Professional Documents
Culture Documents
VOLUME 1
ISSUE NO. 5
JANUARY 2011
[this page not used]
GENERAL MATERIALS AND WORKMANSHIP SPECIFICATION
TABLE OF CONTENTS
VOLUME 1 CIVIL AND STRUCTURAL WORKS
Section 1 General – Civil and Structural Works
2 Temporary Works
3 Site Clearance
4 Landscaping Works
5 Fencing
6 Drainage Works
7 Earthworks
8 Geotechnical Works
9 Carriageways: Sub-base Material and Bituminous Materials
10 Concrete Carriageways
11 Miscellaneous Roadworks
12 Traffic Signs, Road Markings and Road Studs
13 Work for Electrical and Mechanical Installations
14 Water Supply Pipeworks
15 Not Used
16 Not Used
17 Piling Works
18 Formwork and Finishes to Concrete
19 Steel Reinforcement
20 Concrete and Joints in Concrete
21 Prestressing
22 Steelwork
23 Bridgeworks
24 Water Retaining Structures
2.1 Introduction
2.2 Design and Performance Criteria
A2.1.1 Preamble
A2.1.2 Ground Movement
A2.1.3 Ground Water
A2.1.4 Construction Method
A2.1.5 Loads and Forces
A2.1.6 Excavation
A2.1.7 Design Life
A2.1.8 Cofferdams and Temporary Retaining Walls
A2.1.9 Temporary Decks and Pedestrian Bridges
A2.1.10 Falsework
A2.1.11 Formwork
A2.1.12 Earthworks
3.1 General
3.2 Relevant Codes and Standards
3.3 Submissions
3.4 Workmanship
3.5 Inspection
4.1 General
4.2 Definitions and Abbreviations
4.3 Relevant Codes and Standards
4.4 Materials
4.5 Submissions
4.6 Workmanship
4.7 Inspection, Testing and Commissioning
SECTION 5 FENCING
5.1 General
5.2 Design and Performance Criteria
5.3 Materials
5.4 Submissions
5.5 Workmanship
6.1 General
6.2 Glossary of Terms
6.3 Materials
6.4 Submissions
6.5 Workmanship
6.6 Inspection, Testing and Commissioning
A6.1.1 Scope
A6.1.2 Equipment
A6.1.3 Procedure
A6.1.4 Recording of Results
A6.2.1 Scope
A6.2.2 Apparatus
A6.2.3 Procedure
A6.2.4 Calculation
A6.2.5 Reporting of Results
A6.3.1 Scope
A6.3.2 Equipment
A6.3.3 Procedure
A6.3.4 Reporting of Results
A6.4.1 Scope
A6.4.2 Equipment
A6.4.3 Procedure: Before Tests and Inspections
A6.4.4 Procedure: Water Test
A6.4.5 Procedure: Air Test
A6.4.6 Procedure: Visual Inspection
A6.4.7 Procedure: Infiltration Test
A6.4.8 Calculation
A6.4.9 Reporting of Results
A6.5.1 Scope
A6.5.2 Equipment
A6.5.3 Procedure
A6.5.4 Calculation
A6.5.5 Reporting of Results
SECTION 7 EARTHWORKS
A7.1.1 General
A7.1.2 Terms and Symbols
A7.1.3 Grouping of Material
APPENDIX A7.2 Determination of the Moisture Content of Fine Grained and Medium
Grained Material by the Microwave Oven Drying Method
A7.2.1 Scope
A7.2.2 Apparatus
A7.2.3 Procedure
A7.2.4 Calculation
A7.2.5 Reporting of Results
APPENDIX A7.3 Determination of the In-Situ Bulk Density and the In-Situ Dry Density
of Fine Grained And Medium Grained Material by the Nuclear
Densometer Method
A7.3.1 Scope
A7.3.2 Apparatus
A7.3.3 Procedure: Comparability of Test Methods
A7.3.4 Procedure: Routine Denosometer Check
A7.3.5 Procedure: Determination of In-situ Bulk Density
A7.3.6 Calculation
A7.3.7 Reporting of Results
General Materials & Workmanship Specification
Issue No. 5, Volume 1 – Civil & Structural Works
Table of Contents 3/9 January 2011
APPENDIX A7.4 Determination of the Maximum Converted Bulk Density by the HILF
Method
A7.4.1 Scope
A7.4.2 Apparatus
A7.4.3 Procedure
A7.4.4 Calculation
A7.4.5 Reporting of Results
APPENDIX A7.5 Adjustment of the Maximum Converted Bulk Density for the
Determination of the Relative Compaction
A7.5.1 Scope
A7.5.2 Apparatus
A7.5.3 Procedure
A7.5.4 Calculation
A7.5.5 Reporting of Results
A8.1.1 Scope
A8.1.2 Apparatus
A8.1.3 Procedure
A8.1.4 Reporting of Results
A8.2.1 Scope
A8.2.2 Apparatus
A8.2.3 Procedure: Calibration
A8.2.4 Procedure: Flow Test
A8.2.5 Calculation
A8.2.6 Reporting of Results
A9.1.1 Scope
A9.1.2 Apparatus
A9.1.3 Procedure
A9.1.4 Reporting of Results
10.1 General
10.2 Materials
10.3 Submissions
10.4 Workmanship
10.5 Inspection, Testing and Commissioning
A10.1.1 Scope
A10.1.2 Materials
A10.1.3 Apparatus
A10.1.4 Procedure
A10.1.5 Calculation
A10.1.6 Reporting of Results
11.1 General
11.2 Design and Performance Criteria
11.3 Materials
11.4 Submissions
11.5 Workmanship
11.6 Inspection, Testing and Commissioning
A11.1.1 Scope
A11.1.2 Apparatus
A11.1.3 Procedure
A11.1.4 Calculation
A11.1.5 Reporting of Results
12.1 General
12.2 Definitions and Abbreviations
12.3 Relevant Codes and Standards
12.4 Materials
12.5 Submissions
12.6 Workmanship
12.7 Inspection, Testing and Commissioning
13.1 General
13.2 Materials
13.3 Workmanship
13.4 Inspection, Testing and Commissioning
14.1 General
14.2 Definitions and Abbreviations
14.3 Materials
14.4 Submissions
14.5 Workmanship
14.6 Inspection, Testing and Commissioning
17.1 General
17.2 Definitions and Abbreviations
17.3 Relevant Codes and Standards
17.4 Materials
17.5 Submissions
17.6 Workmanship
17.7 Inspection Testing and Commissioning
A17.1.1 Scope
A17.1.2 Equipment
A17.1.3 Procedure: Before Testing
A17.1.4 Procedure: Load Test
A17.1.5 Procedure: After Testing
A17.1.6 Reporting of Results
APPENDIX A17.2 Pile Driving Record (Prefabricated Steel and Driven Cast-in-place
Piles)
18.1 General
18.2 Definitions and Abbreviations
18.3 Design and Performance Criteria
18.4 Materials
18.5 Submissions
18.6 Workmanship
18.7 Inspection, Testing and Commissioning
20.1 General
20.2 Definitions and Abbreviations
20.3 Relevant Codes and Standards
20.4 Design and Performance Criteria
20.5 Materials
20.6 Submissions
20.7 Workmanship
20.8 Inspection, Testing and Commissioning
A20.1.1. Scope
A20.1.2. Materials
A20.1.3. Apparatus
A20.1.4. Procedure: Preparation of Specimens
A20.1.5. Procedure: Determination of Efficiency Index
A20.1.6. Calculation
A20.1.7. Reporting of Results
A20.2.1 Scope
A20.2.2 Equipment
A20.2.3 Procedure
A20.2.4 Reporting of Results
A20.3.1 Scope
A20.3.2 Apparatus
A20.3.3 Procedure: Weathering Test
A20.3.4 Procedure: Compression and Recovery Test
A20.3.5 Procedure: Extrusion Test
A20.3.6 Calculation
A20.3.7 Reporting of Results
21.1 General
21.2 Definitions and Abbreviations
21.3 Materials
21.4 Submissions
21.5 Workmanship
21.6 Inspection Testing and Commissioning
SECTION 22 STEELWORK
21.7 General
21.8 Relevant Codes and Standards
21.9 Materials
21.10 Submissions
21.11 Workmanship
21.12 Inspection Testing and Commissioning
SECTION 23 BRIDGEWORKS
23.1 General
23.2 Definitions and Abbreviations
23.3 Design and Performance Criteria
23.4 Materials
23.5 Submissions
23.6 Workmanship
23.7 Inspection Testing and Commissioning
A23.1.1 Scope
A23.1.2 Equipment
A23.1.3 Procedure
A23.1.4 Calculation
A23.1.5 Reporting of Results
24.1 General
24.2 Definitions and Abbreviations
24.3 Materials
24.4 Submissions
24.5 Workmanship
24.6 Inspection Testing and Commissioning
1.1.1 Definitions
Words and expressions, to which meanings have been assigned in the General
Conditions and General Specification, shall have the same meanings in this
volume.
1.1.2 Abbreviations
1.2.1 General
The Standards and Codes of Practice specified in this section are listed below for
information only. The Contractor shall comply with the edition of the Standard or
Code of Practice listed in the text when stated, or the latest edition when no edition
is listed. Where British Standards have been replaced by the new BS EN
documents, the old BS number is retained in the text, with the new BS EN number
listed below.
Swedish Standards
2.1 INTRODUCTION
2.1.1 This Section specifies materials and workmanship required for the design and
construction of Temporary Works.
2.1.2 Any details of Temporary Works shown on the Employer’s Drawings are for
reference only and such details shall not relieve or reduce the Contractor’s full
design responsibility for all Temporary Works under the Contract.
2.2.1 Design
(a) Unless otherwise stated in the Contract, Temporary Works shall be designed
by the Contractor who shall submit for the Project Manager's review without
objection copies of calculations and drawings of the Temporary Works in
accordance with the requirements stated in the Contract.
(b) The Contractor shall design Temporary Works in accordance with the
principles of BS 5975 except that the criteria as set out in Appendix A2.2 shall
prevail when designing for Hong Kong conditions.
(c) Where appropriate, Temporary Works design shall comply with the
requirements of the Building Ordinance.
(a) The Contractor shall appoint a person "the Temporary Works Co-ordinator"
whose duties shall in general follow the recommendations of Clause 10.2.2 of
BS 5975. The Contractor shall submit for review without objection by the
Project Manager the details and duties of the Temporary Works Co-ordinator.
(b) The Temporary Works Co-ordinator shall certify the design, loading, and
dismantling of falsework in accordance with Appendices A2.2 and A2.3.
Unless the Contract provides expressly to the contrary, the design of the
Temporary Works shall be checked and certified as being satisfactory by the
Checking Engineer in accordance with Appendices A2.2 and A2.3; and all the
certificates endorsed by the Checking Engineer in relation thereto shall be
submitted to the Project Manager for review without objection.
2.2.4 Method
The Contractor shall submit for the Project Manager's review without objection,
method statements giving full details of materials, Contractor's Equipment and
timing and sequence of operations involved in the construction of Temporary
Works.
(a) Temporary Works shall be constructed to the same workmanship and quality
standards as the Permanent Works save that the Temporary Works need not
be new.
(b) The Contractor shall ensure that the Temporary Works are constructed, used
and removed in accordance with the certified design. If the Contractor wishes
to change the construction, use or removal of the Temporary Works he shall
submit to the Project Manager for review without objection details of such
changes together with further certification in accordance with Appendices
A2.2 and A2.3. Such details shall be reviewed without objection by the
Project Manager before the Contractor implements any such change.
(c) Erection of falsework may not commence until the design has been certified
by the Temporary Works Co-ordinator and the Checking Engineer in
accordance with Appendix A2.2.
(e) Temporary Works whether above or below ground or water level shall be
dismantled and completely removed after completion of the Permanent Works
as shown on the Contractor's Drawings unless otherwise shown on the
Employer's Drawings.
(a) Scaffolding and staging shall be provided and erected in accordance with the
Construction Sites (Safety) Regulations (Cap. 59). In addition, all walkways
and elevated working platforms shall have properly constructed kickboards
and handrailing.
(b) The use of "bamboo" for scaffolding or staging shall not be permitted without
the prior consent of the Project Manager and if permitted shall be subject to
compliance with the requirements of the Construction Site (Safety)
Regulations in relation to Scaffold, Working Platforms and Ladders.
(a) Sheet piles shall be of the interlocking type and shall be of a suitable class for
a particular location.
(b) Sheet piles shall be rolled from mild steel complying BS 4360. Each pile shall
be in one length throughout but where required may be extended by welding
an additional length subject to the permission of the Project Manager.
Welding shall be in accordance with the requirements of Section 22 of this
General Materials and Workmanship Specification.
(c) Holes in the piling for ties and attachment of waling etc. shall be drilled after
driving. Burning of holes shall not be carried out without the permission of the
Project Manager.
(e) Propriety trench support systems shall be reviewed without objection by the
Project Manager prior to use on Site. Propriety systems shall be installed in
accordance with the manufacturers recommendations and shall comply with
CIRIA Technical Note 95; 1986.
(f) Hard driving for piling works shall not be permitted without the prior consent of
the Project Manager.
2.2.8 Anchors
(a) Where the Contractor proposes to use anchors as part of his Temporary
Works he shall, as part of his method statement, submit to the Project
Manager for review without objection a detailed specification for the anchors
based on the current edition of the Government publication: Geospec 1,
Model Specification for Ground Anchors, and shall include in the relevant
quality plan a detailed scheme for installation of the anchors. Work shall not
commence on Site until the Project Manager has reviewed without objection
the Contractor's proposals. Anchors may be subject to the approval of the
Building Ordinance Office and/or the Geotechnical Engineering Office and the
Contractor must take full cognizance of the time required for the approval
procedure in such a case.
(b) As soon as progress of the Works permits, and with the permission of the
Project Manager, temporary ties shall be destressed and as far as is
practicable, physically severed from any part of the Works.
Piling to Temporary Works shall not adversely affect the geotechnical properties of
the strata on which foundations for Permanent Works are to be constructed.
Temporary Works piling adjacent to or in the near vicinity of foundations for
Permanent Works shall be subject to the review without objection of the Project
Manager.
(a) Temporary deck panels, unless of concrete construction, shall have an anti-
skid surface such as a graded calcined bauxite aggregate bedded in epoxy
resin. The skid resistance value of the surface shall be in excess of 45,
measured in accordance with BS 3262.
(b) The drainage of the temporary deck shall be such that all the surface water
shall be retained within the plan area of the temporary deck and be
discharged properly and effectively through connections to the existing
drainage system.
(c) The finished level, falls and camber of the temporary deck shall be in
accordance with the existing roadway. Walkways, which shall be drained
properly and effectively, shall be provided to replace existing pavements
which are overlapped by the temporary decking. Where walkways are
covered they shall be lit for pedestrian safety.
(a) The Contractor shall install, operate and maintain all temporary pumping plant
and drainage facilities and remove all accumulated silt and debris necessary
for the proper execution and completion of the Works.
All materials which present a fire hazard or which may give off noxious fumes in the
event of ignition will be rejected for use in the Temporary Works and the Contractor
shall immediately remove such materials from Site.
2.2.13 Welding
The Contractor's Equipment used for welding shall be in accordance with the
appropriate British Standard and the safety regulations applicable in Hong Kong
Construction Safety Regulations. Welding shall be carried out in compliance with
Section 22 of this General Materials and Workmanship Specification.
A2.1.1 Preamble
This Appendix specifies the criteria which shall be used for the design of Temporary
Works.
(1) The design of the Temporary Works shall investigate, evaluate and define
acceptable limits for ground movement within and around the Site and
thereby avoid damage to adjacent property, land footways, roads and utilities.
(2) The installation of any wall (prior to dewatering and excavation) shall not
produce settlement in the adjacent ground or buildings greater than 25 mm.
No dewatering will be permitted during the wall installation. In general,
dewatering of an excavation will not be permitted until a closed perimeter of
impermeable wall is completed.
The ground water level at the Airport may be at or near to ground level and the
effect of ground water must be taken into account in the design of Temporary
Works.
The design of Temporary Works shall take full account of the proposed construction
method. The Temporary Works drawings and calculations shall demonstrate the
adequacy of the proposed construction method at each construction stage.
The design of Temporary Works shall take account of all the applied external forces
and imposed structural deformations.
(1) The Temporary Works design shall take into account the temporary condition
when the excavation nears the bottom of permanent or temporary retaining
walls. Unless otherwise stated on the Employer's Drawings, the factors of
safety against base failure from bottom heave, failure from inward yielding,
failure from piping or blows, shall be a minimum value of 1.5.
The design of Temporary Works may take into account the limited duration over
which the Temporary Works are expected to function. Drawings submitted by the
Contractor shall make clear where provision for limited life has been taken into
account, particularly where this may have an influence on the stability of the
Temporary Works.
(1) The type of cofferdam and retaining wall proposed shall be suitable for the
designed purpose, taking into account the ground and other local conditions.
(2) Calculations shall be carried out in accordance with the relevant British
Standards.
(i) the influence of wind, temperature, settlement, creep and the like
shall be taken into account;
(b) All materials used as load carrying elements shall conform to the
relevant British Standard. The design shall be based on the basic
permissible stresses as recommended in the relevant British Standard
and the Building (Construction) Regulations (Cap. 123) where
appropriate.
(a) An overstress of 25% greater than the basic permissible stresses may
be allowed on a secondary load resisting system, such as steel sheet
piles, provided that a method exists to rectify the system if over
deflection or similar signs of distress become apparent.
(i) steel sheet piling: 25% increase in allowable bending and shear
stresses;
(e) Tendons for ground anchors shall not be stressed to greater than 64%
of their nominal failure load.
(4) The design and construction of a cofferdam shall limit ground movement
around the Site and avoid damage to adjacent property, roads, footways and
utilities.
(b) During dewatering the piezometric pressure in the soil level effectively
supporting the adjacent property shall be maintained. This piezometric
pressure may be lowered by a maximum of 2 m.
(1) The design of temporary decks which are required to carry traffic shall be
carried out by:
Where loads from Contractor's Equipment are likely to exceed these design
loads the deck and supporting structure shall be strengthened accordingly.
(2) The design of the temporary decks and support systems shall allow for
environmental loads, including temperature difference.
(4) Permissible stresses shall comply with the relevant British Standard and the
Building (Construction) Regulations (Cap. 123) where appropriate. An
overstress of 25% shall be allowed when checking the design of temporary
road decks using HB loads only.
(5) All other types of temporary decks shall be designed using loading criteria
reviewed without objection by the Project Manager.
A2.1.10 Falsework
(1) The design shall demonstrate that it includes full allowance for all dead,
environmental (wind and temperature, as appropriate), and applied loads.
The latter shall include an allowance for vertical loading on all parts of the
falsework, for access and working conditions, which shall not be less than 1.5
kN/m2. Where heavy items of Contractor's Equipment are used or materials
stored on the falsework or on the completed structure before it becomes self-
supporting, this allowance shall be increased. The drawings shall be clearly
marked with the maximum safe limit for loading of the falsework from items of
Contractor's Equipment or materials.
(2) The falsework shall be designed to sustain the following horizontal loading,
which may act transversely or longitudinally, separately or simultaneously.
(a) Dynamic pressure head due to a wind speed in accordance with the
recommendations stated in the "Code of Practice on Wind Effects,
Hong Kong".
(3) (a) The design of the Temporary Works shall ensure that the falsework
receives the loads from, and maintains in the required position,
elements of the Permanent Works until they become self supporting.
Facilities shall be provided for compensating for falsework deflections,
the order of magnitude of which shall be calculated by the Contractor
and reviewed without objection by the Project Manager.
(6) All materials used as load carrying elements in the falsework shall conform to
the relevant British Standards and the Building (Construction) Regulations
(Cap. 123) where appropriate in respect of quality, and the design shall use
the basic permissible stresses in those standards. Materials not conforming
with the relevant British Standard may be used, but only if the yield stress can
be established. In which case the basic permissible stress shall be
calculated by applying the same safety factor on that yield stress as used in
the relevant British Standard.
(8) Testing of materials or components shall be carried out when their quality or
adequacy is in doubt. As far as possible, such tests shall conform to the
appropriate British Standards or shall be as stated in the Contract.
(9) Where materials are re-used, the basic permissible stresses shall be reduced
to suit the condition of the material.
(2) construction loading including the dynamic effects of placing and compacting
concrete and construction traffic; and
A2.1.12 Earthworks
Part 1
(To be signed by a professionally qualified member of the Contractor’s staff, or of his sub-
contractor’s staff, responsible for the Contractor’s Design)
Calculations Title:
Prepared by:
Certification
I certify that the Temporary Works described above has been designed in accordance with
the Contract and that the design and drawings have been checked and found satisfactory by
the undersigned.
Signed: Date:
For and on behalf of the Contractor
Certification
I certify that the Temporary Works described above has been designed using all the skill
and care to be expected of a professionally qualified and competent designer experienced in
work of a similar nature and scope and that I have checked the design and drawings and
found them satisfactory.
Signed: Date:
Signed: Date:
For and on behalf of the Contractor
Signed: Date:
Checking Engineer
CERTIFICATION OF LOADING,
DISMANTLING OR REMOVAL OF TEMPORARY WORKS
a) I certify that the Temporary Works described above have been constructed in
accordance with the Contractor's Drawings and that they have been checked and
found satisfactory for loading by the undersigned.
b) I certify that any structure supported by the falsework described above has been
checked by the undersigned and that it has become self supporting and that the
Temporary Works may be dismantled or removed.
[a)/*b)]
Date Signed
a) I certify that the Temporary Works described above have been constructed in
accordance with the Contractor's Drawings and that they have been checked and
found satisfactory for loading.
b) I certify that any structure supported by the Temporary Works described above has
become self supporting and that the Temporary Works may be dismantled or
removed.
[a)/*b)]
Date Signed
Print name of Checking Engineer, qualifications, and name of any company he represents
3.1 GENERAL
The works and materials specified below shall comply with the Sections stated,
unless otherwise stated in this Section.
(a) The abandonment of pipes and manholes shall comply with Section 6.
(c) ‘blasting’.
All demolition works shall be carried out in accordance with Building (Demolition
Works) Regulations, Code of Practice for Demolition of Buildings, Technical
Memorandum for Supervision Plans and Code of Practice for Site Safety
Supervision issued by the Buildings Department; approved demolition plans by the
Buildings Department, Practice Note for Authorized Persons and Registered
Structural Engineers (PNAP) No. 71, all other relevant PNAP and all relevant
requirements issued by the HK Government and/or Statutory Authorities.
The Contractor shall appoint a Registered Structural Engineer registered under the
Buildings Ordinance for the preparation of demolition method statement,
supervision and control of demolition works, scaffolding, shoring and strutting etc.
3.3 SUBMISSIONS
3.3.1 Survey
(c) method of transporting debris from the upper floors to ground level;
(d) method of raising mobile plant to the roof or upper floors and movement
between floors;
(e) the weight and size of plants used above ground. The support to the floors
and other restrictions must be illustrated;
(f) design calculations and drawings showing the maximum debris loadings for
all areas and combinations thereof, layout of all necessary falsework or
temporary works required for all stages of the works; and
(g) location of all chutes for conveying debris down the building floors, and offsite.
A Waste Management Plan shall be prepared in accordance with PNAP 243 and
submitted to the Project Manager for review.
A method statement for the sorting, processing and disposal of materials arising
from or in connection the demolition work shall be prepared in accordance with
PNAP 243 and Section 7 of the General Specification and submitted to the Project
Manager for review without objection before the commencement of any demolition
works.
The Contractor shall submit to the Project Manager for review without objection, the
Site Safety Supervision Plan, prepared in accordance with the Technical
Memorandum for Supervision Plan and Code of Practice for Site Safety Supervision
of Building Works and Street Works.
3.4 WORKMANSHIP
(a) locate and identify the position of existing services and utilities affected by the
works; and
(b) arrange with the relevant Authorities for the disconnections or diversion of all
services and utilities and the removal of all associated fittings and equipment.
3.4.2 Trees
(a) The roots of trees and shrubs which have been cut down shall be grubbed up.
Branches shall not be removed from trees which are to be retained unless
permitted by the Project Manager; if permitted, the branches shall be removed
in accordance with BS 3998 and the cut surfaces shall be treated with a
wound sealant.
(b) In respect of existing trees and woodland the Contractor shall ensure for the
duration of the Contract, the following:
(ii) the limits of site clearance shall be reviewed without objection by the
Project Manager on Site before site clearance commences. All trees to
be cleared shall be marked by the Contractor and reviewed without
objection by the Project Manager before felling;
(iii) trees not required to be trimmed, pruned or felled shall not be marked;
(vi) trees shall not be used as anchors for ropes or chains used in guying,
pulling and the like; and
(vii) fires shall not be lit under or in the close proximity of trees.
(c) As soon as the Site or any part thereof becomes available the Contractor shall
erect temporary protective fencing reviewed without objection by the Project
Manager around any tree and group of trees which are required to be
protected. The fence shall not be closer than 2 m from the trunk of any such
tree and all such work shall be executed using only hand-held tools.
At the commencement of any excavation and prior to any filling the Contractor shall
strip any humus topsoil capable of being used as soil conditioner and set it aside for
subsequent use in the Works. Any topsoil surplus to the requirement of the Works
shall be disposed of in accordance with Clause 7.5.9. Temporary stockpiles of
topsoil shall not exceed 2 m in height.
Demolition works shall not commence until all the required precautionary measures
have been installed in accordance with Building (Demolition Works) Regulations,
Code of Practice for Demolition Works, Technical Memorandum for Supervision
Plans and Code of Practice for Site Safety Supervision issued by the Buildings
Department; approved demolition plans by the Buildings Department, PNAP 71, all
other relevant PNAP and all other relevant requirements issued by the HK
Government and/or Statutory Authorities.
(a) not overload the structure under demolition with demolition plant and/or
resulting debris;
(b) comply with the propping requirements or temporary propping system during
the operation of mechanical plant on suspension floor as stipulated in the
Code of Practice for Demolition of Buildings;
(d) secure and wedge tight top and bottom supports to props. The props shall be
braced to provide lateral restraints in at least 2 directions;
(e) not allow mobile equipment to move to within 2 m of the building edge, 1 m of
any floor opening or on to any cantilevered structures; and
(f) provide adequate spreaders for props bearing on ground, where necessary, to
avoid any undue settlement;
The Contractor shall take precautions to prevent fire or explosion from gas or
vapour release, electricity or any other source, especially when removing tanks or
pipes which may have contained flammable liquids or gases.
General Materials & Workmanship Specification 4/7 January 2011
Issue No. 5, Volume 1- Civil & Structural Works
Section 3 – Site Clearance & Demolition
3.4.9 Weatherproofing Retained Areas of Partially Demolished Buildings
(b) Screens shall be constructed with close boarding fixed to framing and faced
outside with roofing felt of a type reviewed without objection. The exposed
floor beyond the screening shall be covered with roofing felt of similar type to
that used to face screens and a waterproof seal formed between floor and
screen. Doors in the screens shall be constructed and fixed with secure
fastenings and hanging devices as necessary to provide authorised access.
The Contractor shall leave the Site and partly demolished structures in a safe
condition at the end of each day’s work. No accumulation of debris shall be
allowed, particularly at working floors and at ground floor, which causes excessive
pressure on the floors, slopes, retaining structures, hoardings/covered walkways,
catchfans and walls of adjoining structures.
The Contractor shall take every precaution to prevent damage and to exercise
extreme care during execution of the work in the vicinity of live electrical cables.
The Contractor shall disconnect and seal off all storm water drains or sewers from
the last manhole to the Government storm water drain or sewer in accordance with
the requirements of the Relevant Authorities.
3.4.13 Burning
The Contractor shall not burn any rubbish or materials arising from the demolition
on Site.
(a) The Contractor shall prevent excessive lateral pressure due to stockpiling of
debris against walls, adjoining structures and steel hoardings adjoining the
public footpaths or carriageways.
(b) Spoil heaps shall be not be placed on catch platforms or on top of covered
walkways. Spoil heaps shall be cleared away immediately to prevent
overloading any part of the existing structure.
3.4.15 Reinstatement
(i) Fine fill material shall be deposited and compacted in voids which are
left in the ground.
(ii) Holes which are left in structures and pavements shall be made good
using material similar to the material in the adjoining area.
General Materials & Workmanship Specification 5/7 January 2011
Issue No. 5, Volume 1- Civil & Structural Works
Section 3 – Site Clearance & Demolition
(iii) The ends of fences, walls, structures, utilities and other items shall be
made good in such a manner that the affected parts will not corrode or
deteriorate, and will remain stable.
(iv) Straining posts shall be fixed at the end of strained fences which have
been cut and the fences shall be restrained.
(b) Items to be re-used in the Works shall be kept in stores provided by the
Contractor.
(c) Items which are to be taken to the Employer's store shall be delivered by the
Contractor.
(d) Materials or equipment which are to be reused or taken to store and which are
damaged due to the Contractor’s negligence shall be repaired by the
Contractor by a method reviewed without objection by the Project Manager.
Materials or equipment which are lost or which are not capable of being
repaired satisfactorily shall be replaced by the Contractor. Except for items
which are to be re-used or taken to store, demolished items, trees, shrubs,
vegetation, boulders, debris, rubbish and other items arising from site
clearance shall be disposed of by the Contractor and shall become the
property of the Contractor when they are removed from the Site.
(e) All construction and demolition materials arising from or in connection with the
demolition work shall be sorted on-Site and separated into different groups for
disposal at landfills, public filling areas, in filling areas provided by the
Contractor, or recycling as appropriate.
(f) Unless otherwise stated in the Contract, all construction and demolition
materials arising from or in connection the demolition work shall become the
property of the Contractor. The Contractor shall promptly remove all sorted
and processed materials arising from or in connection with the demolition
work from the Site on a regular basis as demolition work proceeds.
(a) All construction and demolition materials arising from or in connection with the
demolition work shall be sorted on-Site and separated into different groups for
disposal at landfills, public filling areas, in filling areas provided by the
Contractor, or recycling as appropriate.
(b) Unless otherwise stated in the Contract, all construction and demolition
materials arising from or in connection the demolition work shall become the
property of the Contractor. The Contractor shall promptly remove all sorted
and processed materials arising from or in connection with the demolition
work from the Site on a regular basis as demolition work proceeds.
Prior to the commencement of site clearance and demolition, and after completion,
the Contractor shall undertake joint inspections with the Project Manager of all
existing structures to be retained within the Site and produce a Condition Survey
Report submitted to the Project Manager for review. Any damage noted to the
structures during the second inspection shall be made good by the Contractor to the
satisfaction of the Project Manager. Photographic records, taken by the Contractor
and reviewed without objection by the Project Manager, shall be kept as part of the
joint inspection.
4.1. GENERAL
The works and materials specified below shall comply with the Sections stated,
unless otherwise stated in this Section.
Chemicals shall not be used for landscape softworks and establishment works
except with the permission of the Project Manager. Chemicals shall be used,
stored, mixed and applied in accordance with the manufacturer's
recommendations. Containers for chemicals shall be disposed of off-Site by
methods reviewed without objection by the Project Manager.
Landscape softworks are all works of a horticultural nature, and shall include the
placing, cultivation and preparation of topsoil and subsoil layers, and the supply
and planting of trees, shrubs and other plant material, and any associated works.
Landscape hardworks shall include the paving, tree grilles, tree guards and tree
rings and any other items stated as such in the Contract.
4.4. MATERIALS
(d) height above soil level of between 150 mm and 900 mm; and
(b) single central stem well furnished with side branches according to species;
(d) height above soil level of between 900 mm and 2000 mm; and
(a) sturdy straight stem at least 1500 mm high from soil level to the lowest
branch;
(c) according to species, either a well balanced branching head or a well defined
straight and upright leader with branches growing out from the stem with
reasonable symmetry;
(a) sturdy straight stem at least 1800 mm high from soil level to the lowest
branch;
(c) according to species, either a well balanced branching head or a well defined
straight and upright leader with branches growing out from the stem with
reasonable symmetry;
(d) total height above soil level of between 2750 mm and 3500 mm; and
(a) sturdy, straight stem at least 2100 mm high between the soil level and the
lowest branch;
(c) according to species, either a well balanced branching head or a well defined
straight and upright leader with branches growing out from the stem with
reasonable symmetry;
(d) total height above soil level exceeding 3500 mm; and
(a) at least two one-year old vigorous stems arising at or near the base;
(c) according to species, height above soil level not less than the height stated in
the Contract; and
(d) grown and supplied in a container at least 75 mm diameter and 125 mm deep.
(a) bush with at least three one-year old vigorous stems arising at or near the
base, with an overall diameter equal to 2/3 of the height;
(c) according to species height above soil level not less than the height stated in
the Contract; and
(d) grown and supplied in a container at least 100 mm diameter and 125 mm
deep.
4.4.8 Conifers
(a) well developed stem well furnished with leaf or needle bearing side shoots;
(c) size not less than that stated in the Contract; and
(d) grown and supplied in a container with dimensions not less than the
dimensions stated in the Contract.
4.4.9 Palms
(a) well developed upright habit with a well balanced, symmetrical head;
(c) for single stem species, height above soil level to the growth point not less
than the height stated in the Contract;
(d) for multi-stemmed species, height above soil level to the growth point not less
than the overall height stated in the Contract; and
(e) rootball or grown and supplied in a container at least 300 mm diameter and
300 mm deep.
4.4.10 Bamboo
(b) for single stem species, a single shoot or trunk with height above soil level not
less than the height stated in the Contract;
(d) rootball or grown and supplied in a container at least 200 mm diameter and
200 mm deep.
(c) height above soil level or diameter of plant for clumps not less than the height
or diameter stated in the Contract; and
Containerised plants shall be grown in open ground and then lifted and placed in a
rigid or semi-rigid container. Plants shall be left to grow in the containers for at least
3 months before being delivered to Site. The dimensions of containers shall not be
less than the relevant rootball or container dimensions stated in Clauses 4.4.1 to
4.4.10.
(a) Grass seed shall be supplied true to species and variety and shall not contain
impurities except as stated in Clause 4.6.13(b). Containers shall be labeled
with the origin of all seed contained therein and the name of the supplier.
(b) The quality of grass seed shall be gauged by purity, germination percentage
and freedom from weeds. The total weed seed content shall not exceed 0.5%
by mass and the total content of other crop seeds shall not exceed 1% by
mass.
4.4.14 Turf
(a) First quality turf shall consist of 75%-85% axonopus compressus and 15%-
25% cynodon dactylon and other stoloniferous species unless otherwise
stated in the Contract.
(b) The grass shall be of even density, forming a turf which is sufficiently fibrous
to hold together when handled. The grass shall be free from pest or disease.
Turf shall consist of sods with soil and roots.
4.4.15 Sprigs
(a) Soil conditioner shall be organic material and shall be free from impurities and
substances injurious to plants. Soil conditioner shall have the following
properties :
(b) Soil conditioner shall be peat moss or properly composted organic material.
Composted organic material shall be stable and shall not be liable to
decompose further generating heat.
4.4.18 Mulch
Mulch shall be a composted organic material either as stated in Clause 4.4.17 for
soil conditioner or granulated tree bark or wood shavings. The properties of mulch
shall be as stated in Clause 4.4.17 for soil conditioner except that the consistency
shall be coarser to avoid being blown away by wind.
4.4.20 Fertilizer
Soil binder shall be a proprietary type reviewed without objection by the Project
Manager and shall consist of a binding medium applied in aqueous suspension by
spraying onto the surface of the soil to stabilise and condition the soil. The binding
agent shall not be injurious to plant growth.
(b) Ties shall be rot-proof rope or straps fitted with plastic, bamboo or other
spacers and a protective sleeve to fit around the plant; ties shall be capable of
adjustment after fixing.
4.5. SUBMISSIONS
4.5.1 Particulars of Seed Mixture, Turf, Sprigs, Soil Conditioner and Water
(a) The following particulars of the proposed materials for landscape softworks
and establishment works shall be submitted to the Project Manager for review
without objection:
(i) origin of trees, shrubs, turves, sprigs and other plant material;
(iii) a certificate or a numbered seed analysis report for each seed mixture
issued within 6 months before the date of use of the seed showing the
species and variety of the seed, the date of testing and including results
of tests for;
• percentage germination of pure seed in a fixed time under standard
laboratory conditions; and
• percentage composition by weight, including details of impurities;
(a) The following particulars of the proposed materials and methods for
hydroseeding shall be submitted to the Project Manager for review without
objection:
(ii) type and rate of application of fertilizer, mulch and soil binder;
(v) details of the company employed to carry out the hydroseeding and the
equipment to be used; and
(ii) turf;
(iv) soil-mix.
(c) A certificate of purity of the grass seed to be used in the Works shall be
submitted to the Project Manager. The batch number of the certificate shall be
checked against that on the bag. The certificate shall not be more than 6
months operations, a 500 g seed sample shall be supplied and retained under
refrigeration by the Project Manager until the viability of the seed is proven or
disproven on Site. Impurities in the seed mix such as stores, soil, twigs and
other foreign matter shall not be accepted.
4.6. WORKMANSHIP
Plants grown in open ground shall be well watered before lifting and shall be
lifted in such a manner that the specified rootball is obtained with minimum
disturbance to the roots. The rootball shall be securely wrapped immediately
after lifting to prevent loss of soil and moisture using hessian or straw. The
wrapping material shall not be removed until the plant is required for planting.
(i) Plants shall be protected from exposure to conditions which may affect
the plant adversely.
(ii) Plants shall be protected from damage and damaged plants shall not be
used in the Permanent Works unless permitted by the Project Manager.
If the Project Manager permits damaged plants to be used, damaged
material shall be pruned and wounds shall be dressed as stated in
Clause 4.6.5(g).
Trees and shrubs which are not immediately planted in their permanent
positions shall be supported upright on level ground, regularly watered and
maintained in good condition.
Turf and sprigs shall not be lifted when waterlogged or very dry and shall be
packed to avoid drying out. Turf and sprigs shall be stored by spreading out
and shall not be stacked. Turf and sprigs shall be kept moist and in good
condition and shall be delivered and laid within 72 hours of lifting.
Grass seed shall be stored in bags off the ground in a clean, dry, well
ventilated location free from vermin. Prolonged storage shall be carried out
under controlled conditions of temperature and humidity.
Fertilizer shall be stored off the ground in sealed waterproof bags and shall be
protected from exposure to conditions which may adversely affect the
fertilizer.
(c) Ripping:
The ground shall be ripped by drawing a tine through the soil to a depth of
300 mm at 500 mm centres. All obstructions to cultivation or deleterious
material brought to the surface shall be removed and voids left by the ripping
operation shall be filled with soil of the same type as existing. Ground at a
slope exceeding 15° to the horizontal shall not be ripped.
(e) Soiling:
Soil-mix shall be spread and levelled to the depth stated in the Contract. The
depth of uncompacted soil-mix shall be sufficient to allow the level of the area
to comply with finished levels after natural settlement has taken place. The
finished level of soil-mix over areas to be grassed shall be 25 mm above
adjacent kerbs, paving, covers, frames and other hardware.
(g) Scarifying:
4.6.3 Planting
(a) General:
Planting shall be carried out between 1st March and 30th September unless
otherwise specified in the Contract.
Material excavated from planting pits which complies with the specified
requirements for decomposed granite shall be used for soil-mix. Material
excavated from planting pits which does not comply with the specified
requirements for decomposed granite shall be disposed of by the Contractor
and shall be replaced by material which complies with the specified
requirements for decomposed granite.
(c) Planting:
(i) Plants shall be well watered several hours before planting; the soil in the
container or rootball shall be moist and cohesive. Containers or rootball
wrapping shall not be removed until the time of planting and the rootball
shall not be disturbed by loosening or breaking.
(iii) Soil-mix shall be deposited and compacted in layers around the rootball
until level with the surrounding ground in such manner that the rootball
is not disturbed. Plant shall be well watered to soak the rootball and
soil-mix immediately after planting.
(i) Stakes shall be driven into the ground after the pit has been excavated
and before planting in such a manner that the rootball and aerial parts of
the plant are not damaged. The stake shall be secure after driving and
shall be higher than 70% of the overall height of the plant.
(ii) Guys and sleeves shall be fixed to prevent chafing, rubbing and
abrasion of the plant and shall be secured to a well driven steel stake or
other anchor. Each plant shall be fitted with three guys secured at a
point not higher than 60% of the overall height of the plant. Turnbuckles
shall be adjusted as necessary after planting.
(e) Mulching:
Notch planting of seedlings shall be carried out by forming a notch making two
cuts at approximately 90° using a hand held pick or spade with the apex
pointing up any slope; the notch shall be sufficiently deep to accommodate
the root system of the seedling. The notch shall be opened on the second cut
to receive the plant and shall then be pushed firmly back into place.
(i) The size of pits for seedlings, shrubs, whips and herbaceous plants
shall be 100 mm greater than the rootball or container diameter and
50 mm deeper than the rootball or container. 50g of pre-planting
fertilizer shall be mixed into the soil-mix.
(ii) Whips which require staking shall be secured using one 2 m long stake
and one tie.
(i) The size of pits for light standard trees and standard trees shall be
200 mm greater than the rootball or container diameter and 100 mm
deeper than the rootball or container. The bottom of the pit shall be
broken up to a depth of 150 mm. 150 g of pre-planting fertilizer shall be
mixed into the soil-mix.
(ii) Each tree shall be secured using two 2.5 m long steel stakes and two
ties.
(i) Pit planting of heavy standard trees:
(i) The size of pits for heavy standard trees shall be 300 mm greater than
the rootball or container diameter and 150 mm deeper than the rootball
or container. The bottom of the pit shall be broken up to a depth of
150 mm. 250 g of pre-planting fertilizer shall be mixed into the soil-mix.
(ii) Each tree shall be secured using two 3 m long steel stakes and two ties.
Trees exceeding 4 m overall height shall be guyed.
Pits excavated for planting on or adjacent to slopes shall not be left open
during wet weather.
4.6.4 Grassing
(a) Hydroseeding:
Hydroseeding shall be carried out between 1st March and 30th September
unless otherwise specified in the Contract.
(ii) Materials for hydroseeding shall be well mixed on the Site in the
hydroseeding equipment immediately before spraying. Seed shall not
be damaged from the hydroseeding process.
Areas which have been hydroseeded shall be covered with protective material
within 2 days after hydroseeding. The material shall be spiked or stapled to
the soil surface with a minimum of 150 mm overlap.
(ii) Areas which in the opinion of the Project Manager are not accessible or
are too small for the use of a hydroseeder shall be patched up by
broadcasting seed. The area shall be lightly scarified with a rake or
similar implement and the seed and fertilizer shall be broadcast over the
area at a rate of not less than 75 g/m². The seed shall be covered by
lightly working into the surface or by spreading sufficient soil to just
cover the seed. Broadcast seeding shall be carried out using Bermuda
grass (cynodon dactylon) perennial ryegrass (lolium perenne) or carpet
grass (axonopus compressus).
(h) Turfing:
(i) Turf shall not be laid on slopes exceeding 15° to the horizontal.
(iii) The turves shall be laid on the prepared soil and shall be firmed into
position using wooden beaters; the beaters shall be frequently scraped
clean of accumulated soil or mud. A top dressing of soil-mix shall be
applied and well worked into joints and spaces. Irregularities in finished
levels due to variation in turf thickness or uneven consolidation of the
soil shall be adjusted.
(iv) Turfed areas shall be watered immediately after turf has been laid and
as often as is necessary to ensure establishment. If shrinkage occurs
and the joints open, soil-mix shall be worked in and well watered.
(i) Sprigging:
(i) Sprigging shall not be used on slopes exceeding 45° to the horizontal.
(ii) The area to be sprigged shall be scarified before sprigging and sprigs
shall be evenly spread over the area at approximately 50 mm centres.
The area shall be topdressed with soil-mix to just cover the sprigs and
pre-planting fertilizer shall be applied at a uniform rate of 40 g/m².
(ii) Bare patches or areas which fail to become established shall be returfed
or resprigged to maintain 90% cover throughout the establishment
period. Areas affected by repairs to washouts and gullies and other
erosion shall be returfed or resprigged.
(ii) All necessary measures shall be taken to ensure that grass, trees and
other plants become established and to keep the landscape softworks
neat and tidy and free from litter and rubbish.
(ii) 90% cover of the grass area shall be maintained throughout the period
for establishment works and the grass shall provide effective cover of
90% of the area at the end of the period for establishment works. The
grass shall be healthy, vigorous and free from perennials and other
weeds. Areas which do not comply with this requirements of the
Contract shall be reseeded by hydroseeding or broadcast seeding as
stated in Clause 4.6.4(f)(ii) or returfed as stated in Clause 4.6.4(h) or
sprigged as stated in Clause 4.6.4(i). Measures shall be taken to ensure
satisfactory establishment of the replacement grass or turf before the
end of the period for establishment works.
The Contractor shall be responsible for the security of stakes and ties
throughout the establishment period. An inspection of stakes and ties shall be
carried out each month by the Contractor; broken, damaged and other
unsatisfactory stakes and ties shall be replaced and ties which are causing
chafing or abrasion of the plant shall be adjusted.
Plants which become loose as a result of wind, rock or other causes shall be
firmed up.
(i) Fresh water shall be used for watering landscape softworks. Water
shall be applied using a rose or sprinkler of a type reviewed without
objection by the Project Manager and in such a manner that
compaction, washout of soil or loosening of plants will not be caused;
any damage caused shall be made good immediately.
(f) Weeding:
(i) All grassed and planted areas shall be kept free from weeds throughout
the period for establishment works.
(g) Pruning:
Pruning and removal of branches shall be carried out using sharp, clean
implements. Pruning shall be carried out with the cut just above and sloping
away from an outward facing healthy bud. Removal of branches shall be
carried out by cutting outside of a line drawn between the branch bark ridge
and the branch collar in such a way that no part of the stem is damaged or
torn, and leaving no snags or stumps.
All litter exposed by grass cutting shall be gathered up and disposed of within
24 hours.
Post-planting fertilizer shall be applied not less than 100 days, and not more
than 300 days, after grassing or planting. The fertilizer shall be applied at a
rate of :
(ii) 100 g for each light standard, standard and heavy standard tree;
(m) Mulching:
(i) all tree and shrub planting shall be free from weeds;
(ii) all planted and grassed areas shall be free from litter;
(v) all grassed areas shall be cut and the edges trimmed.
(a) Tests shall be carried out to determine the grass cover. The tests shall be
carried out 100 days after grassing and at the end of the period for
establishment works. The grass shall be cut to a height of 300 mm if
necessary over the parts of the area to be tested.
(b) The method and number of tests shall be reviewed without objection by the
Project Manager.
(c) Testing to determine the grass cover will be carried out by the Contractor in
the presence of the Project Manager.
(d) Tests shall be carried out at locations which are representative of the grassed
area as a whole. At each test location an approximately square area of 10 m²
shall be marked.
(e) The percentage of bare ground other than rock and other hard material in
each 10 m² test area shall be measured.
(f) At least 90% of each test area shall be covered with grass.
(g) If the result of any test for grass cover of landscape softworks and
establishment works does not comply with the specified requirements for
gross cover the area shall be rehydroseeded or reseeded in accordance with
Clause 4.6.4(f)(i) or (ii) determined by the Project Manager, depending upon
the size of the defective area.
B.S. 3882 : 1965 (1978) Recommendation and classification for top soil
B.S. 3969 : 1968 (1975) Recommendations for turf for general landscape purposes
B.S. 5236 : 1975 Recommendations for the cultivation and planting of trees
in the advanced nursery stock category
B.S. 5837 : 1980 Code of practice for trees in relation to construction (under
review)
5.1 GENERAL
The Permanent Works and materials specified below shall comply with the Sections
stated, unless otherwise stated in this Section:
(d) formwork and finishes to concrete shall comply with Section 18;
(a) The design working load for acrylic sheets shall be 6.9 kPa. Each panel shall
be assumed to be simply supported unless the Contractor can demonstrate
the amount of fixity that the support can offer either by test on Site which is
acceptable to the Project Manager or by producing satisfactory test results
performed under similar conditions.
(b) Movement joints shall be designed to allow for thermal movement of the
sheeting due to a temperature variation of ±50º and the movement of the
structure without affecting their performance in any respect. Sealing
compounds, taps and gaskets should be sufficiently flexible to permit
movement of the sheeting.
5.3 MATERIALS
5.3.1 Wire
(a) Wire for fencing, including plastic coated wire, shall be galvanised mild steel
complying with BS 4102.
(b) Barbed wire shall consist of two line wires and point wire formed in
accordance with BS 4102, Clause 4.1.
(d) Plastic coatings to steel wire shall comply with BS 4102, Section 6.
General Materials & Workmanship Specification 1/7 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 5 - Fencing
5.3.2 Chain Link Fence
5.3.3 Plywood
Plywood for hoardings shall comply with BS 6566 and shall have a grade 2 veneer.
The bonding adhesive between veneer layers shall be phenol formaldehyde resin
adhesive, classified as weather-proof and boil-proof in accordance with BS 1203.
5.3.4 Timber
(a) Timber for fencing shall be of mature growth and shall be seasoned and free
from large, loose or dead knots, wood wasp holes, infestation, splits and other
defects that will reduce the strength or produce blemishes. The moisture
content in timber at the time of fabrication shall not exceed 20%.
(b) Hardwood shall be ‘San Cheung’ (Kapore) and shall have a minimum density
of 720 kg/m3 at 15% moisture content.
(d) Timber that is not to be painted shall be preserved with coal tar creosote. The
creosote shall comply and be applied by pressure impregnation in accordance
with BS 144.
5.3.5 Steel
(a) Bolts, nuts and washers for fences shall comply with the following:
(i) ISO metric black hexagon bolts, screws and nuts BS 4190;
(ii) ISO metric black cup and countersunk head bolts and BS 4933; and
screws with hexagon nuts
(iii) Metal washers for general engineering purposes BS 4320.
(b) The length of bolts shall be such that the threaded portion of each bolt projects
through the nut by at least one and not more than four, threads.
(c) Fittings, including eye bolt strainers, cleats, winding brackets, stretcher bars,
extension arms, hook bolts and base plates, shall be galvanised mild steel.
(b) The light transmission measured in accordance with DIN 5036 shall not be
less than 90% for a 4 mm thick sample.
(c) Acrylic sheets shall comply with BS 6262, and in no case be less than 15 mm
thick. The tolerance in thickness shall not exceed ±5%.
(d) Acrylic sheets shall carry the manufacturer's guarantee under outdoor
conditions in Hong Kong on the following properties:
(ii) Modulus of elasticity; after 10 years the elastic modulus shall not be less
than 2800 MPa
(iii) Tensile strength; after 10 years the tensile yield stress shall not be less
than 60 MPa.
(e) Acrylic sheets shall have impact strength in compliance with Class A materials
according to BS 6206.
(g) All steel fixings and accessories shall have corrosion protection treatment not
inferior to the structural steel frame shown on the Employer’s Drawings and
they shall be painted to the same colour as the structural steel frame.
(h) All acrylic sheets shall be covered with a protective sheeting to the
manufacturer's recommendation during transport, storage on Site, and
construction until the application for the Completion Certificate
(i) Fixing details, which require drilling holes in the acrylic sheets are not
acceptable.
(b) Galvanising to steel shall be applied, as far as possible, after welding, drilling
and/or cutting are complete.
(a) Welds to steel for fencing shall be in accordance with Clause 22.5.2. Weld
surfaces shall be clean and flush before application of the protective coating.
(b) Steel shall not be welded after galvanising except with the express permission
of the Project Manager. If permitted, the welded areas shall be free from scale
and slag and shall be treated after welding, with an alternative galvanising or
zinc coating system, reviewed without objection by the Project Manager.
(a) Concrete posts and struts for fencing shall be precast units using Grade 30/10
concrete. The finish to formed surfaces shall be Class F4 and the finish to
unformed surfaces shall be Class U5. The tops of posts and all arises shall be
rounded or chamfered.
(b) Reinforcement for concrete posts and struts shall be Grade 250 plain round
steel bars.
(c) No concrete posts shall be removed from the mould for a period of at least 24
hours and shall not be shifted or transported until at least seven days have
elapsed since casting.
5.3.12 Gates
(a) Steel gates shall be of welded construction. The frame shall be square with
the corners mitred or saddled.
(b) Chain link infilling in gates shall be of the same type and size as in the
adjoining fence and shall be attached to the framework by stretcher bars.
(a) Plywood and timber posts, rails and struts for fencing shall be stored on level
supports in a dry, weatherproof store.
(b) Gates, concrete and steel posts and struts for fencing shall be stored off the
ground on level supports.
The following particulars of the proposed fencing shall be submitted to the Project
Manager for review:
(a) Contractor’s Drawings showing the fabrication details of fences and gates;
(b) details of the source, type and properties of all fencing materials; and
(c) Contractor’s Drawings showing details, fixings and movement joints (including
calculations) for all acrylic sheet sound barriers.
5.4.2 Samples
The following samples of the proposed materials shall be submitted to the Project
Manager together with the particulars referred to Clause 5.4.1 above:
5.5 WORKMANSHIP
5.5.1 Tolerances
(b) the level of the top of posts shall be within 25 mm of the specified level; and
(c) posts shall be vertical to within 5 mm over the height of the post.
(a) Straining posts for fencing shall be provided at all ends and corners, at
changes in direction, at abrupt changes in level, at gate posts and at intervals
not exceeding 30 m along straight lengths of fencing. Struts shall be fitted to
straining posts in the direction of each wire secured to the post.
(a) Posts and struts for fencing shall be set in excavations for foundations and the
excavations shall be filled with Grade 30/20 concrete up to 50 mm below
ground level.
(b) Struts shall be fitted into slots in timber and concrete posts and bolted to steel
posts.
(c) The ground surface around posts shall be made good with the same material
as in the adjoining area.
(a) Line wire, chain link mesh and barbed wire for fencing shall be strained tightly
between straining posts. Winding brackets shall be used for straining between
steel posts. Winding brackets or eye bolt strainers shall be used for straining
between concrete and timber posts. The tension in the wire on each side of
straining posts shall be equal. Wire shall not be strained until at least 14 days
after concrete has been placed in the foundation.
(b) Chain link mesh shall be secured at each straining post by a stretcher bar and
shall be tied to the line wire by tying wire at 150 mm intervals.
(c) Each line wire and each line of barbed wire shall be secured to each
intermediate post by one of the following methods as stated in Table 5.1:
(i) a hairpin staple shall be passed through a hole in the post and secured
to the wire by three complete turns on each side of the post;
(ii) a stirrup shall be passed through a hole in the post and the ends bent
over twice;
(v) a hook bolt shall be passed through a hole in the post and secured with
a nut and washer.
Gates shall be hung plumb and shall not be installed until the wire has been
strained.
The ends of timber rails for fencing shall be closely butted together and the rails
shall be securely nailed to each post. The ends of plywood sheets in hoardings shall
be closely butted together and the sheets shall be securely nailed to each post and
to the horizontal rails.
6.1 GENERAL
The Permanent Works and materials specified below shall comply with the Sections
stated, unless otherwise stated in this Section.
(a) Metalwork for handrailing, ladders, stairs, metal flooring, toe plates and safety
chains shall comply with Section 35 and Section 22.
(c) Formwork and finishes to concrete shall comply with Section 18.
(h) Cable duct systems for electrical and mechanical installations shall comply
with Section 13.
6.2.1 Pipes
Pipes for drainage works are pipes for conveying sewage, greywater and surface
water.
6.3 MATERIALS
(a) Precast concrete pipes and fittings shall comply with BS 5911:Part 100.
(b) Precast concrete pipes and fittings shall have flexible spigot and socket joints.
(a) Vitrified clay pipes and fittings shall comply with BS 65; the pipes and fittings
shall be glazed and shall be the chemical resistant type.
(b) Vitrified clay pipes and fittings shall have flexible mechanical joints.
(a) DI pipes and fittings shall comply with BS 4772. Pipes and fittings shall be
lined internally with cement mortar in accordance with BS 4772, Appendix C.
Pipes and fitting shall be coated externally with bituminous coating in
accordance with BS 4772 Section 16.3.
(b) Flexible joints in DI pipes and fittings shall be the push-in type and shall be
capable of withstanding a minimum angular deflection of 4°. Flexible joints
shall also be capable of withstanding axial movements and shall allow a
minimum withdrawal of 38 mm when there is no deflection of the joint.
(c) Flanged joints in DI pipes and fittings shall be PN 16 rating complying with BS
4504: Section 3.1.
(d) Pipes to be built in to structures shall have puddle flanges welded on.
(a) Unplasticised (UPVC) pipes and fittings shall comply with the relevant British
Standard stated in Table 6.1.
(b) UPVC pipes and fittings above ground shall have solvent welded spigot and
socket joints. UPVC pipes and fittings below ground shall have either solvent
welded spigot and socket joints or flexible spigot and socket joints with
elastomeric joint rings as stated in the Contract.
(c) Joints and fittings for UPVC pressure pipes complying with BS 3506 shall
comply with the following:
(d) Solvent cement for UPVC pressure pipes shall comply with BS 4346: Part 3.
(e) The class of UPVC pressure pipes complying with BS 3506 shall depend on
the pressure rating.
(b) GI pipes and fittings shall be medium class thickness and shall be galvanized
in accordance with BS 729.
(a) Polyethylene pipes and fittings shall comply with the requirements set out in
the Appendix A6.6.
(b) Size of polyethylene pipes and fittings shall be designated by the nominal size
in millimeters. Nominal Size shall mean the minimum outside diameter of a
pipe, or in the case of a fitting, the minimum outside diameter of the pipe with
which the fitting is intended to use. For the purpose of connecting to pipes of
other materials or connecting to other non-polyethylene standard fittings
which are of the same nominal internal bore, the foIlowing equivalent sizes in
DN shall be used:
(a) Bolts, nuts and washers for flanged joints, detachable couplings and flange
adapters shall comply with the following:
(i) ISO metric black hexagon bolts, screws and nuts : BS 4190;
(iii) the bolts, nuts and washers shall be hot-dip galvanised in accordance
with BS 729.
(b) Stainless steel bolts and nuts shall comply with BS 6105, steel Grade A4 and
property Class 80. Washers shall be Grade 316 S 31 in the softened condition
complying with BS 1449: Part 2.
(c) Spheroidal graphite iron bolts shall be Grade 500/7 metal complying with BS
2789.
(d) Bolts, nuts and washers shall be insulated from electrochemically dissimilar
metal by non-metallic washers and sleeves.
(e) Bolts and nuts shall be compatible with the type of joint and shall be obtained
from the same manufacturer as the joint.
(f) The length of bolts shall be such that the threaded portion of each bolt
projects through the nut by at least one thread and by not more than four
threads.
(a) Elastomeric joint rings shall comply with BS 2494, Type D. The rings shall be
compatible with the type of joint and shall be obtained from the same
manufacturer as the joint.
(b) Elastomeric joint rings for flanged pipes shall be the inside diameter bolt circle
type. The rings shall be natural rubber with a thickness of 3.2 mm and with
other dimensions complying with BS 4865: Part 1.
(b) Detachable couplings and flange adapters shall accommodate the angular
deflection and straight draw stated in Table 6.2 for the different nominal
diameters of pipes connected.
(b) Anticorrosion tape shall be applied to valves, flanged joints, slip-on couplings
and flange adapters. Type 1 shall be used for pipes smaller than 700 mm
diameter and Type 2 shall be used for pipes 700 mm diameter and above.
(c) Primer and mastic filler for use with anticorrosion tape shall be compatible
with the tape and shall be a type recommended by the manufacturer of the
tape and reviewed without objection by the Project Manager.
Value
Property
Type 1 Type 2
Thickness of PVC backing (μm) 85 500
Tensile strength (N/mm) 8 10
Elongation (%) ≤ 26 ≤ 26
Tear strength (N) 20 36
Adhesion strength (N/mm) 2 2
Holiday test voltage (kV)
- single layer 10 10
- double layer 15 15
Impact strength (J) 3.5 8
Temperature range (°C) 5 - 60 8 - 60
Total thickness (mm) 1.6 2.0
Mass (kg/m2) 1.8 2.4
(b) Bituminous coatings used for repairing joints and coatings shall be compatible
with the adjacent coating.
(a) Granular bed shall be Type A material and granular fill shall be Type B
material.
(b) Type A or Type B material shall consist of hard, clean, crushed slag, gravel,
crushed rock, crushed concrete or crushed inert demolition material having a
grading within the limits of Table 6.4. The ten percent fines values shall be at
least 50kN. The material passing the 425μm BS test sieve shall be non-plastic
when tested in accordance with BS1377.
(c) Type A and Type B material shall be obtained from a source reviewed without
objection by the Project Manager.
(d) Aggregates for granular bed shall have the compacting fraction values stated
in Clause 6.6.3(d).
(a) Joint filler for joints in concrete bed, haunch and surround shall be a
proprietary type reviewed without objection by the Project Manager and shall
be a firm, compressible, single thickness, non-rotting filler. The thickness of
the filler shall be as stated in Table 6.5.
Table 6.5: Joint Filler for Concrete Bed, Haunch and Surround
Precast concrete manhole units shall comply with BS 5911: Part 200. Cover slabs
and reducing slabs shall be reinforced as required to comply with the load test
requirements stated in BS 5911: Part 200. The type of cement for the manufacture
of precast concrete manhole units, cover slabs, and reducing slabs shall be as
stated in BS 5911: Part 200, or combination of PFA and OPC complying with BS
12, or PPFAC. The PFA content shall not exceed 40% by mass of the cementitious
content.
(a) Precast concrete chambers and gullies shall comply with BS 5911: Part 2.
Cover slabs shall be reinforced as required to comply with the load test
requirements stated in BS 5911: Part 2. The types of cement for the
manufacture of precast concrete chambers and gullies, and cover slabs shall
be as stated in BS 5911: Part 2, or a combination of PFA and OPC complying
with BS 12, or PPFAC. The PFA content shall not exceed 40% by mass of
the cementitious content.
Step irons shall comply with BS 1247. Step irons shall be malleable cast iron
complying with BS 6681 and shall be hot-dip galvanised in accordance with BS 729.
(a) Manhole covers, gully gratings and kerb overflow weirs shall be Grade 50 cast
iron complying with BS 1452; bolts and nuts shall comply with BS 4190.
(b) Covers, gratings and weirs shall be cleanly cast, free from air holes, sand
holes, cold shuts and chill and shall be neatly dressed and fettled. Castings
shall be free from voids whether due to shrinkage, gas inclusions or other
causes. Bolts and nuts shall not be over tightened.
(d) Covers, gratings and weirs shall have the manufacturer's name cast integrally
with the unit in a raised form and shall be protected with bituminous coating.
Covers shall have a raised design on the top surface as stated in the
Contract.
(e) The Contractor shall provide the Project Manager two keys for each pattern of
cover used.
Test requirements
Minimum
Type of gully grating Diameter of Test
mass Grade
and frame block load
(kg)
(mm) (t)
Grating for hinged 28.0 Heavy duty 300 20
gully grating
Type GA2-325
Frame 24.5 Heavy duty 300 20
Grating for double 57.5 Heavy duty 300 20
triangular gully grating
Type GA1-450
Shallow frame
- adjacent to kerb 33.5 Heavy duty 300 20
- away from kerb 36.5 Heavy duty 300 20
Deep frame
- adjacent to kerb 40.5 Heavy duty 300 20
- away from kerb 44.0 Heavy duty 300 20
Grating for hinged gully 61.5 Heavy duty 300 20
grating Type GA2-450
Frame 37.0 Heavy duty 300 20
6.3.20 Penstocks
(i) frames and gates shall be cast iron complying with BS 1452, Grade
220;
(ii) stems shall be stainless steel complying with BS 970: Part 1, Grade 316
S 31;
(iii) operating nuts shall be gunmetal complying with BS 1400, Grade LG2;
(iv) sealing faces shall be phosphor bronze complying with BS 2874, Grade
PB 102;
(vi) assembly and fixing nuts and bolts shall be stainless steel complying
with Clause 6.3.7(b); and
(c) Sealing faces shall be of rectangular sections and shall be fixed to the frames
and gates using taperhead screws of the same material as the sealing faces.
(d) Adjustable wedges shall have sufficient contact areas with the gates to
minimise wear.
(e) Frames shall include guide rails or guide faces for gates. Clearance within
guides shall be as small as practicable such that the gates will not vibrate
under flow conditions.
(f) Penstocks shall have rising stems unless otherwise stated in the Contract.
Rising stems shall have perspex protection tubes with open/close indicators.
(a) Gate valves shall comply with BS 5150 and with the following requirements:
(i) bodies and wedges shall be cast iron complying with BS 1452, Grade
220 and shall have renewable gunmetal seat rings;
(ii) gunmetal for renewable seat rings shall be Grade LG2 complying with
BS 1400;
(iii) stem nuts shall be gunmetal complying with BS 1400, Grade LG2;
(v) assembly and fixing nuts and bolts shall be stainless steel complying
with Clause 6.3.7(b).
(b) Gate valves shall be double flange-ended solid wedge type with nominal
pressure designation PN 16. Flanges shall be PN 16 complying with BS
4504: Part 1.
(c) Gate valves shall have outside screw rising stems unless otherwise stated in
the Contract. Rising stems shall have perspex protection tubes with
open/close indicators.
(d) Gate valves shall be fitted with a plate showing the operating position of the
valve in the closed, quarter closed, half closed, three-quarters closed and
open positions.
(e) Chains for chain operated gate valves shall be mild steel complying with BS
970:Part 1 and hot-dip galvanized in accordance with BS 729. The chains
shall be continuous.
(f) Gear boxes shall have enclosures effectively sealed against the intrusion of
foreign bodies and moisture to the degree IP68 (i.e. dust-tight and protection
against complete and continuous submersion in water from 15m or 50ft) as
defined in the standard IEC 60529.
(i) frames and flaps shall be cast iron complying with BS 1452, Grade 220;
and
(ii) sealing faces and hinge pins shall be gunmetal complying with BS 1400,
Grade LG2.
(b) The flap shall be hung with double hinges and secured with hinge pins.
(c) Flanges for flange mounting types of flap valves shall be PN 16 complying
with BS 4504: Part 1.
(i) bodies and valve sections shall be cast iron complying with BS 1452,
Grade 220;
(ii) sealing faces and stem nuts shall be gunmetal complying with BS 1400,
Grade LG2; and
(b) The stems of sludge valves shall operate through non-rising stem nuts
housed in bridges bolted over the body sections.
(a) Air valves shall be of the elongated body type and shall have a pressure
rating of 3 bars unless otherwise stated in the Contract.
(i) a small orifice valve for releasing air at working pressure, and
(ii) a large orifice valve for allowing air to pass at atmospheric pressure
during emptying and filling of pipework.
(c) The bodies and covers of small and large orifice valves shall be cast iron
complying with BS 1452, Grade 220; the trim and float shall be stainless steel
complying with BS 970:Part 1, Grade 316 S 31.
(d) Small orifice valves shall have an adjustable Vitron or equivalent orifice button
to ensure positive sealing. Large orifice valves shall have a Buna-N or
equivalent seat.
(a) Handwheels and tee keys for penstocks and valves shall turn in a clockwise
direction for closing. Handwheels shall have smooth rims and the direction of
opening and closing shall be clearly cast on the handwheel. The opening
effort required at any point on the handwheel rim shall not exceed 250 N
when operated against the full unbalanced pressure.
(b) Extension stems for penstocks and valves shall be stainless steel of the same
grade as the stems. Extension stems shall be connected by muff couplings.
(c) Handwheels, tee keys, headstocks, guide brackets for stems, supporting
brackets, surface boxes and other fittings for penstocks and valves shall be
cast iron complying with BS 1452.
(d) Bolts and nuts for fixing penstocks and valves to structures shall be stainless
steel complying with Clause 6.3.7(b). Bolts shall be indented foundation bolts.
(e) Grout for filling rebates and box-outs shall be a proprietary type reviewed
without objection by the Project Manager and shall contain a non-shrink
admixture.
Foam concrete for filling abandoned pipes, culverts, manholes and voids shall be
composed of OPC (or PPFAC), fine aggregate, water, admixtures for accelerating
or retarding the setting time and foam to reduce the density and to produce a
flowing self levelling material.
6.4 SUBMISSIONS
(a) The following particulars of the proposed pipes, joints and fittings for drainage
works shall be submitted to the Project Manager for review without objection:
(a) The following particulars of the proposed anti-corrosion tape and joint filler for
drainage works shall be submitted to the Project Manager for review without
objection:
(i) manufacturer's literature for the joint filler and anticorrosion tape; and
(ii) certificates for anticorrosion tape and joint filler showing the
manufacturers' name, the date and place of manufacture and showing
that the material complies with the requirements stated in the Contract
and including results of tests in accordance with the Contract.
A certificate for each type of aggregate showing the source of the aggregate and
showing that the aggregate complies with the requirements stated in the Contract,
and including the results of tests in accordance with the Contract, shall be
submitted to the Project Manager for review without objection for the proposed
aggregates for granular bed for drainage works.
(a) The following particulars of the proposed materials for manholes, chambers
and gullies for drainage works shall be submitted to the Project Manager for
review without objection:
(i) a certificate for each type of manhole and chamber unit and for each
type of gully showing the manufacturer's name, the date and place of
manufacture and showing that the materials comply with the
requirements stated in the Contract and including results of tests
required in accordance with the relevant British Standard;
(ii) a certificate for step irons showing the manufacturer's name, the date
and place of manufacture and showing that the step irons comply with
the requirements stated in the Contract, and including results of tests
required in accordance with the Contract; and
(iii) a certificate for each type of manhole cover, gully grating and kerb
overflow weir showing the manufacturer's name, the date and place of
manufacture and showing that the materials comply with the
requirements stated in the Contract and including results of loading
tests in accordance with the Contract.
(a) The following particulars of the proposed penstocks and valves for drainage
works shall be submitted to the Project Manager for review without objection:
(a) The following particulars of the foam concrete mix (or grout mix) and
procedure for filling abandoned pipes, culverts, manholes and voids shall be
submitted to the Project Manager for review without objection:
(v) strength;
(a) The following particulars of the proposed procedures for tests on pipelines
and penstocks for drainage works shall be submitted to the Project Manager
for review without objection:
(a) The following particulars of the proposed procedure for CCTV inspections
shall be submitted to the Project Manager for review without objection:
6.5 WORKMANSHIP
(i) Pipes, joints and fittings for drainage works shall be transported,
handled and stored in accordance with the manufacturers'
recommendations and in a manner which will not result in damage or
deformation to the pipes, joints and fittings or in contamination of the
pipes, joints and fittings.
(ii) Pipes, joints and fittings shall be protected from damage and damaged
pipes, joints and fittings shall not be used in the Permanent Works.
Pipes, joints and fittings shall be securely packed and supported to
prevent movement when being transported.
(iii) UPVC pipes, joints and fittings shall be protected from exposure to
conditions which may affect the material.
(v) Elastomeric joint rings shall be packed in bags and lubricant for joints
shall be stored in sealed containers marked to identify the contents.
The rings and lubricant shall be protected from exposure to conditions
which may affect the material.
(iii) Pipes and fittings shall not be subjected to rough handling, shock
loading or dropping.
(ii) Socket and spigot pipes shall be stored with the sockets alternating and
in such a manner that loads are not applied to the sockets.
(iii) The height of stacks of pipes shall not exceed the maximum height
recommended by the pipe manufacturer.
Anticorrosion tape and joint filler shall be stored in accordance with the
manufacturer's recommendations in a dry, weatherproof store with a raised
floor.
Aggregates for granular bed shall not be handled or stored in a manner which
will result in mixing of the different types and sizes or in contamination of the
aggregates. Different types and sizes of aggregates shall be stored in
separate stockpiles.
(f) Handling and storage of units for manholes, chambers and gullies:
(i) Units for manholes, chambers and gullies shall be lifted only at the lifting
points recommended by the manufacturer and shall not be subjected to
rough handling, shock loading or dropping.
(ii) Units for manholes, chambers and gullies shall be stored off the ground
on level supports and in a manner which will not result in damage or
deformation to the units or in contamination of the units. The units shall
be protected from damage and damaged or deformed units shall not be
used in the Permanent Works.
Manhole covers, gully gratings, kerb overflow weirs, penstocks and valves,
including fittings, shall be stored off the ground on level supports and in a
manner which will not result in damage to the units or in contamination or
deformation of the units. The units shall be protected from damage and
damaged or deformed units shall not be used in the Permanent Works.
(a) Excavation for any section of a trench for drainage works shall not commence
until the nature, location and size of existing utilities which may be affected by
the excavation have been ascertained and the setting out details have been
reviewed without objection by the Project Manager.
(b) The effective trench width of trenches for drainage works shall not exceed the
relevant effective trench widths stated in Table 6.9 for the different diameters
of pipe. Unless otherwise stated in the Contract, effective trench width for
different trench profiles shall be measured in accordance with the
requirements of the Hong Kong Government Drainage Services Department
Standard Drawings.
(c) The bottom of the excavation shall be formed to the levels and falls as stated
in the Contract and well rammed and consolidated. Any backfill in the areas
of overbreak shall be provided by material reviewed without objection by the
Project Manager.
(d) The sides of trenches, manholes and other excavations shall be adequately
supported at all times. Where shown on the Employer’s Drawings or directed
by the Project Manager the supports shall be left in trenches or pits.
(e) The materials excavated in forming pipe drains shall, if containing materials
as defined in Clause 7.3.1(b), be disposed of off Site and replaced with fill
material. Excavated fill material shall be set aside for use as fill.
(f) Surplus material shall be used for fill or disposed of in accordance with Clause
7.5.1 as agreed with, or directed by the Project Manager.
(i) The Contractor shall allow the Project Manager to inspect trenches,
bedding, pipes, joints, fittings and valves before pipelaying for drainage
works starts. The Contractor shall notify the Project Manager before
pipelaying starts in any part of the Permanent Works.
(ii) The Contractor shall inspect pipes, joints, fittings and valves, including
internal and external coatings, immediately before and after pipelaying;
valves shall be inspected to ensure that they are in working order and
are capable of being fully opened and closed. Deleterious material shall
be removed and damage shall be repaired immediately before and after
pipelaying.
(iii) The inside of pipelines shall be kept clean and free from water, dirt,
stones, debris and deleterious material. Except when pipes are being
jointed, the open ends of pipelines shall be sealed with a wooden plug
or stopper.
(vi) Pipelines shall be laid in an uphill direction with sockets facing uphill.
(vii) Pipes shall be laid in such a manner that water will not pond in locations
with zero or shallow gradients and such that the pipes will comply with
the specified tolerances.
(i) Surfaces on which pipes for drainage works will be laid shall be cleaned
and objects which may damage the pipes shall be removed before
pipes are laid.
(ii) The bottom of trenches on which pipes will be laid directly shall be
shaped to support the pipes uniformly along the length of the barrel;
holes shall be dug to prevent pipes resting on the sockets and to allow
the pipes to be jointed.
(i) The laying of poIyethylene pipe shall comply with CP 3 12: Part 3: 1973.
(ii) Storage and jointing of polyethylene pipe and fittings shall be in strict
accordance with the manufacturer's recommendations and to the
satisfaction of the Project Manager.
(iv) Dragging of polyethylene pipe over trench bottom or over the ground is
not permitted.
(vi) Naked flame inside trench shall not be used unless with the permission
of the
(a) Pipes for drainage works shall be cut and the ends shall be prepared in
accordance with the manufacturers' recommendations; purpose-made
equipment recommended by the manufacturer and reviewed without objection
by the Project Manager shall be used for cutting the pipes.
(b) Cut ends of pipes shall be square or cut to the correct angle and without
damage to the pipe or coating. Cut ends shall be trimmed and chamfered to
suit the type of joint and in such a manner that elastomeric joint rings will not
be damaged by the cut end.
(c) Pipes requiring to be cut to form closing lengths shall not be cut until adjacent
pipes have been laid and jointed and the length to be cut can be accurately
measured.
(d) Reinforcement in precast concrete pipes which are cut shall be cut back flush
with the concrete and protected with epoxy resin.
(e) Pipes which terminate at the inside face of structures shall be cut such that
the end of the pipe is flush with the face.
(a) General:
(i) Pipes for drainage works shall be jointed in accordance with the
manufacturers' recommendations and using jointing equipment and
jointing materials recommended by the manufacturer and reviewed
without objection by the Project Manager.
(ii) The Contractor shall inspect pipes, joints, fittings and valves, including
internal and external coatings, immediately before and after jointing.
Deleterious material shall be removed and damage shall be repaired
immediately before and after jointing. Surfaces which are to be jointed
and jointing materials shall be cleaned immediately before jointing.
Pipes shall be cleaned out with clean water.
General Materials & Workmanship Specification 19/51 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 6 – Drainage Works
(iii) All joints in pipelines shall be watertight.
(i) Flanged joints in pipes for drainage works shall be provided as stated in
Clause 6.5.5(b)(ii).
(ii) Bolt holes in flanged joints shall be orientated symmetrically about the
vertical diameter with no bolt holes on the vertical diameter.
Elastomeric joint rings shall be the correct size and shall not protrude
into the bore of the pipe. The rings may be temporarily fixed to the face
of the flange using a minimum amount of adhesive of a type
recommended by the manufacturer; jointing compound or paste shall
not be used for this purpose.
(i) Flexible collar joints in pipes for drainage works shall be provided as
stated in Clause 6.5.5(c)(ii) to (iv).
(ii) The elastomeric joint rings shall be placed in position inside the grooves
of the sleeve. The ends of the pipes shall be well smeared with
lubricant over a distance of at least 100 mm from the end of the pipe.
(iii) The sleeve shall be placed on the end of the laid pipe and pushed home
to the location mark on the pipe. The location mark shall be at a
distance of half the length of the sleeve minus 3 mm from the end of the
pipe unless otherwise recommended by the manufacturer.
(iv) The pipe which is to be jointed to the laid pipe shall be placed in the
sleeve and pushed home to the location mark on the pipe.
Push-in joints in pipes for drainage works shall be made by smearing the
elastomeric joint ring with lubricant and placing the ring in position on the
spigot end of the pipe. The spigot shall be placed in the socket of the laid
pipe and pushed home.
(i) Detachable joints in pipes for drainage works shall be jointed as stated
in Clause 6.5.5(e)(ii) and (iii).
(iii) The flanges, elastomeric joint rings and central collar shall be moved
into position at the ends of the pipes; the central collar shall be
positioned centrally over the gap between the ends of the pipe before
the bolts are tightened.
Joints with flange adapters in pipes for drainage works shall be made by
placing the flange adaptor on the plain end before the bolts are tightened.
Solvent welded joints in pipes for drainage works shall be made by applying
solvent cement to the pipes to be jointed and pushing the pipes home.
Surplus solvent shall be removed after jointing. Solvent welded pipes jointed
outside the trench shall not be placed in the trench until the solvent setting
period recommended by the manufacturer has elapsed. In addition, any
material or thing contaminated by the solvent shall not be left in the pipe or
trench.
(i) Screw joints in pipes for drainage works shall be made using a threaded
coupler. The threaded surfaces of the pipes and coupler shall be
cleaned and the threads shall be painted with two coats of bituminous
paint. The pipe thread shall be wrapped with three turns of spun yarn
and the joint tightened using purpose made tools. Coal tar compounds
or white lead paint shall not be used. Locking nuts to branch
connections shall be tightened. Branch connections shall not protrude
inside the pipe.
(ii) Cast iron pipes shall be laid and bedded one at a time. Each cast iron
pipe should bear evenly on it’s bed. Joint holes shall be cut in the
foundation for the purpose of making joints. The spigot of each pipe
shall fit easily into the socket of the preceding pipe without any jamming
or twisting and shall be pushed well home so that the inverts of the
socket and spigot when joined shall be level. Joint gaskets shall be
formed with about 2 turns of yarn caulked tightly to the bottom of the
socket, a depth of at least 50 mm being left in the socket for lead
jointing, which shall be run in molten and caulked into the edge of the
socket. Proprietary joints may be proposed for review without objection
by the Project Manager.
(ii) Site fusion jointing shall be made in accordance with WIS No. 4-32-08
using automatic equipment with data printout facilities
(iii) A specific joint number shall be assigned to each heat fusion joint and a
sketch showing the location of the joint shall be prepared. In case of butt
fusion joint, the removed beads shall be properly stored in a transparent
plastic bag which shall be marked to indicate the joint number and
whether the beads are external or internal beads. External and internal
beads for the same joint shall be placed in two different plastic bags.
The sketch, data printout, the name of the jointer, and all other
information as required by the Project Manager together with beads (if
the joint is a butt fusion joint) for each heat fusion joint shall be
submitted to the Project Manager for review without objection within
three calendar days after completion of the joint.
(iv) For socket fusion, electro-fusion and heat fusion saddle jointings, the
fusion areas of polyethylene pipes shall be cleaned by using
isopropanol wipes before and after scrapping. The fusion areas of the
fittings shall also be cleaned by using isopropanol wipes before
connecting the polyethylene pipes to the fittings.
(a) Flanged joints, detachable couplings and flange adapters on buried pipes for
drainage works shall be protected as stated in Clause 6.5.6(b) to (d).
(b) The joint, including bolts and nuts, shall be cleaned to remove all moisture,
dust, oil, grease and deleterious material. Bolts and nuts shall be painted with
two coats of bituminous paint and the joint shall be coated with primer. Mastic
filler shall be applied in such a manner that all depressions, corners and voids
between the bolts and nuts are filled and a smooth surface is available on
which to apply the anticorrosion tape.
(c) At least two layers anticorrosion tape shall be applied to all parts of the joint
and to the adjacent pipe for at least 200 mm beyond each end of the joint.
The tape shall be applied in accordance with the manufacturer's
recommendations and shall be wrapped spirally around the joint and pipe with
at least 55% overlap per spiral.
(d) The tape shall be moulded manually after application to take up the contours
of the parts being protected.
Damage to coatings and linings of pipes for drainage works shall not be repaired
unless permitted by the Project Manager. If permitted, repairs shall be carried out
using materials recommended by the manufacturer and reviewed without objection
by the Project Manager.
(a) Thrust or anchor blocks shall be used to resist forces at bends, branches and
stopends in pressure pipelines for drainage works except where self
anchoring joints are used. Concrete for thrust and anchor blocks shall be
Grade 20.
(b) The bearing face, and other faces stated in the Contract, of concrete anchor
and thrust blocks shall be cast directly against undisturbed ground; the faces
of excavations shall be trimmed to remove loose material before concreting.
Excavation required for the block beyond the trench width shall be carried out
after the pipe or fitting has been jointed. Excess excavation beyond the face
at the block shall be filled with concrete of the same grade as the block.
(c) Internal pressure shall not be applied to the pipeline until thrust and anchor
blocks have developed the specified grade strength.
(ii) Aggregates for granular bed shall be deposited in the trench in layers
not exceeding 150 mm thick and for the complete width of the trench.
Each layer shall be compacted using a plate vibrator or by other
methods reviewed without objection by the Project Manager.
(iii) Holes shall be dug in the granular bed to prevent pipes resting on the
sockets and to allow the pipes to be jointed. The pipes shall be laid
directly on the granular bed; temporary supports shall not be used.
(iv) After the pipes have been jointed, aggregate shall be deposited in
layers not exceeding 150 mm thick equally on both sides of the pipe to
the specified level for the complete width of the trench. Each layer shall
be compacted using a plate vibrator.
(i) Concrete bed, haunch and surround to pipelines for drainage works
shall be constructed as stated in Clause 6.5.9(b)(ii) to (vii).
(ii) Concrete for concrete bed, haunch and surround shall be Grade 20.
(v) Flexible joints shall be formed in concrete bed, haunch and surround at
flexible joints in pipelines. Joint filler shall be placed next to the flexible
joint in the pipeline and shall extend for the complete thickness of the
bed, haunch and surround.
(vi) Concrete shall be placed evenly over the complete width of the bed and
over the complete length of the pipe being concreted up to a level of 25
mm below the underside of the pipe. Concrete shall then be placed on
one side of the pipe only and worked under the pipe until the concrete
spreads under the pipe. Concrete shall then be placed equally on both
sides of the pipe to the specified level.
(vii) Pipes for drainage works which are 1 m or less below the surface of a
carriageway shall be protected with Grade 20 concrete surround.
(viii) The aggregate for Grade 20 concrete stated in Clause 6.5.9(b)(i) to (vii)
shall be natural stone, crushed rock or crushed concrete. Such Grade
20 concrete shall have the following minimum cementitous content:
(i) Fill material surround to pipelines for drainage works shall be deposited
and compacted as stated in Clauses 7.4.34 and 7.4.35.
(i) The locations of the brackets shall be determined by the Contractor and
arranged to satisfy the following requirements:
(ii) The interface between the brackets and the concrete shall be protected
by an inert layer of corrosion resisting tape reviewed without objection
by the Project Manager.
(ii) Termination pipes in pipelines for drainage works which are designed to
connect to pipes or fittings laid by others shall comply with the following
requirements:
• the position of the centre of the termination face of the pipe in the
longitudinal direction shall be within 10 mm of the specified
position;
• the position of the centre of the termination face of the pipe in the
lateral direction shall be within 3 mm of the specified position;
• the gradient of the termination pipe shall be within 0.5° of the
specified gradient; and
• the invert level at the termination face of the pipe shall be within 3
mm of the specified invert level.
6.5.11 Connections
(i) The joints between pipes for drainage works and structures into which
the pipes are built shall be watertight; protective coatings shall be
removed over the length to be built in before the pipe is built in. Pipe
collars and sockets shall not be built in to structures.
(ii) Two flexible joints shall be provided in pipelines adjacent to the outside
faces of structures into which pipes will be built. The distances from the
outside face of the structure to the first joint and from the first joint to the
second joint shall be as stated in Table 6.10.
(iii) The ends of pipes which are built in to structures shall be temporarily
sealed with a blank flange, brickwork or timber boarding. The
temporary seals shall be left in position until the Project Manager
permits their removal.
(ii) UPVC pipe saddles shall be fixed to UPVC pipes using a purpose-made
mechanical clip or solvent cement of a type recommended by the
manufacturer and reviewed without objection by the Project Manager.
(iv) The positions of the pipe junctions relative to the manhole or structure
immediately downstream shall be measured and recorded before
backfilling.
(v) The ends of connecting pipes not required for immediate use shall be
sealed with a blank flange or brickwork and the position measured and
recorded before backfilling.
(vi) The Contractor shall allow for the existing flow of water when
connecting new sewers, drains and culverts to existing pipelines,
culverts, manholes and other drainage chambers.
(i) Bases, inverts and benching for precast concrete manholes shall be
constructed in-situ using Grade 20 concrete, unless otherwise stated in
the Contract.
(ii) Precast concrete units for manholes and chambers shall be set
vertically with step irons staggered and vertically aligned above each
other. Joints between precast units shall be the rebated type and shall
be sealed with cement mortar; lifting holes shall be filled with cement
mortar. Surplus cement mortar shall be removed and joints shall be
pointed.
(iv) The frames for manhole covers and gully gratings shall be set to the
same levels as the surrounding surface, allowing for falls and cambers,
using brickwork and/or concrete. The number of courses of brickwork
used below frames shall not exceed three and the minimum grade for
concrete shall be Grade 20.
(v) Cement mortar for fixing manhole covers and gully gratings in position
and bonding brickwork shall consist of cement and sand in the
proportions 1:3 by mass.
The top surfaces of side walls of concrete open channels shall be constructed
to the same levels as the adjoining Permanent Works. Excess excavation
beyond the channel walls shall be filled with Grade 10 concrete.
(a) The ends of pipes which do not terminate at a manhole, chamber, gully or
structure shall be marked with marker blocks. The blocks shall be 150 mm x
150 mm x 150 mm and shall be constructed using Grade 20 concrete.
(b) A wire shall be connected from a hook at the underside of the block to the
plug at the end of pipes.
(c) Marker blocks shall be set flush level with the adjacent Permanent Works and
shall have the letters ‘CD’ marked on the upper surface.
(a) Penstocks and valves shall be installed in accordance with the manufacturer's
recommendations and in the closed position.
(b) Frames for penstocks shall be fixed in position leaving a 20 mm gap between
the frame and the concrete surface. Contact between the penstock door and
frame shall be checked using a feeler gauge 0.1 mm thick or other size
recommended by the manufacturer.
(c) Box-outs and rebates for penstock and valve frames and gaps between
frames and concrete surfaces shall be filled with cement mortar.
(d) After installation, penstocks and valves shall be cleaned and moving parts
shall be lightly greased and checked for ease of operation. Penstocks and
valves shall be left in a closed position.
(b) If the top of a pipe or culvert, or the bottom of a manhole, chamber or gully to
be abandoned is 1 m or less below the finished ground level, the pipe,
manhole, chamber or gully shall be removed and disposed of by the
Contractor. The void shall be filled with foam concrete, granular fill material or
special fill material which has been reviewed without objection by the Project
Manager.
(c) If the top of a pipe or culvert, or the bottom of a manhole, chamber or gully to
be abandoned is more than 1 m below the finished ground level, the pipe,
culvert, manhole, chamber or gully shall be filled with foam concrete or grout
as stated in Clause 6.3.25.
(a) Pipelines for drainage works shall be cleaned by pigging or by high pressure
water jetting; manholes and chambers shall be cleaned and washed.
Cleaning shall be carried out:
(i) before and after the complete pipeline, or parts of the pipeline if
permitted by the Project Manager, have been tested;
(ii) after the Temporary Works required for testing have been removed; and
(iii) after parts of the pipeline removed for testing have been reconnected.
(b) Pipelines shall be cleaned not more than 7 days before the application for
Completion Certificate for the pipeline works is submitted.
(a) A qualified polyethylene pipe layer shall mean a worker or supervisory staff
who has successfully completed the short course "Installation of Polyethylene
Pipes" organized by Hong Kong Institute Vocational Education and passed
the examination or equivalent.
(b) All connections or jointing of polyethylene pipe works must be carried out by
qualified polyethylene pipe layers. The Contractor shall employ sufficient
number of qualified polyethylene pipe layers to suit the workload of
polyethylene pipe works.
(c) The Contractor shall submit to the Project Manager within seven days a name
list and supporting document of the qualified polyethylene pipe layers
employed after commencement of polyethylene pipe works.
(d) The Contractor shall keep records of the names and supporting documents of
the qualified polyethylene pipe layers employed and shall make such records
available for inspection by the Project Manager when required.
One sample of pipe for drainage works and each type of fitting shall be
provided from each 50 pipes or fittings or part thereof in a batch.
(i) Each sample of pipes and fittings for drainage works shall be tested in
accordance with the relevant British Standard.
(i) If the result of any test required in accordance with the relevant British
Standard for pipes and fittings for drainage works does not comply with
the specified requirements for the test, one additional sample shall be
provided from the same batch and additional tests for the property shall
be carried out.
(ii) The batch shall be considered as not complying with the specified
requirements for the property if the result of any additional test does not
comply with the specified requirements for the property.
(i) One sample of aggregates for granular bed shall be provided from each
batch of aggregates for granular bed delivered to the Site.
(iii) The method of sampling shall be in accordance with BS 812: Part 102.
The results of tests for compaction fraction value of aggregates for granular
bed shall comply with the following requirements:
(i) The compaction fraction value for pipe bed not exceeding 300 mm
nominal diameter shall not exceed 0.3; and
(ii) The compaction fraction value for pipe bed exceeding 300 mm nominal
diameter shall not exceed 0.15.
6.6.4 Testing of Precast Concrete Units for Manholes, Chambers and Gullies
(i) If the result of any test required in accordance with the relevant British
Standard for precast concrete units for manholes, chambers or gullies
does not comply with the specified requirements for the test, one
additional sample shall be provided from the same batch and additional
tests for the property shall be carried out.
(ii) The batch shall be considered as not complying with the specified
requirements for the property if the result of any additional test does not
comply with the specified requirements for the property.
6.6.5 Testing of Manhole Covers, Gully Gratings and Kerb Overflow Weirs
One sample of manhole covers, gully gratings or kerb overflow weirs shall be
provided from each batch of 20 covers, gratings or weirs or part thereof
delivered to Site.
(i) Each sample of manhole covers, gully gratings or kerb overflow weirs
shall be weighed to determine the mass, a load test shall be carried out
on each sample of covering and grating to determine the resistance to
fracture.
(ii) The method of testing shall be as stated in Appendix A6.3. The test
loads shall be as stated in Table 6.6 and Table 6.7.
Manhole covers and gully gratings shall withstand the test load without
fracture or cracking.
(i) If the result of any test for mass of any manhole cover, gully grating or
kerb overflow weir does not comply with the specified requirements for
mass, every cover, grating and frame in the batch shall be weighed to
determine its mass.
(ii) If any cover, grating or weir does not comply with the specified
requirements for mass, it shall not be used in the Permanent Works.
(i) If any manhole cover or gully grating does not comply with the specified
requirements for resistance to fracture, two additional samples shall be
provided from the same batch and tested to determine their resistance
to fracture.
(ii) The batch shall be considered as not complying with the specified
requirements for resistance to fracture if the result of either additional
test does not comply with the specified requirements for resistance to
fracture.
(ii) The method of testing shall be as submitted for review without objection
by the Project Manager.
The results of tests for watertightness of penstocks shall comply with the
following requirements:
(i) there shall be no leaks through the penstock during the test; and
(ii) there shall be no leaks or damp patches visible at the joint between the
penstock and the structure during the test.
If the result of any test for watertightness of penstocks does not comply with
the specified requirements for the test, the Contractor shall investigate the
reason. Remedial or replacement work reviewed without objection by the
Project Manager shall be carried out and the penstock shall be re-tested.
(a) Gravity pipelines for drainage works shall be tested as stated in Clause
6.6.7.(b) to (h).
(b) Gravity pipelines for sewage shall be tested by the methods stated in Table
6.11 at the following times:
(i) after the pipes have been jointed and the bedding has been placed and
immediately before haunch or surround is placed or fill material is
deposited;
(ii) after haunch and surround has been placed and fill material has been
deposited and compacted; and
(iii) not more than 7 days before a Completion Certificate for the pipeline
works is applied for.
(c) Gravity pipelines for surface water shall be tested by the methods stated in
Table 6.11 at the following times:
(i) after the pipes have been jointed and the bedding has been placed and
immediately before haunch or surround is placed or fill material is
deposited; and
(ii) after haunch and surround has been placed and fill material has been
deposited and compacted.
(d) Water tests and air tests on pipelines shall be carried out on the complete
pipeline between manholes, chambers and structures; pipelines shall not be
tested in parts unless the specified test pressure will be exceeded. Short
branch pipelines shall be tested with the main pipeline and long branch
pipelines shall be tested separately.
(e) Infiltration tests shall be carried out on the complete pipeline between
manholes, chambers and structures, including manholes, chambers and
branches within the pipeline system.
(g) Visual inspections shall be carried out on the complete pipeline between
manholes, chambers and structures.
(h) Visual inspections shall be carried out by the Contractor in the presence of the
Project Manager.
(a) The results of tests on gravity pipelines for drainage works shall comply with
the following requirements:
(i) the leakage of water from the pipeline determined by the water test shall
not exceed the permitted leakage calculated in accordance with Clause
A6.4.8 of Appendix A6.4;
(ii) there shall be no discernable leakage from the pipe or from any joint
during the water test;
(iii) the air pressure shall remain above 75 mm head of water at the end of
the air test; and
(b) The Contractor shall investigate the reason for any non compliance.
Remedial or replacement work reviewed without objection by the Project
Manager shall be carried out and the pipeline shall be re-tested.
(a) Pressure pipelines for drainage works shall be tested as stated in Clause
6.6.9(b) to (g).
(i) after the pipes have been jointed and the bedding has been placed and
immediately before haunch or surround is placed or fill material is
deposited; and
(ii) after haunch and surround has been placed and fill material has been
deposited and compacted for the complete pipeline.
(c) The test stated in Clause 6.6.9(b)(i) shall not be carried out on parts of a
pipeline unless permitted by the Project Manager. The test stated in Clause
6.6.9(b)(ii) shall be carried out on the complete pipeline.
(d) The test pressure shall be as stated in the Contract. If the test pressure is not
stated in the Contract, the test pressure shall be 1.5 times the maximum
working pressure in the part of the pipeline tested.
(e) Tests shall not be carried out simultaneously on more than one pipeline in the
same trench.
(g) Testing of pressure pipelines by means of tests on individual joints shall not
be carried out instead of tests stated in Clause 6.6.9(b) to (f).
(a) The results of tests on pressure pipelines for drainage works shall comply with
the following requirements:
(i) The leakage of water from the pipeline determined by the pressure test
shall not exceed the permitted leakage calculated in accordance with
Clause A6.5.4 of Appendix A6.5.
(ii) There shall be no discernable leakage of water from the pipeline or from
any joint during the pressure test.
(b) If the result of any test on pressure pipelines for drainage works does not
comply with the specified requirements for the test, the Contractor shall
investigate the reason. Remedial or replacement work reviewed without
objection by the Project Manager shall be carried out and the pipeline shall be
re-tested.
A6.1.1 Scope
This method covers the internal inspection of pipelines by means of closed circuit
television. (CCTV)
A6.1.2 Equipment
(1) The equipment specified in Clauses A6.1.2(l) (a) to (g) shall be provided:
(a) A CCTV colour camera with integral lighting unit. The camera shall be a
type designed and constructed for the specified purpose and shall be
capable of operating in 100% relative humidity. The camera shall be
fitted with a rotating mirror for complete circumferential viewing. The
system shall be capable of producing a clear and high quality picture of
the entire periphery of the pipe on the monitor screen and recording
tape. The camera and lighting unit shall be mounted on a self-propelled
crawler or on skids linked to a manual or power operated winch.
(b) A monitor screen which displays the camera view during the inspection.
The monitor screen shall be housed in covered accommodation with
facilities for inspection by the Project Manager and others.
(c) A screen writer which displays on the monitor screen details of the
inspection including date, location, pipe material, diameter of pipe,
direction of view and comments on the condition of the pipe.
(d) A linear measuring device which displays the chainage of the camera
position automatically on the monitor screen. The device shall be
capable of measuring the chainage to within an accuracy of 0.1% of the
length of the pipeline or ±0.3 m whichever is the greater.
(f) A VHS video recording system to record the inspection and information
displayed on the monitor screen.
(1) The procedure shall be as specified in Clause A6.1.3 (1) (a) – (d)
(a) The camera shall be moved through the pipeline in the direction
directed by the Project Manager at a speed not exceeding 0.15 m/s. If
the camera cannot pass through the complete pipeline in one operation,
the inspection shall be carried out from both ends of the pipeline.
(b) The camera shall be stopped whenever directed by the Project Manager
to allow inspection by the Project Manager.
(c) The video system shall be operated during the complete inspection to
provide a continuous record of the inspection and information on the
monitor screen.
(1) Records of the inspections shall be kept by the Contractor on the Site and a
report shall be submitted to the Project Manager for review within 14 days of
completion of the inspection. The report shall contain the following details:
(b) tables listing details of inspection, including date, location, pipe material,
diameter of pipe, chainage, manholes, junctions and other features and
the condition of pipes and joints; the condition of pipes and joints shall
be illustrated by a coding systems in accordance with the `Manual of
Sewer Condition Classification' (1980) published by the U.K. National
Water Council, and
(c) a summary showing the number and type of defects in each pipeline
inspected.
(2) The following items shall be submitted at the same time as the report:
(b) photographs of the monitor screen including date and chainage; the
photographs shall be 3R size and shall be mounted in photograph
albums.
A6.2.1 Scope
A6.2.2 Apparatus
(1) a steel open-ended cylinder, 150 mm internal diameter by 250 mm high, with
a wall thickness of not less than 3.5 mm;
A6.2.3 Procedure
(1) The procedure shall be as described in Clauses A6.2.5 (1) (a) – (e)
(a) The sample shall be placed on a clean surface and shall be divided by
quartering or by using a riffle box to obtain a specimen weighing
approximately 10 kg.
(b) The cylinder shall be placed on a firm level surface and shall be filled
without tamping with material taken from the sample. Surplus material
shall be struck off level with the top of the cylinder, and cleared from the
area around the cylinder.
(c) The cylinder shall be lifted clear of the contents and placed alongside
the material.
(d) Approximately one quarter of the material shall be placed in the cylinder
and compacted using the rammer until no further compaction can be
achieved. The procedure shall be repeated for each of the remaining
three quarters of the material. The top surface shall be compacted as
level as practicable.
(e) The distance (d) from the top of the cylinder to the top surface of the
material shall be measured to the nearest 1 mm.
The compaction fraction value of the material shall be calculated from the equation:
where:
- d is the distance from the top of the cylinder to the top surface of the material
(mm),
- h is the height of the cylinder (mm).
The following shall be included in the report submitted to the Project Manager:
(5) statement that the test method used was in accordance with this General
Materials and Workmanship Specification.
A6.3.1 Scope
A6.3.2 Equipment
(1) manufacturer's recommended test frame for the manhole cover or gully
grating or a fabricated test frame of a type reviewed without objection by the
Project Manager which will simulate the normal conditions of use of the cover
or grating;
(2) circular hardwood bearing block faced with hard rubber or other resilient
material. The diameter of the block shall be as stated in Table 6.6 or Table
6.7 for the relevant cover or grating. The block shall be sufficiently rigid to
ensure that the load is equally distributed over the whole area of the block;
(4) equipment for measuring the loads applied, readable and accurate to 0.05 t or
2% of the specified test load, whichever is greater.
A6.3.3 Procedure
(1) the full bearing area of the frame shall be rigidly supported;
(2) the cover or grating shall be placed in the frame. The bearing block shall be
placed centrally on the cover or grating;
(3) the specified test load as stated in Table 6.6 and 6.7 shall be applied without
shock; and
(4) the specified test load shall be maintained for at least 30 seconds and
removed.
The following shall be induced in the report submitted to the Project Manager:
(2) the load applied, to the nearest 0.05 t or 2% of the specified test load,
whichever is greater;
(4) statement that the test method used was in accordance with this General
Materials and Workmanship Specification.
General Materials & Workmanship Specification 41/51 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 6 – Drainage Works
APPENDIX A6.4
A6.4.1 Scope
This method covers water tests, air tests, visual inspections and infiltration tests on
gravity pipelines for drainage works.
A6.4.2 Equipment
(5) measuring vessel for water test, readable and accurate to 0.01 litre;
(7) trolleys to obtain access inside pipelines for visual inspections. Mechanical
fans shall be provided to ensure that an adequate air supply is available;
internal combustion engine driven fans shall be fitted with a flexible exhaust or
other methods of keeping exhaust fumes clear of the fresh air intake.
(1) debris and water shall be removed from the pipeline; and
(2) openings to the pipeline shall be sealed using expanding disc stoppers or air
bags and the seals secured against movement.
(1) the pipeline shall be filled with water and shall be kept filled for two hours
before testing starts to allow absorption to take place;
(2) test pressure of 1.2 m head of water above the soffit of the pipe at the high
end shall be applied at the standpipe and maintained for 30 minutes; the test
pressure applied shall not exceed 6 m head of water at the invert of the low
end of the pipe;
(3) the head of water at the standpipe shall be topped up at 5 minute intervals
during the test, and shall be filled to the specified head at the end of the test
period; the amounts of water added to the standpipe shall be measured using
the measuring vessel; and
(1) air shall be pumped into the pipeline until a test pressure of slightly more than
100 mm of water is registered on a U-tube manometer connected to the
pipeline. Five minutes shall be allowed for stabilisation of the air temperature,
and the air pressure shall then be adjusted to 100 mm of water; and
(2) the pressure shall be read from the U-tube at the end of a five-minute period
without further pumping.
The inside of the pipeline shall be inspected visually, and infiltration or damage to
pipes or joints shall be recorded.
The procedure for the infiltration test shall be in accordance with BS 8005: Part 1
Clause 13.6.
A6.4.8 Calculation
The permitted leakage of water from the pipeline during the water test shall be
calculated from the equation:
t
Permitted leakage = d x 1 x x P litre
60
where:
The following shall be included in the report submitted to the Project Manager:
(3) test pressure applied during the water test to the nearest 0.01 m, and during
the air test to the nearest 1 mm head of water;
(5) leakage and permitted leakage for the water test to the nearest 0.1 litre;
(7) details of any discernable leakage of water from the pipe or from any joint
during the water test; and
(8) statement that the test method used was in accordance with this General
Materials and Workmanship Specification.
A6.5.1 Scope
This method covers the determination of the leakage of water from pressure
pipelines for drainage works by means of a pressure test.
A6.5.2 Equipment
(5) pressure gauge, readable and accurate to 0.01 m head of water. The gauge
shall be either a conventional circular type of at least 300 mm diameter or
shall be a digital indicator type; and
A6.5.3 Procedure
(1) pipes and valves shall be cleaned and the operation of valves shall be
checked. Air valves shall be isolated.
(2) blank flanges or caps shall be fixed to the ends of the pipeline, or part of the
pipeline, to be tested. Tests shall not be made against closed valves.
(3) the blank flanges and caps and closed valves against which tests are made
shall be secured with struts and wedges against temporary concrete blocks or
other anchors. The blocks shall be completed and shall have hardened
sufficiently before testing starts. Thrust and anchor blocks, pipe straps and
other devices required to prevent movement of pipes and fittings shall be
completed before testing starts.
(4) the pipeline shall be filled with water and all air shall be removed; measures
shall be taken during filling to provide free outlets for air and to prevent water
hammer.
(5) the pressure in the pipeline shall be increased to working pressure and the
pipeline shall remain filled at this pressure for 2 hours to allow absorption to
take place and to achieve conditions which are as stable as practicable.
(6) the pressure in the pipeline shall be increased slowly by pumping water into
the pipeline using a force pump until the specified test pressure is reached at
the lowest part of the pipeline being tested.
(8) at the end of the 1 hour period the pressure shall be increased, if necessary,
to the specified test pressure and pumps and water supply points shall be
disconnected.
(9) the pipeline shall be left in this condition for a test period of 1 hour; no water
shall be allowed to enter the pipeline during the test period.
(10) at the end of the test period the pressure in the pipeline shall be recorded.
(11) the pumps and water supply points shall be reconnected and the pressure
shall be increased to the specified test pressure.
(12) water shall be drawn off from the pipeline until the pressure in the pipeline is
the same as at the end of the test period. The leakage of water from the
pipeline shall be measured as the amount of water drawn off.
A6.5.4 Calculation
(1) The average test pressure (P) shall be calculated as the average of the
specified test Pressure and the pressure at the end of the test period.
(2) The permitted leakage of water from the pipeline during the pressure test shall
be calculated from the equation:
t
Permitted leakage = d x 1 x x P litre
12
where:
The following shall be included in the report submitted to the Project Manager:
(2) the location and length of pipeline tested to the nearest 0.3 m;
(4) the specified test pressure to the nearest 0.01 m head of water;
(5) the pressure at the end of the test period to the nearest 0.01 m head of water;
(6) the average test pressure to the nearest 0.01 m head of water;
(8) details of any discernable leakage of water from the pipeline during the test;
and
(9) that the test method used was in accordance with this General Materials and
Workmanship Specification.
1. General
1.1 The manufacturer for the supply of polyethylene pipes and fittings shall
operate a quality system relating to the relevant part(s) of the specification
stated hereunder in accordance with BS EN ISO 9002 or similar equivalent
standard. The manufacturer's quality assurance certificates issued by an
independent third party certification body shall be submitted to the Project
Manager for review without objection. Such certificates shall be valid at the
time the pipes and fittings are manufactured.
1.2 Polyethylene pipes and fittings shall be used aboveground for the
conveyance of sewage discharge.
2. Definitions
2.1 Nominal outside diameter of a polyethylene pipe shall mean the minimum
mean outside diameter of the pipe as described in Clause 3.1 of IS0 16 1-1.
2.2 Nominal wall thickness of a polyethylene pipe shall mean the minimum wall
thickness of the pipe as described in Clause 3.4.5 of BS IS0 11922-1.
2.3 The Standard Dimension Ratio (SDR) of a polyethylene pipe shall mean the
ratio of its nominal outside diameter to its nominal wall thickness as described
in Clause 3.8 of IS0 161-1.
2.4 WIS shall mean the Water Industry Specification produced and published by
WRc.
3. Polyethylene Pipes
3.1 PE80 and PE 100 pipes with nominal outside diameter from 90mm to
1000mm inclusive shall conform to IS0 4427.
3.2 PE80 and PE100 pipes shall have a SDR of 17.6 and have nominal pressure
rating as follows:
PEl00 - 10 bar (PNl0)
3.3 The colour for polyethylene pipes shall be black within the range below:
3.4 The tolerance on the nominal outside diameter of polyethylene pipes shall be
in accordance with Grade B of BS ISO 11922-1.
3.7 Melt flow rate of PE80 and PE 100 pipes tested at a temperature of 190°C
under a nominal load of 5kg shall be within the range of 0.2g/10 min to
1.3g/10 min.
4.1 All fittings for polyethylene pipes shall have a pressure rating the same as or
higher than the nominal pressure rating of the pipes. The fittings shall be
supplied with complete set of accessories including insert, liners, joint rings,
flange gaskets, studs, bolts and nuts, etc. whatever appropriate.
4.2 The flanges of all fittings shall be constructed in such a way that they may be
attached to flanges designated PN16 whose dimensions conform to Table 9
of BS EN 1092-2. One complete set of bolts and nuts and one gasket shall
be supplied with each flange of flanged fittings. The strength of bolts shall be
Grade 4.8 and the strength of nuts shall be Grade 4 complying with BS 4190.
The bolts and nuts shall be hot dip galvanized or have other protective
coatings reviewed without objection by the Project Manager.
4.3.2 Melt flow rate of PE80 and PE100 electrofusion fittings tested at a
temperature of 190°C under a nominal load of 5kg shall be within the range of
0.2g/10 min to 1.3g/10 min.
4.3.3 Notwithstanding Clause 5.1.6 of WIS 4-32-14, the fittings shall be capable of
being fused in the tropics.
4.3.4 The design of fitting terminals and shrouds shall be similar to that stated in
Clause 5.2.3 of WIS 4-32-14. Other designs of terminals will only be
considered if the Contractor can demonstrate that the appropriate lead
adaptor is readily available such that electrofusion of their fittings can be
conducted using common electrofusion control units available in the market.
4.3.5 All electrofusion fittings shall be black in colour within the range as specified
in Clause 3.3 of this Appendix A6.6.
4.4.1 Compression fittings with external and/or internal threads shall be compatible
with pipes and fittings threaded to BS 21.
4.5.1 Mechanical fittings for polyethylene pipes of nominal outside diameter 90mm
and above shall be Type 1 fittings conforming to WIS 4-24-01.
4.5.2 Mechanical fittings shall be coated with a minimum thickness of 250 microns
of epoxy or plastic based coating complying with the performance
requirement of WIS 4-52-01.
5.1 A sample for each of the polyethylene pipes and fittings supplied shall be
submitted to the Project Manager for review without objection before placing
material order.
5.2 If required, a copy of the latest Manufacturer's type test reports required
under each of the above ISO and WIS shall be submitted to the Project
Manager for information.
5.3 For all non-metallic components of the polyethylene pipes and fittings
including coatings, certificates issued by an independent testing
laboratory/inspection authority showing compliance with BS 6920 shall be
submitted to the Project Manager for review without objection.
6. Markings
6.1 Markings on the polyethylene pipes and fittings shall be in accordance with
the relevant clauses in the ISO or WIS appropriate to the pipes and fittings
supplied.
6.2 Notwithstanding Clause 8 of ISO 4427, the pipes series in SDR shall be
marked on the pipes.
7. Packaging of Fittings
8.1 The quality control tests listed in the following clauses of WIS shall be subject
to inspection by an independent inspection agent:
8.2 For quality control on manufacturing of the pipes, the following tests listed in
ISO 4427 shall be subject to inspection by an independent inspection agent:
In addition, the internal and external surfaces of the pipes shall be smooth
and free from defects which might otherwise impair their performance in
service.
8.3 For quality control on manufacturing of the compression fittings, the following
tests listed in ISO 14236 shall be subject to inspection by an independent
inspection agent:
8.4 Polyethylene materials for both PE80 and PE100 shall be tested in
accordance with the Chlorine Water Test specified in Clause 9.8 of the
Japanese Industrial Standard (JIS) K6762 and the performance of the
polyethylene materials shall comply with the chlorine-water resistance for
single wall pipe specified in Clause 5 of the JIS K6762. Test certificates shall
be submitted to the Project Manager for review without objection.
Areas of fill are areas within the Site, including areas in embankments, platforms
and slopes and in excavations for structures, pits and trenches, in which fill material
is deposited and compacted as part of the Permanent Works.
“Earthworks final surface” is the surface to which the work included in Section 7 is
finished. “Formation” is that part of the earthworks final surface on which a
pavement, structure or utility, is constructed, or on which the blinding or bedding for
a pavement, structure or utility is placed.
Earthworks material may consist of soil, rock, crushed concrete or crushed inert
demolition material which is on or below the Site at the commencement of the
Contract, or which is imported to the Site to carry out the Works.
7.1.4 Topsoil
“Topsoil” shall mean the surface material which contains humus and supports
vegetation.
“Rock” shall mean all naturally occurring hard strata which would normally be
removed by blasting, by ripping, by chemical, gas or mechanical bursting agents, by
hydraulic breaker, by pneumatic drills or by wedges and sledge hammers if
removed by hand.
Boulders are isolated volumes of Rock which exceed 0.2m³ and are contained in a
matrix of “Material other than Rock”.
“Material other than Rock” shall mean material which cannot be classified as
Topsoil or Rock.
Public fill shall mean the inert material arising from construction and demolition
activities such as site clearance, excavation, construction, refurbishment,
renovation, demolition and roadworks. Public fill comprises material including stone,
rock, masonry, brick, concrete, soil and other inert material. There is no size
limitation on the public fill, and a small amount of timber mixed with otherwise
suitable material is permissible. The public fill may also consist of wet soil.
(a) Fill material, other than public fill, shall consist of naturally occurring or
processed material which at the time of deposition is capable of being
compacted in accordance with the specified requirements to form stable areas
of fill.
(i) material susceptible to volume change, including marine mud soil with a
liquid limit exceeding 65% or a plasiticity index exceeding 35%, swelling
clays and collapsible soils;
(c) The different types of fill material shall have the particle size distributions
within the ranges stated in Table 7.1.
(d) Special fill material shall consist of material which has a liquid limit not
exceeding 45%, a plasticity index not exceeding 20% and a coefficient of
uniformity exceeding 50.
(e) Granular fill material shall consist of clean, hard, durable material.
(f) Rock fill material shall consist of pieces of hard, durable rock of which not
more than 30% by mass is discoloured or shows other evidence of
decomposition. Crushed rock or crushed concrete may be permitted subject
to review without objection by the Project Manager.
(g) The Contractor will not be permitted to erect a crushing plant under the Contact.
(h) The soluble sulphate content of fill material placed within 500 mm of concrete,
cement bound material or cementitious material shall not exceed 1.9 grams of
sulphate, expressed as SO3, per litre.
(i) The total sulphate content, expressed as SO3, of fill material placed within
500 mm of metalwork shall not exceed 0.5% by mass.
(j) The use of public fill as fill material for earthworks shall only be permitted if the
fill material complies with the particular requirements stated in the Contract
and is reviewed without objection by the Project Manager.
7.3 SUBMISSIONS
(iii) use of different types of excavated material and sources of imported fill
material;
(iv) arrangements for stockpiling excavated material and fill material and for
disposing of earthworks material;
(b) Where the Contractor proposes to form temporary slopes or proposes any
form of temporary support to earthworks, then he shall submit full supporting
calculations and the provisions of Section 2 of this General Materials and
Workmanship Specification shall apply.
7.4 WORKMANSHIP
(a) Earthworks material within the Site at the commencement of the Contract
shall remain the property of the Employer except as stated in Clause 7.4.1(b).
The Contractor shall be fully responsible for the design, installation, dismantling and
removal of all temporary supporting systems for earthworks. The Contractor shall
submit to the Project Manager for review without objection the full supporting
calculations for any proposed temporary slopes or any form of temporary support to
earthworks and the provisions of Section 2 of this General Materials and
Workmanship Specification shall apply.
The Contractor shall provide and maintain temporary access roads and temporary
drainage and shall divert and reinstate permanent drainage systems. Temporary
access roads shall be provided with drainage ditches over their full length. Details of
any such temporary works shall be submitted to the Project Manager and his
consent in writing shall be obtained before construction commences.
(a) Earthworks material shall not be handled or stored in a manner which will
result in segregation, deterioration, erosion or instability of the material.
(b) Different types of earthworks material shall be kept separate from each other.
Earthworks material which is suitable for use as fill material shall be
maintained in a suitable condition and shall not be contaminated.
(a) Earthworks after site clearance, excavation or filling and earthworks material
after excavation shall be kept free from water and shall be protected from
damage due to water and from exposure to weather conditions which may
affect the earthworks or earthworks material. The measures to be taken shall
include the following:
(iv) surface water flowing into the Site and within the Site shall be
intercepted and diverted from the Site to a suitable discharge point;
(vi) all drainage works shall be kept clear of debris and silt; and
(vii) where partially completed drainage works discharge within the Site a
temporary conduit shall be provided to the discharge point.
(b) Excavations for structures, pits and trenches shall not be carried out on or
adjacent to slopes unless measures are taken to drain the excavation and to
prevent water from the excavation entering the slope.
(i) The Contractor shall note the existence of any instrumentation, for
example, piezometers, inclinometers and surface movement
monuments, and shall install a prominent marker post at each such
instrument.
(iv) Certain instruments shall be removed as the Works proceed but not
until the Project Manager has confirmed that it is necessary for the
progress of the Works in each case.
(a) Earthworks material which has been used, or is required for use, in the
Permanent Works and which is allowed to become unsuitable such that in the
opinion of the Project Manager it no longer complies with the specified
requirements for that type of material shall be replaced or dealt with by
methods reviewed without objection by the Project Manager.
(b) Earthworks material which is not stated in the Contract to be excavated and
which the Contractor causes or allows to deteriorate such that in the opinion
of the Project Manager the Permanent Works will be affected shall be
replaced or dealt with by methods reviewed without objection by the Project
Manager.
(c) Material provided to replace earthworks material which has been allowed to
become unsuitable or which the Contractor causes or allows to deteriorate
shall be an equivalent material reviewed without objection by the Project
Manager. The replacement material shall have the same volume after
compaction as the material replaced.
(a) Earthworks material which is not stated in the Contract to be excavated but
which in the opinion of the Project Manager has inadequate strength,
durability or stability shall be dealt with by additional excavation and filling as
stated in Clause 7.4.7(b) or by stabilisation as stated in Clause 7.4.7(c).
(b) Additional excavation shall be carried out and the resulting voids shall be
dealt with as follows:
(i) general fill material, fine fill material or special fill material shall be
deposited and compacted below areas of fill and below formations other
than in rock;
(c) Stabilisation shall be carried out using rock fill material (Grade 400) deposited
directly into the original unstable material and compacted to form a stable
foundation on which to construct the subsequent work.
(d) During the wet season where temporary bare earth slope faces are
unavoidable they shall be protected with impermeable sheeting well secured
against the wind. Where slope faces steeper than 50º and higher than 5 m are
to be temporarily exposed for more than two weeks temporary hard surfacing,
such as chunam, shall be provided and temporary drains shall be installed.
Earthworks material which is required for use in the Permanent Works as fill
material shall not be removed from the Site. The Contractor shall notify the Project
Manager before any earthworks material is removed from the Site.
7.4.10 Disposal of Surplus Fill and Fill Containing Materials as Defined in Clause
7.2.1(b)
(b) Rock fill material which cannot be incorporated in the Works shall be deposited
in the stockpiles designated by the Project Manager.
(c) Fill materials other than rock fill material and materials as defined in Clause
7.2.1(b)(i) to (vi) which cannot be incorporated in the Works shall be deposited
and compacted in accordance with Clause 7.4.26 in the stockpiles designated
by the Project Manager.
(d) Materials as defined in Clause 7.2.1(b)(i) to (vi) shall become the property of
the Contractor who shall dispose of such materials off-Site.
(a) Excavated material required for use in the Permanent Works which is capable
of being selected, processed and mixed to make it suitable for use as fill
material shall not be used for any other purposes.
(c) Excavated material which is required for use in the Permanent Works as fill
material and which the Project Manager permits to be removed from the Site
or used for other purposes shall be replaced by an equivalent material
reviewed without objection by the Project Manager. The replacement material
shall have the same volume after compaction as the material which is
replaced.
Boulders which project through the earthworks final surface or formation shall be
dealt with as excavation proceeds by methods reviewed without objection by the
Project Manager. Boulders shall not be left protruding.
7.4.13 Excavation
(a) Excavations shall be carried out by hand adjacent to, and around utilities that
are known, proven or suspected to exist.
(a) Excavations for structures, pits and trenches shall be the minimum size
necessary to construct the Permanent Works.
(b) The length of trench excavation left open at any one time shall not exceed
that permitted by the Project Manager.
(c) Trenches for utilities in areas of fill shall not be excavated until the fill material
has been deposited and compacted up to the earthworks final surface or
formation or up to 1 m above the top of the utility, whichever is lower.
(d) The sides of pits and trenches shall be adequately supported at all times.
Alternatively except where the Contract expressly requires otherwise they may
be suitably battered.
(e) The bottom of all excavations shall be levelled carefully and stepped or
benched horizontally as shown on the Employer’s Drawings. Any pockets of
soft material or loose rock in the bottoms of pits and trenches shall be removed
and the resulting cavities and any large fissures filled with Grade 10 concrete.
After the placing of any blinding concrete required by the Contract, no trimming
of the side faces shall be carried out for 24 hours.
(i) Any excavation greater than the net volume required for the works as
described in the Contract.
(b) Parallel holes shall be drilled in the final excavation face. The spacing of the
holes shall be determined in relation to the diameter of the drillhole and shall
be within the range of 400-1000 mm.
(c) Before starting splitting along the final excavation face in any given type and
condition of rock, trials shall be carried out at least 6 m away from the final
face to produce results acceptable to the Project Manager, with a minimum
trial length of 4 m. The following details of the procedures used shall be
submitted to the Project Manager at least 24 hours before starting to drill in
the final excavation face:-
(d) After review without objection by the Project Manager of the trial results, the
procedures used shall be the same in all respects as in the trial. Drilling a set
of rock-splitting holes in the plane of the final rock-face shall not proceed until
at least 50% of the face formed by the previous adjacent splitting has been
exposed and the results assessed.
(f) Chemical grout holes shall not be charged until the rock broken by previous
operations has been mucked out.
(g) When the chemical grout has expanded fully, the rock in front of the plane of
the drillholes shall be broken out and all traces of the solidified chemical
removed.
(h) After drilling the rock-splitting holes, (for uncharged drillholes) the rock in front
of the plane of the drillholes shall be broken out by a mechanical rock breaker.
General Materials & Workmanship Specification 9/37 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 7 - Earthworks
7.4.17 Surface Preparation for Fill Material
(b) soft spots, boulders and other materials which are unsuitable or unstable shall
be removed;
(d) benches shall be cut and sub-soil drainage systems installed as stated in the
Contract;
(e) voids shall be dealt with as stated in the Contract or instructed by the Project
Manager; and
(f) topsoil, soil, material other than rock and all material which is capable of being
scarified, shall be scarified to a depth of 200 mm and compacted to the same
standard as the fill material which is to be deposited.
The Contractor shall notify the Project Manager before deposition of fill material
starts in any area of fill.
Haulage of fill material to an area of fill shall commence only when the specified
requirements for relative compaction of the fill material have been achieved.
(a) Fill material obtained from excavations within the Site shall be deposited in its
final location as soon as practicable after it has been excavated.
(c) Layers of fill material shall be horizontal, except for any gradient required for
drainage, and the thickness of each layer shall be uniform over the area to be
filled.
(d) Except in excavations for structures, pits and trenches, if the difference in
level between adjacent areas to be filled exceeds 1 m the edge of the higher
area shall be benched before fill material is placed against it.
(e) The construction of the Works shall be controlled in such a manner that any
compaction of the fill material, including that resulting from the passage of
Contractor's Equipment or haulage vehicles is uniform.
(g) Isolated boulders each within the range 0.015 cu m to 0.10 cu m in size may be
incorporated in embankments not of rockfill at the discretion of the Project
Manager provided that the specified compaction requirements are met and no
stone exceeding 0.015 cu m shall be placed less than 2 m below formation
level of carriageways or hardshoulders.
(h) In reclamation, before any other material is dumped within 90 m of any seawall,
material shall first be dumped immediately behind the wall to a width of 15 m to
30 m by working outwards from the wall unless the Project Manager directs
otherwise. If directed, the Contractor shall also dump material in bunds to form
self-contained areas before filling the remaining area.
(i) An accurate and up-to-date record showing dates, weather conditions,
approximate elevations, source of materials, compactive effort etc shall be kept
by the Contractor showing when fill is placed in various locations within the Site.
This record shall be available for inspection by the Project Manager. The
Contractor shall also record the results of all compaction and in-situ density
tests and shall identify these results with the various locations and elevations at
which fill material has been placed and the location from which the fill material
was obtained.
7.4.21 Overfilling
In areas of fill formed of fill material other than rock fill material, earthworks final
surfaces sloping at a gradient exceeding 1 vertical to 3 horizontal shall be formed
by overfilling and cutting back after compaction. Over-filling shall extend beyond the
earthworks final surface by a horizontal distance of 0.5 m or two times the thickness
of the compacted layer, whichever is greater.
(a) Except as stated in Clause 7.4.22(d), fill material deposited within 0.5 m of a
structure or utility shall be fine fill material unless otherwise stated in the
Contract. In addition, the material may contain up to 5% by weight of fresh,
slightly decomposed or moderately decomposed rock fragments of up to 200
mm provided that these do not cause any damage to structures, nor do they
interfere with the compaction requirements.
(b) Fill material shall not be deposited adjacent to or above structures or utilities
until the construction of the structure or utility is sufficiently advanced to
accept the imposed forces without disturbance or damage.
(c) Fill material shall be deposited evenly on all sides of structures and utilities
and in such a manner that the structure or utility is not disturbed or damaged.
(d) Unless otherwise stated in the Contract, fill material around water, sewage
and drainage pipes which are constructed as part of the Permanent Works
shall be special fill material as defined in Clause 7.2. Fill material shall be
deposited in layers not exceeding 100 mm thick to a level of 300 mm above
the top of the pipe. Fill material shall be deposited in such a manner that the
layer on one side of the pipe is not more than 100 mm higher than the layer
on the other side.
General Materials & Workmanship Specification 11/37 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 7 - Earthworks
(e) Backfill material more than 300 mm above the top of the pipe should be
general fill material compacted in layers not exceeding 250 mm thick.
(f) Fill material shall be brought up to original ground level or the earthworks final
level or as directed by the Project Manager.
(a) The final compacted thickness of each layer of rock fill material shall exceed
1.5 times and shall not exceed twice the nominal grade size of the rock fill
material.
(b) The surface voids of each layer of rock fill material shall be filled with
fragments of rock before the next layer is deposited. The final surface of rock
fill material shall also be blinded with fine fill material.
7.4.24 Deposition of Fill Material in Excavations for Structures, Pits and Trenches
(a) Trenches and pits cut in carriageways and footways, which are to remain
open to traffic only during the term of the Contract, shall be backfilled and
compacted, to the underside of the adjacent pavement construction or to a
level 260 mm below the surface, whichever is the lower. The next layer of
backfilling shall be sub-base to a level 60-100 mm, as directed by the Project
Manager, below the surface of adjacent construction.
(b) A tack coat of bituminous emulsion shall be applied to the surface of the
compacted sub-base and the edges of the existing pavement except the
edges of the friction course exposed by the excavation. Tack coating shall be
applied as specified in Clause 9.5.6(d).
(a) Fill material in areas of fill shall be compacted in layers to a stable condition
as soon as practicable after deposition and in a manner appropriate to the
location and to the material to be compacted.
(b) The Contractor shall notify the Project Manager before the next layer is
deposited on each layer of compacted fill material.
7.4.27 Compaction of General Fill Material with a Large Portion of Coarse Material
(a) General fill material with material of which less than 90% passes a 20 mm BS
test sieve, where it is not possible to determine the moisture content and
maximum dry density according to the testing methods stated in Appendices
A7.1 to A7.5, shall be compacted to the requirements of Sub-Clauses (b), and
(c), or (d) of this clause.
(b) Spread and level each horizontal layer of general fill material with a thickness
not less than 1.5 times of the maximum size of the general fill material and not
exceeding the maximum depth of compacted layer in accordance with Table
7.2. If this criterion is not met due to the presence of over-sized coarse
material in the general fill, the over-sized coarse material shall be removed or
broken down to sizes acceptable to the Project Manager. Each layer shall be
systematically compacted by a vibratory roller with the stipulated minimum
number of passes corresponding to the minimum static load per 100 mm
width of the roller.
(c) The number of passes of the roller shall only be counted when the roller has
travelled on the material to be compacted at a speed of not more than 2 km
per hour with full vibration. Plant other than a vibratory roller used to carry out
material spreading or to provide some preliminary compaction only to assist
the use of heavier plant shall be disregarded in counting the number of
passes.
(d) Variation from the method or the use of plant different from that specified in
Sub-Clause (b) of this Clause will be permitted only if the Contractor
demonstrates by Site trials that equivalent compaction is achieved by the
alternative method. The procedure to be adopted for these Site trials shall be
agreed with and reviewed without objection by the Project Manager.
(e) Without prejudice to the General Conditions and in order that the Project
Manager may make proper provision for the supervision of compaction in the
permanent work, the Contractor shall, not less than 48 hours before he
proposes to carry out compaction processes, apply in writing to the Project
Manager for permission to do so.
(g) If more than one class of material is being used in such a way that it is not
practicable to define the areas in which each class occurs, compaction plant
shall be operated as if only the material which requires the greatest
compactive effort is being compacted.
Fill material other than rock fill material and material as stated in Clause 7.4.27(a)
shall be at optimum moisture content during compaction. Fill material at a moisture
content within ± 3% of the optimum moisture content, may be acceptable provided
that it is capable of compaction, in accordance with the specified requirements, to
form stable areas of fill.
(a) Fill material shall be compacted in such a manner that structures or utilities
are not disturbed or damaged.
(b) Fill material around water, sewage and drainage pipes which are constructed
as part of the Permanent Works shall be compacted by hand-rammers or
manually operated power equipment. Fill material within 300 mm above the
top of sewage and drainage pipes shall be compacted to obtain a relative
compaction of at least 85% throughout.
(a) Every layer of rock fill material shall be compacted by at least eight passes of
a vibrating roller or by other equivalent compaction method reviewed without
objection by the Project Manager. The final surface of rock fill material shall
be compacted by at least two additional passes of a vibrating roller or by other
equivalent compaction method reviewed without objection by the Project
Manager.
(b) Vibratory rollers used for the compaction of rock fill material shall have a static
load per 100 mm width of roll of at least 2 kN for layers with a compacted
thickness not exceeding 500 mm and at least 4 kN for layers with a
compacted thickness exceeding 500 mm.
(b) Except in excavations in rock and in areas of fill formed of rock fill material or
fill material as stated in Clause 7.4.27(a), formations shall be compacted to
obtain a relative compaction of at least 98% to a depth of 200 mm below the
formation.
(c) Proof rolling shall be carried out on formations unless otherwise reviewed
without objection by the Project Manager. The Project Manager shall be
notified prior to commencement of proof rolling. The formation shall be rolled
by at least two passes of a non-vibrating rubber tyred roller. The roller shall
have a static load per 100 mm width of roll of at least 4 kN and shall travel at
a speed not exceeding 2 km/h. Any defect in the formation which is revealed
during proof rolling by deformation of the formation which in the opinion of the
Project Manager is excessive shall be made good as directed by the Project
Manager.
(d) After all other formation work and testing have been completed and damage
caused by testing reinstated, formations for pavements shall be rolled with
one pass of a smooth steel-wheeled non-vibrating roller. The roller shall have
a load per 100 mm width of roll of at least 2 kN.
(f) Surface irregularities in formation after trimming of the rock excavation shall be
regulated to the requirements of this Section with granular fill material, no-fines
concrete or lean concrete as determined by the Project Manager.
(d) In areas of shallow filling where after removal of topsoil the ground level is
within 300 mm of the earthworks final surface level, construction traffic shall not
use the surface unless the Contractor brings up and maintains the surface level
at least 300 mm above the earthworks final surface level. Any damage to the
subgrade arising from such use shall be made good by the Contractor with
material having the same characteristics as the damaged material.
(a) Earthworks final surfaces and formations shall be within the tolerances stated
in Table 7.3 of the specified lines and levels. The tolerances for formations do
not apply for pipes or preformed structures which require support over their
complete length or area.
Tolerance (mm)
Type of surface Method of forming surface
+ -
Excavation except in rock 0 25
Formations for structures and Excavation in rock 0 150
utilities Deposition and compaction of fill
0 25
material
Formations for pavements Excavation except in rock 0 50
including carriageways, footways, Excavation in rock 0 150
cycletracks, paved areas, aircraft Deposition and compaction of fill
0 50
pavements and railway trackbeds. material
Earthworks final surfaces other Excavation except in rock 0 100
than formations, with a gradient Excavation in rock 0 200
not exceeding 1 vertical to 10 Deposition and compaction of fill
0 100
horizontal material
Excavation except in rock 100 100
Excavation in rock 100 200
Other earthworks final surfaces
Deposition and compaction of fill
100 100
material
(a) The Contractor shall note the existence of any instrumentation (e.g.
piezometers, inclinometers and surface movement monuments) shown on the
Employer’s Drawings and shall install a prominent marker post at each such
instrument.
The Contractor shall form trenches for the installation of utilities at locations where
excavation is in hard materials. He shall programme the trench excavation so that it
is completed in advance of the work by the utility undertaking. He shall backfill the
trenches with fine fill material in horizontal layers and compact as directed by the
Project Manager.
A batch of fill material is any quantity of fill material of the same type and which has
similar properties throughout. For the purpose of testing for moisture content and
relative compaction a batch shall, in addition to the above, be fill material which is
deposited in a single layer in any area of fill presented by the Contractor for testing
on one occasion.
(a) Each sample of fill material shall consist of at least four increments taken from
different parts of the batch. The increments shall be combined and thoroughly
mixed and shall then be divided by quartering or by using a riffle box to obtain
specimens of an appropriate size to carry out the individual tests.
(b) The size of samples of fill material other than rock fill material shall be in
accordance with Section 2.5 in Geospec 3. Each sample of rock fill material
of grade size not exceeding 200 shall have a mass of at least 250 kg and
each sample of rock fill material of grade size exceeding 200 shall have a
mass of at least 1000 kg.
All tests as required by the Project Manager shall be carried out by a HOKLAS
accredited laboratory reviewed without objection by the Project Manager.
7.5.4 Samples: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient
of Uniformity, Sulphate Content
Samples of fill material to be tested for particle size distribution, liquid limit, plasticity
index, coefficient of uniformity and sulphate content shall be delivered at least 14
days, before deposition of the fill material starts. The number of samples to be
provided from each batch shall be as stated in Table 7.4.
7.5.5 Testing: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of
Uniformity, Sulphate Content
(a) Each sample of fill material taken as stated in Clause 7.5.4 shall be tested to
determine the particle size distribution. In the case of special fill material
testing shall include calculation of the coefficient of uniformity as stated in
Clause 7.5.5(d). Each sample of fill material other than rock fill material shall
be tested to determine the liquid limit and the plasticity index of that portion of
the fill material passing a 425m BS test sieve. Each sample of fill material
which will be deposited within 500 mm of concrete, cement bound material,
cementitious material or metalwork shall be tested to determine the soluble
sulphate content.
(c) The particle size distribution of fill material passing a 75mm BS test sieve
shall be determined in accordance with a test specified in Section 3 in
Geospec 3, whichever as instructed by the Project Manager. The size of
particles of fill material which do not pass a 75 mm BS test sieve shall be
taken as the largest dimension measured in any plane.
(d) The coefficient of uniformity (Cu) shall be calculated from the equation:
Cu = D60/D10
Where:
- D60 and D10 are the equivalent sieve sizes in millimetres, interpolated
from the particle size distribution curve, through which 60% and 10% of
the fill material would pass respectively.
(a) If the result of any test for soluble sulphate content of fill material does not
comply with the specified requirements for soluble sulphate content, each
sample shall be tested to determine the total sulphate content.
(b) If the result of any test for particle size distribution, liquid limit, plasticity index,
coefficient of uniformity or total sulphate content of fill material does not
comply with the specified requirements for the property, additional samples
shall be provided from the same batch and additional tests for the property
shall be carried out. The number of additional samples shall be as stated in
Table 7.4.
(a) Samples of fill material to be tested for optimum moisture content and
maximum dry density shall be delivered at least 72 hours before deposition of
the fill material starts. The number of samples to be provided from each batch
shall be stated in Table 7.4
(b) The Contractor shall notify the Project Manager of the exact location in which
the fill material from which each sample is taken is to be deposited.
(d) Samples shall not be provided from fill material including rock fill material
which contains an insufficient proportion of particles passing a 20 mm BS test
sieve to permit determination of the moisture content and maximum dry
density.
(a) Each sample of fill material taken as stated in Clause 7.5.7 shall be tested to
determine the optimum moisture content and the maximum dry density.
(c) If permitted by the Project Manager, the Hilf method stated in Appendix A7.4
may be used instead of the methods stipulated in Clause 7.5.8(b) to
determine the optimum moisture content and maximum dry density.
(d) If in the opinion of the Project Manager there is any undue discrepancy
between the results of tests for optimum moisture content of fill material using
methods stipulated in Clause 7.5.8(b) and the results of tests using the Hilf
method, the results of tests using methods stipulated in Clause 7.5.8(b) shall
prevail.
If the result of any test for optimum moisture content or maximum dry density of fill
material indicates that the batch contains material which differs to such an extent
that subsequent tests for relative compaction may be affected, the batch shall be
divided into smaller batches; each of the smaller batches shall comprise material
with similar properties throughout. Additional samples shall be provided from each
of the smaller batches and additional tests for optimum moisture content and
maximum dry density shall be carried out. The number of additional samples shall
be as stated in Table 7.4.
(a) Samples of fill material to be tested for moisture content shall be taken during
deposition and compaction of fill material and shall be delivered to the
laboratory not more than 1 hour after the fill material has been deposited in its
final position.
(b) The number of samples to be provided from each batch shall be as stated in
Table 7.5. Samples shall not be provided if, in accordance with Clause 7.5.7
d(i) or (ii), the optimum moisture content has not been determined.
(a) Each sample of fill material taken as stated in Clause 7.5.10 shall be tested to
determine the moisture content.
(b) The method of testing shall be in accordance with one of the following
methods:
If in the opinion of the Project Manager there is any undue discrepancy between the
results of tests for moisture content of fill material using Method 1 and the results of
tests using Method 2 in Clause 7.5.11, the results of tests using Method 1 shall
prevail.
If the result of any test for moisture content of fill material differs from the optimum
moisture content by more than the specified amount, the moisture content of the
whole of the batch of fill material shall be adjusted. Additional samples shall be
provided from the same batch and additional tests for moisture content shall be
carried out. The number of additional samples shall be as stated in Table 7.5.
Table 7.5: Number of Samples to be Tested for Moisture Content and Number
of Tests for Relative Compaction
(a) Each batch of fill material shall be tested to determine the relative compaction.
Tests shall be carried out after the fill material has been deposited and
compacted in its final position. The number of tests on each batch shall be as
stated in Table 7.5. Tests shall not be carried out on fill material including
rock fill material which contains an insufficient proportion of particles passing
a 20 mm BS test sieve to permit determination of the relative compaction.
(d) The relative compaction of fill material shall be determined in accordance with
one of the following methods:
(i) Method 1: The relative compaction (RC) shall be calculated from the
equation:
RC = IDD/MDD x 100%
where:
RC = IBD/MCBD x 100%
where:
(e) The in-situ bulk density and the in-situ dry density of fill material shall be
determined in accordance with one of the following methods:
(i) Method 1: GEO Report No. 36, Test 9.2.1or 9.2.2 as appropriate to
the grain size of the fill material; or
(f) The maximum converted bulk density of fill material of which more than 5% is
retained on a BS 20 mm test sieve shall be adjusted as stated in Appendix
A7.5.
If in the opinion of the Project Manager there is any undue discrepancy between the
results of tests for relative compaction of fill material using Method 1 and the results
of tests using Method 2 in Clause 7.5.14, the results of tests using Method 1 shall
prevail.
General Materials & Workmanship Specification 22/37 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 7 - Earthworks
7.5.16 Non-compliance: Relative Compaction
If the result of any test for relative compaction of fill material does not comply with
the specified requirements for relative compaction, additional tests for relative
compaction shall be carried out on the same batch. The number of additional tests
shall be as stated in Table 7.5.
A7.1.1 General
Terms used in the Specification, and in BS 1377: 1975 are identified by the
abbreviations and symbols stated in Table A7.1.1.
Abbreviation/Symbol Term
BD bulk density
CBD Converted bulk density
DD dry density
IBD In-situ bulk density
IDD in-situ dry density
MDD Maximum dry density
MCBD Maximum converted bulk density
RC Relative compaction
w moisture content
wi in-situ moisture content
wo Optimum moisture content
(1) Fine grained material is material of which at least 90% passes a 2 mm BS test
sieve.
A7.2.1 Scope
This method covers the determination of the moisture content of fine grained and
medium grained material as a percentage of the mass of the dry material.
A7.2.2 Apparatus
A7.2.3 Procedure
(1) The container shall be cleaned, dried and weighed to the nearest 0.01 g (m1).
(2) A specimen shall be crumbled and placed loosely in the container and the lid
shall be replaced. Each specimen of fine grained material shall be at least 30
g and each specimen of medium grained material shall be at least 300 g.
Specimens of medium grained material may be tested in several parts each
less than 300 g and the results aggregated.
(3) The container and contents shall be weighed to the nearest 0.01 g (m2).
(4) The lid of the specimen container shall be removed and the container with its
lid and contents shall be placed in the microwave oven and dried. The
specimen shall be considered to be dry when, after an initial drying period,
successive weighings at intervals of 1 minute produce results which are the
same to the nearest 0.01 g. Alternatively, the oven may be set to an
appropriate time and power setting to dry the specimen as determined by
calibration of the oven on soil of a similar type.
(5) After drying, the container and contents shall be removed from the microwave
oven and placed in the desiccator to cool.
(6) The lid shall be replaced and the container and contents shall be weighed to
the nearest 0.01 g (m3).
The moisture content of the material (w) shall be calculated as a percentage of the
dry mass of the material from the equation:
where:
(2) the moisture content of the material to the nearest 0.1%; and
(3) that the test method used was in accordance with this General Materials and
Workmanship Specification.
A7.3.1 Scope
This method covers the determination of the in-situ bulk density of fine grained and
medium grained material by the attenuation of gamma rays and calculation of the
in-situ dry density using a moisture content determined in accordance with either
GEO Report No. 36, Test 2.3.2A or 2.3.2B or Appendix A7.2, whichever as
instructed by the Project Manager.
A7.3.2 Apparatus
(1) A nuclear device for the measurement of density (densometer). The details of
construction of the densometer may vary but the following general
requirements shall apply:
(4) A hole forming device, such as an auger or steel pin, to form a hole to
accommodate the probe. The device shall have a nominal diameter which
exceeds the probe diameter by not more than 3 mm and shall be graduated to
indicate the depth of the hole. The device shall have a guide which will
ensure that the hole is formed normal to the prepared surface.
(5) Sampling equipment, such as augers, spades, picks, small digging tools,
scoops, airtight containers and bags, to obtain samples of the material.
(6) Apparatus for the determination of the moisture content in accordance with
either GEO Report No. 36, Test 2.3.2A or 2.3.2B or Appendix A7.2, whichever
as instructed by the Project Manager.
(1) Before using the densometer on material for which it has not previously been
used, the results of determinations of in-situ bulk density using the
densometer shall be compared with the results of determinations of in-situ
bulk density in accordance with GEO Report No. 36, Test 9.2.2. The location
of each determination in accordance with GEO Report No. 36, Test 9.2.2 shall
correspond to the midpoint of the densometer probe and the gamma sensor.
A minimum of ten pairs of determinations shall be carried out.
(2) If the difference between any pair of results does not exceed 0.08 Mg/m³ and
if the densometer produces results which are both higher and lower than
those produced in accordance with GEO Report No. 36, Test 9.2.2, the
densometer may be used without correction.
(3) If either of the criteria stated in Clause A7.3.3(2) is not met, the densometer
shall not be used.
The procedure for carrying out a routine densometer check shall be as follows:
(2) A standard count shall be carried out in accordance with the manufacturer's
recommendations. The standard count shall be carried out by placing the
reference standard on a hard, level surface consisting of material with a
density of at least 1.6 Mg/m³. The reference standard shall be placed at a
distance of at least 10 m from any other nuclear device and at least 3 m from
any large object. At least three count readings shall be taken and the mean of
the three readings shall be determined. The mean shall be the standard
count reading for the day.
(3) The standard count reading for the day shall be compared with the mean of
the standard count readings for the previous 4 days. If the difference is
greater than that recommended by the manufacturer or if no recommendation
is made and the difference is greater than 1%, the densometer shall not be
used.
(4) The densometer shall be left switched on with the probe in the locked
position. If the densometer is switched off a further standard count shall be
carried out in accordance with Clause A7.3.4(2) and (3).
The procedure for determination of the in-situ bulk density shall be as follows:
(4) The probe shall be positioned and inserted into the hole in such a manner that
the gamma source is shielded at all times. The probe shall be seated firmly
against the side of the hole nearest to the back of the densometer by gently
pulling the densometer backwards until contact is achieved. The operator
shall ensure that the densometer is correctly seated and the depth setting on
the control panel is the same as the probe depth.
(5) The operator shall ensure that there are no other radioactive sources within
10 m of the densometer.
(6) Three readings of the in-situ bulk density shall be taken in accordance with
the manufacturer's recommendations and the mean determined. If any one
reading differs from any other reading by more than 0.015 Mg/m³, additional
readings shall be taken until three consecutive readings which do not differ by
more than 0.015 Mg/m³ are obtained and the mean determined. The mean of
the three readings shall be taken as the in-situ bulk density (IBD). If the
above criterion is not met after six readings, the densometer shall not be
used.
(7) The densometer shall be removed and a minimum 500 g sample of the
material directly beneath the densometer position shall be taken for
determination of the moisture content. The sample shall be obtained by
augering or digging to the test depth. The sample shall be placed in a
moisture tight container and the lid replaced. The moisture content (w) shall
be determined in accordance with either GEO Report No. 36, Test 2.3.2A or
2.3.2B or Appendix A7.2, whichever as instructed by the Project Manager.
(8) If a sample of material at the same location as the densometer test is required
for determination of the maximum dry density or the maximum converted bulk
density, the sample shall be obtained by digging to the test depth, keeping the
sides of the excavation vertical and the bottom flat and level. The appropriate
quantity of material required for the test shall be taken, placed in a moisture
tight container and the container sealed.
A7.3.6 Calculation
The in-situ dry density of the material (IDD) shall be calculated from the equation:
(4) that the test method used was in accordance with this General Materials and
Workmanship Specification.
A7.4.1 Scope
This method covers the determination of the maximum converted bulk density and
the difference between the optimum moisture content and the in-situ moisture
content of a material by relating the converted bulk density and the moisture added.
A7.4.2 Apparatus
(1) Apparatus in accordance with GEO Report No. 36, Test 4.3.3A or 4.3.3B,
whichever as instructed by the Project Manager.
(2) Apparatus for determination of the moisture content in accordance with either
GEO Report No. 36, Test 2.3.2A or 2.3.2B or Appendix A7.2, whichever as
instructed by the Project Manager.
(4) Apparatus, such as a warm air blower, for rapid drying of the material.
A7.4.3 Procedure
(1) A sample of material shall be taken immediately after completing the in-situ
bulk density test at the same location as the test. The sample shall be
obtained by digging to the same depth as that of the in-situ bulk density test,
keeping the sides of the excavation vertical and the bottom flat and level. The
size of the sample shall be sufficient to yield a minimum of 10 kg after
screening over a 20 mm BS test sieve.
(3) The sample shall be screened over a 20 mm BS test sieve, ensuring that
moisture loss is kept to a minimum and that any free moisture appearing in
the containers is worked back into the sample.
(4) The amount retained on the sieve shall be weighed to the nearest 0.01g and
expressed as a percentage of the mass of the sample. If the percentage
exceeds 5%, an adjustment for coarse material shall be made in accordance
with Appendix A7.5. If the percentage does not exceed 5%, no adjustment is
required.
(5) The material to be tested shall be thoroughly mixed and divided by quartering
or by using a riffle box to obtain a minimum of four specimens of at least
2500g each, ensuring that moisture loss is kept to a minimum. Alternatively,
if it has previously been ascertained that the material is not susceptible to
crushing, a single specimen of at least 2500 g may be used for repeat testing.
General Materials & Workmanship Specification 31/37 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 7 - Earthworks
(6) Each specimen shall be weighed to the nearest 0.01g and the result shall be
taken as the mass of the specimen at the in-situ moisture content.
(7) Each specimen and any remaining material shall be placed in separate
moisture-tight containers and the containers sealed.
(8) The converted bulk density of at least three specimens shall be plotted
against the amount of water added or removed as a percentage of the mass
of the specimen at the in-situ moisture content (z) on a graph as shown in the
Hong Kong Government Civil Engineering Department Standard Drawing No.
C2006, in accordance with the procedure stated in Clause A7.4.3(9) to (15).
(11) If the in-situ moisture content of the second specimen obviously exceeds the
optimum moisture content, the specimen shall be dried until the amount of
water removed is approximately 2% of the mass of the specimen and cooled.
The specimen shall be thoroughly mixed and compacted in accordance with
the method stipulated in Clause 7.4.3(9). The amount of water removed shall
be determined. The bulk density (BD2) shall be calculated as stated
in Clause A7.4.4(1), adjusted to converted bulk density (CBD2) as stated in
Clause A7.4.4(2) and plotted on the negative ordinate of the graph at a point
which corresponds to the amount of water removed.
- If the plotted value of CBD2 is less than the plotted value of CBD1, the
third specimen shall be dried until the amount of water removed is
approximately 2% of the mass of the specimen after cooling.
Alternatively, if the procedure stated in Clause A7.4.3(11) has been
followed, the moisture content shall be increased by adding an amount
of water equal to 2% of the mass of the specimen.
(13) If the centre point of the three points plotted is lower than one of the other two
points, or is higher than one point and equal to the other, an additional point
or points shall be obtained by proceeding in 2% increments or decrements as
appropriate.
(14) If it is apparent that the moisture condition of the material is such that a total
of five points will not result in the determination of the optimum moisture
content, increments and decrements of 3% moisture content may be adopted
for the entire procedure.
(15) A smooth approximately parabolic curve shall be drawn to the plotted points.
The peak value of the curve shall be determined as the maximum converted
bulk density (MCBD).
(16) The amount of water added or removed as a percentage of the mass of the
specimen at the in-situ moisture content corresponding to the maximum
converted bulk density shall be determined (zm).
(17) The value of the moisture correction curve passing through the peak value of
the plotted parabolic curve shall be determined (zc). If there is no moisture
correction curve passing through the peak value of the curve, a moisture
correction curve shall be drawn through the peak by interpolating to the
nearest 0.1%.
(1) The bulk density (BD) shall be calculated from the equation:
where:
(2) The converted bulk density (CBD) shall be calculated from the equation:
where:
(3) The difference between the optimum moisture content (wo) and the in-situ
moisture content (wi) of the material shall be calculated from the equation:
wo - wi = zm + zc %
where:
(4) The optimum moisture content (wo) shall be calculated from the equation:
wo = wi + (1 + wi/100) zm %
where:
(5) The maximum dry density (MDD) shall be calculated from the equation:
where:
RC = IBD/MCBD x 100%
where:
(2) the graph showing the plotted points and the parabolic curve passing through
them;
(3) the maximum converted bulk density to the nearest 0.01 Mg/m³;
(7) the percentage retained on the 20 mm BS test sieve and the percentage
retained on the 37.5 mm BS test sieve to the nearest 1%, if applicable;
(8) whether the test was carried out using individual specimens or repeat testing
of a single specimen;
(10) that the test method used was in accordance with this General Materials and
Workmanship Specification.
A7.5.1 Scope
This method covers the adjustment of the maximum converted bulk density
determined in accordance with Appendix A7.4 for the determination of the relative
compaction of a material containing more than 5% of the mass of the material at the
in-situ moisture content retained on a 20 mm BS test sieve.
A7.5.2 Apparatus
(3) A mould with collar as used for determination of the California Bearing Ratio
(CBR mould).
(4) An extrusion device as used for determination of the California Bearing Ratio.
A7.5.3 Procedure
(2) If the amount of material retained on the 20 mm BS test sieve exceeds 20%,
the retained material shall be screened over the 37.5 mm BS test sieve. The
procedure stated in either Clause A7.5.3(3) or Clause A7.5.3(4) as
appropriate shall be followed.
(3) If the amount of material retained on the 37.5 mm BS test sieve does not
exceed 5%, the procedure stated in Clause A7.5.3(5) shall be followed.
(4) If the amount of material retained on the 37.5 mm BS test sieve exceeds 5%
and does not exceed 20%, the retained material shall be replaced with an
equal mass of material which is of a similar nature and which is retained on a
20 mm BS test sieve but passes a 37.5 mm BS test sieve. The procedure
stated in Clause A7.5.3(5) shall be followed.
(5) The procedure stated in Appendix A7.4 shall be followed except that the
material shall be compacted into the CBR mould and each layer shall be
subjected to 62 blows of the rammer.
The maximum converted bulk density (MCBD) shall be calculated from the
equation:
- MCBD20 is the maximum converted bulk density of the material passing the
20 mm BS test sieve (Mg/m³)
(3) the mass of the original material not passing the 20 mm and 37.5 mm BS test
sieve as a percentage of the mass of the material at the in-situ moisture
content to the nearest 0.1%;
(6) whether the specific gravity was measured or assumed and, if measured, the
method used; and
(7) that the test method used was in accordance with this General Materials and
Workmanship Specification, and the results have been adjusted in
accordance with this Appendix.
The Permanent Works and materials specified below shall comply with the Sections
stated, unless otherwise stated in this Section:
(a) Details of trials to be carried out for geotechnical works shall be as stated in
the Contract.
(b) The trials shall be carried out to demonstrate that the proposed materials and
methods of construction will produce work which complies with the specified
requirements.
(c) Trials shall be carried out in sufficient time before commencement of the
relevant Permanent Works starts to allow the Project Manager a sufficient
period to determine if the trial complies with the specified requirements.
(d) The Contractor shall notify the Project Manager before the trial starts.
(e) Trials shall be carried out using the materials and methods of construction
submitted to the Project Manager for review. Trials shall be carried out at
locations reviewed without objection by the Project Manager.
(f) If work which complies with the specified requirements has not been produced
in the trial, particulars of proposed changes to the material or methods of
construction shall be submitted to the Project Manager for review; further trials
shall be carried out until work which complies with the specified requirements
has been produced in the trial.
(g) Geotechnical works for which trials are required shall not commence until
work which complies with the specified requirements has been produced in
the trial.
(h) The material and methods of construction used to produce work which
complies with the specified requirements in a trial shall not be changed.
Inspection pit is a pit for locating and identifying underground utilities and structures.
8.3.6 Sample
Sample is any quantity of material obtained from the ground for the purposes of
inspection, logging or testing.
Slope surface stripping is the removal of surface protection and vegetation from
existing slopes to expose underlying soil or rock for inspection.
Trial pit is a pit for inspecting and logging the ground and in which to carry out in-
situ testing and sampling.
(c) details of filter materials and fill materials for drilling and testing,
(a) The plan dimensions at the bottom of a trial pit shall be at least 1.2 m x 1.2 m
and the sides of trial pits shall be vertical.
(b) The sides of trial pits shall be trimmed by manual methods to remove all
disturbed material. Supports to the sides of trial pits shall be such that the cut
surface is clearly visible throughout the height of each face.
(c) The Project Manager shall be notified before fill material is deposited in trial
pits.
(a) Slope surface stripping shall start at the top of the slope and shall proceed
downwards. All loose material remaining on the slope after stripping shall be
removed.
(c) Stripped areas shall be covered up at the end of each working day and during
rainstorms to prevent the ingress of water into the slope.
(d) Stripped areas shall be reinstated in form, colour and conditions similar to the
original. The Project Manager shall be notified before reinstatement starts.
Records of inspection pits shall be kept by the Contractor on Site and a report shall
be submitted to the Project Manager for review within 3 days after each inspection
pit has been excavated. The report shall contain details of the positions, depths
and dimensions of all utilities and structures encountered in each inspection pit.
(a) Each trial pit shall be photographed as soon as excavation is complete. The
full face of each of the sides and the bottom of the trial pit shall be
photographed individually. One copy of specimen prints of 127 mm x 76 mm
size shall be submitted to the Project Manager for review before fill material is
deposited in the trial pit. The photographs shall contain the following
information:
(iii) a suitable colour comparison chart placed alongside the trial pit face.
(b) Records of trial pits shall be kept by the Contractor on Site and a report shall
be submitted to the Project Manager for review within 24 hours after each trial
pit has been excavated. The report shall contain the following:
(iii) details of water levels, including dates and details of fluctuation; and
(c) Records of slope surface stripping shall be kept by the Contractor on Site and
a report shall be submitted to the Project Manager for information within 24
hours of the surface stripping. The report shall contain a detailed geological
description of the materials exposed, and details and locations of groundwater
seepage.
(a) Drilling rigs for ground investigation shall be the hydraulic feed type and shall
have a rating of at least 26.5 kW to drive a rotary tool tipped with diamonds or
tungsten carbide. Drilling rigs shall be capable of drilling in the specified sizes
and to the specified depths without excessive vibration.
(b) The weight of each rig shall be such that a force of 12 kN can be applied to
the drilling bit without movement of the rig.
(c) Drilling rigs shall be capable of providing stable drill-string rotation at speeds
of between 50 rpm and 1250 rpm and have a ram stroke length of at least 600
mm. The rigs shall be fitted with a tachometer and a hydraulic feed pressure
gauge, both of appropriate scales, and a device for measuring the rate of
penetration of the drill strings.
(a) Spare drill bits shall be available for use during drilling.
(b) The size of casings shall be appropriate to the drilling, coring, sampling,
testing and other installation requirements.
(c) Core barrels for sampling soil shall be equipped with a sediment catcher tube.
The tube shall have the same external diameter as the core barrel and shall
be approximately 0.75 m long.
(d) Casings shall be used to stabilize caving ground. The size of casing and drill
rod in use shall be appropriate to the size of core barrel in use. Casings and
drill rods shall be straight and shall be clean at the time of drilling and free
from scale, dirt and other loose material.
(e) Only regular lengths of casings and drill rods shall be used and imperial and
metric lengths shall not be mixed.
(f) Short lengths of drill rods shall be used to enable continuous coring to be
carried out in such a manner that each core run can be completed within one
ram stroke.
(g) Short lengths of casing not exceeding the ram stroke length shall be used to
enable casings to be advanced after each core run where necessary.
(h) Core barrels and drill rods shall be stored on steel frame trestles.
(a) Drillholes for ground investigation shall be sunk by rotary methods. The
methods and equipment used shall be such that:
(i) the overall hole alignment is within 2% for vertical drillholes and is within
5% of the specified alignment for non-vertical drillholes;
(ii) the soil encountered and the levels at which changes in ground
conditions occur can be accurately identified;
(iv) in-situ tests can be carried out and field installations can be
incorporated at any depth in the drillhole; and
(c) Larger casings shall be set concentric with drillholes which are being reamed.
(d) The flushing medium for drilling shall be clean water, air, air mist or air foam;
other substances or materials shall not be introduced into drillholes. The
flushing medium for drilling shall be passed through a sedimentation basin
and shall either be reused or be discharged to surface drains or natural
stream courses. Measures shall be taken to prevent flushing mediums
seeping through the ground.
(e) The flushing medium for drilling shall not be discharged to stream courses
which are used as a supply of drinking water.
(a) Jar samples from drillholes shall be taken from the cutting shoe of each
undisturbed sample, from any anomalous material, from each standard
penetration test and at other locations as directed by the Project Manager.
(b) All loose material and material disturbed by drilling or in-situ tests shall be
removed from the sides and bottom of the drillhole before each undisturbed
sample is taken.
(a) Granular fill material of a type reviewed without objection by the Project
Manager, or 4:1 cement bentonite grout where directed by the Project
Manager, shall be deposited in drillholes for ground investigation and
compacted to the same relative compaction as the surrounding ground. The
casing shall be gradually withdrawn; the fill material shall be kept above the
bottom of the casing during withdrawal. Subsequent depressions in the
ground surface shall be filled and reinstated. The drillhole position shall be
marked with a metal marker and flag or a 300 mm x 300 mm x 150 mm thick
concrete block; the hole number shall be inscribed on the surface and
highlighted in red paint.
(b) The Project Manager shall be notified before fill material is deposited in
drillholes and before the casing is withdrawn. The ground surface around
drillholes shall be reinstated as soon as practicable after the fill material has
deposited and compacted in each drillhole.
(a) Records of drillholes for ground investigation shall be kept by the Contractor
on Site and two copies of a preliminary drillhole log, stamped PRELIMINARY,
shall be submitted to the Project Manager for review within 24 hours after
completion of each drillhole. Drillhole logs shall be comprehensive and shall
be in a form similar to that shown in Figure 44 of 'Geoguide 2 : Guide to Site
Investigation', Hong Kong Government, 1987; soil and rock descriptions shall
comply with those stated in the insert titled 'Checklist for Soil Descriptions'
and 'Checklist for Rock Descriptions' in 'Geoguide 3 : Guide to Rock and Soil
Descriptions', Hong Kong Government, 1988.
(i) information shown and in the format in Figure 44 and Paragraphs 40.2.6
(2), (4) and (5) of 'Geoguide 2 : Guide to Site Investigation', Hong Kong
Government, 1987;
(iii) details of utilities identified in the inspection pit excavated at the drillhole
location.
Sampling equipment and containers for ground investigation shall comply with
BS5930 and the following :
(a) For general purpose open tube samples and thin-walled samples, the sample
tube and cutting shoe shall be free from rust, pitting, burring or any other
defect. The use of oil inside the sampler shall be limited to the minimum
practical. Each sample tube shall have a unique reference number and the
word 'TOP' engraved on its exterior at one end. The sample tube shall be
driven with the end marked 'TOP' uppermost. The dimensions, construction
and condition of each sample tube, cutting shoe and adaptor head shall be
reviewed by the Project Manager prior to sampling. The adaptor head shall be
fitted with a ball valve to permit the exit of air or water during driving and to
assist in retaining the sample during withdrawal, and it shall have an
allowance for over-driving. In soil of low cohesion such as silts and silty fine
sands the sampler shall be equipped with a basket core retainer to enhance
core recovery.
(b) U100, U76 and U40 thin-walled samplers shall be 102 mm (for U100), 78 mm
(for U76) and 42 mm (for U40) diameter open drive sample tubes made from
thin-walled seamless cadmium plated or stainless steel not less than 450 mm
(for U100), 350 mm (for U76) and 200 mm (for U40) in length fitted with a
cutting shoe tapered at an angle not exceeding 20º. The area ratio of the
sampler as defined in Figure 13 of 'Geoguide 2 : Guide to Site Investigation',
Hong Kong Government, 1987 shall not exceed 30%.
(c) Piston samplers shall be a thin-walled fixed piston sampler. The piston
sampler shall be capable of operating to a depth of at least 20 m below
ground level with no lateral movement during the actual sampling operation.
The design and maintenance of the sampler shall be such that a partial
vacuum is formed over the retained sample in the tube. The minimum
recovered sample length shall be 900 mm. The thin-walled tube shall have an
external diameter of 75 mm or 100 mm as directed by the Project Manager.
The area ratio of the sampler as defined in Figure 13 of 'Geoguide 2 : Guide
to Site Investigation', Hong Kong Government, 1987 shall not exceed 10%.
(e) Split spoon samplers for the standard penetration test shall be provided with a
thin smooth stainless steel.
(a) A reference number shall be assigned to each soil sample taken from a
drillhole or trial pit. The number shall be unique for that drillhole or trial pit and
shall be in order of depth below ground level.
(b) The visible ends of each undisturbed sample shall be trimmed of any
disturbed material immediately after recovery from the ground. The sides of
the tube or box shall be cleaned and the ends of the sample shall be coated
with three successive thin films of just-molten microcrystalline wax. A metal
foil disc or plate shall be added and followed by more molten wax to give a
total thickness of at least 20 mm. Any space remaining in the ends of the
sample tube or box shall be solidly filled with damp sawdust and the ends of
the sample tube shall be covered with tight fitting rubber caps.
(c) Each sample shall be identified by a label. The label shall be written with
permanent ink and protected from moisture, damage and loss. The minimum
labelling requirements shall be as follows:
(iv) For core samples stored in core boxes, a stapled card, stick-on label or
permanent ink shall be used externally on the front of the box and
repeated inside. The hole reference number shall be written in
permanent ink or paint on each end of the core box.
(a) Samples for ground investigation shall be delivered to, and stored at, a core
store at a location reviewed without objection by the Project Manager.
Samples shall be delivered to the testing laboratory at a time reviewed without
objection by the Project Manager.
(b) Undisturbed soil samples shall be stored and delivered in a wooden crate of
appropriate dimensions. The samples shall be kept in an upright position with
a separate compartment for each sample. The compartment shall be properly
padded and the lower end of the sample shall be placed in the bottom of the
compartment.
(c) The samples shall not be disturbed during transportation, handling and
storage.
Bulk samples shall be obtained from undisturbed ground. Each bulk sample shall
be sealed into a metal or plastic container immediately after it has been taken.
Mazier samples shall be taken by a Mazier sampler and in accordance with Clause
8.5.12.
(a) Sample tubes shall be advanced by jacking action. The jack shall be arranged
to align with the sampler. Measures shall be taken to prevent lateral
movement during the sampling operation.
(b) Each U100 sample shall contain at least 300 mm net length of undisturbed
material and each U 76 sample shall contain at least 200 mm net length of
undisturbed sample.
(a) Block samples shall be taken from the sides or bottom of trial pits at locations
and orientations determined by the Project Manager.
(b) Each block sample shall be at least 230 mm x 230 mm x 230 mm and shall be
excavated, trimmed, cut, wrapped, waxed and packed in metal or wooden
boxes in accordance with the procedure stated in Part A of Des. E-2 of the
United States Bureau of Reclamation Earth Manual.
(a) Rock cores obtained from drillholes shall be removed from the core barrel
without damage by gentle hammering with a wooden mallet on the side of the
core barrel to free wedges pieces; other methods shall not be used.
(b) As the rock core is extruded, it shall be arranged in the box in sequence
starting with the shallowest core on the left side of the box against the hinge
and working along the slat and subsequently outwards towards the staple.
The depths at which each core run started and finished shall be recorded
within the box by painting on wooden blocks which fit between the dividing
slats. Fractured rock core shall be spread throughout its length and packed
securely. Rock core losses shall be shown by wooden blocks or polystyrene
of a square cross section to fill the core box; the length of the wooden block or
polystyrene shall be equal to the length of core lost.
(a) The apparatus and procedure for standard penetration tests shall comply with
BS1377:1975, Test 19. The drive hammer shall be a type incorporating an
automatic trip mechanism to ensure free fall. The 60º solid core shoe shall be
used in soil containing coarse gravel.
(c) Standard penetration tests shall be carried out below the level of the casing.
The base of the drillhole shall be fully cleaned before the test starts. Jar
samples shall be taken from the split-barrel shoe after each test.
(d) The number of blows of the drive hammer required to achieve each 75 mm of
shoe penetration until a total penetration of 450 mm has been achieved shall
be recorded. The N-value shall be recorded as the sum of the number of
blows of the drive hammer required to achieve the last 300 mm of shoe
penetration. The number of blows recorded for the initial 150 mm of shoe
penetration shall not be included in the N-value calculation. If any increment
of 75 mm of shoe penetration is not achieved after 100 blows of the drive
hammer, the number of blows and the penetration achieved shall be recorded
and the test shall be terminated.
GEO probe tests shall be carried out in accordance with Appendix A8.1. The GEO
probe hole shall be sealed with cement grout on completion of the test for at least
the top 600 mm of the hole. The grout shall consist of cement and water in the
proportions 0.4:1 by mass.
(a) In-situ density tests shall be carried out by the sand replacement method in
accordance with Clause 7.5.14 (e) and (f).
(b) A jar sample shall be taken at each location where an in-situ density test is
carried out.
(a) Rising and falling head permeability tests shall be carried out using the
apparatus described in Figure 27 of 'Geoguide 2: Guide to Site Investigation',
Hong Kong Government, 1987. The method of testing shall be in accordance
with Figure 30 of 'Geoguide 2: Guide to Site Investigation', the method of
flushing of the bottom of the drillhole stated in Clause 8.5.23(d) shall be used.
The type of filter material and sand to be used shall be in accordance with
Clause 8.24.10(b), and shall be placed in the drillhole using a tremie pipe.
(b) Rising head permeability tests shall be carried out by lowering the water level
in the standpipe by approximately 3 m. The water level in the standpipe shall
be allowed to rise to equalise with the ground water level and the time for
each 0.2 m rise in water level shall be recorded.
(c) Falling head permeability tests shall be carried out by raising the water level in
the standpipe by approximately 3 m. The water level in the standpipe shall be
allowed to fall to equalise with the ground water level and the time for each
0.2 m drop in water level shall be recorded.
(d) The method of flushing of the bottom of the hole for field permeability tests
shall be as follows:
(ii) The flushing water shall be withdrawn from the casing through a 38mm
diameter pipe positioned with its open end between 150 mm and 200
mm above the base of the borehole. The discharge shall be by means
of a pump of sufficient capacity to extract the flushing water from the
base of the borehole. Control of the flow of clean water and discharge
water shall be by means of valves positioned on the inflow pipe and the
discharge pipe.
(a) Constant head permeability tests shall be carried out using the apparatus
described in Clause 8.5.23(a). Clean water shall be fed into the standpipe at
a constant rate and the time for each 0.2 m rise in water level shall be
recorded until either a constant water level is established or until the water
level is 0.3 m below the top of the casing. The constant rate of inflow which is
required to maintain a constant head shall be recorded.
(b) After a constant water level has been achieved as stated by Clause 8.5.24(a),
the cumulative inflow readings required to maintain the constant head shall be
recorded in the following sequence:
(a) Records of each in-situ test shall be kept by the Contractor on Site. The
Project Manager shall be notified before test apparatus is dismantled.
(b) The results of standard penetration tests shall be recorded on drillhole logs as
stated in Clauses 8.5.11 and 8.6.2.
(c) The results of GEO probe tests shall be recorded as stated in Clause 8.5.21
and shall be submitted to the Project Manager for review within 24 hours after
the test.
(d) The results of in-situ density tests shall be recorded in a form reviewed
without objection by the Project Manager and shall be submitted to the Project
Manager for review within 24 hours after the test.
(e) The results of rising, falling and constant head permeability tests shall be
recorded as stated in Clauses 8.5.23 and 8.5.24 and shall be submitted to the
Project Manager for review within 24 hours after the test. The results of the
rising and falling head permeability tests shall be recorded in the format
shown in Figure 30 of 'Geoguide 2 : Guide to Site Investigation', Hong Kong
Government, 1987.
(ii) for each sample, drilling or core run for each test, installation or strata
encountered, the following where applicable:
• start and finish depths below ground level;
• start and finish times;
• casing diameter and depth;
• bit number and type;
• sample reference number and type;
• SPT test result in number of blows recorded;
• percentage water returns and core recovery;
• a description of the soil and rock strata or sample; and
• a description of field tests or instruments installed.
(a) Cement mortar for in-filling joints in rock faces, for bedding rock for masonry
infilling and for surfacing slopes shall consist of OPC and sand in the
proportions 1:3 by volume.
(c) Sand shall be natural sand or crushed natural stone complying with BS 1200.
Rock for masonry infilling shall not exceed 300 mm in size and shall be obtained
from a source reviewed without objection by the Project Manager.
(a) Soil-cement shall consist of OPC, sand and inorganic soil in the proportions
1:3:12 by mass.
(b) OPC shall comply with BS 12.
(d) Inorganic soil shall be free from organic matter and shall contain not more
than 30% of soil particles passing a 63 μm BS test sieve.
8.7.4 Chunam
(a) Chunam for surfacing shall consist of OPC, hydrated lime and inorganic soil in
the proportions 1:3:20 by mass.
The nominal maximum aggregate size of aggregates for sprayed concrete shall not
exceed 10 mm.
(a) Protective mesh for slopes shall be PVC coated galvanized steel wire woven
into a double twist hexagonal mesh; each hexagon shall be 80 mm x 60 mm.
The steel wire shall be at least 2.2 mm diameter and the PVC coating shall be
at least 0.4 mm thick.
(b) Tying wire for protective mesh shall be 2.2 mm diameter PVC coated
galvanized soft annealed steel wire.
(c) Bolts for fastening protective mesh to rock shall be galvanized mild steel
hooks as stated in the Contract.
(a) Rock bolts shall be a proprietary type reviewed without objection by the
Project Manager. Rock bolts shall comply with CS2 and shall be mild steel or
high yield deformed steel as stated in the Contract. Rock bolts shall be
galvanized to a minimum average mass coating of 610 g/m² in accordance
with BS 729.
(b) The rated working load of rock bolts shall not exceed 50% of the ultimate
tensile strength. A reduction of 4 mm in the diameter of the bolt shall be taken
into account for corrosion when calculating the ultimate tensile strength.
Grout for rock bolts shall be as stated in Clauses 8.11.2 and 8.14.5 except that the
water cement ratio shall not exceed 0.45.
Rock dowels shall comply with CS2 and shall be high yield deformed steel as stated
in the Contract.
Grout for rock dowels shall be as stated in Clauses 8.11.2 and 8.14.5 with a water
cement ratio not greater than 0.45.
Particulars of the proposed means of access for slope treatment works, including
access structures and reinstatement, shall be submitted to the Project Manager for
review.
(ii) details of water sprays and associated pumps for surface spraying;
(a) The following particulars of the materials and methods of construction for rock
bolts shall be submitted to the Project Manager for review:
(v) details of equipment for testing rock bolts, including test and calibration
certificates.
(b) A system of safety ropes shall be installed on the means of access; safety
ropes shall be 12 mm diameter and shall have a breaking force of at least 22
kN. The system of safety ropes shall consist of:
The system of safety ropes shall be constructed in such a manner that the ropes
are tied at not more than 3 m spacings in both directions to form a net.
(a) Protection fences and barriers for slope treatment works shall be constructed
as stated in the Contract before slope treatment work starts.
(b) Damage to protection fences and barriers shall be repaired immediately. The
Contractor shall notify the Project Manager before protection fences and
barriers are dismantled.
(a) Vegetation shall be cleared and existing impermeable surfaces and topsoil
shall be removed from existing soil slopes before slope treatment works start.
(b) Loose material shall be removed from the surface of new soil slopes and the
surface shall be trimmed and scarified before slope treatment works start.
The surface shall be moistened immediately before the slope surface
treatment works start.
(c) Rock faces and joints, and the surface and joints of retaining walls shall be
cleaned of moss, vegetation and loose material, immediately before slope
treatment works start, and surplus water shall be removed by an air jet.
Water flowing from or across the rock face shall be diverted by relief drains
before the application of impermeable surfaces. All vegetation and loose
material shall be removed from rock joints. Moss and loose materials shall be
removed by wire brushing or scraping.
(a) Scaling and trimming of rock slopes shall be carried out in such a manner that
soil and rock is removed from the slope face without affecting the stability and
integrity of the slope. Measures shall be taken to prevent uncontrolled falls of
debris arising from scaling and trimming works. Scaling and trimming of rock
slopes shall be carried out using hand-held tools, pneumatic tools or feather
and wedge.
(b) All material removed or excavated by scaling and trimming and loose
fragments of soil and rock shall be removed from the slope. Rock faces shall
be cleaned using a water jet coupled to compressed air after scaling and
trimming is complete.
Rock splitting shall be carried out using percussive hammers, drills, hydraulic
splitters, chemical expanding agents or hand-tools. Explosive shall not be used.
Boulders which are to be removed from slopes shall be broken down by means of
line drilling, expansive grouts or rock breakers. Explosives shall not be used.
Joints in rock faces shall be sealed with Grade 20/20 concrete, cement mortar or
masonry. Rock for masonry infilling shall be bedded in cement mortar. Relief
drains directed by the Project Manager shall be installed before rock joints are
sealed or infilled.
(a) Concrete for buttresses shall be Grade 20/20 unless otherwise stated in the
Contract.
(b) Drainage which is required behind buttresses shall consist of relief drains
connected to 50 mm diameter PVC outlet pipes laid at a gradient of at least 1
in 50; the PVC pipes shall be securely fixed to the formwork before concreting
starts.
(a) Soil-cement fill shall be deposited in its final position and compacted within 30
minutes after the cement has been added to the mix.
(b) Soil-cement fill shall be compacted as stated in Clauses 7.4.26 and 7.4.29,
using the layer thickness and compactive effort successfully demonstrated in
the field trials and reviewed without objection by the Project Manager.
(c) The moisture content of the soil cement mix shall not be less than the
optimum value as determined by the vibrating compaction method of BS 1924
: Part 2, nor more than 2% above this optimum value.
(d) The relative compaction of the soil cement fill will be as reviewed without
objection by the Project Manager following review of the results of the field
trials, but in any case will not be less than 95% of the maximum dry density
for the agreed mix as determined by the vibrating compaction method of BS
1924 : Part 2.
(e) The in-situ density of compacted soil cement fill shall be determined using the
sand replacement method of BS 1924 : Part 2.
The cement and lime for chunam shall be mixed dry before adding the soil. The
materials shall then be mixed thoroughly, with water sprinkled, until the colour and
consistency are uniform.
(a) Bamboo dowels shall be driven into the face of the slope on which chunam
will be placed at 1.5 m centres on a staggered pitch to leave a 25 mm
projection from the slope face to receive the chunam. Bamboo dowels shall
be at least 25 mm in diameter and shall be 150 mm long. Bamboo dowels
shall not be used on slopes less than 30º to the horizontal.
(b) The chunam shall be laid to a total thickness of 50 mm in two equal layers;
the layers shall be well compacted by ramming. The bottom layer of chunam
shall be left with a rough finish to provide bonding for the top layer.
Joints in chunam shall be neat and straight and panels shall be rectangular. Joints
in the top and bottom layers shall not coincide.
(a) Weak material along joints or seams in slope surfaces to which sprayed
concrete will be applied shall be removed to a depth equal to the width of the
weak zone.
(b) When the soil surface temperature exceeds 25°C or the moisture content is
less than 10%, the surface to be sprayed shall be watered using sprays.
Hoses without sprays shall not be used. Spraying of water onto the slope
surface shall be carried out not more than 1 hour before spraying of concrete
starts.
Fabric reinforcement for sprayed concrete shall be fixed securely to the slope by
steel nails or rawl bolts and shall be laid without sharp bends or creases. The cover
to the reinforcement shall be at least 20 mm and laps between adjacent sheets
shall be at least 150 mm.
Equipment for spraying concrete shall be the dry mix delivery type with water added
at the nozzle. The equipment shall be fitted with weighbatching facilities. The
equipment shall be capable of projecting a mixture of cement, fine and coarse
aggregate and water at high velocity on to the surface of the slope to produce a
dense homogeneous cover.
General Materials & Workmanship Specification 19/75 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 8 – Geotechnical Works
8.9.20 Spraying concrete
(a) The surface temperature and moisture content of the soil shall be measured,
and the results submitted to the Project Manager for review, immediately
before sprayed concrete is applied.
(b) The aggregate and sand for sprayed concrete shall be kept dry before mixing.
The water shall be added at the nozzle at the instant of application. The air
and water supply, the rate of application and all other factors affecting the
quality of the work shall be adjusted to produce dense concrete with no
sloughing. Rebound material shall not be reused and shall be removed within
8 hours after spraying.
(c) Sprayed concrete shall be applied in layers not exceeding 50 mm thick to the
total thickness stated in the Contract. The maximum panel dimension shall not
exceed 15 m.
Sprayed concrete shall be cured for at least 4 days after application by either
Method 1, Method 2 or Method 3 as stated in Clause 20.7.15.
Protective mesh for slopes shall be suspended down the rock face and bolted into
the slope face at 250 mm centres at the top and sides of the mesh and at 5 m
intervals at the toe of the slope. Laps in the mesh shall be at least 300 mm and
each side of the lap shall be tied at 125 mm centres with galvanised and PVC
coated binding wire.
The design bond length of rock bolts with bonded anchorages shall be determined
for each rock type by a pull-out trial. The proof load of a pull-out trial shall be twice
the working load. Pull-out trials shall be carried out on two bolts for each
combination of rock bolt and rock type. The bolts used in trials shall be discarded
and shall not form part of the Permanent Works, and the hole shall be sealed by
grouting.
(a) Holes for rock bolts shall be drilled at the locations and to depths directed by
the Project Manager. The diameter of the hole shall be at least 20 mm larger
than the diameter of the rock bolt or the outer diameter of the connectors,
whichever is larger. The method of drilling shall be rotary or rotary percussive
with water flush or air flush accompanied by the operation of an effective dust
extraction and filtering device. Holes shall be drilled to provide 50 mm cover
to the end of bolts for which cement grout is used to form the bond length.
(b) Holes for rock bolt shall be flushed with clean water before rock bolt
installation starts until the return water runs clear. Standing water shall be
blown out from the hole using compressed air after flushing.
(c) Holes for rock bolts shall be tested by the Packer test as stated in Clauses
8.10.11, 8.10.12 and 8.10.13 and the results of the tests shall be submitted to
the Project Manager for review, before installation of rock bolts starts.
General Materials & Workmanship Specification 20/75 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 8 – Geotechnical Works
8.9.25 Fixing rock bolts
(a) The Project Manager shall be notified before installation of rock bolts starts.
(d) Installation of rock bolts, including grouting of the free length and installation
of head protection, shall be completed as soon as practicable and not more
than 14 days after completion of the drillhole.
(e) Rock bolts with a grouted anchorage shall not be stressed until the grout
crushing strength has attained a value of 21 MPa when tested in accordance
with Clauses 8.15.9, 8.15.10 and 8.15.11.
(a) Grouting for rock bolts shall be in accordance with the requirements stated in
Clauses 8.11 to 8.15 except as stated in Clause 8.9.26(b) and (c).
(b) Grout shall be introduced at the lower end of drillholes with downward
inclinations and shall displace all air and water through the top of the drillhole.
(c) Packers and return ducts which maintain a head on the grout until the grout
has set shall be used for drillholes with upward inclinations or with inadequate
downward inclinations. The packers and ducts shall be such that separate
grouting of the anchorage zone and free-length zone of the drillhole can be
carried out. The head to be maintained on the grout shall be as reviewed
without objection by the Project Manager.
Each installed rock bolt shall be proved as stated in Clauses 8.10.14 to 8.10.16
Rock bolts shall be locked off at 1.1 times the working load after proving. The
complete bolt head assembly shall be encased by a concrete block after locking off.
Records of installation of rock bolts shall be kept by the Contractor on Site and a
copy shall be submitted to the Project Manager for review within 7 days after each
installation operation. Records shall contain the following:
(iii) location, level, inclination, bearing, length and diameter of drillhole; and
The drilling and preparation of holes for rock dowels shall be as stated in Clause
8.9.24(a) and (b).
(a) Grouting for rock dowels shall be in accordance with the requirements stated
in Clauses 8.11 to 8.15 except as stated in Clause 8.9.30(b).
(b) Rock dowels shall be grouted over the complete length of the drillhole in
which the dowel is installed. Centralisers shall be fitted to rock dowels before
grouting to ensure an even annulus of grout.
Records of installation of rock dowels shall be kept by the Contractor on Site and a
copy shall be submitted to the Project Manager for review within 7 days after each
installation operation. The records shall contain at least the following details:-
(iii) location, level, inclination, bearing, length and diameter of drillhole; and
Records of sprayed concrete operations shall be kept by the Contractor on Site and
shall be submitted daily to the Project Manager for review. The records shall contain
details of the quantities of all materials used at each location.
8.10.5 Testing: Optimum moisture content and maximum dry density of soil-cement
fill
The maximum dry density and optimum moisture content of soil-cement fill shall be
tested as stated in Clauses 7.5.7 to 7.5.13 except that the method of testing shall
be the Vibrating Hammer Test Method in accordance with BS 1924.
(a) The strength of sprayed concrete shall be determined from concrete cores cut
from a test panel constructed at the same time as sprayed concrete is
applied.
(b) One test panel shall be constructed for each area of sprayed concrete of
500m² or part thereof.
(c) The test panel shall be 250 mm thick and shall be at least 1 m x 1 m. The
mould shall be securely fixed in position at the same height and inclination as
the surface being sprayed. The panel shall be constructed by spraying
concrete into the mould at the same time as the concrete to be tested is
applied. The test panel shall be cured by the same method as the sprayed
concrete.
(a) Three concrete cores shall be provided from each test panel; cores shall not
be taken within 125 mm from the edges of the panel.
(b) Concrete cores shall be 100 mm diameter and shall be the full depth of the
test panel.
(a) Each concrete core shall be tested to determine the compressive strength and
density.
(b) The method of preparing and testing the cores to determine the compressive
strength shall be in accordance with CS 1; the method of testing the cores to
determine the density shall be in accordance with CS 1. Three concrete cores
shall be tested at 28 days.
The results of tests for compressive strength of concrete cores shall be interpreted
in accordance with BS 6089. Adjustments to the measured strength in respect of
the age of the core when tested shall not be made. The minimum compressive
strength of concrete cores, converted to estimated in-situ cube strength in
accordance with BS 6089 shall be 20 MPa at 28 days.
If the result of any test for compressive strength or density of concrete cores from
sprayed concrete does not comply with the specified requirements for the property,
particulars of proposed changes to the materials, mix design, methods of production
or methods of construction shall be submitted to the Project Manager for review;
further trial mixes shall be made and further trial panels shall be constructed.
(a) The water loss from drillholes for rock bolts shall be determined by the Packer
test. The number of drillholes to be tested will be directed by the Project
Manager.
(b) The Packer test shall be carried out on the bond length of the drillhole at a
test pressure of 100 kPa. The method of testing shall be as stated in Clause
8.15.12.
The water loss determined by the Packer test in the grouted hole shall not exceed 5
Lugeons when measured over a 10 minute period.
If the result of any Packer test on drillholes for rock bolts does not comply with the
specified requirements for the test, the drillhole shall be grouted, re-drilled and
retested. Grouting, re-drilling and retesting shall be continued until the result of the
Packer test complies with the specified requirements for the test.
Each installed rock bolt shall be tested to determine the loss in stress by applying a
test load of 1.5 times the working load for 5 minutes.
The loss in stress in installed rock bolts shall not exceed 5% of the test load in 5
minutes.
(a) If the result of any test for loss in stress of installed rock bolts does not comply
with the specified requirements for the test, an additional test for loss of stress
shall be carried out on the rock bolt.
(b) If the result of any additional test for loss of stress of installed rock bolts does
not comply with the specified requirements for the test, the rock bolt shall be
replaced.
8.11.1 Ground
Ground, for the purpose of grouting for geotechnical works, is fill material, soil and
rock and the interfaces between fill material, soil and rock and any structures.
8.11.2 Grout
Grout, for the purpose of grouting for geotechnical works, is cement grout,
cement-sand grout, cement-bentonite grout and proprietary grout reviewed without
objection by the Project Manager.
8.11.3 Grouting
Grouting, for the purpose of grouting for geotechnical works, is the mixing and
injection of grout through predrilled or preformed holes.
Grouting stage, for the purpose of grouting for geotechnical works, is the discrete
length of drillhole into which grout is to be injected in a continuous operation.
Lugeon is a water loss of 1 litre per minute per metre length of hole tested at an
effective pressure of 1 MPa.
A batch of grout for geotechnical works is any quantity of grout used for grouting
geotechnical works in one continuous operation in one day.
Materials for grout shall comply with Section 20 except as stated in this Section.
(a) Cement grout for geotechnical works shall consist of OPC, sand and water.
Admixtures shall not be used.
(b) Sand for grout shall be clean dry sand complying with BS 1200 and shall have
a particle size distribution such that 100% passes a 2 mm BS test sieve and
not more than 30% passes a 0.2 mm BS test sieve.
(c) Water for grout shall be clean fresh water having a temperature not exceeding
30°C or less than 5°C.
(d) Unless otherwise stated in the Contract, cement grout shall have a minimum
crushing strength of 30 MPa at 28 days.
(e) The amount of bleeding of grout shall not exceed 0.5% by volume 3 hours
after mixing or 1.0% maximum when measured at 23 ±2°C in a covered glass
or metal cylinder of 100 mm internal diameter and with a grout depth of
approximately 100mm. In addition, the water shall be reabsorbed by the grout
within 24 hours.
(f) The flow cone efflux time of grout shall not be less than 15 seconds.
8.12.3 Standpipes
Standpipes for grouting shall be standard black metal pipe complying with BS 1387.
(a) Holes in rock for grouting for geotechnical works shall be drilled using rotary
or percussion type drills. The tolerance for the holes shall be as stated in
Clause 8.5.8(a). Grease and other lubricants shall not be used in the flushing
medium or on the rods, except around the threads at the ends of the rods.
Drilling methods which result in drill cuttings causing blockages such that
grouting cannot be performed satisfactorily shall not be used.
(b) The flushing medium for drilling shall be air, air mist, clean water or air
accompanied by the operation of an effective dust extraction and filtering
device.
(c) The minimum size of hole for grouting in rock shall be 40 mm.
(d) Holes in soil for grouting for geotechnical works shall be drilled by a method
which is suitable to the ground conditions and which is reviewed without
objection by the Project Manager.
(e) The location of all underground obstructions and utilities shall be determined
by the Contractor before drilling starts and the drilling pattern shall take
account of the location of obstructions and utilities.
(f) Casings required to prevent the collapse of grout holes shall be as stated in
Clause 8.5.7. Casings shall be removed immediately before or simultaneously
with the grouting or sleeve grouting operation in such a manner that the grout
hole will not collapse and the injection of grout will not be hindered.
(g) Grout holes shall be flushed clean with water or compressed air introduced at
the bottom of the hole after drilling is complete. The holes shall be protected
with capping pipes or standpipes to prevent subsequent collapse or clogging
after flushing.
(a) Grout holes shall be capped after drilling and before grouting. Capping shall
be by a suitably sealed grout connection, standpipe or packer. The cap shall
seal the hole to prevent contamination or clogging of the hole until grouting
operations start.
(b) Standpipes, if stated in the Contract, shall be installed in holes after drilling.
The pipe shall be sealed into the hole using cement grout consisting of OPC
and water in the proportions 1:1 by volume.
(b) The accuracy of the instruments shall be checked before grouting starts and
at regular intervals reviewed without objection by the Project Manager.
(a) Standby grouting equipment shall be available at all times and shall be
capable of being brought into operation immediately in the event of
breakdowns during grouting operations.
(b) Grout mixers shall be high speed colloidal mixers having a rotor speed of at
least 1000 rpm and capable of producing a colloidal grout mix. Mixers shall
be fitted with a water volume measuring device for batching purposes.
(c) Holding tanks shall be fitted with an agitator to provide continuous agitation of
the grout at 100 rpm. The tank shall be fitted with a dipstick to allow
continuous measurement of the volume of grout in the tank. A 2.36 mm
removable screen shall be provided between the tank and the pump or grout
lines.
(d) Grout pumps shall be a positive displacement type. Pumps shall be fitted with
bypass valves to allow a standby pump to be brought into operation.
(f) Packers shall be such that they seal holes in rock at the specified level and
shall be capable of withstanding the maximum grout or water pressure to be
used at that level without leakage. Packers shall be of the mechanical or
inflatable rubber type. A sufficient number of packers of a size to suit the
holes shall be available on Site.
(g) Grout hoses shall be of sufficient length and shall be arranged in such a
manner to allow continuous circulation of the grout from the pump to the hole
and back to the agitator and holding tank. Circulation hose lengths shall be
kept to a minimum and sufficient spare hose shall be available in the event of
ruptures.
(a) Grout for geotechnical works shall be batched by weight. The mix proportions
may be adjusted if permitted by the Project Manager depending on the results
of the trial grouting, water tests in the hole or the results of previously grouted
holes.
(b) Grout shall be mixed by adding approximately two-thirds of the cement to the
water adding any admixture and adding the remaining one-third of cement.
Other mixing procedures shall not be used.
(c) The time for which grout shall be mixed in high speed mixers shall be suitable
for the type of mixer used. Grout shall be continuously agitated in a holding
tank after mixing and shall be screened before being circulated in the grout
lines. Mixed grout shall be continuously circulated in such a manner that
grout which is not taken in a hole can be returned to the holding tank.
(d) Grout to which a retarding agent has not been added, and which is not used
within 2 hours after mixing, shall not be used for grouting.
(a) Holes in rock shall be grouted in grouting stages not exceeding 3 m. Grouting
shall be carried out in either an upstage or a downstage sequence.
(b) Ground other than rock shall be grouted in such a manner that grout can be
injected at various points along the grout hole in a multi-stage operation. The
grouting method shall employ perforated pipes with rubber sleeve valves.
(c) Grouting pressures shall initially be 100 kPa per 4 metre depth of hole and
shall not exceed the overburden pressure.
(d) Holes shall be grouted in a continuous operation at the grouting stages and
pressures stated in the Contract. Grouting shall be carried out by injecting the
grout under pressure into each grouting stage of the hole until the grouting
stage refuses to take further grout.
(a) If during the grouting of any hole, grout is found to flow from adjacent grout
holes in quantities which interfere with the grouting operation or to cause
appreciable loss of grout, the holes shall be temporarily capped. If capping is
not essential, ungrouted holes shall be left open to allow air and water to
escape.
(b) If during the grouting of any hole grout is found to flow from joints in the
geological formation at the Site or any other location, the leaks shall be
plugged or caulked in a manner reviewed without objection by the Project
Manager.
(c) If during the grouting of any hole the grout take increases suddenly by a
significant amount, the Project Manager shall be notified immediately.
(a) Grout holes through concrete shall be made good using concrete reviewed
without objection by the Project Manager. The concrete shall be firmly
compacted and shall be finished to match the adjacent surface.
(b) Uncapped holes in rock shall be topped up after grouting using cement grout
consisting of OPC and water in the proportions 1:1 by volume, or 1:3 cement
sand mortar.
A grouting trial shall be carried out. The extent and depth of holes for grouting trials
and the tests to be carried out shall be as stated in the Contract or as directed by
the Project Manager.
(a) Records of grouting for geotechnical works shall be kept by the Contractor on
Site and shall be available for inspection by the Project Manager at all times.
Records shall include the following details:
(b) A record of grouting for each hole shall be submitted to the Project Manager
for review within 24 hours after completion of grouting of the hole. The record
shall contain the following details:
(c) A record of the testing for each hole, including test results, shall be submitted
to the Project Manager for review within 24 hours after completion of testing of
a hole. Records of Packer tests shall contain the following details:
(d) A report of grouting for each part of the Works as stated in the Contract,
including record drawings and logs of holes, shall be submitted to the Project
Manager for review within one week after completion and testing of grouting
for that part of the Works. The form of records, logs and record drawings
shall be submitted to the Project Manager for review.
(a) One sample of grout shall be provided from each batch of grout for
geotechnical works to determine the amount of bleeding of the grout.
(b) Samples shall be provided not more than 30 minutes after the grout has been
mixed and shall be protected from moisture content changes before the tests
for amount of bleeding are carried out.
(a) Each sample of grout taken as stated in Clause 8.15.3 shall be divided into
three specimens; each specimen shall be tested to determine the amount of
bleeding.
(b) Grout for geotechnical works shall be tested for bleeding in accordance with
Clause 21.6.24.
If the result of any test for amount of bleeding of grout for geotechnical works does
not comply with the specified requirements for amount of bleeding, particulars of
proposed changes to the materials, grout mix or methods of production shall be
submitted to the Project Manager for review; further grouting trials shall be carried
out.
One sample of grout shall be provided from each batch of grout for geotechnical
works to determine the flow cone efflux time of the grout.
Each sample of grout taken as stated in Clause 8.15.6 shall be tested to determine
the flow cone efflux time. The method of testing shall be in accordance with
Appendix A8.2.
If the result of any test for flow cone efflux time of grout does not comply with the
specified requirements for flow cone efflux time, particulars of proposed changes to
the materials, grout mix or methods of production shall be submitted to the Project
Manager; further grouting trials shall be carried out.
(a) One sample of grout shall be provided from each batch of grout for
geotechnical works to determine the crushing strength of the grout.
(b) Samples shall be provided not more than one hour after the grout has been
mixed and shall be protected from moisture content changes before test
cubes are made.
(a) Nine 100 mm test cubes shall be made from each sample of grout taken as
stated in Clause 8.15.9. Three test cubes shall be tested to determine the
crushing strength at 3 days, three test cubes shall be tested to determine the
crushing strength at 7 days and three test cubes shall be tested to determine
the crushing strength at 28 days.
(b) The method of making, curing and testing the test cubes shall be as stated in
Clause 20.8.12(b), (c) and (d).
If the result of any test for crushing strength of grout for geotechnical works does
not comply with the specified requirements for grout, particulars of proposed
changes to the materials, grout mix or method of production shall be submitted to
the Project Manager for review. Further trial mixes shall be made and further
grouting trials shall be carried out.
(a) The water loss from drillholes for grouting and from grouted and regrouted
drillholes shall be determined by the Packer test.
(b) The number of drillholes for grouting to be tested to determine the water loss
shall be proposed by the Contractor and reviewed without objection by the
Project Manager.
(c) Every grouted drillhole and every regrouted drillhole shall be tested to
determine the water loss.
(d) Packer tests shall be carried out in accordance with BS 5930, Chapter 21.5,
and Clauses 8.15.12(e) to (h).
(e) Tests shall be carried out using clean water, in grouting stages not exceeding
3 m in length. The rate of flow of water in the test shall be determined to an
accuracy of 10% for flows exceeding 1 L/min.
(f) The test pressure shall be equal to the overburden pressure and shall not
exceed the specified maximum grouting pressure for the grouting stage being
tested.
(g) The test shall be carried out between a packer and the base of the hole for
grouting stages at the base of a hole and shall be carried out between two
packers in other cases.
(h) The test shall be carried out by pumping water at the specified pressure into
the grouting stage being tested and measuring with a volume meter the water
loss over three consecutive 10 minute periods. The result shall be calculated
in Lugeons for each 10 minute period.
The water loss determined by the Packer test in the grouted hole shall not exceed 5
Lugeons when measured over a 10 minute period.
If the result of any Packer test on drillholes for grouting does not comply with the
specified requirements for the test, the drillhole shall be grouted, re-drilled and
retested. Grouting, re-drilling and retesting shall continue until the result of the
Packer test complies with the specified requirements for the test.
If the result of any Packer test on grouted drillholes or regrouted drillholes does not
comply with the specified requirements for the test, the grout shall be removed and
the drillhole shall be regrouted and retested. Removal of grout, regrouting and
retesting shall continue until the result of the Packer test complies with the specified
requirements for the test.
Caisson drain is an excavated vertical shaft, with or without raking drains, to provide
drainage by intercepting and lowering the groundwater level in the vicinity.
Geotextile filter is a permeable sheet of synthetic material used like a granular filter
for filtration and in-plane drainage.
Granular filter is a graded sand or gravel placed against soil to prevent the
migration of fine particles out of the soil caused by water flow, and graded such that
free discharge of water flowing into the filter is allowed.
Prefabricated band drain is a synthetic drain which, when installed in a soil strata,
acts as a drainage medium for dissipation of pore water pressure.
Raking drain is a drillhole, with or without perforated filter pipes and geotextile filter
sheath, installed generally at an upward inclination for groundwater lowering by
gravity flow.
Trench drain is a trench wholly or partly filled with granular material or clean
crushed rock, with or without filter pipes and geotextile filter.
Granular filter material for granular filter, trench drains and caisson drains shall
consist of durable, inert, natural material free from clay, organic material and other
impurities. Granular filter material shall have the particle size distribution stated in
the Contract.
Geotextile filter shall be a proprietary type reviewed without objection by the Project
Manager and unless otherwise stated in the Contract shall have the following
properties :
: 090 ≥ 0.05mm.
where :-
090 is the pore size below which lies 90% of the pore sizes in the geotextile;
D85, D15 is the particle sizes below which lie 85% and 15% by weight of the soil to be
filtered (only fraction smaller than 5mm to be considered)
DI pipes : BS 4772
(c) The perforations in perforated pipes shall be cleanly cut and shall be uniformly
spaced along the length and circumference of the pipe.
(a) Type O raking drains shall be unlined raking drains; drain holes shall be at
least 40 mm diameter.
(b) Type 1 raking drains shall be single pipe raking drains consisting of a single
perforated pipe with a non-perforated invert.
(c) Type 2 raking drains shall be single pipe raking drains consisting of a single
perforated pipe with a non-perforated invert and enclosed within a geotextile
filter sheath.
(d) Type 3 raking drains shall be double pipe raking drains consisting of an outer
permanent pipe and an inner removable pipe enclosed within a geotextile filter
sheath; the outer and inner pipes shall be perforated pipes with a
non-perforated invert.
(e) Pipes for raking drains shall be as stated in Clause 8.17.3 (a) and (b); the
openings and slots in pipes with non-perforated inverts shall cover
approximately two-thirds of the circumference of the pipe.
(f) Geotextile filter sheaths for raking drains shall be formed of woven or
non-woven geotextile filter complying with Clause 8.17.2.
(a) Fill material to be used with geotextile filter in trench drains shall be clean
crushed rock. Type A and Type B fill material shall have the particle size
distributions stated in Table 8.2.
(c) The D15 particle size of Type A fill material for use with perforated pipes shall
be at least 15% larger than twice the maximum dimension of the perforations,
where D15 is the equivalent sieve size in millimetres, interpolated from the
particle size distribution curve, through which 15% of the fill material would
pass.
(d) The Contractor shall check if the fill material to be used as a filter medium is in
the following relationship with the base soil, including any necessary soil
testing:-
(vi) Not more than 5% of the material shall pass the 63 micron sieve and
that fraction shall be cohesionless.
Legend
(I) D15F is used to designate the fifteen percent size of the filter
material, that is, the size of the sieve that allows fifteen percent by
weight of the filter material to pass through. Similarly, D85S
designates the size of sieve that allows eighty-five percent by
weight of the base soil to pass through. The subscript ‘c’ denotes
the coarse side of the envelope; the subscript `f' denotes the fine
side.
(II) If the filter grading Type A or B in Table 8.2 does not satisfy
Clause 8.17.5(d), the Contractor shall design the filter material so
as to comply with this Clause. The Contractor shall submit the
relevant details to the Project Manager at least four weeks in
advance of the commencement of laying of filter material on Site.
(III) The Contractor shall also design the filter so as to prevent filter
material being washed into the pipe as defined in Clause
8.17.5(c).
(e) Filter material shall be placed and compacted in such a manner as to avoid
segregation of the various grain sizes.
Table 8.2: Particle Size Distribution of Fill Material for Trench Drains
Caisson liners shall be concrete tapered rings at least 100 mm thick and not
exceeding 1 m deep. The liners shall be constructed with well-compacted concrete
of Grade 20/20 or greater.
(a) Prefabricated band drains shall consist of a core and a filter. The drains may
be manufactured as a single unit or the filter may be wrapped around the
core, and overlapped and sealed to contain the core. The drains shall be
made from chemically treated paper, polyethylene, polyester, polyolefine or
other synthetic material or combination of such materials.
(c) The strength of the materials in prefabricated band drains shall be such that
the drains will withstand all forces resulting from handling and installation.
(d) The filter jacket for prefabricated band drains shall be a type which:
(i) has been previously proved effective under similar soil and pressure
conditions,
(ii) is in all cases able to prevent excessive migration of soil particles into
the core, and
(iii) has a permeability not less than that of the surrounding soil.
(e) Prefabricated band drains shall be able to conform to soil deformation without
buckling or crimping of the core.
(f) Prior to the installation of the drains within the designated areas, the
Contractor shall demonstrate that his equipment, method and materials
produce a satisfactory installation in accordance with the Specification. The
Contractor shall install trial drains at locations designated by the Project
Manager.
(g) The end of each drain shall be provided with a suitable disposable shoe of an
acceptable type to ensure that the drain is securely anchored at its base level.
(vii) results of three tests for particle size distribution of the fill material
against which the granular filter is to be placed.
(iii) a certificate for the geotextile filter showing the manufacturer's name,
the date and place of manufacture and showing that the geotextile filter
complies with the requirements stated in the Contract, and including
results of the following tests :
- particle size distribution of sub-grade (BS 1377 : 1975 : Part 3); and
(iv) calculations showing that the geotextile filter complies with the filtration
characteristics stated in the Contract;
(ii) a certificate showing the manufacturer's name, the date and place of
manufacture and showing that the drains comply with the requirements
stated in the Contract;
(i) a detailed layout of drains with reference numbers, which shall comply
with the spacing requirements shown on the Employer’s Drawings. In
his proposed layout, the Contractor shall take into account all
foreseeable obstructions to the installation of drains (e.g. transition pile
caps, retaining wall etc) and shall include proposals to revise the area
limits of drains as necessary to avoid such obstructions;
(ii) the base level of each vertical drain which shall comply with the
requirements shown on Employer’s Drawings; and
(iii) the supporting calculations and ground investigation logs on which his
proposal is based.
(c) The Contractor shall carry out confirmatory drilling before the installation of
pneumatic piezometer tips and drains.
(ii) a certificate showing the manufacturer's name, the date and place of
manufacture and showing that the pipes comply with the requirements
stated in the Contract;
(b) geotextile filter and two pieces of geotextile filter joined in accordance with the
manufacturer's recommendations for each type of joint; and
(a) Granular filter material shall not be handled or stored in a manner which will
result in mixing of the different types and sizes or in segregation,
contamination, deterioration or erosion of the material.
(a) Geotextile filter shall be delivered in secure wrappings to ensure that the
geotextile filter is dry and protected from damage, contamination and
exposure to conditions which may adversely affect it.
(b) Geotextile filter shall be stored on a level surface and shall be kept in a secure
and dry condition, which will not result in damage to the fabric or in
contamination of the fabric.
(c) Geotextile filter which is damaged shall not be used in the Permanent Works.
(a) Prefabricated band drains shall be supplied in rolls, securely packed in light-
proof wrappings.
Granular filter material shall be thoroughly mixed by the method reviewed without
objection by the Project Manager. Material which has been stockpiled shall be
remixed before deposition.
(b) Granular filter material shall be deposited in a manner which will not result in
segregation or contamination of the material.
(c) Granular filter material shall be deposited in such a manner that a continuous
free draining zone is formed. The surface of each layer shall be cleaned and
scarified before the next layer is deposited.
(a) The total period for which geotextile filter is exposed to daylight or other
sources of ultra-violet radiation during handling, delivery, storage and
installation shall not exceed 7 days.
(b) Geotextile filter which has been damaged or exposed to daylight or other
sources of ultra-violet radiation for longer than the period stated in Clause
8.19.3(a) shall not be used in the Permanent Works.
(c) Repairs to geotextile filter which has been torn or damaged during installation
shall be carried out using a patch of the same material extending at least 300
mm beyond the edge of the damaged area. Repairs shall not be carried out
on geotextile filter which has been damaged during storage or storage before
installation.
(a) Geotextile filter shall be installed in such a manner that the individual yarns,
webs or layers of the fabric retain their intended orientation and relative
positions with respect to each another.
(b) Geotextile filter shall be installed, cut and jointed in accordance with the
manufacturer's recommendations.
(c) Fabric reinforcement stated in the Contract not to be jointed shall be lapped
by at least 300 mm.
Contractor's Equipment and other vehicles shall not operate on installed geotextile
filter unless it is adequately protected by a cover of fill material.
(a) The length of raking drains assembled before installation shall not exceed
12.5 m. Connections between adjacent pipes shall be secured in such a
manner that the cumulative longitudinal extension of a 12.5 m assembled
length of pipe does not exceed 5 mm when pulled by hand.
(a) Drilling lubricants other than clean air or fresh water shall not be used for
drilling holes for raking drains. Casings shall be used to prevent collapse of
the hole and to permit unobstructed insertion of the pipes and geotextile filter
sheath.
(b) The drillhole entry point shall be positioned within a tolerance of ±75 mm.
Deviation in alignment shall not exceed 1 in 20. Deviation from straight shall
not exceed 20 mm in any 3 m length of drillhole. A positive gradient shall be
maintained throughout the complete length of the hole. The inclination of
holes shall be measured by a method reviewed without objection by the
Project Manager.
(c) Drilling and sampling for undisturbed soil samples and rock cores directed by
the Project Manager to be recovered from drillholes shall be as stated in
Clauses 8.5.6 to 8.5.19.
The width of trench drains shall be at least 450 mm. The width of trench drains with
filter pipes not exceeding 150 mm diameter shall be at least four times the nominal
diameter of the pipe. The width of trench drains for pipes exceeding 150 mm
diameter shall be at least the same as the external diameter of the pipe plus 450
mm.
Geotextile filter surround for trench drains shall be installed as stated in Clause
8.19.4.
(a) Concrete bed for filter pipes in trench drains shall be at least 75 mm thick and
shall be Grade 20/20 concrete.
(b) Granular bed for filter pipes for trench drains shall have a thickness at least
the same as the diameter of the pipe or 150 mm, whichever is greater.
(a) The material for granular bed for trench drains shall be deposited in the trench
in layers not exceeding 150 mm thick and for the complete width of the trench.
Each layer shall be compacted with six passes of a plate vibrator or by other
method reviewed without objection by the Project Manager.
Trench drains shall be backfilled with Type A or Type B material of Table 8.2.
Type A or Type B material shall consist of hard, clean, crushed rock, crushed
slag or gravel having a grading within the limits of Table 8.2. The aggregate
crushing value of the material shall not exceed 30 per cent. The material
passing the 425 μm BS sieve shall be non-plastic when tested in accordance
with BS 1377.
(b) Fill material around filter pipes in trench drains shall be deposited and
compacted as stated in Clauses 7.4.20(b) and (c) and 7.4.27. The Project
Manager shall be notified before fill material is deposited around filter pipes.
(a) Excavation for caisson drains shall be carried out by manual methods in
stages not exceeding 1.0 m depth. Dewatering shall be carried out for
excavation below the groundwater level so that work shall be carried out, as
near as practicable in the circumstances, in dry conditions. Dewatering shall
be carried out as stated in Clauses 8.19.16 and 8.19.17.
(b) The caisson drain shaft shall be supported at all times during construction
using concrete liners. Voids between liners and excavated faces shall be
filled with no fines concrete. Caisson liners for each 1.0 m stage shall be
installed on the same day as that stage is excavated.
(c) Softened and loose material shall be removed from the base of the caisson
drain immediately before granular filter material is deposited in the caisson
drain.
(d) Part or all of the concrete liner adjacent to the granular filter layer shall be
removed before granular filter material or fill material is deposited. Debris
from the concrete liner shall be removed from the caisson drain.
(e) Granular filter material shall be deposited in layers not exceeding 500 mm and
shall be compacted by methods reviewed without objection by the Project
Manager.
Water collected in caisson drains shall be discharged to the outlets stated in the
Contract or reviewed without objection by the Project Manager
(a) The installed location of prefabricated band drains shall be within 300 mm of
the specified location in plan on the ground surface and the drain shall be
within 2% of the installed length to the vertical.
(b) Each prefabricated band drain shall be installed in one continuous length
without joints.
(c) The depth of penetration of prefabricated band drains shall be as stated in the
Contract, modified as directed by the Project Manager during installation
based on the resistance of the soil to penetration. The Contractor shall notify
the Project Manager immediately of any sudden change in the penetration
resistance to the mandrel.
(d) Augering, hammering, vibration or other methods may be used to assist vertical
drain installation through the filter drains and the reclamation fill. Such
augering, hammering, vibration or other methods shall not extend into the
underlying marine clay stratum.
(e) Where obstructions above the marine clay stratum are encountered which
cannot be penetrated using normal and accepted procedures mentioned
above, the Contractor shall complete the drain from the elevation of the
obstruction to its top level and notify the Project Manager. At the discretion of
the Project Manager, the Contractor shall then install a new drain at a location
as directed by him.
(f) The Contractor shall keep daily records of the drains installed. Copies of these
shall be submitted to the Project Manager on the day following the installation.
The records shall give the date, the reference no. of each drain and the depth
of placement below its top level. Brief notes on any unexpected conditions or
problems encountered shall be included.
The groundwater table shall not be drawn down to more than 2 m below the
earthworks final surface as defined in Clause 7.1.2 for excavation.
8.19.17 Dewatering
(a) Dewatering shall be carried out in such a manner that no loss of fines from the
ground occurs.
(b) Silt traps shall be provided and shall be regularly maintained; all dewatering
pumps shall discharge into silt traps.
(c) Pumped groundwater shall not be discharged onto roads, footpaths, kerb
channels or adjacent land. The Contractor shall make all arrangements with,
and obtain the necessary approvals and consents from the Relevant
Authorities and the Project Manager for discharging water to drainage
systems, watercourses or the sea. Dewatering shall not start until the
permitted arrangements for disposal of the water have been implemented.
Water entering the Site shall not be discharged into the same silt traps as are
used for dewatering.
(e) Half of the total pump capacity shall be equipped with a secondary motive
power source in addition to the primary motive power. The secondary motive
power source shall commence operation automatically in the event of failure
of the primary motive power source or an effective alarm system shall be set
up which will warn of failure of the primary motive power source. The
maximum allowable delay between failure of the primary motive power source
and full operation of the secondary motive power source shall not exceed 15
minutes.
(f) A full-time attendant shall be available on the Site at all times to execute the
changeover if manual operation of equipment is required to bring the
secondary motive power into operation.
(b) The capacity of pumps and the power sources which are to be used for
groundwater recharge shall be as stated in Clause 8.19.17(d) except that the
rate of flow shall refer to the maximum rate of groundwater recharge required.
(c) The groundwater table at any location shall not be raised above the
background groundwater table measured before the relevant work starts.
(a) Monitoring of groundwater levels shall be carried out at locations stated in the
Contract or instructed by the Project Manager at all times when groundwater
control and drawdown is carried out. Arrangements for installing instruments
and taking measurements both inside and outside the Site shall be made by
the Contractor.
(b) The survey marks for monitoring shall be located in position and level to the
Hong Kong standard survey grid and to PD to within 10 mm in every direction.
(e) The Contractor shall notify the Project Manager immediately if any increment
settlement reading exceeds 5 mm or if the accumulated settlement exceeds
the maximum allowable settlement stated in the Contract.
Records of installation of geotextile filter shall be kept by the Contractor on Site and
a copy shall be submitted to the Project Manager for review each day. Records
shall contain the following details:
(d) type of joint, amount of overlap, method of holding in place and any repairs to
geotextile filter carried out during installation;
Records of drillholes for raking drains shall be kept by the Contractor on Site and a
drillhole log for each drillhole shall be submitted to the Project Manager for review
before installation of the raking drain starts. The borehole log shall contain the
following details:
(a) Records of caisson drains shall be kept by the Contractor on Site and a copy
shall be submitted to the Project Manager for review within 14 days after
completion of construction of caisson drains. The records shall contain the
following details:
(ii) drawings showing the exact locations of caisson drains and the final
depths relative to PD.
(b) Detailed face logs of caisson drains shall be kept by the Contractor on Site
and shall be available for inspection by the Project Manager at all times. The
logs shall contain the information required in Clause 8.5.5(b)(ii), (b)(iii) and
(b)(iv) and the format shall be as shown in Figure 10 of 'Geoguide 2: Guide to
Site Investigation', Hong Kong Government 1987.
A batch of granular filter material is any quantity of granular filter material of the
same type and grading delivered to Site at any one time.
(a) One sample of granular filter material shall be provided from each 500 m3 or
part thereof of the material delivered to Site.
(b) One sample of granular material shall be provided from each 500 m3 or part
thereof of granular filter material which has been deposited and compacted.
(c) The size of each sample taken as stated in Clause 8.20.7(a) shall be 10 kg.
The method of sampling shall be in accordance with BS 812:Part 102.
(a) Each sample of granular filter material shall be tested to determine the particle
size distribution.
(b) The method of testing shall be in accordance with the wet sieving method
stated in Geospec 3, Test Method 8.1 or 8.2 as appropriate.
(a) If the result of any test for particle size distribution on a sample of granular
filter material taken as stated in Clause 8.20.7(a) does not comply with the
specified requirements for particle size distribution, additional samples shall
be provided from the same batch and additional tests for particle size
distribution shall be carried out.
(b) The batch shall be considered as not complying with the specified
requirements for particle size distribution if the result of any additional test for
particle size distribution does not comply with the specified requirements for
particle size distribution.
(c) If the result of any test for particle size distribution on a sample of granular
filter material taken as stated in Clause 8.20.7(b) does not comply with the
specified requirements for particle size distribution, additional samples shall
be provided from the same batch and additional tests for particle size
distribution shall be carried out.
(d) The batch shall be considered as not complying with the specified
requirements for particle size distribution if the result of any additional test for
particle size distribution does not comply with the specified requirements for
particle size distribution.
A batch of fill material for trench drains is any quantity of fill material for trench
drains of the same type delivered to Site at any one time.
(a) One sample of fill material for trench drains shall be provided from each batch
of fill material for trench drains delivered to Site.
(b) The size of each sample and the method of sampling shall be in accordance
with Clause 8.20.7(c).
(a) Each sample of fill material for trench drains shall be tested to determine the
particle size distribution; fill material passing a 425 μm BS test sieve shall also
be tested to determine the plasticity index.
(b) The method of testing to determine the particle size distribution shall be in
accordance with Geospec 3, Test Method 8.1 or 8.2 as appropriate. The
method of testing to determine the plasticity index shall be in accordance with
Geospec 3, Test Method 6.1.
Datum station is a mark for which horizontal or vertical values, or both, have been
fixed, and which is used as a datum for monitoring or control surveys.
Reference point is a mark placed close to another important survey mark to aid
recovery or replacement.
Survey station is a mark on a stone, concrete, metal or wooden block, pipe, peg or
other item defining a surveyed position.
(c) Instruments shall be handled, stored, installed and used in accordance with
the manufacturer's recommendations and in such a manner that the
performance of the instruments will not be impaired.
(d) Instruments shall be protected from damage and measures shall be taken to
ensure that the instruments suffer the minimum practicable amount of
disturbance.
The general layout of the apparatus shall conform to the details shown in Geoguide
2 Figures 19 and 21.
(ix) name and experience of persons responsible for installation, testing and
monitoring of instruments;
(c) At least two reference points shall be established for each survey station or
monitoring mark.
(d) The survey station which has the least chance of being disturbed shall be
selected as datum station. The datum station shall be stainless steel. At
least three reference points shall be established for each datum station.
(e) The survey network shall be related to the master survey stations provided by
the Project Manager.
(a) The Contractor shall notify the Project Manager before the installation of each
instrument for geotechnical instrumentation starts.
(b) Tests shall be carried out after installation to demonstrate that the instruments
have been correctly installed and are functioning correctly. Instruments which
are not correctly installed or are not functioning correctly shall be reinstalled or
replaced as directed by the Project Manager.
(c) All installed instruments, tubes and wires shall be clearly marked with a
unique and conspicuous identification number.
(a) Tubes and cables attached to instruments for geotechnical instrumentation for
remote reading shall be impervious to air and water, and shall have sufficient
strength and stiffness to withstand the internal and external pressures. Tubes
and cables shall be protected from mechanical damage and from the harmful
effects of direct sunlight, heat and ultra violet radiation at all times.
(b) Tubes and cables shall be marked with identification colours and numbers at
5 m intervals. The tubes and cables shall be wound onto reels in such a
manner that kinks are not formed and strain is not induced. Open ends of
tubes and cables shall be blocked with stop ends at all times.
(c) Tubes and cables shall be buried at least 0.5 m below ground level.
(b) The Contractor shall notify the Project Manager immediately of any
instruments found damaged or instruments found not to be in working order.
Replacements shall be installed for read-out units which are faulty or under
repair.
(c) Contractor’s Drawing showing the locations and details of survey stations,
monitoring marks and reference points shall be submitted to the Project
Manager for review within 3 days after the survey network has been
established.
(b) Initial readings shall be taken immediately after the instruments have been
installed and after the effects of installation have subsided. The initial
readings shall be submitted to the Project Manager for record and shall form
the basis of comparison of subsequent readings. The instruments and the
initial readings shall be replaced if the initial readings are not repeatable.
(b) Settlement plates shall be protected from damage and shall be kept in
position by a 600 mm thick layer of granular fill material or bags of sand which
shall be placed by manual methods and shall extend 600 mm beyond the
edges of the plate. The initial survey of levels and positions shall be taken
immediately after the fill material or bags of sand have been placed.
(c) The metal rod fixed to the centre of the plate shall be in an upright position,
and protected by a tubular sleeve. The sleeve and the metal rod shall be
extended as fill material is placed such that at any time the sleeve and rod are
at least 500 mm above the level of the surrounding fill material or high water
mark, and the metal rod is within 2% of the embedded length to the vertical.
(d) The level of the top of the metal rod shall be recorded immediately before and
immediately after each extension piece is added. Marker-buoys shall be fixed
to the tops of tubular sleeves installed in water.
(b) A protective cap or cover shall be fitted to protect the tilt-plates from damage.
(c) Tilt-plates and the tiltmeter shall be cleaned and inspected for damage before
readings are taken. The tiltmeter shall be accurately located on the tilt-plate
and a reading taken. The tiltmeter shall then be removed and the contact
surface recleaned. The procedure shall be repeated until consistent readings
are obtained. The tiltmeter shall then be rotated through 180° and the
procedures repeated.
(d) The accuracy of the tiltmeter and its readout system shall be checked both
before and after the readings taken each day. Instrument errors shall be
investigated and immediately corrected; a record of calibrations and
adjustments shall be submitted to the Project Manager for review together
with the monitoring data.
(b) The sand filter surrounding the piezometer tip shall be between 1000 mm and
1500 mm long and shall consist of sand between the sizes of 200 μm and
1210 μm. Measurements shall be made to determine the actual location of
the sand filter column.
(c) A seal shall be formed above the sand filter by placing 500 mm of bentonite
pellets of between 10 mm and 15 mm in size. The pellets shall be placed in
the hole and tamped with a suitably shaped tamper to form a homogeneous
plug to the hole.
(d) If the depth of the completed hole is greater than the depth at which the
piezometer tip and sand filter are to be placed, the bottom of the drillhole shall
be grouted with grout consisting of cement and bentonite in the proportions
1:1 by mass together with sufficient water to achieve the required workability.
The drillhole above the plug shall be grouted with the same type of material.
(e) The water level in the piezometer shall be measured after the standpipe
piezometer has been installed and the standpipe shall be topped up with
clean water. The rate of drop of water level or pressure head shall be
recorded at times of 0, 1/4, 1/2, 1, 2, 4, 8, 15, 30 minutes or until the water
has returned to its initial level.
(f) The water level shall be measured by an electrical type water level probe
reviewed without objection by the Project Manager. The water may be salted
if necessary for response to the probe.
(g) Measurements of the depth of piezometer tip and sand filter and the readings
taken as stated in Clause 8.24.10(f) shall be submitted to the Project Manager
for review within 24 hours after completion of installation of the piezometer
standpipe.
(i) The hole reference number shall be permanently inscribed on the surface box
either by welding a numbered steel plate to the box cover or by inscribing the
number in the concrete surround.
(b) The observation well shall consist of rigid PVC tubing to the dimensions and
installation details as described in Clause 8.24.10 except that the tube shall
be capped at its lower end and perforated with 6 mm diameter holes for a
minimum of 5% of its surface area over a length of 1.5 m or as instructed by
the Project Manager. The upper end of the tube shall be set in concrete and
fitted with a surface box as shown in Geoguide 2 Figure 21. The perforated
length shall be wrapped with two layers of nylon mesh. The granular surround
to the perforated length shall be 10 to 16 mm washed aggregate.
(c) The elevation of the base and the top of the granular surround shall be
recorded on the log. The depth to the base of the observation well shall be
confirmed by dipping on completion of the installation.
8.25.1 General
(a) The Contractor shall, when instructed by the Project Manager, carry out soil
tests specified in this Section at a HOKLAS accredited laboratory reviewed
without objection by the Project Manager.
(b) The laboratory shall hold current HOKLAS accreditation for tests according to
Geospec 3.
(c) The “Laboratory Work” shall be completed within four weeks of the completion
of the “Field Works”.
Senior technician - a person with at least 10 years experience gained in a soil testing
laboratory and fully familiar with triaxial testing procedures.
The results of the tests shall become the property of the Employer and shall not be
divulged by the Contractor except to the Employer or the Project Manager.
Samples and the original sample containers are the property of the Employer and
the Contractor shall not dispose of any samples, original sample containers or parts
thereof except as directed by the Project Manager.
For testing purposes, 'Mazier' samples shall be cut to the appropriate length for
testing and then extruded in the direction of the top of the sample in a manner
reviewed by the Project Manager.
When laboratory tests are carried out on only part of a soil sample, the remainder of
the soil in the sampler or container shall be resealed with wax as soon as possible
and retained. Soil on which laboratory tests have been carried out, including that
wasted during the preparation of test specimens, shall be retained in airtight
containers until the presentation of the “Final Report”.
The following laboratory soil classification tests shall where applicable be carried
out in accordance with the procedures described in Geospec 3 :-
(b) determination of liquid limit (Test Method 6.1). The sample shall not be
completely dried before testing;
(c) determination of plastic limit, plasticity index and liquidity index (Test Method
6.1 and 6.2). The soil shall not be completely dried before testing;
(d) determination of particle density for soils containing gravel sized particles
(Test Method 7.1). Samples at natural moisture content of dry weight
approximately equal to that specified in BS 1377 shall be used. The sample
shall not be dried prior to testing but shall be oven dried and weighed on
completion of the test. The test shall be carried out using distilled water; and
(i) essentially cohesionless soil down to the fine sand size (Test Method
8.1 or 8.2 as appropriate); and
(ii) coarse sand to clay size (Test Method 8.3, 8.4, 8.5 or 8.6 as
appropriate).
“Triaxial Test Procedures” as specified in Clauses 8.26.5, 8.26.21 and 8.26.22 shall
be based upon "The Measurement of Soil Properties in the Triaxial Test" (Second
edition, 1962) by A.W. Bishop and D.J. Henkel, unless otherwise instructed by the
Project Manager.
De-aired water shall be used to saturate soil specimens and for cell water.
Adequate provision shall be made at any air/water interfaces in the pressure
application system to minimise air contamination of the water.
In the case of gritty soils two membranes shall be used for jacketing the soil
specimen, unless agreed otherwise with the Project Manager. Membranes shall be
checked for leakage before use.
(b) the back-pressure shall be brought up to the value of the cell pressure minus
5 kPa with the drain closed. The drain shall then be opened and the volume
change shall be noted and adequate time shall be allowed for this change to
cease. Procedure (1) shall then be repeated.
(c) the cell pressure shall be taken up in undrained increments of 50 kPa or less
to the value of the test cell pressure allowing pore water stabilization at each
increment, and the pore water pressure shall be recorded immediately after
application of each additional increment of pressure.
(a) if saturation by back-pressure has been attempted, the cell pressure shall be
reduced to 50 kPa and simultaneously the back-pressure shall be reduced to
40 kPa. If saturation by back-pressure has not been attempted, cell pressure
shall be set at 50 kPa and back-pressure at 40 kPa; and
(b) maintaining these pressures, the drain shall be opened from the sample top
cap to the atmosphere and de-aired water shall be allowed to flow through the
sample until bubbling ceases. The drain shall then be closed and the sample
saturated by back-pressure as specified in sub-clause (a) above.
The following corrections, where appropriate, shall be applied when calculating the
deviator stress and shall be indicated in the results:-
(b) restraint from the rubber membrane and filter paper drains (Bishop and
Henkel, p. 167); and
Shear failure for single stage triaxial tests shall be defined in terms of maximum
principal stress difference (σ1 - σ3). Shear failure for multi-stage triaxial tests shall
normally be defined in terms of maximum principal effective stress ratio (σ 1'/ σ3')
unless otherwise instructed by the Project Manager.
For specimens which fail along a shear plane, the axial strain at which the shear
plane becomes apparent shall be recorded.
A sketch shall be made of the mode of specimen failure. The angle of any distinct
shear planes shall be measured with respect to the horizontal and noted both
before splitting and after splitting the specimen.
(b) The report of each test shall include the following information:-
(v) initial and final moisture content, volume and bulk density and specified
effective cell pressure;
(ix) standard increment of cell pressure (50 kPa, unless otherwise specified
by the Project Manager); and
Shearing Stage:
(xviii) maximum principal effective stress ratio and corresponding axial strain;
(b) If failure has not occurred in a particular stage, shearing for that stage shall be
stopped at the following cumulative strains, subject to the Project Manager’s
agreement:
(b) The report of each test shall include the requirements listed in
Clause 8.26.16(b) together with a volume change/axial strain plot.
The tests shall be carried out in accordance with Part 7 Method 8 of BS 1377.
(b) The report of each test shall include the following information:
(v) initial and final moisture content, volume and dry/bulk density;
(x) standard increment of cell pressure (50 kPa, unless otherwise specified
by the Project Manager); and
A Mohr stress circle diagram shall be prepared for results of a series of tests on the
same sample or for results of one multi-stage test providing plastic failure has
occurred in each specimen or planar failure has been on planes included at
approximately (45 degrees +0/'/2) to the horizontal. The apparent cohesion (c') and
angle of shearing resistance (0/') with respect to changes in effective stress shall be
determined by the "least-squares" fitting technique. For failure of specimens on
planes not inclined at an angle of approximately (45 degrees +0/'/2) to the
horizontal, the Project Manager shall decide on the mode of presentation of the
results.
(a) A colour photographic record shall be kept of triaxial test specimens after
testing. The Contractor shall take all photographs required by the Project
Manager.
(b) A reference label, scale and colour chart from the manufacturer applicable to
the type of film and paper used shall be placed together with the specimen in
the camera's field of view and a photograph shall be taken at a magnification
agreed with the Project Manager.
(a) “Drained Modulus Tests” shall be carried out in a triaxial testing machine. The
test specimens shall be prepared, saturated and consolidated prior to the
application of axial strain in accordance with procedures relating to
“Consolidated-Drained Single Stage Triaxial Tests” (Clause 8.26.18). The
specimen shall then be loaded to a deviator stress as instructed by the Project
Manager before being unloaded. The rate of application of axial strain during
loading/unloading shall be sufficiently low to ensure at least 95 per cent
dissipation of excess pore-pressure. The above loading/unloading procedures
shall be repeated for four other cycles to different deviator stresses instructed
by the Project Manager.
(b) The report of each test shall include the requirements given in Clause
8.26.16(b) except that items (xiii) to (xviii) shall be replaced by:
Loading/Unloading Stage:
(a) Consolidated-drained single-stage and multi-stage direct shear box tests shall
be carried out on samples of soil containing relict joints or discontinuities in
accordance with the requirements specified in this Clause. The Contractor
shall submit to the Project Manager for review:
(c) After applying the initial normal pressure (30 kPa), water shall be added to the
carriage to a level such that the specimen is completely immersed. Then the
normal pressure shall be increased to the required value for shearing and
maintained for a minimum period of 12 hours for consolidation. Any
settlement of swelling taking place during the process shall be measured by
dial gauge at suitable time intervals. The specimen shall be maintained in a
soaked condition throughout the test.
(d) The rate of testing shall be not greater than 0.1 mm/min, and the suitability of
the rate shall be checked from consolidation stage data. Shearing shall be
continued for the full travel of the shear box.
(e) Colour photographs shall be taken of all specimens before and after testing.
A reference label, scale and colour chart from the manufacturer applicable to
the type of film and paper used shall be placed together with the specimen in
the camera's field of view and a photograph shall be taken at a magnification
agreed with the Project Manager. The photographs shall be processed so as
to ensure accurate reproduction of colours, as shown by the colour chart. One
print of each photograph, and a copy of the colour chart, shall be attached to
each copy of the “Draft Final Report” and to each copy of the “Final Report”.
The set of negatives shall be attached to the master copy of the “Final
Report”.
(f) Testing shall otherwise be carried out in accordance with the procedure given
in "Laboratory Testing in Soil Engineering" by T.N.W. Akroyd.
(g) Preparation of specimens for testing shall be carried out in the presence of an
experienced geotechnical engineer.
(h) The report on each test shall include the following information:-
Falling head permeability tests (Akroyd p. 147) and constant head permeability
tests (Akroyd p. 154) shall be carried out on specimens of up to 110 mm in length
and diameter. The report of each test shall include the following information:-
(a) “California Bearing Ratio” (CBR) Tests shall be carried out in accordance with
the procedures described in BS 1377 Part 4 Method 7. The test shall be
carried out on each sample over a range of moisture contents so that the
relationship of CBR to moisture content can be determined. The test shall
include at least 5 determinations with moisture contents chosen from the
results of the “Soil Compaction Test” and including optimum moisture content
and the values of moisture content corresponding to a dry density of 95 per
cent of the maximum.
(b) The results shall be recorded on forms similar to Forms 4E to 4G, BS 1377
and acceptable to the Project Manager.
(a) Soil Compaction Tests shall be carried out in accordance with the procedures
described in BS 1377 Part 4 Method 3.3 or 3.4 as appropriate (2.5 Kg
rammer)(at least 5 determinations per test are required).
(b) In the case of density determinations carried out at moisture contents less
than the natural moisture content in a compaction test, the soil shall not be
allowed to dry to a moisture content lower than the moisture content at which
the density determination is to be made.
(c) The results shall be recorded on a form similar to Form 4A, BS 1377 and
acceptable to the Project Manager.
“One Dimensional Consolidation Tests” shall be carried out in accordance with the
procedures described in BS 1377 Part 5 Method 3. The results shall be recorded on
a form similar to Forms 5A to 5D, BS 1377 and acceptable to the Project Manager.
(a) Point load tests shall be conducted and reported according to the “Suggested
Method of Determining Point Load Strength” by ISRM (1985). Test results
shall be presented according to relevant ISRM figures, or according to an
alternative reviewed without objection by the Project Manager.
(b) When testing core samples, each test specimen shall first be tested with the
direction of loading perpendicular to the axis of the core (i.e. the diametral
test), and secondly with the direction of loading either along the axis of the
core or perpendicular to observable planes of anisotropy (i.e. the axial test).
When testing irregular specimens that show anisotropy, one-half of the test
specimens shall be tested with the load perpendicular to the planes of
anisotropy, and the remaining half of the test specimens shall be tested with
the load parallel to the planes of anisotropy.
Rock joint shear tests shall be conducted according to “Suggested Methods for
Determining Shear Strength” by ISRM (1974), as modified by the following:
(a) rock joint shear tests shall be conducted using either a Golder or Roberston
Shear Box. The choice of shear box shall be as directed by the Project
Manager;
(c) the following items shall be included for rock joint shear tests, with test results
presented according to relevant ISRM figures, or according to alternatives
reviewed without objection by the Project Manager:
(i) the dimensions of the top and bottom shear surfaces shall be
determined and recorded;
(ii) the actual area of contact between the top and bottom shear surfaces
shall be estimated: areas that have regular shapes shall be calculated:
areas that have irregular shapes shall be estimated using graph paper;
(iii) the roughness profile shall be recorded, before and after shear, with the
aid of a profilometer. A description of the rock joint shall also be made,
including colour, tightness and nature of joint infill materials, if any;
(iv) photographs of top and bottom joint surfaces, before and after shear,
shall be taken according to Clause 8.26.21;
(vi) the specimen shall be soaked in water overnight before testing, unless
otherwise instructed by the Project Manager.
(i) hydraulic ram springs: when hydraulic ram springs have been used a
correction shall be applied to gauge readings to account for the
resistance provided by the ram return springs;
(e) the following plots shall be prepared according to the relevant ISRM, or
according to an alternative reviewed without objection by the Project
Manager:
(ii) shear stresses and vertical displacement shall use the same abscissa
that represents the horizontal displacement; and
(iii) peak shear stresses versus normal stress, uncorrected and corrected
for dilation; and
(f) the variations to the above procedure for testing tight joints shall be as
reviewed without objection by the Project Manager.
The determination of porosity and dry density of rock shall be made according to
“Suggested Method for Porosity/Density Determination Using Saturation and
Calliper Techniques” Method 2, or “Suggested Method for Porosity/Density
Determination Using Saturation and Buoyancy Techniques” Method 3, by ISRM in
“Rock Characterisation Testing and Monitoring” by E.T. Brown (editor)(1981).
(a) The test results shall be presented in tabular and/or graphical form as
appropriate and on forms acceptable to the Project Manager. Examples of
suitable forms for presentation are given in BS 1377 and also in Manual of
Soil Laboratory Testing by K H Head Published by Pentech Press Limited,
Graham Lodge, Graham Road, London NW4 3DG, England.
(b) Four preliminary copies of the results of each test complete with test data and
photographs shall be submitted to the Project Manager within two days of
completion of the test. The records shall be legible and intelligible and shall be
stamped PRELIMINARY.
Whilst laboratory testing is in progress, the Contractor shall inform the Project
Manager without delay of any unusual or irregular occurrences observed during any
of the laboratory tests ordered.
Within three days of completion of the “Laboratory Work” the Contractor shall
submit three copies of the “Draft Final Report”. The contents and standard of
presentation shall be as proposed for the “Final Report”. The presentation shall be
neat, clear and intelligible. Each page, and the cover, shall be stamped “DRAFT”.
The Project Manager will return one copy of the “Draft Report” to the Contractor
with his comments within three weeks of receipt of the report.
(a) The “Final Report” shall contain the information described in the following
sub-clauses relevant to the Works. In preparing the “Final Report”, account
shall be taken of comments made by the Project Manager after examining the
“Draft Final Report”.
(vi) methods used in making holes, taking samples and carrying out in-situ
tests;
(viii) details of any bench marks and/or survey beacons to which the “Field
Work” is referenced; and
(b) The location of holes and tests shall be shown on a plan or plans of the Site.
(c) Final logs and any photographs specified shall be appended. The master
copy of each final log together with the negatives of all photographs specified
shall be included with the master of the “Final Report”. Logs shall be ring
bound to facilitate photocopying.
(d) The results of in-situ tests shall be presented on the logs of holes and/or in
tabular and/or graphical form, as appropriate. The information given shall
include that provided for by the relevant test procedure in accordance with
Clause 8.6.1 together with other information necessary for a full
understanding of the results.
(f) Page size shall be A4. (Tables and figures shall be A4 height but greater
width, folded in such a way that the essential titles can be read without
opening).
(g) One master and ten bound copies of the “Final Report” shall be submitted.
(h) The “Final Report” shall be submitted within 2 weeks of the return to the
Contractor of the “Draft Report” with the Project Manager’s comments.
A8.1.1 Scope
This method covers the determination of the penetration resistance of soil using the
GEO probe.
A8.1.2 Apparatus
(2) Extension rods with a length of 1000 mm ±10 mm. The rods shall be attached
to bear against each other by means of external couplers.
A8.1.3 Procedure
(1) The lower end of the probe shall be rested against the ground at the test
location, with the first extension rod and guide rod in a vertical position.
(2) The hammer shall be raised to bear against the upper anvil, and shall be
allowed to fall freely. It shall not be connected to objects which may influence
its acceleration and deceleration, and shall be stationary when released in the
upper position. The fall shall be 300 mm ± 5 mm.
(3) The hammer shall be used to drive the probe into the ground, with a rate of
driving between 20 and 60 blows per minute.
(4) Additional extension rods shall be added as necessary. The rods shall be
rotated clockwise one full turn each time a rod is added to ensure that screw
joints are tight.
(5) The blow count for every 100 mm of penetration shall be recorded, or at
refusal the penetration distance for 50 blows of the hammer. Interruptions
exceeding 5 minutes shall be recorded.
(1) Blow count for every 100 mm penetration or at refusal the penetration
distance for 50 blows of the hammer.
(4) That the test was carried out in accordance with this General Materials and
Workmanship Specification.
A8.2.1 Scope
This method covers the determination of the flow of grout by measuring the time of
efflux of a specified volume of grout from a standard flow cone.
A8.2.2 Apparatus
(2) A stop watch with a least reading of not more than 0.2s.
(3) A thermometer.
(1) The flow cone shall be firmly mounted in such a manner that the top will be
level and the cone will be free from vibration.
(2) The discharge tube shall be closed by placing the finger over the lower end.
A quantity of 1725 mL ± 1 mL of water shall be introduced to the cone.
(3) The point gauge shall be adjusted to show the level of the water surface.
The procedure for determination of the flow of the grout shall be as follows :
(1) Two specimens of grout shall be taken from the sample of grout. The size of
each specimen shall be 1725 mL ± 1 mL.
(2) The inside surface of the flow cone shall be wetted by filling the cone with
water and allowing the water to drain from the cone 1 minute before the
specimen of grout is introduced to the cone.
(4) The discharge tube shall be closed by placing the finger over the lower end.
The specimen shall be introduced to the cone until the surface of the grout is
in contact with the point gauge.
(5) The stop watch shall be started and the finger removed from the discharge
tube simultaneously.
(7) The cone shall be thoroughly cleaned and the procedure stated in Clauses
A8.2.3 and A8.2.4 (1) to (6) shall be repeated for the second specimen.
A8.2.5 Calculation
(7) That the test was carried out in accordance with this General Materials and
Workmanship Specification.
Nominal maximum aggregate size is the smallest BS sieve size for which the upper
limit of the percentage of the aggregate by mass passing is 100%.
(a) Sub-base material and bituminous roadbase materials shall be recipe mixes.
Laboratory design mixes other than those for sub-base material and
bituminous roadbase materials shall be made and tested as part of the design
procedure at a laboratory reviewed without objection by the Project Manager.
(b) Mix designs and associated tests shall be carried out by the Contractor in the
presence of the Project Manager. The Contractor shall notify the Project
Manager at least 7 days before carrying out the mix designs.
(a) Bituminous materials shall consist of coarse and fine aggregates complying
with Clause 9.3.2, filler complying with Clause 9.3.3 and bitumen complying
with Clause 9.3.4. The different types of bituminous materials shall have
particle size distribution and bitumen content within the limits stated in Table
9.4.
(b) The properties of the different types of bituminous materials shall be as stated
in Table 9.1.
(c) Bituminous materials of all aggregate sizes, other than bituminous roadbase
material, shall be designed in accordance with the “Marshall Method of Mix
Design” stated in The Asphalt Institute Handbook 'MS-2 Mix Design Methods
for Asphalt Concrete and other Hot-mix Types,' 1984. The compaction
standard shall be 75 blows per side.
(d) Design procedures for bituminous friction course material shall be as stated in
Clause 9.2.2(c) except that the mixing and compaction temperatures shall be
consistent with bitumen viscosities of 900 ± 100 centistokes and 2000 ± 200
centistokes respectively.
9.3 MATERIALS
Sub-base material shall be crushed rock and shall have the properties stated in
Table 9.2. Sub-base material passing the 425 μm BS test sieve, when tested in
accordance with Clause 9.6.10(c) shall be non-plastic.
Percentage by
Properties BS test sieve
mass passing
Particle size distribution 75 mm 100
37.5 mm 85 - 100
20 mm 60 - 85
10 mm 40 - 70
5 mm 25 - 45
600 μm 8 - 22
75 μm 0 - 10
Ten percent fines value > 50 kN
(a) Coarse aggregate for bituminous materials shall be crushed rock all retained
on a 5 mm BS test sieve and shall have the properties stated in Table 9.3.
(b) Fine aggregate for bituminous materials shall be crushed rock, river sand or a
mixture of crushed rock and river sand all passing 5 mm BS test sieve. The
water absorption of fine aggregate shall not exceed 2.0%.
Properties 37.5 28 20 10
Table 9.4: Design Limits for Particle Size Distribution and Bitumen Content
for Bituminous Materials
(a) Filler for bituminous materials shall be crushed rock filler, OPC, PPFAC, PFA
or hydrated lime. Filler shall be free-flowing and dry before addition to the
bituminous mixture.
(b) Filler for bituminous friction course material shall contain hydrated lime; the
amount of hydrated lime, expressed as a percentage by mass of the total
aggregates, shall be at least 1.5%.
(c) OPC shall comply with BS 12. PPFAC shall comply with BS 6588.
(d) PFA shall comply with BS 3892 : Part 1 except that the criterion for maximum
water requirement shall not apply.
(e) Crushed rock filler and hydrated lime shall comply with ASTM D 242.
9.3.4 Bitumen
Bitumen for bituminous materials shall comply with ASTM D 946, Grade 60-70 and
shall have a softening point exceeding 44°C and less than 55°C. Blending or mixing
of bitumen shall be carried out at a refinery reviewed without objection by the Project
Manager.
(b) Sub-base material and bituminous materials shall not be handled or stored in a
manner which will result in mixing of the different types and sizes or in
segregation or contamination of the materials.
(c) Bituminous materials shall not be stored in heated surge bins for more than 12
hours or in transport vehicles for more than 3 hours.
(d) Bituminous friction course material shall not be stored in surge bins for more
than 30 minutes.
(a) Sub-base material and bituminous materials shall be protected by covers while
being transported and before laying. Covers for bituminous materials shall be
heavy canvas or a similar insulating material; the covers shall completely
cover the material and shall be securely fixed to minimise loss of heat and to
protect the materials from contamination by dust or other deleterious material.
(c) The trays of vehicles transporting bituminous materials may be lubricated with
soap solution or light oil sprayed on the trays. Vehicles transporting
bituminous friction course material shall not be lubricated with light oil.
9.4 SUBMISSIONS
(a) The following particulars of the proposed filler and bitumen for bituminous
materials shall be submitted to the Project Manager for review:
(i) a certificate from the manufacturer for each type of filler showing the
manufacturer's name, the date and place of manufacture and showing
that the filler complies with the Specification and including results of tests
for particle size distribution; and
(b) Further certificates showing that the materials comply with the Specification
shall be submitted at intervals reviewed without objection by the Project
Manager.
(i) certified copies of work sheets for mix designs, which shall include the
relative density of the mixed aggregates;
(iii) past test records of the same mix produced in the same plant.
The name of the supplier and the location of each plant from which the Contractor
proposes to obtain sub-base material and bituminous materials shall be submitted to
the Project Manager for review, together with a certificate of origin and certificate of
quality.
(a) The following particulars of the proposed methods of laying and compacting
sub-bases and bituminous materials shall be submitted to the Project Manager
for review:
9.5 WORKMANSHIP
Mixing of sub-base material and mixing of bituminous materials shall be carried out
before delivery to Site at mixing plants reviewed without objection by the Project
Manager. The plants shall be designed and operated to produce uniform mixes
which comply with the specified requirements.
(a) The mixing plant for bituminous materials shall have at least four separate cold
feed bins for preliminary cold batching of the coarse and fine aggregates, and
a rotary drum dryer which will continuously agitate the aggregates during the
heating and drying processes. After passing through the dryer, the aggregates
shall be screened into at least four hot storage bins before mixing.
(b) Bitumen heating and storage tanks shall be fitted with circulating pumps to
ensure an even temperature throughout the tanks.
(c) The mixing plant shall be provided with sampling devices to enable samples of
hot aggregates, filler and bitumen to be taken before mixing.
(d) Insulated surge bins, if fitted to the mixing plant, shall be designed and
operated to prevent segregation occurring in the mix. Heating devices fitted to
surge bins shall be capable of maintaining the temperature of the mix to within
the specified limits.
(b) Mixing of bituminous materials shall continue after the addition of all
constituents for such period as is necessary to ensure that the aggregates and
filler are uniformly coated with bitumen.
Roadbase, Friction
base course course
Type of bituminous material and wearing
course
Aggregate temperature at mixing ( °C) Min. 130 115
Max. 175 135
Binder temperature at mixing ( °C) Min. 135 115
Max. 165 165
Bituminous mixture temperature Min. 130 115
after mixing ( °C) Max. 165 135
Bituminous mixture temperature Min. - 110
at laying ( °C) Max. - 135
Bituminous mixture temperature Min. - 85
at start of compaction ( °C)
(a) Pipes, cables, manholes, chambers, gullies and other utilities below
carriageways shall be completed and fill material shall be deposited and
compacted in trenches before the carriageway is constructed. Openings to
manholes, chambers and gullies shall be protected by temporary covers.
(b) Covers, frames and other hardware which will prevent continuous laying of
bituminous materials for roadbase and base course shall not be fixed in
position until such work is complete.
(c) After the penultimate layer of bituminous material has been laid and
compacted, the layers of asphalt shall be cut out, temporary covers shall be
removed and the permanent covers, frames and other hardware shall be
installed.
(d) Finishing around covers, frames and other hardware shall be carried out using
bituminous material of the same type as that in the adjacent surface. The
material shall be compacted in layers not exceeding 50 mm thick using
handrammers or mechanical equipment up to the underside of the wearing
course or friction course.
(a) Sub-base material shall be laid and compacted in a manner which will not
result in segregation of the material and at a moisture content which allows the
compaction stated in Clause 9.5.5(f) to be achieved. The moisture content
shall not be less than 2%.
(b) Sub-base material shall be laid in layers and compacted. The thickness of
each compacted layer shall not exceed 225mm. The minimum thickness of
each layer shall be 100mm and, if the layers are of unequal thickness, the
lowest layer shall be the thickest.
(c) Each layer of sub-base material shall be evenly spread immediately after
placing in position and shall be compacted immediately after spreading.
(e) The Project Manager shall be notified before the next layer is placed on each
layer of compacted sub-base material.
(a) Bituminous materials shall not be laid during periods of wet weather or when
ponded water is present on the underlying surface.
(b) Bituminous wearing course material shall not be laid when the ambient air
temperature is below 8°C and bituminous friction course material shall not be
laid when the ambient air temperature is below 10°C. Temperatures shall be
measured in the shade near to the surface on which laying is to be carried out.
(c) Surfaces on which bituminous materials are laid shall be clean and free from
mud, grit and other deleterious material.
(g) Where paved hard shoulders are provided, friction course shall be left proud of
the immediate underlying layer and in line with the front edge of the gully
gratings or drainage channel, provided the friction course extends more than
0.5 m beyond the lane edge.
(a) Bituminous materials shall be placed and spread using a self-propelled paving
machine with a screw auger and attached screed capable of spreading and
laying the material to the full width required. The paving machine shall be
capable of giving initial compaction to the material and finishing it to a level
suitable for subsequent compaction.
(b) Paving machines may be fitted with cut-off shoes or extensions to limit or
extend the width of the screed; screed extensions shall not be used unless the
screw auger is extended in accordance with the manufacturer's
recommendations. The surface texture produced by paving machines shall be
free from segregation and from pushing or dragging marks.
(c) Bituminous materials laid by paving machines shall be placed directly from the
vehicles transporting the material into the hopper of the paving machine.
Delivery of materials to the paving machine and laying of the materials shall be
at a uniform rate appropriate to the capacity of the paving machine and
compaction plant.
(f) Manual placing of materials on freshly laid surfaces shall only be used for the
purpose of locally correcting levels as paving operations proceed, before
compaction by rolling is commenced.
Bituminous materials shall be laid by manual methods only if in the opinion of the
Project Manager the use of a paving machine is impracticable. If permitted by the
Project Manager, bituminous materials may be laid by manual methods:
(c) adjacent to expansion joints, covers, frames and other hardware; and
(ii) other types of rollers, vibrating plates and rammers reviewed without
objection by the Project Manager, or other similar plant reviewed without
objection by the Project Manager, necessary to produce the required
degree of compaction.
(b) Bituminous roadbase, base course, regulating course and wearing course
materials shall be initially rolled using a steel-wheeled roller operated in a
longitudinal direction along the carriageway with the driving wheels nearest the
paving machine.
(c) All roller marks shall be removed from the surface of bituminous roadbase,
base course and wearing course materials using either a smooth-wheeled
dead-weight roller or a smooth-wheeled vibratory roller in non-vibrating mode.
(e) Rollers shall not be parked on newly laid or compacted bituminous materials.
(f) Bituminous materials immediately adjacent to kerbs, covers, frames and other
hardware where rollers cannot operate effectively shall be compacted using
hand-operated mechanical compaction plant.
(a) The screed of the paving machine shall overlap previously laid strips of
bituminous material by at least 50 mm and shall be sufficiently high that
compaction will produce a smooth dense flush joint. Bituminous materials
overlapping the previously laid strip shall be pushed back to the edge of the
previously laid strip and the excess material shall be removed.
(c) A prepared joint shall be formed between hot bituminous material and cold
material or existing bituminous material which is at a temperature below the
minimum specified laying temperature.
(d) The distance between prepared longitudinal joints in different layers shall be at
least 150 mm and the distance between prepared transverse joints in different
layers shall be at least 500 mm.
(e) Prepared joints in base course and wearing course shall be formed by cutting
back the face of the cold material or existing bituminous material for a
minimum distance of twice the depth of the layer or 100 mm, whichever is
greater; a vertical face shall be cut for the full depth of the layer. All loosened
materials shall be removed and the face shall be coated with bituminous
emulsion; the bituminous emulsion shall not be applied beyond the edges of
the joint. The hot bituminous materials shall be laid and compacted against
the coated face with a joint formed as stated in this sub-section.
(f) Friction course joints shall not be coated with bituminous emulsion.
(a) The surface of each layer of sub-base material and bituminous materials shall
be kept clean and free from deleterious material. Bituminous priming coat
shall be applied to the final surface of the sub-base layer at a rate of between
0.9 L/m² and 1.1 L/m².
The line of the edges of carriageways shall be within 25 mm of the specified line,
except at the edges of structures where it shall be within 6 mm.
(a) The levels of the surface of each layer of sub-base, roadbase, base course,
wearing course and friction course shall be determined on a grid at 10 m
centres in the longitudinal direction and at 2 m centres in the transverse
direction.
(b) The level of the surface of each layer of sub-base, roadbase, base course,
wearing course and friction course shall be within the tolerances stated in
Table 9.6.
(c) The difference in level of the surface of wearing course and friction course
across joints shall not exceed 3 mm.
(d) The combination of permitted tolerances in levels shall not result in a reduction
in the thickness of the pavement, excluding the sub-base, of more than 15 mm
from the specified thickness nor a reduction in the thickness of the bituminous
wearing course or friction course of more than 5 mm from the specified
thickness.
The level of covers, frames and other hardware shall be not lower than, and shall
not be more than 5 mm higher than the surface of the carriageway. The level of
gully gratings shall not be higher than, and shall not be more than 5 mm lower than,
the surface of the carriageway.
(a) The Contractor shall produce trial areas of each type and layer of bituminous
materials to demonstrate that the proposed materials, mixes, methods of
production and methods of construction are capable of producing a
carriageway which complies with the specified requirements. Unless
otherwise stated in the Contract, the trial areas shall be constructed as part of
the Permanent Works at locations reviewed without objection by the Project
Manager. The width of each trial area shall be at least one lane of
carriageway, and the length shall be at least 60 m.
(b) Trial areas shall be constructed using the materials, mixes, methods of
production and methods of construction submitted to and reviewed without
objection by the Project Manager. Materials shall be delivered in not less than
two loads.
(c) The Contractor shall notify the Project Manager 48 hours before constructing
trial areas.
(d) The Contractor shall notify the Project Manager before each layer of material
is placed in the trial area.
(e) The Contractor shall not proceed placing materials of the same type in the
permanent carriageway until he obtains a notice of no objection from the
Project Manager.
Methods of Methods of
Type of material Properties
sampling testing
Bituminous base Particle size Clause 9.6.13(b) Clause 9.6.13(c)
course and wearing distribution Clause 9.6.13(b) Clause 9.6.13(c)
course material Bitumen content Clause 9.6.13(b) Clause 9.6.13(c)
Rice's specific gravity Clause 9.6.15(a) Clause 9.6.15(b)
Void content
Bituminous friction Particle size Clause 9.6.14(b) Clause 9.6.14(a)
course material distribution
Bitumen content Clause 9.6.14(b) Clause 9.6.14(a)
Texture depth and - Clause 9.6.16(a)
permeability
(b) Ten cores shall be cut from each layer of base course and wearing course in
trial areas. The method of taking cores shall be as stated in Clause 9.6.15 (a).
(a) Each sample of bituminous material taken as stated in Clause 9.6.2, shall be
tested to determine the properties stated in Table 9.5. The method of testing
shall be as stated in Table 9.5.
(b) If the layer is to form part of the Permanent Works, each layer of bituminous
material in trial areas, excluding bituminous roadbase material, shall be tested
as stated in Clause 9.5.13 to determine the level of the surface.
(c) The layer which is to be the final layer of the carriageway in each trial area
shall be tested as stated in Clauses 9.6.9 (a) and 9.6.9 (b) to determine the
surface regularity, if the layer is to form part of the Permanent Works.
(d) The layer of friction course in each trial area shall be tested as stated in
Clauses 9.6.16 (a) to 9.6.16 (c) to determine the texture depth and
permeability.
(e) Cores shall be tested as stated in Clauses 9.6.15 (a) to 9.6.15 (d) to determine
the compacted layer thickness and air void content.
The properties of the materials, the levels of the surface, compaction, surface
regularity, texture depth and permeability of bituminous materials laid in the trial
areas shall comply with the specified requirements for the permanent carriageway.
(a) If the result of any test on trial areas does not comply with the specified
requirements for trial areas, particulars of proposed changes to the materials,
mixes, methods of production or methods of construction shall be submitted to
the Project Manager for review and further trial areas shall be constructed until
the result of every test on trial areas complies with the specified requirements
for the trial areas.
(b) Trial areas, or parts of trial areas, which do not comply with the specified
requirements for the trial area shall be removed.
9.6.6 Acceptable mix for bituminous materials other than bituminous roadbase
material
(a) A mix for bituminous materials other than bituminous roadbase material which
complies with the specified requirements for designed mixes and for trial areas
is defined as an "Acceptable Mix".
(b) The "Acceptable Gradation Envelope" for bituminous materials other than
bituminous roadbase material is defined as the gradation envelope found by
applying the tolerances stated in Table 9.8 to the particle size distribution of
the "Acceptable Mix".
(c) The "Acceptable Bitumen Content Range" for bituminous materials other than
bituminous roadbase material is defined as the bitumen content range formed
by applying a tolerance of ±0.5% to the bitumen content of the "Acceptable
Mix".
Bituminous material shall not be placed in the Permanent Works until the mix has
been reviewed without objection by the Project Manager.
The materials and methods of production used in producing the mixes and the
methods of construction used in trial areas shall not be changed after having been
reviewed without objection by the Project Manager.
The surface regularity of the final layer of the pavement shall be determined
as stated in Clause 10.5.8(a).
The results of tests for surface regularity shall comply with Clause 10.5.8(b)
(i) One sample of each type of sub-base material shall be provided from
each batch of sub-base material delivered to Site.
(ii) The size of each sample shall be at least 50 kg. The method of
sampling shall be in accordance with BS 812 : Part 102.
(ii) The method of testing for particle size distribution shall be in accordance
with BS 812:Part 103.1.
(iii) The method of testing for ten percent fines value shall be in accordance
with BS 812:Part 111, except that the sample shall be soaked in water at
room temperature for 24 hours and shall not be oven-dried before
testing.
(iv) The method of testing for plasticity index shall be in accordance with
GEO Report No. 36, Tests 2.4.3 and 2.5.3, except that sample
preparation shall be by wet sieving the material over a 425 μm BS test
sieve.
(v) The method of testing for maximum dry density and optimum moisture
content shall be in accordance with BS 1377 : 1975, Test 13, and
Appendix 7.5 of this General Materials and Workmanship Specification.
(i) Each area of sub-base which contains sub-base material of the same
type and same mix produced at the same mixing plant and which is laid
and compacted in a single layer in one day shall be tested to determine
the relative compaction. Tests shall be carried out after the sub-base
material has been laid and compacted in the final position.
(ii) Two tests shall be carried out on each area of 1000 m² or part thereof
laid and compacted each day.
(iii) Tests shall be carried out at positions which are representative of the
area of compacted sub-base as a whole.
The results of tests for relative compaction of sub-base shall comply with the
requirements stated in Clause 9.5.5(f).
If the result of any test for relative compaction of sub-base does not comply
with the specified requirements for relative compaction of sub-base, the area
shall be re-compacted and two additional tests for relative compaction of
sub-base shall be carried out on the area.
(i) One sample of each type of aggregate, filler and bitumen for bituminous
materials shall be provided from each batch.
(ii) The size of each sample and the method of sampling shall be as stated
in Table 9.9.
Table 9.9: Size of Samples and Method of Sampling for Aggregates, Filler and
Bitumen
Minimum size
Material Method of sampling
of sample
Aggregate, nominal maximum
50 kg
aggregate size exceeding 28 mm
Aggregate, nominal maximum
25 kg BS 812:Part 102
aggregate size 5 mm to 28 mm
Aggregate, nominal maximum
10 kg
aggregate size less than 5 mm
Filler 5 kg ASTM D 242
Bitumen 2 litres ASTM D 140
Each sample of aggregate, filler and bitumen for bituminous materials shall be
tested to determine the properties stated in Table 9.10. The method of testing
shall be as stated in Table 9.10.
(a) Batch: bituminous materials other than bituminous friction course material
Table 9.11: Maximum Size of Batch for Bituminous Materials other than
Bituminous Friction Course Material
(b) Samples: bituminous materials other than bituminous friction course material
(i) One sample of bituminous material other than bituminous friction course
material shall be provided from each batch unless otherwise required by
the Project Manager.
(iii) Samples shall be taken at the mixing plant or at the location where the
bituminous material will be laid as directed by the Project Manager.
Samples taken at the mixing plant shall be taken from the delivery
vehicle immediately after loading from the plant or from the surge bin.
Samples taken at the location where the bituminous materials will be laid
shall be taken from the delivery vehicle.
Table 9.12: Size of Samples for Bituminous Materials other than Bituminous
Friction Course Material
(c) Testing: bituminous materials other than bituminous friction course material
37.5 2.5
28.0 2.0
20.0 1.5
10.0 1.0
(i) The particle size distribution shall be such that not more than two points
on the particle size distribution curve are outside the "Acceptable
Gradation Envelopes" determined as stated in Clause 9.6.6(b). The
percentage passing the 75 μm BS test sieve shall not exceed the
acceptable design value by more than 3%.
(ii) The bitumen content shall be within the "Acceptable Bitumen Content
Range" determined as stated in Clause 9.6.6(c).
(i) One sample of bituminous friction course material shall be provided from
each batch of bituminous friction course material.
(iii) Samples shall be taken at the mixing plant from the delivery vehicle
immediately after loading from the plant or from the surge bin.
(iii) For particle size distribution tests in accordance with ASTM C 136, the
modifications are:
37.5 2.5
28.0 2.0
20.0 1.5
10.0 1.0
The results of tests on bituminous friction course material shall comply with
the following requirements:
(i) The particle size distribution shall be within the "Acceptable Gradation
Envelopes" as determined in Clause 9.6.6(b).
(ii) The bitumen content shall be within the "Acceptable Bitumen Content
Range" as determined in Clause 9.6.6(c).
(i) Each area of roadbase, base course and wearing course which contains
bituminous material of the same type and same mix produced at the
same mixing plant and which is laid and compacted in a single layer in
one day shall be tested to determine the compacted layer thickness.
(iii) Cores shall not be taken from within 300 mm of covers, frames and other
hardware, or construction joints in the bituminous material.
(v) Cores shall be 150 mm diameter for bituminous material with a designed
layer thickness of 40 mm or greater and shall be 100 mm diameter for
bituminous material with a designed layer thickness of less than 40 mm.
(vi) Cores shall be taken as soon as practicable but not later than 48 hours
after completion of the paving operation.
(vii) If permitted by the Project Manager, the sampling rate for roadbase may
be applied to wearing course and base course.
(viii) Holes formed by taking cores shall be filled with compatible bituminous
material as soon as practicable after the core has been taken.
No. of sub-areas/cores
Area of bituminous material
Wearing course
laid and compacted in one day Roadbase
and Base course
< 5 000 m² 4 10
5 000 - 10 000 m² 10 15
> 10 000 m² 20 20
(ii) The method of testing for air void content shall be in accordance with
ASTM D 3203.
The results of tests on bituminous material cores shall comply with the
following requirements:
(i) The average air void content of the cores taken from an area of
bituminous base course or wearing course material shall be not less than
3.0% and not greater than 6.0%.
(ii) The air void content of each core taken from an area of bituminous base
course or wearing course material shall be not less than 2.5% and not
greater than 7.5%.
(iii) The air void content of each core taken from an area of bituminous
roadbase material shall be not less than 3.0% and not greater than
9.0%.
(iv) The compacted layer thickness as measured from each core shall
comply with the thickness requirements stated in Clause 9.5.13(d) and
shall be compatible with the level tolerances stated in Table 9.6.
(i) If the result of any test for air void content of cores does not comply with
the specified requirements for air void content, the following procedure
shall apply:
• Four additional cores, shall be taken from each sub-area for which
the original core did not comply with the specified requirements
for air void content. The cores shall be taken at locations evenly
spaced throughout the sub-area such that they are representative
of the sub-area as a whole.
• Each additional core shall be tested to determine the air void
content and the test results of the additional cores from the same
sub-area shall be averaged.
• The average air void content of the sub-area thus obtained shall
replace the original air void content of the respective sub-area.
The new average air void content of the area of bituminous
material tested shall then be calculated for compliance checking.
(ii) If the air void content of any of the four additional cores determined as
stated in Clause 9.6.15(b)(ii) is less than 2.5% or greater than 7.5% for
bituminous base course material and bituminous wearing course
material, or less than 3.0% or greater than 9.0% for bituminous roadbase
material, the sub-area from which the cores were taken shall be
considered as not complying with the specified requirements.
(iv) If the result of any test for compacted layer thickness of cores is not
compatible with the requirements of Table 9.6 or Clause 9.5.13(d), four
additional cores shall be taken from the same sub-area and the results
averaged to determine the average compacted layer thickness. The
cores shall be taken at locations evenly spaced throughout the sub-area
such that they are representative of the sub-area as a whole.
(ii) If permitted by the Project Manager the number of tests for texture depth
and permeability may be reduced to the minimum stated in Table 9.14.
(iv) Testing to determine the texture depth will be carried out by the
Contractor in the presence of the Project Manager. The method of
testing shall be by the sand patch test in accordance with Appendix 10.1.
The results of tests for texture depth on an area of course shall comply with
the following requirements:
(i) the average texture depth shall not be less than 1.5 mm; and
(ii) not more than one of the tests for texture depth shall give a result of less
than 1.2 mm.
The time for 150 mL of water to drain into the friction course in the
permeability test stated in Clause 9.6.16(a)(v) shall not exceed 30 seconds.
A9.1.1 Scope
This method covers the determination of the permeability of friction course material
by measuring the time taken for 150 mL of water to drain into the material.
A9.1.2 Apparatus
(2) suitable sealant for sealing one end of the ring onto the friction course
surface;
(4) two containers, each suitable for containing and pouring 150 mL of water; and
A9.1.3 Procedure
(1) carefully inspect the specified test location and record any unusual features;
(2) place one end of the ring on the friction course at the location to be tested,
and seal the interface with sealant to prevent any leakage of water;
(3) prepare two volumes of water of 150 mL each using the measuring cylinder
and the two containers;
(4) pour one 150 mL measure of water into the ring quickly and steadily without
spillage;
(5) as soon as all of the water has drained into the friction course, pour the
second 150 mL of water into the ring quickly and steadily without spillage, and
at the same time start the stop watch;
(6) record the time taken for the second 150 mL of water to drain into the friction
course surface.
(2) the time taken for the second 150 mL of water to drain into the friction course
surface, to the nearest one second.
General Materials & Workmanship Specification 25/25 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 9 – Carriageways: Sub-base Material &
Bituminous Materials
[this page not used]
SECTION 10 CONCRETE CARRIAGEWAYS
10.1 GENERAL
The Permanent Works and materials specified shall comply with the Sections
stated, unless otherwise stated in this Section.
(a) Formwork and finishes to concrete for concrete carriageways shall comply
with Section 18.
(b) Steel reinforcement for concrete carriageways shall comply with Section 19.
(c) Concrete for concrete carriageways shall comply with Section 20.
(d) Curing compound for concrete carriageways shall comply with Section 20.
10.2 MATERIALS
10.2.1 Reinforcement
(a) Fabric reinforcement shall be steel fabric complying with BS 4483; the fabric
shall be manufactured from steel wire which complies with BS 4482 and which
has a type 2 bond classification.
(b) Dowel bars, tie bars, cradles and tie bars for cradles shall be Grade 250 plain
round steel bars complying with CS2. Dowel bars and tie bars shall be
straight; both ends of dowel bars and one end of tie bars shall be sawn square
with all burrs removed.
Cement mortar for supporting cradles shall consist of 1 part of cement to 3 parts of
fine aggregate together with the minimum amount of water necessary to achieve a
consistency suitable for the required work. Fine aggregates shall be sand or
crushed rock to BS 1200 and shall pass a 5 mm BS test sieve.
Joint filler shall be a proprietary type reviewed without objection by the Project
Manager and shall be a firm, compressible, single thickness, non-rotting filler.
(a) Joint sealant shall be of a grade suited to the climatic conditions of Hong Kong
and shall perform effectively over a temperature range of 0°C to 60°C.
(b) Joint sealant shall be a cold poured two-part polymer-based sealant complying
with BS 5212, Type N.
(c) Primers and caulking material for use with joint sealant shall be proprietary
types recommended by the joint sealant manufacturer and reviewed without
objection by the Project Manager.
Bond breaker tape shall be a proprietary type recommended by the joint sealant
manufacturer and reviewed without objection by the Project Manager. The tape
shall be a polyethylene film with adhesive applied on one side and shall be the full
width of the groove.
(a) Groove forming strip shall be a proprietary type reviewed without objection by
the Project Manager. The strip shall be a firm compressible strip of either
ethylene vinyl acetate foam with a density of at least 90 kg/m³ or synthetic
rubber. The strip shall be 25 mm deep and 5 mm thick and shall be
sufficiently rigid to remain in position during concreting without deforming or
stretching.
(b) Adhesive for groove forming strip shall be a proprietary type recommended by
the groove forming strip manufacturer and reviewed without objection by the
Project Manager.
Sleeves for dowel bars and tie bars shall be PVC and shall have a nominal wall
thickness not exceeding 1.5 mm; the sleeves shall fit tightly to the bars.
Epoxy resin grout shall be a proprietary type reviewed without objection by the
Project Manager.
Concrete for concrete carriageways shall comply with the following requirements:
(b) the concrete mix shall contain either PPFAC or a minimum of 265 kg of OPC
plus a minimum of 85 kg of PFA per m³ of compacted concrete;
(c) the percentage by mass of fine aggregate to total aggregate shall be at least
30%; and
(d) the workability in terms of designed slump value shall not exceed 25 mm.
10.3 SUBMISSIONS
(a) The following particulars of the proposed materials for joints in concrete
carriageways shall be submitted to the Project Manager:
(i) manufacturer's literature and a certificate for joint filler showing the
manufacturer's name, the date and place of manufacture and stating
that the joint filler complies with the Specification, including results of
tests for:
• disintegration and shrinkage;
• recovery value and reduction in mass; and
• extrusion;
(ii) manufacturer's literature for joint sealant, including details of the method
and time required for mixing the different components, and a certificate
showing the manufacturer's name, the date and place of manufacture
and stating that the sealant complies with the Specification, including
results of tests for:
• application life;
• tack-free time;
• resistance to flow;
• recovery;
• adhesion and cohesion in tension and compression; and
• resistance to heat ageing;
(e) sleeves for dowel bars, including compressible filler, and for tie bars.
10.4 WORKMANSHIP
(a) Pipes, cables, manholes, chambers, gullies and other utilities below concrete
carriageways shall be completed and fill material shall be deposited and
compacted in trenches before the carriageway is constructed. Openings to
manholes, chambers and gullies shall be protected by temporary covers.
(b) Box-outs shall be formed in concrete carriageways for covers, frames and
other hardware; the covers, frames and other hardware shall be fixed in
position after the main slab has been concreted and before the infill slab is
concreted.
10.4.4 Formwork
(a) Formwork for concrete carriageways shall be steel. The finish to concrete
surfaces for transverse and longitudinal joints shall be Class F3; the finish to
concrete surfaces for other edges of the carriageway shall be Class F2.
(b) Concrete shall not be placed against excavated surfaces or against kerbs.
(c) Formwork shall not be loosened or removed until at least 7 hours after
concreting has been completed.
(a) Materials for joints in concrete carriageways shall be used in accordance with
the manufacturers' recommendations or as otherwise specified in the
Specification.
(b) Dowel bars, tie bars and their sleeves shall be securely fixed in position
through holes in the formwork before concreting. The bars shall be parallel to
the top surface of the slab and to each other. Bars at transverse joints shall
be parallel to the adjacent longitudinal joint or to the longitudinal axis of the
carriageway if there is no longitudinal joint or to other lines directed by the
Project Manager.
(c) Joint filler shall be cut to size before fixing and shall be securely fixed in
position to the existing concrete surface before concreting. There shall be no
gaps between the joint filler and the formation. Holes in joint filler for dowel
bars shall be cut to form a sliding fit to the sleeved bar.
(d) Joints shall be formed perpendicular to the top surface of the slab.
(b) Transverse expansion joints and transverse contraction joints shall be formed
only at the specified positions. The joints shall be continued across
longitudinal joints and shall be in line and of the same type on both sides of
the longitudinal joint. The joints shall be continued through kerbs, edgings and
quadrants and their foundation and backing; the joint dimensions and
materials shall be the same as the transverse joints with the omission of dowel
bars. The location of additional contraction joints in accordance with Clause
11.5.15(c) shall be as directed by the Project Manager.
(c) The joint filler and groove for joint sealant at transverse expansion joints shall
provide complete separation of adjacent slabs.
(a) Grooves in concrete carriageways for joint sealant shall be straight, shall have
parallel sides and shall be perpendicular to the top surface of the slab. The
bottom of the groove shall be flat and shall be parallel to the top surface of the
slab.
(b) Grooves at transverse expansion joints and at isolation joints at manholes and
chambers shall be formed by sawing the groove to the specified width and
depth not less than 7 days after concreting. The grooves shall be located
over the joint filler such that the upper surface of the joint filler is entirely
contained in the groove.
(c) Grooves at transverse contraction joints shall be formed using one of the
following methods:
(i) Method 1 :
An initial groove shall be sawn as soon as practicable after concreting
without causing spalling of the edges. The width of the initial groove
shall be less than the specified width of the final groove and the depth of
the initial groove shall be between 1/4 and 1/3 of the thickness of the
slab. The final groove shall be sawn to the specified width and depth not
less than 7 days after concreting; or
(ii) Method 2 :
The final groove shall be sawn to the specified width and depth as soon
as practicable after concreting without causing spalling of the edges.
The centre lines of the initial and final grooves shall coincide.
Before permanent sealing, grooves in concrete carriageways for joint sealant shall
be protected from contamination by a temporary sealing strip.
(a) The permanent sealing of joints in concrete carriageways shall be carried out
at least 7 days after concreting.
(c) Caulking material shall be firmly packed in the bottom of the groove if the joint
sealant is not required to extend to the bottom of the groove.
(d) Bond breaker tape shall be fixed continuously and evenly along the bottom of
the groove for the full width and length of the groove.
(e) Primer for the joint sealant shall be applied to the sides of the groove in
accordance with the manufacturer's recommendations.
(f) Joint sealant shall be applied between the minimum and maximum drying
times of the primer recommended by the manufacturer. The components of
the sealant shall be thoroughly mixed in accordance with the manufacturer's
recommendations using a power operated paddle mixer for sufficient time to
produce a homogeneous mass without entrapped air. The sealant shall be
dispensed into the groove as soon as practicable after mixing and within the
time recommended by the manufacturer.
(g) The groove shall be clean and dry at the time of applying the primer and joint
sealant.
(h) Excess joint sealant shall be removed by using a purpose made finishing tool
such that the finished surface of the sealant is between 4 mm and 6 mm below
the surface of the slab.
(c) Concrete in unreinforced slabs shall be placed and compacted to the full
thickness of the slab in one operation.
(e) Concrete in infill slabs at covers, frames and other hardware shall be placed
and compacted after the covers, frames and hardware have been fixed in
position and shall not be placed at the same time as the concrete in the main
slab.
(ii) breaking back from an unformed edge and fixing the tie bars and
sleeves with epoxy resin grout in drilled holes.
(b) Regulating machines shall be purpose made and shall span the full width of
the slab either transversely or obliquely. The machine shall be equipped with
at least two oscillating-type transverse screeds and shall be supported on a
carriage.
(c) Vibrating beams shall have a steel or aluminium surface and shall be mounted
on a separate carriage. The beam shall be driven by a motor to provide a
vibration frequency of at least 3500 cycles per minute.
(d) After regulation by the regulating machine or vibrating beam, the surface of
the carriageway shall be regulated by at least two passes of a scraping
straight-edge with a blade length of at least 1.8 m. Scraping straight-edges
which operate in conjunction with regulating machines shall pass across the
surface at right angles to the longitudinal axis of the carriageway. If the
surface is torn by the straight-edge, the surface shall be regulated again by
the regulating machine or vibrating beam and by the scraping straight-edge.
(a) After the surface of the concrete carriageway has been regulated and before
the curing compound is applied, the surface, other than the surface of
channels and edges of slabs which do not require to be textured, shall be
textured by brushing with a wire broom.
(b) The wire broom shall be at least 450 mm wide and shall have two rows of
tufts. The rows shall be 20 mm apart and the tufts in each row shall be at 10
mm centres and in line with the centre of the gaps between the tufts in the
other row. The tufts shall contain an average of 14 wires, each of 32 gauge
and initially 100 mm long. The broom shall be replaced if any tuft wears down
to a length of 90 mm.
(c) The surface texture shall be produced by brushing evenly across the slab in
one direction at right angles to the longitudinal axis of the carriageway.
Brushing shall be carried out after the moisture film has disappeared from the
concrete surface and before the initial set is complete.
The surface and edges of concrete carriageways shall be protected by one of the
methods stated in Clause 20.7.15 except that covering with hessian, sacking,
canvas or other absorbent material as stated in Method 2 shall not be used. If
Method 1 is used, the curing compound shall be applied to the surface immediately
after the surface has been textured and shall be applied to the edges immediately
after the formwork has been removed.
(a) Immediately after the curing system has been applied, the concrete
carriageway shall be fenced off from pedestrian traffic and covered with
protective sheeting for at least 24 hours. The sheeting shall be lapped and
securely held in position in such a manner that the surface of the carriageway
will not be damaged.
(b) Loads from materials not forming part of the Permanent Works or from
Contractor's Equipment or other vehicles shall not be applied to the concrete
carriageway until at least 7 days after concreting has been completed and until
all grooves at joints have been temporarily or permanently sealed or
protected.
(c) When Contractor's Equipment or other vehicles will turn on the concrete
carriageway the Contractor shall lay a 100 mm thick protection layer of mesh
reinforced 30/20 concrete over the turning area. The protection concrete shall
be separated from the concrete carriageway by two layers of polythene and it
shall be removed by the Contractor without damage to the concrete
carriageway when construction traffic ceases.
(a) The level of the formation below concrete carriageways shall not be more than
10 mm higher, and shall not be more than 40 mm lower, than the specified
level.
(b) The level of the sub-base below concrete carriageways shall not be more than
10 mm higher, and shall not be more than 20 mm lower, than the specified
level.
(a) The line of formwork for concrete carriageways shall be within 10 mm of the
specified line of the concrete carriageway.
(b) The level of the top of the formwork shall be within 3 mm of the specified level
of the concrete carriageway.
(c) Abrupt irregularities in the line of the formwork and in the level of the top of
formwork shall not exceed 3 mm.
(b) Dowel bars shall be parallel to within 3 mm in half the length of the bar to:
(i) the longitudinal joint, or the longitudinal axis of the concrete carriageway
if there is no longitudinal joint;
The depth of grooves for joint sealant in concrete carriageways shall be within 3 mm
of the specified depth.
The level of covers, frames and other hardware shall not be higher than, and shall
not be more than 3 mm lower than, the surface of the adjacent carriageway.
(a) The best fit straight line of straight joints and of straight edges of concrete
carriageways shall be within 25 mm of the specified line. The line of straight
joints and of straight edges of concrete carriageways shall be within 10 mm of
the best fit straight line.
(b) The best fit curved line of curved joints and of curved edges of concrete
carriageways shall be within 25 mm of the specified line. The line of curved
joints and of curved edges of concrete carriageways shall be within 10 mm of
the best fit curved line.
(a) The levels of the surface of concrete carriageways shall be determined 200
mm from the edges of each bay at 10 m centres in the longitudinal direction
and at 2 m centres in the transverse direction.
(b) The level of the surface of concrete carriageways shall be within 6 mm of the
specified level. In low lying and flat areas the Contractor shall pay special
attention to level control to ensure that falls on the surface of the carriageway
are in the specified direction.
(c) The difference in level of the surface of concrete carriageways across joints
shall not exceed 3 mm.
(d) The thickness of concrete carriageway slabs shall not be less than the
specified thickness minus 10 mm.
10.4.26 Rectification
(a) Where any tolerance is exceeded, the Project Manager will determine the full
extent of the area which is out of tolerance and the Contractor shall make
good the surface of the concrete carriageway as detailed in Clause 10.4.26(c).
(b) Where any joint tolerance is exceeded or joint construction does not meet
requirements stipulated elsewhere, the Project Manager will determine the full
extent of the area to be made good and rectification shall comprise a minimum
depth of 50 mm from the carriageway surface and a minimum distance of 50
mm from the area determined as requiring repair. Cut lines shall either be
parallel to transverse joints or parallel to longitudinal joints and shall be sawn
the full depth of the 50 mm. The remaining area shall be broken out by a
method, reviewed without objection by the Project Manager and the repair
shall be undertaken using thin bonded concrete.
(c) High areas shall be ground or milled down to within tolerance or regularity and
the surface texture to comply with Section 11. Low areas shall be rectified by
cutting out the surface to a depth not less than 25 mm and replacing it with
concrete of a mix and method of placement reviewed without objection by the
Project Manager. Surface texture shall be restored to comply with Section 11.
The results of the tests on trial mix concrete for concrete carriageways shall comply
with the following requirements: none of the six slump values shall not exceed 35
mm, and the average of the six slump values shall not exceed 30 mm.
(b) The trial length shall be constructed using the materials, mix design, methods
of production and methods of construction submitted to and reviewed without
objection by the Project Manager.
(c) Unless otherwise stated that the trial length shall be constructed in a location
separate from the permanent carriageway, the trial length shall comprise the
first 30 m of the permanent carriageway. The trial length shall be constructed
over a width of two bays and shall include at least one expansion joint, one
contraction joint and the longitudinal joint between the bays.
(d) The Contractor shall notify the Project Manager at least 48 hours before
constructing the trial length.
(e) The trial length shall be completed in sufficient time before the permanent
carriageway is constructed to allow the Project Manager a period of at least 7
days to determine if the specified requirements have been complied with in the
trial length.
(a) The trial length shall be tested to determine the accuracy of the alignment and
level, the surface regularity and the texture depth. The method of testing the
surface regularity shall be as stated in Clause 10.5.8. The method of testing
the texture depth shall be as stated in Clause 10.5.9.
(b) Concrete cores shall be cut from the trial length to determine the thickness of
the slab, the position of the reinforcement and joint components, the amount
of segregation of the constituents and the presence of voids. The method of
taking, preparing, inspecting and testing concrete cores shall be as stated in
Clauses 10.5.11.
The results of tests on trial lengths shall comply with the following requirements:
(a) The alignment, levels and thickness of the carriageway shall comply with
Clauses 10.4.24 and 10.4.25.
(d) The positions of the reinforcement and joint components shall comply with
Clauses 10.4.20, 10.4.21, 10.4.22 and 10.4.24.
(e) The amount of segregation of the constituents and the presence of voids shall
comply with Clause 10.5.11(c).
(a) If the result of any test on the trial length does not comply with the specified
requirements for the trial length, particulars of proposed changes to the
materials, mix design, methods of production or methods of construction shall
be submitted to the Project Manager for review; further trial lengths shall be
constructed until the result of every test on the trial length complies with the
specified requirements for the trial length.
(b) Trial lengths, or parts of trial lengths, which do not comply with the specified
requirements for the trial length shall be removed.
(a) Concrete shall not be placed in the permanent carriageway other than in a trial
length until the result of every test on the trial length complies with the
specified requirements for the trial length.
(b) Concrete shall not be placed in the permanent carriageway before the results
of tests for compressive strength of the trial mix are available unless the result
of every other test on the trial mix and trial length complies with the specified
requirements for trial mix concrete and for the trial length.
Unless permitted by the Project Manager, the materials, mix design, methods of
production and methods of construction used to produce a trial length which
complies with the specified requirements shall not be changed.
(iv) Testing to determine the surface regularity shall be carried out by the
Contractor in the presence of the Project Manager.
The results of tests for surface regularity of carriageways shall comply with the
following requirements:
(i) the size and number of irregularities in the longitudinal direction shall not
exceed the size and permitted number of irregularities stated in Table
10.1; and
Category A roads are roads with a legal speed limit greater than 70 km/hour; all
other roads are Category B roads.
(ii) Each carriageway lane shall be divided into sections of equal length not
exceeding 150 m. Tests shall be carried out at ten locations on each
section at approximately equal spacings as directed by the Project
Manager. No measurement shall be taken within 300 mm of the
longitudinal edges of the sections.
(iii) Testing to determine the texture depth shall be carried out by the
Contractor in the presence of the Project Manager. The method of
testing shall be in accordance with Appendix A10.1.
The results of tests for texture depth for each section of concrete carriageway
lane shall comply with the following requirements:
(i) the average texture depth shall not be less than 0.7mm; and
(ii) not more than one out of the ten measured texture depths shall be less
than 0.6 mm.
The average slump value of the two specimens taken from one sample of
concrete shall not exceed the specified slump value by more than 10 mm.
(i) Two concrete cores shall be provided from each bay, and one core shall
be provided from each joint, of concrete carriageway in the trial length.
The positions from which the cores are taken shall be as directed by the
Project Manager.
(ii) Concrete cores shall be 150 mm diameter and shall be the full depth of
the slab. Cores shall be taken as soon as the concrete has hardened
sufficiently for the core to be taken.
(iv) Holes formed by taking concrete cores from trial lengths which form part
of the permanent carriageway shall be reinstated using the concrete mix
previously reviewed without objection by the Project Manager; joints
shall be repaired in accordance with the method submitted to and
reviewed without objection by the Project Manager.
(i) Each concrete core from trial lengths in concrete carriageways shall be
inspected to determine the thickness of the slab and the positions of the
reinforcement and joint components. Each core shall be inspected for
evidence of segregation of the constituents and for the presence of
voids.
Concrete cores from trial lengths in concrete carriageways shall not show
evidence of segregation. The extent of voids in the core shall be "few" in
accordance with Table 4 of CS 1 and there shall be no honeycombing.
A batch of joint filler or joint sealant shall comply with Clause 20.8.24.
Samples of joint filler or joint sealant shall comply with Clause 20.8.25.
Testing of joint filler and joint sealant for joints in concrete carriageways shall
be as stated in Clauses 20.8.26 and 20.8.27 except as stated in Clause
10.5.12 (d).
Each sample of joint sealant shall be tested to determine the application life,
tack-free time, resistance to flow, recovery, adhesion and cohesion in tension
and compression and resistance to heat ageing. The method of testing shall
be in accordance with BS 5212.
A10.1.1 Scope
This method covers the determination of the texture depth of carriageways by the
sand patch test.
A10.1.2 Materials
dry natural sand, with a rounded particle shape, which has been washed and then
screened such that it meets the grading stated in table 10.1.1.
BS test Percentage by
Sieve mass passing
600 μm 100
300 μm 95 - 100
150 μm 0-6
A10.1.3 Apparatus
(3) a flat wooden disc of 65 mm diameter with a 1.5 mm thick hard rubber disc
attached to one face and a handle fixed to the other face;
(6) a funnel with an outlet tube at least 100 mm long with a bore of between 4 mm
and 6 mm, and capable of accepting a volume of at least 200 mL;
(7) a steel straight edge for screeding off the measuring cylinder; and
(1) the test location shall be at least 300 mm square. It shall be vigorously
brushed ten times in two directions at right angles using the steel wire brush,
and then dried and swept clean with the soft brush;
(2) sand shall be poured into the measuring cylinder to fill it to overflowing, and
any excess sand shall be screeded off using the straight edge. All sand on
the outside of the cylinder shall be removed, taking care not to drop any sand
onto the test location. Alternatively, this step in the procedure shall be carried
out in a laboratory, and the sand transferred to a suitable container ready for
pouring;
(3) the measured volume of sand shall be poured onto the centre of the test
location through the funnel to form a heap. The wind shield shall be used to
protect the test location if required;
(4) the sand shall be spread outwards with a circular motion over the test location,
using the rubber-faced disc with its face parallel to the surface of the
carriageway. This shall be continued until the patch of sand is approximately
circular and will spread outwards no more;
(5) the size of the circular patch of sand shall be measured to the nearest 1 mm
along three diameters which are aligned at approximately 120 degrees to each
other;
(6) if the difference between the maximum and minimum of the three
measurements exceeds 20% of the average of the three measurements, then
all the measurements shall be discarded and the test repeated at an adjacent
location; and
(7) the test shall be repeated for all the ten test locations for each section of
carriageway lane.
A10.1.5 Calculation
(1) The texture depth (T) for each test shall be calculated from the equation:
T = 31000 / D2 mm
where:
(2) The average texture depth for the ten tests shall be calculated.
(2) average diameter of the sand patch for each test to the nearest 1 mm;
(3) texture depth for each test to the nearest 0.1 mm; and
11.1 GENERAL
The works and materials specified below shall comply with the Sections stated,
unless otherwise stated in this Section.
(b) Sub-base material and bituminous materials shall comply with Section 9.
(d) Formwork and finishes to concrete shall comply with Section 18.
11.1.2 Unit
11.3 MATERIALS
Cement mortar shall consist of one part of cement to three parts of fine aggregate
by volume together with the minimum amount of water necessary to achieve a
consistency suitable for the required work. Fine aggregates shall be sand or
crushed rock to BS 1200 and shall pass a 5 mm BS test sieve.
Hot rolled structural steel sections - equal and unequal angles : BS 4848:Part 4
Stainless steel for pedestrian guard-railing shall be Grade 316 S 31 and shall
comply with the following:
(a) Aluminium for pedestrian guard-railing shall be H 30 TF and shall comply with
the following:
(a) Bolts, nuts, screws, washers and rivets for pedestrian guard-railing shall
comply with the following:
(b) The length of bolts shall be such that the threaded portion of each bolt
projects through the nut by at least one thread and by not more than
four threads.
(c) Rag and indented bolts shall comply with BS1494 : Part 2. Expansion bolts
and resin bonded bolts shall be proprietary types reviewed without objection
by the Project Manager and shall be capable of withstanding the design
loading.
(d) Galvanized bolts, nuts, screws, washers and rivets shall be used with
galvanized pedestrian guard-railing unless shown otherwise in the Contract.
Non-ferrous or stainless steel components shall be insulated from ferrous
materials by a non-conductive insulator of a type reviewed without objection
by the Project Manager.
Mesh infill for pedestrian guard-railing shall comply with BS 4483. The mesh infill
shall be free from surface defects, surface irregularities and mesh misalignment.
Pedestrian guard-railing shall be stored off the ground on level supports and in a
manner which will not result in damage or deformation to the guard-railing or in
contamination of the guard-railing. Pedestrian guard-railing shall be protected from
damage and damaged guard-railing shall not be used in the Permanent Works.
(a) Beams for untensioned beam barriers shall be formed from steel plates
complying with BS 1449 : Part 1, type BHR, grade 43/25.
(b) The beams shall be capable of withstanding a tensile force of at least 300 kN
and shall not deflect by more than 40 mm when loaded centrally with a point
load of 1 tonne over a simply supported span of 3 m.
(i) the base metal thickness shall be within 0.2 mm of the specified
thickness;
(ii) the strip width shall be within + 2.5 mm and - 0 mm of the specified
width;
(iii) the camber of the strip length shall be within 8 mm of the specified
camber;
(iv) the beam shall be straight to within 1.5 mm in a 1.5 m length; and
(d) Bolt slots in beams for connection to posts shall be prepared in the workshop
by cold saw-cutting. The spacing of the slots shall be such that posts will be
spaced at either 4 m or 2 m.
(f) Welds for end beam sections shall be full-penetration butt welds.
(g) Beams shall be shaped so as to present no sharp edges to traffic and except
where shown on the Employer’s Drawings shall be straight and of uniform
cross-section within manufacturing tolerances.
(h) The beams shall be separated from the posts by blocking-out pieces which
are fabricated from materials of the same quality as the posts.
(i) Posts and blocking-out pieces shall be drilled to take the specified post bolts
for affixing the beams.
(a) Posts for untensioned beam barriers shall be formed from Grade 43A steel
complying with BS 4360.
(b) Posts and blocking-out pieces shall be hot-dip galvanized in accordance with
BS 729 to a coating thickness of at least 610 g/m².
(c) Posts fabricated from hollow sections shall be sealed by welding mild steel
sealing plates over the open ends; the plates shall be at least 3 mm thick.
(a) End beam sections shall be cut and welded with full-strength butt welds.
(b) Anchor blocks shall be constructed of concrete which shall be cast directly
against the sides of the excavation.
(a) Cleats and struts for untensioned beam barriers shall be fabricated from angle
sections complying with BS 4 and shall be weldable structural steel complying
with BS 4360, Grade 43A.
(b) Cleats and struts shall be hot-dip galvanized in accordance with BS 729 to a
coating thickness of at least 610 g/m².
(c) The dimensional tolerances of steel angles for cleats and struts shall comply
with BS 4.
(a) Bolts for untensioned beam barriers shall be M 16 size and strength grade 4.6
complying with BS 4190. Bolts for beam splicing, bolts for connecting beams
to posts and bolts for connecting beams to cleats shall be round or
button-headed with oval shoulders; other bolts shall be ISO metric black
hexagon type.
(c) Bolts and nuts shall be hot-dip galvanized in accordance with BS 729 to a
coating thickness of at least 375 g/m².
(e) The length of bolts shall be such that the threaded portion of each bolt
projects through the nut by at least one thread and by not more than
four threads.
(f) Rag and indented bolts shall comply with BS1494 : Part 2. Expansion bolts
and resin bonded bolts shall be proprietary types reviewed without objection
by the Project Manager and shall be capable of withstanding the design
loading.
11.3.15 Washers
(a) Washers for untensioned beam barriers shall be black mild steel and shall
comply with BS 4320, Form E, F or G; washers shall be manufactured from
steel complying with BS 1449 : Part 1, grade 250.
(b) Plain washers shall be 2 mm thick and shall be of dimensions suitable for use
with M 16 bolts and nuts.
(d) Shaped washers shall have a thickness of at least 5 mm and shall be cast
iron complying with BS 3468; the washers shall be shaped to fit the curvature
of circular hollow sections used as posts.
Beams and posts for untensioned beam barriers shall be stored off the ground on
level supports and in a manner which will not result in damage or deformation to the
beams and posts or in contamination of the beams and posts. Beams and posts
shall be protected from damage and damaged beams and posts shall not be used
in the Permanent Works.
(a) Concrete for kerbs, edgings and quadrants shall be Grade 30/20. Concrete
for foundations and backings to kerbs, edgings and quadrants shall be
Grade 20/20.
(b) Precast concrete kerbs, edgings and quadrants shall comply with BS 7263 :
Part 1 except that the requirement for testing of water absorption shall not be
applied. The nominal length of kerbs shall be 1 m and the nominal length of
edgings shall be 750 mm.
(a) The Contractor shall, within 6 weeks from the date for commencement of
Works, submit a programme prepared to such detail as the Project Manager
may require showing a month by month batch forecast of the total kerb
requirements. The Project Manager will forward this programme to the
Superintendent of the Tai Lam Correctional Institute who will advise whether he
will be able to fulfil the order to the programme required.
(b) The Contractor shall update this programme from time to time and shall
provide the Project Manager with 3 months notice of his requirements for any
particular batch. The Project Manager will forward a copy of this notice to the
Superintendent who will confirm within 1 month of the date of the notice
whether or not he will be able to supply the particular batch.
(c) Having regard to the progress of the Works and upon receipt of confirmation
from the Correctional Services Department that a particular batch or part
thereof can be supplied the Project Manager will issue a copy of the
Requisition Order to the Contractor who shall thereafter be responsible for
agreeing with the Superintendent of Tai Lam Correctional Institute a suitable
date and time for collection of the kerbs.
(a) Granite kerbs, edgings and quadrants shall be worked straight or circular.
Corners shall be square and the top front and back edges shall be parallel.
The length of granite kerbs and edgings shall be at least 600 mm.
Concrete for footways, cycletracks and paved areas shall be Grade 30/20.
Cobble-stone paving shall consist of stones placed in a 100 mm thick grade 30/20
concrete bed. The stones shall be roughly elliptical and have a maximum dimension
not exceeding 150mm and a minimum dimension not less than 100mm.
Rubble stone facing and paving shall consist of random stone whose maximum
dimension on the exposed face shall not be less than 300 mm, whose minimum
dimension on the exposed face shall not be less than 200 mm and whose thickness
shall not be less than 200 mm.
(a) Concrete for precast concrete paving slabs shall be Grade 30.
(b) Concrete for precast concrete interlocking blocks in footways and cycletracks
shall be Grade 30; concrete for precast concrete interlocking blocks in
carriageways or areas to which vehicles will have access shall be Grade 45.
(c) The nominal maximum aggregate size of aggregate for concrete in precast
units shall be 10 mm.
(d) The dimensions of the precast units shall be within 3 mm of the specified
dimensions; chamfers shall not exceed 8 mm.
(e) Paving slabs shall be square or rectangular and interlocking blocks shall be
rectangular unless otherwise selected in the Contract.
(f) The colour of precast units shall be consistent over the area to be paved.
(a) Sand for bedding precast units shall have the particle size distribution stated
in Table 11.1. The sand shall have a moisture content exceeding 4% and not
exceeding 8% at the time of laying.
(b) Sand for filling joints between precast units shall have the particle size
distribution stated in Table 11.2. The sand shall have a moisture content of
less than 0.5% at the time of filling joints.
Table 11.2 : Particle Size Distribution of Sand for Filling Joint between
Precast Units
2.36 mm 100
1.18 mm 90 - 100
600 μm 60 - 90
300 μm 30 - 60
150 μm 15 - 30
75 μm 5 – 10
Units shall be handled and stored on pallets to avoid damage to corners and
chamfer edges. Pallets shall be stored on a level base and in a manner which will
not result in damage to the units or in contamination of the units. The units shall be
protected from damage and damaged units shall not be used.
Sand for filling joints between units shall be stored in waterproof bags and shall be
kept under cover until used.
(a) The following particulars of the proposed methods of construction for concrete
profile barriers shall be submitted to the Project Manager for review without
objection:
(i) a certificate from the manufacturer for beams in the format stated in
BS 4360 showing the manufacturer's name, the date and place of
manufacture and showing that the beams comply with the requirements
stated in the Contract and including carbon equivalent values; and
(a) Beams;
(iii) Contractor’s Drawings showing the layout of the units within the paved
area.
11.5 WORKMANSHIP
(a) Formwork for concrete profile barriers shall be steel. The Contractor shall
take measures, reviewed without objection by the Project Manager, to avoid
retention of air bubbles on the inside face of the formwork.
(b) Formwork shall not be loosened or removed until at least 7 hours after
concreting has been completed.
(a) The finish to unformed concrete surfaces of concrete profile barriers shall be
Class U5.
(b) The finish to concrete surfaces for transverse joints shall be Class F3 and the
finish to exposed concrete surfaces shall be Class F5.
(a) Joints shall be formed in concrete profile barriers at locations which coincide
with expansion or construction joints in the adjoining structure or carriageway
or at intervals not exceeding 12 m, whichever is less.
(b) Joints in concrete profile barriers shall comply with Section 20.
Immediately after the formwork has been removed or the curing compound has
been applied, concrete profile barriers shall be protected by polyethylene sheeting
for at least 24 hours from exposure to conditions which may affect the concrete.
The sheeting shall be lapped and securely held in position in such a manner that
the surface of the concrete will not be damaged.
(c) The horizontal alignment along the centreline shall be within 10 mm of the
specified centreline.
(d) The level of the formation shall be within 10 mm of the specified level.
(e) The level of the top of the barriers shall be within 10 mm of the specified level.
(b) Galvanizing to steel shall be applied after welding, drilling and cutting are
complete.
(b) Steel shall not be welded after galvanizing unless permitted by the Project
Manager; if permitted, the welded areas shall be free from scale and slag and
shall be treated with a zinc-coating system reviewed without objection by the
Project Manager.
(a) Untensioned beam barriers shall be ready for assembly when delivered to
Site. Beams and posts shall be free from blisters, flux, uncoated spots and
other defects.
(b) The horizontal alignment of fences shall not depart from the road alignment by
more than (+ or -) 30mm nor deviate from the straight by more than 12mm in
any two section lengths. The horizontal centre line of the beam shall be
600mm above the edge of the adjacent carriageway or above the datum level
shown on the Employer’s Drawings, within a tolerance of (+ or -) 30mm. In
addition the deviation from the straight shall not exceed (+ or -) 6mm in any
two section lengths.
(c) Beams which are to be installed to a radius of less than 45 m shall be curved
in the workshop.
(e) Untensioned beam barriers shall be fixed to concrete using rag, indented,
expansion or resin bonded bolts and shall be bolted to metalwork. Bolts for
fixing to concrete shall be fitted into pockets filled with cement mortar or resin
grout.
(a) Sub-base material shall be deposited and compacted in the bottom 250 mm
of pits for foundations of untensioned beam barriers with compacted earth
footings. Fine fill material shall be deposited and compacted to the remainder
of the pit. The sub-base material and fill material shall be compacted to
obtain a relative compaction of at least 95% throughout.
(b) Posts for untensioned beam barriers shall be securely fixed in position during
deposition and compaction of fill material.
(b) The top surface of concrete footings shall be finished level with the adjoining
ground unless otherwise shown on the Employer's Drawings; the finish to the
concrete surface shall be Class U5.
(b) The finish to concrete surfaces of anchor blocks shall be Class F5 for formed
finishes and Class U5 for unformed finishes.
11.5.14 Construction of precast concrete and granite kerbs, edgings and quadrants
(a) Precast concrete and granite kerbs, edgings and quadrants shall be laid and
bedded on a regulating layer of cement mortar; the thickness of the layer shall
be at least 10 mm and shall not exceed 40 mm.
(b) Except as stated in this Clause, joints between each kerb, edging and
quadrant shall not exceed 10 mm in width and shall be filled and flush pointed
with cement mortar. Joints in kerbs, edgings and quadrants at expansion
joints on bridge decks shall be as stated in the Contract. Transverse
expansion and contraction joints in kerbs, edgings and quadrants laid on or
adjacent to concrete carriageways shall be in accordance with
Clause 10.4.6(b).
(c) Radius kerbs shall be used for curves less than 10 m external radius.
(b) In-situ concrete kerbs, quadrants and edgings shall have regular sides,
edges, arrises and chamfers; the finish to the concrete surface shall be
Class U5. Kerbs, edges and quadrants shall not be finished or dressed with
cement mortar.
(c) Contraction joints shall be formed at intervals not greater than approximately
4 m. Transverse expansion and contraction joints in kerbs, edgings and
quadrants which are laid on or adjacent to concrete carriageways shall be in
accordance with Clause 10.4.6(b). Joints shall be flush pointed with cement
mortar.
(a) The line of kerbs, edgings and quadrants shall be within 3 mm of the specified
line.
(b) The level of the top of kerbs, edgings and quadrants shall be within 3 mm of
the specified level.
(a) In-situ concrete for footways, cycletracks and paved areas shall be laid in
areas not exceeding 20 m². The finish to the concrete surface shall be
Class U4.
(b) Expansion joints shall be formed in concrete footways and cycle tracks at a
spacing of not more than 8 metres.
(a) Bituminous materials for footways, cycletracks and paved areas shall be laid
and compacted with steel-wheeled and pneumatic-tyred rollers. Compaction
shall start before the temperature of the newly laid material falls below 100°C
and shall continue until all roller marks have been removed. For locations
where rollers cannot operate effectively, the bituminous material can be
compacted by hand-operated mechanical compaction plant reviewed without
objection by the Project Manager.
(b) Cores shall be taken in accordance with Clause 9.6.15(a) for the checking of
air void content and compacted layer thickness of the bituminous material for
works with area of not less than 200 m2. For works with area smaller than 200
m2 but greater than 50 m2, at least 2 cores shall be taken from each layer of
bituminous material laid. For works with area less than 50 m2, no coring is
required unless otherwise instructed by the Project Manager.
(d) Each core taken from the final surfacing layer shall also be measured to
determine the compacted layer thickness that shall not deviate by more than 5
mm from the specified thickness. If the measured thickness does not comply
with the requirement, 2 additional cores shall be taken at locations agreed by
the Project Manager and the average thickness determined from these 2
cores shall replace the original measured value for compliance checking.
(e) If no bulk sample is taken for determination of the Rice’s specific gravity, the
corresponding value obtained from the mix design shall be used in
determining the air void content of the core unless other value is suggested by
the Contractor and agreed by the Project Manager.
The stones shall be placed on the concrete bed to such a depth that the nominal
line of the horizontal diameter of the stones is about 10 mm below the finished
concrete level. The clearance between each stone shall be 75 mm maximum and
40 mm minimum. Cement wash shall not coat the exposed surface of the stones.
Before the Contractor places any cobble-stone paving in the Permanent Works he
shall prepare, for review without objection by the Project Manager, a 2 m square
trial panel of finished cobble-stone paving.
Stones shall be carefully shaped to obtain as close a fit as possible at beds and
joints. When placed on the ground the stones shall be placed on material trimmed
and compacted to make a firm bed.
Rubble stone paving stones shall be bedded on 100 mm of concrete Grade 20/40
and sufficient space shall be left between stones to allow the joints to be filled
completely with concrete or mortar. The stones shall be bedded on the concrete
while it is still fresh, or alternatively the concrete shall be left with a rough finish and
the stones shall be bedded on a thin layer of mortar after the concrete has set. No
cavities shall be left under or between the stones.
(i) Paving slabs and interlocking blocks shall not be laid until the layout of
the units within the paved area has been reviewed without objection by
the Project Manager.
(ii) Kerbs and edgings shall be completed before the units are laid; the
compressive strength of the concrete used for in-situ concrete kerbs
and edgings shall be at least 20 MPa before units are laid.
(iii) Measures shall be taken to prevent water draining across or through the
area during laying, bedding and compaction of the units.
(iv) Laying of units shall start as soon as practicable after the formation has
been completed. The formation shall be protected as stated in
Clause 7.4.33 until laying starts.
(v) Interlocking blocks for carriageways and paved areas to which vehicles
will have access shall be laid in a herring-bone pattern unless otherwise
stated in the Contract.
(vi) Units shall be cut to size where required using mechanical cutting
devices. The cut edge shall be similar to that of an uncut unit and shall
be true to line and free from chips and cracks.
(vii) On circular work where the radius is 12 m or less all flags shall be
radially cut on both edges to the required line.
(i) A layer of sand shall be laid and shall be screeded and tamped to a
uniform depth over the complete width of the area to be paved. The
quantity of sand shall be sufficient to permit screeding to waste and to
achieve a tamped thickness which exceeds 20 mm and does not
exceed 30 mm.
(ii) The sand layer shall not be disturbed by additional compaction, foot-
marks or other damage after the layer has been screeded and tamped
to the required level and before the units are laid.
(iii) Sand shall not be screeded and tamped more than 1 m in advance of
the units which have been laid.
(i) Paving slabs shall be laid on the prepared sand layer immediately after
screeding and tamping in such a manner that the sand is not disturbed.
(ii) Paving slabs shall be adjusted to form uniform joints between 2 mm and
3 mm wide and shall be bedded into the final position using a wooden
mallet or a plate vibrator fitted with a rubber base-pad.
(iv) Final levelling of the slabs shall be carried out as soon as practicable
after bedding and before changes in the moisture content of the
prepared sand layer occur.
(i) Interlocking blocks shall be laid on the prepared sand layer immediately
after screeding and tamping in such a manner that the sand is not
disturbed. Interlocking blocks shall be individually laid on the prepared
sand layer by manual methods or in clusters by mechanical methods.
(ii) Interlocking blocks shall be laid in such a manner that the blocks are not
in direct contact with each other and that uniform joints of between
2 mm and 3 mm wide are formed. Interlocking blocks shall be bedded
flush by at least two passes of a heavy-duty plate compactor fitted with
a rubber base-pad.
(iii) Interlocking blocks shall not be bedded closer than 1 m behind the
laying edge other than on completion of the paved area against a kerb
or edging.
(iv) Final levelling of the blocks shall be carried out as soon as practicable
after bedding and before changes in the moisture content of the
prepared sand layer occur.
(i) After the units have been bedded, sand for filling the joints shall be
spread over the surface of the units and brushed into the joints in such a
manner that all joints are completely filled.
(ii) Joints shall be filled as soon as practicable after bedding and on the day
the units are laid and bedded.
(iv) Carriageways and paved areas to which vehicles will have access shall
be compacted by at least ten evenly-spaced passes of a pneumatic
tyred roller having a gross weight of between 10 t and 12 t. Sand shall
be added as required and brushed and compacted into the joints.
Pigmented mortar or concrete shall be placed to the full depth of the unit to
form a seal between units and adjacent kerbs, edgings, quadrants, covers,
frames and other hardware. The pigment shall match the colour of the
adjacent units.
(ii) Unbroken units shall be thoroughly cleaned to remove all sand and
deleterious material. The units shall be stacked on pallets for re-use.
(ii) The trial length shall be constructed in sufficient time before the
permanent barrier is constructed to allow the Project Manager a period
of at least 7 days to determine if the specified requirements have been
produced in the trial length.
(iii) The Contractor shall notify the Project Manager at least 24 hours before
constructing the trial length.
(v) The trial length shall be used as a means of comparison against which
the Project Manager shall determine the compliance or otherwise of the
permanent concrete profile barrier. The trial length shall be protected
from damage and shall be left in position unless the Project Manager
directs its removal. A trial length which forms part of the permanent
barrier and which complies with the specified requirements shall not be
removed.
(i) The trial length shall be tested to determine the accuracy of the
alignment and level and the finish of the concrete surface.
(ii) Concrete cores shall be cut from the trial length to determine the
amount of segregation of the constituents and the presence of voids.
The method of taking, preparing, inspecting and testing concrete cores
shall be as stated in Clause 11.6.2.
The results of tests on trial lengths shall comply with the following
requirements:
(i) The alignment and levels of the barrier shall comply with Clause 11.5.6.
(ii) The finish of concrete surfaces shall comply with Clause 18.44.
(i) If the result of any test on the trial length does not comply with the
specified requirements for the trial length, particulars of proposed
changes to the materials, mix design, methods of production or methods
of construction shall be submitted to the Project Manager for review
without objection; further trial lengths shall be constructed until the result
of every test on the trial length complies with the specified requirements
for the trial length. Further trial mixes shall be made unless non-
compliance of the trial length was not due to the concrete mix.
(ii) Trial lengths, or parts of trial lengths, which do not comply with the
specified requirements for the trial length shall be removed.
11.6.2 Testing concrete profile barriers: concrete cores from trial lengths
(a) Two concrete cores shall be provided from each trial length of concrete profile
barriers. The positions from which the cores are taken shall be as directed by
the Project Manager.
(b) Samples, testing and compliance criteria for concrete cores from trial lengths
shall be as stated in Clauses 10.5.11(a)(ii) to (iv), 10.5.11(b) & (c) for concrete
carriageways.
(i) One sample of each type of interlocking blocks shall be provided from
every 1000 interlocking blocks or part thereof.
(ii) 45 MPa for blocks in carriageways and paved areas to which vehicles
will have access.
General Materials & Workmanship Specification 20/24 January 2011
Issue No. 5, Volume 1 - Civil & Structural Works
Section 11 – Miscellaneous Roadworks
11.6.4 Testing: Grading of bedding and filling sand
A batch of filling sand is any quantity of bags of filling sand of the same
source, covered by the same certificate and delivered to Site at any one time.
(c) Sample: bedding or filling sand
(i) One sample of bedding or filling sand shall be provided from each
batch. The method of sampling shall comply with BS 812 Part 102.
(d) Testing
(i) Each sample shall be tested to confirm compliance with the grading
requirements of Table 11.1.
(ii) The method of testing shall be in accordance with BS 812 Part 103.
A11.1.1 Scope
A11.1.2 Apparatus
(2) If a test machine with platens smaller than the interlocking blocks is used,
auxiliary plates of adequate size shall be placed centrally between the platens
and the interlocking block to be tested. The flatness tolerance of the bearing
faces of the auxiliary platens measured in accordance with CS1 shall not be
more than 0.05 mm and the thickness of the plates shall be at least 25 mm.
(3) Two pieces of packing, each with a thickness of between 5 mm and 6 mm and
dimensions exceeding the interlocking block by between 15 mm and 25 mm.
The packing shall be plywood, chipboard or medium density hardboard.
A11.1.3 Procedure
(1) The interlocking block shall be capped on the running surface and underside
with a suitable capping material in accordance with Clause 15.5.2 of CS 1 and
immersed in water for at least 24 hours before compression.
(2) The interlocking block shall be placed symmetrically on the lower platen of the
test machine, between the two pieces of packing with the running surface
facing upwards.
(3) Load shall be applied without shock and shall be steadily increased at a
constant rate within a stress range of between 150 kPa/s and 700 kPa/s.
(4) The load at which the interlocking block fractures shall be recorded as the
breaking load.
(5) The test shall be repeated for the other four blocks.
(1) The compressive strength (C) of each interlocking block shall be calculated
from the equation:
W 2.5
C= __ x _______ MPa
A L
1.5 +
H
where:
(2) The unbiased standard deviation (s) shall be calculated from the following
equation:
_____________
√ ΣC² - 5(Cm)²
s = _______________ Mpa
4
where:
− ΣC² is the sum of the compressive strengths of the five interlocking blocks
(MPa)
(3) The characteristic strength (Cc) of the batch shall be calculated from the
following equation:
Cc = Cm - 1.65s MPa
where:
(4) Nominal gross plan area of each block to the nearest 100 mm².
(11) That the test method used was in accordance with this General Materials and
Workmanship Specification.
12.1 GENERAL
(a) The works and materials specified shall comply with the Sections stated,
unless otherwise stated in this Section.
(a) Traffic signs shall comply with the Road Traffic Ordinance, Cap 374 and its
subsidiary legislation. Traffic signs for road tunnels shall comply with the
Road Tunnels (Government) Ordinance, Cap 368 and its subsidiary
legislation.
(b) The design of traffic signs, including letters, characters, numbers, symbols
and borders, shall be in accordance with conditions and restrictions imposed
by the Commissioner for Transport.
(c) Unless otherwise stated in the Contract, traffic signs shall comply with the
following:
except that the requirements for marking signs shall not apply.
12.4.1 Steel
Hot rolled structural steel sections - equal and unequal : BS 4848 : Part 4
angles
Stainless steel for traffic signs shall be Grade 316 S 31 and shall comply with the
following:
12.4.3 Aluminium
(a) Aluminium for traffic signs shall be H 30 TF and shall comply with the
following:
(c) Aluminium sheet shall be free from twisting, warping and buckling and the
surfaces shall be free from blemishes and other defects.
(a) Bolts, nuts, screws, washers and rivets for traffic signs shall comply with the
following:
ISO metric black cup and countersunk head bolts and : BS 4933
screws with hexagon nuts
(b) The length of bolts shall be such that after assembly the threaded portion of
each bolt projects through the nut by at least one thread and by not more than
four threads.
(c) Rag and indented bolts shall comply with BS 1494 : Part 2. Expansion bolts
and resin bonded bolts shall be a proprietary type reviewed without objection
by the Project Manager and shall be capable of withstanding the design
loading.
(d) Galvanised bolts, nuts, screws, washers and rivets shall be used with traffic
signs secured to galvanised pedestrian guard-railing. Aluminium materials
shall be insulated from ferrous materials including any coated ferrous
materials by a non-conductive insulator at least 2 mm thick of a type reviewed
without objection by the Project Manager.
(c) Plastic sheeting shall be a proprietary type reviewed without objection by the
Project Manager.
(a) Hot applied thermoplastic material shall comply with BS 3262 : Part 1 except
that:
(ii) the flow resistance shall be such that a cone made and tested in
accordance with BS 3262 : Part 1 shall not slump by more than 25%
after 48 hours at 40°C ±2°C.
(b) Solid glass beads shall be included in the supplied mixture of hot applied
thermoplastic material.
(a) Cold applied preformed material for road markings shall be a proprietary type
reviewed without objection by the Project Manager
(b) Solid glass beads shall be applied to cold applied preformed material at the
place of manufacture.
Hot applied thermoplastic material shall be delivered and stored in accordance with
BS 3262 : Part 1, Clauses 9 and 10 and the manufacturer's recommendations.
(a) Road studs shall comply with the Road Traffic Ordinance, Cap 374 and its
subsidiary legislation.
(b) Road studs shall be a proprietary type reviewed without objection by the
Project Manager.
(c) Permanent reflecting road studs to be used as lane line markers on dual
carriageway trunk roads and primary distributor roads shall be a type to which
traffic cylinders of a type reviewed without objection by the Project Manager
can be attached. The method of attachment shall be such that the traffic
cylinder can be easily detached from the road stud.
(a) Bitumen grout for road studs shall consist of bitumen and filler. The bitumen
content shall be 25% to 30% of the total mass.
(b) Bitumen shall be tropical grade filled bitumen, oxidised grade R 85/25.
(c) Filler shall be hydrated lime; the percentage by mass of hydrated lime passing
a 75 m BS test sieve shall be at least 85%.
(d) The properties of bitumen grout for road studs shall comply with the following
requirements:
12.5 SUBMISSIONS
(a) The following particulars of the proposed traffic signs shall be submitted to the
Project Manager for review:
The following particulars of the proposed materials for road markings shall be
submitted to the Project Manager for review:-
(a) certificates for thermoplastic material, paint and solid glass beads showing the
manufacturer's name, the date and place of manufacture and showing that
the material complies with the requirements stated in the Contract and
including results of tests for softening point and flow resistance of
thermoplastic material.
(a) Posts for beacons at zebra crossings shall be painted with alternate black and
white stripes. Other posts shall be painted grey in accordance with
BS 5252F, Code 18B19 or shall be galvanized in accordance with BS 729.
(b) Galvanised areas affected by cutting and drilling shall be treated using a
method reviewed without objection by the Project Manager.
(c) Posts other than posts supporting an external luminaire shall not protrude
above the top of signs. The length of posts supporting external luminaries
protruding above the top of signs shall be as short as practicable.
(a) Backing plates for traffic signs shall be fabricated from 3 mm aluminium sheet.
Backing plates for traffic signs not exceeding 1200 mm high x 2400 mm wide
shall be fabricated from a single sheet. If more than one sheet is used, the
number of sheets shall be kept to a minimum; the separate sheets shall be
rectangular and shall be approximately the same size.
(b) Holes in backing plates shall be drilled before the plate is painted and before
retroreflective or non-retroreflective sheeting is applied.
(a) Top and bottom light spill screens shall be fabricated from the same material
as the backing plate. The spill screens shall extend for the complete width of
the backing plate and the corners shall be cut to the same radius as the
corners of the backing plate.
(b) Spill screens shall be considered as part of the backing plate and stiffeners
and mountings shall be designed to accommodate the combined size.
(a) Faces for traffic signs shall be formed using retroreflective or non-
retroreflective plastic sheeting. Unless otherwise permitted by the Project
Manager, a single piece of sheeting shall be used. If more than one sheet is
used, the number of sheets shall be kept to a minimum. Sheeting shall be
fixed in accordance with the manufacturer's recommendations.
(b) Materials for faces of traffic signs, including the background, letters,
characters, numerals, symbols and borders, shall be matched for colour in
accordance with the sheeting manufacturer's recommendations at the time of
fabrication to provide a uniform appearance by day and by night.
(c) Letters, characters, numerals, symbols and borders shall be clear cut and
sharp-edged and shall have no cracks.
Lacquer coatings to faces for traffic signs shall be uniform and continuous and shall
be applied at the time of manufacture of the face.
(a) Faces of traffic signs to which a painted or stoved finish is to be applied shall
be thoroughly cleaned and pre-treated before painting and stoving.
(c) At least one undercoat and at least one finishing coat of paint shall be applied
and stoved to a thickness of between 0.0315 mm and 0.0375 mm of enamel
over a minimum thickness of 0.025 mm of primer. If light colours are to be
applied over dark colours, at least two coats of the light colour shall be
applied. The final surface shall have a uniform thickness and an egg-shell flat
finish and shall be smooth and free from defects.
(d) The colours of the finished coating shall be uniform. The colours, including
white, shall comply with the chromaticity co-ordinates of BS 873 : Part 6,
Table 4 and, for comparative purposes, shall comply with the following gloss
paint colours in accordance with BS 381C:
(e) Parts of faces coloured black shall be non-retroreflective and shall have a
luminance factor not exceeding 0.05 as measured in accordance with BS 873
: Part 6.
(a) Fittings for traffic signs shall be non-corrodible material reviewed without
objection by the Project Manager.
(b) Joints for framework and stiffeners which are not an integral part of the
backing plate shall be welded or joined using brackets, nuts, bolts and
washers.
(c) Materials for rivets and other fixings for joining backing plates to framework
and stiffeners shall be compatible with the materials to be joined. The
spacing of rivets and other fixings shall be uniform; the spacing shall not
exceed 150 mm around the outside edge of sheets and shall not exceed
300 mm on cross braces.
(f) A lacquer coating shall be applied to the edges of holes drilled in plates with
plastic sheeting immediately before rivets and bolts are inserted. The
surfaces of rivets and bolts on the faces of traffic signs shall be covered with a
material coloured to match the part of the face with which it is in contact.
(g) Fixings for traffic signs erected on road lighting columns shall be compatible
with the column cross section. Columns shall not be drilled.
(a) Traffic signs which are to be blanked out shall be covered by the following
methods:
(i) Plate signs shall be covered using a 1.5 mm thick sheet which is
compatible with the material in the sign.
(ii) Plate signs which are to be blanked out for a period not exceeding one
year shall alternatively be covered using a self-adhesive plastic film.
(iii) Other signs shall be covered using a loose cover sheet of material
reviewed without objection by the Project Manager.
(b) Cover sheets shall be fixed using 5 mm diameter stainless steel bolts,
washers and nuts or non-ferrous rivets at spacings not exceeding 600 mm.
Bolts shall pass through 5 mm x 12 mm diameter plastic distance pieces
between the face of the sign and the cover plate. Holes which remain on the
finished face of the sign shall be filled using blocked rivets; the face of the
rivets shall be coloured by a method reviewed without objection by the Project
Manager.
(c) Self-adhesive plastic film shall be compatible with the material in the face of
the sign and shall be fixed and removed in accordance with the
manufacturer's recommendations.
(d) Loose covers shall be securely fastened to the back of the sign. Tape or
other adhesive material shall not be applied to the faces of signs.
(e) Coverings to traffic signs shall be sufficiently opaque to prevent reflection from
the covered sign and shall not be removed until the Project Manager so
directs.
(f) The faces of traffic signs which have been erected and which do not relate
either wholly or in part to the traffic situation which applies at that time shall be
blanked out as stated in this Clause.
(a) Road markings shall not be laid over loose detritus, mud or similar extraneous
matter. Oil and grease shall be removed from the surface of carriageways on
which road markings will be laid.
(b) Curing compound shall be removed from the surface of new concrete
carriageways on which road markings will be laid, by wire brushing or by other
methods reviewed without objection by the Project Manager.
(c) Existing road markings which are to be replaced by a different type of material
shall be removed by high pressure water jetting, shot blasting or rotary
grinding; the existing markings shall not be masked using black paint or
similar methods.
(d) Existing road markings which are to be renewed using a similar type of
material shall be roughened by a method reviewed without objection by the
Project Manager until the thickness of the existing material is reduced by
approximately 50%.
(e) A tack coat shall be applied to the surface of concrete carriageways before
hot thermoplastic material is laid. The tack coat shall be compatible with the
road marking material and shall be applied in accordance with the
manufacturer's recommendations.
(f) Rotary grinding machines shall not be used to remove or roughen existing
road markings within 100 mm of longitudinal or transverse joints on concrete
carriageways.
(a) Hot applied thermoplastic material shall be prepared and laid in accordance
with BS 3262 : Part 3, Clauses 4 and 5. The material shall not be laid when
the surface of the carriageway is wet, or the air ambient temperature in the
shade is less than 10°C.
(c) The thickness of road markings, not including surface applied solid glass
beads, shall comply with the following:
(ii) sprayed lines other than yellow edge lines : ≥ 1.5 mm; and
(d) Traffic shall not be permitted to run over road markings until they are dry and
set.
General Materials & Workmanship Specification 9/11 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 12 – Traffic Signs, Road Markings &
Road Studs
12.6.11 Laying cold applied preformed material
(a) Cold applied preformed material shall be laid in accordance with the
manufacturer's recommendations. The material shall not be laid when the
surface of the carriageway is wet.
(c) Traffic shall not be permitted to run over road markings until they are dry and
set.
Road marking paint shall not be used other than for temporary road markings.
12.6.13 Reflectorisation
Solid glass beads shall be applied to the surface of hot applied thermoplastic
material and road marking paint immediately after the material or paint has been
applied, to enhance the reflectivity of the surface. The solid glass beads shall be
uniformly applied by a mechanical method at a rate of between 400 g/m² and
500 g/m².
(a) Temporary road markings shall be used at locations directed by the Project
Manager. Cold applied preformed material shall be used for temporary road
markings which are to be removed.
The skid resistance level of road markings measured in accordance with BS 3262 :
Part 1 shall be at least 45.
The lengths, thicknesses and widths of hot applied thermoplastic material road
markings shall comply with the following requirements:
(b) The length and width of screed markings and sprayed lines shall be within
+10%, -5% of the specified dimension.
(c) Road studs shall not be installed on concrete carriageways until the concrete
has reached the specified grade strength.
(d) Surfaces to which bonded road studs are to be fixed shall be clean and all
dust, grease and other deleterious material shall be removed immediately
before the studs are installed.
(a) The number of traffic signs to be tested shall be as stated in the Contract or
as directed by the Project Manager.
(b) The number and type of tests to be carried out on the traffic signs shall be as
stated in the Contract or as directed by the Project Manager.
(c) Testing shall be carried out in such a manner that the traffic sign will not be
damaged.
(d) Testing shall be carried out by the Contractor at a laboratory reviewed without
objection by the Project Manager.
The compliance criteria for testing traffic signs shall be in accordance with
BS 873:Part 1.
13.1 GENERAL
(a) The works and materials specified in the following sub-clauses shall comply
with the Sections stated, unless otherwise stated in this Section.
(b) For the purposes of this Section 13 of the General Materials and
Workmanship Specification, the term electrical and mechanical work shall
consist of all mechanical and electrical services, systems and equipment
including but not limited to the following :
(a) The principle requirements for electrical and mechanical installations will be
as shown on the Employer's Drawings. Confirmation of these provisions and
identification of any other requirements, including holes, sleeves and
recesses, shall be carried out in accordance with the requirements of the
Section 11 of the General Specification.
(b) Where holes, sleeves and recesses are to be provided in concrete structures
they shall be formed prior to placing of concrete and shall not be cut through
hardened concrete.
(c) Where pipework, cables, cable trunking or trays, ducts or fire dampers or
other elements of electrical and mechanical system pass through structural or
non-structural elements, the requirements of Sections 44-60 of the General
Materials and Workmanship Specification shall apply.
(d) Holes, sleeves and recesses in internal floors, stairways and platforms shall
be protected with temporary covers until the electrical and mechanical
installation starts. Holes, sleeves and recesses in roofs, external walls and
external floors shall be sealed with watertight temporary covers reviewed
without objection by the Project Manager until the electrical and mechanical
installation starts.
13.2 MATERIALS
(a) Electrical conduits and fittings shall comply with BS 4568 : Parts 1 and 2 and
shall have Class 4 heavy protection inside and outside. Conduits shall be
heavy gauge with screw-end construction in steel and shall have an external
diameter of at least 20 mm; conduits shall be longitudinally welded.
(b) Metal boxes for enclosing electrical accessories shall comply with BS 4662
and shall have heavy protection inside and outside; the boxes shall be of
preferred sizes and shall be 35 mm or 47 mm deep as appropriate. Circular
ceiling boxes of deep pattern shall comply with BS 4568 : Part 2 and shall
have Class 4 heavy protection inside and outside; the boxes shall be at least
60 mm deep internally.
(c) Circular boxes, dome covers and hook covers shall be cast iron. Bushes and
plugs shall be brass.
(a) UPVC cable ducts for installation above ground or for casting into concrete
shall be Class 0 UPVC pipes complying with BS 3506. Cable ducts for
installation below ground shall be Class B UPVC pipes complying with
BS 3506. For road lighting systems, the colour of the underground UPVC pipe
shall be purple.
(b) Joints and fittings for use with UPVC cable ducts shall comply with BS 4346 :
Part 1 and BS 4346 : Part 2. Solvent cement for UPVC pipes and fittings shall
comply with BS 4346 : Part 3.
(c) Steel cable ducts shall be steel tubes complying with BS 1387, medium
series, screwed and socketed tubes and shall have screwed sockets suitable
for screwing to BS 21, Table 2 pipe threads. The tubes, sockets, clamps and
saddles for ducts shall be galvanized in accordance with BS 729.
(a) Bituminous paint for steel conduits and steel cable ducts shall comply with
BS 3416, type 1.
(b) Anti-rust paint for concealed electrical conduit systems shall be a proprietary
type reviewed without objection by the Project Manager.
(c) Zinc chromate primer for cable duct systems shall comply with BS 4652.
(d) Galvanizing paint for cable duct systems shall be a proprietary type reviewed
without objection by the Project Manager.
Internal fire barriers shall be a type offering adequate fire resistance for the
application. The material shall be reviewed without objection by the Project
Manager in compliance with Fire Services Department requirements and shall be
resistant to fire, smoke, gas and water.
(b) The different types of cement grout for electrical and mechanical installations
shall consist of ordinary Portland cement, sand and PFA in the proportions by
mass stated in Table 13.1 together with the minimum amount of water
necessary to achieve a consistency suitable for completely filling the voids.
The mix shall contain a non-shrink admixture.
13.2.6 Cables
(a) PVC insulated cables shall be single core of copper conductors, 450/750V
grade and flame retardant PVC insulation to BS 6004.
(b) The current carrying capacity shall be in accordance with IEE Wiring
Regulations. Minimum size of cables shall be as follows unless other
specified:
Lighting 2.5 sq mm
Control 1.5 sq mm
(c) All wiring shall be carried out on the loop-in system and the wires shall be
drawn into the conduits after the whole of this installation has been
completed. No joints or connectors will be allowed in any such cable, except
that connectors may be used in accessible positions with lighting fittings.
(d) All PVC insulated cables shall be installed in galvanized conduit.
13.3 WORKMANSHIP
(c) Principal conduit runs shall be either vertical or horizontal. Tee pieces and
elbows, including those with provision for inspection, shall not be used.
(d) Joints shall be made using coupler units into which the ends of the conduits
shall be inserted and tightened. Running couplings shall not be used unless
permitted by the Project Manager; if permitted, the couplings shall be made by
screwing each of the conduits half way into the coupler with a hexagonal lock
nut against each end of the coupler.
(f) Adaptable boxes for conduits installed in floor screeds shall have the lids set
flush with the adjacent floor; the boxes shall be covered with the same
material as the remainder of the floor and shall remain accessible at all times.
(g) The clearance between conduits entering adaptable boxes and between
adjacent or parallel conduits shall be at least the nominal maximum coarse
aggregate size of the concrete plus 5 mm.
(b) All conduit systems shall be installed fully in accordance with the
requirements of the current IEE Wiring Regulation.
(d) Conduits shall not be bent by more than 90° and the internal radius at bends
shall be at least 2.5 times the external diameter of the conduit. Conduits shall
not be flattened at bends.
(e) Burrs and sharp edges shall be removed from the ends of conduits before
installation.
(f) Concealed electrical conduit systems which are to be cast into concrete shall
be fastened to the reinforcement with tying wire of the same type used for the
reinforcement. The conduit systems shall not be positioned between the
reinforcement and the outside face of the concrete.
(g) Conduit boxes shall be of a compatible size and shall have a single extension
ring of the required depth if the plaster finish exceeds 13 mm thick; multiple
extension rings shall not be used.
Screw fitting couplers shall be provided at each end of conduits which terminate in
distribution boards, busbar chambers, motor starters, cable ducts, boxes or similar
termination points. The item at which the conduit terminates shall be drilled with an
unthreaded clearance hole to receive a brass male bush; the bush shall be screwed
into the coupler from the inside of the item in such a manner that the surface of the
item is gripped between the coupler and the bush. The threads shall be at least half
the length of the coupler.
(b) Steel conduit systems laid in contact with or adjacent to other metal work shall
have efficient and permanent metallic connection made between the conduit
and the metal work.
(c) Underground steel conduits and conduits in contact with soil shall be painted
with two coats of bituminous paint before installation.
(d) Exposed threads and damage to protective coatings of conduit systems shall
be painted with two coats of anti-rust paint.
(f) Water, moisture and deleterious material shall be prevented from entering
permanent and temporary terminations in concealed electrical conduit
systems, including conduit boxes, by using conduit stopping plugs of a type
reviewed without objection by the Project Manager; paper or rags shall not be
used.
After installation, concealed electrical conduit systems shall be swabbed out with
draw-in tapes and absorbent cloth of a type reviewed without objection by the
Project Manager; all obstructions shall be removed and draw wires shall be
installed. After cleaning, exposed conduit ends shall be sealed as stated in Clause
13.3.4(f).
(b) UPVC cable ducts shall be jointed in accordance with the manufacturer's
recommendations.
(c) Steel cable ducts shall be jointed using screwed galvanized sockets and spun
yarn such that the jointed pipes abut; the threads shall be painted with two
coats of bituminous paint. Internal rags and burrs shall be removed to provide
a smooth bore through joints in the cable duct system.
(d) Surface mounted cable ducts shall be secured by galvanised steel clamps or
saddles at spacings not exceeding 3 m.
(i) High Voltage single core cables (exceeding 650 Volts) ..............450 mm
(iii) Low and Medium Voltage cables (not exceeding 650 Volts) .......150 mm
where the duct and electricity supply cable cross with minimum separation a
layer of concrete 50 mm thick shall be provided.
(f) To ensure the correct alignment of ducts, a wooden mandrel shall be drawn
forward as the ducts are laid.
(a) After jointing, exposed bare metal in cable duct systems shall be cleaned and
painted with two coats of zinc chromate primer and two coats of galvanizing
paint.
(b) Surface mounted galvanized steel cable ducts shall be cleaned and painted
after fittings and jointing have been completed.
After jointing, cable duct systems shall be cleaned internally by scrubbing with a
cylindrical brush of a type reviewed without objection by the Project Manager. The
ends of ducts, including ends of ducts in draw-in pits and spare ducts, shall be fitted
with tapered hardwood plugs to prevent water, moisture and deleterious material
from entering the system and a 6 mm diameter nylon draw line shall be installed.
The plugs shall be centrally drilled for the draw line and the draw line shall be
secured by a knot tied on the outer face of the plug to leave at least 1500 mm of
surplus line at each plug.
(a) Pits and trenches for electrical earthing systems shall be excavated at
positions and at the times directed by the Project Manager.
(b) After the electrical earthing systems have been installed fill material shall be
deposited and compacted in the pits and trenches to a depth of 300 mm
above the electrical earthing system. Fill material shall be sand or fine fill
material which has been selected from the excavated material, and which is
free from stones retained on a 20 mm BS test sieve. Fill material shall be
compacted by handrammers in a manner reviewed without objection by the
Project Manager.
(a) Grouting to structural steelwork, machine bases, crane rails, electrical and
mechanical equipment and other electrical and mechanical installations shall
comply with the requirements stated in Clause 13.3.10(b) to (g).
(b) The Contractor shall notify the Project Manager before items or equipment are
grouted.
(c) Concrete surfaces shall be scabbled to remove laitance and loose material
and to expose the aggregate before the item or equipment is installed in
position.
(d) The voids to be grouted shall be cleaned and thoroughly wetted immediately
before grouting. Excess water shall be removed by using a compressed air
jet.
(e) Grout shall be mixed and placed by methods reviewed without objection by
the Project Manager.
(f) If grouting is to be carried out in two operations, holding down bolts shall be
grouted into preformed pockets and sufficient time shall be allowed for the
grout to cure and for the bolts to be tensioned before the remaining voids are
grouted.
(g) Exposed grout surfaces shall have a uniform, dense and smooth surface free
from trowel marks and which is produced by steel trowelling the surface under
firm pressure. The exposed surfaces shall be cured by either:
(ii) covering the surface with hessian or sacking; the hessian or sacking
shall be lapped and securely held in position and shall be kept damp for
at least 4 days.
(a) Unless otherwise stated in the Contract work shall be completed to the
conditions stated in Clause 13.3.11(b) to (g) inclusive before structures are
made available to Other Contractors for electrical and mechanical
installations.
(b) Structures shall be clean, dry and free from dust. Work which will produce
large quantities of dust shall be complete.
(d) Plinths, trenches, louvres, openings and similar work shall be complete and
shall have hardened sufficiently to allow the installation to proceed.
(e) Floors and slabs shall be complete to the specified finishes except that floor
tiles shall not be laid until after the installation is complete.
(f) Plant rooms shall be complete, including fixtures and fittings, to a secure and
weatherproof condition. Two sets of door keys for each plant room shall be
provided for the Project Manager.
(g) Paintwork and similar finishes in plant rooms shall be complete to undercoat
level; final coats shall not be applied until after the installation is complete.
(a) Structures in which electrical and mechanical installations are being carried
out shall be maintained in a clean, dry condition, free from dust, during the
installation.
(b) The dust level in plant rooms shall be kept to a minimum by using industrial
dust extractors of a type reviewed without objection by the Project Manager
during and after the installation. Temporary screens shall be installed to
separate dust-affected areas from the installations or temporary covers shall
be installed around the installation.
(a) The Contractor shall allow the Project Manager to inspect the following work
for electrical and mechanical installations:
(iii) structures which are to be made available for electrical and mechanical
installations.
(b) The Contractor shall notify the Project Manager three days, before work is
covered up, tested or made available.
(a) Concealed electrical conduit systems shall be tested to determine the earthing
continuity. The system shall be tested:
(b) The method of testing shall be in accordance with the 16th Edition of IEE
Wiring Regulations issued by the Institution of Electrical Engineers.
(c) The results of tests for earthing continuity shall comply with the 16th Edition of
IEE Wiring Regulations issued by the Institution of Electrical Engineers.
(a) Load tests shall be carried out on lifting beams, rolled steel joists, lifting
hooks, eyes and anchorage points which are installed by the Contractor for
electrical and mechanical work or other Permanent Works.
(c) A certificate showing the results of the load tests and signed by the testing
authority shall be submitted to the Project Manager for review without
objection within 7 days of the test.
(d) The results of tests on lifting beams, rolled steel joists, lifting hooks, eyes and
anchorage points shall comply with the Factories and Industrial Undertakings
(Lifting Appliances and Lifting Gear) Regulations, 1978 issued by the Labour
Department.
14.1 GENERAL
The Permanent Works and materials specified below shall comply with the Sections
stated, unless otherwise stated in this Section.
(c) Formwork and finishes to concrete shall comply with Section 18.
14.2.1 Fitting
Fitting is a component fitted to a pipe for jointing or connecting or for changing the
direction or bore of a pipe.
Flexible joint is a connection between pipes and fittings which provides angular
deflection or axial movement or a combination of both in service without impairing
the efficiency of the connection.
Mechanical joint is a flexible joint in which an elastomeric joint ring is located in the
socket and the joint sealed by applying pressure to the joint ring by means of a
gland bolted to the socket.
Push-in joint is a flexible joint in which an elastomeric joint ring is located in the
socket and the joint is effected by entering the spigot through the joint ring into the
socket.
Thin walled pipe is a pipe, including pipes of DN 1200 or greater, which has a ratio
of nominal size to wall thickness, excluding linings and coatings, exceeding 125.
Nominal outside diameter of a polyethylene pipe shall mean the minimum mean
outside diameter of the pipe as described in Clause 3.1 of ISO 161-1.
Nominal wall thickness of a polyethylene pipe shall mean the minimum wall
thickness of the pipe as described in Clause 3.4.5 of BS ISO 11922-1.
The Standard Dimension Ratio (SDR) of a polyethylene pipe shall mean the ratio of
its nominal outside diameter to its nominal wall thickness as described in Clause 3.8
of ISO 161-1.
14.2.11 WIS
WIS shall mean the Water Industry Specification produced and published by WRC.
14.3 MATERIALS
Materials for water supply pipeworks for potable water shall be non-toxic, shall not
promote microbial growth and shall not impart a taste, odour, cloudiness or
discolouration to the water after disinfection and washing out of the pipelines as
stated in Clause 14.6.8.
Water supply pipework shall be either ductile iron or polyethylene unless otherwise
reviewed without objection by the Project Manager.
(a) DI pipes and fittings shall comply with BS 4772. Pipes and fittings other than
collars, caps and blank flanges shall be lined internally with cement mortar in
accordance with BS 4772, Clause 3.2. Linings shall be made with
sulphate-resisting Portland cement complying with BS 4027.
14.3.3 Flanges
(a) Bolts and nuts for flanged joints shall comply with BS 4504 : Section 3.1,
Section 6.
(b) Bolts and nuts shall be compatible with the type of joint and shall be obtained
from the same manufacturer as the joint.
(c) Bolts shall be sufficiently long and shall be suitably threaded for jointing the
relevant flanges.
Elastomeric joint rings for DI pipes and fittings shall comply with BS 4772,
Clause 2.3.4. The dimensions of rings for use with flanged joints shall comply with
BS 4865 : Part 1. The rings shall be compatible with the type of joint and shall be
obtained from the same manufacturer as the joint.
(a) Polyethylene pipes shall be either PE80 or PE100 grade pipes in accordance
with Clauses 14.3.6 (b) to (h)
(b) PE80 pipes with nominal outside diameter from 20mm to 63mm inclusive and
PE100 pipes with nominal outside diameter from 90mm to 180mm inclusive
shall conform to ISO 4427.
(c) PE80 and PE100 pipes shall have a SDR of 11 and have nominal pressure
rating as follows:
(e) The tolerance on the nominal outside diameter of polyethylene pipes shall be
in accordance with Grade B of BS ISO 11922-1.
(f) The end of the pipe shall be cut cleanly and square to the axis of the pipe to
within the tolerances given below:
(h) Melt flow rate of PE80 and PE100 pipes tested at a temperature of 190°C
under a nominal load of 5 kg shall be within the range of 0.2 g/10 min to 1.3
g/10 min.
(a) All fittings for polyethylene pipes shall have a pressure rating the same as or
higher than the nominal pressure rating of the pipes. The fittings shall be
supplied with complete set of accessories including insert, liners, joint rings,
flange gaskets, studs, bolts and nuts, etc. whatever appropriate.
(b) The flanges of all fittings shall be constructed in such a way that they may be
attached to flanges designated PN16 whose dimensions conform to Table 9
of BS EN 1092-2. One complete set of bolts and nuts and one gasket shall
be supplied with each flange of flanged fittings. The strength of bolts shall be
Grade 4.8 and the strength of nuts shall be Grade 4 complying with BS 4190.
The bolts and nuts shall be hot dip galvanized or have other protective
coatings reviewed without objection by the Project Manager.
(b) Melt flow rate of PE80 and PE100 electrofusion fittings tested at a
temperature of 190°C under a nominal load of 5kg shall be within the range of
0.2 g/10 min to 1.3 g/10 min.
(d) The design for fitting terminals and shrouds shall be similar to that stated in
Clause 5.2.3 of WIS 4-32-14. Other designs of terminals will only be
considered if the Contractor can demonstrate that appropriate lead adaptor is
readily available such that electrofusion of their fittings can be conducted
using common electrofusion control units available in the market.
(e) Unless otherwise reviewed without objection by the Project Manager, all
electrofusion fittings shall be blue in colour within the range as specified in
Clause 14.3.6(d).
(b) Compression fittings with external and/or internal threads shall be compatible
with pipes and fittings threaded to BS 21.
(b) Mechanical fittings shall be coated with a minimum thickness of 250 microns
of epoxy or plastic based coating complying with the performance requirement
of WIS 4-52-01.
(a) Markings on the polyethylene pipes and fittings shall be in accordance with
the relevant Clauses in the ISO or WIS appropriate to the pipes and fittings
supplied.
(b) Notwithstanding Clause 8 of ISO 4427, the pipes series in SDR shall be
marked on the pipes.
(a) Anticorrosion tape shall be a propriety type reviewed without objection by the
Project Manager. The tape shall either be a petrolatum tape with fabric
reinforcement or a bituminous tape with PVC backing. Petrolatum tape shall
be used for valves, flanged joints, slip-on type couplings and flange adaptors
of all sizes. Bituminous tape shall be used in buried or non-exposed condition
for welded joints of steel pipe, repair of steel pipe sheathing and other
applications as specified on the Employer’s Drawings.
(c) Primer and mastic filler for use with anticorrosion tape shall be compatible
with the tape and shall be a type recommended by the manufacturer of the
tape and reviewed without objection by the Project Manager.
(d) Bituminous tapes shall be stored in a cool dry place away from the sun’s rays.
The tape shall be free of dirt or grit immediately prior to application.
(b) Bituminous coatings used for repairing joints and coatings shall be compatible
with the adjacent coating.
(a) Zinc-based paint shall be a proprietary type reviewed without objection by the
Project Manager.
(c) Rust inhibitor shall be a chemical agent which is capable of converting rust
into iron phosphate.
(a) Joint filler for joints in concrete bed, haunch and surround shall be a
proprietary type reviewed without objection by the Project Manager and shall
be a firm, compressible, single thickness, non-rotting filler. The thickness of
the filler shall be as stated in Table 14.2.
Table 14.2: Joint Filler for Concrete Bed, Haunch and Surround
Extension keys and clamps for valves shall be Grade 43A steel complying with
BS 4360 and shall be hot-dip galvanised in accordance with BS 729 after
fabrication.
(a) Pipes, joints and fittings for water supply pipeworks shall be transported,
handled and stored in accordance with the manufacturers' recommendations
and in a manner which will not result in damage or deformation to the pipes,
joints and fittings or in contamination of the pipes, joints and fittings.
(b) Pipes, joints and fittings shall be protected from damage and damaged pipes,
joints and fittings shall not be used in the Permanent Works. Pipes, joints and
fittings shall be securely packed and supported to prevent movement when
being transported.
(d) Elastomeric joint rings shall be packed in bags and lubricant for joints shall be
stored in sealed containers marked to identify the contents. The rings and
lubricant shall be protected from exposure to conditions which may affect the
material.
(e) Boxed or crated materials or those in sealed containers shall remain in their
original boxes, crates or containers.
(a) Pipes and fittings other than thin walled pipes shall be handled by manual
methods or by using lifting appliances or chains, wire rope or canvas slings of
a type recommended by the pipe manufacturer and reviewed without
objection by the Project Manager. Hooks shall not be used.
(b) Slings shall be placed around the pipes and fittings and padding shall be
provided at points of contact between pipes and fittings and metal lifting
appliances or slings. Pipes and fittings shall not be handled by means of
metal slings passed through the pipes.
(c) Pipes and fittings shall not be subjected to rough handling, shock loading or
dropping.
(a) Pipes other than thin walled pipes shall be stored horizontally at least 75 mm
above the ground on wedged timber bearers. The pipes shall be securely
wedged to prevent sideways movement.
(b) Socket and spigot pipes shall be stored with the sockets alternating and in
such a manner that loads are not applied to the sockets.
(c) The height of stacks of pipes other than thin walled pipes shall not exceed the
maximum height recommended by the pipe manufacturer.
(d) Pipes shall not be strung out along the route of the pipeline.
When being transported, thin walled pipes shall be supported on three rubber
covered saddles shaped such that the pipes are supported over at least one-quarter
of the circumference. The pipes shall be securely fixed in position at each saddle
by straps tightened by turnbuckles. One saddle shall be placed at the mid-point of
the length of the pipe and the other two saddles shall be placed at distances of
one-fifth of the length of the pipe from each end of the pipe.
(a) When being handled and stored, thin walled pipes shall be protected from
deformation by means of at least two screw jack cruciform struts with rubber
padded ends shaped to fit the circumference of the pipes. The struts shall be
fitted inside the pipes; any temporary struts fixed by the manufacturer shall be
left in position until the cruciform struts have been fixed.
(b) Thin walled pipes shall be handled by using two reinforced canvas slings at
least 300 mm wide. The slings shall be suspended from a lifting beam and
shall be placed at a distance of one-fifth of the length of the pipe from each
end of the pipe.
(e) Thin walled pipes shall not be stacked on top of each other.
14.4 SUBMISSIONS
Particulars of the proposed independent inspection authority for pipes, joints, fittings
and valves for water supply pipeworks, including name and address, previous
experience, and names of inspectors, shall be submitted to the Project Manager for
review without objection.
(a) The following particulars of the proposed pipes, joints and fittings for water
supply pipeworks shall be submitted to the Project Manager for review without
objection:
(ii) a certificate for each material showing the manufacturer's name, the
date and place of manufacture and showing that the material complies
with the requirements stated in the Contract and including results of
tests required in accordance with the relevant British Standard;
(a) The following particulars of the proposed procedures for pressure tests on
pipelines for water supply pipeworks shall be submitted to the Project
Manager for review without objection:
The following particulars of the proposed anticorrosion tape for water supply
pipeworks shall be submitted to the Project Manager:
(b) certificate for anticorrosion tape showing the manufacturer’s name, the date
and place of manufacture and showing that the material complies with the
requirements stated in the Contract and including results of tests in
accordance with the Contract.
14.5 WORKMANSHIP
(a) Rubber wheeled trolleys shall be provided to obtain access inside pipelines
exceeding DN 500 for water supply pipeworks in order to joint pipes, repair
joints, coatings and linings and inspect the pipeline. Persons entering
pipelines shall wear clean soft-soled footwear.
(b) Mechanical fans shall be provided to ensure that an adequate air supply is
available to those entering pipelines for inspection. Engine driven fans shall
be fitted with a flexible exhaust or other methods of keeping exhaust fumes
clear of the fresh air intake.
(a) The Contractor shall notify the Project Manager before pipelaying starts in any
part of the Permanent Works.
(b) The Contractor shall inspect pipes, joints, fittings and valves, including internal
and external coatings, immediately before and after pipelaying; valves shall
be inspected to ensure that they are in working order and are capable of
being fully opened and closed. Deleterious material shall be removed and
damage shall be repaired immediately before and after pipelaying; potable
water shall be used for washing.
(e) Pipelaying shall follow closely on excavation of the trench. Lengths of trench
which in the opinion of the Project Manager are excessive shall not be left
open.
(g) Pipes shall be laid in such a manner that water will not pond in locations with
either zero or shallow gradients, and the line and level of pipes shall comply
with the specified tolerances.
The degree of the curve of pipes for water supply pipeworks with flexible joints
which are to be laid to a curve shall be equally distributed over all joints within the
curved section. The deflection at a completed joint shall not exceed 3° or
three-quarters of the maximum deflection recommended by the manufacturer
whichever is less.
(a) Operating gear and associated fittings shall be installed and fixed at the same
time as valves, for water supply pipework, are installed. After installation,
valves shall be cleaned inside and outside and left in a closed position.
(b) Extension keys and clamps shall be fixed to valves in valve chambers if the
vertical distance between the top of the valve spindle and the finished ground
level exceeds 600 mm. The length of extension keys shall be such that the
top of the extension key is not more than 300 mm below the finished ground
level.
(a) Surfaces on which pipes for water supply pipeworks will be laid shall be
cleaned and objects which may damage the pipes shall be removed before
pipes are laid.
(b) The bottom of trenches on which pipes will be laid directly shall be shaped to
support the pipes uniformly along the length of the barrel; holes shall be dug
to prevent pipes resting on the sockets and to allow the pipes to be jointed.
(a) Pipes for water supply pipeworks shall be cut and the ends shall be prepared
in accordance with the manufacturer's recommendations. Pipes shall be cut
using purpose made equipment recommended by the manufacturer and
reviewed without objection by the Project Manager.
(c) Pipes requiring to be cut to form closing lengths shall not be cut until adjacent
pipes have been laid and jointed and the length to be cut can be accurately
measured.
(a) Pipes for water supply pipeworks shall be jointed in accordance with the
manufacturer's recommendations and using jointing equipment and jointing
materials recommended by the manufacturer and reviewed without objection
by the Project Manager.
(b) The Contractor shall inspect pipes, joints, fittings and valves, including internal
and external coatings, immediately before and after jointing. Deleterious
material shall be removed and damage shall be repaired immediately before
and after jointing; potable water shall be used for washing. Surfaces which
are to be jointed and jointing materials shall be cleaned immediately before
jointing.
(d) The widths of gaps at joints shall be in accordance with the manufacturer's
recommendations and shall be achieved by marking the outside of the pipe or
by using metal feelers. The position of elastomeric joint rings shall be
checked by using metal feelers after jointing.
(e) Gaps at joints in pipes shall be protected after jointing by methods reviewed
without objection by the Project Manager to prevent dirt, stones or other
material entering the joint.
(f) Bolt holes in flanged joints and joints incorporating bolted components shall
be correctly orientated before the bolts are tightened. The correct size of bolts
and nuts shall be used. Bolt threads shall be lubricated and bolts shall be
tightened using the correct size of spanner. Bolts shall be tightened in
diametrically opposite pairs working around the bolt circle until all bolts are
tightened to the torque recommended by the manufacturer.
(g) Bolt holes in flanged joints shall be orientated symmetrically about the vertical
diameter with no bolt holes on the vertical diameter. Elastomeric joint rings
shall be the correct size and shall not protrude into the bore of the pipe. The
rings may be temporarily fixed to the face of the flange using a minimum
amount of adhesive of a type recommended by the manufacturer; jointing
compound or paste shall not be used.
DI pipes with push-in joints for water supply pipeworks shall be jointed by smearing
the spigot end of the pipe with lubricant and placing the elastomeric joint ring in
position inside the groove of the socket end of the laid pipe. The spigot end of the
pipe shall be placed in the socket end of the laid pipe and pushed home.
(a) DI pipes with mechanical joints for water supply pipeworks shall be jointed as
stated in Clauses 14.5.10(b) to (d).
(b) The elastomeric joint ring and the ends of the pipe shall be smeared with
lubricant over a distance recommended by the manufacturer.
(c) The gland and the elastomeric joint ring shall be placed in position on the
spigot end of the pipe.
(d) The spigot end of the pipe shall be placed in the socket end of the laid pipe
before the bolts are tightened.
(a) Joints and damage to coatings and linings of pipes, joints and fittings for water
supply pipeworks shall be repaired as stated in Clauses 14.5.11 to 14.5.13.
(b) Repairs to joints, coatings and linings shall be carried out using materials of
the same type and grade as in the pipe, joint or fitting.
(c) External repairs shall be completed before internal repairs are carried out.
(d) Internal repairs and adjacent areas shall be washed with potable water after
the repair is complete.
Internal and external repairs to joints and coatings of DI pipes with bitumen coatings
shall be carried out using bituminous paint. The area to be repaired shall be
cleaned to bare metal and dried. The area to be repaired shall be painted with
bituminous paint to the same thickness as the adjacent coating; the paint shall be
finished to a smooth uniform surface.
(a) Internal repairs to joints and linings of DI pipes with cement mortar linings
shall be carried out as stated in Clause 14.5.13(b) to (d).
(b) The area to be repaired shall be cut back to leave clean, bright metal. The
area surrounding the area to be repaired shall be wetted.
(d) The inside of pipe sockets and the faces of flanges shall be kept free from
cement mortar.
(a) The bearing face, and other faces stated in the Contract, of concrete thrust
and anchor blocks for water supply pipeworks shall be cast directly against
undisturbed ground; the faces of excavations shall be trimmed to remove
loose material before concreting. Excess excavation and working space shall
be filled with concrete of the same grade as the block.
(b) Internal pressure shall not be applied to the pipeline until thrust and anchor
blocks have developed the specified grade strength.
(a) Concrete bed, haunch and surround to pipelines for water supply pipeworks
shall be constructed as stated in Clause 14.5.15(b) to (e).
(b) Pipes shall be supported at the required level by Grade 20 precast concrete
wedges, blocks or cradles. One support shall be placed adjacent to each end
of each pipe and the spacing between supports shall not exceed 3 m.
Compressible sheeting shall be placed between the pipes and supports.
(c) Flexible joints shall be formed in concrete bed, haunch and surround at
flexible joints in pipelines. Joint filler shall be placed next to the flexible joint in
the pipeline and shall extend for the complete thickness of the bed, haunch
and surround.
(d) Polyethylene sheeting shall be placed on the trench bottom before concreting.
(e) Concrete shall be placed evenly over the complete width of the bed and over
the complete length of the pipe being concreted up to a level of 25 mm below
the underside of the pipe. Concrete shall then be placed on one side of the
pipe only and worked under the pipe until the concrete spreads under the
pipe. Concrete shall then be placed equally on both sides of the pipe to the
specified level.
The line and level of pipelines for water supply pipeworks shall be within 25 mm of
the specified line and level.
The finished level of manholes and chambers shall be within 5mm of the specified
level.
(a) The manufacture and testing of pipes, joints, fitting and valves for water
supply pipeworks shall be inspected by an independent inspection authority
reviewed without objection by the Project Manager.
(b) The inspections shall be carried out at the manufacturer's works or at other
locations stated in the Contract or directed by the Project Manager. The
facilities and equipment required for inspections shall be provided by the
Contractor.
(a) Trials shall be carried out to demonstrate that the pipes, joints and fittings for
water supply pipeworks fit correctly.
(b) The trials shall be carried out at least 6 weeks before the materials are
proposed to be incorporated in the Permanent Works.
(c) The Contractor shall notify the Project Manager before carrying out trials.
(d) The Contractor shall immediately notify the Project Manager of any pipes,
joints or fittings which do not fit correctly. Modifications shall be made to
pipes, joints and fittings which do not fit correctly or replacements shall be
provided as directed by the Project Manager.
(a) Trials shall be carried out to demonstrate that the proposed equipment and
methods of drilling and tapping pipes for water supply pipeworks will produce
connections which comply with the specified requirements.
(b) The trials shall be carried out at least 14 days before drilling and tappingis
programmed to commence.
(c) The Contractor shall notify the Project Manager before carrying out trials.
(a) For quality control on manufacturing of the pipes, the following tests listed in
ISO 4427 shall be subject to inspection by the independent inspection
authority:
(iv) Clause 5.1 – 100 hour at 20°C and 165 hour at 80°C only; and
(c) Polyethylene materials for both PE80 and PE100 shall be tested in
accordance with the Chlorine Water Test specified in Clause 9.8 of the
Japanese Industrial Standard (JIS) K6762 and the performance of the
polyethylene materials shall comply with the chlorine-water resistance for
single wall pipe specified in Clause 5 of the JIS K6762. Test certificates shall
be submitted to the Project Manager for review without objection.
(a) Sampling procedures for inspection shall be in accordance with BS6001 : Part
1 unless specified otherwise and shall meet the following requirements:
(b) Sample size for dimensional, appearance, casting quality and BS21 threading
checks on pipe materials shall be determined in accordance with BS6001 :
Part 1 at Inspection Level II for single sampling plan. Materials from different
sources shall be sampled as isolated batches. Normal inspection shall be
used at the start of inspection. Inspection may be switched to tightened or
reduced inspection and switched back to normal inspection in accordance
with the procedures stipulated in Clause 9.3 of BS6001:Part 1. Acceptable
Quality Level (AQL) shall be 4.0.
(c) For material and marking checks, one sample shall be selected from each
type and size of pipe materials in each batch. Materials from different sources
shall be sampled as isolated batches.
(i) Notwithstanding Clause 6.1 of BS6001 : Part 1, each batch shall, as far
as practicable, consist of units of pipes of a single type, grade, class and
composition, of different sizes, manufactured under essentially the same
conditions, and at essentially the same time. Two samples shall be
selected from each size of the pipes in each batch.
(i) Notwithstanding Clause 6.1 of BS6001 : Part 1, each batch shall, as far
as practicable, consist of units of pipes of a single type, grade, class and
composition, of different sizes, manufactured under essentially the same
conditions, and at essentially the same time. Two samples shall be
selected from each size of the pipes in each batch.
(a) Fresh water and potable water pipelines for water supply pipeworks shall be
cleaned and flushed through with potable water. Cleaning and flushing shall
be carried out:
(i) before and after the complete pipeline, or part thereof permitted by the
Project Manager, has been tested;
(ii) after the Temporary Works required for testing have been removed; and
(iii) after parts of the pipeline removed for testing have been reconnected.
(b) The pipeline shall be completely filled with water that has been dosed with a
homogeneous solution of sterilising chemicals such that the final
concentration of free chlorine in the water is at least 30 ppm. The water shall
be left in the pipeline for at least 24 hours.
(c) After the 24 hour period, the pipeline shall be drained down and the sterilising
water shall be flushed out using potable water until the concentration of the
remaining chlorine is less than 1 ppm.
(d) Pipelines shall be cleaned and sterilised not more than 7 days before the
application for Completion Certificate.
(e) Swabbing shall be carried out to the pipes not exceeding DN600.
Swabs shall be suitable for clearing out new pipelines and removing dirt and
materials inadvertently left in the pipeline during construction. Swabs may be
fitted with a signalling device to enable the swab to be located within the
pipeline.
(g) The Contractor shall be responsible for the supply of water to the place where
swabbing work is required and if necessary, pressurize the water to a level
sufficient for the swabbing work.
(h) The swab shall be inserted into a short plain ended pipe at ground level
adjacent to the trench and the pipe shall then be fitted, by means of flange
adaptors, into position in the pipeline between two gate valves which shall then
be opened to allow the swab to pass through the pipeline.
(i) The swab shall be fully immersed in water during the entire operation using
water as the driving medium. Foam swabs shall not be air driven and the water
must not drain away from the swab on downhill sections. The velocity of the
swab, which shall be controlled by the rate of flow of water downstream of the
swab, shall be kept within a range of 300 mm/sec to 1200 mm/sec.
(j) All air valves and valves on tees/branches from the pipeline shall be closed
before swabbing work commences.
(k) At least 14 days before the swabbing operation is to be carried out, the
Contractor shall submit the following information for review without objection by
the Project Manager:
(vii) Means of recovering swab from pipeline at the end of the swabbing run.
(a) Pressure pipelines for water supply pipeworks shall be tested as stated in
Clause 14.6.9(b) to (f).
(b) The pipeline shall be tested in sections as stated in the Contract unless
otherwise permitted by the Project Manager; if testing in sections other than
those stated in the Contract is permitted, the section to be tested shall be as
long as practicable provided that the specified test pressure will not be
exceeded. Final tests on complete pipelines which have been tested in
sections shall not be carried out unless stated in the Contract.
(c) The test pressure shall be as stated in the Contract. If the test pressure is not
stated in the Contract, the test pressure shall be:
(i) 1.5 times the maximum working pressure if the maximum working
pressure does not exceed 1.5 Mpa; or
(ii) 1.3 times the maximum working pressure if the maximum working
pressure exceeds 1.5 MPa.
(d) Unless otherwise permitted by the Project Manager, pressure tests shall not
be carried out until fill material has been deposited and compacted over the
complete length of the pipeline to be tested; if permitted, sufficient fill material
shall be deposited to restrain the pipeline in position during the test.
(e) Tests shall not be carried out simultaneously on pipelines in the same trench.
(g) The pipeline shall be left charged with water at a head of at least 15 m after
testing and until the pipeline has been sterilized.
The results of tests on pressure pipelines for water supply pipeworks shall comply
with the following requirements:
(a) the leakage of water from the pipeline determined by the pressure test shall
not exceed the permitted leakage calculated in accordance with
Clause A14.1.4 in Appendix A14.1; and
(b) there shall be no discernable leakage of water from the pipeline or from any
joint during the pressure test.
If the result of any test on pressure pipelines for water supply pipeworks does not
comply with the specified requirements for the test, the Contractor shall investigate
the reason. Remedial or replacement work reviewed without objection by the
Project Manager shall be carried out and the pipeline shall be retested.
After the pressure test on fresh water and potable water pipelines have been
completed, samples of the water in the pipelines shall be taken by the Contractor in
the presence of the Project Manager. The number of samples and locations of
sampling shall be as directed by the Project Manager. Testing shall be carried out
as stated in Clauses 24.6.11 to 24.6.12 for water sterilisation of water retaining
structures. The colour, odour, appearance, turbidity, conductivity, free residual
chlorine, E.Coli, total coliforms, total bacterial count and pH values of the water
samples shall be tested to demonstrate the quality of each sample of water is
comparable to that drawn from the supply point and the results shall be reviewed
without objection by the Project Manager.
A14.1.1 Scope
This method covers the determination of the leakage of water from pipelines for
water supply pipeworks by means of a pressure test.
A14.1.2 Equipment
A14.1.3 Procedure
(1) pipes and valves shall be checked for cleanliness and the operation of valves
shall be checked;
(2) blank flanges or caps shall be fixed to the ends of the pipeline, or section of
the pipeline, to be tested. Tests shall not be made against valve gates;
(3) the blank flanges and caps shall be secured with struts and wedges against
temporary concrete blocks or other anchors. The blocks and anchors shall be
completed and shall have hardened sufficiently before testing starts;
(4) thrust and anchor blocks, pipe straps and other devices required to prevent
movement of pipes and fittings shall be completed before testing starts;
(5) the pipeline shall be filled with water and all air shall be removed;
(6) the pipeline shall remain filled for 3 days before testing starts to allow
absorption to take place and to achieve conditions which are as stable as
practicable;
(7) the pressure in the pipeline shall be increased slowly to the specified test
pressure by pumping water into the pipeline using a force pump;
(8) the pressure in the pipeline shall be maintained within +0% and -5% of the
specified test pressure for a test period of at least 2 hours;
(10) the pressure shall be adjusted to within the specified tolerances for the test
pressure at any time during the test period if the pressure falls outside the
specified tolerances;
(11) the pressure shall be monitored during the test by means of a continuous
pressure recorder with purpose made charts; and
(12) the leakage of water from the pipeline shall be measured as the amount of
water required to maintain the specified test pressure in the pipeline; the
amount of water shall be determined from the fall in level of water in the pump
feed tank.
A14.1.4 Calculation
(1) The average test pressure (P) shall be calculated as the average of the
pressures (p) recorded during the test.
(2) The permitted leakage of water from the pipeline during the pressure test
shall be calculated from the equation:
t P
Permitted leakage = 0.02 x d x l x x litre
24 10
where:
(4) the pressures recorded during the test to the nearest 0.01 m;
(6) the leakage and permitted leakage of water to the nearest 0.1 litre;
(9) that the test method used was in accordance with this General Materials and
Workmanship Specification.
17.1 GENERAL
The works and materials specified below shall comply with the Sections stated,
unless otherwise stated in this Section.
(d) Materials for grout for piling works shall comply with Section 20.
(e) Grouting for piling works shall comply with Section 21.
17.2.1 Barrette
Bored piles are cast-in-situ concrete piles formed by boring or grabbing. Piles with a
diameter 600 mm or less are commonly referred to as small diameter piles, while
piles with a diameter greater than 600 mm are referred to as large diameter piles.
17.2.3 Minipiles
A minipile is a pile with a diameter of less than 400 mm in which the load bearing
element consists of one or more steel reinforcement bars. Permanent steel casing
above rockhead level is used to contain the grout.
A rock socketted steel H-pile is a pile formed by inserting a steel H-pile in a pre-
bored hole sunk into Grade III or better rock, with a temporary steel casing above
the rock head level and subsequent filling of the holes with cement grout.
A continuous flight augur pile is a pile formed by a flight augur and subsequent
pressurized injection with cement-sand grout through the augur’s stem as it is being
withdrawn.
Piling works shall comply with the Building (Construction) Regulations of Hong
Kong, Practice Notes for Authorised Persons and Registered Structural Engineers
(PNAP) and other codes and standards set out below.
Pile caps shall comply with the Hong Kong Code of Practice for the Structural Use of
Concrete in respect of all materials and workmanship for reinforced concrete pile
caps and for structural concrete above piles. Where BS 8110 is used, specific
requirements as specified in PNAP 187 shall be followed. Editions of BS 8110 other
than the 1985 version shall not be used unless otherwise reviewed without objection
by the Project Manager.
(d) BS 5573: Code of practice for safety precautions in the construction of large
diameter boreholes for piling and other purposes
17.4 MATERIALS
(a) Steel bearing piles shall be of a proprietary section reviewed without objection
by the Project Manager.
(b) Steel sheet piles shall be of a proprietary section reviewed without objection
by the Project Manager.
(d) Steel pipe piles shall comply with BS 3601 or BS 6232:Parts 1 and 2, except
for the requirements of hydraulic pressure tests.
(e) All steel piles shall be free from loose scale and rust.
(a) Pile shoes for driven cast-in-place piles shall be manufactured from durable
materials capable of withstanding driving stresses without damage. The shoes
shall be designed to provide a watertight joint with permanent casings.
(b) Cast steel pile shoes for steel bearing piles shall be manufactured from steel
complying with BS 3100, Grade A.
(c) Welded fabricated pile shoes for steel bearing piles shall be manufactured
from steel complying with BS 4360, Grade 43A.
Epoxy based paint for epoxy coatings to steel piles shall be a proprietary type
reviewed without objection by the Project Manager.
Bituminous coating material for steel piles shall be hot-applied filled or unfilled
bituminous material complying with BS 4147.
(a) Grout for piling works shall consist of OPC and water. Sand, PFA and
admixtures may be used subject to review without objection by the Project
Manager.
(c) Grout used to fill core holes shall be non-shrink grout and have a minimum
characteristic compressive strength of not less than the specified grade
strength of the concrete surrounding the core hole.
(d) Grout used to fill minipiles and pre-bored rock socketted steel H-piles shall be
non-shrink grout and have a minimum characteristic compressive strength of
30 MPa at 28 days.
(e) Water used in the grout must be clean and fresh with a temperature not
exceeding 30°C nor less than 5°C.
(f) The maximum amount of bleeding of grout shall not exceed 2% in the first 3
hours and shall not exceed 4% in total; the water shall be reabsorbed by the
grout during the 24 hours after mixing.
(g) Free expansion of grout shall not exceed 10% at the ambient temperature.
(j) Admixtures shall be chloride free and comply with BS 5075 and shall be
submitted for review without objection by the Project Manager before use.
(b) Connectors shall be capable of transmitting the total pile load in tension or
compression as appropriate.
(ii) capable of developing the full tensile strength of the parent bar; and
(iii) comprised of high tensile studs and seamless steel tubes fitted with
protective plastic caps.
(d) Connectors for compression joints, shall be wedge locking, bolted sleeve type.
(b) The method of application of protective coatings to steel piles, the ambient
temperature and humidity at the time of application and the time interval
between the application of successive coats shall be in accordance with the
manufacturer's recommendations. The complete coating shall be applied in
and around clutches.
The surfaces of steel piles to which protective coatings will be applied shall be
prepared by blast cleaning to either:
(a) Epoxy coatings to steel piles shall consist of three coats of epoxy based paint,
each coat having a minimum dry film thickness of 75 μm. The first coat shall
be applied within two hours of blast cleaning.
(b) The finished surface of epoxy coatings shall be smooth with a dense and
uniform texture and shall be free from sharp protuberances and pinholes. The
thickness and continuity of completed epoxy coatings shall be measured using
a magnetic thickness gauge.
(c) Damaged areas of epoxy coatings shall be repaired by cleaning the damaged
areas to bare metal, feathering back the adjacent areas with coarse grade
sand-paper and re-applying the coatings.
(b) Damaged areas of bituminous coatings shall be cleaned back and overcoated
with the same bituminous coating material to restore the specified thickness.
(c) Steel H-piles shall be protected with a bituminous coating for eight (8) metres
below cut-off level.
The splice areas of steel piles which are extended in-situ shall be prepared by blast
cleaning prior to splicing. The protective coating shall be re-applied to the splice
area before the piles are driven.
Protective coatings shall be removed from the heads of steel piles which will be
encased in concrete by blast cleaning or flame cleaning. The coatings shall be
removed to a level of 75 mm above the underside of the concrete into which the pile
will be encased.
(a) The identification number, grade of steel and length of pile shall be marked on
steel piles.
(b) Piles shall be stored horizontally off the ground on level supports and in a
manner which will not result in damage to the coatings. Bituminous coated
piles shall not be stacked.
Bentonite shall be handled and stored in a manner which will not result in spillages
on Site. It shall be stored in cool dry conditions and particular care shall be taken
with bulk storage to prevent balling of the bentonite powder due to damp, or
deterioration of properties due to damp and heat.
17.5 SUBMISSIONS
(i) a certificate for bentonite showing the type, the manufacturer's name,
the date and place of manufacture and including details of the apparent
viscosity range in Pa.s and the gel strength range in N/m2 for solids in
water;
(i) details of pile head, reinforcement and permanent steel casing including
spacers and couplings;
(ii) details of grout mix as stated in Clause 21.4.3 including fine aggregate
and admixtures as appropriate;
(i) details of pile head, steel H-pile and the external casing, including splice
joint and welding details;
(ii) details of grout mix as stated in Clause 21.4.3 including fine aggregate
and admixtures as appropriate;
(ii) details of grout mix as stated in Clause 21.4.3 including fine aggregate
and admixtures as appropriate;
(v) length of piles when designed as friction piles or rock socket detail when
designed as end bearing piles.
17.6 WORKMANSHIP
Piling works, including groundwater control and ground treatment for piling works,
shall not commence until:
(a) “Site Safety Supervision Plan” and “Quality Supervision Plan” as stipulated in
the PNAP 242 are submitted to the satisfaction of the Buildings Department
and the Project Manager;
(a) Piling works shall not damage any structure, utility service or previously
installed pile. The position of existing utilities shall be determined and
underground utilities adjacent to the piles shall be exposed or otherwise
accurately located before piling works start.
(b) All necessary measures shall be taken to minimise the settlement of the
ground and adjacent structures and utilities and to prevent the formation of
cavities in the ground resulting from piling works.
(c) The vibrations due to piling works at previously installed piles measured in
terms of peak particle velocity shall not exceed 25 mm/s.
(d) The vibrations due to piling works at other structures and installations in terms
of peak particle velocity shall not exceed the values stated in Table 17.1 or
such limits imposed by the Project Manager or the Buildings Department.
(b) Measurements of noise level and vibration shall be made with instruments of a
type reviewed without objection by the Project Manager.
(d) The Contractor shall inform the Project Manager immediately of any
unanticipated change in measurements.
(b) The Contractor shall ensure that the Registered Specialist Contractor (Ground
Investigation Field Work) (RSC (GIFW)) accurately logs and places cores in
the correct order in specially constructed core boxes. The RSC (GIFW) shall
clearly mark the corehole numbers on the cores and the boxes. Logging of
cores shall be preformed by a suitably qualified person in accordance with
PNAP 132. The Contractor shall notify the Project Manager before the start
and at the completion of core drilling.
(c) Core logs and photographic records of cores shall be submitted to the Project
Manager for review within 7 days of completion of the drilling and shall be in a
format suitable for submission to Buildings Department.
(d) The Contractor shall store the cores on Site during the Contract and shall
relocate or dispose of the cores and boxes as directed by the Project
Manager.
(e) Unless otherwise stated in this section, drilling for ground investigation for
piling works shall be carried out in accordance with the requirements of
Section 8 of this General Materials and Workmanship Specification.
(f) Soil samples and rock samples shall be taken by the Contractor from pile
excavations for visual inspection and testing. The method of sampling and
testing shall be as stated in Section 8 of this General Materials and
Workmanship Specification.
(b) Pre-boring
(i) The RSC (GIFW) shall pre-bore each pile location in accordance with
PNAP 66 and the cores shall be minimum Nx size.
(ii) The RSC (GIFW) shall accurately log and place the cores in the correct
order in properly constructed core boxes supplied by the RSC (GIFW)
and clearly mark the corehole numbers on the cores and boxes. The
logging of the core shall be carried out by a suitably qualified person in
accordance with PNAP 132 and the Contractor shall notify the Project
Manager before the start and at the completion of core drilling.
(iii) Core logs and a photographic record of all cores shall be submitted to
the Project Manager for review without objection within seven (7) days of
completion of core drilling, in a format suitable for submission to
Buildings Department.
(iv) The Contractor shall store the cores on Site during the Contract and
shall relocate or dispose of these cores and boxes as directed by the
Project Manager.
(c) Pile shafts shall be excavated to founding levels in accordance with founding
criteria shown on the Employer's Drawings. This shall be established at each
pile location by means of the site investigation pre-bore as specified in Clause
17.6.5(b)(i).
(d) Unless otherwise stated in the Contract, the pile base shall be levelled and
shall fully penetrate the founding stratum in the case where it is on an inclined
plane.
(e) The Contractor shall notify the Project Manager immediately the pile founding
level is reached. The Contractor shall also submit, for the Project Manager’s
review, a sample of the material taken from the arisings at the proposed pile
founding level.
(f) Unless otherwise stated in the Contract, bored cast-in-situ piles shall be
founded on and continue into rock in accordance with the founding criteria
shown on the Employer’s Drawings, or for a minimum depth of 800 mm,
whichever is the greater.
(g) Obstructions are objects encountered during installation of piles that impede
or stop the pile being installed in accordance with the founding criteria shown
on the Employer’s Drawings or specified strata. Obstructions shall be broken
out or drilled through to enable the pile to be installed in accordance with the
founding criteria shown on the Employer’s Drawings or specified strata.
(a) Preliminary piles shall be constructed using the materials and methods of
construction proposed for the working piles and which have been submitted to
the Project Manager for review without objection. The installation of
preliminary piles shall be as follows:
(ii) install the piles at a location outside the permanent structure and to the
anticipated founding depth;
(iii) test the preliminary pile by “Pile Driving Analyser” with CAPWAP
analysis after installation to the founding depth reviewed without
objection by the Project Manager;
(iv) carry out loading testing on the preliminary piles in accordance with
PNAP 66 and PNAP 242 immediately after driving to determine the
ultimate shaft friction and end bearing capacity of each of the piles; and
(v) cut off each preliminary pile two metres below the finished ground level,
or as directed by the Project Manager, after completion of the loading
test.
(b) The relevant piling works shall not commence until the construction, testing
and records of the preliminary piles have been reviewed without objection by
the Project Manager.
(a) Driven piles shall be supported and restrained by means of leaders, trestles,
temporary supports or other guide arrangements in such a manner that :
(b) The supports and restraints shall be maintained at all times during driving and
until the piles are self supporting.
17.6.8 Followers
(a) Followers or long dollies shall not be used unless reviewed without objection
by the Project Manager and permitted by the Buildings Department. If
permitted, the set shall be revised by the Contractor and submitted to the
Project Manager in a format suitable for submission to the Buildings
Department for review, to allow for the reduction in effectiveness of the
hammer blows.
(b) Whenever followers are used, the Contractor shall assess the energy
reduction factor of each follower for each pile size and submit the calculations
to the Project Manager, in a format suitable for submission to the Buildings
Department, for review without objection.
(d) The energy reduction factor for every combination of follower and pile size
shall be determined by averaging the results of 5 sets of dynamic pile tests
performed at or near to the set of 5 different piles of the same size.
(a) Each pile, other than sheet piles, shall be driven without interruption until the
required depth or set has been achieved. If a minimum depth of penetration is
stated in the Contract, the Contractor shall submit to the Project Manager for
review his proposals for achieving this requirement. The Contractor shall
ensure that the minimum penetration and set are achieved without causing
damage to the pile.
(b) The sequence and method of driving piles shall minimise the detrimental
effects of heave and lateral displacement of the ground and cause the least
possible displacement to previously installed piles. The Contractor shall drive
piles from the centre of the pile group and work outwards. Piles, including
casings, shall not be driven within a centre to centre distance of 3 m or five
times the diameter of the pile or casing, whichever is less, from an unfilled
excavation or from an uncased concrete pile which has been cast for less than
48 hours.
(c) The Contractor shall inform the Project Manager without delay of any sudden
change in driving characteristics. The Contractor shall investigate the cause of
any sudden change in driving characteristics and further driving shall not
continue until these investigations have been completed and the results
reviewed without objection by the Project Manager
Piles which have been displaced as a result of driving adjacent piles shall be
corrected. Particulars of the method of correction and measures to be taken to avoid
displacement in subsequent driving shall be submitted to the Project Manager for
review without objection.
(a) Re-drive checks shall be carried out on all preliminary piles and as directed by
the Project Manager. The pile driving formula proposed by the Contractor shall
be revised if the final set on re-driving is more than the final set achieved
during the initial driving.
(b) Preliminary piles which fail the re-drive check shall be deemed unacceptable.
Additional preliminary piles shall be proposed together with the revised pile
driving formula for the review without objection of the Project Manager.
(c) No re-drive checks shall be carried out within 24 hours of completion of first
driving.
The strength of piles at joints shall not be less than the strength at any normal
section of the pile. Lengthened piles shall not be driven until the joint has
developed the designed strength. Pile joints shall be tested as stated in the
Contract.
(ii) Welding for splicing of H-piles shall be carried out in accordance with
Section 22 of this General Materials and Workmanship Specification.
(iii) Testing of welding for splicing of H-piles shall be carried out in
accordance with Sections 17.7.8(a) and 17.7.8(b).
(iv) Piles shall be accurately located and aligned during welding. The
Contractor shall ensure that the straightness of the complete pile shall
not deviate by more than 3 mm along a 3 m straight edge or by 1 in
1,000 overall.
(a) Set shall be measured for each driven pile in the presence of the Project
Manager and reviewed without objection by the Project Manager. The final set
shall be measured as either:
(b) If driving is interrupted for more than 30 minutes, set shall not be measured
after driving restarts until at least 20 blows of the same driving energy as at
final set have been struck.
(i) the exposed part of the pile shall be in good condition without damage or
distortion;
(iii) the final hammer blows shall be in line with the axis of the pile and the
impact surfaces shall be flat and at right angles to the axes of the pile
and hammer; and
(e) The Contractor shall notify the Project Manager at least 1 hour before final set
and temporary compression are to be measured.
(f) Piles shall be driven by hydraulic hammer. The Contractor shall assess the
pile working load capacity according to a pile-driving formula (e.g. the modified
Hiley Formula with the adoption of a single efficiency factor for hydraulic
hammer, Kh, multiplied by the impact energy. The value of Kh shall be
reviewed without objection by the Project Manager and the Buildings
Department). The factor of safety shall not be less than two (2) for ultimate
driving resistance against working load.
(g) The pile-driving formula shall be calibrated against load tests carried out on
preliminary piles and checked as other piles are tested. The pile-driving
formula and correlation with test loading data shall be submitted to the Project
Manager for review without objection prior to carrying out piling works other
than preliminary piles
(h) The pile shall not be considered to have attained the theoretical calculated
safe loading capacity should the penetration at final set be in excess of the
value reviewed without objection by the Project Manager.
(i) The temporary compression of the driving cap shall be taken as not less than
7.5 mm when hardwood packing at the pile head and in the dolly are 100 mm
thick.
(a) Excavation for cast-in-situ concrete piles shall be carried out by mechanical
methods; blasting and compressed air shall not be used.
(b) The stability of excavation for cast-in-situ concrete piles shall be maintained
where necessary by:
(c) The bottom of casings shall be kept sufficiently deep to prevent the flow of soil
into the casing.
(f) Where an enlarged base of a cast-in-situ concrete pile is required, this shall be
formed by under-reaming with reverse circulation heads.
(a) Excavation for barrettes shall be carried out by mechanical methods; blasting
shall not be used.
(c) The height of guide walls for barrettes shall be such that the head of slurry
shall ensure the stability of excavations and prevent movement of the adjacent
ground in excess of that specified in the Contract. The position, alignment and
level of guide walls shall be checked at regular intervals and submitted for
review without objection by the Project Manager.
The Contractor shall install minipiles without the use of bentonite slurry or other
drilling muds. The stability of excavations for minipiles shall be maintained where
necessary by permanent casings which shall :
(c) have an internal diameter of not less than the finished pile diameter shown or
as scheduled on the Employer’s Drawings;
(d) be free from distortion and internal projections throughout the whole length
which might prevent the proper formation of the piles; and
(e) be of uniform cross-section throughout the whole length.
The Contractor shall check the inclination of every inclined pile at each stage, during
installation. The Contractor shall arrange for a number of piles, as directed by the
Project Manger, to be checked by the use of an inclinometer or other method
reviewed without objection by the Project Manager, before grouting. The Contractor
shall record the inclination and orientations of the holes and submit the records to
the Project Manager for review.
(a) The prebored holes shall be large enough to allow a minimum cover of 40 mm
to the steel H-piles.
(b) A temporary casing, the quality of which has been reviewed without objection,
shall be provided in the pre-boring process down to at least 500 mm or such
depth as required, below rockhead level, to prevent soil from falling into the
pre-bored hole.
(c) Before the steel H-pile is inserted in the pre-bored hole, the hole should be
cleaned with air flushing to ensure that is free from debris and soil.
(d) Extraction of the temporary casing shall be carried out while the grout is
sufficiently workable to ensure that the grout is not lifted with the casing. A
vibratory extractor, which has been reviewed without objection by the Project
Manager, may be used.
(i) Excavations for piles using bentonite slurry shall be filled with slurry from
the time that excavation commences until concreting is complete. The
slurry shall be maintained at a level of at least 1 m above the level of the
external groundwater and such that the slurry pressure exceeds the
pressure exerted by the soil and ground water.
(i) Bentonite shall be thoroughly mixed with water in a colloidal mixer. The
water for bentonite shall be clean, uncontaminated and from a source
reviewed without objection by the Project Manager. The Contractor shall
test the water in accordance with the requirements of Section 20.8.3.
The water shall be at a temperature of at least 5oC. The temperature of
the bentonite slurry shall be at least 5oC when supplied to the
excavation.
Any remaining bentonite slurry shall be removed from the Site and disposed in
accordance with Section 7.
(a) Fixing reinforcement for large diameter bored piles and continuous flight augur
piles
Prefabricated reinforcement cages for piles shall be marked and fitted with
spacers to ensure that the cage is correctly orientated and positioned within
the pile.
(a) The bases of excavations for piles shall be cleaned by air lifting before
concrete is placed. If excavation is carried out under water, cleaning shall
continue until the water is clear and free from particles of soil. Measures shall
be taken to prevent the accumulation of silt and other material at the base of
the excavation.
(i) the Contractor shall take measures to remove all silt or other material at
the base of the boring. The Contractor shall remove heavily
contaminated bentonite suspension, which could impair the free flow of
concrete from the pipe of the tremie, from the bottom of the hole; and
(ii) the Contractor shall take a sample of the bentonite suspension from the
base of the boring using a sampling device reviewed without objection
by the Project Manager. If the specific gravity of the suspension exceeds
1.25 the placing of concrete shall not proceed, and the bentonite shall be
replaced.
(c) Provided the rate of ingress of water does not exceed 0.3 l/s, the base of
excavations for piles shall be dried immediately before concrete is placed.
(a) Each pile shall be concreted as soon as practicable. Concrete shall be placed
without interruption until the complete pile is concreted.
(b) In the event that excavations for piles are supported by bentonite slurry or if
the rate of ingress of water exceeds 0.3 l/s, the Contractor shall comply with
the following :
(ii) the hopper and pipe of the tremie shall be clean and watertight
throughout. The pipe shall extend to the base of the boring and a sliding
plug or barrier shall be placed in the pipe to prevent direct contact
between the first charge of concrete in the pipe of the tremie and the
water or drilling fluid. After the first charge of concrete the pipe shall at
all times penetrate the concrete which has previously been placed and
shall not be withdrawn from the concrete until completion of the
concreting. Sufficient concrete shall be maintained within the pipe to
ensure that the pressure from it exceeds that from the water or drilling
fluid. The internal diameter of the pipe of the tremie shall be not less
than 150 mm for concrete made with 20 mm aggregate. It shall be so
designed that external projections are minimized, allowing the tremie to
pass through reinforcing cages without causing damage. The internal
face of the pipe of the tremie shall be free from projections;
(iii) the minimum cement content of the concrete shall be 375 kg/m3;
(iv) the level of the top of the concrete in piles shall be at least 1 m above
the specified cut-off level; and
(v) if the top of the guide wall of barrettes is at the specified cut-off level,
concrete shall continue to be placed until the top of the pile is free from
contamination.
(c) Operations which in the opinion of the Project Manager are likely to disturb or
affect the concrete or placing of the concrete shall not be carried out.
(d) For piles concreted in dry conditions, the concreted level shall be not less than
150 mm and not more than 500 mm above the specified cut-off level. For piles
cast using tremie concrete, the concrete level shall be not less than 1 m and
not more than 2 m above the specified cut-off level.
(e) The Contractor shall trim back the concrete of all piles to final cut-off level.
Trimming back shall be carried out at least 7 days after placing the concrete.
(a) Grout material shall be mixed by weight batching. The amount of water used
shall be measured by a calibrated flowmeter or a measuring tank. The mixing
time in high speed mixers shall be suitable for the type of mixer used. After
mixing, the grout shall be continuously agitated in a holding tank and screened
before injection.
(b) Before grouting, the bottom of the hole shall be flushed by high pressure air.
(b) Temporary casings in contact with concrete and not withdrawn before the
initial set of the concrete shall be left in place.
(c) The Contractor shall take precautions reviewed without objection by the
Project Manager in all cases where excess heads of water or drilling fluid
could be caused as the casing is withdrawn due to the displacement of water
or fluid by the concrete as it flows into its final position against the walls of the
shaft.
(d) Where two or more discontinuous lengths of casing (double casing) are used
in the construction, the proposed method of working shall be reviewed without
objection by the Project Manager.
Empty bores and shafts which remain above the pile after concrete has been placed
shall be temporarily protected or filled with material, of a type which has been
reviewed without objection by the Project Manager as soon as practicable.
Dimensional tolerances of steel bearing pile sections shall comply with the BS 4360,
BS 5950 and BS 5400 as stated in Section 22.3.1. Fabrication tolerances for steel
bearing piles and related steelwork shall comply with BS 5950:Part 2.
(a) Piles, including mini-piles, shall be installed to within the tolerances stated in
Table 17.2.
(b) Piles which do not comply with the specified tolerances shall not be forcibly
corrected.
Description Tolerance
Deviation from specified position in plan, measured at cut-off level 75 mm
Deviation from vertical
(a) all piles except bored piles 1 in 75
(b) bored piles 1 in 300
Deviation of raking piles from specified batter 1 in 25
Deviation from specified cut-off level -25 mm, +0
The diameter of cast in-situ piles shall be at least 97% of the specified diameter at
all points.
Materials & Workmanship Specification 20/40 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 17 – Piling Works
17.6.32 Remedial Works to Out of Tolerance Piles
(a) In the event that one or more piles are identified as being outside the
tolerances for installed piles, the Contractor shall submit proposals for
remedial works to the Project Manager for review without objection, in a format
suitable for submission to the Buildings Department, within 10 days of the
completion of the piling work survey.
(b) The Contractor’s remedial works proposals shall include design calculations
and Contractor’s Drawings prepared by a registered structural engineer. The
proposals shall show the extent of additional reinforcement necessary such
that stresses in the pile and related structure are within acceptable limits.
(c) Remedial works shall be carried out upon approval and consent by the
Buildings Department and review without objection by the Project Manager,
prior to commencing any works over the affected pile.
The Contractor shall comply with the requirements for quality supervision in
accordance with PNAP 242.
(a) Where pile bores or excavations are retained by bentonite slurry, the
Contractor shall arrange Koden tests to be carried out on each pile by an
independent testing body reviewed without objection by the Project Manager.
The Contractor shall submit the test report to the Project Manager prior to
placing concrete in piles.
(b) The Contractor shall notify the Project Manager before placing concrete in
piles.
(a) If directed by the Project Manager, installed piles shall be exposed for
inspection or testing. Excavations for exposing piles shall be of a depth
reviewed without objection by the Project Manager, and the face of the
excavation shall be at least 750 mm from the face of the pile. The excavation
shall be maintained in a stable condition and kept free from water.
(b) The surface of the pile shall be washed clean of all silt, mud or other adhering
materials to permit inspection.
(c) After inspection, excavations for exposing piles shall be filled using suitable fill
material, of a type reviewed without objection by the Project Manager, which
shall be compacted to obtain a relative compaction of at least 95% above the
groundwater table.
(a) Post construction proof drilling shall be carried out after the construction of
piles in accordance with PNAP 66, PNAP 132 and PNAP 242.
(b) For large diameter bored piles and barrettes where core-drilling at the
concrete/rock interface is to be carried out at each pile, the concrete shall be
in contact with rock at the interface. If imperfections such as a thin layer of
sediment, segregated concrete, honeycomb are found, the Contractor shall
submit remedial proposals to the Project Manager, for review without
objection, in a format suitable for submission to the Buildings Department.
(i) The number of piles to be tested by load testing shall be as stated in the
Contract or as required by the Buildings Department, whichever is the
greater.
(ii) The piles shall be tested to determine the settlement of the pile under
load. Testing shall be carried out in accordance with the method of
testing as stated in PNAP 66 and requirements imposed by the Buildings
Department.
(iii) Piles shall not be tested until the concrete or grout has attained sufficient
strength to withstand the tests. The Contractor shall notify the Project
Manager 7 days prior to the commencement of the test.
(iv) Records of pile load tests shall be kept by the Contractor and submitted
to the Project Manager within 24 hours of each test completion. The
records shall be kept on the standard forms as shown in Appendix
A17.6.
Unless otherwise stated in the Contract, the results of load tests on piles shall
comply with criteria described in PNAP 66 and requirements imposed by the
Buildings Department.
If the result of any load test on piles does not comply with the specified
requirements for settlement, the Contractor shall submit remedial proposals to
the Project Manager for review without objection. In the event the remedial
proposal involves any change of design, the design calculations and
Contractor’s Drawings shall be prepared by a registered structural engineer
and shall be submitted to the Project Manager for onward submission to
Buildings Department for approval. No remedial works shall be undertaken,
before review without objection by the Project Manager and approval by the
Buildings Department.
(i) The number of concrete cores to be provided for testing from concrete
piles shall be the larger of, the number required to satisfy the Buildings
Department, and the number stated in the Contract. The positions from
which the cores are taken shall be as directed by the Project Manager.
(iii) The method of taking concrete cores shall be in accordance with CS1.
(iv) Holes formed by taking concrete cores from piles shall be reinstated
using non-shrink concrete or grout, of the same characteristic
compressive strength as the concrete of the pile and reviewed without
objection by the Project Manager.
(i) Each concrete core from a pile shall be inspected for evidence of
segregation of the constituents and for the presence of voids.
Specimens selected from each core shall be tested to determine the
compressive strength.
(ii) The method of preparing, inspecting and testing concrete cores shall be
as stated in Section 20.8.17.
The compliance criteria for concrete cores from piles shall be as stated in
PNAP 66 and Section 20.8.18.
(i) If the result of any test on a concrete core from a pile does not comply
with PNAP 66 and/or Clause 20.8.18, additional cores shall be taken
from the same pile and additional tests shall be carried out.
(iii) If the result of any additional test does not comply with the compliance
criteria for concrete cores the Contractor shall submit remedial proposals
to the Project Manager for review without objection. The number of
additional piles and additional tests shall be as directed by the Project
Manager.
(i) The number and type of non-destructive tests on welds in piles shall be
as stated in the Contract or as required by the Buildings Department,
whichever is the greater.
(ii) Radiographic tests shall comply with BS 2600:Part 1 and ultrasonic tests
shall comply with BS 3923:Part 2.
If the result of any test on a weld in a pile does not comply with the specified
requirements, the complete weld shall be cut out, the joint shall be re-welded
and the weld shall be retested.
(i) In all bored cast-in-situ piles excavated by machine the Contractor shall
install three 50 mm and one 150 mm internal diameter steel tubes
securely tied to the reinforcement cage. The tubes shall be extended to
the full depth of the pile and terminate above the finished concrete level.
The tubes shall be watertight, corrosion free, continuous with sealed
joints and with the top and bottom sealed with a 2.0 mm thick steel plate
welded to the tube. The tubes shall be equally spaced around the piles.
The Contractor shall submit details of the proposed method of
installation of the tubes for the Project Manager's review without
objection.
(ii) The Contractor shall carry out sonic tests at cast-in-situ pile at locations
reviewed without objection by the Project Manager to verify the integrity
and homogeneity of the pile.
(iii) The Contractor shall carry out vibration tests at all cast-in-situ piles
which have not been sonic tested to verify the integrity and homogeneity
of these piles.
(iv) Sonic and vibration testing shall be carried out by an independent testing
company.
(v) The Contractor shall submit the details of the proposed independent
testing company and the proposed procedures for sonic and vibration
testing to the Project Manager for review without objection.
(vi) All reports, and photographic traces from sonic and vibration tests shall
be submitted to the Project Manager for review without objection within
48 hours of completion the test.
(vii) All tubes shall be cut-off flush with the concrete and filled with non-shrink
grout having the same characteristic compressive strength as the
concrete on completion of all testing.
If the results of any sonic or vibration test indicate that the pile does not
comply with the specified requirements or indicate any weakness or
discontinuity in the pile, additional tests shall be carried out by the Contractor
to confirm that the quality and bearing capacity of the pile satisfy the
requirements of the Contract and the Buildings Department. In the event that
the additional tests show that the pile does not comply, the Contractor shall
propose remedial measures for review without objection by the Project
Manager.
(ii) The method of sampling and the sampling apparatus shall be reviewed
without objection by the Project Manager.
(i) Each sample of bentonite slurry shall be tested to determine the density,
viscosity, shear strength and pH value.
(iii) The measuring device for testing density shall be readable and accurate
to ±0.005 g/mL.
(iv) Samples to be tested for viscosity using the Fann viscometer shall be
screened before testing using a 300 μm BS test sieve.
(i) The results of tests on bentonite slurry shall be as stated in Table 17.3.
If the results of tests for density and viscosity do not comply with the specified
requirements, or if the results of tests for shear strength or pH value do not
indicate a consistent working pattern, the bentonite slurry shall be deemed
unsuitable for the work and concrete shall not be placed in the slurry. The
slurry shall be replaced or its composition adjusted before concrete is placed.
A ‘batch’ of grout is any quantity of grout used for grouting in one continuous
operation in one day.
(i) One sample of grout from each batch shall be provided for testing not
more than 30 minutes after mixing and protected from changes in
moisture content before tests are carried out.
(ii) Each sample shall be divided into 3. Each third shall be placed in a
covered cylinder with a diameter of 100 ± 10 mm to a depth of 100 ± 5
mm and the amount of bleeding and free expansion shall be measured
by a scale fixed to the outside of the cylinder.
(iii) If the result of any test for the amount of bleeding or free expansion of
the grout does not comply with the specified requirements, proposed
changes to the materials, grout mix or method of production shall be
submitted to the Project Manager for review without objection.
(i) One sample from each batch shall be taken and tested in accordance
with ASTM C939-94 to determine the “Flow Cone Efflux” time.
(ii) Grout mixes containing additives with an efflux time of less than 15
seconds shall be rejected.
(i) One sample of the grout shall be taken from each grouting operation
after mixing and protected from changes in moisture content before
making test cubes.
(i) In addition to load tests on piles, dynamic testing on driven piles shall be
carried out by the Contractor. The dynamic pile test is a test applied to
the pile by means of a falling weight, hammer or other percussive
device. The response of the pile to the impact force is measured in
terms of pile strain, acceleration and displacement. The results of the
dynamic pile test shall allow a determination to be made by the
Contractor on the load capacity of the pile. The Contractor shall take
measurements at one level on the pile surface near the pile cap.
(ii) The dynamic pile testing method shall be reviewed without objection by
the Project Manager prior to carrying out testing.
(iii) The number of dynamic pile tests shall be as stated in the Contract and
the tests shall be carried out on piles selected by the Project Manager.
Records of tests of bentonite slurry shall be kept by the Contractor on Site and
a report shall be submitted to the Project Manager at frequencies reviewed
without objection by the Project Manager. The records shall be kept on
standard forms as shown in Appendix A17.5.
Records of load tests on piles shall be kept by the Contractor on Site and a
report shall be submitted to the Project Manager for review without objection
within 48 hours after the test has been completed. The records shall be kept
on standard forms as shown in Appendix A17.6. The records shall include
graphs showing load and settlement versus time, plotted in the format shown
in BS 8004, Figure 15(a).
The Contractor shall submit the records to the Project Manager for onward
submission to the Buildings Department.
(a) Record drawings of installed piles shall be prepared by the Contractor and
four copies shall be submitted to the Project Manager for review within 14
days of completing each group of the piles.
(b) The drawings shall include a plan showing characteristic features of the Site,
the as-constructed co-ordinates of the centre of each pile at cut-off level, the
final depth and cut-off level and size of each pile as constructed and other
information to the satisfaction of the Buildings Department and the Project
Manager.
(c) The Contractor shall submit record drawings and Form BA 14 to certify
completion of piling works, to the Project Manager for onward submission to
the Buildings Department. For the avoidance of doubt, these record drawings
are in addition to the as-constructed drawings required under the Contract.
A17.1.1 Scope
A17.1.2 Equipment
(b) A load measuring device which shall consist of a load column, pressure cell,
or other appropriate system, calibrated before and after each series of tests,
or whenever adjustments are made to the device, or at time intervals
recommended by the manufacturer of the equipment.
(e) A reference frame for supporting deflectometers and providing a datum for
deflectometer measurements.
(g) Screens and protection from exposure to conditions which may affect the test.
(a) The kentledge, anchor piles or other anchorages shall be installed. The
centre of each anchor pile shall be at least 2 m or three times the pile
diameter, whichever is greater, from the centre of the pile to be tested and
from the centre of any adjacent pile.
(b) If required, the pile to be tested shall be extended from cut-off level to ground
level. The strength of piles at joints shall not be less than any normal section
of the pile.
(c) A temporary square pile cap designed by the Contractor shall be constructed.
(e) The reference frame shall be set up on supports which are at least 2 m or
three times the pile diameter, whichever is greater, from the test pile and
anchor pile. The four deflectometers shall be mounted on the reference frame
to measure the deflection of the four corners of the temporary pile cap.
(a) Preliminary piles shall be tested to not less than twice the working load of the
pile. Working piles shall be tested to not less than 1.8 times working load.
Reductions for group or boundary effects shall not be made in determining the
test loads.
(b) Test loads shall be applied and removed in three stages as stated in Table
A17.1.1.
(c) The test loads shall be applied in increments, and removed in decrements, of
25% of the working load. Increments of load shall not be applied until the rate
of settlement of the pile is less than 0.1 mm in 20 minutes.
(d) The full test loads for Stage I, defined in Table A17.1.1, shall be applied in
increments and shall then be maintained for at least 24 hours after the rate of
settlement has reduced to less than 0.1 mm per hour. The test loads shall be
removed in decrements and the recovery of the pile determined before
loading is resumed.
(e) The procedure stated in Clause A17.1.4 (d) shall be repeated for Stage II,
defined in Table A17.1.1, loading.
(f) The procedure stated in Clause A17.1.4 (d) shall be repeated for Stage III,
defined in Table A17.1.1, loading unless the Project Manager directs the
loading to be maintained for a longer period.
(g) The settlement of the pile shall be measured at hourly intervals. The
settlement of the pile under each increment and decrement of loading shall be
measured. The exact times at which increments are applied and decrements
are removed shall be recorded. Settlements shall be measured and times
shall be recorded in the presence of the Project Manager.
(h) The level of the reference beam shall be checked at regular intervals, as
reviewed without objection by the Project Manager during the test.
After testing, equipment shall be removed, temporary pile caps shall be demolished
and pile extensions shall be removed to cut-off level. Anchor piles shall be
withdrawn.
(b) The settlement of the pile to the nearest 0.05 mm at hourly intervals and
under each increment and decrement of loading.
(c) The exact times at which increments were applied and decrements removed.
(d) The levels of the reference beam, to the nearest 0.05 mm.
Contractor
Pile data
Levels
Date Drop Depth No. of Cumulative Length of individual Remarks (State details
& (m) pene- blows+ No. of segments, location of of obstruction, delays,
Time trated blows splices and tests interruptions and
(m) carried out location of concrete
samples++)
(*delete as appropriate)
y-y mm
Reported by Verified by
Contractor's Representative Project Manager's Representative
Date Date
(* delete as appropriate)
PILE RECORDS
Contractor
Pile data
Date Depth Details of strata Details of soil testing, Remarks (State details
& pene- penetrated/ground proving of bedrock and of obstruction, delays
Time trated water level under-ream interruptions, and
location of concrete
samples)
(*delete as appropriate)
Concrete record
Lt
Overall __ = %
La
Reported by Verified by
Contractor's Representative Project Manager's Representative
Date Date
Note : The Project Manager shall be informed of any deviation greater than ± 10%
from the expected (theoretical) level of concrete placed.
(* delete as appropriate)
PILE RECORDS
(Barrettes)
Contractor
Pile data
Design Length m
Excavation data
y-y mm
(Barrettes)
Concrete record
Lt
Overall __ = %
La
Report by Verified by
Contractor's Representative Project Manager's Representative
Date Date
Note The Project Manager shall be informed of any deviation greater than ± 10% from the
expected (theoretical) level of concrete placed.
(*delete as appropriate)
Contractor
Sample data
Density (g/mL)
Viscosity (seconds)
pH
Temperature (°C)
Remarks : -
Reported by Verified by
Contractor's Representative Project Manager's Representative
Date Date
(* delete as appropriate)
(Test Result)
Contractor
Pile data
Type Size
Testing data
(Test Result)
Load in kN
1000 2000 3000 4000 5000 6000
0 --
5 --
10 --
15 --
Settlement
in 20 --
mm
25 --
30 --
35 --
40 --
Maximum settlement at working load: (Allowable = 20 mm for buildings and 10 mm for all
other structures)
Actual =
Settlement at maximum test load (S1): (Allowable = S1 less than twice settlement at 90% of
maximum test load (2S2).)
Actual S1 = 2S1 =
Reported by Verified by
Contractor's Representative Project Manager's Representative
Date Date
(delete as appropriate)
18.1 GENERAL
The works and materials specified herein shall comply with the Sections stated,
unless otherwise stated in this Section:
(a) surface finish to concrete carriageways shall comply with Section 10;
(b) cover spacers for steel reinforcement shall comply with Section 19; and
(c) materials for cement mortar shall comply with Section 20.
18.2.1 Class
“Class” is a term used to identify the different types and standards of formed,
unformed and treated finishes.
18.2.2 Falsework
Formed finish is the finish of the concrete surface produced by the use of formwork.
18.2.4 Formwork
Formwork is the mould against which concrete is cast and which gives the shape
and finish to the concrete surface.
(b) Trough mould is the mould used with complementary moulds to create an
elongated recess in the underside of a slab.
(c) Waffle mould is the mould used with complementary moulds to create square
recesses in a concrete slab.
Sealed plywood is plywood which has been sealed with a factory-applied film of
phenolic resin or plastic material.
18.2.8 Spatterdash
Spatterdash is a mixture of cement, coarse sand, granite fines and water, used as a
rendering on concrete surfaces.
Treated finish is the finish of the concrete surface produced by a treatment applied
to a formed or unformed finish.
Unformed finish is the finish of the concrete surface produced without formwork and
by working the concrete surface before the concrete has hardened.
(b) Falsework and formwork shall be capable of being dismantled and removed
without shock, disturbance, damage or loading to the concrete and in such a
manner that the specified requirements for removing or leaving in position
side formwork, soffit formwork and falsework will be achieved without
disturbing other formwork or falsework.
(c) Formwork shall be used to form the top surface of concrete inclined at a slope
exceeding 15° to the horizontal unless it can be demonstrated that the
specified finish will be produced without the use of formwork. Formwork to
top surfaces shall be anchored to prevent floatation.
18.4 MATERIALS
18.4.1 Formwork
(a) Formwork shall be timber, metal, plastic, fibreglass or other material which will
produce the specified finish. Materials used as formers for profiled formwork,
chamfers, splays, rebates and other features shall be such that they produce
the same finish as the main formwork.
(b) Plywood for formwork shall have a close, uniform grain and the edges shall be
sealed with barrier paint, polyurethane varnish or other impermeable material.
(d) The formwork used for F3, F4 and F5 finished surfaces shall be formed of one
material only. All make up pieces shall be of that material to ensure the same
finish is obtained across the whole surface.
(e) All concrete to receive a waterproof membrane shall have a surface finish
either formed or unformed that is compatible with the membrane to be
applied.
(f) The surface finish of floor slabs in toilet and kitchen areas where the
waterproofing is to be laid by others shall be unformed finish type U3 unless
shown otherwise.
(a) The characteristics of each class of finish shall be as stated in Tables 18.1,
18.2 and 18.3.
(b) Formwork of the type stated in Table 18.1 shall produce a concrete surface
which complies with the characteristics of finish stated in Table 18.1.
(c) Unless otherwise shown on the Employer's Drawings, the class of formed and
unformed finish required for different concrete surfaces shall be as stated in
Table 18.4. The higher class of finish shall start at least 150 mm below the
finished ground level for concrete surfaces which are partly buried.
(a) Release agents shall be a proprietary type reviewed without objection by the
Project Manager. Release agents containing mineral oils shall not be used.
Barrier paint, polyurethane varnish, wax or other materials shall not be used
instead of a release agent.
(ii) affect the bond between the concrete and subsequent coverings; or
(c) Release agents other than those which incorporate a surface retarder to
produce a Class T1 finish shall not affect the hardening of the concrete.
(d) Release agents used on formwork for water retaining structures for potable
and fresh water shall be non-toxic and shall not impart a taste to the water.
(e) Release agents used on steel formwork shall contain a rust-inhibiting agent.
(f) Release agents used on formwork for Class F4, F5 and F6 finishes shall be a
chemical release agent.
Characteristics of finish
Class Method of
of producing Abrupt Gradual Specific
finish finish irregularities irregularities requirements
permitted permitted
U1 Levelling the surface of the Screed marks < 10 mm in 2 m No specific
compacted concrete with a < 5 mm requirements
screed board
U2 Forming a Class U1 finish Tamp marks Not applicable Ridged surface
and tamping the surface < 10 mm
U3 Forming a Class U1 finish Float marks < 10 mm in 2 m Uniform, dense and
and wood floating, steel < 3 mm smooth surface
trowelling or power floating
the surface
U4 Forming a Class U3 finish Brush marks < 10 mm in 2 m Rough texture
and brushing the surface < 3 mm
with a stiff brush
U5 Forming a Class U3 finish Nil < 5 mm in 2 m Uniform, dense and
and steel trowelling the smooth surface, free
surface under firm from trowel marks
pressure or power floating No staining or
the surface discolouration
Class Method
Type of
of of Characteristics of finish
finish
finish producing finish
T1 Exposed Washing and brushing Cement matrix removed and coarse
aggregate the concrete surface aggregate exposed to a depth not
exceeding one-third of the nominal
maximum coarse aggregate size
T2 Point tooled Point tooling the Cement matrix and aggregate surface
concrete surface removed sufficiently to expose the
aggregate with a minimum penetration into
T3 Bush Bush hammering the the matrix between aggregates
hammered concrete surface
T4 Broken rib Hammering or chiselling Cement matrix and aggregate surface
the edges and faces of removed
the concrete surface
Fragments of concrete ribs removed
T5 Light Blasting the concrete Cement matrix removed and coarse
blasting surface by abrasives aggregate exposed to a minimum depth
Class of finish
Description of surface
Formed Unformed
Surfaces to be covered − screeded - U2
− rendered, plastered F2 -
− tiled F2 U3
− painted F4 U5
Movement joints F3 U3
Benching, screeds F3 U5
(a) Formwork ties shall not be used in any structure which bears against the
ground or retains water.
(b) Formwork ties and components shall be a type such that any removable part
can be removed without damaging the concrete; any part left in the concrete
shall be at least 40 mm or the specified nominal cover to the reinforcement,
whichever is greater, from the concrete surface.
(c) Formwork ties and components used with profiled formwork shall be a type
such that holes left by the ties and components are small enough to be
located completely within the recesses in the concrete surface.
(a) All formwork ties and component holes including blowholes shall be filled.
(b) Cement mortar for filling blowholes shall consist of cement and fine aggregate
together with the minimum amount of water necessary to achieve a
consistency suitable for completely filling the blowholes.
(c) Cement mortar for filling holes left by formwork ties and components shall
consist of 1 part of cement to 3 parts of fine aggregate together with the
minimum amount of water necessary to achieve a consistency suitable for
compacting the mortar into the holes. The mix shall contain a non-shrink
admixture.
(d) Cement mortar for filling blowholes and holes left by formwork ties and
components in concrete surfaces with Class F4, F5 and F6 finishes shall be
the same colour as the hardened concrete; light-coloured sand or white
cement may be used for this purpose.
18.4.7 Abrasives
Abrasives for blasting shall be grit and shall not contain any silica, iron, clay or other
materials which will stain or colour the concrete.
(c) Design calculations for formwork and falsework, in accordance with the
requirements of Section 2 of this General Materials and Workmanship
Specification, shall be submitted to the Project Manager for review without
objection.
: Column construction
- Layout and pattern of column X - X
moulds, joints rebates and
formwork ties
Design calculations : Check on formwork, falsework, X
Permanent Works
Method statement : Method statement of formwork X X X
and falsework erection, including
sequence for floor slab and
columns
Samples : Formwork, F3, F4 and F5 X - -
Formwork ties X - X
Cover spaces X - X
Brand name and : Release agent X - X
manufacturer's Curing compound X X X
literature Surface retarder - - X
Programme : Removing formwork X - -
Applying treated finishes - - X
Details : Sources of formwork, formwork
ties and cover spacers X - X
Curing method X X X
Filling blowholes X - -
Filling formwork tie holes X - X
Protecting finishes X X X
(a) A trial panel shall be constructed for each Class F4, F5, F6, U5 and T finish to
demonstrate that the proposed materials, mix design, methods of production
and methods of construction, including curing and removal of formwork, shall
produce the specified finish.
(b) Trial panels for Class F4, F5 and F6 finishes shall be constructed before the
relevant formwork for the Permanent Works is erected, and trial panels for
Class U5 and T finishes shall be constructed before the relevant Permanent
Works is concreted. The trial panels shall be completed at least 4 weeks
before the relevant Permanent Works are programmed to commence.
(c) The Contractor shall notify the Project Manager before constructing trial
panels.
(d) Trial panels shall be constructed using the materials, mix design, methods of
production and methods of construction, including curing and removal of
formwork, submitted to and reviewed without objection by the Project
Manager.
(e) Trial panels shall be horizontal, vertical or inclined as appropriate and shall be
constructed at locations reviewed without objection by the Project Manager.
Unless otherwise stated in the Contract each trial panel shall be not less than
2 m by 2 m by 300 mm thick, and shall contain reinforcement representative
of the most congested reinforcement which will be used in the Permanent
Works. Trial panels shall incorporate formwork ties and components,
horizontal joints, vertical joints, chamfers, splays, rebates and other features
representative of those which will be used in the Permanent Works, including
the filling of formwork ties, components and blowholes.
(f) The Contractor shall submit the trial panels to the Project Manager for review
without objection. When the Project Manager has issued a notice of no
objection for the trial panels, they shall become a benchmark against which all
subsequent finishes of concrete surfaces shall comply. Benchmarks shall be
protected from damage and shall be left in position until the Project Manager
directs their removal.
If the Project Manager determines that the specified finish has not been produced in
the trial panel, particulars of proposed changes to the materials, mix design,
methods of production or methods of construction shall be submitted to the Project
Manager for review without objection and further trial panels shall be constructed
until the specified finish is produced in the trial panel. Further trial mixes shall be
made unless the Project Manager directs otherwise.
Formwork for Class F4, F5 and F6 finishes shall not be erected and elements with
Class U5 and T finishes shall not be concreted until the Project Manager has
determined that the specified finish has been produced in the trial panel.
(a) Formwork shall be stored off the ground on level supports and in a manner
which will not result in damage, deformation or contamination of the
formwork.
(b) Formwork for Class F3, F4, F5 and F6 finishes shall be covered and protected
from exposure to conditions which may affect the formwork.
Release agents and surface retarders shall be stored in sealed containers marked
to identify the contents and protected from exposure to conditions which may affect
the material. The materials shall be stored in accordance with the manufacturers'
recommendations and shall not be used after the recommended shelf life has been
exceeded.
(a) Formwork shall not have any splits, cracks or other defects. The faces and
edges of formwork shall be clean and formwork faces shall be free of
projections.
(b) Formwork which has been previously used shall be repaired and the edges
resealed before it is erected.
(c) Formwork shall be firmly supported and individual panels shall be rigid. Joints
between formwork panels, stop ends and adjoining concrete shall be tight and
shall not permit grout loss.
(d) Formwork shall be cut in such a manner that reinforcement and built-in
components passing through the formwork are maintained in position; the
joints shall be tight and shall not permit grout loss.
(e) Formers for profiled formwork, chamfers, splays, rebates and other features
shall be rigidly and evenly fixed to the formwork along the complete length
and shall not permit grout loss.
(f) Formwork ties and components shall be fixed in such a manner that they do
not touch reinforcement or built-in components. Formwork ties and
components shall fit tightly against formwork faces and shall not permit grout
loss.
(a) Formwork panels for Class F2, F3, F4, F5 and F6 finishes shall be the same
size and shall form a regular pattern as shown on the Employer's Drawings
and/or reviewed without objection by the Project Manager. The lines of joints
between panels shall be straight and continuous, horizontal and vertical, or
inclined to suit the pattern of profiled formwork, and shall be coincident with
construction joints and other joints and with recesses in the concrete surface.
The number of make-up pieces shall be kept to a minimum and shall be the
same material as the formwork system.
(b) Holes left by formwork ties and components in concrete surfaces with
Class F2, F3 and F4 finishes shall be in line horizontally and vertically and
shall form a regular pattern reviewed without objection by the Project
Manager. Holes in profiled formwork shall be located in such a manner that
the holes are completely within recesses in the concrete surface.
(c) Chamfers shall be provided for all external angles of 90° or less in concrete
surfaces with Class F2, F3, F4, F5 and F6 finishes.
(d) Formwork for curved concrete surfaces with Class F2, F3, F4, F5 and F6
finishes shall not be made up of a series of flats or straights.
(a) Each type of formwork for either Class F3, F4, F5 and F6 finishes shall be
obtained from one source and different types of formwork shall not be mixed.
Damaged formwork shall not be used. Parts of steel formwork which will be in
contact with concrete shall be free from rust.
(b) For concrete surfaces with Class F3, F4, F5 and F6 finishes, joints between
formwork panels shall be sealed with foamed rubber strips. The foamed
rubber strips shall be sufficiently compressible to form a grout-tight joint. The
width of the resulting gap between the panels shall not be greater than 1 mm
and the sealing strips shall not protrude proud of the surface of the formwork
panels. Joints between formwork panels shall not be sealed by tape fixed to
the formwork faces.
(c) For concrete surfaces with Class F3, F4, F5 and F6 finishes, joints between
the formwork and its ends, adjoining concrete and built-in components shall
be sealed with gaskets of rubber or flexible foamed polyurethane; the gaskets
shall be fixed firmly and evenly to the formwork. The joints shall not be sealed
by tape fixed to the formwork faces, putty or other sealants.
(d) Formwork for Class F3, F4, F5 and F6 finishes shall be protected from
spillages, rust marks and stains.
(e) For concrete surfaces with Class F3, F4 and F5 finishes, the formed face at
all joints between formwork panels and moulds shall be flush.
(a) Built-in components, void formers and box-outs shall be fixed in position
before concreting. Void formers and box-outs shall not be used instead of
built-in components. Polystyrene shall not be used for void formers and box-
outs.
(b) Hardened concrete shall not be cut or broken to provide holes or chases
without being reviewed without objection by the Project Manager.
(c) Pipe sleeves, inserts and ducts shall be securely and correctly located within
the specified tolerances.
(d) Formwork for openings, chases and holes shall not interfere with the
reinforcement.
(e) Cast-in items shall be temporarily sealed where necessary to ensure that no
unintended seepage of grout occurs into channels or recesses of the cast-in
item.
(a) A release agent shall be used on all formwork other than permanent formwork
and formwork on which a surface retarder is used to produce a Class T1
finish. The release agent shall be applied by the method and at the rate of
application recommended by the manufacturer or as demonstrated to be
satisfactory by use in the trial panel.
(b) Formwork faces shall be cleaned before release agents are applied.
Concrete, reinforcement and built-in components shall not be contaminated
by release agents.
(c) Each type of release agent used on formwork for Class F3, F4, F5 and F6
finishes shall be obtained from one manufacturer and different types of
release agent shall not be used on formwork for the same element.
(d) Release agents shall be applied to formwork for Class F3, F4, F5 and F6
finishes after the formwork has been erected and before the reinforcement is
fixed or, if this is not practicable, immediately before the formwork is erected.
The release agent covering shall be complete and uniform.
(a) Falsework and formwork shall not be loosened or removed before the
minimum times stated in Table 18.6 have elapsed. The times stated are for a
minimum ambient temperature of 15°C, for elements without superimposed
loads and for concrete containing OPC, PPFAC or both OPC and PFA.
(b) For the purpose of determining the minimum times for loosening or removing
falsework and formwork, copings at the top of columns in water retaining
structures shall be classified as slabs and roof slabs in water retaining
structures shall be classified as beams.
(c) For the purpose of Table 18.6, ‘props left in’ shall include a minimum of 4
props over any one span in each orthogonal direction.
(a) Formwork shall be removed without hammering or levering the concrete and
in such a manner that there is no shock, disturbance, damage or loading to
the concrete or damage to the specified finish. Side formwork shall be
removed without disturbing soffit formwork. Soffit formwork shall be removed
without disturbing props except where the Contractor has previously
submitted a method statement, reviewed without objection by the Project
Manager, that demonstrates that the intended prop removal or replacement
sequence can be achieved without overstressing the structure, giving due
consideration to the strength of the concrete at the time.
(c) Formwork shall be thoroughly cleaned to remove all traces of concrete and
made good to the original standard before any reuse.
(d) Unless formwork has been left in place for curing requirements it must be fully
removed immediately after initial loosening so that curing may be carried out.
(a) Unformed finishes shall be produced by the methods stated in Table 18.2.
(b) Brushing to produce a Class U4 finish shall be carried out in straight lines in a
direction reviewed without objection by the Project Manager. Brushing shall
be carried out when the concrete has hardened sufficiently for the float marks
to be removed and for the ridges to be formed without displacing the
aggregate.
(c) Floating and trowelling shall not be carried out until the concrete has
hardened sufficiently to allow the specified finish to be produced with the
minimum amount of floating and trowelling. Excess laitance shall not be
produced.
(a) Washing and brushing to produce a Class T1 finish shall not be carried out
until the concrete has hardened sufficiently for the cement matrix to be
removed without disturbing the coarse aggregate. After washing and
brushing have been completed and the concrete surface has hardened, the
surface shall be cleaned.
(b) The cement matrix shall not be removed or the aggregate exposed by
mechanical methods.
(c) Class T1 finishes may be produced by using a surface retarder applied to the
formwork or to the concrete surface. The surface retarder shall be applied by
the method and at the rate of application recommended by the manufacturer,
or as demonstrated to be satisfactory by use on the trial panel.
(e) Formwork to which a surface retarder has been applied shall not be re-used
unless a surface retarder is to be used again on the formwork. Formwork to
which a surface retarder has been applied and which is to be re-used shall be
cleaned before the retarder is reapplied.
Hammering or chiseling to produce a Class T4 finish shall be applied from only one
direction and only either hammering or chiseling shall be applied, on any one face.
Hammering and chiseling shall not start until at least 14 days after concreting.
(a) Blasting to produce Class T5 and T6 finishes shall not be carried out until the
concrete has hardened sufficiently for the cement matrix to be removed
without disturbing the coarse aggregate. Adjacent surfaces shall be protected
from blasting and dust shall be controlled by screens and by water-spraying.
(a) Remedial or repair work shall not be carried out on concrete surfaces unless
reviewed without objection by the Project Manager.
(b) Prior to any mechanical work being carried out to any concrete surface, a trial
repair panel shall be offered to the Project Manager for review without
objection.
(c) Abrupt irregularities shall be removed from concrete surfaces which will be
painted or to which tiles will be fixed with adhesives.
(d) For slipformed surfaces, as the concrete emerges from the shutter, any drag
cracks shall immediately be closed by means of a wooden float. The surface
of the concrete shall then be gently brushed horizontally to produce a light
uniform texture. Any necessary cutting out of concrete shall be carried out
immediately and made good as soon as possible thereafter using concrete
taken from the slipforming mix with the coarse aggregate sieved out as
necessary.
(b) Holes left by formwork ties and components shall be cleaned and filled by
ramming cement mortar into the holes in layers. Holes in concrete surfaces
with a Class F4 finish shall be filled to a level slightly below the concrete
surface; the holes shall not be overfilled and rubbed down.
(c) Filling of blowholes and holes left by formwork ties and components shall be
carried out as soon as practicable after the Project Manager has inspected
the finish and with the minimum interruption to curing. Filling of blow holes in
Class F5 finish shall not be permitted.
(a) Spatterdash shall consist of cement and coarse sand or granite fines in the
proportions 1:2 by volume mixed with the minimum amount of water
necessary to achieve the consistency of a thick slurry. Spatterdash shall be
thrown with a hand trowel onto the surface to a thickness not exceeding 6 mm
and shall cover at least 60% of the area which is to be plastered or rendered.
Spatterdash shall be wetted one hour after application and shall be allowed to
cure and harden before under coats are applied.
(b) Spatterdash shall be applied as soon as practicable after the Project Manager
has inspected the finish and after the concrete surface has been cleaned and
wetted.
(b) Final measurements to confirm that the Works are within the specified
tolerances shall be made at 28 days after casting for in-situ construction.
(iv) Variation from the horizontal (Refer Table No more than 1:500, up
18.2 for unformed surfaces other than slab to +10 mm, -5 mm
surfaces) maximum for upper
slab surfaces
(v) Variation from true plan position and from No more than 1:300, up
correct lines to 15 mm maximum
measured horizontally
from true plan position
- Variation of location 6 mm
- Variation of size ± 3 mm
(v) The plan distance between ends and sides of escalator and moving walkway
voids and pits shall be within +10mm/-0mm.
(g) Note that where a tolerance is related to a given length, the tolerance for any
lesser length shall be in linear proportion thereto, subject to review without
objection by the Project Manager. For verticality, the tolerance for each lift of
concrete shall be calculated on the same basis with a normal maximum of 3
mm deviation from true vertical.
(h) The Contractor shall determine the amount of pre-set deflection and/or pre-
camber that may be necessary in formwork to ensure that the as constructed
position of the concrete is within the specified tolerances.
Temporary fixings left in the completed concrete structure shall be left with a
minimum of 40mm cover and filled over with a polymer modified mortar, reviewed
without objection by the Project Manager. Temporary fixings shall not be left in on
concrete surfaces that are exposed to public view or in water retaining structures.
(a) The Contractor shall allow sufficient time for the Project Manager to inspect
the completed formwork and reinforcement, including trial panels, before
carrying out any work, including fixing reinforcement adjacent to formwork and
erecting formwork adjacent to reinforcement, which will make access to the
formwork faces or reinforcement difficult.
(b) The Contractor shall allow sufficient time for the Project Manager to inspect
formwork for Class F3, F4, F5 and F6 finishes before it is erected and shall
notify the Project Manager before erecting the formwork.
(a) Before any subsequent work is carried out on a concrete surface, the surface
will be inspected by the Project Manager to determine if the specified finish
has been produced. Formed finishes shall be inspected as soon as the
formwork has been removed.
(b) Blowholes or holes left by formwork ties and components shall not be filled
and spatterdash or other coverings shall not be applied before the inspection.
(a) Concrete surfaces shall have the characteristics stated in Tables 18.1 and
18.2 for the different classes of formed and unformed finish before any
subsequent work is carried out on the concrete surface and shall have the
characteristics stated in Table 18.3 for the different classes of treated finish.
(b) The Project Manager will determine if the specified finish has been produced
and will use the trial panels as a benchmark.
(d) All exposed in-situ and pre-cast concrete surfaces shall match for colour and
surface texture.
“Bar reinforcement” is hot rolled steel bar or cold worked steel bar or cold reduced
wire reinforcement.
19.2 MATERIALS
(a) Except where noted on the Employer's Drawings, bar reinforcement and
fabric reinforcement shall comply with the following:
(b) All reinforcement shall comply with the requirements of Practice Note for
Authorised Persons and Registered Structural Engineers (PNAP) 122 issued
by the Buildings Department.
(a) Epoxy coatings to reinforcement and patching material for epoxy coatings
shall comply with ASTM A775M except as stated in Sections 19.2.2 (b),
19.4.5, 19.5.3, 19.5.4 and 19.5.8. The coatings shall be applied by the
electrostatic spray method in accordance with ASTM A775M at a factory
reviewed without objection by the Project Manager.
(b) The film thickness of the coating after curing shall be at least 0.15 mm and
shall not exceed 0.25 mm over the complete periphery including deformations
and ribs. The bond classification of coated bars determined in bond
performance tests shall not be less than that of uncoated bars.
(b) Metallic zinc-rich priming paint for repairs to galvanized reinforcement shall
comply with BS 4652.
(d) The concrete cover to reinforcement connectors shall not be less than the
specified minimum.
(e) Reinforcement connectors shall not be used with galvanized or epoxy coated
reinforcement.
(b) Cover spacers for Class F3, F4, F5 and F6 finishes shall be a proprietary
plastic or concrete type. Cover spacers for epoxy coated reinforcement and
galvanized reinforcement shall be a proprietary plastic type.
(d) The strength and durability of concrete blocks and proprietary concrete cover
spacers shall not be less than that of the surrounding concrete.
(e) Cover spacers for Class F3, F4, F5 and F6 finishes shall be of a colour similar
to that of the surrounding concrete and shall not cause indentations in the
formwork.
(f) The use of Site manufactured concrete spacer blocks will only be permitted if
the Project Manager has reviewed without objection the method of
manufacture and quality of the block.
Chairs, supports and spacers other than cover spacers for reinforcement shall be
steel. The steel shall be coated with nylon, epoxy, plastic or other dielectric
material for epoxy coated reinforcement and shall be galvanized for galvanized
reinforcement.
Tying wire for reinforcement adjacent to and above Class F4, F5 and F6 finishes
shall be 1.2 mm diameter stainless steel wire. Tying wire for epoxy coated
reinforcement shall be 1.6 mm diameter soft annealed steel wire coated with nylon,
epoxy, plastic or other dielectric material. Tying wire for galvanized reinforcement
shall be 1.6 mm diameter galvanized soft annealed steel wire. Tying wire for other
reinforcement shall be 1.6 mm diameter soft annealed steel wire.
Tying devices and clips for reinforcement shall be a proprietary steel type reviewed
without objection by the Project Manager. Tying devices and clips for reinforcement
adjacent to and above Class F4, F5 and F6 finishes shall be stainless steel. Tying
devices and clips for epoxy coated reinforcement shall be coated with nylon, epoxy,
plastic or other dielectric material. Tying devices and clips for galvanized
reinforcement shall be galvanized.
19.3 SUBMISSIONS
(a) for Class 1 bar reinforcement, a mill certificate from the quality assured
stocklist in accordance with CS2 Cl.4.1.3 and a copy of the manufacturer's
third party certificate;
(b) for Class 2 bar reinforcement, a mill certificate from the quality assured
stocklist in accordance with CS2 Cl.4.1.4 and a copy of the manufacturer’s
third party certificate;
(d) Upon delivery of bar reinforcement the Contractor shall submit a test report
containing the details specified in CS2, Cl.3.3.3 and Cl.3.3.5; and
(e) for fabric reinforcement, a certificate form the manufacturer showing the
manufacturer's name, the date and place of manufacture and showing that
the reinforcement complies with the requirements stated in the Contract
including details of:
(iv) results of tensile, bend and rebend tests, including the effective
cross-sectional area for tensile tests;
(v) results of bond performance tests for deformed bar reinforcement and
for fabric reinforcement; and
(c) a certificate from the manufacturer showing the date and place of application
of the coating and showing that the epoxy coatings comply with the
requirements stated in the Contract and including results of tests for:
(ix) hardness.
Materials & Workmanship Specification 4/14 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 19 – Steel Reinforcement
19.3.3 Particulars of Galvanized Coatings to Reinforcement
(b) a certificate from the manufacturer showing the date and place of application
of the coating and showing that the galvanized coatings comply with the
requirements stated in the Contract and including results of tests for:
All submissions under Clauses 19.3.1 – 19.3.4 shall be in a form suitable for
submission to the Buildings Department.
(a) Unless otherwise stated in the Contract, for works designed in detail by the
Employer, any bending schedules by the Employer are provided for the
information of the Contractor but are not guaranteed correct. The Contractor
shall check the schedules and submit to the Project Manager for review
without objection, any amendments, additions or deductions as may be
necessary to conform to the Employer's Drawings and the Specification at
least 28 days before bending of the reinforcement commences.
(b) Should any alterations to the bending schedules be required by the Contractor
to facilitate his sequence of construction, location of construction joints, box-
outs, openings and the like, then the revised bending schedules together with
explanatory notes and diagrams shall be submitted to the Project Manager for
review without objection at least 28 days before bending of the reinforcement
commences.
19.4 WORKMANSHIP
(b) Nylon, rope or padded slings shall be used for lifting epoxy coated
reinforcement and galvanized reinforcement; bundles shall be lifted with a
strongback or with multiple supports to prevent abrasion.
(a) Reinforcement shall be stored off the ground on level supports and in a
manner which will not result in damage or deformation to, or in contamination
of, the reinforcement. Fabric reinforcement shall be stored horizontally.
Where conditions of saline water exist the Contractor shall provide hard
standing reviewed without objection by the Project Manager for steel storage
and bending and shall prevent contact between steel and saline water.
(a) Reinforcement shall be cut and bent in accordance with BS 4466 to the
specified shapes and dimensions and shall be bent at temperatures of at least
5°C and not exceeding 100°C.
(b) Epoxy coated reinforcement shall be bent cold. Bar cutting and bar bending
equipment for epoxy coated reinforcement shall have padded supports and
contact areas shall be fitted with nylon or plastic mandrels.
(c) Grade 460 reinforcement shall not be rebent or straightened after bending,
with the exception of reinforcement of 20mm diameter (or less) which projects
from hardened concrete or is out of position. Such reinforcement and Grade
250 reinforcement which projects from hardened concrete may be bent aside
and rebent provided that the internal radius of the bend is at least three times
the diameter of the bar for Grade 460 and twice the diameter of the bar for
Grade 250, and that bending is not carried out by levering against the
concrete or by other methods which will damage the concrete.
(d) The ends of bars to be used with reinforcement connectors for compression
joints shall be sawn square with all burrs removed.
(a) Reinforcement shall be clean at the time of fixing and shall be free from loose
mill scale, loose rust or any substance which is likely to reduce the bond or
affect the reinforcement or concrete chemically. Reinforcement shall be
maintained in this condition until concrete is placed around it.
(b) If the surface condition of the reinforcement deteriorates such that it does not
comply with the requirements stated in Section 19.4.4(a), the reinforcement
shall be cleaned or dealt with by other methods reviewed without objection by
the Project Manager, prior to being used.
(iii) at more than six points in the cut and bent length of a bar by amounts
each not exceeding 25 mm² in area or 50 mm in length,
then that part of the reinforcement shall not be used in the Permanent Works.
(b) Damaged areas not exceeding 25 mm² in area or 50 mm in length and cut
ends of epoxy coated reinforcement, other than that rejected under Section
19.4.5(a) shall be repaired using patching material applied in accordance with
the manufacturer's recommendations.
(c) Damaged areas not exceeding 25 mm² in area or 50 mm in length and cut
ends of galvanized reinforcement shall be repaired by applying two coats of
metallic zinc-rich priming paint. Sufficient paint shall be applied to provide a
zinc coating of at least the same thickness as the galvanized coating.
(d) Repairs to epoxy coatings and galvanized coatings shall be carried out within
8 hours of cutting or damage. Traces of rust shall be removed from the
surface of the reinforcement before the repair is carried out.
(c) A sufficient number of intersecting and lapping bars shall be tied using tying
wire, tying devices or clips to prevent movement of the reinforcement. The
ends of tying wire, tying devices and clips shall not encroach into the cover to
reinforcement.
Materials & Workmanship Specification 7/14 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 19 – Steel Reinforcement
(d) Laps and joints in reinforcement shall be made only at the positions specified
on the Employer's Drawings and by the specified methods except where
otherwise reviewed without objection by the Project Manager in accordance
with Section 19.3.5(b).
(e) Sufficient numbers of cover spacers, chairs, supports and spacers other than
cover spacers shall be provided to maintain the reinforcement in the correct
location and to maintain the specified cover at all positions. Cover spacers,
chairs, supports and spacers other than cover spacers shall be placed at a
maximum spacing of 1.5 m. Chairs, supports and spacers other than cover
spacers shall be positioned adjacent to or above cover spacers and shall
have at least the same cover as that specified for the reinforcement.
(a) Tolerances on cutting and bending reinforcement shall comply with BS 4466,
Table 1, 2 and 4.
(b) Unless otherwise stated on the Employer's Drawings, reinforcement shall not
be out of the designed position by more than 5 mm and shall not encroach
into the minimum specified cover.
The Contractor shall allow sufficient time for the Project Manager to inspect the
completed reinforcement before carrying out any work, including erecting formwork
adjacent to reinforcement, which will make access to the reinforcement difficult.
The Contractor shall notify the Project Manager before carrying out such work.
(c) The list of bars currently acceptable for abbreviated testing are given in
Construction Standard CS2.
(e) Each specimen of bar reinforcement and fabric reinforcement shall be taken
from different bars or sheets in the batch. The ends of specimens shall be cut
square and loose mill scale and rust shall be removed by wire brushing before
delivery to the laboratory.
No. of samples
Description Size of Batch
per batch
In accordance with
Bar reinforcement
Table 9 of CS2
0 – 50 tonnes 1
Fabric reinforcement exceeding 50 tonnes 1 for each 50 tonnes or part
thereof
less than 100 No. 1
Reinforcement connectors
100 – 500 No. 2
for tension joints
exceeding 500 No. 3
(b) Each sample of bar reinforcement and fabric reinforcement shall be tested to
determine the yield stress, elongation, tensile strength, bending and
rebending properties and unit mass. Each sample of fabric reinforcement
shall also be tested to determine the weld shear strength. Each sample of
epoxy coated reinforcement shall also be tested to determine the thickness,
adhesion and continuity of the coating. Each sample of galvanized
reinforcement shall also be tested to determine the weight and uniformity of
coating.
(c) Each sample of reinforcement connectors for tension joints shall be tested to
determine the tensile strength and the slip between the reinforcement
connector and the parent bars.
(d) The number of tests on each sample shall be as stated in Table 19.2.
(f) The method of testing epoxy coatings shall be in accordance with ASTM A775
except that the test for adhesion of coating shall be carried out on 180° bends
to design radii in accordance with BS 4466, Table 1. Bends shall be
performed at a uniform rate and shall be capable of being completed within
15 seconds without visual distress to the coating.
(g) Tests shall be carried out on specimens having a temperature of between 5°C
and 30°C.
The results of tests for thickness, adhesion and continuity of epoxy coatings to
reinforcement shall comply with the following requirements:
(a) at least 90% of measurements taken to determine the thickness of the coating
shall be within the specified limits. The thickness of the coating shall be at
least 0.10 mm and shall not exceed 0.30 mm at any point, other than at
repaired areas of coating;
(b) cracking or debonding of the coating shall not be visible to the unaided eye on
any part of the bent bar; and
(c) the continuity of the coating shall comply with ASTM A775, Clause 7.2.
(b) If the yield stress in any tensile test is less than the specified characteristic
strength but equal to or greater than 93% of the specified characteristic
strength, additional samples shall be provided from the same batch and
additional tests for yield stress shall be carried out. The number of samples
shall be as stated in Clause 5.1.4 of the Construction Standard CS2. The
batch shall be deemed to comply with the Specification if the test specimens
meet the requirements of Clause 5.1.2 of the Construction Standard CS2.
(d) The number of tests on each additional sample of bar reinforcement shall be
seven. The number of tests on the longitudinal wires and on the transverse
wires of each additional sample of fabric reinforcement shall be seven.
(e) The batch shall be considered as not complying with the specified
requirements for characteristic strength if the yield stress in any additional test
is less than 93% of the specified characteristic strength.
If any test specimen fails to meet the tensile strength, elongation, bend or rebend
test requirements as stipulated in Construction Standard CS2, two additional test
specimens may be taken from different bars of the same batch and be subjected to
the test or tests which the original specimen failed. If both additional test
specimens pass the retests the batch from which they were taken shall be deemed
to comply with this Specification. If either of them fails, the batch shall be deemed
not to comply with this Specification.
(a) If the result of any test for thickness, adhesion or continuity of epoxy coatings
to reinforcement does not comply with the specified requirements for the
property, additional samples shall be provided from the same batch and
additional tests for the property shall be carried out. The number of additional
samples shall be as stated in Table 19.1.
(d) The batch shall be considered as not complying with the specified
requirements for the property if the result of any additional test does not
comply with the specified requirements for the property.
(a) If the result of any test for weight or uniformity of galvanized coatings to
reinforcement does not comply with the specified requirements for the
property, additional samples shall be provided from the same batch and
additional tests for the property shall be carried out. The number of additional
samples shall be as stated in Table 19.1.
(d) The batch shall be considered as not complying with the specified
requirements for the property if the result of any additional test does not
comply with the specified requirements for the property.
(a) the tensile strength shall not be less than the specified requirements for the
parent bar; and
(b) the slip between the reinforcement connector and the parent bars shall not
exceed 0.2 mm in 2 minutes at the specified characteristic strength.
(a) If the result of any test for slip of reinforcement connectors for tension joints
does not comply with the specified requirements for slip, additional samples
shall be provided from the same batch and additional tests for slip shall be
carried out. The number of additional samples shall be as stated in
Table 19.1.
(d) The batch shall be considered as not complying with the specified
requirements for slip if the result of any additional test does not comply with
the specified requirements for slip.
20.1 GENERAL
Sprayed concrete shall comply with Section 8 except as stated in this section.
“Cementitious content” or “cement content” is the mass of cement per cubic metre
of compacted concrete or, if cement and PFA are used as separate constituents,
the combined mass of cement and PFA per cubic metre of compacted concrete.
20.2.2 Grade
“Grade” is a term used to identify the different concrete mixes in terms of grade
strength or in terms of grade strength and nominal maximum aggregate size.
Grade strength is the compressive strength of concrete stated in the Contract. For
designed mix concrete, compliance with the grade strength shall be ascertained in
accordance with Clause 20.8.14.
(a) Designed mix concrete shall be designated by the grade strength in MPa
followed by the nominal maximum aggregate size in mm and the suffix D.
(b) Standard mix concrete shall be designated by the grade strength in MPa
followed by the nominal maximum aggregate size in mm and the suffix S.
(d) Prescribed mix concrete shall be designated by the grade strength in MPa
followed by the nominal maximum aggregate size in mm and the suffix P.
20.3.1 Cement
20.3.2 PFA
20.3.3 Aggregates
(a) Fine aggregate shall be clean, hard, durable crushed rock, or natural sand,
complying with BS 882 except as specified herein.
(b) Coarse aggregate shall be clean, hard, durable crushed rock complying with
BS 882.
20.3.4 Admixtures
(i) Pigments for Portland cement and Portland cement products : BS 1014
(a) Concrete shall be a designed mix unless the Project Manager reviews without
objection the use of a standard or prescribed mix. Designed mixes shall be
designed by the Contractor. The Contractor shall select the mix proportions
with due regard to workability, strength, durability, temperature control and
other requirements stated in the Specifications and on the Employer's
Drawings. Prescribed mixes shall be in accordance with the requirements of
the Hong Kong Building (Construction) Regulations.
(b) The minimum design slump value for designed mix concrete for reinforced
elements, after the addition of superplasticiser if used, shall be as shown in
Table 20.1. Should the Contractor wish to use designed mix concrete with a
design slump value less than that shown in Table 20.1 in reinforced elements,
the Contractor shall submit his proposal to the Project Manager for review
without objection to demonstrate that such concrete can be satisfactorily
placed and compacted in trial sections simulating the appropriate sections of
the Works.
(c) Cement, PFA, aggregates, water and admixtures for concrete shall comply
with Clauses 20.5.1 to 20.5.5. All-in aggregate shall not be used.
(d) SRPC shall only be used if stated in the Contract. PFA shall not be used with
SRPC.
20 mm max. 40 mm max.
Degree of size size Uses of which Concrete is
Workability aggregate aggregate suitable
Slump (mm) Slump (mm)
Simply reinforced large
Low 12-25 25-50
sections with vibration
Moderately reinforced sections
Medium 25-50 50-100 with vibration, such as ordinary
beams and slabs
Sections with heavily
High 50-125 100-175 congested reinforcement
where vibration is difficult
(b) The total acid-soluble sulphate content of the concrete mix, expressed as
SO3, shall not exceed 4% SO3 by weight of the cement in the mix. The
sulphate content should be calculated as the various constituents of the mix.
The 4% limit does not apply to concrete made with supersulphated cement
complying with BS 4248.
Maximum total
Type of concrete
chloride content (%)
Prestressed concrete.
0.1
Steam-cured structural concrete
Concrete with reinforcement or other
embedded metal and made with
0.35
ordinary or rapid hardening Portland
cement.
(c) The maximum cementitious content of designed mix concrete for water
retaining structures and watertight structures shall be 400 kg/m³ for concrete
containing OPC and shall be 450 kg/m³ for concrete containing either OPC
and PFA or PPFAC. The maximum cementitious content of designed mix
concrete other than for water retaining structures and water tight structures
shall be 550 kg/m³.
(d) The cementitious content of designed mix concrete may be varied during
routine production at the discretion of the Contractor by an amount not
exceeding 20 kg/m³, provided that the total cementitious content is not less
than the specified minimum value and does not exceed the specified
maximum value.
(g) When microsilica and corrosion inhibitor admixtures are incorporated in the
concrete, mixing water used in the designed mix shall be adjusted in
accordance with the manufacturer’s recommendations.
(h) For prestressed concrete, the minimum cementitious content shall be 360
kg/m3 for 10 mm nominal maximum aggregate size and 300 kg/m3 for 40 mm
nominal maximum aggregate size.
Minimum cementitious
290 290 310 330 350 375 400
content (kg/m3)
(b) the total mass of dry aggregate to be used with 100 kg of OPC or with 110 kg
of PPFAC shall be as stated in Table 20.4;
(c) the percentage by mass of fine aggregate to total aggregate shall be as stated
in Table 20.5; and
(d) admixtures other than water-reducing admixtures shall not be used unless
reviewed without objection by the Project Manager.
Nominal maximum
Grade
aggregate size 40 20 10
Strength
(mm)
(MPa)
Slump value (mm) 85 –170 75 – 150 65 – 130
10 800 690 -
20 Mass of total 550 500 400
25 aggregate (kg) 490 440 360
30 440 380 300
Nominal
Grade Grading of fine
maximum
strength aggregate 40 20 10
aggregate size
(MPa) (BS 882: Table 5)
(mm)
10 C, M or F Percentage by 30 - 45 35 - 50 -
C mass 30 - 40 35 - 45 45 - 55
20, 25 of fine aggregate
M 25 - 35 30 - 40 40 - 50
or 30 to total aggregate
F 25 - 30 25 - 35 35 - 45
(%)
(ii) the nominal maximum aggregate size shall be 20 mm; not more than
15% by mass shall be retained on a 20 mm BS test sieve and not more
than 10% by mass shall pass a 10 mm BS test sieve;
(iv) the cement content shall be such that each particle of aggregate is
coated with cement paste but the compacted concrete has an open
texture which permits the flow of water through the hardened concrete.
(b) If the Project Manager requires cubes to be made of the no-fines concrete,
these shall be prepared and cured in accordance with the instructions given in
BS 1881: Part 113 and shall achieve a strength of 10 MPa when crushed.
(c) No-fines concrete shall be placed with the minimum of punning. No traffic
shall be allowed on the finished work and the surface shall be kept clean.
(d) Before placing normal concrete over no-fines concrete a layer of polyethylene
sheet of 500 grade or 0.5 mm thickness shall be laid over it and it shall be well
lapped to ensure that no mortar from the overlying concrete penetrates to the
no-fines concrete.
(i) cement;
(iii) natural stone aggregates including crushed rock and natural sand;
(v) water.
(b) Exceptionally special additives such as silica fume or ground granulated blast
furnace slag may be required to be incorporated in mixes, but if so required
this will be specified in the Specification.
(c) All materials used in concrete shall be fully identified and shall be traceable to
their sources of extraction or manufacture.
(e) Portland cements having a tricalcium aluminate (C3A) content for the previous
6 months production, which when calculated according to the procedure given
in ASTM-C-150 exceeds either 11.5% for any individual test result or an
average value of 11.0% shall not be used.
(f) The PFA content of PPFAC shall not exceed 25% by mass of the PPFAC.
20.5.2 PFA
PFA shall comply with BS 3892:Part 1 except that the criterion for maximum water
requirement shall not apply.
20.5.3 Aggregates
(a) Aggregates shall be obtained from a source reviewed without objection by the
Project Manager.
(b) Fine aggregate shall be clean, hard, durable crushed rock, or natural sand,
complying with BS 882, except that the note in Table 5 of BS 882 shall not
apply.
(c) Coarse aggregate shall be clean, hard, durable crushed rock complying with
BS 882. The ten percent fines value shall be at least 100 kN. The water
absorption shall not exceed 0.8%. The flakiness index shall not exceed 35%.
Materials & Workmanship Specification 7/53 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 20 – Concrete & Joints in Concrete
20.5.4 Water
(a) Water for concrete and for curing concrete shall be clean, uncontaminated
and from a source reviewed without objection by the Project Manager. The
Contractor shall test water proposed to be used to produce concrete in
accordance with the requirements of Clause 20.8.3.
20.5.5 Admixtures
(a) Admixtures will normally only be permitted if they are liquids and they shall be
measured by volume or weight. If the Project Manager has reviewed without
objection the use of a solid or paste admixture this shall be thoroughly
dispersed or dissolved in at least 10 times its weight of water so that it will be
distributed uniformly in the concrete before any concrete is placed. The water
used for dispersing the admixture shall be considered as part of the mixing
water in the concrete and shall be included in the calculation of the
water/cement ratio of the concrete.
(c) The chloride ion content of admixtures for concrete containing embedded
metal or for concrete made with SRPC shall not exceed 2% by mass of the
admixture or 0.03% by mass of the cementitious content, whichever is less.
(b) Curing compounds shall contain a fugitive dye. Curing compounds containing
organic solvents shall not be used. The curing compound shall become
stable and achieve the specified resistance to evaporation of water from the
concrete surface within 60 minutes after application. Curing compounds shall
not react chemically with the concrete to be cured and shall not crack, peel or
disintegrate within one week after application. Curing compounds shall
degrade completely within three weeks after application and the concrete
surface so treated shall not impair the bonding of applied finishes.
(c) Curing compounds for use on concrete surfaces against which potable or
fresh water will be stored or conveyed shall be non-toxic and shall not impart
a taste to the water.
(a) Materials for joints in water retaining structures and water tight structures for
sewage shall be resistant to aerobic and anaerobic bacteriological attack and
to attack by petrol, diesel oil, dilute acids and alkalis.
(b) Materials for joints in water retaining structures for potable and fresh water
shall be non-toxic and shall not impart taste and colour to the water.
Joint filler shall be a proprietary type reviewed without objection by the Project
Manager and shall be a firm, compressible, single-thickness, non-rotting filler. Joint
filler for joints in water retaining structures and watertight structures shall be
non-absorbent.
Bitumen emulsion for joints in water retaining structures and watertight structures
shall comply with BS 3416. Bitumen emulsion for surfaces against which potable or
fresh water will be stored or conveyed shall comply with BS 3416, Type II.
(a) Joint sealant shall be a grade suited to the climatic conditions of Hong Kong
and shall perform effectively over a temperature range of 0°C to 60°C. The
colour of all sealants in exposed areas shall be reviewed without objection by
the Project Manager. Joint sealant for exposed joints in water retaining
structures shall be grey.
(b) Joint sealant other than cold-applied bitumen rubber sealant shall be:
(i) a gun grade for horizontal joints 15 mm wide or less and for vertical and
inclined joints; and
(e) Hot-applied bitumen rubber sealant shall comply with BS 2499, Type A1.
(g) Joint sealant for joints in water retaining structures and watertight structures
shall be as stated in Table 20.6.
(i) Different types of joint sealant and primers which will be in contact, shall be
demonstrated as being compatible.
Table 20.6: Joint Sealant for Water Retaining Structures and Water Tight
Structures
Bond breaker tape shall be a proprietary type recommended by the joint sealant
manufacturer and reviewed without objection by the Project Manager. The tape
shall be a polyethylene film with adhesive applied on one side and shall be the full
width of the groove.
(a) Strip bearings shall be used where specified on the Employer's Drawings.
The preferred type of bearings shall consist of a polished stainless steel
sliding against a P.T.F.E. coated natural rubber strip blocked out either side
with expanded polystyrene spacer strips. Bearings shall be continuous over
the length of joint as indicated on the Employer's Drawings. Other proprietary
types of strip bearings may be submitted for review without objection by the
Project Manager.
(b) Pad bearings shall be used where specified on the Employer's Drawings. The
preferred type of bearings shall consist of a stainless steel top plate
roughened on the upper surface and polished on the lower, sliding against a
P.T.F.E. coated natural rubber/reinforced rubber pad, blocked out all around
with expanded polystyrene spacer blocks. Bearings shall be placed at the
centres indicated on the Employer's Drawings. Other proprietary types of pad
bearings may be submitted for review without objection by the Project
Manager.
20.5.13 Waterstops
≥ 250 250
200 - 250 200
< 200 150
20.6 SUBMISSIONS
(a) The following particulars of the proposed cement, PFA and aggregates shall
be submitted to the Project Manager for review without objection:
(i) a certificate applicable to the material to be supplied and not older than
6 months for each type of cement showing the manufacturer's name,
the date and place of manufacture and showing that the cement
complies with the requirements stated in the Contract and including
results of tests for:
• chemical composition;
• fineness;
• compressive strength at 3, 7 and 28 days;
• initial and final setting times;
• soundness; and
• proportion by mass of PFA contained in PPFAC.
• chemical composition;
• fineness; and
• moisture content.
(iii) a certificate applicable to the material to be supplied and not older than
6 months for each nominal maximum aggregate size showing the
source of the aggregate and showing that the aggregate complies with
the requirements stated in the Contract and including results of tests for:
• grading;
• silt content;
• chloride content;
• flakiness index of coarse aggregate;
• ten percent fines value; and
• water absorption.
(b) The following particulars of the proposed admixtures shall be submitted to the
Project Manager for review without objection:
• uniformity;
• chloride content; and
• details of toxicity.
(vi) a certificate showing the manufacturer's name, the date and place of
manufacture and showing that the curing compound complies with the
requirements stated in the Contract and including results of tests for
efficiency index.
(a) The following particulars of each proposed designed concrete mix shall be
submitted to the Project Manager for review without objection:
(i) quantity of each constituent per batch and per cubic metre of
compacted concrete, with required tolerances on quantities of
aggregates to allow for minor variations in grading, silt content etc. The
maximum permitted variation in the quantity of fine aggregate shall be
± 20 kg of fine aggregate per 100 kg of cement;
(v) grading details in tabular and graphical form of coarse and fine
aggregates, including combined grading curves; and
(vii) workability in terms of designed slump value before and after the
addition of superplasticisers;
(x) test or trial mix data for designed mix concrete of the same Grade and
with similar constituents and properties, if available;
(xi) test data for designed mix concrete of the same or other grade
produced in the plant or plants proposed to be used, if available; and
(a) The name of the suppliers and the location of each plant, including a back-up
plant, from which the Contractor proposes to obtain ready-mixed concrete
shall be submitted to the Project Manager at least 14 days before trial mixes
are made or, if trial mixes are not required, at least 30 days before the ready-
mixed concrete is programmed to be placed in the Permanent Works.
(b) The plant producing the concrete shall be operated in accordance with the
Quality Scheme for the Production and Supply of Concrete (QSPSC) of the
Hong Kong Quality Assurance Agency (HKQAA).
Particulars of the proposed batching and mixing plant to be used on Site, including
a layout plan and the output of the plant, shall be submitted to the Project Manager
for review without objection at least 28 days before the plant is delivered to Site.
(a) The method of manufacture of precast concrete units on or off Site shall be
reviewed without objection by the Project Manager before work commences.
No changes shall be made thereafter without prior review without objection by
the Project Manager.
(b) The following particulars of the proposed precast concrete units shall be
submitted to the Project Manager for review without objection:
(i) Contractor’s Drawings showing the full details of the elements including
dimensions, fixings, lifting points, reinforcement and chases;
• place of manufacture;
• proposed formwork systems and materials;
• method of placing and compacting concrete;
• method of curing concrete;
• proposed quality control procedures; and
• details of lifting points and methods of handling;
(vi) not more than seven days after the transfer of stress, a certificate
showing the force and extension in the tendons after anchorage, the
strength and age of the test cubes cast as described in this section and
the minimum age in hours of the concrete at the time the stress was
applied to the member; and
(c) The following particulars of the constructed precast concrete units shall be
submitted to the Project Manger for onward submission to the Buildings
Department:
(i) the date and place of manufacture, the identification numbers of the
precast concrete units and including results of tests for compressive
strength of concrete cubes at 28 days tested by a HOKLAS accredited
testing laboratory;
(iv) a copy of the site log book recording the date and time of inspections
and details of Site activities.
(a) The following particulars of the proposed concrete mix shall be submitted to
the Project Manager for review without objection:
(i) HOKLAS endorsed test certificates not older than 6 months giving the
results of tests required in Section 20.8.4(c)(ii) to (vi); and
(b) New HOKLAS endorsed test certificates giving the results of tests required in
Section 20.8.4(c)(ii) to (vi) shall be submitted at quarterly intervals together
with any necessary further calculations to demonstrate that the mix continues
to comply with the limit on reactive alkali.
(a) Trial mixes are not required for designed mix concrete of Grade 20 and below,
for standard mix concrete or for prescribed mix concrete.
(b) If test data for designed mix concrete of the proposed Grade and with similar
constituents and properties and produced in the plant or plants proposed to
be used are submitted in accordance with Section 20.6.2, and are reviewed
without objection by the Project Manager, no trials for that designed mix will
be required.
(c) If test data for designed mix concrete of the proposed Grade and with similar
constituents and properties produced in plant other than that proposed to be
used are submitted in accordance with Section 20.6.2, and are reviewed
without objection by the Project Manager, the Project Manager may require
plant trials to be carried out in accordance with Section 20.6.9.
(d) If test data for designed mix concrete produced in the plant or plants proposed
to be used, but of a Grade or with constituents and properties other than
those proposed, are submitted in accordance with Section 20.6.2, and are
reviewed without objection by the Project Manager, the Project Manager may
require laboratory mix trials to be carried out in accordance with Section
20.6.10.
(e) If no test data for designed mix concrete are submitted or if test data
submitted in accordance with Section 20.6.2 does not in the opinion of the
Project Manager demonstrate the suitability of the proposed plant and mix
design, the Project Manager may require both plant trials and laboratory mix
trials in accordance with Sections 20.6.9 and 20.6.10 respectively.
(f) Plant trials and laboratory mix trials shall be completed at least 35 days before
the concrete mix is programmed to be placed in the Permanent Works.
(g) The Contractor shall notify the Project Manager before conducting plant trials
or laboratory mix trials.
(a) Plant trials shall be made using the plant or plants proposed and the mix
designs and constituents submitted to and reviewed without objection by the
Project Manager.
(b) One batch of concrete of a proposed designed mix shall be made on each of
three days in each plant proposed to be used. The batch shall be at least
60% of the mixer's nominal capacity. If the concrete is batched in a central
plant and mixed in a truck mixer, three different truck mixers shall be used.
(e) Two 150 mm test cubes shall be made from each of the three samples taken
in accordance with Section 20.6.9(c) and stored, cured and tested to
determine the compressive strength at 28 days in accordance with CS1.
(a) Laboratory mix trials shall be made in the Contractor's laboratory using the
mix designs and constituents submitted to and reviewed without objection by
the Project Manager.
(b) Laboratory mix trials shall be carried out in accordance with Section 11 of
CS1. Three separate batches shall be made, each of sufficient size to
provide samples for two slump tests and to make six 150 mm test cubes.
(c) Two slump tests in accordance with CS1 shall be performed on separate
specimens from each batch of laboratory trial mix concrete.
(d) Six 150 mm test cubes shall be made from each batch of laboratory trial mix
concrete, stored, cured and tested for compressive strength at 28 days in
accordance with CS1.
(a) The results of tests on concrete taken from plant trials in accordance with
Section 20.6.9 shall comply with the following requirements :
(i) the average of the three slump values shall be within 20mm or 25%,
whichever is the greater, of the designed slump value;
(ii) the range of the three slump values for each batch of concrete shall not
exceed 20% of the average of the three slump values for that batch;
(iii) the average compressive strength at 28 days of the 6 test cubes shall
exceed the Grade strength by at least 10 MPa and the compressive
strength of each individual test cube shall exceed the Grade strength by
at least 4 Mpa; and
(iv) the range of the compressive strength of the six test cubes from each
batch of concrete shall not exceed 20% of the average compressive
strength of the six test cubes from that batch.
(a) When test data relating to the proposed plant or plants submitted in
accordance with Section 20.6.2 show that the plant standard deviation
exceeds 5 MPa, or in the absence of acceptable data, the results of tests on
laboratory trial mix concrete shall comply with the following requirements:
(i) the average of the six slump values shall be within 20 mm or 25%,
whichever is the greater, of the design slump value; and
(b) When test data relating to the proposed plant or plants submitted in
accordance with Section 20.6.2 show that the plant standard deviation does
not exceed 5 MPa, the results of tests on laboratory mix trial concrete shall
comply with the following requirements :
(i) the average of the six slump values shall be within 20 mm or 25%,
whichever is the greater, of the design slump value; and
(ii) the average compressive strength at 28 days of the 18 test cubes shall
exceed the Grade strength by at least 8 MPa and the compressive
strength of each individual test cube shall exceed the Grade strength by
at least 2 MPa.
Trial lengths required in accordance with Sections 10.5.2 to 10.5.5 and trial panels
required in accordance with Sections 18.5.2 and 18.5.3 shall be constructed for
each concrete mix as appropriate.
(a) If the result of any test for workability or compressive strength of laboratory
mix trial and plant trial concrete does not comply with the specified
requirements for the property, particulars of proposed changes to the
materials, mix design or methods of production shall be submitted to the
Project Manager for review without objection. Further laboratory mix trials or
plant trials shall be made until the result of every test complies with the
specified requirements for workability and compressive strength of laboratory
mix trial and plant trial concrete.
(b) If trial lengths or trial panels are constructed using the non-complying trial mix,
further trial lengths or trial panels shall be constructed.
(a) A concrete mix which complies with the specified requirements for laboratory
mix trials, plant trials and for trial lengths or trial panels is defined as an
"Acceptable Concrete Mix". The designed slump value used to produce an
"Acceptable Concrete Mix" shall become the "Acceptable Slump Value".
(b) If laboratory mix trials or plant trials are not required, a concrete mix submitted
as stated in Section 20.6.12 and which complies with the specified
requirements for trial lengths or trial panels shall become an "Acceptable
Concrete Mix". The designed slump value of the concrete mix shall become
the "Acceptable Slump Value".
(x) quantity of water in litres per cubic metre of concrete and the time of
introduction of water to the concrete;
(xi) moisture content of fine aggregate and amount of water subtracted from
the batch quantities to compensate for this;
(i) date;
(c) The Contractor shall submit to the Project Manager for review without
objection a statement covering the method of placing concreting at any one
location. The statement shall cover all items of plant to be used and their
respective layout and shall include the extent of bays, sequence of concreting
and proposals for stop ends. With respect to concrete temperature, the
Contractor shall submit to the Project Manager for review without objection a
detailed method statement of his proposed temperature control and
monitoring strategy and the substantiation of this strategy. The information to
be submitted shall include, but shall not be limited to, the following:
(i) concrete mix details including heat of hydration and specific heat
characteristics of the proposed constituents;
(a) The following particulars of the proposed materials for joints shall be
submitted to the Project Manager for review without objection:
(i) manufacturer's literature and a certificate for joint filler showing the
manufacturer's name, the date and place of manufacture and showing
that the joint filler complies with the requirements stated in the Contract
and including results of tests for;
(iii) manufacturer's literature for joint sealant, including details of the method
and time required for mixing the different components, and a certificate
showing the manufacturer's name, the date and place of manufacture
and showing that the sealant complies with the Specification and
including results of tests as appropriate for:
• rheological properties;
• plastic deformation;
• adhesion and tensile modulus;
Materials & Workmanship Specification 20/53 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 20 – Concrete & Joints in Concrete
• application life;
• adhesion in peel;
• loss of mass after heat ageing;
• staining;
• transverse butt joint movement range;
• extension;
• flow;
• penetration;
• degradation; and
• fire rating, where appropriate;
(iv) manufacturer's literature and a certificate for strip and pad bearings for
sliding joints showing the manufacturer's name, the date and place of
manufacture and showing that the strips comply with the Specification
and including results of tests for:
• vertical load;
• coefficient of friction; and
• a descriptions of the method of installation of bearings;
• density;
• hardness;
• tensile strength;
• elongation at break point;
• water absorption;
• softness number of PVC waterstops; and
• hydrophilic properties, where appropriate; and
(vi) particulars of primers and caulking material for joint sealant and of bond
breaker tape.
(a) Cement in bags shall be stored in a dry, weatherproof store with a raised
floor. Each delivery shall be identified and kept separate and shall be used in
the order of delivery.
(b) Bulk cement and PFA shall be stored in dry, weatherproof silos. Cement and
PFA of different types and from different sources shall be stored in separate
silos clearly marked to identify the different contents of each.
(c) The loading, unloading, transfer, handling or storage of bulk cement or dry
PFA during or after the debagging process must be done in a totally enclosed
system or facility. Any vent or exhaust shall be fitted with fabric filter or
equivalent air pollution control system or equipment.
(d) Consignments of cement and PFA shall be used in order of delivery. Any
cement stored for longer than one month shall be re-tested for moisture
content, soundness and setting time. Any PFA stored for longer than one
month shall be re-tested for moisture content.
(a) Aggregates shall not be handled or stored in a manner which will result in
mixing of the different types and sizes or in segregation or contamination of
the aggregates.
(b) Different types and sizes of aggregates shall be stored in separate hoppers or
in separate stockpiles. The stockpiles shall have well drained concrete floors
and shall have dividing walls of sufficient height to keep the different
aggregates separate.
(a) The identification number, date of casting and lifting points shall be marked on
precast concrete units in a manner reviewed without objection by the Project
Manager.
(b) Precast concrete units shall be lifted and supported only at the designed lifting
points and shall not be subjected to rough handling, shock loading or
dropping.
(c) Precast concrete units shall be stored off the ground on level supports and in
a manner which will not result in damage or deformation to the units or in
contamination of the units. Precast concrete units shall be protected from
damage and damaged units shall not be used in the Permanent Works.
(e) Precast units shall not to be lifted until at least 24 hours after casting or until
concrete has attained a strength adequate to resist the resultant stresses
without inducing cracking or other damage to the concrete.
(b) Measuring and weighing equipment for batching concrete shall be maintained
in a clean, serviceable condition and their accuracy shall be maintained within
the tolerances given in BS 1305. The equipment shall be checked regularly at
intervals reviewed without objection by the Project Manager and at a minimum
in accordance with the requirements of Appendix A20.4, Part 1. The accuracy
of the measuring equipment shall be within 3% of the quantity of cementitious
materials, total aggregates or water being measured and within 5% of the
quantity of admixtures being measured.
(c) The quantities of cement, PFA and fine and coarse aggregates shall be
measured by mass except that cement supplied in bags may be measured by
using a whole number of bags in each batch. The mass of aggregates shall
be adjusted to allow for the free moisture content of the aggregates.
(d) Separate weighing equipment shall be used for cementitious material and
aggregates.
(e) The quantity of water shall be adjusted for the free moisture content of the
aggregates and shall be measured by mass or volume.
(a) The quantities of concrete mixed and the speed of operation of a mixer shall
comply with the manufacturer's recommendations.
(b) A mixer shall not be loaded in excess of its rated capacity and shall be
emptied before being re-charged. A mixer which has been out of use for
more than 30 minutes shall be cleaned before fresh concrete is mixed in it.
Mixers shall be cleaned whenever there is a change in the type of cement
being used.
(c) Mixing times or the number and rate of revolutions of mixer drums shall be in
accordance with the recommendations of the manufacturer unless the
Contractor can demonstrate otherwise. Constituents shall be thoroughly
mixed and admixtures shall be uniformly distributed throughout the concrete.
(d) Water shall be added to truck mixed concrete at the batching plant and shall
not be added in transit or be added at Site.
Materials & Workmanship Specification 23/53 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 20 – Concrete & Joints in Concrete
(e) Superplasticising admixtures used with concrete mixed off Site shall be added
at Site.
(g) Partially hardened concrete shall not be remixed, with or without additional
cement, aggregate or water.
(c) Where an agitator is used for transporting concrete, the discharge shall be
completed within a period reviewed without objection the Project Manager.
The time of contact between cement and water shall be deemed to be the
loading time recorded on the delivery ticket.
Concrete shall not be placed in the Permanent Works until the concrete mix has
been reviewed without objection by the Project Manager.
(a) The Contractor shall notify the Project Manager before concrete is placed in
any part of the Permanent Works, allowing sufficient time for the Project
Manager to inspect the works which are to be concreted.
(b) Concrete shall be compacted in its final position within 1 hour of discharge
from the mixer unless carried in purpose made agitators, operating
continuously, when the time shall be within 2½ hours of the introduction of
cement to the mix and within 30 minutes of discharge from the agitator.
(c) Concrete which does not satisfy the compliance criteria for workability as
stated in Section 20.8.9 shall not be placed in the Permanent Works.
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Issue No. 5, Volume 1 – Civil & Structural Works
Section 20 – Concrete & Joints in Concrete
(d) Where it is necessary to deposit concrete under water, details of the methods,
equipment, materials and proportions of the mixes to be used shall be
submitted to the Project Manager for review without objection before the work
is commenced. Where the concrete is placed by a tremie, its size and method
of operation shall be in accordance with BS 8004. During and after concreting
under water, pumping or dewatering operations in the immediate vicinity shall
be suspended for a period which has been reviewed without objection by the
Project Manager.
(e) All formwork and reinforcement contained within it shall be clean and free
from standing water immediately before the placing of the concrete.
(f) Concrete shall be placed as close as practicable to its final position and shall
not be moved into place by vibration. Trunking or chutes shall be used to
place concrete which would otherwise fall more than 2.0 m. When trunking or
chutes are used they shall be kept clean and used in such a way as to avoid
segregation.
(g) Concrete shall be placed in such a manner that the formwork, reinforcement
or built-in components are not displaced.
(j) Concrete shall not be placed in ground or water which has a temperature
below 5°C.
(k) Where the ambient temperature is greater than 32°C full hot weather
concreting techniques as described in ACI document ACI 305R-89, Clauses
3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 4.1, 4.2 and 4.3 shall be implemented.
(m) Before concrete is placed on a rock foundation the rock surface shall be clean
and free from soft rock and loose rock, dust or other debris. The final
cleaning shall be done with air and/or water jets and excavation with hand
held tools.
(n) After the rock surface has been prepared and reviewed without objection by
the Project Manager and immediately before placing blinding or other
concrete, the surface of the rock shall be covered with a layer of grout 6 mm
thick. The grout shall have the consistency of a stiff paste and it shall be well
brushed over the rock and into all crevices.
(p) The temperature of concrete at the time of placing in the forms shall not be
more than 32°C. The Contractor shall submit details of the proposed
measures to ensure that this temperature will not be exceeded.
(r) The Contractor shall employ effective means such as pre-cooling the
aggregates and mixing water, as necessary, to maintain the temperature of
the concrete below 32°C prior to placing.
(s) After concrete has been placed its temperature shall not be permitted to rise
above 70°C.
(t) The maximum temperature gradient within any structure due to heat of
hydration taken at any two points one metre apart shall not exceed 15°C.
Irrespective of the thickness of a section the maximum temperature
differential between the core and the surface shall not exceed 20°C overall.
(u) Prior to laying slabs on ground a damp proof membrane shall be laid. The
damp proof membrane shall be a polythene sheet at least 0.3mm thick. Each
sheet of damp proof membrane shall be lapped at least 300mm at the edges
and sealed and taped to adjacent sheets. Sealing shall be achieved with
double sided mastic tape or similar as recommended by the manufacturer. All
punctures and tears shall be repaired prior to placing concrete.
(v) Damp proof membranes shall be lapped and sealed to vertical faces of walls
and slab edges by a minimum of 300mm or as shown on the Employer’s
Drawings.
(a) Concrete pumps shall be operated and maintained in accordance with the
manufacturer's recommendations. The pumps and pipelines shall be
maintained in a clean condition. Internal surfaces of pipelines shall not be
aluminum. Joints in pipelines shall not permit grout loss.
(b) Concrete pumps shall be positioned such that pipelines are as short and
straight as practicable and require as little repositioning as practicable. Bends
in pipelines shall be arranged in such a manner that the concrete, formwork,
reinforcement or built-in components are not disturbed.
(c) Pipelines shall be lubricated by passing cement grout or concrete through the
pipeline before the Permanent Works concrete is pumped. This initial
lubricating grout or concrete shall not be placed in the Permanent Works.
(a) Tremies used to place concrete shall be securely supported in position and
the joints shall be watertight. A temporary seal of a type reviewed without
objection by the Project Manager shall be used to keep the water and the
concrete separate at the start of concreting.
(b) After the concrete is flowing, the tremie shall be raised in a manner reviewed
without objection by the Project Manager; the lower end of the tremie shall be
kept immersed in the concrete to a depth of at least 1 m. Water, mud and
other deleterious material shall be prevented from entering the tremie after
concreting has started.
(c) If the tremie becomes blocked or is removed from the concrete, concreting
shall be stopped immediately. Concreting shall not recommence for at least
24 hours; contaminated concrete shall be removed before concreting
recommences.
(d) Concrete placed by tremie shall be placed above the specified level by an
amount to allow for the removal of concrete, including laitance and excess
cement slurry. Contaminated concrete shall be removed.
(c) Vibrators shall be used in such a manner that vibration is applied continuously
and systematically during placing of the concrete until the expulsion of air has
practically ceased. Vibrators shall not be used in a manner which will result in
segregation. Internal vibrators shall be inserted to the full depth of the
concrete placed and shall be withdrawn slowly.
(d) Vibration shall not be applied by way of the reinforcement, and contact
between internal vibrators and formwork, reinforcement or built-in components
shall be avoided as far as possible. Concrete shall be vibrated in such a
manner that the formwork, reinforcement or built-in components shall not be
displaced.
(e) Concrete which has been in position for more than 30 minutes shall not be
vibrated.
(a) The position and details of construction joints shall be arranged in such a
manner that the possibility of cracking due to shrinkage is minimized. The
Contractor shall submit a detailed method statement of its proposed pour
strategy and substantiation of this strategy to the Project Manager for review
without objection.
(b) Construction joints shall be normal to the axis or plane of the element being
constructed.
(e) The surface of the construction joint shall be clean and dry before fresh
concrete is placed against it.
(a) Concrete shall be protected against harmful effects, including those due to
weather, running water and drying out by one of the following methods:
(b) Method 1 shall not be used on concrete surfaces against which concrete will
be placed or which will have a Class T1 finish or which will be painted or tiled.
(e) Hessian, sacking, canvas and polyethylene sheeting shall be lapped and
securely held in position in such a manner that the concrete surface will not
be damaged.
(g) The different methods of protection shall be maintained for the minimum
periods stated in Table 20.8 after the concrete has been placed. The
minimum periods may, subject to review without objection by the Project
Manager, be reduced by the number of days during which formwork is left in
position.
(h) When the ambient temperature exceeds 32°C full hot weather curing
techniques as described in ACI document ACI 305R-89, shall be
implemented. Absorptive wood forms remaining in place shall not be
considered a satisfactory means of curing in hot dry weather. Such forms
shall be covered and kept moist.
(a) For all prestressed pretensioned members the length, cross section
dimensions and straightness of precast concrete shall be measured at 28 ± 2
days after casting;
(b) Unless otherwise stated in the Contract the allowable dimensional variations
for precast concrete units shall not exceed those given in Table 20.9.
Length Variation
Up to 3 m ± 6 mm
3 to 4.5 m ± 9 mm
4.5 to 6 m ± 12 mm
Additional for every subsequent 6 m ± 6 mm
Cross Section Variation
(each direction)
Up to 500 mm ± 6 mm
500 to 750 mm ± 9 mm
Additional for every
subsequent 250 m ± 3 mm
Straightness or bow Deviation
(deviation from intended line)
Up to 3 m 6 mm
3 to 6 m 9 mm
6 to 12 m 12 mm
Additional for every
subsequent 6 m 6 mm
(c) Where the Project Manager requires tests to be carried out on members
manufactured off-Site, no members to which the tests relate shall be
dispatched to Site until the tests have been completed and the results
reviewed without objection by the Project Manager.
(d) All members shall be indelibly marked to show the description of the member
as shown on the Employer's Drawings, the production line on which they were
manufactured, the date on which the concrete was cast and, if they are of
symmetrical section, the face that will be uppermost when the member is in its
correct position in the Permanent Works. The markings shall be so located
that they are not exposed to view when the member is in its permanent
position.
(e) Unless otherwise specified the vibrated top surface of precast concrete
members which will subsequently receive in-situ concrete shall be further
prepared by the following methods:
(i) when the concrete is self-supporting but still sufficiently green the
concrete surface shall be sprayed with a fine spray of water or brushed
with a stiff brush just sufficiently to remove the outer mortar skin and
expose the larger aggregate without disturbing it; or
(h) The joint surface shall be clean and damp but free of standing water
immediately before any fresh concrete is placed against it.
(a) Contact surfaces between in-situ concrete and precast concrete units shall be
prepared as stated in the Contract. Dimensional tolerances shall be checked
before the precast concrete units are lifted into position.
(d) Levelling devices which have no load bearing function in the finished structure
shall be slackened, released or removed after the precast concrete units have
been installed.
(a) Loads which will induce a compressive stress in the concrete exceeding
one-third of the compressive strength of the concrete at the time of loading or
exceeding one-third of the grade strength, whichever is less, shall not be
applied to concrete; allowance shall be made for the weight of the concrete in
determining the loading. The strength of the concrete and the stresses
produced by the loads shall be assessed by a method reviewed without
objection by the Project Manager.
(b) Loads from materials not forming part of the Permanent Works or from
Contractor's Equipment or other vehicles, shall not be applied to no-fines
concrete.
(a) Bitumen emulsion, joint sealant and primer for joint sealant shall be stored in
sealed containers marked to identify the contents and protected from
exposure to conditions which may affect the material. The materials shall be
stored in accordance with the manufacturers' recommendations and shall not
be used after the recommended shelf life has been exceeded.
(b) Joint filler, bond breaker tape and waterstops shall be stored in accordance
with the manufacturers' recommendations in a dry weatherproof store with a
raised floor. Absorbent joint filler shall be stored in sealed plastic bags and
shall not be exposed to moisture or air.
(a) Materials for joints shall be mixed and used in accordance with the
manufacturers' recommendations.
(b) Joint filler shall be cut to size before fixing and shall be securely fixed in
position to the existing concrete surface before concreting. There shall be no
gaps between the joint filler and formation.
(d) Joints shall be formed in straight lines perpendicular to the surface of the
concrete unless otherwise stated in Contract.
(e) Saw-cut joints shall be formed where shown on the Employer's Drawings, in
slab-on-ground areas. Joints shall be formed by use of a rotary-concrete saw
to the depths shown on the Employer's Drawings.
(a) Grooves for joint sealant shall be straight and shall be perpendicular to the
surface of the concrete. The bottom of the groove shall be flat and shall be
parallel to the surface of the concrete.
(b) Grooves shall be formed by using timber or other formers reviewed without
objection by the Project Manager and shall not be formed by cutting back or
raking out the joint filler. The grooves shall be located over the joint filler such
that the upper surface of the joint filler is entirely contained in the groove.
Before permanent sealing, grooves for joint sealant shall be protected from
contamination by a temporary sealing strip or cover.
(a) The permanent sealing of joints shall be carried out at least 7 days after
concreting.
(b) Immediately before permanent sealing, timber formers, temporary seals, dirt
and loose material shall be removed from the groove and the sides of the
groove shall be cleaned and roughened by water jetting or sand blasting.
(d) Bond breaker tape shall be fixed continuously and evenly along the bottom of
the groove for the full width and length of the groove.
(e) Concrete surfaces within 75 mm of the edges of the joint shall be masked with
tape before the primer is applied and until the sealing of the joint is complete.
(f) Primer for the joint sealant shall be applied to the sides of the groove in
accordance with the manufacturer's recommendations.
(g) Joint sealant shall be applied between the minimum and maximum drying
times of the primer recommended by the manufacturer. The components of
the sealant shall be thoroughly mixed in accordance with the manufacturer's
recommendations using a power operated paddle mixer for sufficient time to
produce a homogeneous mass without entrapped air. The sealant shall be
dispensed into the groove as soon as practicable after mixing and within the
time recommended by the manufacturer.
(h) The groove shall be clean and dry at the time of applying the primer and joint
sealant.
(i) Excess joint sealant shall be removed by using a purpose made finishing tool
such that the finished surface of the sealant is between 4 mm and 6 mm
below the face of the concrete.
(a) The concrete surface shall be prepared with a mortar pad as specified on the
Employer's Drawings. The mortar pad should be a minimum of 10 mm thick.
The top surface of the mortar pad must not deviate by more than 3 mm in 1 m
for strip bearings and no more than 2 mm across the mortar seating for pad
bearings. The thickness of the mortar pad shall be such as to allow the
bearing to be seated within the nominal 50 mm distance between concrete
bearing faces, without intrusion into the upper concrete element concrete
cover. The maximum thickness of mortar pad shall be 30 mm.
(b) The bearing shall be placed in position on the mortar pad and fixed in position
with epoxy adhesive of a type recommended by the bearing manufacturer and
reviewed without objection by the Project Manager.
(c) The areas around the bearing must be blocked out with a void former to
ensure that concrete, when poured in the upper element cannot contact the
lower concrete element.
(a) The line of straight joints shall be within 10 mm of the true line.
(b) The line of curved joints shall be within 10 mm of the true curved line.
(d) The depth of grooves for joint sealant shall be within 3 mm of the specified
depth.
Materials & Workmanship Specification 33/53 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 20 – Concrete & Joints in Concrete
20.7.26 Drilled in bolts
The Contractor shall survey by cover meter, chipping of the concrete cover or trial
drilling to the depth of the anchor bolt or bar anchorage to accurately identify the
positions of the reinforcement in the vicinity of the required drill holes. Where holes
clash with existing reinforcement, the Contractor shall submit this survey to the
Project Manager for his review without objection four weeks prior to the
commencement of fabrication of the base plates or other follow on work. The
Contractor shall repair all redundant drill holes and chipped concrete with a non-
shrink grout of equivalent strength to the concrete being investigated.
(a) One sample of each type of cement, PFA, aggregate, admixture, curing
compound and water shall be provided at the same time as particulars of the
material are submitted to the Project Manager for review without objection.
(b) The size of each sample and the method of sampling shall be as stated in
Table 20.10.
(a) Each sample of cement, PFA, aggregate, admixture, water and curing
compound shall be tested to determine the properties stated in Table 20.11.
(c) The maximum total sulphate and chloride content of concrete shall be
determined on the basis of the results of tests for chloride content of each
constituent.
(b) The reactive alkali content of concrete expressed as the equivalent sodium
oxide per cubic metre of concrete shall not exceed 3.0 kg.
Equivalent Na2O = A + B + C
(v) the total alkali content of the pulverised fuel-ash shall be determined in
accordance with BS 4550:Part 2:1970 (excluding amendment AMD
7285, July 1992) and shall be taken as the average of the latest 25 daily
determinations of equivalent sodium oxide plus twice the standard
deviation of the results; and
(vi) the equivalent sodium oxide content of the coarse and fine aggregates
shall be calculated from the quantity of chloride ion present which shall
be measured in accordance with BS 812:Part 4:1976.
(d) The following particulars of the proposed concrete mix shall be submitted for
review without objection by the Project Manger:
(i) HOKLAS endorsed test certificates not older than 6 months giving the
results of tests required in Clauses 20.8.4 (c) (ii)-(vi), with new HOKLAS
test certificates submitted at quarterly intervals together with any
necessary further calculations to demonstrate that the mix continues to
comply with the limit on reactive alkali; and
(a) One sample of concrete shall be provided from each batch of concrete to
determine the workability of the concrete.
(b) The size of each sample and the method of sampling shall be in accordance
with CS1 except that if a superplasticising admixture is included in the
concrete mix to produce flowing concrete, the sample shall be taken before
the superplasticiser is added.
(a) Each sample of concrete taken as stated in Section 20.8.7 shall be divided
into two specimens; each specimen shall be tested to determine the
workability of the concrete. The method of testing shall be the slump test in
accordance with CS1.
(b) The average of the two slump values shall be calculated and referred to as
the average slump value.
(a) The average slump value of the two specimens taken from one sample of
standard mix concrete shall be within the appropriate range stated in
Table 20.1.
(b) The average slump value of the two specimens taken from one sample of
designed mix concrete shall be within 25 mm or 33% of the "Acceptable
Slump Value", whichever is the greater.
(a) For each concrete mix, one sample of concrete shall be provided from each
amount of concrete as stated in Table 20.12 or from the amount of concrete
produced each day, whichever is less. The sample shall be selected at
random as follows:
(ii) in the case of ready-mixed concrete, at the point of discharge from the
delivery vehicle; or
(iv) in no case to be from the first 0.3 m3 of concrete discharged from the
truck.
(c) The size of each sample and the method of sampling shall be in accordance
with CS1. If a superplasticising admixture is included in the concrete mix, the
samples shall be taken after the superplasticiser is added and after the
concrete is remixed.
(a) Two 150 mm test cubes shall be made from each sample of concrete taken
as stated in Section 20.8.11. Each pair of test cubes shall be tested to
determine the compressive strength at 28 days.
(b) The method of making test cubes shall be in accordance with CS1.
(c) The method of storing test cubes shall be in accordance with CS1. Test
cubes which are cured on Site shall be delivered to the HOKLAS accredited
testing laboratory at least 48 hours before the tests are due to be carried out.
(e) For the purpose of assessing compliance of designed mix concrete as stated
in Sections 20.8.14 and 20.8.15, the average of the two compressive
strengths of the pair of test cubes shall be calculated and referred to as the
test result.
If the result of any test for compressive strength at 28 days of standard mix
concrete is less than the grade strength, the Project Manager may direct that tests
as stated in Sections 20.8.16 to 20.8.19 be carried out on concrete cores or on
samples taken from the hardened concrete.
The results of tests for compressive strength at 28 days of designed mix concrete
shall comply with Clause 59 of the Building (Construction) Regulations of Hong
Kong.
(b) The size of samples and the method of sampling shall be in accordance with
CS1.
(c) Cores shall be set out to avoid cutting steel reinforcement. .
(d) After coring, all coring locations shall be made good with non-shrink
cementitious grout with the same minimum compressive strength as at the
core location.
(a) Each concrete core shall be inspected for evidence of segregation of the
constituents and for the presence of voids. Specimens selected from each
core shall be tested to determine the compressive strength.
(b) The method of preparing and inspecting concrete cores and of testing the
cores to determine the compressive strength shall be in accordance with CS1.
Concrete cores shall not be tested for compressive strength until the concrete
has reached an age of 28 days.
(a) Concrete cores shall not show evidence of segregation. The extent of voids
in the core shall not be more than 'few' in accordance with Table 4 of CS1 and
there shall be no honeycombing.
(a) Each sample of hardened concrete shall be tested to determine the properties
or the composition of the concrete as stated in the Contract or, if testing is to
be carried out as a result of the concrete not complying with the specified
requirements, shall be tested as directed by the Project Manager.
(b) Tests on hardened concrete shall be carried out within 14 days of the Project
Manager's request for the test.
(d) When directed by the Project Manager, in-situ rebound hammer tests to
determine the strength of hardened concrete shall be undertaken in
accordance with BS EN 12504-2:2001.
A batch of precast units is any quantity of precast units, including prestressed units,
of the same type and size, of the same concrete mix, manufactured in the same
place, covered by the same certificates and delivered to Site at any one time.
The number of precast units to be provided for testing from each batch shall be as
stated in the Contract.
(a) Load tests shall be carried out to determine the deflection and recovery of
each precast unit, including prestressed units, provided for testing and to
determine the resistance to cracking of each prestressed unit provided for
testing.
(b) Load tests shall be carried out in accordance with a procedure submitted to
and reviewed without objection by the Project Manager. The age at which the
units are to be tested, the test load, the points at which the loads are to be
applied and the points at which the unit is to be supported shall be as stated
in the Contract or as proposed by the Contractor and reviewed without
objection by the Project Manager.
(d) Post-tensioned units shall not be tested until at least 7 days after the ducts
have been grouted.
The results of load tests on precast units shall comply with the requirements stated
in the Contract.
A batch of joint filler, joint sealant or waterstop is any quantity of joint filler, joint
sealant or waterstop of the same type, manufactured by the same manufacturer,
covered by the same certificates and delivered to Site at any one time.
(a) One sample of each type of joint filler, joint sealant or waterstop shall be
provided at the same time as particulars of the material are submitted to the
Project Manager for review without objection. One sample of each type of
material shall be provided from each batch of the material delivered to Site.
One sample of mixed joint sealant shall be provided on each day that joints
are sealed.
(b) The size of each sample of joint filler shall be sufficient to permit all tests
stated in Appendix A20.3 to be carried out.
(c) Samples of unmixed joint sealant and primers for joint sealant shall be taken
from sealed containers delivered to Site. Samples of mixed joint sealant shall
be taken immediately before the sealant is applied to the joint. The method of
sampling shall be as stated in BS 2499, Appendix A. The size of each sample
shall be as follows:
(a) Samples of joint filler shall be tested to determine the disintegration and
shrinkage, the recovery value and reduction in mass and the extrusion. The
method of testing shall be in accordance with Appendix A20.3.
(b) Samples of joint sealant shall be tested to determine the properties stated in
Table 20.13. The method of testing shall be as stated in Table 20.13.
Method of testing
Property
Rubber waterstops PVC waterstops
BS 2782:Part 6,
Density BS 903:Part A1
Methods 620A to 620D
BS 2782:Part 3,
Hardness BS 903:Part A26
Method 365D
BS 903:Part A2
BS 2782:Part 3,
Tensile strength and
Methods 320A to 320F
BS 903:Part A5
BS 903:Part A2
Elongation at BS 2782:Part 3,
and
break point Methods 320A to 320F
BS 903:Part A5
BS 2782:Part 4,
Water absorption BS 903:Part A18
Methods 430A to 430D
BS 2782:Part 3,
Softness number -
Method 365A
(a) The results of tests on joint filler shall comply with the following requirements:
(i) none of the three specimens in the weathering test shall show any sign
of disintegration or shrinkage;
(ii) each of the four specimens in the compression and recovery test shall
have a recovery value of at least 70%, and the reduction in mass of
each of the two new specimens shall not exceed 1%; and
(iii) the extrusion of the free edge of the specimen shall not exceed 6 mm as
determined by the extrusion test.
A20.1.1 Scope
This method covers the determination of the efficiency index of membrane forming
curing compounds for concrete.
A20.1.2 Materials
(i) Ordinary Portland cement complying with BS 12, specially selected for
testing admixtures and identified as 'CAA/BS 5075:Part 1 Reference
Portland Cement'; the cement shall be stored in an airtight container;
(ii) oven-dry natural sand with a rounded particle shape complying with
BS 882 and with the grading stated in Table A20.1.1; and
A20.1.3 Apparatus
(iv) spray equipment, such as the Wagner model W320 electric spray gun,
designed to permit the curing compound to be aspirated and applied
evenly to the specimen;
(v) an electrically driven mixer complying with Clause 8.3 of BS 4551 and
having a nominal capacity of 12 kg;
(viii) a metal tray with sides at least 3 mm high and an area equal to the
surface area of the specimen;
(i) three pairs of specimens shall be prepared, each pair comprising one
test specimen and one control specimen;
(iii) the sand and cement shall be placed in the mixer and mixed for
1 minute. The water shall be added and mixing continued for a further 4
minutes;
(iv) the two moulds shall be cleaned, lightly coated with the petroleum jelly,
mineral oil or release agent and weighed to the nearest 0.1 g (m1);
(vii) a uniform surface, free from undulations and surface defects, shall be
produced using the minimum number of passes of the metal screed
working along the length of the mould in both directions. The finished
surface shall be 7 mm ± 1 mm below the top of the mould;
(viii) the surface shall be brushed lightly with the paint brush to give an even
texture; and
(ix) The moulds and specimens shall each be weighed to the nearest
0.1 g (m2) immediately before the curing compound is applied.
(a) The procedure for determination of the efficiency index shall be as follows:
(i) a sample of the curing compound shall be taken by the method for
sampling admixtures in accordance with BS 5075:Part 1, Appendix A;
(ii) the sample shall be agitated thoroughly and the relative density
determined at room temperature with the hydrometer. The mass
required to give the coverage rate stated in Section A20.1.5(c) shall be
calculated from the relative density. The mass of the curing compound
applied shall be within ± 0.5 g of that required to give the specified
coverage rate;
(iv) the curing compound shall be applied to the test specimen one hour
after the specimen has been prepared, using the spray equipment or in
accordance with the manufacturer's recommendations. The curing
compound shall be shaken well before and during application. The
spray gun shall be held so that the nozzle is as near vertical as possible
and at a height which will result in uniform application and minimum
overspray. The specimen shall be coated uniformly by applying several
layers over the whole surface until the specified coverage is reached,
checked by repeated weighing. Over spray shall be wiped from the
exposed faces and edges of the mould. The whole application
procedure shall be completed in not more than 2 minutes;
(vi) the total time for making the specimens, coating the test specimen and
placing the pair in the cabinet shall not exceed 2 hours;
(vii) the specimens shall be kept in the cabinet for 72 hours ± 15 minutes
after application of the curing compound. Each specimen shall be
weighed to the nearest 0.1 g at 24 hours ± 15 minutes and 48 hours
± 15 minutes. Each specimen shall be weighed to the nearest 0.1 g (m4
and m5) at 72 hours ± 15 minutes; and
(viii) the metal tray shall be weighed to the nearest 0.1 g (m6) and coated
with the same quantity ± 0.5 g of curing compound used on the test
specimen. The coated tray shall be weighed to the nearest 0.1 g (m7)
and placed in the cabinet for 72 hours ± 15 minutes after application of
the curing compound. The tray shall be removed from the cabinet and
weighed to the nearest 0.1 g (m8).
A20.1.6 Calculation
(a) The proportion of solvent lost (V) by the curing compound during the test
period shall be calculated from the equation:
(m7 - m8)
V= ________
(m - m )
7 6
where:
(m2 - m5)
Wc = _______ x 100%
(m2 - m1)
where:
(c) The efficiency index (Et) of the curing compound shall be calculated for each
test specimen from the equation:
(Wc - Wt)
Et = ________ x 100%
Wc
The efficiency index (E) of the curing compound shall be calculated as the
average of Et for the three test specimens.
(iii) method of applying the curing compound and the type of spray gun
used;
(iv) rate of application of the curing compound to the nearest 0.01 L/m²;
A20.2.1 Scope
This method covers the determination of the deflection and recovery of precast
units, including prestressed units, and the resistance to cracking of prestressed
units by means of a load test.
A20.2.2 Equipment
(iii) equipment for measuring the loads applied, readable and accurate to
2% of the specified test load; and
(iv) equipment for measuring the deflection and recovery, readable and
accurate to 0.5 mm.
A20.2.3 Procedure
(iii) specified test load shall be applied at the specified loading points in not
less than ten approximately equal increments;
(iv) specified test load shall be maintained for 5 minutes and removed in not
less than five approximately equal decrements;
(v) deflection at mid-span shall be measured for each load increment and
each load decrement and 5 minutes after the loads have been removed;
(ii) the age of the concrete in the precast unit at the time of the test;
A20.3.1 Scope
This method covers the determination of the disintegration and shrinkage of joint
filler, by weathering test, the recovery value and reduction in mass of joint filler by
the compression and recovery test, and the extrusion of joint filler by the extrusion
test.
A20.3.2 Apparatus
(i) equipment for measuring the size of the joint filler, readable and
accurate to 0.5mm;
(iv) watertight weathering test pan with a ribbed bottom and a fitted slotted
lid designed to hold 3 specimens of joint filler vertically on edge;
(v) refrigerator;
(vi) equipment for measuring the thickness of the joint filler readable and
accurate to 25 μm;
(ix) extrusion mould open on one side only and rigidly fixed to a base
plate. The mould shall be 100 mm x 100 mm (+ 0.5 mm, - 0 mm)
internally and shall be of sufficient depth to test the specimen. The
mould shall be provided with a close fitting pressure plate which shall
fit without binding and with a horizontal measuring dial gauge or
device readable and accurate to 25 μm.
(a) The procedure for determination of the disintegration and shrinkage by the
weathering test shall be as follows:
(i) 3 specimens from the sample shall be prepared, each 115 mm x 115
mm (± 2.5 mm);
(iii) specimens shall be placed in the test pan and the pan shall be filled
with water to half the depth of the specimens;
(v) after the fifth cycle, the specimens shall be removed from the test pan
and air dried at room temperature for 48 hours; and
(a) The procedure for determination of the recovery value and reduction in mass
by the compression and recovery test shall be as follows:
(ii) thickness (t1) of the four specimens shall be measured to the nearest
0.1 mm, and two specimens shall be weighed to within 0.1% of their
mass (m1);
(iv) after the third application of load, a recovery period of 30 minutes shall
be allowed and the thickness (t2) of each specimen shall be measured
to the nearest 0.1 mm; and
(a) The procedure for determination of the extrusion by the extrusion test shall be
as follows:
(ii) thickness of the specimen shall be measured to the nearest 0.1 mm;
and
(iii) specimen shall be placed in the extrusion mould and subjected to one
application of load as stated in Section A20.3.4(c). The extrusion at
the open side of the mould shall be measured to the nearest 0.1 mm
with the gauge or device when the specimen is compressed to 50% of
the original thickness and before the load is released.
A20.3.6 Calculation
(a) The recovery value (R) of each specimen shall be calculated from the
equation:
R = t 2/t1 x 100 %
where:
- t2 is the thickness of the specimen after the third application of load (mm)
(b) The reduction in mass (M) of each specimen shall be calculated from the
equation:
where:
- m2 is the mass of the specimen after the third application of load (g)
Maintain all hoppers and doors in clean and efficient working order.
Remove any cement or concrete build-up in mixer.
Shake out cement silo filler sock and maintain in efficient working order.
Clean knife edges on weighing equipment.
Check calibration of moisture meter.
Inspection and testing of all weigh scales over their complete range.
21.1 GENERAL
Materials for grout for prestressing systems shall comply with Section 20 except as
stated in this Section.
21.2.1 Duct
(i) an individual steel wire, wire strand or alloy steel bar in a duct, or
(ii) an individual steel wire, wire strand or alloy steel bar not in a duct, or
21.2.4 Sheath
Sheath is a tube or lining which is used to form a duct and which is left in place.
21.3 MATERIALS
(b) Steel wire and wire strand shall be in coils of sufficiently large diameter to
allow the steel wire and wire strand to pay off straight, without any permanent
set or bends.
(b) Prestressing anchorages shall comply with BS 4447 and shall allow a
minimum of 25 mm cover to cropped ends of prestressing tendons.
21.3.3 Sheaths
(a) Sheaths shall be a proprietary type reviewed without objection by the Project
Manager and shall be steel or other material reviewed without objection by the
Project Manager. Sheaths shall be rigid and strong enough to retain their
shape during fixing and concreting and to withstand forces from the
prestressing tendons without damage.
(b) The design of ducts shall allow for grout to be injected from either end. There
shall be no sudden changes in the diameter of the duct.
Taps for grout vents in ducts shall be a proprietary type reviewed without objection
by the Project Manager and shall allow closure of the vents without loss of pressure
in the duct. Vents to be used as grout entry points shall be threaded or fitted with
screw connectors or other similar devices for connection to grout pumps.
(a) Grout for prestressing systems shall consist of ordinary Portland cement and
water. Sand, PFA and admixtures shall not be used unless otherwise
specified in the Contract, or reviewed without objection by the Project
Manager.
(c) The amount of bleeding of grout shall not exceed 2% in the first 3 hours and
shall not exceed 4% in total; the water shall be reabsorbed by the grout during
the 24 hours after mixing.
(d) Free expansion of grout shall not exceed 10% at the ambient temperature.
(g) Grout shall have a water cement ratio as low as possible consistent with the
necessary workability and under no circumstances shall the water cement
ratio exceed 0.45.
(a) Each prestressing tendon shall be tagged with a number to identify the coil or
bundle number of the prestressing tendon used.
(b) Prestressing tendons and sheaths shall be stored off the ground on level
supports and in a manner which will not result in damage or deformation to
the materials or in contamination of the materials.
21.4 SUBMISSIONS
(iv) a certificate showing that the tensioning apparatus has been tested and
calibrated by an agent reviewed without objection by the Project
Manager within a period of two years before the apparatus is to be
used;
(vi) details of corrosion protection required for the prestressing system; and
(b) Calculations for loss of prestress due to creep shall be based on the
information stated in the Contract.
(a) The following particulars of the proposed grout mix and grouting procedure for
prestressing systems shall be submitted to the Project Manager for review
without objection:
21.5 WORKMANSHIP
(a) Prestressing operations shall be carried out with due regard to the energy
stored in a stressed tendon.
(a) Prestressing tendons from each batch shall not be installed until testing of the
batch has been completed.
(b) Steel wires, wire strands and alloy steel bars which will be tensioned in one
operation shall be taken from the same batch.
(c) Individual steel wires and wire strands in the same duct shall not be twisted
together. Strands which have become unravelled shall not be used.
(d) Alloy steel bars which have become bent shall not be straightened. Small
adjustments for straightness may be made provided the straightening is
carried out at the ambient temperature by non-mechanical methods and
provided that no force is applied on the threaded portion. Bars which have
become bent in the threaded portion shall not be used.
(e) After manufacture, prestressing tendons shall not be welded and heat
treatment, work-hardening, galvanizing and other metallic coatings shall not
be applied. Prestressing tendons which have been damaged mechanically or
by work-hardening or heating shall not be used.
Prestressing tendons shall be cut using either a high speed abrasive cutting wheel
or a friction saw. Flame cutting shall not be used.
At the time of tensioning, sheaths shall be free from dents or other irregularities
which may affect tensioning.
(a) Joints in sheaths shall be securely taped to prevent penetration of the duct by
concrete or grout. Joints in adjacent sheaths shall be staggered by at least
300 mm.
(b) Where sheaths are used, the number of joints shall be kept to a practicable
minimum and sleeve connectors shall be used for jointing.
(a) Grout vents and taps shall be provided at the following positions:
(b) Vents shall not be placed at positions where they will be blocked by the
prestressing tendons after tensioning.
(a) Apparatus for tensioning prestressing tendons shall impose a controlled total
force gradually and shall not induce excessive secondary stresses in the
prestressing tendons, prestressing components, structure or element to which
prestress is being applied.
(c) Steel wires or wire strands which are tensioned simultaneously shall be
approximately the same length between anchorage points.
(d) The force in the prestressing tendons during tensioning shall be measured by
direct reading load cells or obtained indirectly from pressure gauges fitted in
the hydraulic system. Load measuring devices shall be accurate to within 2%.
(f) Tensioning apparatus and load measuring devices shall be calibrated before
tensioning starts and at regular intervals reviewed without objection by the
Project Manager.
(g) The force in the prestressing tendons shall not be transferred to the concrete
until the concrete has reached the specified transfer strength.
21.5.10 Pretensioning
(a) The stress in prestressing tendons shall be fully maintained during the period
between pretensioning and transfer of stress. Transfer of stress shall take
place gradually to minimise shock or damage to the transmission length and
shall be carried out in conjunction with the release of any hold-down and hold-
up forces in tendon deflectors.
21.5.11 Post-tensioning
(a) A tensioning schedule shall be submitted to the Project Manager for review
without objection at least 7 days before each post-tensioning operation starts.
The schedule shall include the proposed sequence of tensioning the
prestressing tendons, the required prestressing loads and the calculated
extensions of the prestressing tendons.
(b) Spacers used with post-tensioned steel wire or wire strand which are not
tensioned simultaneously shall be sufficiently rigid to ensure that they will not
be displaced during successive tensioning operations.
(c) If both ends of the prestressing tendon are free to move, a demonstration
shall be carried out before post-tensioning starts to show that all prestressing
tendons are free to move in the ducts.
(f) Measurement of extensions shall not commence until any slack in the
prestressing tendon has been taken up. If the design permits, the draw-in of
prestressing tendons at the non-jacking end shall also be measured. The
tensioning shall be applied in increments of load and the extensions shall be
measured at each increment. The average measured extension of the
prestressing tendons shall be within 5% of the calculated extension and the
measured extension of individual prestressing tendons shall be within 10% of
the calculated extension.
(h) If the pull-in of the tendons at completion of anchoring is greater than that
agreed by the Project Manager, tensioning shall be carried out afresh.
(i) The Project Manager may direct that the force in any strand or wire be tested
by re-jacking. The strand or wire shall than be re-anchored at the proper
tension.
(j) When the prestressing has been applied, the tendons shall be anchored. The
jack pressure shall then be released in such a way as to avoid shock to the
anchorage, tendons, or concrete.
(c) Grout pumps shall be fitted with a safety valve to prevent the build-up of
excessive pressure. The connection of the pump to the duct shall be by a
screw connector or other positive method. Baffles to the pump shall be fitted
with 1.18 mm sieve strainers; suction circuits shall be airtight.
(d) Grouting equipment shall be thoroughly washed through with clean water after
every series of grouting operations and at the end of use each day.
Grouting of prestressing tendons shall be effective such that the duct is completely
filled and the prestressing tendon is completely surrounded with grout.
(a) The Contractor shall notify the Project Manager before prestressing tendons
are grouted and when required, shall allow the Project Manager sufficient time
to inspect the tendons which are to be grouted.
(c) Immediately before grouting starts, the ducts shall be thoroughly washed by
pumping clean water through the ducts. The water shall flow through all grout
vents. Partial or complete blockage of grout vents shall be cleared before
grouting starts. After washing, the ducts shall be blown dry with oil-free
compressed air.
(d) Grout shall be used within 30 minutes of mixing unless a retarding agent
reviewed without objection by the Project Manager is incorporated in the
grout. If a retarding agent is used, the time shall be determined by a test
procedure reviewed without objection by the Project Manager.
(e) The grout pressure applied shall be as low as practicable and shall not
exceed 1 MPa. Grout shall be injected from the lower end of ducts. Grout
injection shall be continuous and steady and shall be at a rate which will avoid
grout segregation and trapping air in the duct. Grout shall be allowed to flow
from each of the grout vents until its consistency is equivalent to that of the
grout injected. After the last grout vent has been closed, the pressure shall be
maintained at 0.5 MPa for 5 minutes. The injection vent shall then be closed
under pressure.
(g) The filled ducts shall be protected to the satisfaction of the Project Manager to
ensure that:
(i) they are not subjected to shock or vibration within 48 hours of grouting;
(ii) the grout has achieved a strength of not less than 15 MPa before any
additional load, arising from the movement of Temporary Works or any
construction activity, is applied to concrete containing them; and
(iii) the temperature of the grout does not fall below 3 C for 3 days after its
injection.
(h) The level of grout in grout vents shall be inspected and made good as
reviewed without objection by the Project Manager. Making good shall not be
carried out until at least 2 days after grouting.
(i) Ducts shall not be grouted when the air temperature in the shade exceeds
32 C or is below 3 C. The temperature of the grout at the point of injection
shall not exceed 25 C.
(k) The Contractor shall radiographically test grouted ducts if directed by the
Project Manager.
(a) Records of grouting operations for prestressing systems shall be kept by the
Contractor on Site and a report shall be submitted to the Project Manager for
review without objection within 3 days of each grouting operation. The report
shall contain the following details:
The line of sheaths shall be within 5 mm of the specified line as shown on the
Employer’s Drawings. Sheathing near concrete surfaces shall not infringe the
specified tolerance on concrete cover.
(a) A trial mix for grout for prestressing systems shall be made to demonstrate
that the proposed materials, grout mix and methods of production will produce
grout which complies with the specified requirements.
(b) The trial mixes shall be completed at least 10 days before the grout mix is
used in the Permanent Works.
(c) The Contractor shall notify the Project Manager before making trial mixes.
(d) Trial mixes shall be made using the materials, grout mix and methods of
production which have been reviewed without objection by the Project
Manager.
(a) One sample of grout shall be provided from the trial mix to determine the
amount of bleeding and free expansion of the grout. The method of sampling
shall be as stated in Clause 21.6.23(b).
(b) One sample of grout shall be provided from the trial mix to determine the
crushing strength of the grout. The method of sampling shall be as stated in
Clause 21.6.26(b).
(a) Each sample of grout taken as stated in Clause 21.6.2(a) shall be tested to
determine the amount of bleeding and free expansion. The method of testing
shall be as stated in Clause 21.6.24(b).
(b) Each sample of grout taken as stated in Clause 21.6.2(b) shall be tested to
determine the crushing strength. The method of testing shall be as stated in
Clause 21.6.27.
(a) If the result of any test for amount of bleeding, free expansion or crushing
strength of trial mixes for grout does not comply with the specified
requirements for the property, particulars of proposed changes to the
materials, grout mix or methods of production shall be submitted to the Project
Manager for review without objection. Further trial mixes shall be made until
the result of every test complies with the specified requirements for the
property.
(b) If grouting trials are carried out using a non-complying trial mix, further
grouting trials shall be carried out.
(a) Grouting trials for grout for prestressing systems shall demonstrate that the
proposed materials, grout mix, methods of production and methods of
construction produce a grouted duct which complies with the specified
requirements.
(b) Grouting trials shall be completed at least 7 days before grouting starts.
(c) The Contractor shall notify the Project Manager before carrying out grouting
trials.
(d) Grouting trials shall be carried out using the materials, grout mix, methods of
production and methods of construction, which have been reviewed without
objection by the Project Manager.
(e) The profile of ducts and the method of support for grouting trials shall be
submitted to and reviewed without objection by the Project Manager. Vents
shall be provided in ducts and tendons shall be pulled tight.
Three sections selected by the Project Manager shall be cut from the grouted duct
and inspected not less than 2 hours after the grout used in the grouting trial has
achieved its final set.
The sections of grouted duct cut in grouting trials shall be completely filled and the
prestressing tendon shall be completely surrounded with grout.
If the result of any test on sections of grouted duct cut in grouting trials does not
comply with the specified requirements for the test, or if in the opinion of the Project
Manager any aspect of the grouting procedure as demonstrated by the grouting trial
is unsatisfactory, particulars of proposed changes to the materials, grout mix,
methods of production or methods of construction shall be submitted to the Project
Manager for review without objection and further grouting trials shall be carried out
until the result of every test on sections of grouted duct complies with the specified
requirements for the test and until in the opinion of the Project Manager every
aspect of the grouting procedure is satisfactory. Further trial mixes for grout shall
be made unless in the opinion of the Project Manager non-compliance of the
grouting trial was not due to the grout mix.
A grout mix which complies with the specified requirements for trial mixes for grout
and for grouting trials is defined as an "Acceptable Grout Mix".
Grouting shall not proceed until the grout mix and grouting procedures have been
reviewed without objection by the Project Manager.
The Contractor shall allow sufficient time for the Project Manager to inspect the
completed prestressing system before carrying out any work, including concreting
and grouting, which will make access to the prestressing system difficult. The
Contractor shall notify the Project Manager before carrying out such work.
(d) Each specimen shall be taken from different coils or bars in the batch. The
ends of specimens shall be cut square without unravelling of wires and loose
mill scale and rust shall be removed by wire brushing before delivery to the
laboratory.
High tensile steel wire and strand for the prestressing of concrete : BS 5896
Hot rolled and hot rolled and processed high tensile alloy
steel bars for the prestressing of concrete : BS 4486.
(c) Tests shall be carried out on specimens having a temperature between 5°C
and 30°C.
(a) The standard deviations of the results of tests for characteristic breaking load
and characteristic 0.1% proof load, expressed as equivalent stress values, of
prestressing tendons shall not exceed the following:
(b) The statistical interpretation of the test results shall be in accordance with
BS 2846:Part 3, Table 3 and BS 2846:Part 4, Table E, both for a one-sided
tolerance interval of 0.95 and for a confidence level of 0.95.
(a) If the result of any test for elongation at maximum load, diameter,
cross-sectional area, unit mass, modulus of elasticity or ductility of
prestressing tendons does not comply with the specified requirements for the
property, one additional sample shall be provided from the same batch and
additional tests for the property shall be carried out.
(c) The batch shall be considered as not complying with the specified
requirements for the property if the result of any additional test does not
comply with the specified requirements for the property.
(a) Unless otherwise stated in the Contract, the Contractor shall test, at an early
stage of the Contract, two in-place tendons in order to accurately determine
friction loss.
(b) Prestressing tendons shall be tensioned from one end and the tendon force
shall be measured at both the jacking and non-jacking ends.
(c) The tendon force at the non-jacking end shall be measured by direct-reading
load cells or by a dummy jack of a type reviewed without objection by the
Project Manager. A direct-reading load cell or a dummy jack is considered to
be suitable as a load-measuring device. The load-measuring device shall be
sufficiently rigid to ensure that the movement of the prestressing tendon at the
non-jacking end under the specified tendon force is not excessive. The
deflection of the load-measuring device shall be measured to an accuracy of
0.5 mm. A load-measuring device with a deflection exceeding 10 mm under
the maximum load shall not be used.
(d) The prestressing tendon shall be tensioned to the specified tendon force in
equal increments and the tendon extensions at the jacking end and the
tendon force and tendon movement at the non-jacking end shall be measured
to within 5 mm. The number of load increments shall be suited to the
tensioning operation but shall be at least five.
The force at the non-jacking end of the prestressing tendon determined in the duct
friction test shall be within +10% and -5% of the calculated value.
(a) Reports of duct friction tests shall be submitted to the Project Manager for
review without objection within 3 days of each test. The report shall contain
the following details:
(iii) graph showing tendon forces at jacking end against tendon forces at
non-jacking end; and
A batch of grout for prestressing systems is any quantity of grout produced in one
cycle of operation of a mixer.
(a) For each grout mix one sample of grout shall be provided from each 25
batches of grout, or from the amount of grout produced in one day, whichever
is the lesser, to determine the amount of bleeding and free expansion of the
grout.
(b) Samples shall be provided and testing shall commence within one hour after
the grout has been mixed. Samples shall be protected from rain before the
tests.
(a) Each sample of grout taken as stated in Clause 21.6.23 shall be divided into
three specimens; each specimen shall be tested at a temperature of 20°C to
determine the amount of bleeding and free expansion.
If the result of any test for amount of bleeding or free expansion of grout for
prestressing systems does not comply with the specified requirements for the
property, particulars of proposed changes to the materials, grout mix or methods of
production shall be submitted to the Project Manager for review without objection.
Upon review further trial mixes shall be made and further grouting trials shall be
carried out.
(a) For each grout mix one sample of grout shall be provided from each 25
batches of grout, or from the amount of grout produced in a day, whichever is
the lesser, to determine the crushing strength of the grout.
(b) Samples shall be provided not more than 1 hour after the grout has been
mixed and shall be protected from rain before test cubes are made.
(a) Two 100 mm test cubes shall be made from each sample of grout taken as
stated in Clause 21.6.26 (a). Each pair of test cubes shall be tested to
determine the crushing strength at 7 days.
(b) The method of making, curing and testing the test cubes, and the calculation
of the test results, shall be as stated in Clause 20.8.12(b), (c), (d) and (e),
except that compaction of the grout is not required.
If the result of any test for crushing strength of grout for prestressing systems does
not comply with the specified requirements for crushing strength, particulars of
proposed changes to the materials, grout mix or methods of production shall be
submitted to the Project Manager for review without objection. Upon review further
trial mixes shall be made and further grouting trials shall be carried out.
22.1 GENERAL
(a) Allowances shall be made for the deformation due to permanent loads and
the process and sequence of fabrication, erection and construction such that
steelwork is completed to within the specified tolerances.
(b) The dimensions shown on the Employer’s Drawings show the required as-
constructed position after deflections due to self weight and superimposed
dead loads. The Contractor shall determine any pre-set deflection or camber
that may be necessary to ensure that the as constructed position is within the
specified tolerances.
(c) The compatibility of the dimensions and setting-out data of steelwork shall be
verified by the Contractor before the materials for steelwork are ordered.
The use of steelwork shall comply with the Code of Practice for the Structural Use
of Steel, Hong Kong. BS 5950:Part 1 & 2:1990 may be used provided the specific
requirements as outlined in the Practice Note for Authorized Persons and
Registered Structural Engineers (PNAP) No. 160 apply.
Delete line 1 of text and insert 'the hardness of the edge is reduced to less
than 350 HV 30 of BS 427 by a suitable heat treatment'.
(f) Page 4, Clause 4.7.1, paragraph 2, line 4:
'The Contractor shall determine the dead load camber of beams required to
comply with Section 22.1(a) of this Specification. The camber of plate girders
shall be formed by either of the two following alternatives, whichever is stated
in the Contract:
Type A camber shall be used if the alternative to be used is not stated in the
Contract.
(a) Steel for cold formed sections shall comply with BS 1449:Part 1 with the
quality grades as stated in the Contract.
(b) Steel for cold formed hollow sections shall comply with BS 6363 with quality
grades as stated in the Contract.
(c) Pre-galvanized steel sheet shall comply with BS 2989 with quality grades as
stated in the Contract.
Steel for headed stud type shear connectors shall have a yield stress of at least
385 N/mm2 and an ultimate tensile strength of at least 450 N/mm2. Steel for other
types of shear connectors shall comply with BS 4360.
(a) Bolts, screws and nuts shall comply with the British Standards and strength
grades stated in Table 22.1 unless stated otherwise in the Contract.
(b) Washers for high strength friction grip bolts and nuts shall comply with the
following:
(i) high strength friction grip bolts and associated nuts and washers for
structural engineering :
• general grade : BS 4395:Part 1;
• higher grade bolts and nuts and
general grade washers : BS 4395:Part 2; and
• higher grade bolts (waisted shank),
nuts and general grade washers : BS 4395:Part 3;
(ii) load indicating washers for high strength friction grip bolts and nuts shall
be "Coronet" type manufactured by Cooper and Turner or equivalent
reviewed without objection by the Project Manager; and.
(c) The surface finish for bolts, screws, washers and nuts shall comply with the
following:
(b) Welding consumables and the procedures used shall be such that the
mechanical properties of the deposited weld metal shall not be less than the
respective minimum values of the parent metal being welded.
(c) Welding consumables used with grades of steel other than those complying
with BS 4360 shall be such that the performance requirements stated in
BS 5400:Part 6, Table 1 or BS 5950:Part 2, Table 1 as appropriate are
achieved.
(d) Electrodes for welding Grade 50 and Grade S355 steels shall be capable of
depositing no more than 15 ml of diffusible hydrogen per 100 g of deposited
weld metal, as defined in BS 639.
(e) Covered electrodes for manual metal arc welding shall comply with BS 639.
(f) Filler wires for gas-shielded welding shall comply with BS 2901:Part 1.
Rolled steel pins, including those made from slabs, shall comply with BS 970:Part 1
or BS 4360, Grades 43, 50 or 55.
Table 22.1 : British Standards And Strength Grades For Bolts, Screws And
Nuts
Steel forgings and forged steel pins shall comply with BS 29.
(a) Wrought stainless steel shall comply with BS 970:Part 1, Grade 316 S 16.
(b) Flat rolled stainless steel shall comply with BS 1449:Part 2, Grade 316 S 16 in
the softened condition.
(c) Stainless steel tubes shall comply with BS 6323:Part 1 and BS 6323:Part 8,
designation LW 23 GZF(S).
(d) Stainless steel bolts and nuts shall comply with BS 6105, steel Grade A4 and
property class 80. Stainless steel washers shall comply with BS 1449:Part 2,
Grade 316 S 31 in the softened condition. The dimensions and tolerances of
bolts and nuts shall comply with BS 3692. The dimensions and tolerances of
tapered washers shall comply with BS 3410 and the dimensions and
tolerances of flat washers shall comply with BS 4320, Form C.
(a) Grout for bedding steel bases and for filling bolt pockets and pocket bases
shall be cementitious materials based on OPC and shall have the same or
greater grade strength as the surrounding foundation concrete. The grout
shall contain a non-metallic expanding admixture and shall have a total
chloride content of not more than 0.1% by mass of cement.
(c) A dry packed mortar may be used for bedding steel bases which exceed
75 mm thick. The mortar shall be cementitious material having the same
grade strength of the surrounding concrete and be suitable for thorough
ramming against supports such that the space is completely filled.
(d) Grout for filling pocket bases shall be a mix reviewed without objection by the
Project Manager with a nominal maximum aggregate size of 10 mm and have
the same grade strength as the surrounding concrete.
Lubricant for lubricating nut threads of HSFG bolts shall be a wax based type
reviewed without objection by the Project Manager. Machine oil and other free
flowing lubricants shall not be used.
(a) Unless otherwise stated in the Contract paint for steelwork shall comply with
BS 5493, Section 2, Table 4. Organic zinc-rich paint shall comply with
BS 4652. Lead-based paint shall not be used for finishing coats.
(b) Paint shall be supplied in sealed containers of not more than 5 litres capacity.
Each container shall be marked on the side to show the following:
(iv) batch number, date of manufacture, expiry date and pot life; and
(a) All steelwork shall be clearly marked for identification and erection purposes
as:
(iv) marking for erection purposes: The Contractor shall tag, hard stamp or
pencil weld each member with an individual identification mark, which
can not be obliterated by surface coatings. The Contractor shall submit
a Contractor’s Drawing identifying markings and indicating the positions
of members in structures; and
(v) permanent identification: The Contractor shall supply and fix to each
structure after erection, a brass identification plate. The plate shall
indicate with lettering not less than 15 mm high, etched or punched to a
depth not less than 1.5 mm, the following:
• grade of steel in structure; and
• date of fabrication.
(a) Steelwork shall not be subject to rough handling, shock loading or dropping
from a height.
(b) During handling and transport of coated steelwork, the steelwork shall be
separated from wires, lashings, supports and other steel by rubber padding in
such a manner that the coatings are not damaged or discoloured. The
Contractor shall take such measures to prevent permanent distortion such as
stiffening free ends and protecting machined surfaces.
(c) Steelwork shall not be lifted from the painting bed until the last applied coating
is sufficiently dry or cured for handling.
(d) Rivets, bolts, nuts, washers, screws and small plates and articles shall be
packed in containers marked to identify the contents.
(ii) sit components on softwood supports covered with soft clean pads.
(iii) use softwood with soft padding and man-made fibre ropes and strops to
prevent movement and contact;
(a) Steelwork shall be stored off the ground on level supports in well drained
areas in a manner which will not result in damage or deformation to, or in
contamination of, the steelwork or coatings. Packing shall be placed between
steelwork which is stacked.
(d) Steelwork shall not be stored on or adjacent to concrete surfaces which form
part of the Permanent Works.
(e) Steelwork shall be protected from exposure to conditions which may affect the
steelwork or coatings.
(f) Wet paint films, steelwork surfaces which are to be primed or overcoated and
joint surfaces which are to be assembled shall be protected from exposure to
conditions which may affect the film or surface.
(g) Except as stated in Section 22.3.16(h) and (i), steelwork shall be stored in an
enclosed workshop and protected from conditions which may affect the
steelwork after it has been cleaned as stated in Section 22.5.12 until the
following times:
(i) when the second undercoat to painted steelwork has hard dried;
(iii) when the sealer to metal sprayed and sealed steelwork has been
completely absorbed; and
(iv) when the first undercoat to metal sprayed and painted steelwork has
hard dried.
(h) Primed steelwork surfaces may be exposed outside the enclosed workshop
for a period not exceeding two weeks.
(i) Micaceous iron oxide undercoats to steelwork may be exposed outside the
enclosed workshop for the minimum period necessary to move the steelwork
from one part of the workshop to the other. Undercoated surfaces shall be
covered when the steelwork is being moved.
(j) All painted steelwork shall be checked for undercoat contamination prior to
the application of subsequent coats.
(k) Steel members shall be stored and stacked such that markings are clearly
visible.
(b) Sherardized zinc coatings shall comply with BS 4921, Table 1, Class 1.
(c) Sprayed zinc and aluminium coatings shall comply with BS 2569:Part 1. The
nominal coating thickness shall be 100 µm. The sprayed metal shall be
pre-treated with product CP1 and sealed with product CP3C in accordance
with BS 5493.
(e) Metal coatings which will be overcoated with paint shall not be passivated and
shall be treated in accordance with the manufacturer's recommendations for
the specific coating system selected.
(f) Allowance for the thickness of the metal coating shall be made in the sizes of
the threads of metal coated threaded components. Nuts shall not be tapped
oversize by more than 0.4 mm. Metal coated HSFG bolts and nuts shall not
be tapped oversize.
(g) Damaged areas of metal coatings shall be rubbed down to remove excessive
roughness, cleaned and made good with a compatible coating of a type
reviewed without objection by the Project Manager.
(h) Metal coatings required on part of a component shall be completed before the
rest of the component is painted.
(a) The painting system to be used for steelwork shall be as stated in the
Contract.
(b) The different types of paints within each painting system shall be compatible
with each other and shall be manufactured by the same manufacturer.
Successive coats in a painting system, including stripe coats, shall be in
contrasting colours to aid identification.
(a) The original or certified true copy of the manufacturer's mill certificates for
steel shall be submitted to the Project Manager for review without objection in
accordance with BS 4360, Clause 12 and Appendix B 6.
(b) The mill certificates shall be submitted to the Project Manager not more than
7 days after the steel has been delivered to the place of fabrication.
(a) Two sets of Contractor’s Drawings of the steelwork shall be submitted to the
Project Manager for review without objection at least 6 weeks before
fabrication of the steelwork starts. These Contractor’s Drawings shall show
details of the following:
(iii) welds, including any stud welds, marked with the relevant welding
procedures;
(viii) details of holding down bolts and fittings to be cast into the concrete or
masonry.
(b) Fabrication work shall not commence until the Contractor’s Drawings and the
associated method statements have been reviewed without objection by the
Project Manager.
(a) The following particulars of the proposed method of erecting steelwork shall
be submitted to the Project Manager for review without objection:
(b) The welder certificates shall be submitted at least 2 weeks before fabrication
of the steelwork starts.
(a) The following particulars of the proposed stud welding, flame cutting and
shearing procedures for steelwork complying with BS 5400:Part 6 shall be
submitted to the Project Manager for review without objection:
(i) procedures for stud welding, flame cutting and shearing processes
complying with BS 5400:Part 6, Clause 4.3.3(a), (d) or (c);
(ii) documentation endorsed by an independent HOKLAS accredited
inspecting authority to show that the stud welding, flame cutting or
shearing procedure has complied with the procedure trial requirements
stated in the Contract in previous tests; and
Particulars of the method of plugging vent holes required for hot-dip galvanizing
hollow or box sections shall be submitted to the Project Manager for review without
objection.
Particulars of the proposed method for carrying out non-destructive testing on welds
shall be submitted to the Project Manager for review without objection.
(b) The name of the proposed testing consultant stated in Section 22.6.13 shall
be submitted to the Project Manager for review without objection.
(a) The following particulars of the proposed paints and associated products shall
be submitted to the Project Manager for review without objection:
(a) A representative sample of blast cleaned steel plate shall be submitted to the
Project Manager for review without objection. The sample shall be
150 mm x 150 mm x 6 mm and shall be enclosed in a sealed, colourless,
transparent wrapping. The grade of steel and the method of blasting shall be
representative of those which will be used in the Permanent Works.
(b) Two representative samples of painted metal plates for each painting system
shall be submitted to the Project Manager for review without objection. Each
plate shall be 150 mm x 75 mm x 1 mm and shall have smooth edges and
10 mm corner radii. The plates shall be brush cleaned and painted on one
face with the painting system in such a manner that each coat is stepped back
from the underlying coat in equal strips. The degree of gloss of the finishing
coat shall be reviewed without objection by the Project Manager.
(c) Representative samples of each type of nut, bolt, washer, stud and rivet shall
be submitted to the Project Manager for review without objection.
22.5 WORKMANSHIP
(a) Welding shall only be carried out by welders who possess a valid welding
certificate for the appropriate category of welding. A welder shall cease to
carry out welding if any of the circumstances stated in BS 4570, Clause 21.1,
BS 4871:Part 1, Clause 11 or BS 4872:Part 1, Clause 6 as appropriate occur.
(c) Butt welds shall be complete penetration butt welds made between fusion
faces.
(d) Butt welds in each component part shall be completed before the final
assembly of built-up assemblies.
(e) To ensure full throat thickness at the ends of butt welds run-on and run-off
plates shall be used. These plates shall comply with the following :
(vii) welding, heating or thermal cutting processes which give off toxic or
irritant gases shall not be used;
(ix) materials, procedures, fixing and equipment for shear studs shall be in
accordance with the manufacturer's recommendations; and
(b) Except in steel base plates or where otherwise noted on the Employer's
Drawings the size of holes for ordinary bolts shall be of diameter not more
than 2 mm greater than the diameter of the bolts for bolts up to 24 mm
diameter, and not more than 3 mm greater than the diameter of the bolt for
bolts over 24 mm diameter.
(d) Bolt and vent holes in hollow sections shall be sealed to prevent the ingress of
moisture. Where not specified on the Employer's Drawings the method shall
be proposed on the Contractor’s Drawings submitted in accordance with
Section 22.4.2.
(a) Nuts shall not be used with bolts or screws which comply with a different
standard.
(a) Washers for HSFG bolts shall be provided in accordance with BS 4604:Part 1
or BS 4604:Part 2 as appropriate. Washers shall be provided for bolts
complying with BS 3692, BS 4190 and BS 4933 under the nut or bolt head,
whichever is rotated during tightening, if the parts to be connected are to be
coated with protective coatings before assembly. Washers shall be provided
under the nuts and heads of bolts in oversized and slotted holes.
(b) Tapered washers shall be used under bolt heads and nuts bearing on
surfaces sloping 3° or more from a plane at right angles to the bolt axis.
(c) Bolt assemblies containing spring washers shall be tightened until the spring
washer is completely flattened.
(a) The degree of preliminary tightening of bolts and nuts complying with
BS 4395:Part 1 which are tightened by the part turn method shall be torque
controlled. The tightening equipment for preliminary tightening shall be
calibrated with a bolt load meter. The value of bedding torque for the
preliminary tightening shall be within 10% of the values stated in Table 22.2.
(b) Bolts and nuts at each joint with bolts or washers with load indicating devices
shall be initially tightened to bring the faying surfaces into close contact over
the full area. The range of the average gap after initial tightening shall be
reviewed without objection by the Project Manager. The bolts and nuts shall
be re-tightened if necessary to close the average gap back to the agreed
range. After all bolts and nuts at the joint have been initially tightened, the
bolts and nuts shall be finally tightened to attain the shank tension stated in
BS 4604:Part 1 or BS 4604:Part 2 as appropriate. The range of average gap
corresponding to the required shank tension shall be established for each
batch as defined in BS 4395:Part 1 or BS 4395:Part 2 as appropriate by
testing at least three bolt, nut and washer assemblies in a bolt load meter and
shall be reviewed without objection by the Project Manager. The average gap
after final tightening shall be within the established range.
Materials & Workmanship Specification 15/36 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 22 - Steelwork
(c) The threads of nuts for HSFG bolts which are to be tightened by the part turn
method or the load indicating method shall not be lubricated unless reviewed
without objection by the Project Manager. If the use of lubricant is permitted
in the part turn method, the bedding torque shall be established by a bolt load
meter and shall be reviewed without objection by the Project Manager. The
lubricant shall be applied at the place of manufacture and shall only be
applied to the nut threads. The bearing surfaces of the nuts and the faying
surfaces shall not be contaminated with the lubricant.
(d) The bolt load meter for measuring bolt shank tension in the part turn, torque
control or load indicating methods of tightening shall be calibrated by a
laboratory reviewed without objection by the Project Manager before
tightening of bolts and nuts starts and at regular intervals reviewed without
objection by the Project Manager. During re-calibration, a replacement
calibrated bolt load meter shall be provided on Site. Calibration results shall
be submitted to the Project Manager for review without objection at least one
week before the bolt load meter is used.
(e) If after tightening, a bolt or nut is slackened-off for any reason, the complete
bolt assembly shall be discarded and not re-used in the Permanent Works.
(f) The faying surfaces for HSFG fasteners shall be in accordance with the
following :
(ii) free from distortion, deformities or contaminants which may reduce the
slip factor below the design value; and
(iii) deformed surfaces shall be machined flat and tested in accordance with
BS 4604 to determine the slip factor after machining.
(g) Following complete assembly of all bolted connections, the fit and tightness of
the bolts shall be checked at locations reviewed without objection by the
Project Manager.
(h) Prior to Site painting of HSFG bolted connections the following shall be
confirmed :
(ii) appropriate hardened washers have been fitted in accordance with the
requirements of BS 6404.
(a) Where slotted holes are provided for movement connections, the joints shall
be free to move.
(i) the slotted hole shall be wider than the unslotted hole;
(ii) shouldered bolt shall be used with a spring washer under the head and
shoulder bearing on the faying surface of the unslotted member; and
(iii) a flat washer shall be provided under the nut and the nut tightened into
the unslotted member.
Defective components for steelwork shall not be used in the Permanent Works
unless repair of the defects is permitted by the Project Manager. If permitted,
defective components shall be repaired by methods reviewed without objection by
the Project Manager.
(a) Soil, concrete and other adherent matter shall be removed immediately from
steelwork or coated surfaces and the surfaces shall be made good by
methods reviewed without objection by the Project Manager.
(b) Dust, soot, grit, detritus, metallic or other loose particles shall be removed by
vacuum cleaning after steelwork surfaces have been blast cleaned or before
coated surfaces are washed or steam cleaned.
(c) Oil and grease shall be removed by emulsion cleaners, by steam cleaning or
by high pressure water jets before removing rust and mill scale or
overcoating. Oil and grease shall not be removed by turpentine or other
solvents. If steam cleaning is used, steam cleaning shall be carried out after
the greasy deposits have been removed by scraping and a detergent shall be
added to the feed water of the steam generator.
(d) Salts, chemicals, corrosion or paint degradation products, including zinc salts
on zinc coatings or zinc-rich paints, shall be removed by washing with
detergent solution and rinsed with fresh water before coating steelwork
surfaces or overcoating.
(e) Rust spotting on blast cleaned surfaces shall be rejected and steel shall be re-
blasted to the required standard before any coating is applied.
(g) The final shop coats on external surfaces shall be thoroughly washed with a
detergent solution at Site before being overcoated.
(j) Cleaning tools shall not damage the surfaces being cleaned. Wire brushes
and brooms shall not be used for cleaning coated surfaces.
(a) Bare metal surfaces of steelwork which are to be painted or metal coated
shall be treated before rust and mill scale are removed in accordance with the
following requirements:
(i) burrs, arrises and serrations shall be smoothed by grinding or filing. All
surface irregularities shall be removed, including sharp edges and
laminations, by grinding until smooth; and
(ii) weld spatter, weld slag and raised metal laminations shall be removed
by grinding or chipping and the surface shall be made good.
(b) At no time shall steel surfaces have rusted beyond Rust Grade C of Swedish
Standard S1S 05 59 00.
(c) Rust and mill scale shall be removed from steelwork which is to be metal
coated in factories by a pickling process compatible with the metal coating
process.
(d) Rust and mill scale shall be removed from steelwork which is to be metal
sprayed by blast cleaning carried out in accordance with BS 2569:Part 1,
Clause 3.
(e) Rust and mill scale shall be removed from steelwork to be painted by blast
cleaning as stated in Section 22.5.14 unless the use of acid-pickling,
mechanical cleaning or flame cleaning as stated in Sections 22.5.15 to
22.5.17 has been reviewed without objection by the Project Manager.
(f) Excess acid or other chemicals used in the pickling process shall be removed
from steelwork which has been prepared by pickling before the application of
the metal coating. Pickling shall not be carried out for longer than is
necessary to remove the rust and mill scale.
(g) After surface preparation has been completed, the surface roughness shall be
compatible with the specified coating and at no location should the peak-to-
trough amplitude exceed 80 m.
(h) All defects in the substrate surface exposed during surface preparation which
are not acceptable in accordance with BS 4360 shall be rectified in
accordance with BS 4360.
(i) Defects which are acceptable in accordance with BS 4360 but which will
prevent the satisfactory coating of the steelwork shall be rectified and
reviewed without objection by the Project Manager.
(k) Prefabrication coatings may be applied but this coating will be considered
additional to the main protective-system. If a prefabrication coating is to be
applied the Contractor shall provide evidence that it is fully compatible with
the main protective system.
(a) Blast cleaning of steelwork shall be carried out to second quality of surface
finish in accordance with Sa2½ in Swedish Standard SIS 05 59 00 using
chilled iron abrasive.
(b) Chilled iron grit shall be graded in accordance with BS 2451. The maximum
size of grit shall be G17 for use in automatic impeller type equipment and
shall be G12 for manual or compressed air equipment. The difference in level
between a peak and the adjacent trough of the blasted surface profile shall
not exceed 0.1 mm or in accordance with the paint manufacturer's
recommendation.
(c) All compressed air for grit blasting shall be passed through aftercoolers and
oil separation equipment to ensure that the air is dry and oil free. Air shall be
tested each day by placing a white cloth at the compressed air outlet for one
minute. The cloth shall remain clean after one minute.
(d) Abrasives shall not contain materials which may contaminate the steel
surfaces and shall be cleaned and free of chloride, dust, dirt, grease, oil and
moisture. Sand shall not be used except in a wet cleaning system.
Expandable abrasive shall be used once only. Recyclable steel abrasive shall
be cleaned and free of contaminants before re-use. Recyclable abrasives
shall be discarded when the particle size fails to achieve the specified profile.
(a) Flame cleaning of steelwork shall not be carried out at the following locations:
(i) within 2 m of HSFG bolts, cold worked high tensile steel and surfaces
already coated with paint or cadmium, lead-based or carbonaceous
materials, or
(b) Flame cleaning shall be carried out without distorting the steelwork and
without adversely affecting the properties of the steel. The temperature of the
steel surface being flame cleaned shall not exceed 200°C.
(c) Loose materials shall be removed from the flame-cleaned surface by wire
brushing followed by blowing dry air or vacuum cleaning. The priming coat
shall be applied when the surface temperature of the steel is between 35°C
and 40°C. Surfaces with temperatures of less than 35°C shall be reheated.
Bolts, nuts and washers for steelwork shall be kept free from dirt and deleterious
material. Oil and grease on bolts, nuts and washers, other than lubricants reviewed
without objection by the Project Manager for nuts of HSFG bolts, shall be removed
before assembling and coating the exposed parts of assembled bolts, nuts and
washers.
Surfaces shall not be coated until the cleaning and preparation of the surfaces has
been carried out. The Contractor shall notify the Project Manager when the surfaces
are available for inspection.
(a) Surfaces which are to be painted shall be dry immediately before paint is
applied.
(b) Paint shall be taken from the paint store ready for application. Thinning, if
necessary, shall be carried out in the paint store using the type of thinner in
the ratio stated in the manufacturer's data sheets.
(c) Paint shall be applied by brush, by air pressure spray or by airless spray.
Sealer and primers shall be applied by continuous spraying.
(d) Each coat in the paintwork system shall be sufficiently dry or cured before the
next coat is applied. The time between application of successive coats shall
be within the limits recommended by the manufacturer and the limits stated in
Section 22.5.22.
(e) Paints having a pot life specified by the manufacturer, including two pack
paints and moisture cured paints, shall be discarded on expiry of the pot life or
at the end of each working day, whichever comes first. Other paints in
opened containers shall be kept in sealed containers with not more than 10%
ullage in store after each day's work and shall not be thinned or mixed with
fresh paint when re-issued for another day's work.
(g) Paint shall not be applied to friction grip interfaces. The faying surfaces shall
be masked to prevent rusting beyond Rust Grade C of Swedish Standard SIS
05 59 00. If galvanizing or other metal coatings have been applied, evidence
shall be provided to demonstrate that a slip factor not less than the design
value shall be achieved.
(h) Bolt connections in externally exposed steelwork, other than friction grip
connections, shall be assembled with a coat of primer still wet on the contact
surfaces.
(j) After erection some parts of the steelwork may not be accessible for the
application of site-applied coatings. The complete system shall be applied
prior to erection of these areas.
(a) Paint shall not be applied to steelwork under the following conditions:
(i) when the ambient temperature falls below 4°C or the relative humidity
rises above 90%;
(ii) for outdoor work, during periods of inclement weather including fog,
frost, mist and rain or when condensation has occurred or is likely to
occur on the metal;
(iii) when the surface temperature of the metal to be painted is less than
3°C above the dew point of the ambient air; or
(iv) when the amount of dust in the air or on the surface to be painted is in
the opinion of the Project Manager excessive.
(b) Two pack paints of the epoxide resin type shall not be applied and cured
when the temperature is below that recommended by the manufacturer.
(a) Blast cleaned steel shall be primed or metal coated within 4 hours after blast
cleaning and before any visible signs of oxidations appear on the prepared
surface. Prepared surfaces shall be blown clean with dry, oil free compressed
air to remove dust, dirt and grit residues before coating.
(b) Primed steel surfaces shall be overcoated within 8 weeks after priming.
(c) Second undercoats shall be applied within 72 hours after application of the
first undercoat.
(e) Etch primer to galvanized steelwork shall be applied within 14 days after
delivery of the steelwork to Site. The etch primed surfaces shall be
overcoated within 48 hours after priming. Prior to application of the etch
primer to galvanized steelwork the surface shall :
(f) Overcoats to two pack paints of the epoxide or polyurethane type shall be
applied within 48 hours after application of the two pack paint. If it is not
possible to overcoat within 48 hours, the two pack paint shall be abraded to
produce a roughened surface and shall be given a flash coat of primer of a
type reviewed without objection by the Project Manager; the primer shall be
allowed to dry for at least 4 hours before application of the next coat of the
system.
Immediately after the first undercoat of the painting system to steelwork has dried, a
stripe coat of undercoat paint shall be applied by brush to edges, corners, crevices,
exposed parts of bolts, nuts, rivets and welds. Another stripe coat of finishing paint
shall be applied in the same manner after the last undercoat has dried.
(a) The dry film thickness of the paint coats to steelwork shall be measured using
a magnetic dry film thickness gauge. The total dry film thickness shall be
measured at spacings of approximately 1.0 m. If the measured dry film
thickness is less than 75% of the specified nominal dry film thicknesses or if
more than 10% of the measured dry film thickness are less than 95% of the
specified nominal dry film thickness, repair work shall be carried out as stated
in Clause 22.5.26.
(b) Dry film thickness readings on structural members shall be taken at three
points for each linear metre. Wet film thickness gauges shall not be used as a
means of predicting the dry film thickness, but only as an indication that
sufficient material has been applied at the time of application.
(c) Each coat of paint shall be free from embedded foreign matter, mechanical
damage and surface defects, including bittiness, blistering, brush marks,
bubbling, cissing, cracking, cratering, dry spray, floating, pinholing, rivelling,
runs, sagging, spotting and spray mottle as defined in BS 2015. The finished
paintwork system shall have an even and uniform appearance.
(d) Each coat of paint shall adhere firmly to the substrate without blistering,
chipping, flaking or peeling. Adhesion tests in accordance with BS 3900:Part
E6 shall be carried out on representative areas to confirm that the adhesion of
the completed paint scheme is equivalent to classification 2 of that standard.
The test area shall be repaired in accordance with the Specification.
Materials & Workmanship Specification 22/36 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 22 - Steelwork
22.5.25 Etch Primers and Blast Primers
Etch primers and blast primers shall not be applied on phosphated steel and shall
not be overcoated with zinc-rich primers.
(a) Areas of paint to steelwork which have been damaged shall be cleaned to
bare metal or to the metal coating. The edges of the undamaged paint shall
be bevelled.
(b) The full specified painting system shall be restored in such a manner that
each new paint coat overlaps the existing paint by at least 50 mm all round
the affected part.
(a) The faying surfaces of HSFG bolted joints in steelwork which is metal sprayed
overall and sealed or metal sprayed and painted overall, shall be coated with
the sprayed metal. The sealer on the parent material shall extend for a
distance of between 10 mm and 20 mm inside the perimeter of the faying
surfaces. Free surfaces and edges of the joint material shall be coated with
the same sealer.
(b) The joint material and the faying surfaces on the parent material of steelwork
which is metal sprayed only at joints and painted overall shall be metal
sprayed. The sprayed metal on the parent material shall extend for a distance
of between 10 mm and 20 mm outside the perimeter of the faying surfaces.
The primer on the parent material shall extend for a distance of between
10 mm and 20 mm inside the perimeter of the faying surfaces. Sprayed metal
on the free surfaces and edges of the joint material shall be coated with a
sealer which is compatible with the painting system.
(c) The primer on the parent material of steelwork which is painted overall and
uncoated at faying surfaces of HSFG bolted joints shall extend for a distance
of between 10 mm and 20 mm inside the perimeter of the faying surfaces.
Blast primer for painted steelwork or sprayed metal plus sealer for metal sprayed
steelwork shall be applied to the joint and parent material of shop-bolted joints other
than HSFG bolted joints; joints for painted steelwork shall be assembled after the
first undercoat of the painting system has been applied to the contact surfaces and
while the undercoat is still wet.
Surfaces of the parent and joint material of Site-bolted joints other than HSFG
bolted joints shall be coated with the same protective system as the parent material.
Welds and steelwork surfaces which have been affected by welding shall be coated
with the same protective system as the parent material.
(a) Hot-dip galvanizing and electroplating to steelwork shall not be carried out
until all welds for the steelwork which is to be galvanized or electroplated have
been completed.
(b) Except as stated in Section 22.5.31(d), sprayed metal on the parent material
shall be kept at least 15 mm, but not more than 300 mm, clear of areas which
are to be welded. The restricted area shall be masked during metal spraying.
(d) If the parent metal in the welding procedure reviewed without objection by the
Project Manager is coated with the pre-fabrication primer or sprayed metal
such coatings are permitted to cover the area to be welded. After welding the
pre-fabrication primer or sprayed metal adjacent to the weld shall be made
good.
(e) The parent material, joint material, exposed parts of bolts, nuts and washers,
welds and weld affected areas shall be cleaned, prepared and brought up to
the same protective system as the adjoining surfaces not more than 14 days
after the joints have been made.
(a) The different parts of joints in steelwork shall be dry immediately before the
joints are assembled.
(b) Gaps around the perimeter of bolted joints and load indicator gaps of HSFG
bolts in steelwork painted overall shall be sealed by brush application of the
same painting system as the parent material; gaps shall be plugged if
necessary with soft solder wire without flux core as a backing before sealing
with paint.
The ends of hollow steel sections shall be sealed by welding mild steel plates, at
least 2mm thick, over the open ends. Immediately before hollow steel sections are
sealed, porous bags containing anhydrous silica gel shall be inserted in each void
at the rate of 0.25 kg/m³ of void.
Dirt, oil, grease, rust and mill scale shall be removed from the metal bearing
surfaces for bridge bearings. The surfaces shall be masked with tape and shall not
be primed or painted until the bonding agent has been applied.
The coated surfaces of steelwork coated over part of the surface shall be protected
from rust which may form on the uncoated surfaces. Temporary coatings which
may affect the bond between concrete and uncoated surfaces against which the
concrete is to be placed shall be removed and the uncoated surfaces shall be
cleaned before the concrete is placed. The full coating system shall extend 25 mm,
or 75 mm for steel piles, into areas against which concrete is to be placed.
(b) Riveted and bolted connections shall be aligned using drifts complying with
BS 5400:Part 6, Clause 4.12 and shall be temporarily fastened using service
bolts.
(c) The Contractor shall design and fabricate all temporary attachments for use
as assembly and erection aids to ensure their use will not damage the
structure of its surface protection.
22.5.37 Falsework
(a) Steelwork shall be erected in such a manner that the alignment and levels of
the steelwork comply with the tolerances stated in Section 22.5.49. The
Contractor shall make allowance for the effects of temperature on the
steelwork.
(b) Measures shall be taken to ensure that the steelwork will remain stable before
temporary supports and fastenings are slackened or removed for lining,
levelling, plumbing or other purposes. The temporary supports and fastenings
shall be re-tightened or replaced as soon as the adjustments are complete
and at the end of each continuous period of working.
(a) Foundation bolts for steelwork shall be held firmly in the set position during
fixing. Measures shall be taken to ensure that the full movement tolerances
are achieved and the bolts are not displaced during concreting. Bolts and
nuts, including the threads, shall be protected against damage, corrosion and
contamination.
(b) Bolt pockets shall be kept dry and clean. Tubes which are cast in concrete for
grouting bolt pockets shall be securely fixed and sealed to prevent ingress of
grout during concreting.
(c) Bolts in bolt pockets shall be installed to allow the bolt movement inside the
pocket as designed without hindrance.
The material, size, position and cover of packs, shims and other supporting devices
for steelwork which are to be embedded shall be as reviewed without objection by
the Project Manager.
(a) Column bases for each portion of steelwork shall not be bedded or grouted
until the portion has been lined, levelled, plumbed and permanently
connected. Spaces below the steel shall be dry, clean and free from rust
immediately before bedding or grouting.
(b) Proprietary types of grout shall be used in accordance with the manufacturer's
recommendations.
(c) Temporary timber wedges holding steel columns in position shall not project
into pocket bases by more than one-third of the embedded length of the steel
column. The pocket shall be initially concreted up to the underside of the
wedges and the steel column shall be left undisturbed until 48 hours after
concreting; the wedges shall then be removed and the remainder of the
pocket shall be concreted.
Thermal cutting equipment shall not be used on Site unless reviewed without
objection by the Project Manager.
22.5.44 Erectors
The Contractor shall carry out all work by trained and experienced erectors. The
Contractor shall submit to the Project Manager for review without objection
evidence of the erector’s competence.
The Contractor shall not carry out complex operations at height except from safe
platforms large enough to support operators and equipments. Platforms and safe
access shall be maintained until work has been completed.
22.5.46 Stability
(a) Unless otherwise stated in the Contract, steelwork shall be fabricated to within
the tolerances stated in Sections 22.5.47(b) to (i).
(b) Steelwork shall be fabricated to an accuracy that will enable erection within
the specified limits to take place without inducing excessive stresses,
deflection or distortion into the structure.
(d) The length of members with both ends prepared for contact bearing shall not
deviate from the detailed length by more than 1 mm.
(e) The length of members without ends prepared for contact bearing, which are
to be framed to other steel parts of the structure, shall not deviate from the
detailed length by more than 2 mm for members 10 m or less in length, and 4
mm for members greater than 10 m in length.
(f) The deviation of a member from a straight line drawn between adjacent points
of subsequent effective lateral restraint shall not exceed the greater of 3 mm
or 0.1% of the distance between restraints.
(g) The deviation from the specified or proposed camber shall not exceed the
greater of 12 mm or 0.1% of the length of the member.
(h) The gaps in joints which depend on contact bearing when assembled during
fabrication shall not exceed 0.75 mm.
(i) Fabrication tolerances shall comply with the following British Standards:
The position of cast-in foundation bolts at the top of base plates shall be within
3 mm of the specified position. The position of foundation bolts in bolt pockets at
the top of base plates shall be within 5 mm of the specified position. The line of
bolts shall not be tilted from the specified line by more than 1 in 40.
Materials & Workmanship Specification 27/36 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 22 - Steelwork
22.5.49 Tolerances: Erection of Steelwork
(a) Unless otherwise stated in the Contract, steelwork shall be erected to within
the tolerances stated in Sections 22.5.49(b) to (j) after lining, levelling,
plumbing and making the permanent connections.
(b) The position in plan of vertical components at the base shall be within 10 mm
of the specified position along either principle setting out axis.
(c) The level of the top of base plates and the level of the lower end of vertical or
raking components in a pocket base shall be within 10 mm of the specified
level.
(d) The thickness of bedding shall be within one-third of the nominal thickness or
10 mm, whichever is less, of the specified nominal thickness.
(e) The line of vertical or raking components other than in portal frames shall be
within 1 in 600 and within 5 mm of the specified line in every direction.
(f) The line of vertical or raking components in portal frames shall be within 1 in
600 and within 5 mm of the specified line in every direction.
(g) The position and level of components connected with other components shall
be within 5 mm of the specified position and level relative to the other
components at the point of connection.
(j) Gaps in joints which depend on contact bearing after alignment shall not
exceed 0.75 mm.
(a) Welding of any attachment to cast-in components shall not take place less
than 7 days after casting of the concrete. Where welding is requested to a
cast-in item, the Contractor shall demonstrate that the heat generated at the
interface with the concrete will not have a detrimental effect on the
mechanical properties of the concrete and will not compromise the capacity of
the cast-in detail.
(c) For cast-in fixings designed by the Contractor, the Contractor shall design and
install reinforcement which shall be additional to that shown on the Employer’s
Drawings and capable of transmitting the fixing imposed loads into the
structure without adversely affecting the structural integrity of the surrounding
concrete.
(b) Procedure trials for welding for structural steel shall comply with
BS 5400:Part 6, Clauses 4.7.3, 5.4.1.1 and 5.4.1.2.
(c) Procedure trials for welding for steel castings shall comply with
BS 5400:Part 6, Clauses 4.7.3 and 5.4.2.
(d) Procedure trials for welding of studs shall comply with BS 5400:Part 6,
Clauses 4.7.4 and 5.4.4.
(e) Procedure trials for flame cutting and shearing shall comply with
BS 5400:Part 6, Clauses 4.7.3 and 5.4.3.
(f) Welds for grade A steels complying with BS 4360 are not required to comply
with the requirements for Charpy V-notch impact tests. The temperature of -
20°C stated in BS 5400:Part 6, Clause 5.4.1.2(a)(3) shall be amended to 0°C.
(g) If in a welding procedure one or more of the parts to be welded is coated with
a prefabrication primer or metal coating before welding, the same primer or
coating shall be applied to the sample before the procedure trial for the
welding procedure is carried out.
(h) The thickness of the sample of material to be used in procedure trials for
flame cutting shall be:
22.6.2 Inspection of Procedure Trials for Welding, Flame Cutting and Shearing
Procedure trials for welding, flame cutting and shearing shall be carried out in the
presence of an independent HOKLAS accredited inspecting authority.
22.6.3 Results of Procedure Trials for Welding, Flame Cutting and Shearing
If a procedure trial for welding, flame cutting or shearing does not comply with the
specified requirements for the procedure trial, the cause of failure shall be
established by the Contractor and particulars of proposed changes shall be
submitted to the Project Manager for review without objection. Further procedure
trials shall be carried out to establish the amended procedure.
(a) A welding, flame cutting or shearing procedure which complies with the
specified requirements for the procedure trial is defined as an "Acceptable
Procedure".
(b) If a procedure trial is not required, the procedure for welding, flame cutting or
shearing submitted as stated in Sections 22.4.5 and 22.4.6 shall become an
"Acceptable Procedure".
Welding, flame cutting or shearing shall not commence until the procedure has
been reviewed without objection by the Project Manager.
22.6.7 Records of Procedure Trials for Welding, Flame Cutting and Shearing
(a) A record of the approval test for welding procedures shall be submitted to the
Project Manager for review without objection. The record shall be in the form
stated in BS 4870:Part 1, Appendix B or BS 4570, Appendix A as appropriate
and shall be endorsed by the independent HOKLAS accredited inspecting
authority.
(b) Reports of procedure trials for stud welding, fl ame cutting and shearing shall
be submitted to the Project Manager for review without objection.
(a) A painting trial shall be carried out for each painting system which will be
applied to areas exceeding 10 m2 to demonstrate that the proposed materials
and methods of application will produce a painted surface which complies with
the specified requirements.
(b) Painting trials shall be carried out at the place where painting to the
Permanent Works will be carried out and using the labour and equipment
which will be used to carry out painting to the Permanent Works.
(c) Painting trials shall be carried out on steel cleaned in accordance with the
requirements of the Contract.
The painted surface produced in a painting trial shall be tested in accordance with
BS 3900 and in the event that the test piece does not comply with the specified
requirements for the paintwork, the cause of failure shall be established by the
Contractor and particulars of proposed changes shall be submitted to the Project
Manager for review without objection. Proposed changes to the paint formulation,
other than an adjustment in the amount of thinners, shall be carried out at the paint
manufacturer's works before the final painting trial and before the first batch of paint
is delivered.
Materials & Workmanship Specification 30/36 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 22 - Steelwork
22.6.10 Commencement of Painting
Painting shall not commence until the painted surface produced in painting trials
complies with the specified requirements for paintwork.
The materials and methods of application used in a painting trial which complies
with the specified requirements shall not be changed.
22.6.12 Inspection of Fabricated Steelwork
(ii) erected; or
until the steelwork, complies with the specified test and inspection
requirements and has been reviewed without objection by the Project
Manager.
Tests which are stated in this section to be carried out by an independent testing
consultant shall be carried out by a HOKLAS accredited testing consultant reviewed
without objection by the Project Manager.
(b) Tests shall be carried out on bolts, nuts and washers in accordance with
BS 3692, BS 4190, BS 4395:Part 1, BS 4395:Part 2 or BS 4933 as
appropriate; the tests shall be carried out on full size bolts. The rates of
sampling and testing shall be in accordance with BS 4395:Part 1.
(c) The tests shall be carried out by the manufacturer at the manufacturer's works
on samples selected by the Project Manager if the manufacturer's works are
in Hong Kong and on samples selected by the independent testing consultant
reviewed without objection by the Project Manager if the manufacturer's works
are not in Hong Kong.
(b) The Contractor shall submit to the Project Manager for review without
objection a list of the components included in each batch at least 7 days
before testing starts.
(b) Samples shall be selected from positions which, in the opinion of the Project
Manager or the independent testing consultant, are representative of the
batch as a whole.
(c) The Project Manager will inform the Contractor of the samples selected for
testing at least 3 days before testing is programmed to commence.
(a) The relevant tests stated in Sections 22.6.21 to 22.6.24 shall be carried out on
each batch of steelwork.
(b) The Contractor shall notify the Project Manager at least 7 days before tests in
Hong Kong are carried out.
(a) Records of tests on steelwork and a report shall be submitted to the Project
Manager for review without objection at least 7 days before the Project
Manager's notification of no objection is required. The report shall contain the
following details:
(i) procedure under which the testing took place and the exact test location
in the steelwork;
(b) Reports shall be certified by the Contractor and by the independent testing
consultant, who carried out the tests.
(a) If the result of any test on steelwork stated in Sections 22.6.21 to 22.6.24
does not comply with the Specification for the test, the test shall be carried out
on additional samples from the batch. The number of additional tests shall be
twice the number of original tests.
(b) If the result of every additional test complies with the Specification, the part of
the batch on which the original tests were carried out shall be considered as
complying with the specified requirements for the test.
(c) The batch shall be considered as not complying with the Specification if the
result of any additional test does not comply with the Specification for the test.
Samples of steel shall be provided from each batch of steel within 3 days after
delivery of the batch to the fabricator's works or to Site. The rate of sampling and
the position and direction of the samples shall be in accordance with BS 4360.
(a) The tensile test and the impact test shall be carried out on each sample of
steel. The method of testing shall be in accordance with BS 4360.
(b) Where stated in the Contract the material shall be subject to the following
additional tests :
(c) Quality grading of structural steel shall be carried out on steel which has not
been tested for quality grades by the manufacturer. Quality grading shall be
carried out in accordance with BS 5400:Part 6, Clause 3.1.4 or
BS 5950:Part 2, Clause 2.1.6 as appropriate.
(d) Testing and quality grading shall be carried out by the independent testing
consultant.
(a) Examination and testing of welds shall be carried out after post-weld heat
treatment and before the application of corrosion protective coatings. De-
burring, dressing, grinding, machining and peening shall be carried out after
the visual inspection for cracks, surface pores and joint fit-up and before other
inspections and tests are carried out.
(b) Where the Specification requires that butt welds are subject to non-destructive
examination, the following shall apply:
(c) Where the Specification requires that fillet welds are subject to the non-
destructive examinations, the following shall apply:
(iii) for welds with a leg length equal to or greater than 12 mm ultrasonic
examination to BS 3923:Part 1.
(ii) weld sizes and lengths shall not be less than those dimensions
specified in the Specification;
(iii) any undercut shall be intermittent and not greater than 0.5 mm deep;
(v) root gap in fillet welds shall not exceed 1.0 mm and shall only exceed
0.5 mm intermittently;
(vii) weld reinforcement shall blend smoothly with the parent metal with no
signs of overlap; and
(viii) linear misalignment shall not exceed t/10 where t is the thickness of the
thinner part or 3 mm, whichever is the lesser.
(e) Welds subject to ultrasonic examination shall satisfy the following criteria:
(i) the weld shall have no reflectors which could be interpreted as planar
defects such as cracks, tears, lack of fusion or lack of penetration. A
planar defect is any flaw whose thickness is less than 25% of its width.
In the case of partial penetration welds, the nominated unfused
thickness shall not be subject to rejection. The amount of unfused
thickness shall be measured and recorded and shall not exceed the
nominated width;
(ii) all volumetric defects, where the thickness is equal to or greater than
25% of its width, shall be sized and the weld rejected if:
(iii) two adjacent defects, if not separated by at least twice the length of the
longer defect, shall be regarded as one continuous defect; and
(iv) a defect shall not begin at a distance less than twice its own length from
the end of the weld.
(f) Welds subject to magnetic particle or penetrant examination shall satisfy the
following criteria :
(ii) any undercut shall be intermittent and not greater than 0.5 mm deep;
(v) the defect shall be further than three times the larger of its own width or
length from the end of the weld or from an adjacent defect;
(ii) any stud weld which does not exhibit full 360 degree "flash" shall be
subjected to a 15 degree bend test at locations to be reviewed without
objection by the Project Manager. Under this test the weld is to show
no visible signs of cracking;
(iv) where the bend test reveals an unsatisfactory stud weld, an additional
stud on each side of the defective stud shall be tested; and
(i) Testing of welds shall be carried out by the independent testing consultant.
(j) Records of weld testing shall be on HOKLAS endorsed certificates and shall
be submitted to the Project Manager for review without objection in a form
suitable for submission to the Buildings Department.
Materials & Workmanship Specification 35/36 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 22 - Steelwork
22.6.23 Testing: Fabrication Tolerances
(a) Rolled and built-up sections of steelwork complying with BS 5400:Part 6 shall
be tested to determine compliance with fabrication tolerances in accordance
with BS 5400:Part 6, Clauses 5.6.1 to 5.6.6.
Defects which have been repaired and adjoining areas which in the opinion of the
Project Manager may have been affected by the repair shall be retested.
23.1 GENERAL
Movement joints formed in place shall comply with Section 20 except as stated in
this Section.
“Type of bridge bearing” is a term used to identify bridge bearings of exactly the
same design and same capacity for all bearing loads, movements and rotations.
A batch of bridge bearings is any quantity of bridge bearings of the same type
fabricated by the same manufacturer and which for the purpose of testing
elastomeric bearings contains the same type of elastomer.
(a) Bridge bearings shall be designed by the Contractor unless otherwise stated
in the Contract.
(d) The deflection of bridge bearings which have a specified zero horizontal
movement in a particular direction shall not exceed 1 mm in that direction
under the maximum horizontal loadings
(a) Clause 4.3.4.2 of BS 5400:Part 9:Section 9.2 shall not apply to sliding
bearings.
(b) Stainless steel sliding surfaces of sliding bearings which are attached to
backing plates by mechanical fasteners instead of continuous welding along
the edges shall be bonded to the backing over the full area and supplemented
with peripheral sealing if necessary. Mechanical fixing by peripheral sealing
only shall not be used.
(c) The design of sliding bearings shall prevent sliding surfaces becoming
contaminated with dirt that would increase the friction coefficient and increase
the rate of wear.
(a) Except for elastomeric bearings, bridge bearings, including bearings which are
not required to provide horizontal restraint, shall be fixed to the superstructure
and substructure with mechanical fixings or by other methods reviewed
without objection by the Project Manager. The Contractor may propose to use
friction between the bearing and the superstructure or substructure to resist
the horizontal forces provided he shall apply a factor of safety of at least 2 to
the proven coefficient of friction and that the worst combination of vertical load
and horizontal load is considered.
(b) The ultimate capacity of the mechanical fixings for bridge bearings shall not be
less than the worst combination of loading at ultimate limit state stated in the
schedule of bearings.
(i) vertically: two 112.5 kN wheel loads, 1 m apart, each spread over a
contact area giving an average pressure of 1 MPa and applied in such a
manner as to produce the worst possible effect; and
(ii) horizontally: a traction force of 75 kN/m run of the joint applied
perpendicular to the alignment of the joint, together with any forces
arising from strain of the joint.
(c) Fabricated movement joints shall accommodate the movements and rotations
stated in the Specification without damaging the joint and without loading the
supporting structure with forces which arise from strain of the joint exceeding
5 kN/m run of the joint.
(e) Fabricated movement joints shall provide easy clearance of grit or silt entering
slots, grooves or channels forming or associated with the joint.
(f) Surfaces of fabricated movement joints which will be exposed at finished road
level shall provide a resistance to skidding not less than that of the adjacent
road surface.
(g) Fabricated movement joints shall not impair the riding quality of the road
surface for vehicular traffic and the passage of vehicular traffic shall not cause
undue noise or vibration. The size of gaps, including gaps sealed with flexible
material, on the riding surface of the joint shall not exceed 65 mm.
(h) The passage of pedestrians and cyclists shall not be impeded or endangered
by fabricated movement joints.
(a) The holding down and fixing arrangements for fabricated movement joints
shall be capable of withstanding the loads stated in Clause 23.3.6(b). The
diameter of bolts fixed as double row bolts on one side shall be at least 12 mm
and the diameter of other holding down bolts and studs shall be at
least 16 mm.
(b) Fixings for fabricated movement joints shall be compatible with the
reinforcement in the underlying concrete. Any revisions to the reinforcement
required to suit the fixings shall be designed by the Contractor and submitted
to the Project Manager for review without objection.
(b) Prefabricated sheeting shall not rot or support the growth of mildew and shall
be compatible with the materials with which it is in contact. Prefabricated
sheeting which will be exposed to sunlight after installation shall be of a type
unaffected by ultraviolet light.
(c) Prefabricated sheeting shall have a tensile strength, pliability and puncture
resistance such that the sheeting will withstand the stresses induced during
handling and laying without damage. The elongation properties of
prefabricated sheeting shall be such that the sheeting can accommodate the
creep, shrinkage and thermal movements of concrete without distress.
(f) Primers and mastic for prefabricated sheeting shall be a proprietary type
recommended by the sheeting manufacturer and reviewed without objection
by the Project Manager.
(b) Bentonite panels for slabs less than 200 mm thick or with soil cover of less
than 450 mm shall be special panels with specific provision for swelling to
prevent lifting of the slab.
(c) Bentonite joint seal and bentonite granules shall be a proprietary type
recommended by the bentonite panel manufacturer and reviewed without
objection by the Project Manager.
(d) Polyethylene sheeting for use with bentonite panels shall be a heavy duty
type.
(b) Bituminous paint shall be stored in sealed containers marked to identify the
contents and protected from exposure to conditions which may affect the
bituminous paint. The bituminous paint shall be stored in accordance with the
manufacturer's recommendations and shall not be used after the
recommended shelf life has been exceeded.
Holding down bolts for bridge bearings shall be a proprietary type reviewed without
objection by the Project Manager.
(a) Cement mortar for bedding and construction of unreinforced plinths for bridge
bearings shall be a proprietary non-shrink type with a grade strength of at
least 50 MPa reviewed without objection by the Project Manager.
(b) Chemical-resin mortar for the construction of plinths for bridge bearings shall
be a proprietary non-shrink type with a grade strength of at least 50 MPa
reviewed without objection by the Project Manager.
(c) Grout for grouting base plates and holding down bolts shall be a proprietary
non-shrink cementitious type with a grade strength of at least 50 MPa
reviewed without objection by the Project Manager. The grout shall readily
flow under base plates and shall not bleed or segregate. The suitability of the
grout shall be demonstrated by Site trials and reviewed without objection by
the Project Manager.
(d) Adhesives and chemical resin mortars for locating and bedding elastomeric
bridge bearings shall be a proprietary type reviewed without objection by the
Project Manager. They shall be compatible with the elastomer.
Dowel bars for bridge bearings shall be Grade 316 S 31 or 316 S 33 stainless steel
complying with BS 970:Part 1.
(a) Bridge bearings shall be marked by the manufacturer either with the type
numbers stated in the schedule of bearings or with the manufacturer's own
type or other numbers. A schedule shall be provided which relates the
manufacturer's own type or other numbers to the type numbers stated in the
schedule of bearings.
(b) The design movement directions and magnitudes and the axes of bearing
shall be marked on the upper faces of bridge bearings to facilitate checking of
the installation. Movement indicators shall be provided for sliding and roller
bearings to permit checking of movements of the bearings before and after
installation.
(b) Steel for vehicular parapets, including welding, shall comply with Section 18
except that the requirements for testing shall not apply.
(c) Protective treatment to steel for vehicular parapets shall comply with
Section 18 and shall be applied after welding, drilling and cutting is complete.
(d) Aluminium for vehicular parapets shall comply with the following:
(f) Welding of aluminium for vehicular parapets shall comply with the following:
(i) Stainless steel bolts, nuts and washers for vehicular parapets shall be Grade
A4-80 and shall comply with BS 6105.
Holding down bolts for vehicular parapets shall be a proprietary type reviewed
without objection by the Project Manager.
Grout for holding down bolts for vehicular parapets shall be based on polyester
resins and shall be a proprietary type reviewed without objection by the Project
Manager.
(a) Joint sealant for movement joints formed in place shall be a polysulphide-
based sealant. Polyurethane-based sealant shall not be used.
(b) Joint sealant shall be resistant to attack by petrol, diesel oil, dilute acids and
alkalis, synthetic and mineral oils, hydraulic fluids and paraffin. The sealant
shall have a transverse butt joint movement range for repeated cyclic
movement of at least 25% of the width of the joint.
PVC capping strip shall be a proprietary type reviewed without objection by the
Project Manager.
Holding-down bolts for movement joints shall be a proprietary type reviewed without
objection by the Project Manager.
Grout for holding-down bolts for movement joints shall be based on polyester resins
and shall be a proprietary type reviewed without objection by the Project Manager.
• tensile strength;
• pliability;
• puncture resistance; and
• elongation;
(a) The following particulars of the proposed bridge bearings shall be submitted to
the Project Manager for review without objection:
(i) details of type of bridge bearings, including materials, and the name and
address of the manufacturer;
• friction tests;
• load tests;
• tests on elastomers;
• quick production tests; and
• stiffness tests;
Representative samples of the proposed posts and rails for vehicular parapets shall
be submitted to the Project Manager for review without objection.
(a) The following particulars of the proposed movement joints shall be submitted
to the Project Manager for review without objection:
(i) details of type of movement joint and the name and address of the
manufacturer;
(iii) details of fixings, including the size, length and spacing of holding down
bolts and any necessary revisions to the reinforcement;
(iv) details of materials for making good adjoining road surfaces and
nosings, including reinforcement, jointing and curing details;
(vi) for fabricated movement joints, a written undertaking from the Contractor
stating that the movement joint supplier shall install the proposed
movement joint.
(a) Surfaces on which waterproofing systems will be laid shall be clean, dry and
free from voids, loose aggregate, sharp protrusions, projecting tying wire,
release agents and other items or substances which are likely to damage or
affect the waterproofing system.
(c) Before waterproofing systems are laid on concrete surfaces, the concrete
surface shall have been cured for at least 7 days and shall be cleaned with a
broom and sealed with one coat of primer. Primed surfaces shall not be
covered until the solvent constituent has evaporated. Water shall be allowed
to evaporate from primers containing bituminous emulsion before the surface
is covered. Primed surfaces shall be protected from contamination
(a) Prefabricated sheeting shall be laid one sheet at a time from low points and
drains, towards high points. The sheeting shall be firmly and tightly brought
into contact with the primer or underlying sheeting.
(c) The perimeter of prefabricated sheeting laid each day shall be sealed with a
trowelled bead of mastic.
(d) A double layer of prefabricated sheeting shall be laid around pipes, posts or
other components which pass through the sheeting and the edges shall be
sealed with a trowelled bead of mastic.
(a) Bentonite panels shall not be laid in water or during wet weather.
(b) Immediately before bentonite panels are laid on a surface, joints and cracks in
the surface shall be sealed with bentonite joint seal.
(c) Polyethylene sheeting shall be laid below and above bentonite panels to
prevent prehydration. Laps of at least 100 mm shall be formed at joints in the
sheeting.
(d) Laps shall be formed at the edges of bentonite panels or the edges shall be
closely butted together and the seam filled with loose bentonite granules.
(e) Bentonite panels shall not be fixed to the underlying surface unless permitted
by the Project Manager. If permitted, the method of fixing shall be by 25 mm
masonry washerhead nails or by other methods reviewed without objection by
the Project Manager.
(g) Bentonite which is exposed at the edges of bentonite panels cut to fit around
pipes, posts or other components which pass through the panel shall be taped
or sealed by other methods reviewed without objection by the Project Manager
to prevent loss of the bentonite filler. The joint between panels and the pipe,
post or component shall be sealed with a continuous bentonite seal.
Surfaces to which bituminous paint will be applied shall be treated with a primer
before the paint is applied if recommended by the paint manufacturer. Bituminous
paint shall be applied in two coats; the first coat shall be allowed to dry before the
second coat is applied.
(b) Bridge bearings which have been pre-assembled shall not be dis-assembled.
(c) The levels of substructures stated in the Contract on which bridge bearings
will be installed shall be adjusted to suit the thickness of the bearing so that
the superstructure will be at the specified level after completion.
(d) Bridge bearings, other than elastomeric bridge bearings, shall be set level on
substructures using only a thin layer of cementitious mortar, unless the Project
Manager permits the bearings to be set on plinths. If setting on plinths is
permitted, the plinths shall be constructed of cementitious mortar or grout,
unless otherwise reviewed without objection by the Project Manager, and the
thickness of such plinths shall be at least 25 mm and shall not exceed 40 mm.
If reviewed without objection by the Project Manager, the plinths may be
constructed of chemical resin mortar, having a thickness of at least 5 mm and
not exceeding 10 mm.
(e) Elastomeric bearings shall be set directly on the substructure. A thin layer of
cementitious mortar may be used to level the surface if the substructure is
concrete. Elastomeric bearings shall not be set in position by grouting
between the substructure and the underside of the bearing.
(f) The top surface of bridge bearings which will support precast concrete or other
prefabricated beams shall be covered with a thin layer of cementitious mortar
immediately before the beam is placed. The beam shall be temporarily
supported on folding wedges until the mortar has achieved sufficient strength
to transmit the weight of the beam to the bearings. Thereafter the temporary
supports shall be removed.
Materials & Workmanship Specification 11/18 January 2011
Issue No. 5, Volume 1 – Civil & Structural Works
Section 23 - Bridgeworks
(g) Temporary locking devices for bridge bearings shall be removed before
post-tensioned superstructures are stressed. Temporary locking devices for
other types of superstructures shall be removed at times reviewed without
objection by the Project Manager.
(b) The level of bridge bearings shall be within 0.0001 times the adjacent span or
the lesser of the adjacent spans or within 5 mm of the specified level,
whichever is less.
(c) The inclination of bridge bearings shall be within 1 in 200 of the specified
inclination.
(d) The horizontal axis of bridge bearings shall be within 0.005 radian of the
specified alignment.
(e) Departure from the common plane between twin or multiple bridge bearings
shall be within the tolerances stated in the Contract.
(a) Vehicular parapets shall be installed to a smooth alignment and with the posts
vertical.
(b) Grouting shall be carried out by setting the vehicular parapets in position and
grouting the gap between the vehicular parapets and the structure. Vehicular
parapets shall be held in position until connections and fixings are complete
and until the fixings have gained sufficient strength.
(b) The vertical faces of recesses in bridge decks for fabricated movement joints
shall be formed by saw-cutting. Holding-down bolts shall be cast into the
concrete for direct mounting of the joints unless the Project Manager permits
the bolts to be grouted. If grouting is permitted, the grouting shall be carried
out by setting the movement joint in position and grouting the gap between the
movement joint and the structure. Rebates and pockets for subsequent
trimming to line and level or for holding-down bolts shall not be used.
(c) The bedding to fabricated movement joints shall be formed such that there
shall be no gaps between the joint and the bedding.
(e) When one side of a fabricated movement joint is being set, the other side shall
be free from longitudinal restraint. Strongbacks or templates used to locate
the sides of a joint shall not be fixed to both sides at any one time.
(a) The gap between fabricated movement joints and the adjoining road surface
or nosing shall be made good after installation of the joint with material which
has properties as similar as practicable to those of the material in the adjoining
road surface.
(b) Bituminous road surfaces shall be made good with a bituminous mixture or
elastomeric concrete. Concrete road surfaces shall be made good with a
cementitious matrix reinforced with metal or glass fibres or with elastomeric or
polymer concrete. Epoxy resin mortar shall not be used.
(c) Elastomeric and polymer concrete shall be prepared, laid and cured in
accordance with the manufacturer's recommendations.
(a) The Project Manager shall be notified before Contractor's Equipment or other
vehicles cross a fabricated movement joint or the adjacent road surface.
(b) Contractor's Equipment or other vehicles shall not cross fabricated movement
joints or adjacent road surfaces until installation of the joint is complete unless
reviewed without objection by the Project Manager. Ramps shall be provided
to allow the vehicles to cross without loads being applied to the joint.
Gaps forming part of movement joints formed in place shall be filled with joint filler
fixed in position with adhesive. The edge of the joint filler shall be covered with
bond breaker tape or a PVC capping strip.
Grooves for joint sealant and compression seals for movement joints formed in
place shall be formed by saw cutting.
Grooves for movement joints formed in place shall be sealed with joint sealant or
with a compression seal.
The surface of fabricated movement joints shall be at least 1 mm, and not more than
3 mm, below the surrounding road surface.
(b) The Contractor shall inform the Project Manager of the date and place of
testing at least 28 days before testing starts.
(c) The procedures for testing bridge bearings shall be submitted to the Project
Manager for review without objection and thereafter shall not be changed.
(d) The reports of tests on bridge bearings shall include load/deflection graphs
and shall be submitted to the Project Manager for review without objection at
least 28 days before installation of the bridge bearings is programmed to start.
One sample of bridge bearing shall be provided from each batch of sliding bearings
and from each batch of other types of bridge bearings which contain sliding parts.
(a) The friction test shall be carried out on each sample of bridge bearing
provided as stated in Clause 23.7.2 to determine the coefficient of friction,
flatness, bonding properties and resistance to mechanical damage. The
method of testing shall be in accordance with Appendix A23.1.
(a) The results of friction tests for bridge bearings shall comply with the following
requirements:
(i) the coefficient of friction in any test position shall not exceed 0.04;
(ii) the flatness of the stainless steel shall be within the specified limits
after testing;
(iii) the bond to the backing plate shall be unaffected by the friction test;
and
One sample of bridge bearing shall be provided from each batch of bridge bearings
other than elastomeric bearings.
Vertical load tests and horizontal load tests shall be carried out on each sample of
bridge bearing provided as stated in Clause 23.7.5. The test loads shall be the
serviceability limit state loads. The method of testing shall be in accordance with
Clause 7.2(b)(1) of the guidance notes to BS 5400:Section 9.2.
The results of tests on bridge bearings other than elastomeric bearings shall comply
with the requirements stated in Clause 7.2(b)(1) of the guidance notes to
BS 5400:Section 9.2.
(a) Except as stated in Clause 23.7.8(b), one sample of elastomeric bearing shall
be provided from each batch of elastomeric bearings for testing by the "Quick
Production Test".
(b) If the Contractor considers there is sufficient evidence that “Quick Production
Tests” have been successfully completed on identical materials in the previous
18 months he may submit the evidence to the Project Manager and propose
that the tests are not necessary. The Project Manager will respond within 14
days of the date of receipt of the submission.
(c) Two samples of elastomeric bearings shall be provided from each batch of ten
or part thereof of elastomeric bearings to determine the stiffness in
compression and stiffness in shear.
(a) The results of tests on elastomeric bearings shall comply with the following
requirements:
(iv) the stiffness in shear shall be within 20% of the value quoted by the
manufacturer and reviewed without objection by the Project Manager.
A23.1.1 Scope
This method covers the determination of the coefficient of friction, flatness, bonding
properties and resistance to mechanical damage of bridge bearings by means of a
friction test.
A23.1.2 Equipment
(iii) equipment for measuring the loads applied, readable and accurate to
within 2% of the measured load;
A23.1.3 Procedure
(i) the PTFE surface of the bearing shall be lubricated with the lubricant;
(ii) two sets of sliding surfaces shall be mounted back to back between
the platens of the compression testing rig with the stainless steel
sliding surfaces in the center;
(iii) a vertical load equal to the permanent load stated in the schedule of
bearings shall be applied for 1 hour;
(iv) a horizontal load shall then be applied steadily and without shock to
the pair of stainless steel sliding surfaces and shall be increased at a
rate of 0.2% of the vertical load per minute until movement occurs
between the sliding surfaces;
(vii) the sliding surfaces shall be removed from the rig and inspected.
(v) the total movement and rate of movement at the maximum horizontal
force applied;
(viii) that the test method used was in accordance with this General
Materials and Workmanship Specification.
24.1 GENERAL
(a) The works and materials specified below shall comply with the sections
stated, unless otherwise stated in this Section.
(ii) formwork and finishes to concrete shall comply with Section 18;
24.3 MATERIALS
Sliding layers below floor slabs of water retaining structures shall be a proprietary
type of polyethylene sheeting reviewed without objection by the Project Manager.
Polyethylene sheeting shall be impermeable and shall have a nominal thickness of
1.1 mm.
24.4 SUBMISSIONS
Particulars of the source and type of proposed sliding layers for water retaining
structures shall be submitted to the Project Manager for review without objection.
(i) sequence and method of concreting bays in floor slabs, walls and roof
slabs and in columns and footings;
(ii) details of alternative locations of construction joints if required;
(iii) details of type and size of waterstops at construction joints and box-
outs;
Representative samples of the proposed sliding layers for water retaining structures
shall be submitted to the Project Manager for review without objection.
24.5 WORKMANSHIP
Measures shall be taken to prevent concrete and deleterious material from being
deposited in drainage systems under floors and on roofs of water retaining
structures. After construction and before testing, the drainage system shall be
thoroughly cleaned by rodding and flushing to remove any deleterious material
which may impede the flow of water into or through the drainage system. The lines
and levels of drainage systems shall be within 20 mm of the specified horizontal
alignment and within 10 mm of the specified vertical alignment.
(b) The first lift in each bay in the walls of water retaining structures shall be
concreted within seven days after completion of concreting the adjacent base
of the wall. Individual lifts shall be concreted in one continuous operation
without cold joints, whether or not the full height of the wall is concreted in one
lift. If the full height of the wall is not placed in one lift, succeeding lifts shall
be concreted within seven days from concreting of the adjacent lift.
If reinforcement is continuous across the joint between bays in the roof slab of
water retaining structures, the bays shall be concreted contiguously, in sequence,
with a minimum period of 48 hours between completion of concreting one bay and
commencement of concreting the adjacent bay.
Unless otherwise stated in the Contract, puddle flanges on built-in pipes in water
retaining structures shall be located centrally within the formwork. Waterstops shall
be fixed around the perimeter of box-outs to the built-in pipes.
(a) Immediately after the roof slab of water retaining structures has been tested,
the slab shall be protected with damp sacks or by other methods reviewed
without objection by the Project Manager from exposure to conditions which
may affect the slab; the protection shall be continued until the roof drainage
system has been constructed or the fill material has been deposited and
compacted.
(b) Materials shall not be stockpiled on roof slabs of water retaining structures.
Contractor's Equipment or other vehicles shall not stand or run on floor slabs
or roof slabs of water retaining structures.
(a) Fill material shall not be deposited behind sections of walls of water retaining
structures until at least seven days after completion of concreting to the
section of wall.
(a) Immediately before water retaining structures are tested for watertightness, all
dust, debris, unused materials and equipment shall be removed from the
structure and the interior of the structure shall be washed and brushed down
with water.
(b) Water for washing water retaining structures for potable or fresh water shall
be fresh, potable water incorporating a mixture of sterilising chemicals added
before the structure is washed at a concentration reviewed without objection
by the Project Manager. The structure shall be maintained in a clean condition
after cleaning.
(a) Drainage systems under floors and on roofs of water retaining structures shall
be tested in accordance with the following requirements:
(a) The results of tests on drainage systems for water retaining structures shall
comply with the following requirements:
(ii) bore, linearity and jointing of pipes shall comply with the specified
requirements.
If the result of any test on the drainage system for water retaining structures does
not comply with the specified requirements for the test, the Contractor shall
investigate the reason. Remedial or replacement work reviewed without objection
by the Project Manager shall be carried out and the drainage system shall be
retested.
(a) The roofs of water retaining structures shall be tested for watertightness over
the complete area of the roof, including perimeter joints. Roofs shall not be
tested in sections.
(b) Water shall be ponded on the roof for a period of three days and topped up to
maintain a depth of at least 75 mm. The test shall be carried out before fill
material is deposited or drainage systems are constructed on the roof.
There shall be no leaks or damp patches visible on the soffits of roofs of water
retaining structures during or at the end of the test for watertightness.
If the result of any test for watertightness of the roof of a water retaining structure
does not comply with the specified requirements for the test, the Contractor shall
investigate the reason. Remedial or replacement work reviewed without objection
by the Project Manager shall be carried out and the roof shall be retested.
(b) The structure shall be filled with water at an approximately uniform rate not
exceeding 2 m depth in 24 hours to the levels stated in Table 24.1. The water
used for testing water retaining structures for potable or fresh water shall be
fresh potable water. The Project Manager shall be notified before filling starts.
The structure or each compartment of the structure being tested shall be kept
full for 7 days before testing to allow for absorption.
(c) After the period for absorption, the water shall be topped up to the specified
level and the test shall begin. During testing, the oscillatory motion of the
water surface shall be dampened. The test period shall be 7 days.
(d) The equipment for recording water levels shall be installed in a temporary
enclosure of minimum dimensions 2 m x 2 m x 2.5 m high with a lockable
door; the enclosure shall be located over stilling wells, manhole openings or
other points of recording water levels. The temporary enclosure shall be
removed on completion of the test. The equipment shall be calibrated before
testing starts and at regular intervals reviewed without objection by the Project
Manager and shall be readable and accurate to 0.5 mm.
(e) The fall in water level in water retaining structures shall be measured at hourly
intervals between 8 a.m. and 5 p.m. each day; the total fall shall be measured
at the end of the test period.
(g) The water used for the final tests on water retaining structures for potable or
fresh water shall be retained in the structure and shall not be wasted or
contaminated.
(a) The results of tests for watertightness of water retaining structures shall
comply with the following requirements:
(i) the total fall in water level at the end of the test period, after adjustment
for evaporation and rainfall, shall not exceed 1/500 times the maximum
specified depth of water in the test or 10 mm, whichever is less; and
(ii) there shall be no leaks or damp patches visible on the surface of the
structure, including any division walls, during or at the end of the test.
If the result of any test for watertightness of a water retaining structure does not
comply with the specified requirements for the test, the Contractor shall investigate
the reason. Remedial or replacement work reviewed without objection by the
Project Manager shall be carried out and the structure shall be retested.
After the test for watertightness of a water retaining structure for potable or fresh
water has been completed, samples of the water in the structure shall be taken by
the Contractor in the presence of the Project Manager. The number of samples and
location of sampling shall be reviewed without objection by the Project Manager.
The results of tests for bacteriological content of the water shall demonstrate that
the structure has been adequately sterilized in compliance with the requirements of
the Contract and the Relevant Authorities.