tension Indicator Method. Direct tension indicators (DTIs) are compressible
washers capable of indicating that a specified minimum bolt tension has been
attained. DTIs installed with high strength bolts to indicate bolt tension shall be
subjected to field verification testing prior to installation and the installation
requirements specified below.
The bolt, DTI, hardened washer and nut assembly used in the verification testing
device and installed in the work shall be such that at least 3 and preferably not
more than threads are located in the grip. The grip is defined as the distance
between the bearing face of the nut and the bolt head.
The Contractor shall supply 5 mil tapered feeler gages, a calibrated bolt
tensionmeasuring device and equipment necessary to perform field verification
testing and inspection of tensioned bolts. The feeler gages, fasteners and impact
and manual wrenches shall be the same as that to be used in the work.
The Contractor shall obtain the services of a qualified technical advisor employed
by the DTI manufacturer to make at least one site visit to assist the Contractor and
to assure the proper installation and use of DTIs.
Verification testing shall be performed in a calibrated bolt tension measuring

device, such as a Skidmore-Welhelm Calibrator, with a special flat insert (supplied
by the Contractor) replacing the normal bolt head-holding insert. The special insert
allows the DTI to be located on the flat front face of the tension measuring device
for ease of observation and improved access for measuring the DTI gap during
testing.
The verification testing shall demonstrate that the DTIs were properly
manufactured. The fastener shall develop a tension of at least 5 percent in excess
of the minimum bolt tension specified in Table A
Three verification tests are required to be performed on random samples of each

combination of fastener rotational-capacity lot, DTI lot and DTI position (under the
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nut or bolt head) used on the project. All three tests must pass for the DTI and
assembly combination to be approved. Testing shall be performed at the project
site by the Contractor and witnessed by the Engineer.
When testing for the normal DTI position, the nut shall be turned with the bolt head
against the DTI restrained from turning with another wrench. When testing with the
DTI under the turned element, the turned element shall be placed on the flat front
face of the tension measuring device and the unturned element will be in the rear
held by another wrench.
a. Verification Test. The verification test shall be conducted in two stages as

follows:
Stage 1. Tension the fastener to the Verification Tension load specified in Table C
for the grade and size of fastener. If an impact wrench is used, tension to a load
two-thirds below the required load and use a manual wrench to attain the required
tension. Determine and record the number of entries of a 5 mil feeler gage in the
spaces between the protrusions. When using coated (galvanized or epoxy coated)
DTIs under the turned element, there shall be at least one entry of the feeler gage.
The DTI lot will be rejected if the number of entries is less than the value in column
3 of Table C, or for coated DTIs used under the turned element, there are no
entries.
Stage 2. Further tension the fastener beyond the verification load with a manual
wrench until there are no entries for the 5 mil feeler gage but a visible gap exists in
at least one space. Note and record the load in the bolt at this condition (the
maximum allowable limit of DTI compression) and remove the fastener from the
tension measuring device. The capability of the bolt to tolerate the maximum
allowable limit of DTI compression is determined in two ways.
The simplest is to hand turn the nut down the complete thread length of the bolt,
excluding thread run out. If this is successful, then the bolt has not undergone
significant plastic deformation and the assembly passes the verification test.
Alternatively, if the nut cannot be turned down the complete thread length, the DTI
lot will be rejected unless the load recorded is less than 95% of the average load
measured in the rotational capacity test of the fastener lot as specified in the
applicable AASHTO design code, in which case the assembly is deemed to have
passed the test.
Bolts and DTIs used in verification tests shall be marked and shall not be reused in
the work.
If the bolts are too short to be tested in the tension measuring device, Stage 1 of
the Verification Test for the DTI shall be conducted on a longer bolt Stage 2 of the
Verification Test shall be conducted for the short bolt with the short bolt in a
convenient hole in the work. The fastener assembly shall be tensioned with a
manual wrench until there are no entries for the 5 mil feeler gage but a visible gap
exists in at least one space. The fastener shall then be disassembled.
Subsequently, the nut must be run down, by hand, for the complete thread length
of the bolt excluding thread runout. The DTI lot will be rejected if the nut cannot be
assembled to this thread length. Three verification tests are required as specified
above.
b. Installation. Installation of fasteners utilizing DTIs shall be conducted in two

steps as follows:
Step 1. All of the bolts in a connection shall be installed to a snug tight condition.
Snugging shall progress systematically beginning at the most rigid part of the
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connection and progressing to the free edges until the connection is fully
compacted. At the snug tight condition all of the DTIs shall be inspected with the
feeler gage to verify that they meet the number listed in column 3 of Table C. If the
number of entries is less than the values specified in the Table, the fastener must
be removed and another DTI installed, followed by resnugging of the fastener.
This is required because a fastener's tension may have relaxed during the
snugging of adjacent fasteners. A compressed DTI does not rebound if the
fastener tension is reduced. If a DTI which has fewer entries were left in place, it
would give a false indication of bolt tension
Step 2. The bolts in the connection shall then be further tensioned to the point that
the number of entries for a 5 mil feeler gage meets the number listed in Column 5
of Table C. Tightening shall progress systematically beginning at the most rigid
part of the connection and progressing to the free edges. Drift pins shall be
removed during this process. Several cycles may be required. If the fastener is
tightened so that no visible gap in any space remains, the bolt and DTI shall be
removed and replaced by a new properly tightened fastener and DTI.
209
e. All bolts shall be kept in dry storage until needed for installation.
1. A325 bolts 28 mm and 32 mm diameter and A490 bolts 25 mm diameter and over
shall have Johnson's Stick Wax No. 140 applied to their threads before being
assembled in the work.
2. If bolts have been left out and have become rusty before use, they shall be
rejected and shall not be used until they have been cleaned and waxed with
Johnson's Stick Wax No. 140.
f. Welded and bolted connections shall be comply with BS 5950: Part 1, BS 449: Part 2
and AISC S329 and tested in accordance with the requirements of paragraph 1.05,
Testing.
3.05 SETTING BASES AND BEARING PLATES
A. The Contractor shall clean concrete and masonry bearing surfaces of bond-reducing
materials and roughen the surface to improve bond to surfaces. Clean the bottom
surface of base and bearing plates.
B. Set loose and attached base plates and bearing plates for structural members on
wedges or other adjusting devices.
C. Tighten the anchor bolts after the supported members have been positioned and
plumbed. Do not remove wedges or shims, but if protruding, cut off flush with edge of
the base or bearing plate before packing with grout.
D. Pack grout solidly between bearing surfaces and bases or plates to ensure that no
voids remain. Finish exposed surfaces, protect installed materials, and allow to cure
in strict compliance with the manufacturer’s instructions, or as otherwise required.
3.06 WELD TESTING SCHEDULE
Length of Weld to be Type of

Weld Location Test ASTM Test
Tested Specification Weld
Other stress magnetic
300 mm in 3 m Fillet E709
Carrying Welds particle*
300 mm (min. test) Groove U.T. E164
Flange Splice 100% Groove U.T. E94 - Shop
(Full Penetration) (Weld only) E164 - Field
Web Splice Top - 100% Groove U.T. E94 - Shop
Bottom - 33% E164 - Field
Middle - 34%
300 mm in 1.2 m magnetic
Bearing Stiffener to Web Fillet E709
300 mm (min. test) particle*
Misc. Secondary Members 300 mm in 3 m magnetic
Fillet E709
Tension Zones (min. test) particle*
Compression Zones Visual only
* Only for field welds E165, liquid penetrant test may be substituted.
3.07 SURVEY
A. Make an accurate survey of actual locations of steel members immediately upon the
completion of erection of steel but before removal of shoring.
B. Promptly submit same to the Employer.
210
C. Should locations vary beyond the allowable tolerances, necessary corrective
measures and procedures shall be performed with approval of the Employer.
D. Survey the final erected structural steel after release of shoring but before final
removal of shoring elements and before the start of any other work.
E. Report any discrepancies from Contract requirements to the Employer.
3.08 PAINTING
A. Immediately after surface preparation, apply structural steel primer paint in

accordance with manufacturer's instructions and at a rate to provide dry film thickness
of not less than 3.0 mils (76 microns). Use painting methods that result in full
coverage of joints, corners, edges, and exposed surfaces.
B. The Contractor shall use spray application for painting as required below:
1. Minimum thickness shall be maintained on all corners, edges and ends of pieces.
2. Surface to be painted shall be dry and above 2°C.
3. Temperature of the air shall be over 5°C.
4. Do not paint outdoors in rainy and dusty weather.
5. Paint surface within 4 hours sandblasting a surface profile of 1 mil (25 microns)
minimum to 3mils (76 microns) maximum is adequate for new surfaces,
measurements shall be determined in accordance with ASTM D4417, Methods B
or C .
6. Allow paint at least 12 hours drying time in good weather before re-coating.
3.09 CORROSION PROTECTION SCHEDULE
A.1 PERFORMANCE SPECIFICATION
The Contractor/Sub-Contractor shall provide corrosion protection to the steelwork,

which has the following durability and maintenance characteristics:
1. Fully compliant to the pertinent provisions of either BS 5493, BS EN ISO 12944,

or BS EN ISO 14713. Time to first maintenance shall be 15 to 20 years as a
minimum for all categories of systems defined below and shall conform to one of
the Standards listed below:
a. Long Life to BS 5493

b. High durability (H) to Tables A.5, A.7 or A.9 to BS EN 12944-5 for Corrosivity
Category C5-M.
c. Long Life to Table 2f of BS EN 14713.
2. Contractor/Paint Manufacturer guarantee shall be provided for a period as

specified by the Engineer.
A.2 EXPOSURE CATEGORIES
A.2.1 Corrosion protection systems are required for the following project nominated
exposure categories:
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Exposure
Exposure Conditions
Category
A External - Directly exposed to the environment
B External - Concealed beneath cladding
C Internal - Exposed
D Internal - Concealed
E Internal - with intumescent paint coating
F Internal - Concrete encased
A.2.2 All steelwork will have a period of external exposure during transportation
and construction.
A.3 ENVIRONMENT
Corrovisity Category C5 - high salinity coastal environment in accordance with BS

EN ISO 14713 Table 1 and Category C5-M in accordance with BS EN 12944-2.
A.4 CORROSION PROTECTION SYSTEMS
A.4.1 The Contractor is responsible to the Engineer for demonstration that the
proposed corrosion protection systems satisfy the nominated performance
specification. Some indicative corrosion protections systems are specified
below for each project exposure category. These systems are in accordance
with BS 5493, which is now obsolete, but it is still cited by statutory authorities
and furthermore, the systems described have a proven track record in the
Arabian Gulf. However, the Contractor/Sub-Contractor is encouraged to
propose alternative systems that also have a proven track record in the
Arabian Gulf.
A.4.2 Paint Systems

The Contractor/Sub-Contractor is encouraged to propose alternative systems
that have a proven track record in the Gulf. Some indicative corrosion
protections systems are specified below:
Exposure Category A: External - Directly exposed to the Environment

Preparation : Grit blast clean to BS 7079 Part A1 Sa2½
Primer : 2 pack epoxy zinc rich to BS 5493 Type DF to 50 microns DFT
Build and Finish coats: 2 pack high build epoxy to BS 5493 Table 4K Part ¾.
Stripe coat plus 2 coats at 200 microns DFT each
Total nominal DFT : 400 microns
The Contractor/Sub-Contractor shall allow for inclusion of a stripe coat where sharp
corners could lead to premature breakdown of the system or where future access
for maintenance is prevented by the close proximity of the cladding system. The
stripe coat shall be applied immediately after the primer.
Consideration will also be given to a single build/finish coat if the Contractor can
substantiate the quality and thickness.
Exposure Category B: External - Concealed beneath cladding

Primer : 2 pack epoxy zinc rich to BS 5493 Type DF to 50 microns DFT
Build and Finish Coats : 2 pack high build epoxy to BS 5493 Table K Part ¾.
Stripe coat plus 2 coats at 175 microns DFT each
Total nominal DFT : 400 microns
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Exposure Category C: Internal - Exposed
Holding Primer : 2 pack epoxy zinc phosphate to BS 5493 Table 4K Type KP1A. 75
microns DFT
Build Coat: 2 pack epoxy MIO to BS 5493 Table 4K Part ¾, 125 micons DFT
Finish Coat: 2 pack polyurethane to BS 5493 Table 4K Part 4, or acrylic urethane. 1
or 2 coats as necessary to provide a high quality finish. Gloss and colour
to be advised by Client. Minimum 50 microns DFT.
Total nominal DFT: 250 microns
Exposure Category D: Internal - Concealed

microns DFT
Build Coat : 2 pack epoxy MIO to BS 5493 Table 4K Part ¾,125 microns DFT
Total nomination DFT: 200 microns
Exposure Category E: Internal - With intumescent paint coating

microns DFT
Intumescent coating with a sealer coat to satisfy fire resistance. Gloss and colour to
be advised and approved by the Engineer.
Exposure Category F: Internal - Concrete encased

Preparation : Free from oil, grease, dirt, sand, loose rust and mill scale
Holding primer : Unpainted
A.4.3 Galvanizing
Exposure Category B: External - Concealed beneath cladding
Finish Coat : Galvanize to BS 5493 Table 4B, 140 microns nominal thickness
(1000g/m2)
Note that it may be necessary to use more than 0.3% silicon steel or silicon-killed
steel to achieve this coating thickness.
3.10 GROUTING
A. Nonmetallic, Shrinkage-Resistant Grout: ASTM C1107, factory-packaged,

nonmetallic aggregate grout, noncorrosive, nonstaining, mixed with water to
consistency suitable for application and a 30-minute working time.
B. Grouting shall not be carried out under column base plates until a sufficient
portion of the structure has been aligned, leveled, plumbed and adequately
braced.
C. Immediately before grouting, the space under column base plates shall be
clean and free of all deleterious matter.
D. Grout material shall be a non-shrink free flowing cementitious grout with the
following properties:
a. Compressive strength 50 N/mm2 at 28 days.

b. Expansion range 1-4% with the total expansion occurring within 2 hours.
c. The material must be free of chlorides and iron or other deleterious
material.
d. The storage, handling and placement of the grout must be in strict
accordance with the manufacture’s recommendations.
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3.11 FIRE PROTECTION FOR STRUCTURAL ELEMENTS
A. General: Fire protection of structural elements shall consist of furnishing and

constructing all materials metal framing and constructing shapes, forms to
enclose the structural steel frame members to provide 1 hour fire resistance.
B. Material: The fire protection board shall be rigid board type calcium silicate,
perlite or Vermiculite sheets. The board must be suitable for use in external
conditions for the climatic conditions in Baghdad.
The board should retain its properties in moist conditions and not sag, stain or
support mould growth.
The board should be fair face type that can be coated with multi-textured
resin ways finish.
C. Fire Protection Properties: The board must provide 1 hour fire protection
the thickness being determined from the Hp / A for the structural section that
is being protected in accordance with BS 5950 : 1990 and BS 476: Part 21:
1987. The thickness must not exceed 25 mm.
The material must be classified “Non-combustible to BS 476: Part 4: 1970
(1984) and have Class 1 surface spread of flame to BS 476: Part 7: 1997.
D. Material Information Submission: The Contractor shall submit for approval

by the Engineer the following information matching to the fire protection
board.
1. Material Name
2. Place of Manufacture
3. Local Agent (if applicable)
4. Thickness of Board
5. Fixing Details
6. Method Statement for Material Installation
7. Sample of Boards including Proposed Finish
8. Calculation to justify Selected Board Thickness
9. Details of Material Composition including compatibility to other material.
E. Required Material Properties:
Density between - 500 - 900kg / m3

Flexural strength - 3.0 N/mm2 min. (BS 4626)
Hard-body impact resistance to BS 8200 - 6.0 Nm.
Thermal conductivity (w/mc) - 0 to max. 0.20.
Specific heat - (J/kg c) - 1100 to 1500
Moisture movement (30% RM to 100%) - max. movement 0.09%
F. FIRE PROTECTION MATERIAL: shall also confirm to section 5.3
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SECTION 5.2 METAL FABRICATIONS
PART 1 - GENERAL
1.01 SUMMARY
A. This Section specifies metal fabrications.
A. Fabricator’s Qualifications
1. Only approved fabricators thoroughly familiar with the type of fabrication

required shall be permitted to carry out fabrication and coating works.
2. The Contractor’s staff will not be allowed to carry out the fabrication coating
or installation, unless approved by the Employer.
B. Metal fabrication shall comply with the following general requirements, unless
1. The Fabricator shall verify all necessary field measurements before

fabrication to assure proper fit up.
2. The Fabricator shall be responsible for all detailing, fabrication, and
installation to assure correct fitting of all members or components.
3. Substitution of sections or modification of connection details, or both, will not
be accepted, unless authorised in writing by the Employer.
4. Connections fully designed and detailed on the Drawings shall be furnished
as shown, unless otherwise approved by the Employer.
5. Members and connections, for any part of the structure, not shown on the
Drawings shall be the Contractor’s responsibility. Such connections shall be
considered standard and shall be designed and detailed in accordance with
AISC M016.
6. Welding shall be in accordance with AWS D1.1.
7. The following materials shall be isolated from each other by bituminous paint,
plastic sleeves, PVC pads or rubber gaskets or as directed by the Employer
to prevent galvanic action or chemical corrosion.
a. Galvanized steel and stainless steel

b. Stainless steel and aluminum
c. Aluminum and Concrete
C. Painting or Coating Application
1. Ferrous or galvanized metals shall be coated as specified in Part 11section 9.

2. Unless noted otherwise, all aluminum products are to be anodised after
fabrication.
3. All stainless steels are to be suitably cleaned with approved pickling solution
or paste and treated with approved passivating fluid according to ASTM A380
procedures before installation.
1.03 SUBMITTALS
A. Submit fabricator’s prequalification documents complete with information on staff,

equipment, and past experience.
B. The contractor shall submit the following to the Contractor before purchase:
Manufacturer’s name.
Supplier’s name.
215
Product name (if applicable).
Product description.
Manufacturer’s technical data.
Storage instructions.
Mill certificates.
Connection details.
Load tables (if applicable).
Installation instructions.
Welding procedures.
Welder’s certificates.
Paint or coating information.
C. Samples shall be supplied for at least the following products and as requested by
the Contractor.
1. Handrail and accessories showing joints, bends, toe-plate, posts and

anchorage.
2. Stair treads and safety nosings (300 mm long).
3. Gratings, support angles and fasteners (300 x 300 mm).
4. All fasteners and anchoring devices.
5. Ladders.
6. Floor plate (300 x 300 mm).
7. Vent pipes.
8. Lintels.
9. Castings.
10. Marker posts.
D. The Contractor shall provide separate method statements meeting the

requirements of Section 1.3, for at least the following activities or as requested by
the Contractor.
1. Anodising process for aluminium.

2. Passivating treatment for stainless steels.
3. Powder coating process.
4. Staircase and handrail installation.
E. The Contractor shall submit shop drawings according to section 1.3 for at least
the following items.
1. Shop drawings for the fabrication and erection of all assemblies of metal
fabrication work which are not completely shown by the manufacturer’s data
sheets.
2. Include plans and elevations of not less than 1:10 scale, and include details
of sections and connections of not less than 1:4 scale.
3. Show anchorage and accessory items.
4. Give location, type, size and extent of welding and bolted connections and
clearly distinguish between shop and field connections.
5. Before submittal coordinate shop drawings with related trades to ensure
proper mating of assemblies.
6. Detailed drawings shall show material type, thickness, grade/class,
dimensions, and construction scheme.
7. The submittal shall include catalog pages, erection description,
manufacturer’s data/instructions and templates.
216
F. The contractor shall prepare a mock-up meeting the requirements of PART4 for
at staircase and handrail assemblies or as requested by the Employer.
1.04 QUALITY ASSURANCE
A. Before dispatch from the factory, the Contractor shall notify the Contractor, in
sufficient time to allow the Contractor or his representatives to inspect and test
the products, if so desired. All notifications shall be made by written “Inspection
Requests” in accordance with PART4. An advance copy may be faxed to the
Contractors office, but the original must arrive before the scheduled day of
inspection. Minimum notification times shall be as follows:
1. 24 hours on site.
2. 48 hours within Baghdad city and surrounding areas.
3. 72 hours for other areas within Iraq.
4. 2 weeks outside of Iraq.
B. “Inspection Requests” shall be submitted to the Contractor after on site

installation for final inspection. Minimum notification time shall be 24 hours. Any
products found to be fabricated from unapproved materials or incorrectly
fabricated, incorrectly installed, poorly fitted or damaged shall be rejected and
removed from the works. No site repairs will be allowed, unless authorised by the
Contractor. The Contractor shall bear all costs for replacing unacceptable work.
A. Delivery, storage and handling shall be according to the manufacturer’s

1. Transportation, handling and storage shall at all times be performed in a

manner to avoid product damage.
2. Only nylon slings shall be allowed for lifting products. Steel chains, clamps or
cables shall not be allowed for lifting purposes, unless approved by the
Employer. Steel chains or cables may be allowed for securing products
during transport or storage provided protective padding or timber blocking is
used.
3. Do not store products directly on ground, unless approved by the Employer.
Ensure adequate timber blocking is used to provide sufficient support.
4. Special care shall be taken to avoid damage to protective coatings.
5. If stored outside, cover products to prevent UV degradation as recommended
by the manufacturer.
damage to the Employer.
a. Any products found to be fabricated from unapproved materials shall be

rejected and removed from site.
b. Any products found to be incorrectly fabricated shall be marked and set
aside.
c. Any products damaged during delivery, storage or installation shall be
marked by the Contractor and set aside.
d. Proposals for repair of any damaged or misfabricated products shall be
submitted in writing to the Employer for approval.
e. No repairs to damaged products shall be attempted without the
f. Any products deemed unsuitable for repair or alteration by the Employer
shall be removed from site and replaced at the Contractors expense.
217
PART 2 – PRODUCTS
2.01 MATERIALS
A. Metallic materials shall conform to the following requirements, unless otherwise

noted or unless otherwise approved by the Employer.
B. Steel
1. Structural steel BS 4, Grade 43A or ASTM A36 Grade

36, or EN 10025 Grade S275
2. Steel pipe ASTM A53, Types E or S, Grade B
3. Structural Tubing ASTM A500, Grade B
4. Steel forgings ASTM A668
5. Electrodes for welding steel AWS A5.1, E70 Series
C. Iron
1. Ductile iron ASTM A536 or BS 2789

2. Gray cast iron ASTM A48
3. Malleable iron ASTM A47, A197
D. Stainless Steel
1. Stainless steel shall conform to ASTM A167 and ASTM A276 and the alloy
types shall be as follows:
a. Plates, bars and tubing Grade 316 for machined items or 316L for
welded items.
b. Bolts, nuts, washers and screws Grade 316
1. Yield Strength minimum 270 MPa

2. Tensile Strength minimum 480 MPa
c. Electrodes for welding stainless steel: Use electrodes and techniques

per AWS 5.0 series specifications or as approved by the Employer.
E. Aluminum
1. Rolled shapes and extrusions ASTM B308, B221or BS 1474 Grade

6063-T6
2. Castings ASTM B26 or BS 1490 Grade LM6
a. No scrape aluminum shall be used in the castings.

b. Maximum allowable iron content 06%.
c. Samples of castings shall be taken and tested physically and chemically at the
Contractors directions.
3. Aluminum angles, beams, pipes, plates

and channels Alloy 6063-T6
4. Aluminum weir plates and baffles Alloy 6063-T6
5. Aluminum bolts ASTM F468, alloy 2024 T4
6. Aluminum nuts ASTM F467, alloy 2024 T4
7. Electrodes for welding aluminum AWS D1.2, filler alloy 4043 or 5356
F. Washers
1. Same materials and alloy as found in accompanying bolts and nuts.

2. Provide two washers per each nut and bolt.
3. Provide neoprene pad between dissimilar metals.
218
G. Galvanizing
1. Iron and Steel
a. Galvanizing shall be done in accordance with ASTM A123 with an

2
average coating weight of 600 g/m .
b. All components shall be galvanized after fabrication.
2. Touch-up material for galvanized coatings: Galvanized coatings which are

marred or damaged during erection may only be repaired with the Employer’s
consent.
H. Post Drilled Anchors (Mechanical or resin): Grade 316 stainless steel.
I. Headed Studs
1. Conform to ASTM A108.

2. Yield Strength minimum 345 MPa
3. Tensile Strength minimum 414 MPa.
J. Deformed Bar Anchors
1. Conform to ASTM A496.

2. Tensile Strength minimum 550 MPa.
3. Yield Strength minimum 482 MPa.
K. Powder Coating
1. Use only approved polyester powerder suitable for exterior exposure.

2. Minimum thickness shall be 120 microns.
2.02 LADDERS
A. Material shall be as indicated below, unless noted otherwise or unless otherwise

1. Galvanized steel for interior dry well areas.

2. Aluminum alloy for exterior exposures.
3. Stainless steel for interior wet well chambers.
B. Stringers: Minimum 30 mm outside diameter tube with a minimum thickness of 3

mm.
C. Rungs
1. Solid, minimum 20 mm diameter.

2. Shall be at 250 mm centers.
3. Minimum 400 mm wide between stringers.
4. Minimum 200 mm from adjacent wall.
5. Non-slip tread pattern.
6. Capable of withstanding a point load of 5000 N applied at the center or close
to one end.
D. Brackets
1. Fixing brackets shall be at maximum 2000 mm centers.

2. Capable of withstanding shear and pullout load of 5000 N.
219
E. Safety cages shall be provided when the distance between landings or floor
exceeds 3500 mm. Cage construction shall be as follows:
1. Flat Hoops: minimum 50 x 8 mm with a minimum internal diameter of 760

mm
2. Vertical Flats: minimum 40 x 4 mm
3. Hoops shall be at maximum 750 mm centers, supported by a minimum of
three vertical straps at equal centers inside the hoops.
4. First hoop shall be 2400 mm above lowest platform.
5. Each hoop shall be able to withstand both a tangential point load of 740 N
and a vertical point load of 1200 N applied at any point on the hoop.
6. All connections shall be constructed from same material as ladder.
F. A rest platform shall be provided if the height of the ladder is more than 9m.
1. Size : minimum 840 x 840 mm

2. Handrail : minimum 1000 mm high
3. Landing shall be provided at every 6 m.
G. Construction: Fully welded type, unless otherwise approved by the Employer.
H. Ladder shall extend 1000 mm above the upper access level or shall be provided
with ladder extensions that automatically lock into place when fully extended.
1. Ladder extensions shall be constructed from same material as ladder.

2. Corrosion-resistant spring (if required).
3. Factory assembled with all hardware necessary for mounting to ladder.
2.03 STEEL LINTELS
A. Conform to BS 5977: Part 2
B. Steel lintels shall be provided for openings as noted on the drawings, for
openings left in masonry work for ducts, and for similar items where openings are
not steel framed.
C. Lintels, unless otherwise shown, shall be fabricated from galvanized steel

conforming to BS EN 10142.
D. Size as scheduled or the width of the opening plus at least 200 mm where not
scheduled, bearing on supports at each end.
2.04 VENT PIPES
A. Vent pipes for enclosed chambers or reservoirs shall be fabricated from

aluminum alloy components and shall conform to the following requirements.
1. Size and length shall be as shown on drawings.

2. Tubing shall be BS 1474 Grade 6063 alloy.
3. All cast parts shall be aluminum alloy to BS 1490 Grade LM-6.
4. Minimum wall thickness for tubing shall be 5 mm.
5. A welded puddle flange shall be provided for casting into concrete slabs.
Puddle flanges shall be positioned to fall at the center of the slab.
220
6. A partially enclosed hood with heavy-duty aluminum mesh (bird screen) shall
be provided for ventilation. Minimum thickness of hood sheeting shall be 3
mm.
7. Any fixing bolts shall be stainless steel (A4) or (A316).
8. All welding shall be Tungsten Inert Gas (TIG).
9. Minimum clearance between top of slab and bottom of hood shall be 500
mm.
10. Entire assembly shall be chemically treated and polyester powder coated
(120 micron nominal thickness) and hot cured. Color shall be light gray
(RAL-7035), unless otherwise directed by the Employer.
2.05 STEEL DECK
A. MATERIALS
1. Uncoated (Black) Sheet Steel: Deck panels shall conform to SDI Publication No.29, and
ASTM A611. See plans for type, size and finish.
Minimum Yield Strength: 33 ksi (230 MPa)
2. Minimum Thickness: 0.028 in (0.71 mm), unless indicated otherwise.
3. Grade
Composite Steel Deck: Grades C or D.
Non-Composite Steel Deck: Grades C, D, or E.
Steel Roof Deck: Grades C, D, or E.
B. Galvanized Sheet Steel:
Deck panels shall conform to SDI Publication No. 29, and ASTM A653 Structural
Quality. See plans for type, size and finish.
1. Minimum Yield Strength: 33 ksi (230 MPa).
2. Minimum Uncoated Thickness: 0.028 in (0.71 mm), unless indicated otherwise.
3. Galvanization: Conform to ASTM A924 (replaced ASTM A525) with a minimum
coating class of G60 as defined in ASTM A653.
C. Miscellaneous Finishes
1. Shop Primer: Manufacturer’s baked on, lead-free and chromate- free, rust inhibitive primer,
conforming to performance requirements of FS TT-P-664.
2. Galvanized Repair Paint: Comply with requirements of MIL P-21035B, Type I or II.
3. Concrete Topping: Unless indicated otherwise, all deck to receive concrete shall be
galvanized.
D. ACCESSORIES
1. General: Provide accessory materials for steel deck that comply with requirements
indicated and recommendations of the steel deck manufacturer.
2. Column Closures, End Closures, and Z-Closures: Steel sheet, of same material and
thickness as deck panels, unless indicated otherwise on the Contract drawings.
3. Hanger Tabs: Manufacturer’s standard hanger tabs for floor deck installation, where
indicated on the Contract drawings.
4. Cover Plates: Fabricate covers for abutting deck ends, of same material and gage as deck
units, in matching profile, and not less than six (6) inches (152 mm) wide.
221
5. Pour Stops: Shall be adequate to support concrete and any construction loads.
6. Filler Sheets and Girder Fillers: Fabricate of same material, gage and profile, as deck units,
to complete horizontal closure.
7. Rubber Closures (Top and Underside): Manufacturer’s standard synthetic rubber to match
deck profile.
8. Cant Strips and Eave Plates: Fabricate of same material and gage as deck units, with
flange for attachment and of dimensions as indicated on Contract drawings.
9. Roof Sump Pan: Fabricate of not less than 0.071 inch (1.80 mm) thick galvanized steel,
with flat bottom and sloped sides, recessed 1-1/2 inches (38 mm) below deck surface, with
bearing flange not less than three (3) inches (76 mm) wide, and with all joints sealed
watertight.
10. Miscellaneous Roof Deck Accessories: Steel sheet, minimum 0.0359- inch (0.91 mm)
thick ridge and valley plates, finish strips, and reinforcing channels, of same materials as
roof deck.
11. Fasteners: Manufacturer’s standard galvanized hardened steel, self-tapping.
12. Weld Washers: Manufacturer’s standard uncoated steel sheet weld washers, minimum
thickness of 0.056 in. (1.5 mm) with a minimum 3/8-inch (9.5 mm) diameter hole.
SECTION 5.3 FIRE PROTECTION FOR STEEL STRUCTURE
PART 1 - REQUIREMENTS
1.1 STEELWORK
Provide fire protection to structural and supporting steelwork which

comprised of vertical and horizontal steel sections supporting floors and
roofs (primary steelwork) and horizontal and vertical elements that support
building services, wind bracings etc. (secondary steelwork).
1.2 QUALIFICATIONS
Only installers approved or authorized by the coating manufacturer or

supplier should carry out the installation/application of intumescent coatings.
All suppliers and installers of intumescent coatings must be legally
appointed agents or distributors & approved by the Local Civil Defense
Authority.
The installer shall submit documentary evidence in support of the above.
222
1.3 PRODUCT CERTIFICATION
All intumescent coatings used for the fire protection of structural steelwork
shall be tested and/or assessed to the relevant British Standard for fire
resistant tests.
The installer shall submit test reports in support of the above to the
satisfaction of the Engineer.
1.4 SUBMITTALS
The Contractor shall submit product samples, technical data sheet

installation manuals and Material Safety Data sheets to the Engineer for its
satisfaction.
1.5 QUALITY ASSURANCE
The installer shall be able to demonstrate that the applied intumescent

coating complies with the requirements for correct thickness of coating to
achieve the specified fire resistance period.
1.6 REFERENCE DOCUMENTS
A. S476 Part 20: Method for determination of the fire resistance of

elements of construction (general principles)
B. BS 476 Part 21: Methods for determination of the fire resistance of load
bearing elements of construction
C. BS 476 Part 22: Methods for determination of the fire resistance of non-
load bearing elements of construction
D. BS 8202 Part 1: Code of practice for the selection and installation of

sprayed mineral coatings
E. BS 8202 Part 2: Code for assessment and use of intumescent coating

systems for providing fire resistance
F. ISO 834: Fire Resistance Tests - Elements of Building Construction
G. Fire Protection for Structural Steel in Buildings (2nd edition - 2nd

revision), The Yellow Book', published by the ASFP
H. On Site Measurement of Intumescent Coatings, ASFP TGN 003: Part 1,

1996
I. ASTM E119 Fire Tests of Building Construction and Materials
J. IBC 2003 International Building Code
223
PART 2 - MATERIALS
2.1 WATER-BASED FIRE PROTECTION SYSTEMS
A. Corrosion Protection Primer
Primers shall be compatible with the intumescent base coat. Suitable

primers shall be heavy-duty zinc phosphates (alkyd & 2 pack epoxy),
water-based alkyds and epoxy's, epoxy esters, red oxides, and zinc
chromates. Zinc silicate primers are also suitable, providing a suitable
tie-coat is used before the intumescent base coat is applied.
Chlorinated rubber and thermoplastic-based primers should not be
used. The installer should confirm primer compatibility with the
manufacturer before use.
B. Intumescent Base Coat
The spray applied fire protection coating shall comprise of a single

component water-based coating capable of wet application at
thicknesses up to 1450 microns in 1 spray. The coating shall have a
volume solids of 67%, a specific gravity of 1.35, a pH value of 8 and
must give a high standard of evenness when cured.
The required thickness of paint is dependent on the size of the
structural element (i.e., structural elements with larger, heavier cross
sections may require less insulation than lightweight members).
Thickness of the applied intumescent paint materials is typically 0.5
mm to a few mm but can be as much as 5 mm.
C. Finish Coat
The finish coat shall be compatible with the intumescent base coat.
Finish coats shall be water-based acrylics, polyurethane alkyds or
white spirit-based finish coats. The finish coat shall give a smooth
surface finish to the satisfaction of Engineer. The installer should
confirm finish coat compatibility with the manufacturer before use.
2.2 CONVENTIONAL SPRAY APPLIED MATERIALS
Spray applied fireproofing materials are typically cement-based

products or gypsum with a light weight aggregate (vermiculite, perlite,
or expanded polystyrene beads) that have some type of cellulosic or
glass fiber reinforcement, Do not use spray applied fireproofing
materials contained asbestos, which is no longer allowed due to
health issues.
Spray applied products are typically used more to protect beams than
columns.
224
2.3 GYPSUM BOARD MATERIALS
A. General
Gypsum board materials and accessories shall be identified by the manufacturer’s

designation to indicate compliance with the appropriate standards referenced in this
section.
B. Standards
Gypsum board materials shall conform to the appropriate standards listed in Table 1,
where required for fire protection, shall conform to the IBC code.
TABL 1 - GYPSUM BOARD MATERIALS AND ACCESSORIES

MATERIAL STANDARD
Accessories for gypsum board ASTM C 1047
Gypsum sheathing ASTM C 79
Gypsum wallboard, type X ASTM C 36
Joint reinforcing tape and compound ASTM C 474; C 475
Nails for gypsum boards ASTM C 514, F 547, F 1667
Steel screws ASTM C 954; C 1002
Steel studs, non load bearing ASTM C 645
Steel studs, load bearing ASTM C 955
Water-resistant gypsum backing board ASTM C 630
Exterior soffit board ASTM C 931
Fiber-reinforced gypsum panels ASTM C 1278
Gypsum backing board and gypsum shaftliner board ASTM C 442
Gypsum ceiling board ASTM C 1395
Standard specification for gypsum board ASTM C 1396
Predecorated gypsum board ASTM C 960
Adhesives for fastening gypsum wallboard ASTM C 557
Testing gypsum and gypsum products ASTM C 22; C 472;C 473
Glass mat gypsum substrate ASTM C 1177
Glass mat gypsum backing panel ASTM C 1178
C. Sampling, Inspection, Rejection, Certification, Packaging, Marking, Shipping,

Handling and Storage
Shall be in accordance with Specification C 1264
D. Resistance to shear (steel framing)
Cold-formed steel framed shear walls sheathed with gypsum board and constructed in
accordance with the materials and provisions of Part 4 Sec 6.5 are permitted to resist
wind and seismic loads.
PART 3 - APPLICATION AND USE
3.1 WATER-BASED FIRE PROTECTION SYSTEMS
A. Independent validation should be based on fire test data derived from fully
loaded fire tests in accordance with BS 476 : Part 21 : 1987, supplemented, if
required, by fire test data determined in accordance with BS 476 : Part 20 :
1987.
225
B. The intumescent base coat shall be applied to the factory-primed steelwork in
accordance with the manufacturers written instructions.
C. The average dry film thickness should be measured using suitable calibrated
gauges, e.g. magnetic induction gauges. Thickness measurements should be
taken on all exposed areas of the section at 500 mm maximum intervals and
minimum of three measurements should be taken at any face. The standard
deviation of the dry film thickness from the mean should not be more than
0.15 or the standard deviation noted in the fire test report.
D. The applicator should visually check the primer for obvious damage before
applying the intumescent base coat. Any damaged or uncured primer should
be removed and replaced in accordance with the primer manufacturers'
instructions.
E. The thickness of the intumescent base coat will conform to the loading tables
for the required period of fire resistance.
F. During spraying operations, wet film thickness checks should be undertaken

using a comb gauge to assist the operator in controlling paint loadings.
G. The applicator shall ensure the intumescent base coat is applied free from
runs, sags and other defects caused by incorrect spraying operations.
H. Dry film thickness checks shall be undertaken on the cured intumescent base
coat using a calibrated electronic measuring device.
I. The intumescent base coat shall be overcoated with a finish coating

depending on the type of base coat applied (see Part 2, Section 3, A & B).
The dry film thickness of the finish coat shall be in accordance with the
manufacturer's recommendations.
J. Upon completion of the intumescent base coat and finish coat application, the
applicator shall submit to the Engineer copies of all Quality Control Records.
K. Un-primed or damaged factory coating.
L. All rust deposits shall be removed and the bare steel prepared by blast
cleaning to Sa 2½ in accordance with BS 7079 Part A1.
M. The primer should be applied immediately before blooming occurs and the
application procedures (above) followed.
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3.2 CONVENTIONAL SPRAY APPLIED MATERIALS
A. Temperature Rise in Steel
The critical temperature for steel members varies with the type of steel
structural member (e.g., beams, columns, bar joists, or reinforcing steel). North
American Test Standards (e.g., ASTM E119) assume a critical temperature of
538 °C (1,000 °F) for structural steel columns. The critical temperatures for
columns and other steel structural elements are given in Table 1.
The critical temperature is defined as approximately the temperature where the
steel has lost approximately 50 percent of its yield strength from that at room
temperature. In an actual structure, the actual impact of such heating of the steel
will also depend on the actual imposed load, member end restraint (axial and
rotational).
Table 1
STEEL TEMPRTURE
COLUMNS 538 C (1000 F)
BEAMS 593 C (1100 F)
OPEN WEB STEEL JOISTS 593 C (1100 F)
RENFORCENG STEEL 593 C (1000 F)
PRESTRESSING STEEL 426 C (800 F)
B. Effectiveness of Fireproofing:
The acceptability of a particular fireproofing material as an insulator is

examined as part of ASTM E119. The fireproofing material should form a stable
thickness of insulating cover for the steel. Mechanical or impact damage to the
fireproofing material prior to the fire exposure that results in a loss of insulating
material reduces the ability of the material to act as an insulator.
During the fire exposure in the ASTM E119 tests, fireproofing material may fall
off as a result of thermal strains caused by differing amounts of expansion in the
fireproofing and steel, excess curvature of the steel, or decomposition of the
fireproofing material. If the fall-off occurs early in the test or fire exposure, the
performance of the assembly is likely to be unsatisfactory. However, if the
fireproofing material falls off late in the test or at the time when the fire is
declining in intensity, the impact of the lost protection may not be significant.
Several test methods other than ASTM E119 can be followed to assess the
performance characteristics of fireproofing material. These tests are indicated in
Table 2.
Table 2 Test Methods for Spray-applied Fireproofing Materials
Standard Title
Thickness and Density of Sprayed Fire-Resistive Material

ASTM E605
(SFRM) Applied to Structural Members
Cohesion/Adhesion of Sprayed Fire-Resistive Materials
ASTM E736
Applied to Structural Members
Effect of Deflection on Sprayed Fire-Resistive Material
ASTM E759
Effect of Impact on Bonding of Sprayed Fire-Resistive
ASTM E760
Material Applied to Structural Members
Compressive Strength of Sprayed Fire-Resistive Material
ASTM E761
Air Erosion of Sprayed Fire-Resistive Materials (SFRMs)
ASTM E859
Corrosion of Steel by Sprayed Fire-Resistive Material (SFRM)
ASTM E937
227
C. Application technique
1. Particular care should be taken to ensure that the required thickness is built up in
the recommended manner so that good cohesive strength is obtained. The
thickness of an individual layer will vary considerably according to the type of
material, the orientation of the substrate, the nature of the substrate and the skill
of the operator. Any spillage or overspray should be cleaned off at the end of
each working period. When using adhesives, the adhesive manufacturers'
recommendations should be followed.
When checking the thickness of spray on site, a deficient area may be
considered acceptable if either:
a. the thickness is not less than 85 % of the specified thickness, the deficient
2
area does not exceed 1 m and no other deficient area occurs within 3 m of
this area; or
b. The thickness is not less than 75 % of the specified thickness, the deficient
2
area does not exceed 0.2 m and no other deficient area occurs within 1 m of
this area.
2. Different spray systems require different methods of application and specialist

contractors should be sought. The names of such contractors are available from
manufacturers.
3. Calculate the dry density ofthe spray, p (in kg/m3), using the following formula:
ρ = m x 10 / (Lx W x t)
9
where
m is the mass of dried spray (in kg);
L is the length of the test specimen (in mm);
W is the width of the test specimen (in mm);
t is the average thickness of the test specimen (in mm).
The finished density of spray should lie within ± 15 % of the density stated by the
manufacturer. The density and mix proportions of the spray should be chosen to
suit its use for fire protection.
D. Protection during application
Spray is affected by some environmental conditions up to the time of final set.

It is therefore essential during this period to prevent exposure to rapid drying,
wind-driven rain, running water, freezing or near freezing conditions,
structural movement, vibration or impact.
3.3 GYPSUM CONSTRUCTION
Gypsum board and gypsum plaster construction shall be of the materials listed in
Tables 3 and 4.
These materials shall be assembled and installed in compliance with the appropriate
standards listed in Tables 5
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TABLE 3 GYPSUM BOARD MATERIALS AND ACCESSORIES
MATERIAL STANDARD
Accessories for gypsum board ASTM C 1047
Adhesives for fastening gypsum wallboard ASTM C 557
Exterior soffit board ASTM C 931
Fiber-reinforced gypsum panels ASTM C 1278
Glass mat gypsum backing panel ASTM C 1178
Glass mat gypsum substrate ASTM C 1177
Gypsum backing board and gypsum shaftliner board ASTM C 442
Gypsum ceiling board ASTM C 1395
Gypsum wallboard ASTM C 36
Joint reinforcing tape and compound ASTM C 474; C 475
Nails for gypsum boards ASTM C 514, F 547, F 1667
Predecorated gypsum board ASTM C 960
Steel screws ASTM C 954; C 1002
Steel studs, load bearing ASTM C 955
Steel studs, nonload bearing ASTM C 645
Standard specification for gypsum board ASTM C 1396
Testing gypsum and gypsum products ASTM C 22; C 472; C 473
Water-resistant gypsum backing board ASTM C 630
Table 4 LATH, PLASTERING MATERIALS AND ACCESSORIES

MATERIAL STANDARD MATERIAL STANDARD
Accessories for gypsum veneer base ASTM C 1047
Blended cement ASTM C 595
Exterior plaster bonding compounds ASTM C 932
Gypsum base for veneer plasters ASTM C 588
Gypsum casting and molding plaster ASTM C 59
Gypsum Keene’s cement ASTM C 61
Gypsum lath ASTM C 37
Gypsum plaster ASTM C 28
Gypsum veneer plaster ASTM C 587
Interior bonding compounds, gypsum ASTM C 631
Lime plasters ASTM C 5; C 206
Masonry cement ASTM C 91
Metal lath ASTM C 847
Plaster aggregates
Sand ASTM C 35; C 897
Perlite ASTM C 35
Vermiculite ASTM C 35
Plastic cement ASTM C 1328 Plastic cement ASTM C 1328
Portland cement ASTM C 150 Portland cement ASTM C 150
Steel screws ASTM C 1002; C 954 Steel screws ASTM C 1002; C 954
Steel studs and track ASTM C 645; C 955
Welded wire lath ASTM C 933
Woven wire plaster base ASTM C 1032
229
TABLE 5 - INSTALLATION OF GYPSUM CONSTRUCTION
MATERIAL STANDARD
Gypsum veneer base ASTM C 844
Gypsum board GA-216; ASTM C 840
Interior lathing and furring ASTM C 841
Interior lathing and furring ASTM C 841
Steel framing for gypsum boards ASTM C 754; C 1007
A. Limitations
Gypsum wall board or gypsum plaster shall not be used in any exterior surface where
such gypsum construction will be exposed directly to the weather. Gypsum wallboard
shall not be used where there will be direct exposure to water or continuous high
humidity conditions. Gypsum sheathing shall be installed on exterior surfaces in
accordance with ASTM C 1280.
B. Weather protection.
Gypsum wall board, gypsum lath or gypsum plaster shall not be installed until weather
protection for the installation is provided.
3.02 GYPSUM BOARD IN SHOWERS AND WATER CLOSETS
A. Wet areas
Showers and public toilet walls shall be of a type that is not adversely affected by
moisture
B. Base for tile
When gyp sum board is used as a base for tile or wall pan els for tubs, shower or wa
ter closet compartment walls, water-resistant gypsum backing board shall be used as
a substrate. Regular gypsum wall board is permit ted under tile or wall panels in other
wall and ceiling areas when installed in accordance with ASTM C 840.
C. Limitations
Water-resistant gyp sum back ing board shall not be used in the following locations:
1. Over a vapor retarder in shower or bath tub compartments.

2. Where there will be direct exposure to water or in areas subject to continuous
high humidity.
3. On ceilings where frame spacing exceeds 12 inches (305mm) o.c. for 1/2-
inch-thick (12.7 mm) water resistant gypsum backing board and more than
16 inches (406mm) o.c. for 5/8-inch-thick (15.9mm) water-resistant gypsum
backing board.
END OF SECTION
230
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231
DIVISION 6
THERMAL AND
MOISTURE
PROTECTION
232
PART 1 - GENERAL
1.01 SUMMARY
A. This section specifies materials and installation for waterproofing & damp-
proofing on external surfaces of concrete and concrete blockwork. And
installation of joint sealants & joint fillers.
1.02 REFERENCES
A. ASTM D36 - Test Method for Softening Point of Bitumen (Ring and Ball Apparatus)
B. ASTM D41 - Standard Specification for Asphalt Primer Used in Roofing,
Dampproofing, and Waterproofing
C. ASTM D449 - Standard Specification for Asphalt Used in Dampproofing and
Waterproofing
D. ASTM D638M - Test Method for Tensile Properties of Plastic (Metric)
E. ASTM D1000 - Test Methods for Pressure – Sensitive Adhesive
F. ASTM D1004 - Tapes Used for Electrical and Electronic Applications
G. ASTM D3746 - Test Method for Impact Resistance of Bituminous Roofing Systems
H. ASTM D5147 - Test Methods for sampling and Testing Modified Bituminous Sheet
I. ASTM D5602 - Test Method for Static Puncture Resistance of Roofing Membrane
J. ASTM E154 - Test Methods for Water Vapor Retarders used in Contact with Earth
Under Concrete Slabs, on Walls or as Ground Cover
K. BS 5889 - One-part gun grade silicon based sealants
L. BS 4254 - Two-part polysuphide based sealants
M. BS 6920 - Suitability of non-metallic products for use in water
N. BS 2499 - Hot applied joint sealants for concrete pavements
O. BS 6920 - Suitability of non-metallic products in contact with water
P. ASTM D1056 - Specification for flexible cellular materials
Q. ASTM D2000 - Classification system for rubber products
PART 2 PRODUCTS, STORGE AND INSTLATION
2.01 WATERPROOFING AND DAMP-PROOFING
Samples of each type of following materials:
1. Membrane sheets 300 mm square

2. Protection board 300 mm square
3. Bituminous Mastic (applied) 200 mm length
4. Primer (applied) 200 mm square
5. Damp-proofing (applied) 200 mm square
Storage
1. Products shall be stored strictly in accordance with the manufacturer’s

recommendations, and in a neat and safe manner.
2. Storage area shall be shaded, ventilated and maintained at a temperature below
0
30 C and shall be located away from all sources of excess heat, sparks or open
flame.
3. Containers of liquid material shall not be left open at any time in the storage area.
233
WATERPROOF SHEET MEMBRANE
A. Waterproofing membrane shall be sourced and supplied by a single manufacturer

with a minimum of ten years experience.
B. Manufacturer shall operate a Quality System which is registered to ISO 9000

series or approved equal.
C. Waterproofing membrane shall be an impermeable, torch applied, prefabricate

sheet, consisting of an APP or SBS rubber/bitumen compound reinforced with a
polyester fabric core.
D. The waterproofing membrane shall be suitable for use in tropical conditions and
shall comply with the properties in Table 1, unless otherwise approved by the
Employer.
TABLE 1
PHYSICAL REQUIREMENTS FOR WATERPROOFING MEMBRANE
Test
Property Minimum Requirement
Method
Nominal thickness NA 4MM
Weight of reinforcing fabric NA 180 g/m² (polyester)
Tensile Strength UEA tc, 500 N/5cm
ASTM D146 (either direction)
Elongation at break (membrane) ASTM D146 40% (either direction)
Tear resistance UEA tc 180 N (either direction)
Puncture resistance UEA tc Static L4
Dynamic I4
Adhesion to primed substrate UNI 8202 0.7 kg/cm²
0
Softening point ASTM D36 110 C
INSTALLATION OF WATERPROOF SHEET MEMBRANE
A. Surfaces to which waterproof membrane will be applied shall be surface dry,

smooth and free of dirt, grease or oil and shall be free from holes, honeycombing
and loose aggregate which prevent satisfactory application of waterproofing
materials. All surfaces to be waterproofed shall meet the approval of the
Employer before application of waterproofing materials.
A. Apply the membrane sheet with 100 mm overlaps at edges and 150 mm at ends.
B. Installation procedures shall be in accordance with the manufacturer’s standards.
D. If the work must be left partially complete, the exposed edges of outside strips of
membrane shall be finished with a trowelled bead of mastic.
E. Water proof membrane shall not be applied to vertical surfaces when the outdoor
o o
ambient temperature is less than 10 C or more than 40 C. If the outdoor
temperature at the proposed time of application is not within the above limits,
application must be delayed until the permissible temperature range prevails or
another system must be submitted for approval complying with these
Specifications.
F. Sub-Employer shall coordinate the waterproofing membrane work so that the

placement of the protection board will follow the waterproofing membrane
installation immediately.
234
G. Apply primer only over cleaned concrete or concrete blockwork surfaces using
quantities and methods in accordance with the membrane manufacturer's printed
instructions.
1. Allow to dry as per manufacturer’s instruction before proceeding.

2. After the primer has properly dried, apply the membrane to the concrete by
lightly heating with a propane torch.
3. Smooth down with heavy hand pressure or a small roller.
4. Edges and ends shall be lapped as specified.
5. Double inside and outside corners by using an initial strip of 300 mm width
membrane, centered along the axis of the corner.
a. Strip shall be covered by the regular application of membrane and the
exposed
edges of the membrane shall have a trowelled bead of mastic over these
edges.
b. Provide a preformed triangular fillet at the internal corners.
6. Membrane shall be protected as follows:
a. 50 mm thick cement/sand screed under concrete slabs/foundations.

b. One layer of 3.0 mm thick protection board and one layer of 4.0 mm
commercial plywood on vertical or other faces.
c. The cement/sand screed specified here-in above shall be placed before
any reinforcement or formwork for the foundations or slabs.
d. Sidewall membrane shall extend down and out to the edge of the
previously applied horizontal slab membrane.
7. Areas around piping and protrusions shall be provided with an additional

layer of membrane for a minimum of 300 mm in each direction. Membrane
edges shall be coated and the gap between the membrane and protrusions
filled with mastic.
INSTALLATION OF PROTECTION BOARD
A. Immediately after membrane application, install protection board over the

membrane.
B. Protection board shall be bonded to the membrane by using rubberized mastic or

a double sided adhesive tape recommended by the membrane manufacturer.
This will then be followed by a layer of commercial plywood, bonded to the
protection board using the same method.
C. The joints between the plywood sheets shall be staggered with the protection
board joints by a minimum distance of 300 mm.
D. Point up with mastic the exposed edges and gaps between penetration and
edges of the protection board.
E. Protection board on horizontal slabs shall terminate at the outer corner of the
concrete structure.
F. Sidewall protection board shall extend down and out to cover the horizontal slab
membrane.
235
DAMP-PROOFING
A. Damp-proofing shall be a cold applied rubberized bitumen emulsion meeting the

following requirements.
1. Solids content: 65% minimum.

2. Rubber content: 10% minimum.
INSTALLATION OF DAMP-PROOF MEMBRANE
A. Surfaces to which damp-proofing membrane will be applied shall be surface dry,

smooth and free of dirt, grease or oil and shall be free from holes, honeycombing
and loose aggregate which prevent satisfactory application of damp-proofing
materials. All surfaces to be damp-proofed shall meet the approval of the
Employer before application of damp-proofing materials.
B. Installation procedures shall be in accordance with the manufacturer’s standards.
C. Damp-proof membrane shall not be applied to vertical surfaces when the outdoor
o o
ambient temperature is less than 10 C or more than 40 C. If the outdoor
temperature at the proposed time of application is not within the above limits,
application must be delayed until the permissible temperature range prevails or
another system must be submitted for approval complying with these
Specifications.
D. Damp-proof liquid shall be mixed or stirred before use as recommended by the

manufacturer.
E. Apply in two coats by brush or squeegee to achieve a minimum dry film thickness
of 400 microns per coat.
1. Allow first coat to completely dry as per manufacturers recommendations

before placing the second coat.
2. Apply second coat at right angles to the first coat.
F. Where the surface is to receive a screed or render, apply clean dry sand to the
second coat to achieve a rough keyed surface.
G. Allow damp-proofing to completely dry before application of subsequent renders

or screeds.
2.02 THERMAL INSULATION
A. Extruded, closed cell polystyrene insulating board.
B. Conform to following minimum requirements:
1. Thickness : 75 mm
3
2. Density : 32 kg/m
O
3. 5 years aged average thermal conductivity at 24 C : 0.032 W/mK
4. Compressive strength at 10% deflection : 300 kPa
5. Water absorption : <1.0%
6. Water vapour permeability : 0.67 perm-cm
236
2.03 PVC WATERSTOPS
A. Materials shall be sourced and supplied by a single manufacturer.
B. Type and configuration shall be as shown on the Drawings unless stated

otherwise herein.
C. Technical back-up service during installation shall be provided by the

manufacturer at no additional cost to the Employer.
D. Material
1. Waterstops shall be extruded from a high-grade elastromeric polyvinyl

chloride compound and manufactured from virgin materials necessary to
meet the performance requirements of this specification.
2. Comply with the requirements of BS 2782.
3. Suitable for storage, handling, installation and service within a range of 15°C
to 50°C.
4. Intersection and transition pieces shall be preformed factory molded
type and or factory prefabricated type.
a. Site jointing shall be limited to butt joints and shall be strictly in

accordance with the manufacturer’s instructions.
b. Joints shall be heat sealed as recommended by the manufacturer.
5. All waterstops shall have reinforced fixing eyes or clips for fixing in place.
6. Physical Properties:
TABLE 2
Property Test Method Minimum Requirements
Tensile Strength ASTM D 638 12 MPa
Ultimate Elongation ASTM D 638 250%
Tear Resistance ASTM D 624 50 kN/m
Stiffness in Flexure ASTM D 747 4.0 MPa
Hardness, shore A/15 ASTM D 2240 70 to 80
E. External Waterstops
1. For Base Slab Expansion Joints:
a. Minimum 250 mm wide.
b. Center bulb shall be 25 mm wide and shall be flat to accept a filler board.
2. For Base Slab Construction and Contraction Joints: Minimum 250 mm wide
3. Angle Guard: Minimum 125 mm horizontally and vertically.
F. Internal Waterstops
1. For Wall and Roof Expansion Joints:
a. Minimum 250 mm wide with four ribs.
b. Shall have a center bulb to accommodate movement.
c. Web shall be 10 mm thick with a thickened central section to transfer
stresses to the center bulbs.
2. For Wall and Roof Construction and Contraction Joints:
a. Minimum 250 mm wide.
b. Web shall be 10 mm thick with a thickened central section to transfer
stresses to the center bulbs.
237
INSTALLATION OF WATERSTOPS
A. Examination
1. Inspect waterstop and field splices for defects immediately before placing of
formwork and again before placing concrete.
2. Replace damaged waterstop and unacceptable defective waterstop splice
fabrications. Remove from site and dispose of defective material.
B. Preparation
1. Ensure steel reinforcing bars do not interfere with proper position of
waterstop.
2. Protect waterstops during progress of work.
3. Uncoil waterstop 24 hours before installation to ease handling, installation
and fabrication.
4. Clean joints of dirt and construction debris.
5. Do not pile material on top of a protruding waterstop.
C. Waterstop splicing defects, which are unacceptable, include, but are not limited to:
1. Tensile strength less than 80% of parent section.

2. Adhesive, solvents and free lap joints.
3. Misalignment of centerbulb, ribs, and fins greater than 1.5 mm.
4. Misalignment, which reduces waterstop cross-section area more than 15%.
5. Bond failure at joint deeper than 1.5 mm or 15% of material thickness.
6. Combination misalignment and bond failure with net reduction of waterstop
cross-section area greater than 15%.
7. Misalignment of waterstop splice resulting in misalignment of waterstop in
excess of 4 mm in 1 m.
8. Visible porosity in the welded joint, including pinholes.
9. Charred or burnt material.
10. Bubbles or inadequate bonding detectable with a penknife.
11. Visible signs of splice separation when cooled splices are bent by hand at a
sharp angle.
12. Edge welding.
D. Field Joints
1. Only straight butt joints are allowed in the field.

2. Mitered joints shall be factory fabricated.
3. Use splicing tools recommended by the waterstop manufacturer to obtain
fully welded joints.
a. All heating irons shall be Teflon coated and fixed with variable
temperature control.
b. Special purpose clamps or jigs must be used to hold the waterstop in
place.
E. Installation
1. Position waterstop in joint as indicated on the Drawings.

2. Waterstops shall not be nailed or damaged in any way.
3. Centre waterstop on joint, with approximately one-half of waterstop width to
be embedded in concrete on each side of joint.
4. Allow clearance between waterstop and reinforcing steel of a minimum 2
times the largest aggregate size. Prevent rock pockets and air voids caused
by aggregate bridging.
5. At expansion joints, do not embed centerbulb.
238
6. Secure waterstop in correct position using pre-manufactured clips or eyelits
wired to adjacent reinforcing steel.
7. Use split formwork for all bulkheads.
8. Carefully place concrete without displacing waterstop from proper position.
9. Thoroughly and systematically vibrate concrete around waterstop to obtain
impervious, void-free concrete in the vicinity of the joint and to maximise
intimate contact between concrete and waterstop.
10. After first pour, clean unembedded waterstop leg to ensure full contact of
second pour concrete. Remove laitance, spillage, oil and dirt.
2.04 SEALNTES
A. Samples
1. Samples of each type of sealant. Provide samples 300 mm long installed

between two samples of the materials to be sealed, fully cured.
2. Samples will be reviewed by the Employer for colour and texture only.
3. Compliance with all other requirements is the exclusive responsibility of the Sub-
Employer.
B. Storage
1. Store materials in a dry location in such a manner as to prevent damage or

intrusion of foreign matter.
2. Conspicuously mark "Rejected" on materials which have once been wet or
damaged and remove from the job site.
3. Provide temperature controlled storage, if necessary, to meet manufacturer’s
recommendations.
MATERIALS - GENERAL
A. Product Variations: If more than one of the manufacturer's products comply with the
requirements for any item specified herein, provide the specific product
recommended by the manufacturer for the particular condition of use in each case.
B. Manufacturers
1. Products and manufacturers specified hereinafter are specified for the purpose of
establishing minimum quality standards.
2. Products equal in quality to, or better that those specified, may be considered
acceptable subject to the Employer’s approval.
3. The manufacturer shall operate a Quality System which is registered to ISO 9000
series or approved equal.
C. Compatibility
1. Provide only sealants and joint primers which are compatible with the joint
surfaces and backing or filler materials as stated in the manufacturer's published
data or as certified by the manufacturer for each application.
2. Confirm compatibility of sealants that may be in contact with each other.
D. Hardness: Determine the proper hardness or consistency of elastomeric sealants in

consultation with the manufacturer, considering joint movement and exposure for the
size of joint shown.
D. Hardness: In general, provide sealants with the following ranges of hardness

o
(fully cured sealant at 24 C):
239
Shore
Exposure for Joints Subject to the Following Conditions
A Hardness
Maximum movement, nominal weather exposure and abrasion. 15 to 25
Moderate movement, severe weather exposure and moderate 25 to 40
abrasion.
Minimum movement and severe abrasion 35 to 60
F. Modulus of Elasticity
1. In general, for elastomeric sealants, provide sealants having the lowest modulus
of elasticity which is consistent with the degree of exposure to wear and abrasion.
2. Any sealant exposed to traffic must have strength and modulus sufficiently high to
resist damage by traffic.
G. Color
1. For fully concealed joints, provide the manufacturer's standard colour of sealant
which has the best overall performance characteristics for the application shown.
2. For exposed joints, provide the colour shown. If the colour is not shown, the
Employer will select the colour from the manufacturer's standard colours.
H. Manufacturer's Representative: At the start of the installation, and periodically as

work progresses, provide the services of the manufacturer’s technical representative
at the job site as often as deemed necessary by the manufacturer to advice on all
phases of this work at no additional cost to the Employer.
SEALANTS
Type Area of Application

One-part, elastomeric, low-modulus 1. Exterior joints in masonry
silicone rubber sealant conforming to 2. Around aluminium doors, window
BS 5889, Type A frames
3. GRP materials
4. Glazing
One-part, elastomeric, high-modulus, 1. Sanitary ware
silicone rubber sealant conforming to 2. Kitchen units
BS 5889, Type B or FS-TT-S-001543A 3. Glazing
Single-component polyurethane Precast concrete joints
sealant/adhesive, resistant to corrosion
and chemicals
Two-part, polysulphide sealant Expansion and contraction joints in concrete
conforming to BS 4254 or FS-TT-S- for storm water and irrigation service
00227E, Type II, Class A
Two part tar/polyurethane sealant, non Expansion joints subject to sewer gasses
biodegradable
Bitumen based sealant conforming to 1. Sealing and filling gaps on roofs
BS 6920 2. Pointing chases for water-proofing
membrane
Pitch/PVC elastomeric fuel resistant Fuel and chemical spillage area
sealant conforming to BS 2499, Type A1
and B1 or FS SS-S-1614
Sealant for fire rated structures 1. Expansion joints
conforming to BS 5889, Type A or DIN 2. Pipe and cable penetration
4102, Class B1.
240
MISCELLANEOUS MATERIALS
A. Joint Cleaners, Primers and Sealers: Provide products as recommended by the

manufacturer of the sealant for each specific joint surface and condition.
B. Bond Breaker Tape: As recommended by the sealant manufacturer.
2.05 JOINT FILLAR
1. GENERAL
A. Manufacturers: Products and manufacturers specified hereinafter are specified for

the purpose of establishing minimum quality standards. Products equal in quality to,
or better that those specified, may be considered acceptable subject to the
B. Size and Shape: Provide joint fillers and gaskets as shown or, if not shown, consult
the manufacturer and determine the proper size and shape considering joint
movement and conditions at time of installation.
C. Hardness and Compressibility: Provide joint fillers and gaskets as specified and as
recommended by the manufacturer for proper performance in each specific condition
of use.
D. Compatibility: Provide only the type of joint filler which is compatible with the joint
surfaces and sealant or caulking compound, as stated in the data published by the
sealant or caulking manufacturers.
E. Pressure-Sensitive Adhesive: Apply to joint fillers and gaskets, wherever applicable

and at Sub-Employer's option to facilitate installation.
F. Colour: For exposed gaskets or joint fillers, provide the colour shown or, if the colour
is not shown, it will be selected by the Employer from the manufacturer's standard
colours. For concealed joints, provide the manufacturer's standard colour which has
the best overall performance characteristics.
2. EXPANSION JOINTS
A. Joint Materials
1. Typical Building and Concrete Paved Roadway Joints: ASTM D994,

preformed strips of a bituminous mastic composition.
2. Slabs-in-Ground, Sidewalks, and Curb and Gutter Joints: ASTM D1751,

preformed expansion joint filler having relatively little extrusion and substantial
recovery after release from compression.
3. Hydraulic Structure Joints: ASTM D1752, preformed expansion joint fillers as

specified on the Contract Documents.
B. Joint Filler Board
1. Non-absorbent, semi rigid, cross linked closed cell, cellular polyethylene filler
board.
2. Non-tainting and rot proof in accordance with BS 6920.
241
3. Fully compatible with the surface sealants and if elastomeric sealants are used
the joint filler shall act as a bond breaker.
4. Sheet form in one layer to the thickness as detailed on the Drawings.
5. Performance Properties:
a. Recovery : Greater than 98% after 50% compression

b. Water Absorption : < 0.05% by volume
c Compressive Strength : minimum 0.15 MPa
C. Backing Rod
1. Closed cell, polyethylene foam.

2. Rot proof and non-absorbent.
3. Rod diameter shall be 25% greater than the joint width.
3. CONCEALED, EXPANDED NEOPRENE GASKET (CENG) - GENERAL PURPOSE
A. Provide closed cell, concealed, expanded neoprene gaskets. Conform to ASTM D

1056, Grade SEC-41.
4. MOULDED, RESILIENT NEOPRENE GASKET (MRNG) :
A. Provide moulded, resilient neoprene gaskets conforming to ASTM D 2000. Shore A

durometer hardness shall be from 50 to 70. Gaskets that are non- cellular, moulded
or otherwise fabricated shall form the sizes and shapes shown or as required to seal
each joint.
5. GASKET LUBRICANT
A. Non-staining gasket lubricant shall be used which bonds and seals the gasket in
place when cured as recommended by the gasket manufacturer.
6. INSTALLATION
A. Comply with manufacturer's instructions for the installation of each type of joint filler
or gasket.
B. Apply in continuous runs without voids or interruptions, except as may be otherwise

shown. Trim for tight fit around obstructions or elements penetrating the joint.
C. Do not puncture the surface or self-skin on moulded or extruded types of cellular joint
fillers.
D. Depress face edge of joint fillers accurately, wherever used as backup for sealant as
shown or as specified by sealant manufacturer for proper application of sealant.
E. Recess exposed edges of joint fillers and gaskets slightly behind face of adjoining
surfaces unless shown otherwise.
END OF SECTION
242
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243
DIVISION 7
FINSHING
244
PART 1 – BRICK
1.01 QUALITY :
Brick shall be of the best quality available, manufactured by any well - known and
approved process. They shall be mechanically processed and properly burnt.
Bricks shall conform to the requirements of IQS 25 - 1988.
A. Classes
Class A: used for structure parts and foundations loaded and exposed to erosion
because of climatic effects and for external walls exposed to erosion.
Class B: used for bearing structure parts un exposed to erosion or for internal
walls protected from moisture.
Class C: used for structure parts unexposed to climatic effects and unloaded as
partitions.
B. General Appearance
The brick shape should be .regular with right angles and straight sides within the
limits of allowable differences. If there is a crack or notch it should not cause
weakness. If the brick properties and the notch should not be more than more
10% from the brick size. The brick should be homogenous, good burning, free of
gravel stone and lime knobs, the ratio of sound and free of defects bricks should
not be less than 90% from the consignment.
C. Types and Dimensions of Bricks

1- Solid bricks free from hole and cavities with the dimensions (240xl15x75) mm
2- Perforated Bricks: the ratio of holes should not be more than 25% from the
total size, with the dimension (240x115x75) mm.
3- Hollow Bricks: the ratio of holes should be more than 25% from the total size
with the dimensions (240x115x75) mm.
D. Tolerances
Maximum limit of tolerances
Length and width ± 3%
Thickness ± 4%
Surface flatness 5 mm
E. Compressive strength and absorption of water and efflorescence.

As mentioned in the table 1
Min limit of
Max. limit of
compressive Strength
Absorption
(N/mm2) Efflorescence
Class Average Strength Average Absorption of (Max. limit)
of 10 of one of 10 one brick
bricks brick bricks (max. limit)
Class A 18 16 20% 22% Light

Class B 13 11 24% 26% Light
Class C 9 7 26% 28% --------
245
1.02 SAMPLING AND TESTING :
Sampling of brick shall be down according to the IQS 24 -1988 with the sample
size specified by this standard. Samples shall be submitted to the Engineer for
his approval and any consignment delivered to the work shall conform to the
quality of samples approved by the Engineers.
Testing of brick shall be carried out according to IQS24-19 and shall conform to
the requirements of IQS 25-19.
1.03 ACCEPTANCE AND REJECTION :

In advance the brick shall:
a. Have sharp edges.
b. Be well burnt (unburnt brick shall never be permitted to be used on works )
c. Be free of any cracks.
d. Be free of any gypsum and salts.
Otherwise, the Engineer has the right to reject any consignment that fails to
possess the aforementioned properties .
PART 2 – CONCRETE BLOCKS
2.01 QUALITY
Concrete (hollow or solid) blocks shall be of best quality available, manufactured
by a well- known approved process. They shall be manufactured mechanically by
both pressure and vibration. Blocks shall not be used with age less than (7)
seven days from the date of manufacturing.
2.02 TESTING :
Tested blocks shall conform the requirements of IQS 1077 - 1985.
PART 3 – ORDINARY AND TERRAZZO TILES
3.01 QUALITY:
Tiles that are used in flooring of buildings shall be of best available quality.
Ordinary and terrazzo tiles shall be manufactured mechanically.
3.02 SAMPLING AND TESTING:

Sampling of tiles shall be down according to the IQS 1042, 1043 for terrazzo and
ordinary tiles respectively.
Testing of tiles shall comply the requirements of IQS 1042 - 1043 - 1984.
PART 4 – CONCRETE FLAGS
4.01 QUALITY
Concrete flags that are used for roofing of building or for finishing sidewalks shall
be of best available quality they shall be manufactured by pressure or vibration or
both.
These flags shall not be used with age less than [7] seven days from the date of
manufacturing.
246
Sampling shall be taken by the Engineer randomly according to the method
specified by the IQS 1107-1987 and with sample sizes specified by this standard.
Testing shall be carried out according to the IQS 1107-1988. Test results shall
conform to the requirement of IQS 1107-1988.
PART 5 – JUSS
5.01 QUALITY:
The juss used shall be factory product and shall be of the ordinary type , hot and
well burnt . The juss shall be clean, free of any foreign matter, and the contractor
shall take necessary measures to protect the juss during transportation and
storage from rain humidity and other factors which are likely to cause damage to
it.

Sampling of juss shall be down in accordance with the IQS 28-1989, by the
Engineer.
Testing shall be carried out according to the methods specified by IQS 27-1989.
Test results shall comply the requirements of IQS 28- 1989.
5.03 ACCEPTANCE AND REJECTION:

If it is found that the supplied juss or part of it is exposed or damaged by rain or
humidity and become cold and inferior, then such juss shall not be used in the
work and the contractor shall remove it from the site, at his own expense .
PART 6 – TIMBER
6.01 GENERAL:
All timber shall be of best duality, free from defects, as specified below and
appropriate to its place and use .
All timber which shows sign of being infected with white ant , beetle or other pests
shall be rejected by the engineer and at once removed from the site .
6.02 TIMBER FOR CARPENTRY WORK:

Timber for carpentry work shall generally be of best quality sound round or sawn
square straight and well seasoned , free from rot , worms beetles , decayed knot
or other defects and shall conform to British standard 1860 structural softwood or
Iraqi Standard 717/1991 .
"Measurement of characteristic affecting strength:

The cresting of timber piles for permanent work, fenders and carpentry work shall
generally be carried out in accordance with the requirements of British standard
913 or Iraqi standards (145/1990 and 15511990).
Pressure cresting of timber. And shall as far as practicable carried out before the
timber is cut or otherwise worked . Where timber is cut or otherwise after cresting,
the exposed part shall be brushed over with tow coats of creosote before being
fitting into positing
.
247
6.03 TIMBER FOR JOINERY :
Timber for joinery shall be sound well seasoned free from warps and twists . sap ,
shakes , large or loose knots , wanew edges or other defects
6.04 SOFT WOOD:

The common timber shall be of the best imported quality of red wood available
with regard to the purpose for which it is to be used , but imported white wood
may be used if destined for internal works only It shall be Sound and free from all
defects loose or dead knots , and shall be sawn dead square to the approval of
the Engineer .
6.05 HARD WOOD:

All hardwood shall be sound properly seasoned and free from sapwood beetles
infection or from any defect rendering it unsuitable for the purpose for which it is
intended.
PART 7 – WINDOWS
7.01 GENERAL:
The window frames can be constructed of steel , wood or aluminum .
The frame shall be provided with evacuation of condensed water.
The name of the maker of the window should be stated in the tender. The
constructional section , type , frames , hardware fittings should be described in
the tender .
7.02 STEEL WINDOWS :

The window frames shall be constructed of mild steel section (iron).
The cross section is being at least 36mm high, and any in case sufficient to
ensure absolute rigidity . All window frames shall be provided with weather-bars
and with a device to ensure the evacuation of condensed water The opening
vents shall be of double contact iron section and shall be mounted on copper
hinges.
The windows shall be welded without deposition of metal. The windows shall be
fitted for the placing of glass panels from the inside of the building. Copper
glazing pins , well fixed in the section iron and of an approved type, shall be
provided to fix the glass panels before placing of putty .
The frames shall be fixed in the masonry or in the concrete by means of metal
lugs at least one for every 70 centimeters of frame perimeter.
The frames shall be sand blasted and metalized by "Scoop process :( - 500 gram
of zinc per m2 Section iron Surface) and receive two coats of oil paint.
The hardware shall be of copper. The operating of opening vents shall be
secured by a metal mechanism with handle and rod , the handle be of copper .
The diameter of the rod shall be Sufficient to avoid distortion during operation.
The necessary guide shall be provided.
The name of the maker of steel windows shall be stated in the tender. The
constructional iron section , types of frames and hardware fittings shall be
described in the tender and are subject to approval by the Engineer .
7,03 ALUMINUM WINDOWS:

The window frames shall be constructed of aluminum section with a cross section
sufficient to ensure absolute rigidity or as described in the drawing.
The frames shall be provided with weatherproof bars and with a device to ensure
the evacuation of condensed water.
248
7.04 WOOD WINDOWS:
The windows frames shall be constructed of best quality of wood. sound, round or
swan square straight sections and shall conform to B.S.1860 of Iraqi Standards
(717/1989 , 145/1990 and 155/1990) DOORS
PART 8 – DOORS
8.01 GENERAL:
The sizes and numbers of doors are specified for the various buildings The
engineer may alter the location of doors to suit the final layout of the buildings
and no extra payment shall be charged for this alteration.
The doors could be constructed of steel , wood or aluminum .
Ail steel doors and frames shall be made of mild steel welded without
deposition of metals and properly reinforced. Corners shall be welded with all
joints face welded and grind smooth. Welds must develop the full strength of the
section and all joints in face to occur over reinforcing members.
Main members shall be designed to carry the dead load with an extreme fiber
stress not exceeding that allowable for the type of steel used.
Exterior doors shall be designed to resist a wind load of 75 kg / m . deflection
under the above wind load shall not exceed 1/ 120 of the span .
After assembly , doors shall be thoroughly cleaned of rust , oil and grease
and given a coat of an approved rust resisting metallic primer with filler as
required .
Doors and frames shall be painted with two coats of an approved oil paint the
colours of which shall be according to the instructions of the Engineer.
Shop drawings of doors , including, the method of hanging doors on frames
shall be Submitted for the written approval of the Engineer before beginning of
fabrication .
8.02 WOODEN DOORS:

All doors shall be flat-smooth-faced and shall be fixed properly in position. Each
door shall be fitted with best hinges and locking arrangements to the schedule
tables. The wood that used for in the door shall conform to Iraqi Standards
717/1989,1637/1991,163811991 .
8.02.1 TEAK WOODEN DOORS:

Teak doors shall be made out of selected "-e11- seasoned teak planks, not
less than 5cm finished thickness and according to the schedule tables and
drawings.
Teak doors shall be sand papered and twice oiled , and shall be put together in
varnish .
8.02..2 PRESSED WOODEN DOORS :

Plywood doors shall be made of soft wood solid core flush faced in plywood,
finished thickness shall not be less than 5cm. Frames shall be solid out of
12cm x 5cm hard wood . The doors and frames shall be painted with two coats
of oil paint according to the instruction of the Engineer.
8.03 SLIDING DOORS:

The dimensions of each sliding door shall be according to the drawings.
Doors shall be double or single horizontal sliding type (as specified).
249
Doors shall consist of 1/8 thick mild steel single plate sheets welded to mild steel
angle iron framing and bracing, or double plate sheets welded to mild steel
channel sections and bracing of suitable sizes .
The leaves of sliding, doors shall be hung from four wheel ball bearing hangers
operating in an overhead corrosion box type track of adequate size fixed by
brackets to the lintels. Also provide corrosion resisting floor channel and guides,
stops handles, hasp and staple and bolts for fastening track brackets and other
hardware to walls.
Doors when required shall be equipped with small hinged pass doors for use by
pedestrians.
8.04 DOUBLE-LEAF HINGED DOORS:

All double leaf-hinged doors shall be double plated, consisting of 1.5 mm
mild steel sheets welded to z-iron framing and shall be well braced.
The frames shall be of suitable section to provide sufficient rigidity.
The hinges shall operate on bush bearing, and shall be strong and durable.
The door shall be fitted with best quality flush type, tower bolts from the inside
and door checked (closers) (if required). It shall have locking arrangement of the
best quality from outside. The lock set shall be with dead bolt operated from
outside by key , the inside by thumb turn and it shall be provided with fixed knobs
or level handles on both sides (as specified) in the drawing .
8.05 SWINGING DOORS:

The specifications of this type shall be similar to the double plated with styles and
rails formed from 1.5 mm thick or heavier steel sheets in to rectangular tubes with
integral rebates , intermittently welded inside the rebates for structural rigidity .
Stiles top rails, center rails and bottom rails shall be of suitable section to provide
sufficient rigidity .
Door corners shall be strengthened by continuous face-weled and Grind smooth
Center rails shall be continuously face-weled to stiles and grind smooth.
Doors shall present the same appearance on both sides except that glazing head
and glazing stop screws (if any shall always be on the inside).
Jambs shall be flush with finished floor with floor amejers attached to jambs with
bolts, to set on the finished floor, or 2.5cm below the finished floor.
Patented rubber door silencer shall be furnished for strike jambs of single doors
and for frame heads of double doors.
Frames shall be prepared for attachment of all required hard ware . All hardware
screw holes shall be reinforced.
No hardware shall be attached to frames with self-tapping or sheet metal screws.
Hinges shall be extra heavy duty cast malleable 40cm high double acting heavy
duty hinges of an approved quality.
Doors shall be supplied with heavy - duty double acting floor closures of and
approved quality and made when required.
All hardware shall be of a quality approved by the Engineer and shall be
furnished and installed by the door manufacturer.
TEST REQUIRED SPECIFICATION LIMITS

1.1 painting liability The surface should be smooth and straight
1.2 odor The odor shall not be disagreeable
1.3 flexibility The paint shall show no cracking over 1/8 Rod when bent
1.4 drying time set to touch Lower limit 1/2 hr upper limit 2 hr
1.5 drying hard Upper limit 16hr
250
PART 9 – PAINT
9.01 GENERAL:
All prepared paints shall be the product of a reputable manufacturer and applied
in strict accordance with the paint manufacturer's directions and according to the
following specifications.
Red lead B.S.2523 Linseed oil B.S.242 or TT-E-206C, Turpentine, B,S, 244 &
290,white spirit B.S. 245 Varnishes BS. 256 Red oxides of iron B,S,272,306
&370,Ready - mixed paints B.S.277-8 ,leaded chromes and Wizen chromes
B.S282 black and purple oxides of iron , B.S.306 &339 , paste and liquid dryers
B.S.331,tung oil ;B.S.391 , linseed oil putty , B.S.544 Manufactured oxides and
Hydrated oxides of iron ,B.S. 851 Lac . B.S. 954. knotting, B.S.1336 white oil
pastes, B.S.2029 Ready mixed oil based priming Paints, B.S 2521 , Ready mixed
oil based undercoat and finishing paints external quality , B.S.2525. Pigments :
white : B.S.239 , blue , B.S283,black , B.S.284
green ,B.S.303 sienna umber and ocher , B.S.313 & 337 ultramarine B.S.314,
colour for ready mixed paints, B.S.381C pigments for colouring cement and
concrete, B.S.
1014 colour or building and decorative paints. B.S2660. the specification at main
building paints shall be according to the following tables
TABLE (2): TESTS OF WATER PAINT ACCORDING TO BS1053

The surface should be smooth and
1.1 painting liability
straight
1.2 odor The odor shall not be disagreeable
The paint shall show no cracking over
1.3 flexibility rod
1/8
1.4 drying time set to touch Lower limit % hr upper limit 2 hr
1.5 drying hard Upper limit 16 hr
1.6 mineral material and lower limit 25%
coloring material
1.7 oil Resin solvent 75% upper limit
Shall not be less than 50% from the
1.8 oil and resin oil
total Resin and solvent
2.1 non volatile 70% lower limit
2.2 oil / resin content 6% lower limit
Include not less than 50% of the litho
2.3 white pigment content titanium dioxide.
When used must not be less than 10%
When mixed with water the mixture
2.4 dilution
must be smooth and homogenous.
When the second coat is applied on
the first One this second can be
2.5 re-coating
completely removed from the first coat
without affection it.
251
TABLE (3): TESTS OF RED LEAD PAINT ACCORDING TO BS 2523
3.1 mineral material and pigment 70 - 75 lower limit
3.2 volatile material 6% upper limit
3.3 oil content Remain
3.4 flow 20 min lower limit
3.5 Painting Liability
3.6 Odor The odor shall not be disagreeable
3.7 Drying time set to touch Drying hard.
TABLE (4): TESTS OF ALUMINUM PAINT ACCORDING TO BS1026

4.1 Painting liability surface should be smooth and straight
4.2 Odor not be disagreeable
4.3 Water Resistance show not lifting, or wrinkling
show no cracking when prepared to be
4.4 flexibility
6.25 cm dip
4.5 flash point 35 C lower limit
4.6 Drying time set to touch 2 hr upper limit
Dry hard 8 hr upper limit
4.7 volatile material 50 % upper limit.
4.8 water content 0.15 upper limit .
9.02: CEMENT PAINT

Cement paint shall contain at least 60% white Portland cement about 3%
hygroscope salts tip to 0.3% water repellent ( for external work ) up to 8%
pigments.
9.03: OIL PAINT

Oil shall be pure linseed raw or processed if required.
Turpentine shall be pure spirit of gum turpentine dryers shall be turpentine liquid.
Pigment shall be of the highest grade finely ground in pure linseed oil.
Unless otherwise specified all oil pint to have eggshell finish.
9.04: ROOF PAINT

Roof paint is to be white or metallic with very high reflecting properties . Samples
are to be submitted for test.
9.05: PLASTIC PAINT

Alkyd Vin] or rubber based paints shall be used in accordance with the
manufacturer's instructions .
9.06: CLEAR LACQUER

Clear lacquer for concrete floors and brick walls shall be an approved plastic
base lacquer suitable for the purpose and not containing ingredients detrimental
to the material to which it is applied.
9.07: EMULSION PAINT

These paints are wall finishes supplied in ready from for use consistency or to be
thinned according to manufacturer’s instructions.
Inspire of the high degree of chemical resistance of most types of these coatings
mechanical damages to the film can be caused by the growth of salt crystals
beneath the film.
252
Alkyd Resin Type Emulsion of drying oil alkyd resins which when pigments
correctly can give pleasing finishes from matt to full gloss. This type of emulsion
when thoroughly dry produces a very touch finish which withstands washing very
well these paints are however liable to attack by alkali and therefore care must be
taken to safeguard against the risk.
P.V.A. type (polyvinyl acetate emulsions ): is a synthetic material emulsified to
make a medium which is pigmented to produce rapid drying coating ranging from
flat to semi-gloss. This type of emulsion paint is resistant to alkalis found in
building materials and no alkali resisting primer is necessary, it with stands
washing . these paints can be applied to damp surfaces and will dry without fear
of chemical attack upon the medium > The film can however be damaged by
efflorescence.
("Styrene type", a) "styrene /drying oil co-polymer" the drying oil portion of the
medium can be saponified with alkali ability B) "Styrene/butadiene copolymer”
this type is sometimes referred to as the synthetic later type emulsion . Paints
alkali must give pleasing Matt finishes.
9.08 FLAT AND SEMI-GLOSS OIL PAINTS

Flat and semi-gloss finishes are made either by reducing the proportion of oil in
the paint or incorporating substances which have the effect of dulling the gloss ,
such as wax and certain metallic soaps . Their use shall be restricted to interior
decoration, as they are not sufficiently weather - resistant for exterior work.
"Sharp pain" is a name used for paint containing a large proportion of pigment
only loosely bound with a small proportion of oil , which dries dead flat .
Paste white lead thinned with turpentine or white spirit only is typical of this class ,
out sharp paints can be made by thinning any pigment ground in oil in same way.
"Under coating paints" are made with a relatively large proportion of thinner
and less oil than finishing paint so that they dry with only a slight gloss.
In 4-coat work , where two undercoats are used the general practice is for the first
to have rather higher gloss than the second , which must flat in order to provide a
good foundation for the Gloss - finishing coating .
9.09 OIL GLOSS PAINTS

These are consisting of pigment around linseed oil and adjusted to necessary
qualities with dryer's thinners .
Paint manufacturers stock a wide range of standard colours.
"Hard gloss paints" it is difficult to obtain to a full gloss finish free from brush
marks, with oil - gloss paints.
Paint manufacturers have own special methods of paints and dry with a perfectly
smooth and even gloss. There are innumerable varieties on the market, supplied
ready of application under proprietary names .
PART 10 – GLASS AND GLAZING
10.01 GENERAL:
All glass shall be of quality and thickness appropriate to its place use .
The glass shall be free from bubbles, scratches or flaws and not less than
4mm.thick and shall confirm to BS. (9529) or Iraqi Standard (1316).
Glass for glazing: classification and its specific weight shall be 2.OOOkg per
square meter and per millimeter thickness .
The surface shall be flat and parallel so that they fit perfectly on one another as
well as on the frames.
253
10.02 SHEET GLASS
Sheet -lass shall be of the ordinary quality suitable for general glazing
prepossess. Its thickness varying from 3 mm up to 6 mm .
10.03 POLISHED PLATE GLASS

Polished plate glass shall be of the “glazing quality” suitable for general glazing
purposes. Normal standard thickness: nominally 6 mm, (tolerance .5 mm to 8
mm).
10.04 REINFORCED GLASS

Reinforced glass shall be of the glazing for glazing quality suitable for special
glazing purposes. Normal standard thickness: nominally 8 mm and shall be
conform to Iraqi Standard (1606 / 1990).
PART 11 – MISCELLANEOUS MATERIALS
11.01 LEAD:
Lead shall not contain more than 1% of impurities and shall be without any traces
of oxidation.
Sheet lead shall be soft and malleable uniform in thickness and texture and free
from cracks and other defects.
11.02 ZINC:
Zinc shall be of uniformed blue-grey coloring the surface shall be smooth it shall
be free from cracks , dross overlaps , scales excess blisters , or any other
detrimental defects .
It shall not contain more than 1.5% of Impurities. Each zinc sheet shall be
marked with its standard gauge number and trade mark of the manufacturer .
The checking of the gauge of a sheet is based on its weight . The agreed
density being 7 .
Here under the table of gauge numbers giving the theoretical weight of sheets
and the corresponding mean thickness:
APPROX THICKNESS
(NO. ZINC SHEETS) I MEAN WEIGHT (kg/m)
(mm.)
8 2.8 0.4
9 3.15 0.45
10 3.5 0.5
11 4.6 0.58
12 4.62 0.66
13 5.18 0.74
14 5.7 0.82
15 6.65 0.95
16 7.569 1.08
Samples taken from the sheet shall fold without cracking, when the folios are
folded around a bar of a diameter equal to twice the thickness of the sheet itself.
254
11.03 COPPER
All copper used shall be pure perfectly malleable , free from impurities and show
no more but traces of oxidation Its density shall be 8.88 .
Copper material shall be neatly cut flawless. Thin cooper sheets shall be of
uniform thickness.
Strips cut in whatever direction out of the sheets whether cold or heated to dark
red, shall fold till the edges are in contact over the whole length without cracking
All copper used shall confirm in composition of the metal to B.S.899.
11.04 BRONZE:
Bronze use for ornamental articles shall be of an alloy containing in weight :27
parts of copper , 6 parts of tin and 5 parts of zinc .
Other alloys will be accepted for small articles of commercial use.
11.05 ASBESTOS CEMENT.

Asbestos - cement for sheets , pipes etc.... is to be composed of fiberized (white
or blue) asbestos (approximately 15%) and cement (approximately
85%). It may either be pressed molded or made by special machines.
The water absorption of sheets , pipes and fittings shall never exceed 25 percent
of the dry weight of the material .
11.06 BITUMEN:
The softening point of the bitumen shall be tip to at least 85C.
The softening point is measured by the ring and ball method.
The Bitumen according to B.S.525 or Iraqi Standards (1196/1988, 1173 / 1988)
11.07 GYPSUM BOARD SUSPENDED CEILING :
A. Samples: Trim Accessories: Full size sample in 300 mm long length.
B. PRODUCTS
1. STEEL FRAMING COMPONENTS FOR SUSPENDED AND FURRED
CEILINGS
a. Components, General: Comply with ASTM C 754.

b. Wire Ties: ASTM A 641 (ASTM A 641M), Class 1 zinc coating, soft
temper, 0.062 inch (1.6 mm) thick.
c. Hangers: 5 mm X 25 mm Galvanized steel straps (ASTM A653M, G60)
or 6 mm diameter galvanized rods (ASTM A510) as approved and height
adjustable.
d. Carrying Channels: Cold-rolled, commercial-steel sheet with a base
metal thickness of 1.37 mm, a minimum 12.7 mm wide flange with ASTM
A 653M, hot-dip galvanized zinc coating, 38.1 mm deep, 0.707 kg/m,
unless otherwise indicated.
e. Furring Channels: Commercial-steel sheet with ASTM A653M, hot-dip
galvanized zinc coating, ASTM C645, 22 mm deep, 0.45 kg/m unless
otherwise indicated.
f. All steel framing/suspension members are to be hot-dip galvanized.
2. GYPSUM BOARD PRODUCTS
a. Provide in maximum lengths and widths available that will minimize joints
in each area and correspond with support system indicated.
b. Gypsum Board: ASTM C 36 and as follows:
1. Type: Water resistant type in areas where indicated on drawings.
2. Edges: Tapered and featured (rounded or bevelled) for prefilling.
3. Thickness: 12.5 mm, unless otherwise indicated on drawings.
255
3. TRIM ACCESSORIES
Accessories for Interior Installation: Complying with ASTM C 1047 and

requirements indicated below:
1. Material: Steel sheet zinc coated by hot-dip process or rolled zinc.

a. Corner bead on outside corners, unless otherwise indicated.
b. LC-bead with both face and back flanges; face flange formed to
receive joint compound. Use LC-beads for edge trim, unless
otherwise indicated.
a. One-piece control joint formed with V-shaped slot and
removable strip covering slot opening.
d. Extruded-Aluminum Edge Moldings and Trim: Where indicated,
provide manufacturer's extruded-aluminum edge moldings and
trim of profile indicated including splice plates, corner pieces,
and attachment and other clips, complying with the following
requirements:
2. Aluminium Alloy: Alloy and temper recommended by aluminum
producer and finisher for type of use and finish indicated, and with not
less than the strength and durability properties of aluminum extrusions
complying with ASTM B 221/B 221M for alloy and temper 6063-T5,
powder coated finish.
4. JOINT TREATMENT MATERIALS
a. General: Comply with ASTM C 475.

b. Joint Tape for Gypsum Board: Paper reinforcing tape, unless otherwise
indicated.
c. Drying-Type Joint Compounds for Gypsum Board: Factory-packaged
vinyl-based products complying with the following requirements for
formulation and intended use.
Ready-Mixed Formulation: Factory-mixed product.
1. Taping compound formulated for embedding tape and for first coat
over fasteners and face flanges of trim accessories.
2. Topping compound formulated for fill (second) and finish (third)
coats.
d. Retempering of joint compound will not be permissible, nor will the use of
partially set joint compound be permitted.
5. ACOUSTICAL SEALANT
Non-sag, paintable, non-staining latex sealant complying with ASTM C 834

that effectively reduces airborne sound transmission through perimeter joints
as demonstrated by representative assemblies according to ASTM E90.
6. AUXILIARY MATERIALS
a. General: Provide auxiliary materials that comply with referenced

installation standards.
b. Steel Drill Screws: ASTM C 1002 unless otherwise indicated.
c. Expansion (Control) Joints: Provide as indicated
256
C. EXECUTION
1. INSTALLING STEEL FRAMING FOR SUSPENDED AND FURRED

CEILINGS
a. Installation Standards: ASTM C 754, and ASTM C 840 requirements that

apply to framing installation.
b. Suspend ceiling hangers from building structural members and as

follows:
1. Install hangers plumb and free from contact with insulation or other
objects within ceiling plenum that are not part of supporting
structural or ceiling suspension system. Splay hangers only where
required to miss obstructions and offset resulting horizontal forces
by bracing, counters playing, or other equally effective means.
2. Where width of ducts and other construction within ceiling plenum
produces hanger spacing’s that interfere with the location of
hangers required to support standard suspension system members,
install supplemental suspension members and hangers in form of
trapezes or equivalent devices.
Size supplemental suspension members and hangers to support
ceiling loads within performance limits established by referenced
standards.
3. Secure hangers either directly to structures or to inserts, eye
screws, or other devices and fasteners that are secure and
appropriate for substrate, and in a manner that will not cause them
to deteriorate or otherwise fail.
c. Install suspended steel framing components in sizes and at spacing’s

indicated, but not less than that required by the referenced steel framing
installation standard.
1. Hangers: 800 mm o.c.

2. Carrying Channels (Main Runners): 800 mm o.c.
3. Furring Channels (Furring Members): 400 mm o.c.
d. Wire-tie or clip furring members to main runners and to other structural

supports as indicated.
e. Provide additional framing and blocking at openings and to support built-

in anchorage and attachment devices for other work.
2. APPLYING AND FINISHING GYPSUM BOARD, GENERAL
a. Gypsum Board Application and Finishing Standards: ASTM C 840 and

GA-216.
b. Install ceiling board panels across framing to minimize the number of

abutting end joints and to avoid abutting end joints in the central area of
each ceiling. Stagger abutting end joints of adjacent panels not less
than one framing member.
c. Install gypsum panels with face side out. Do not install imperfect,
damaged, or damp panels. Butt panels together for a light contact at
edges and ends with not more than 1.5 mm of open space between
panels. Do not force into place.
257
d. Locate both edge or end joints over supports, except in ceiling
applications where intermediate supports or gypsum board back-
blocking is provided behind end joints. Do not place tapered edges
against cut edges or ends. Stagger vertical joints on opposite sides of
partitions. Avoid joints other than control joints at corners of framed
openings where possible.
e. Attach gypsum panels to framing provided at openings and cut-outs.
f. Form control and expansion joints at locations indicated and as detailed,

with space between edges of adjoining gypsum panels, as well as
supporting framing behind gypsum panels.
g. Fasten gypsum board to furring channels at not more than 300 mm O.C.
3. INSTALLING TRIM ACCESSORIES
a. Install corner bead at external corners.
b. Install edge trim where edge of gypsum panels would otherwise be

exposed. Provide edge trim type with face flange formed to receive joint
compound, except where other types are indicated.
c. Install control joints at locations indicated or according to ASTM C 840

and in specific locations approved by Engineer.
4. FIELD QUALITY CONTROL
a. Above-Ceiling Observation: Engineer will conduct an above-ceiling

observation prior to installation of gypsum board ceilings and report any
deficiencies in the Work observed. Do not proceed with installation of
gypsum board to ceiling support framing until deficiencies have been
corrected.
b. Tolerances: Finish surface within 3 mm in 2.4 meter for plumb, level,

warp and bow.
END OF SECTION
258
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259
DIVISION 8
MECHANICAL
260
EXCLUDE (ACORDING TO PROJECT)
261
DIVISION 9
ELECTRICAL
262
EXCLUDE (ACORDING TO PROJECT)
263
REFERENCES
1. Iraqi code for requirements of reinforcement of concrete for buildings - center of

constructions researches. Code 1987.
2. Guide of accuracy quality in manufacture of concrete prepared by Dr. Ruhi AL-

Shareef director of construction researches center scientific royal society - first
edition 1985.
3. Technology of concrete Dr. Muaid AL-Khalaf- Hana'a Abid Yousif Puplication

and classification center Technicial University 1984 Baghdad.
4. Construction of buildings - ZOOair Sako _ Arteen Lefon Baghdad University -

Engineering College - Civil Engineering Dep. First Edition 1983.
5. Technological Specifications for Construction and Complementary Works - First

Volume. National Center for Consultative Engineering - Baghdad. .
6. Construction of buildings - Atif AL-Suheri Baghdad University - Engineering

College First Edition 1991.
7. Material Specification & Construction Works, National Center for Construction

Laboratories &. Researches (NCCLR) .
8. Iraqi Standard Specifications and Guidance Reference Bringing out from (SCCQ)
9. Standard Specification for Roads & Bridges, Republic of Iraq Ministry of-
Housing & Construction State Organization of Roads &Bridges .
10. American Association of State Highway and Transportation Officials (AASHTO)
11. American Concrete Institute (ACI)
12. American Institute of Steel Construction (AISC)
13. International Building Code (IBC)
14. American Standard Testing Material (ASTM)
15. Germany Specifications (DIN)
16. British Standard (BS)
264
CONVERSION FACTORS-INCH-POUND TO SI (METRIC)*
To convert from Multiply by

To
Length
ʄ
inch Millimeter (mm) 25.4E
foot Meter (m) 0.3048E
yard Meter (m) 0.9144E
Mile (ststute) Kilometers (km) 1.609
Area
square inch square centimeter (cm2) 6.451

2
square foot square meter (m ) 0.0929
square yard square meter (m2) 0.8361
Volume (capacity)
ounce cubic centime (cm3) 29.57

ʈ
gallon cubic meter (m3) 0.003785
cubic inch cubic meter (m3) 0.003785
3
cubic foot cubic meter (m ) 0.02832
ʈ
cubic yard cubic meter (m3) 0.7646
Force
kilogram-force newton (N) 9.807

kip-force newton (N) 4448
pound-force newton (N) 4.448
Pressure or stress (force per area)
kilogram-force/square meter pascal (Pa) 9.807

kip-force/square inch (ksi) megapascal (MPa) 6.895
newton/square inch (N/in2) pascal (Pa) 1.000
pound-force/square foot pascal (Pa) 47.88
pound-force/square inch (psi) kilopascal (kPa) 6.895
265
Bending moment or torque
inch-pound-force newton-meter (Nm) 0.1130

foot-pound-force newton-meter (Nm) 1.356
meter-kilogram-force newton-meter (Nm) 9.807
Mass
ounce-mass (avoirdupois) gram (g) 28.34

pound-mass (avoirdupois) kilogram (kg) 0.4536
ton (metric) mega gram (Mg) 1.000
ton (short, 2000 Ibn) mega gram (Mg) 0.9072
Mass per volume
pound-mass/cubic foot kilogram/cubic meter (kg m3) 16.02

pound-mass/cubic yard kilogram/cubic meter (kg m3) 0.5933
3
pound-mass/cubic gallon kilogram/cubic meter (kg m ) 1119.8
Temperatures
deg Fahrenheit (F) deg Celsius (C) tC = (tF-32)/1.8 ʇ

deg Celsius (C) deg Fahrenheit (F) tF = 1.8tC+32
* This selected list gives practical conversion factors of units found in concrete technology. The reference source for
information on SI units and more exact conversion factors is of "Standard for Metric Practice" ASTM E 380.
(Symbols of metric tie units are given in parentheses.)
ʄ E Indicates that the factor given is exact.
ʈ One liter (cubic decimeter) equals 0.001 m3 or 1000 bars cm3.
ʇ These equation convert one temperature reading to another and include the necessary scale corrections. To convert
a difference in temperature from Fahrenheit degrees to Celsius degrees, divided by 1.8 only, i.e., a change from 70
to 88 F represents a change of 18 F or 18/1.8 = 10 C deg.
266
‫ﺩﻟﻳﻝ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻔﻧﻳﺔ ﻟﻠﻣﺷﺎﺭﻳﻊ ﻓﻲ ﺍﻟﻌﺭﺍﻕ‪ -‬ﺍﻟﻁﺑﻌﺔ ﺍﻟﺛﺎﻧﻳﺔ‬
‫ﻳﺗﺿﻣﻥ ﻫﺫ ﺍﻟﻛﺗﺎﺏ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻔﻧﻳﺔ ﺍﻟﺗﻲ ﺗﺷﻣﻝ ﺗﻌﻠﻳﻣﺎﺕ ﻋﺎﻣﺔ ﻭﻭﺻﻑ ﻻﺳﺗﺧﺩﺍﻡ ﺍﻟﻣﻭﺍﺩ‬
‫ﻟﺗﺷﻳﻳﺩ )ﺍﻻﺑﻧﻳﺔ ﺍﻟﻌﺎﻣﺔ ﻭﺍﻟﻁﺭﻕ( ﻭﺍﻟﻧﻅﺭﻳﺎﺕ ﻟﺗﻧﻔﻳﺫ ﺍﻻﻋﻣﺎﻝ ﻭﻗﻳﺎﺳﻬﺎ ﻟﻣﺧﺗﻠﻑ ﺍﻟﻔﻌﻠﻳﺎﺕ ﺍﻟﻣﻁﻠﻭﺑﺔ‬
‫ﻟﺗﻧﻔﻳﺫ ﺍﻟﻣﺷﺭﻭﻉ ‪.‬‬
‫ﻛﻣﺎ ﺗﺗﺿﻣﻥ ﻫﺫﻩ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺿﻭﺍﺑﻁ ﺗﻧﻔﻳﺫ ﺍﻻﻋﻣﺎﻝ ﺍﻻﻧﺷﺎﺋﻳﺔ ﻭﻭﺻﻑ ﻟﻠﻣﻭﺍﺩ ﺍﻻﻧﺷﺎﺋﻳﺔ‬
‫ﺍﻟﻣﺳﺗﺧﺩﻣﺔ ﻓﻲ ﺗﺷﻳﻳﺩ ﺍﻟﻣﺑﺎﻧﻲ ﺍﻟﻌﺎﻣﺔ ﻭﺗﺣﺩﻳﺩ ﻣﻌﺎﻳﻳﺭ ﺗﻘﻳﻳﻣﻬﺎ ﻭﻓﻲ ﺗﺣﺩﻳﺩ ﻋﺩﺩ ﺍﻟﻧﻣﺎﺫﺝ ﻭﻁﺭﻕ‬
‫ﺍﺧﺫﻫﺎ ﻭﻏﻳﺭﻫﺎ ﻣﻥ ﺍﻟﻣﺗﻁﻠﺑﺎﺕ ﻭﺍﻟﺗﻧﻔﻳﺫ ﺑﺄﺳﺎﻟﻳﺏ ﻗﻳﺎﺳﻳﺔ ﻟﺗﺣﻘﻳﻕ ﺃﻓﺿﻝ ﻣﺳﺗﻭﻯ ﺟﻭﺩﺓ ‪.‬‬
‫ﻭﺗﻌﺗﻣﺩ ﻫﺫﻩ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﻋﻠﻰ ﺍﻟﺷﺭﻭﻁ ﺍﻟﻘﻳﺎﺳﻳﺔ ﺍﻟﻌﺭﺍﻗﻳﺔ ﺍﻟﺻﺎﺩﺭﺓ ﻣﻥ ﺍﻟﺟﻬﺎﺯ ﺍﻟﻣﺭﻛﺯﻱ ﻟﻠﺗﻘﻳﻳﺱ‬
‫ﻭﺍﻟﺳﻳﻁﺭﺓ ﺍﻟﻧﻭﻋﻳﺔ ‪ ،‬ﻭﺍﻟﻣﺭﻛﺯ ﺍﻟﻭﻁﻧﻲ ﻟﻠﻣﺧﺗﺑﺭﺍﺕ ﻭﺍﻟﺑﺣﻭﺙ ﺍﻻﻧﺷﺎﺋﻳﺔ )ﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻣﻭﺍﺩ‬
‫ﻭﺃﻋﻣﺎﻝ ﺍﻟﺑﻧﺎء( ﻭﺑﺎﻻﻋﺗﻣﺎﺩ ﻋﻠﻰ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻔﻧﻳﺔ ﻟﻭﺯﺍﺭﺓ ﺍﻻﻋﻣﺎﺭ ﻭﺍﻻﺳﻛﺎﻥ )ﻭﺯﺍﺭﺓ ﺍﻻﺳﻛﺎﻥ‬
‫ﻭﺍﻟﺗﻌﻣﻳﺭ(‪ ،‬ﻛﻣﺎ ﺍﻥ ﻗﺳﻣﺎ ً ﻣﻥ ﻫﺫﻩ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺟﺎﺋﺕ ﻣﻥ ﺍﻟﺧﺑﺭﺓ ﺍﻟﻌﻣﻠﻳﺔ ﻓﻲ ﻫﺫﺍ ﺍﻟﻣﻳﺩﺍﻥ ‪.‬‬
‫ﺣﻳﺙ ﺗﻡ ﺍﻋﺗﻣﺎﺩ ﺍﻟﻣﻭﺍﺻﻔﺔ ﺍﻟﻌﺭﺍﻗﻳﺔ ﺍﻟﻘﻳﺎﺳﻳﺔ ﻛﺄﺳﺎﺱ ﻓﻲ ﻫﺫﺍ ﺍﻟﻛﺗﺎﺏ ﻟﻛﻭﻧﻬﺎ ﺍﻟﻣﻭﺍﺻﻔﺔ ﺍﻟﻣﻌﺗﻣﺩﺓ‬
‫ﻓﻲ ﺍﻟﺑﻼﺩ ﺛﻡ ﺗﻠﻳﻬﺎ ﻣﻥ ﺍﻟﺩﺭﺟﺔ ﺍﻟﺛﺎﻧﻳﺔ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﺩﻭﻟﻳﺔ ﻛﺎﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﺑﺭﻳﻁﺎﻧﻳﺔ )‪(BS‬‬
‫ﻭﺍﻷﻣﻳﺭﻛﻳﺔ )‪ (AASHTO & ASTM‬ﻓﻲ ﺣﺎﻟﺔ ﻏﻳﺎﺏ ﻣﻭﺍﺻﻔﺔ ﻗﻳﺎﺳﻳﺔ ﻟﻣﺎﺩﺓ ﻣﺎ ﺍﻭ‬
‫ﺗﺿﻣﻥ ﺃﺣﻳﺎﻧﺎ ﻛﻣﻠﺣﻕ ﻷﺣﺩ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻌﺭﺍﻗﻳﺔ ‪.‬‬
‫ﺗﻌﺗﺑﺭ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺍﻟﻔﻧﻳﺔ ﻣﻥ ﺍﻟﻌﻧﺎﺻﺭ ﺍﻟﻣﻬﻣﺔ ﻓﻲ ﻣﺳﺗﻧﺩﺍﺕ ﺍﻟﺗﻌﺎﻗﺩ ﻣﻊ ﺍﻟﻣﻘﺎﻭﻝ ﺍﻟﺫﻱ ﻳﻘﻭﻡ ﺑﺗﻧﻔﻳﺫ‬
‫ﺍﻟﻣﺷﺭﻭﻉ ‪ ،‬ﻭﺗﻭﻓﺭﻟﻪ ﻭﻟﺻﺎﺣﺏ ﺍﻟﻌﻣﻝ ﺍﻟﻣﻌﻠﻭﻣﺎﺕ ﺍﻟﺿﺭﻭﺭﻳﺔ ﻟﺗﺣﺩﻳﺩ ﻧﻭﻋﻳﺔ ﺍﻟﻣﻭﺍﺩ ﺍﻟﻣﺳﺗﺧﺩﻣﺔ‬
‫ﻭﺍﻟﻁﺭﻕ ﺍﻟﻣﺗﺑﻌﺔ ﻓﻲ ﺍﻟﺗﻧﻔﻳﺫ ‪ ،‬ﻓﻠﺫﻟﻙ ﺗﻡ ﺗﺑﻭﻳﺏ ﻭﺗﺭﻗﻳﻡ ﺍﻟﻣﺣﺗﻭﻳﺎﺕ ﺑﺎﻥ ﻳﻣﺛﻝ ﻫﺫﺍ ﺍﻟﻛﺗﺎﺏ ﺍﻟﺟﺯء‬
‫ﺍﻟﻔﻧﻲ )ﻓﻳﻣﺎ ﻳﺧﺹ ﺍﻻﻋﻣﺎﻝ ﺍﻻﻧﺷﺎﺋﻳﺔ( ﻛﺄﺣﺩ ﻣﺳﺗﻧﺩﺍﺕ ﻭﺍﻟﻭﺛﺎﺋﻕ ﺍﻟﻘﻳﺎﺳﻳﺔ ﻟﻣﻧﺎﻗﺻﺎﺕ ﻋﻘﻭﺩ ﺗﻧﻔﻳﺫ‬
‫ﺍﻻﺷﻐﺎﻝ )‪ (STANDARD BIDDING DOCUMENTS‬ﻟﻣﺷﺎﺭﻳﻊ ﻓﻲ ﺍﻟﻌﺭﺍﻕ‬
‫ﻟﻠﻭﺯﺍﺭﺍﺕ ﻭﺍﻟﻣﺅﺳﺳﺎﺕ ﺍﻟﻌﺭﺍﻗﻳﺔ ﻭﺗﺳﻬﻡ ﻫﺫﺍ ﺍﻟﻣﻭﺍﺻﻔﺎﺕ ﺇﻟﻰ ﺗﻁﺑﻳﻕ ﻣﺗﻁﻠﺑﺎﺕ ﺍﻟﻌﻘﺩ ﻭﻻ ﺗﻌﻔﻲ‬
‫ﺍﻟﻣﻘﺎﻭﻝ ﺍﻱ ﻣﻥ ﺍﻟﺗﺯﺍﻣﺎﺗﻪ ﺍﻟﺗﻌﺎﻗﺩﻳﺔ ﻭﻓﻕ ﺍﻟﻌﻘﺩ ﺍﻟﻣﺑﺭﻡ ‪.‬‬
‫ﻭﺃﻥ ﻫﺫﺍ ﺍﻟﻛﺗﺎﺏ ﺳﻳﻛﻭﻥ ﺑﻣﺛﺎﺑﺔ ﺩﻟﻳﻝ ﻣﻔﻳﺩ ﻟﻛﺎﻓﺔ ﺍﻟﻌﺎﻣﻠﻳﻥ ﻓﻲ ﻣﺟﺎﻝ ﺍﻟﺑﻧﺎء ﻭﻣﻌﺭﻓﺔ ﻣﻭﺍﺻﻔﺎﺕ‬
‫ﺍﻟﻣﻭﺍﺩ ﺍﻟﻣﺳﺗﺧﺩﻣﺔ ﻓﻲ ﻣﺟﺎﻻﺕ ﺍﻟﻁﺭﻕ ﻭﺍﻟﻣﺑﺎﻧﻲ ‪ ...‬ﻭﺍﻟﻧﺟﺎﺡ ﻫﻭ ﻫﺩﻳﺔ ﻣﻥ ﷲ‪.‬‬

Technical Specifications Guide For Projects in Iraq PDF

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Technical Specifications Guide For Projects in Iraq PDF

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TECHNICAL

Editor: Ahmed A. Elshaibani

۲۰۱۰ ‫ ﻟﺴﻨﺔ‬۱۸۸۱ ‫ﺭﻗﻢ ﺍﻻﻳﺪﺍﻉ ﻓﻲ ﺩﺍﺭ ﺍﻟﻜﺘﺐ ﻭ ﺍﻟﻮﺛﺎﺋﻖ ﺑﺒﻐﺪﺍﺩ‬

Bagdad Library Cataloguing in Publication Data

• DIVISION 1 GENERAL REQUIREMENTS 10

SECTION 1.1 STRUCTURAL DESIGN CRITERIA 11

SECTION 1.2 MECHANICAL AND ELECTRICAL WORK COORDINATOR 19

SECTION 1.3 QUALETY CONTROL & SUBMITTALS 20

SECTION 1.4 PROGRESS SCHEDULES 26

SECTION 2.1 – GENERAL FOR EARTHWORK AND SITE PREPARTION 35

SECTION 2.2 – STRUCTURE EXCAVECATION AND BACKFILL 40

SECTION 2.3 – DEWATERING 44

SECTION 2.4 - SERVICE ROADS, PARKING AREAS AND FOOTPATHS 46

• DIVISION 3 CONCRETE 107

SECTION 3.1 GENERAL 108

SECTION 3.2 FORMWORK AND CONCRETING PRACTICE 114

SECTION 3.3 CONCRETE BATCHING AND DELIVERY 135

SECTION 3.4 CONCRETE REPAIR 160

• DIVISION 4 PILES 175

• DIVISION 5 STEEL STRUCTURE 194

SECTION 5.1 STRUCTURAL STEEL 195

SECTION 5.2 METAL FABRICATIONS 215

SECTION 5.3 FIRE PROTECTION FOR STEEL STRUCTURE 222

• DIVISION 6 THERMAL AND MOISTURE PROTECTION 232

• DIVISION 7 FINSHING 244

• DIVISION 8 MECHANICAL 260

• DIVISION 9 ELECTRICAL 262

In the name of God

These specifications include general instructions and

The Iraqi Standard Specification was the basic subject of this

The Iraqi standard issued by Central system of standardization and

This Specification represents the guide of one set of the contract

Eng. Ahmed A. Elshaibani

This Section is one of a set of SBD for Procurement of Works

PART 1 – BIDDING PROCEDURES

Section I. Instructions to Bidders (ITB)

PART 2 – WORKS REQUIREMENTS

Section VI. Works Requirements

PART 3 – CONDITIONS OF CONTRACT AND CONTRACT FORMS

Section VII. General Conditions (GC)

Part 1 General Information

Client’s requirements are summarized as follows:

The project is located in …………………………………………………….. .

1.04. TYPE OF CONTRACT

Contract is on …………… basis due to the BOQ’s.

Client elects a person to act as his representative; Client Representative is authorized to

1.06 CLIENT's PROJECT COORDINATOR

CLIENT’s project coordinator is the staff of the Ministry of ………………

1.07 OFFICIAL ADDRESSES

a) Correspondence to Client Representative shall be addressed to:

1.08 CLOSING DATE OF TENDER

Closing date of tender will be: / / 20

Part 2 - SUMMARY OF WORK

The following is the Tenderer’s scope of work.

The Client, Ministry of …………….. Intends to further develop ……………….. In

EMPLOYER intends to appoint specialized Sub-contractors to endorse the Basic Engineering

2.03 SCOPE OF WORK

2.04 INFORMATION TO BE SUPPLIED BY CLIENT

Client will provide the following data to Employer –

2. Loads and Load Combinations

2.1 Dead Loads

2.2 Live Loads

2.3 Wind Loads