Water Transmission Pipeline Specifications

PAEW Water Transmission Pipeline from the Water Treatment Plant of Wadi Dayqah Dam
at Mazari in Wilayat Qurayyat to Deem Reservoir in Muscat Governorate
WATER TRANSMISSION PIPELINE FROM THE WATER TREATMENT

PLANT OF WADI DAYQAH DAM AT MAZARI IN WILAYAT QURAYYAT
TO DEEM RESERVOIR IN MUSCAT GOVERNORATE
VOLUME 2
STANDARD TECHNICAL SPECIFICATIONS
PART J – CIVIL WORKS
Specification Part J October 2012

STANDARD TECHNICAL SPECIFICATIONS
PART J – CIVIL WORKS
CONTENTS LIST
SECTION J1 SITE INVESTIGATION 1

J1.1 GENERAL ........................................................................................................................ 1
J1.1.1 Scope 1
J1.1.2 Reference standards 1
J1.1.3 Definitions 1
J1.2 SITE INFORMATION AND REQUIREMENTS ....................................................... 2
J1.2.1 The Site 2
J1.2.2 Geology of the Site 2
J1.2.3 Registration of drillers 2
J1.2.4 Contractor’s superintendence 2
J1.2.5 Contractor’s equipment 2
J1.2.6 Replacement of Contractor’s employees 3
J1.2.7 Assistance for the Engineer’s staff 3
J1.2.8 Contractor’s offices 3
J1.2.9 Welfare, water supplies and hygiene 3
J1.2.10 Disposal of water and waste products 3
J1.2.11 Control of pollution 4
J1.2.12 Disturbance to property 4
J1.2.13 Work in public highways 4
J1.2.14 Method of working 4
J1.2.15 Measurement for payment 4
J1.3 SITE OPERATIONS GENERALLY ............................................................................ 5
J1.3.1 Setting out for Site operations 5
J1.3.2 Casing of boreholes and drillholes 5
J1.3.3 Backfilling boreholes and drillholes 5
J1.3.4 Observation wells 5
J1.3.5 Display of material removed 6
J1.3.6 Daily field records 6
J1.3.7 Water level records 8
J1.3.8 Preliminary records of exploratory holes 8
J1.4 BORING.......................................................................................................................... 10
J1.4.1 Requirements for boring 10
J1.4.2 Boring rigs 10
J1.4.3 Diameter of boreholes 10
J1.4.4 Obstructions in boring 10
J1.4.5 Casing in boreholes 10
J1.5 DRILLING...................................................................................................................... 11
J1.5.1 Requirements for drilling 11
J1.5.2 Drilling rigs 11
J1.5.3 Drilling procedure and core recovery 11
J1.5.4 Length of coring runs 11
J1.5.5 Removal of cores on blocking 11
Specification Part J J-i October 2012

J1.5.6 Casing in drillholes 11

J1.5.7 Flushing media 12
J1.6 TRIAL EXCAVATIONS .............................................................................................. 12
J1.6.1 Starter pits 12
J1.6.2 Hand-dug pits 12
J1.6.3 Backfilling 12
J1.6.4 Protection to pits and trenches left open 12
J1.6.5 Photographs 12
J1.7 SAMPLING .................................................................................................................... 13
J1.7.1 Sampling generally 13
J1.7.2 Sampling equipment 13
J1.7.3 Care of samples and cores 13
J1.7.4 Sampling frequency 13
J1.7.5 Numbering of samples 14
J1.7.6 Labelling samples 14
J1.7.7 Small disturbed samples 14
J1.7.8 Large disturbed samples 14
J1.7.9 Sealing and labelling large disturbed samples 14
J1.7.10 Field moisture content samples 15
J1.7.11 Open-drive undisturbed samplers 15
J1.7.12 Open-drive undisturbed sampling in boreholes 15
J1.7.13 Withdrawing samplers 15
J1.7.14 Sampling in open excavations 15
J1.7.15 Sealing, labelling and storing undisturbed samples 15
J1.7.16 Unsuccessful open-drive sampling 16
J1.7.17 Core boxes 16
J1.7.18 Cores 16
J1.7.19 Marking of core boxes 17
J1.7.20 Storing of core boxes on site 17
J1.7.21 Transport of core boxes off Site 17
J1.7.22 Core samples 17
J1.7.23 Waxing core samples 17
J1.7.24 Labelling core samples 17
J1.7.25 Water samples 18
J1.7.26 Transport of samples to Contractor’s laboratories 18
J1.7.27 Delivery of samples to other destinations 18
J1.8 FIELD TESTING........................................................................................................... 18
J1.8.1 Standard penetration tests 18
J1.8.2 Rock strength testing 18
J1.8.3 Percolation tests in soil (Le Franc tests) 19
J1.8.4 Water pressure tests (Lugeon test) 19
J1.8.5 Pressuremeter tests 20
J1.8.6 Test pit and test trenches 20
J1.8.7 Records of field tests 21
J1.9 INSTRUMENTATION ................................................................................................. 21
J1.10 LABORATORY TESTING.......................................................................................... 21

J1.10.1 Approved laboratory 21
J1.10.2 Schedule of laboratory tests 22
J1.10.3 Type of tests 22
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J1.10.4 Test results and records 23

J1.10.5 Standards for laboratory tests 23
J1.10.6 Unused material to be retained 23
J1.10.7 Use of other laboratories 24
J1.11 REPORTING ................................................................................................................. 24
J1.11.1 Reporting on field work 24
J1.11.2 The report of the Investigation 24
J1.11.3 Contents of the Report 24
J1.11.4 Amendment and submission of final Report 25
SECTION J2 EARTHWORKS 26
J2.1 SCOPE............................................................................................................................. 26
J2.1.1 General 26
J2.2 REFERENCE STANDARDS ....................................................................................... 26
J2.3 SUBMISSIONS BY THE CONTRACTOR ............................................................... 27
J2.4 MATERIALS ................................................................................................................. 28

J2.4.1 Fill material — general 28
J2.4.2 Free-draining fill 28
J2.4.3 Geotextiles 28
J2.5 WORKMANSHIP ......................................................................................................... 28
Sub-section 2.5(a): General 28
J2.5.1 Levels to be recorded 28
J2.5.2 Notification of Rock 28
J2.5.3 Explosives and blasting 29
J2.5.4 Excess Excavation (backfilling) 29
J2.5.5 Trial holes 29
J2.5.6 Excavations: support and working space 30
J2.5.7 Fossils and the like found in excavations 30
J2.5.8 Inspection by the Engineer 30
Sub-section 2.5(b): Site clearance 30
J2.5.9 Site clearance 30
J2.5.10 Trees 31
J2.5.11 Stumps 31
Sub-section 2.5(c): Excavation (other than for pipe trenches) 31
J2.5.12 Excavation generally 31
J2.5.13 Stripping of top surface 31
J2.5.14 Trimming excavations 31
J2.5.15 Disposition of excavated material within the Site 31
J2.5.16 Spoil tips on the Site 32
J2.5.17 Disposal of excavated material off the Site 32
J2.5.18 Field drains 32
J2.5.19 Backfilling of excavation 32
J2.5.20 Filling to structures 33
J2.5.21 Backfilling not to endanger structures 33
Sub-section 2.5(d): Trench Excavation 33
J2.5.22 Trench Excavation generally 33
J2.5.23 Trimming Trench Excavations 34
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J2.5.24 Disposition of material from Trench Excavation 34

J2.5.25 Trenches not to be left open 34
J2.5.26 Refilling Trench Excavations 35
J2.5.27 Refill material: special measures 35
J2.5.28 Crossing watercourses 35
J2.5.29 Geotextiles 35
J2.5.30 Laying of geotextiles 35
J2.6 TESTING ........................................................................................................................ 36
J2.6.1 Testing by the Contractor 36
SECTION J3 CONCRETE WORK 37

J3.1 SCOPE............................................................................................................................. 37
J3.3 SUBMISSIONS BY CONTRACTOR ......................................................................... 39

J3.3.1 General 39
J3.3.2 Certificates and mill test data 39
J3.3.3 Results of tests performed by the Contractor 40
J3.3.4 Samples 40
J3.3.5 Construction plants 40
J3.3.6 Construction details 40
J3.3.7 Concreting records 41
J3.3.8 Welding of reinforcement 41
J3.4 MATERIALS ................................................................................................................. 41
J3.4.1 Cementitious materials 41
J3.4.2 Pozzolanic materials 43
J3.4.3 Aggregates 44
J3.4.4 Water 47
J3.4.5 Admixtures 48
J3.4.6 Concrete Classes 49
J3.4.7 Jointing materials and waterstops 49
J3.4.8 Formwork 51
J3.4.9 Steel reinforcement 52
J3.4.10 Accessories 52
J3.4.11 Joint filler and capping strip 52
J3.4.12 Joint sealant 53
J3.4.13 Epoxy seal coat 53
J3.4.14 Back-up material, bond breaker and primer 54
J3.4.15 Slip membrane 54
J3.4.16 Bituminous paint 54
J3.4.17 Dowel caps 54
J3.4.18 Protective membrane systems (tanking) 54
J3.4.19 Protective coatings to concrete surface 55
J3.5 EQUIPMENT ................................................................................................................. 55
J3.5.1 General 55
J3.5.2 Aggregate production plant 55
J3.5.3 Batching and mixing plant for concrete 56
J3.5.4 Vehicles for transporting concrete 59
J3.5.5 Vibrators for concrete compaction 59
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J3.5.6 Refrigeration plant 59

J3.6 WORKMANSHIP ......................................................................................................... 60
J3.6.1 Proportioning of concrete 60
J3.6.2 Concrete properties and requirements 61
J3.6.3 Concrete consistency 62
J3.6.4 Sampling and testing of concrete 63
J3.6.5 Mixes not approved 64
J3.6.6 Preparing for concreting 64
J3.6.7 Embedded pipes and other item 65
J3.6.8 Fixing and cover to reinforcement 65
J3.6.9 Welding of reinforcement 66
J3.6.10 Design and layout of formwork 66
J3.6.11 Erection of formwork 67
J3.6.12 Removal of formwork 67
J3.6.13 Transporting concrete 68
J3.6.14 Placing concrete 68
J3.6.15 Lift height and time between placement 69
J3.6.16 Placing temperature of concrete 70
J3.6.17 Placing temperature of epoxy concrete and mortar 70
J3.6.18 Concreting in hot weather 71
J3.6.19 Concrete placed in water 71
J3.6.20 Compaction 72
J3.6.21 Attendance of steel fixer and carpenter 72
J3.6.22 Curing of concrete 72
J3.6.23 Joints 73
J3.6.24 Placing of jointing materials 74
J3.6.25 Protective membrane (tanking) 75
J3.6.26 Protective coatings 75
J3.6.27 Epoxy seal coat 76
J3.6.28 Unformed surfaces - class of finish 76
J3.6.29 Sloping surfaces 76
J3.6.30 Formed surfaces - class of finish 77
J3.6.31 Dimensional tolerances and surface finish of concrete 77
J3.6.32 Defects in formed surfaces 78
J3.6.33 Dry-pack mortar 79
J3.6.34 Blinding concrete 79
J3.6.35 Epoxy concrete and mortar 79
J3.6.36 Precast concrete members 79
J3.6.37 Dimensional tolerance of precast concrete 80
J3.6.38 Installation of precast concrete members 81
J3.6.39 Reinforcement details 82
J3.6.40 Bending of reinforcement 82
J3.6.41 Storage of reinforcing bars and fabricated mats 82
SECTION J4 PIPELINES, CABLE DUCTS AND APPURTENANCES 83

J4.1 GENERAL ...................................................................................................................... 83
J4.1.1 Scope 83
J4.3 SUBMISSIONS BY THE CONTRACTOR ............................................................... 91
Specification Part J J-v October 2012

J4.4 MATERIALS ................................................................................................................. 92

J4.4.1 General 92
J4.4.2 Handling and storage 92
J4.4.3 Damage 93
J4.4.4 Pipes, fittings and accessories 93
J4.4.5 Pipe coatings and protection 111
J4.4.6 Valves 116
J4.4.7 Ancillaries 125
J4.5 WORKMANSHIP ....................................................................................................... 126
J4.5.1 Setting out 126
J4.5.2 Trial Length of pipeline 126
J4.5.3 Pipelines in the same trench 126
J4.5.4 Pipeline gradients and cover 126
J4.5.5 Cable duct cover 126
Sub section J4.5 (a) Buried pipes 127
J4.5.6 General 127
J4.5.7 Granular bed and surround 127
J4.5.8 Concrete bed and surround 128
J4.5.9 Jointing 128
J4.5.10 Flanged joints 128
J4.5.11 Work inside pipelines 129
J4.5.12 Cutting of pipes 129
J4.5.13 Closing lengths 129
Sub section J4.5 (b) External protection 129
J4.5.14 Sleeving of pipelines 129
J4.5.15 Tape wrapping with outer wrap for ductile iron pipelines 130
J4.5.16 External wrapping of fusion-bonded epoxy coated pipes and fittings131
J4.5.17 Protection of bolted couplings, adapters and flanges 131
J4.5.18 Painting above ground new ductile iron pipelines and fittings 131
J4.5.19 Connecting to existing pipelines 132
Sub section J14.5(c) Ancillaries 132
J4.5.20 Marker installation 132
J4.5.21 Cable ducts 133
J4.5.22 Anchor and thrust blocks 133
J4.5.23 Diaphragm blocks 133
J4.5.24 Valve and other chambers 134
J4.5.25 Installation of valves 134
J4.5.26 Drawpits 135
J4.5.27 Pipelines built into structures 135
Sub section J14.5(d) Workmanship for high density polyethylene pipelines 136
J4.5.28 PE-HD thermofusion welding 136
J4.5.29 PE-HD bending 136
J4.5.30 PE-HD Storage 137
J4.5.31 Installation of buried PE-HD pipes 137
J4.5.32 Moling PE-HD pipes 137
J4.5.33 Above ground installation of PE-HD pipes 137
J4.5.34 Expansion and contraction of PE-HD pipes 138
J4.6 ROAD CROSSINGS BY TRENCHLESS CONSTRUCTION.............................. 138
J4.6.1 Scope 138
J4.6.2 Submissions by the Contractor 139
J4.6.3 Materials for trenchless construction 140
Specification Part J J - vi October 2012

J4.6.4 Workmanship for trenchless construction 142

J4.7 TESTING PIPES AND DUCTS ................................................................................. 147
J4.7.1 General 147
J4.7.2 Water for testing, cleaning, swabbing and disinfection 148
J4.7.3 Valves 148
J4.7.4 Testing pipelines 148
J4.8 CLEANING OF PIPELINES ..................................................................................... 151
J4.8.1 Water pipelines 151
J4.8.2 Cleaning of cable ducts 152
J4.8.3 Swabbing of pipelines for water supply 152
J4.8.4 Disinfection of Water Pipelines 152
J4.9 COMMISSIONING..................................................................................................... 153
SECTION J5 ENGINEERING METALWORK AND GRP 154

J5.1 SCOPE........................................................................................................................... 154
J5.2 REFERENCE STANDARDS ..................................................................................... 154
J5.3 SUBMISSIONS BY CONTRACTOR ....................................................................... 155
J5.4 MATERIALS ............................................................................................................... 155

J5.4.1 General 155
J5.4.2 Steel items - general 155
J5.4.3 Aluminium items - general 155
J5.4.4 Steel ladders 155
J5.4.5 Steel stairways 156
J5.4.6 Manhole steps 156
J5.4.7 Access covers, road gully gratings and frames 156
J5.4.8 Surface boxes 157
J5.4.9 Metal and GRP flooring and walkways 157
J5.4.10 Chequer plate 157
J5.4.11 Handrailing 157
J5.4.12 Servicing hooks 158
J5.4.13 Fixings for metalwork 158
J5.4.14 Opening tools 159
J5.4.15 Security doors 159
J5.4.16 Security covers 159
J5.5 WORKMANSHIP ....................................................................................................... 160
J5.5.1 Tolerances 160
J5.5.2 Installation 160
SECTION J6 ROADS, PARKING, FOOTPATHS AND DRAINAGE 161

J6.1 GENERAL .................................................................................................................... 161
J6.1.1 Scope 161
J6.1.2 Use of site roads by Contractor 161
J6.3 SUBMISSIONS BY THE CONTRACTOR ............................................................. 163
Specification Part J J - vii October 2012

J6.4 MATERIALS ............................................................................................................... 164

J6.4.1 Materials for roadworks generally 164
J6.4.2 Capping material 164
J6.4.3 Sub-base 165
J6.4.4 Wet mix macadam roadbase 165
J6.4.5 Lean concrete roadbase 166
J6.4.6 Dense bitumen macadam roadbase 166
J6.4.7 Bituminous emulsion 166
J6.4.8 Flexible surfacing 166
J6.4.9 Road marking paint 167
J6.4.10 Pipes for drainage 167
J6.4.11 Pipes for service ducts 167
J6.4.12 Manholes and street gullies 167
J6.4.13 Kerbs, channels, edgings and flags 167
J6.4.14 Concrete and reinforcement for roadworks 167
J6.4.15 Precast concrete block pavements 167
J6.5 WORKMANSHIP ....................................................................................................... 168
J6.5.1 Earthworks 168
J6.5.2 Drainage and service ducts 168
J6.5.3 Concrete - general 168
J6.5.4 Subgrade, capping and formation 169
J6.5.5 Storing material for sub-base and wet mix roadbase 169
J6.5.6 Laying sub-base 170
J6.5.7 Laying of wet mix macadam roadbase 171
J6.5.8 Laying of lean concrete roadbase 171
J6.5.9 Laying of dense bitumen macadam roadbase 171
J6.5.10 Sealing of surfaces 171
J6.5.11 Laying flexible base course and wearing course 172
J6.5.12 Concrete pavement 172
J6.5.13 Surface levels: tolerances 173
J6.5.14 Kerb laying 173
J6.5.15 Footpaths 174
J6.5.16 Parking area 174
J6.5.17 Concrete block pavements 174
J6.5.18 Road markings 174
J6.5.19 Tying in to existing surfaces 175
J6.5.20 Topsoiling, grassing, landscaping and irrigation 175
J6.5.21 Inspection and testing 175
SECTION J7 BUILDINGS 177

J7.1 SCOPE........................................................................................................................... 177
J7.4 MATERIALS ............................................................................................................... 181

J7.4.1 Colours, patterns and textures 181
J7.4.2 Adhesives 181
J7.4.3 Bricks and blocks, sills and copings 181
J7.4.4 Natural stone 181
Specification Part J J - viii October 2012

J7.4.5 Metal ties etc 182

J7.4.6 Materials for mortar 182
J7.4.7 Damp-proof courses and flashings 182
J7.4.8 Sealants and mastics 182
J7.4.9 Materials for plastering and rendering 182
J7.4.10 Materials for terrazzo and granolithic concrete 183
J7.4.11 Tile and slab floors and wall tiles 183
J7.4.12 PVC flooring 183
J7.4.13 Wood block flooring 183
J7.4.14 Textile floor coverings 183
J7.4.15 Roof coverings 184
J7.4.16 Timber 184
J7.4.17 Board and plywood 184
J7.4.18 Decorative laminated plastic sheet 184
J7.4.19 Doors 184
J7.4.20 Windows 185
J7.4.21 Patent glazing 185
J7.4.22 Hardware 185
J7.4.23 Glazing 186
J7.4.24 Partitions 186
J7.4.25 Suspended ceilings 186
J7.4.26 Rainwater goods 186
J7.4.27 Water supply services 186
J7.4.28 Water service pipes 186
J7.4.29 Storage cisterns 187
J7.4.30 Water heaters 187
J7.4.31 Sanitary fittings 187
J7.4.32 Soil, waste and overflow pipes 187
J7.4.33 Waterproof building paper 187
J7.4.34 Aluminium roof edging 188
J7.5 WORKMANSHIP ....................................................................................................... 188
J7.5.1 Colours, patterns and textures 188
J7.5.2 Brickwork and blockwork walling 188
J7.5.3 Mortar for brickwork and blockwork 189
J7.5.4 Joints in brickwork and blockwork 189
J7.5.5 Stonework 189
J7.5.6 Brickwork 189
J7.5.7 Internal plastering 190
J7.5.8 External rendering 190
J7.5.9 Terrazzo and granolithic concrete 191
J7.5.10 Flooring-general 191
J7.5.11 Tile and slab floors and wall tiles 191
J7.5.12 PVC flooring 191
J7.5.13 Wood block flooring 191
J7.5.14 Textile floor coverings 191
J7.5.15 Roof coverings 191
J7.5.16 Roof screeds 192
J7.5.17 Asphalt roofing 192
J7.5.18 Preservation of timber 192
J7.5.19 Carpentry 193
J7.5.20 Joinery 193
J7.5.21 Doors and windows 193
Specification Part J J - ix October 2012

J7.5.22 Glazing 193

J7.5.23 Partitions 193
J7.5.24 Suspended ceilings 193
J7.5.25 Rainwater goods 194
J7.5.26 Water supply services 194
J7.5.27 Water service pipes 194
J7.5.28 Storage cisterns 194
J7.5.29 Water heaters and sanitary fittings 194
J7.5.30 Soil, waste and overflow pipes 194
J7.5.31 Waterproof building paper 195
J7.5.32 Aluminium roof edging 195
J7.5.33 Fix and build into concrete and blockwork 195
J7.5.34 Painting 195
J7.5.35 Galvanising 199
J7.5.36 Protection to exterior surface of faced concrete blockwork 199
J7.5.37 Permanent Access Roads 199
J7.5.38 Marker post /marker plate installation 200
SECTION J8 FURNITURE AND FITTINGS 201

J8.1 SCOPE........................................................................................................................... 201

J8.3.1 Data 202
J8.3.2 Certificates 202
J8.3.3 Samples 202
J8.4 MATERIALS ............................................................................................................... 202
J8.4.1 General 202
J8.4.2 Items of furniture 203
J8.4.3 Window coverings 205
J8.4.4 Floor finishes 205
J8.4.5 Marking and packing 205
J8.5 WORKMANSHIP ....................................................................................................... 205
J8.5.1 Delivery and storage 205
J8.5.2 Installation 206
SECTION J9 BUILDING MECHANICAL SERVICES 207

J9.1 SCOPE........................................................................................................................... 207
J9.4 MATERIALS AND WORKMANSHIP.................................................................... 213

J9.4.1 Environmental conditions 213
J9.4.2 General requirements 213
J9.4.3 Fire and smoke barriers 213
J9.4.4 Circulating pumps 213
J9.4.5 Service pipework distribution systems 215
Specification Part J J-x October 2012

J9.4.6 Electrically heated hot water storage vessels 219

J9.4.7 Cisterns and cold water tanks 219
J9.4.8 Cold and chilled water storage vessels 220
J9.4.9 Valves, taps and cocks 221
J9.4.10 Fans 222
J9.4.11 Automatic sand filters 225
J9.4.12 Air filters 226
J9.4.13 Air heaters 228
J9.4.14 Split air conditioning units 229
J9.4.15 Air coolers 231
J9.4.16 Air washing & humidifying plant 232
J9.4.17 Ductwork 232
J9.4.18 Air terminal devices 234
J9.4.19 Air control devices 236
J9.4.20 Air handling units 237
J9.4.21 Belt drives 238
J9.4.22 Guards 239
J9.4.23 Fan drive pulleys 239
J9.4.24 Refrigeration plant 239
J9.4.25 Condensers 243
J9.4.26 Pressure testing 244
J9.4.27 Refrigerant pipework 245
J9.4.28 Refrigeration plant accessories and controls 245
J9.4.29 Vibration isolation 246
J9.4.30 Noise insulation 246
J9.4.31 Miscellaneous equipment 247
J9.4.32 Controllers 259
J9.4.33 Control cubicles and panels - construction 260
J9.4.34 Automatic controls - motorised dampers 261
J9.4.35 Electrical equipment and wiring 261
J9.4.36 Testing 263
SECTION J10 STRUCTURAL STEELWORK 265

J10.1 SCOPE........................................................................................................................... 265

J10.3.1 General 266
J10.3.2 Design Calculations 266
J10.3.3 Drawings 266
J10.3.4 Certificates 266
J10.4 DESIGN......................................................................................................................... 267
J10.4.1 General principles 267
J10.4.2 Codes and standards 267
J10.4.3 General principles 267
J10.4.4 Design loadings 268
J10.4.5 Deflection limits 268
J10.5 MATERIALS ............................................................................................................... 269
J10.5.1 Structural steelwork generally 269
J10.5.2 Bolts and nuts 269
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J10.5.3 Welding consumables 270

J10.6 WORKMANSHIP ....................................................................................................... 270
J10.6.1 Detailing 270
J10.6.2 Detail drawings and welding procedure sheets 270
J10.6.3 Welding 271
J10.6.4 Fabrication tolerances 271
J10.6.5 Dissimilar metals 272
J10.6.6 Identification of members 272
J10.6.7 Marking of overhead runway beams 272
J10.6.8 Storage 272
J10.6.9 Erection 272
J10.6.10 Bolted connections 273
J10.7 INSPECTION AND TESTING.................................................................................. 274
J10.8 PROTECTIVE COATINGS ...................................................................................... 274

J10.8.1 Surface preparation for coating 274
J10.8.2 Paints 274
J10.8.3 Application 274
J10.8.4 Repairs 275
J10.8.5 Inspection 275
Specification Part J J - xii October 2012

SECTION J1 SITE INVESTIGATION
J1.1 GENERAL
J1.1.1 Scope
Site Investigation, includes Site Operations, Laboratory Testing, and the submission of draft and
final Reports, and is required in connection with completion of the design of by the Engineer of
those part of the Works not specified to be designed by the Contractor.
The nature of the proposed Site Operations (and Ancillary Works if any) and Laboratory Testing
is described in the Specification and the Schedules.
The quantities of work which are thought likely to be required are itemised in the Bill of
Quantities.
Depending on circumstances and conditions found on the Site, the nature and the quantity of
work may be subject to change as ordered by the Engineer.
J1.1.2 Reference standards

Except as may be otherwise stated or instructed by the Engineer, and subject to the following two
paragraphs, the Investigation shall be carried out in accordance with BS 5930 ‘Code of Practice
for Site Investigation’ and with BS 1377 ‘Methods of Testing Soils for Civil Engineering
Purposes’. Core drilling shall use equipment complying with BS 4019 ‘Core Drilling
Equipment” Unless otherwise stated, the applicable issue of these Standards shall be the issue
current at the date three months preceding the date for submission of tenders for the Contract.
Where a relevant European standard or European specification exists, such a standard or
specification may be used as a Reference Standard as an alternative to a British Standard referred
to in the Specification or on the Drawings.
Any other standard or specification having currency in the Sultanate of Oman may be used as a
Reference Standard as an alternative to a British Standard referred to in the Specification or on
the Drawings provided that the Contractor has in his Tender named such standard or
specification and stated his intentions of using it.
J1.1.3 Definitions
The following terms shall have the meanings hereby assigned to them except where the context
otherwise requires:-
A ‘hole’ shall mean and include any borehole, hand-auger hole, drillhole, inspection pit, trial pit
or trial trench required for the Investigation.
‘Boring’ shall mean advancing a hole using a mechanical auger, shell, chisel or clay-cutter. The
rig used shall be called a boring rig and the hole formed shall be called a borehole.
‘Hand-augering’ shall mean advancing a hole using a portable soil auger rotated by hand
principally for shallow exploration and disturbed sampling. The hole formed shall be called an
auger hole.
‘Drilling’ shall mean the use of a machine-driven rig for advancing a hole in rock or soil with a
rotary cutting tool. The hole formed shall be called a drillhole and the rig used shall be called a
drilling rig, which term shall include a boring rig with auxiliary equipment for drilling.
Specification Part J J-1 October 2012

‘Coring’ shall mean drilling for the purpose of recovering cores of rock or soil. Core shall mean
material having a circular clearly defined exterior.
A ‘sample tube’ shall mean the container into which undisturbed soil is forced during sampling
and in which the soil is extracted from the ground and stored, after sealing against loss of
moisture.
A ‘sampler’ shall mean the sample tube and all the accessories that are required to obtain an
undisturbed sample of soil.
‘Made ground’ means any deposits or construction which has been formed by man as distinct
from geological agencies.
J1.2 SITE INFORMATION AND REQUIREMENTS
J1.2.1 The Site

The Site includes working areas at the proposed locations for Site Operations as shown in the
Drawings and other locations in the same general area as may be instructed by the Engineer.
J1.2.2 Geology of the Site

Any geological information given hereunder or elsewhere in the Specification or shown on the
Drawings is to assist the Contractor at the time of tendering. The information is not warranted by
the Employer or the Engineer and the Contractor shall make use of and interpret the same on his
own responsibility.
J1.2.3 Registration of drillers

The Contractor shall only employ drillers who have experience of the equipment proposed and
who are familiar with the methods of investigation, sampling and testing to be carried out.
J1.2.4 Contractor’s superintendence

The Contractor shall include in his superintendence a graduate civil engineer or engineering
geologist and a geophysicist (who shall be constantly on the Site during Site Operations and who
may be the Contractor’s authorised agent or representative). Such person shall be trained and
experienced in the techniques and methods necessary for the successful carrying out of Site
Operations. The Contractor may be asked by the Engineer to submit resumes of the above
personnel for review and approval.
The production of daily field records and logs, taking of samples, field testing, description of
samples and presentation of test results, all as may be required by the Contract, shall be carried
out by suitably skilled and competent employees of the Contractor.
J1.2.5 Contractor’s equipment

The Engineer reserve the right to reject or require the removal from the work site of any
equipment, including drill rigs, rods, bits, and tools, which in their opinion is not capable of
performing the required work in accordance with the technical specifications.
The Engineer may require a reasonable amount of testing of water pressure testing equipment
and other equipment to determine that they are capable of performing the work. The Engineer
may require proof of recent calibration or require re-calibration of pressure gauges, water meters,
and other measuring devices.

Such right of rejection of equipment does not attribute any responsibility for safety of said
equipment, which remains the Contractor’s sole responsibility.
J1.2.6 Replacement of Contractor’s employees

Any person removed from the Investigation at the direction of the Engineer shall be replaced as
soon as possible and the Engineer may suspend the progress of the Investigation until such
replacement is available for work.
In these circumstances the Contractor shall comply with any order from the Engineer for work
already carried out to be repeated. If the results of the repeated work confirm the results of the
work already carried out the cost of the repeated work shall be borne by the Employer but
otherwise shall be borne by the Contractor.
J1.2.7 Assistance for the Engineer’s staff

The Contractor shall provide sufficient supply of pegs poles paint lines spirit levels ladders and
other materials and small tools for checking and setting out and for the measurement of work.
The Contractor shall also provide for the use of the Engineer’s staff all survey and other
instruments necessary for checking the Contractor’s work, such instruments to be maintained in
good order by the Contractor.
J1.2.8 Contractor’s offices

For the use of his own staff and workforce the Contractor shall provide all temporary sanitary
arrangements, stores, workshops, compounds, parking areas and the like necessary for the
completion of Site Operations. The siting and layout of any such facilities shall be to the general
approval of the Engineer. Included in the above shall be a store suitable for the display and
examination of samples.
J1.2.9 Welfare, water supplies and hygiene

The Contractor shall provide suitable welfare facilities and supplies of water for drinking,
washing, sanitation and general purposes in addition to any required for Site Operations and any
requirements in the Period of Maintenance.
The Contractor shall maintain the Site and all working areas in a hygienic condition and in all
matters of health and sanitation shall comply with the requirements of the Ministry of Health or
other competent authority.
J1.2.10 Disposal of water and waste products

The Contractor shall keep working areas well drained and shall take steps to prevent unwanted
water enter the Site Operations.
The Contractor shall make provision for the discharge or disposal from the Site Operations of all
water and waste products howsoever arising and the methods of disposal shall be to the
satisfaction of the Engineer and of any authority or person having an interest in any land or
watercourse over or in which water and waste products may be so discharged.

J1.2.11 Control of pollution

For the purposes of any regulations relating to the Control of Pollution, the Contractor shall be
deemed to be the person responsible for and having control over carrying out the investigation.
The Contractor shall indemnify the Employer against the consequence of any notice served on, or
any complaint laid or proceedings taken against the Employer under the regulations relating to
the Control of Pollution. Providing that the Contractor’s liability to indemnify the Employer shall
be reduced proportionately to the extent that such notice, complaint and proceedings may be the
result of an act of neglect of the Employer, his agents, servants or other contractors (not being
employed by the Contractor).
J1.2.12 Disturbance to property

The Contractor shall ensure that his methods of working cause the minimum of disturbance to
property and to its owners and occupiers, and to any existing amenities.
If the Contractor’s work will cause unavoidable interference with access to adjoining property
the Contractor shall first give seven days notice in writing (or such lesser period of notice as the
Engineer considers to be reasonable) to the occupier of such property and shall provide
temporary means of access for vehicles, animals and pedestrians.
J1.2.13 Work in public highways

Where any work is to be carried out in or adjacent to a public highway the Contractor shall
comply with inter alia the requirements and recommendations of the police, the highway
authorities and any local ordinances.
Wherever the original traffic flow is required to be altered for work, the Contractor shall conform
to the requirements of the relevant authorities. No provision has been made for the closure of any
public highway but if the Contractor wishes to apply for any such closure he shall make all the
proper arrangements for the same with the appropriate persons and authorities. The Contractor
shall bear the full responsibility for the cost of any such closure which may be permitted and
shall indemnify the Employer against any claim whatsoever arising therefrom. The Contractor
shall not be entitled to any extra payment as a result of permission for such closure being refused.
J1.2.14 Method of working

Unless the Contract contains a specific statement to the contrary no programme or method of
work statement nor other statement of working intentions submitted by the Contractor when
tendering shall be taken as amending or limiting the Contractor’s obligations under the Contract.
Any detailed statement of method of construction required by the Engineer shall be submitted not
later than 14 days before the proposed commencement of the operation and the precise timing
shall be agreed with the Engineer 7 days before the commencement of the operation.
J1.2.15 Measurement for payment

All work to be done and goods and services to be provided by the Contractor and other general
obligations of the Contractor under the Contract shall be valued for payment by reference only to
such items as are provided thereof in the Bill of Quantities and (where permitted by the tendering
procedure) to such further items as may have been added thereto by the Contractor when
tendering. The cost of any work goods services and general obligations as aforesaid which are
not so itemised shall be deemed to be included in the rates and prices for other items in the Bill
of Quantities.

J1.3 SITE OPERATIONS GENERALLY
J1.3.1 Setting out for Site operations

The Contractor shall confirm with the Engineer in writing the exact position and proposed depth
of each hole before work is started. The Contractor shall carry out all survey and levelling work
and shall survey the locations of the holes upon completion of Site Operations and shall present
the results of the survey to the Engineer in a form to be approved by him.
The Contractor shall provide all surveying and measuring instruments of every kind necessary for
his own use in the execution of the investigation.
J1.3.2 Casing of boreholes and drillholes

Boreholes and drillholes shall be cased in any stratum which is friable or not sufficiently strong
to stand unsupported, or when directed by the Engineer.
The Contractor shall ensure that casings are of a suitable size and are inserted in such a manner
as to render them recoverable.
J1.3.3 Backfilling boreholes and drillholes

Drillholes shall be backfilled with grout. Test pits, trenches and auger holes shall be backfilled
with well compacted spoil, but excluding soft clays and silts and material softened by rain.
Grout for backfilling holes shall consist of bentonite mixed with cement in the proportion 1 to 4
by weight with no more water than is necessary to permit the grout to flow or be pumped.
Alternatively, holes may be backfilled with purpose-made pellets of bentonite or
bentonite/cement, provided they are of a size which, in the opinion of the Engineer is compatible
with the size of hole and any piezometer tubes to be installed in it and provided they are poured
in carefully so that they do not jam above the bottom of the hole. If there is no standing water in
the hole and there is no requirement for the installation of a piezometer or other instrument, grout
may be poured in from the top. Otherwise the grout shall be fed into the bottom of the hole by a
tremie pipe, the end of which shall always be below the grout-water junction or location of filter
pocket for a piezometer whilst grouting is being carried out.
As far as possible the Contractor shall avoid leaving a hole overnight after he has begun to
withdraw the casing and before he has finished. Where a borehole is to be continued as a drill
hole, drilling casing shall be inserted before the boring casing is withdrawn but no grouting will
be required until the drilling casing is finally withdrawn.
J1.3.4 Observation wells

When directed by the Engineer, the Contractor shall install a standpipe piezometer to form an
observation well in any hole. More than one piezometer and standpipe may be required in any
one hole. The standpipe shall be 20mm-bore rigid PVC or ABS pipe with mechanical joints
which do not rely solely on a cement for their strength and shall be connected at its lower end to
a porous Casagrande piezometer tip of a type approved by the Engineer and sealed with bentonite
above and below. The Contractor shall obtain from the Engineer before starting to backfill,
written instructions as to the depth of the tip, depth of granular material, number of piezometers,
etc in each hole. The cap provided at the top of the tube shall normally be kept closed. All
observation wells shall be provided with lockable covers to prevent plugging or obstruction of
the well.

The Contractor shall take and record water levels in observation wells daily for seven days and
weekly thereafter until completion of the field work.
J1.3.5 Display of material removed

The material removed from all holes, including small and large disturbed samples in their
containers and undisturbed samples in their samplers, shall be laid out in sequence on a clean dry
board for examination by the Engineer. The material shall be displayed in such a manner that,
when required by the Engineer, further small disturbed samples can be taken unmixed with other
material. All the material displayed shall be protected from adverse effects of the weather
including hot sun, rain or frost.
When authorised by the Engineer the Contractor shall remove the samples to his store on the
Site.
J1.3.6 Daily field records

Each day during Site Operations, the Contractor shall hand to the Engineer the original, and post
to the Engineer by first class mail a legible copy, of the records of the previous day’s work
containing the following information in respect of each hole where work was in progress:
1. General
a) Job name, location and coordinates.
b) Rig foreman ‘s name
c) Exploratory hole reference number and level
d) Visitors to rig site (including Contractor’s head office staff
e) Name of supervisory staff
f) Brief description of weather
2. Exploratory Boreholes
a) Plant in use
b) Elevation of top borehole
c) Records of ground water
d) Depth at the end of each working day or shift
e) Depth of each change of stratum
f) Description of subsoil strata encountered
g) Depth at which the bed rock is encountered. Detailed description of features in rock,
naturally occurring breaks, fracture density, mechanical breaks.
h) Detailed description of faults and shear zones, percentage of the gouge, rock
fragments , quarts and calcite veinlets fragment or bressia sizes, shapes surface
features, lithology and strength.
i) Details of obstructions and time spent in and method of overcoming them.
j) Detail of back fill
k) Depth of bottom borehole;
l) Number, type and size of the hole;

m) Date and hours worked on the Site;

n) Brief description of the weather;
o) Total depth of hole at the beginning and end of each shift;
p) Make and type of machine in use;
q) The water levels and the depths at which water inflows were encountered;
r) The approximate quantity of water poured into a borehole and the time(s) when it
was done;
s) Diameter of the hole and depths of any reduction in diameter;
t) The length of hole for which casing was used and the diameter of such casing;
u) A brief description of each stratum encountered;
v) Depth below ground of each change of stratum;
w) Reference number, depths and other details of all small and large disturbed samples,
field moisture content samples and undisturbed samples (giving serial number and
type of the sampler, length of sample recovered and number of blows used, if
driven);
x) Commencing and terminating depths of each drilling run, details of type of bit, core
barrels used and lengths of core and of samples recovered;
y) The depth of any loss and return of flushing fluid;
z) Data obtained during field tests, together with the water level in the hole and the
depth of casing during the test;
aa) Details of any instrumentation installed;
bb) Details of backfilling and grouting;
cc) Details of delays and breakdowns;
dd) Any other relevant information and details of any other operation for which the
Contractor considers he may be entitled to additional payment.
3. Rotary / Percussion borings
a) Rate of penetration;
b) Diameters and depth of all casings used;
c) Any addition of water to the boring;
d) Method of penetration and flushing system;
e) Type of core barrel and bit used;
f) Depth of and finish of each core run;
g) Core diameters and depths to changes the core diameters;
h) Condition of return of water flush and type of cuttings;
i) Total core recovery with information as to possible location of core losses;
j) Details of loss of drilling fluid;
k) Name of contract.

J1.3.7 Water level records

Readings of water levels in all holes where work is in progress shall be taken with an electrically
operated sounder and recorded in the daily field records and logs at the following times:
1. Before work commences in the morning;
2. Before the mid-day break;
3. After the mid-day break;
4. After work has finished in the evening, both before and after water (if any) is added
to stabilise the hole;
5. When a hole has been completed;
6. Immediately prior to backfilling a hole;
7. At the time of undisturbed sampling and standard penetration and other in-situ tests;
8. When the Engineer requires.
The level of the bottom of the hole and the bottom of the casing, if any, shall be measured and
recorded at the same time as each water level reading.
The times when water levels are measured should also be recorded.
If, at any time, the level of the water in a hole fluctuates, a record shall be kept of the fluctuation.
If the hole ‘makes’ or ‘loses’ water, the Engineer shall be informed immediately.
Any addition of water to assist the advance of a hole shall be recorded and any extraordinary
smell or colour of the water recovered and any other unusual circumstances shall be reported.
Water shall not be added to or removed from a hole when, in the opinion of the Engineer, such
action might adversely affect undisturbed sampling and the results of in-situ tests.
When ground water is encountered the depth below ground level of the point of entry shall be
recorded and operations stopped and the depth to water level shall be recorded at 5-minute
intervals until no further rise is observed. On each occasion when groundwater is encountered the
depth of the hole, the depth of any casing and the time shall also be recorded.
Where artesian conditions are encountered, the Contractor shall inform the Engineer
immediately.
J1.3.8 Preliminary records of exploratory holes

The Contractor shall prepare preliminary records for all exploratory holes. The format of all
records shall be subject to the approval of the Engineer. Two draft copies shall be submitted to
the Engineer within 7 working days of the completion of the exploration to which they refer and
shall contain the following information:-
For all exploration holes:
1. Contract title and reference number (if applicable);
2. Contractor’s name;
3. Exploratory hole reference number, location (grid reference or co-ordinates)
and diameter or size;
4. Dates of exploration referred to the depth at the end of each working day or
shift;
5. Equipment in use;

6. Details of services or drains located;

7. Data on the stability of the exploratory hole and details of casing/shoring used
related to progress;
8. Ground level referred to datum;
9. Depth to each change of stratum;
10. Records of groundwater; depth encountered, height to which water rose, rate of
inflow, depth cut off by casing or shoring;
11. The depth at which samples were taken or the limits between which
‘undisturbed’ or ‘bulk disturbed’ samples were obtained;
12. The method used and the driving effort required to drive ‘undisturbed’
samples;
13. The depth details and results of all in situ tests;
14. Elevation of each stratum referred to Ordnance Datum;
15. Symbolic legend of strata encountered in accordance with BS 5930
incorporating a suitable scale;
16. Details of backfilling, grouting and piezometer installation;
17. Systematic engineering description of each stratum in accordance with BS 5930
Clauses 41 and 44.
In addition to the above the following information shall be provided for boring and augering:
18. Any addition of water to the boring.
In addition to items 1 to 18 above the following information shall be provided for drilling:
19. Orientation of the drillhole given as an angle to the horizontal and the azimuth;
20. Method of penetration and flushing system;
21. Type of core barrel, liner and bit used and condition;
22. Depth and times of start and finish of each core run;
23. Core diameters and depth to changes in core diameter;
24. Condition of return of fluid flush and type of cuttings;
25. Total core recovery with information as to possible location of core losses for
each core run;
26. Solid core recovery as percentage of each core run;
27. Rock quality designation (RQD);
28. Fracture index or fracture spacing of each core run;
29. Fracture orientation in relation to core axis with description of any gouge
material, staining and the like.
In addition to items 1 to 29 above the following information shall be provided for inspection pits,
trial pits and trial trenches:
30. Dimensions of the trial excavation in plan and orientation related to a north
sign;
31. Symbolic legend of the strata enclosed on each face of the excavation including
information on types of discontinuities and non-uniform horizons and
incorporating a suitable scale;
32. Data on quantity of water pumped from the excavation.

J1.4 BORING
J1.4.1 Requirements for boring

Boring in superficial deposits and weathered bedrock will be required to the depths and at the
diameters indicated in the Schedules or the Bill of Quantities.
J1.4.2 Boring rigs

Boring rigs shall be capable of completing holes to at least the depths indicated in the Bill of
Quantities at a minimum diameter of 150mm. Boring may be carried out by percussion tools but
not by water jets. Nothing except clean water may be added during boring.
In boring through cohesive materials water shall be added only after specific approval by the
Engineer.
In boring through permeable materials the Contractor shall avoid any unnecessary disturbance to
the material and shall ensure that:
1. The water level in the hole shall be maintained slightly above the water table in the
permeable stratum;
2. The casing shall be left as near to the bottom of the holes as possible; and
3. Close-fitting tools shall be withdrawn slowly to avoid suction pressure.
J1.4.3 Diameter of boreholes

The diameter of the holes shall be at least 150mm at the bottom of the hole and over the entire
depth of the hole shall be such as to permit the taking of all required types of samples and the
removal of all other material in such a way that it can be accurately identified and the levels of
each stratum accurately determined to the full depth of the borehole.
J1.4.4 Obstructions in boring

If any obstruction such as timber, brickwork, concrete, metal or other material is encountered in
any borehole and if the Contractor is of the opinion that such obstruction cannot be removed
unless it first be broken up by the repeated use of a heavy chisel or other similar tool, the
Contractor shall immediately inform the Engineer before endeavouring to break up and remove
the obstruction. Where possible a small sample shall be taken of the material forming the
obstruction.
The Contractor shall carry out such instructions as the Engineer considers are appropriate in the
circumstances, which instructions may include for the use of the chisel, where in the opinion of
the Engineer it is essential for deepening the hole.
J1.4.5 Casing in boreholes

When a borehole is being cased the provisions of Clauses J1.3.2 and J1.3.3 shall be observed.
Additionally, in the case of granular or soft soil the bottom of the casing shall always be
maintained within 150mm of the bottom of the borehole. The casing shall never be in advance of
the bottom of a borehole during undisturbed sampling or standard penetration tests.
Specification Part J J - 10 October 2012

J1.5 DRILLING
J1.5.1 Requirements for drilling

Drilling will be required to the depths and at the diameters indicated in the Schedules or the Bill
of Quantities. Boreholes shall be continued as drillholes when directed by the Engineer. Open-
hole drilling may be carried out where core drilling is not required.
J1.5.2 Drilling rigs

Drilling rigs shall be of the hydraulic feed type capable of using a rotary cutting tool, tipped with
diamonds or other hard material and equipped to recover cores, and a rock roller or similar bit for
drilling without core recovery. Bits, core-barrels and casing shall conform to BS 4019: Part 1:
1974 or an approved equivalent. Core barrels shall normally be double-tube ball-bearing swivel
type with the core lifter located in the lower end of the inner barrel. Use of an internal plastic
lining sheet (such as the ‘Mylar’ type) or thin rigid plastic liner (such as ‘core line’) to retain the
core shall be required for coring in soft or friable formations and where ordered by the Engineer.
The use of standard triple tube or double tube core barrels with split inner tube and thin walled
bits, purpose made for coring loose or weathered formations, may also be accepted.
Coring bits shall be of face-discharge type designed to prevent contact between core and flow of
drilling fluid, unless the Engineer directs otherwise.
Drilling equipment shall be capable of forming holes at angles of up to 45° to vertical.
J1.5.3 Drilling procedure and core recovery

Drilling shall be carried out in such a manner and using such sizes of bits, that the maximum of
core is recovered. This requires close surveillance of flushing media, drilling pressures, lengths
and runs and all other factors relevant to the nature of the material drilled. The drill bit shall be
withdrawn and the core removed as often as may be necessary to secure the maximum possible
amount of core. In soft or friable formations, dry-drilling techniques may be required as directed
by the Engineer.
J1.5.4 Length of coring runs

Coring runs shall be limited to a maximum length of 3m. When less than 80% of the core is
recovered from a run the length of the following run shall be reduced to 50% of the previous
length unless otherwise directed by the Engineer. However reduction in core runs to a length of
less than 0.5m shall not generally be required. In friable rock or when recovery is poor, the
Engineer may require a standard penetration test to be carried out between core runs.
J1.5.5 Removal of cores on blocking

The core shall be removed from the drillhole immediately if blocking of the bit or grinding of the
core is apparent, regardless of the length of run which has been made.
J1.5.6 Casing in drillholes

Where used, casing shall be advanced in sequence with each coring run, and the provisions of
Clauses J1.3.2 and J1.3.3 shall be observed.

J1.5.7 Flushing media

The drilling fluid shall normally be clean water or air unless the Engineer directs otherwise.
Bentonite mud or fluids other than clear water shall not be used for overburden drilling or in
holes intended for permeability testing or piezometer installation.
J1.6 TRIAL EXCAVATIONS
J1.6.1 Starter pits

Starter pits shall be excavated by hand at the position of each borehole unless the Contractor is
certain that there are no buried services. Starter pits shall be not less than 1m² in plan and not
more than 1.2m deep. An electronic detection device shall be used to survey across the bottom of
the pit to check for buried services below the pit.
J1.6.2 Hand-dug pits

Hand-dug pits shall be excavated at the direction of the Engineer to search for services or other
buried items. Unless otherwise directed, hand-dug pits shall not exceed 1.2m in depth.
J1.6.3 Backfilling
Permission for a trial pit or trench to be backfilled will normally be given as soon as the logging
sampling and testing in that pit has been completed.
Material shall be replaced and well compacted in the holes at the same levels from which it was
excavated.
The Contractor shall backfill and compact all trial pits, trenches and inspection pits in such a
manner and using such materials that no subsequent depression is formed at the ground surface
due to settlement of the backfill. Where required by the Engineer, the Contractor shall return
during the Period of Maintenance to fill any subsequent depression or to remove any surplus soil
which has failed to settle sufficiently, without reducing the original depth of topsoil at the ground
surface.
J1.6.4 Protection to pits and trenches left open

Where the Engineer may require pits and trenches to be left open for a period greater than one
day or where pits and trenches are left unattended, the Contractor shall provide fencing together
with all necessary lighting and signing required. The Contractor shall also take precautions to
protect the pits and trenches from adverse effects of weather during this period.
J1.6.5 Photographs
Where required by the Engineer colour photographs of pits and trenches and their arisings shall
be supplied by the Contractor. Each photograph shall show clearly details of the ground
conditions in each pit and trench face with any support in place, and shall contain an indicated
scale which shall be the same in every photograph. A standard colour chart and monochrome
step wedge shall also be included in each photograph. Photographs will generally be required at
the rate of three for every pit or as directed by the Engineer. A single gloss colour print
size178mm x 127mm of each photograph shall be submitted to the Engineer for his approval and
retention not more than 1 week after the excavation of the pit involved. In the event that the

photographs are of a quality unacceptable to the Engineer they shall be re-taken, if reasonably
possible, at the Contractor’s expense.
On acceptance of the quality of the photographs, complete sets of prints size 178mm x 127mm of
all the photographs shall be mounted and submitted by the Contractor in bound volumes together
with the photograph negatives with the Report.
The number of copies required shall be as specified in the Bill of Quantities.
J1.7 SAMPLING
J1.7.1 Sampling generally

The Contractor shall take samples from any hole when ordered to do so by the Engineer and shall
provide all necessary sampling equipment, tubes and containers.
J1.7.2 Sampling equipment

Sampling equipment and containers for samples shall accord with details given in the Schedule
of Information by the Contractor when tendering, provided that they also comply with the
requirements of BS 5930. In any event, no equipment or container shall be used unless approved
by the Engineer.
J1.7.3 Care of samples and cores

The Contractor shall be responsible for the safe keeping of samples and cores of all kinds until
they have been handed over to the Employer or disposed of on the Engineer’s instructions as the
case may be. All samples shall be prepared and packed as quickly as possible after removal from
the ground to preserve the natural condition of the soil. Samples shall be protected at all times
from temperatures below 5°C and above 25°C and from wetting or drying out due to weather
exposure.
J1.7.4 Sampling frequency

Unless otherwise instructed by the Engineer the Contractor shall take samples at the following
intervals:
Undisturbed samples
Bulk disturbed samples Small disturbed samples
(cohesive soil)
Boreholes First sample at 0.5m below At least one sample from At least one sample from
ground level or from base each soil type and at each soil type and at
of inspection pit intervals of 2.0m intervals of 1.0m
At depths 0 to 5m,
interval = 1.0m
At depths >5m,
interval = 1.5m
Pits and Intervals of 1.0m and from At 1.0m intervals and from
trenches each representative soil each soil type

J1.7.5 Numbering of samples

The Contractor shall assign a reference number to each soil and water sample taken from holes.
The number shall be unique for that hole and shall be in order of depth below ground level, as
shown in the specimen logs in the Appendix hereto.
J1.7.6 Labelling samples

Subject to any particular requirements of the Specification all disturbed and undisturbed soil
samples and water samples taken from holes shall be clearly labelled in accordance with
BS 5390. Each label shall include the following information:
1. Name of contract;
2. Reference number of the hole;
3. Reference number of sample;
4. Date of sampling;
5. Brief description of the sample — such as ‘stiff blue silty clay’;
6. Depth of the top and bottom of the sample below ground level;
7. Location, depth and geographical orientation of the sample in the case of test
pits;
8. Number of sampler tube.
J1.7.7 Small disturbed samples

Disturbed samples shall be truly representative of the composition of the in-situ soil. When the
samples have been taken from the hole, they shall be placed without delay in airtight glass or
plastic jars of not less than 1.0kg nominal size. Each sample shall fill the jar as nearly as possible
and the jars shall be labelled. If the material in the ground includes large pieces which it is
impracticable to include in the glass or plastic jars, a separate large sample of the material shall
be taken, sealed and labelled.
Material from the cutting shoes of open-drive undisturbed samplers and from the split spoon
sampler used for Standard Penetration tests shall also be taken as disturbed samples.
J1.7.8 Large disturbed samples

Large disturbed samples shall be taken in both cohesive and non-cohesive soils; they shall be not
less than 10kg. They shall be representative of the zone from which they have been taken and the
following sampling procedure shall be used. Within the limits of the zone being sampled all the
recovered soil shall be placed on a suitable tray, care being taken to retain the fines of water
bearing granular soils. This soil shall be mixed by shovel and quartered until the required amount
of soil is obtained.
J1.7.9 Sealing and labelling large disturbed samples

All large samples shall be sealed into heavy duty plastic bags of at least 500 gauge thickness
immediately they are taken. The sealed bag shall then be placed inside another similar plastic
bag. Each outer bag shall be labelled as specified and a second label giving the same information
shall be placed inside the other bag.

J1.7.10 Field moisture content samples

Field moisture content samples shall be taken with (and separately from) each small disturbed
sample or as otherwise directed by the Engineer. Field moisture content samples may also be
required from cores as directed by the Engineer. The samples shall be placed in airtight
containers immediately after sampling and shall be weighed on Site within two hours of
sampling. The moisture content shall be determined from this weight using the method specified
in BS 1377. The oven and scales necessary for the tests shall be set up on Site before boring
starts.
J1.7.11 Open-drive undisturbed samplers

Undisturbed samples of cohesive soil shall be taken in approved 70mm diameter or larger open-
drive sample tubes made from thin walled seamless steel or aluminium not less than 450mm in
length fitted with a cutting shoe (or having a cutting edge) tapered at an angle not exceeding
20 degrees and having an area-ratio not exceeding 25%, or such other sample tube as is approved
by the Engineer. 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. Each sample tube shall have a unique reference number and the word
“TOP” engraved on its exterior at one end. The internal and external diameter of the cutting shoe
and of the sample tube shall be recorded.
The sample tube and cutting shoe (or edge) 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. The end of
the sample tube marked “TOP” shall be driven uppermost. Care shall be taken to ensure that the
sample is not compressed by over-driving. The dimensions, construction and condition of each
sample tube, cutting edge and adaptor head shall be subject to the approval of the Engineer.
J1.7.12 Open-drive undisturbed sampling in boreholes

The Contractor shall make every effort to avoid disturbance of the material to be sampled. The
number of blows required to drive each 75mm of penetration shall be recorded unless the
sampler is pushed into the ground by hydraulic jacks.
J1.7.13 Withdrawing samplers

Before withdrawal, the sampler shall (if practicable) be rotated through one complete revolution
to shear the soil horizontally at the bottom of the sampler. The sampler shall then be withdrawn
smoothly so as to cause the minimum disturbance to the sample. The total length of the sample
shall be measured and recorded and, if any of the soil has fallen out of the bottom of the tube,
this fact shall also be recorded.
J1.7.14 Sampling in open excavations

Prior to sampling in trial pits the area overlying the soil to be sampled shall be cleared by the
Contractor of all material which has altered from its natural condition.
J1.7.15 Sealing, labelling and storing undisturbed samples

After removing the cutting shoe and the adaptor head with the disturbed material which they
contain, the visible ends of the sample shall each be trimmed of any wet disturbed soil and then
immediately coated with not less than four layers of just molten microcrystalline wax or other
similar material approved by the Engineer. A metal foil disc 10mm greater diameter than the tube

shall then be added and followed by more molten wax to form a plug of total thickness not less
than 25mm. Any space remaining in the ends of the sample tube shall be filled with damp
sawdust or other material approved by the Engineer and the ends of the sample tube shall be
covered with tight-fitting screw caps.
The sample tube shall immediately be labelled as specified and a second label giving the same
information shall be placed inside the sample tube at the top end.
J1.7.16 Unsuccessful open-drive sampling

Where an attempt to take an ‘undisturbed’ sample fails the boring shall be cleaned out for the full
depth to which the sampling tube has been driven and the recovered soil saved as a disturbed
sample. A fresh attempt shall then be made from the level of the base of the failed attempt.
Should this second attempt prove unsuccessful, the Contractor shall adopt means of sampling as
agreed with the Engineer.
A recovered sample which is less than 100mm long shall be deemed to be unsuccessful.
J1.7.17 Core boxes

Core boxes shall be soundly constructed in timber or other approved material, fitted with stout
carrying handles, fastening and hinged lids and shall be to the approval of the Engineer.
Depth shall be indicated by durable markers of a type approved by the Engineer at one metre
intervals and at all significant changes of strata and at the end of each drill run. Where there has
been failure to achieve 100% recovery, core spacer pieces of appropriate size clearly indicating
the missing lengths, shall be placed in the boxes. The location, exploratory hole number and
depth of coring relating to the contents of each box shall be clearly indicated in indelible ink on
labels inside the box, on the top and on each end of the box. All markers and labels shall be such
as to facilitate subsequent photography. At the end of each day’s work, cores shall be stored in
their boxes, secure from interference and protected from the weather. The core boxes shall
become and remain the property of the Employer when the core has been permanently placed
therein.
J1.7.18 Cores
Core barrels shall be held horizontally whilst the core is extruded, in the same direction as it
entered the barrel, by applying a constant pressure, without vibration and in a manner to prevent
disturbance to the cores and shall be extruded directly into the core box or into a correctly sized
detachable channel which forms part of the core box. After extrusion all cores shall immediately
be sealed with transparent flexible sheeting or other approved sealant to prevent drying out and
damage. They shall be resealed immediately following examination, logging and photography.
Where the core is contained in an expendable triple tube liner, the ends of the tube shall be sealed
and waxed as specified for undisturbed open-drive samples. Field moisture samples shall be
taken from the part of the core remaining in the bit.
Core shall be placed in the boxes in the correct sequence, with increasing depth from left to right
in the box and from the hinged side to the hasp side of the box.
Fractured material which does not conform to the definition of core shall be spread throughout its
length and packed securely. Core losses shall be shown by wooden blocks of a square cross
section of approximately the same area and of a length equal to that of the core lost; these should
be inserted immediately after the core is placed in the core box.

Each core run shall be segregated by labelled wooden blocks 25mm thick and the depth of the
bottom of each run shall be marked on the partitions in the core box with paint.
No box shall contain more than 3m of core. The total weight of cores and box shall together not
exceed 60kg.
J1.7.19 Marking of core boxes

The core boxes shall be marked prominently on the top, sides and ends or as directed by the
Engineer using waterproof jet black paint. The markings shall include the name of the Contract,
the working area, the drillhole number, box number and the total number of boxes for the
drillhole. The same markings shall be painted inside the lid so as to be read when the open lid is
viewed from the hasp side of the box.
J1.7.20 Storing of core boxes on site

Before the completion of a drillhole the cores from that hole shall be stored neatly at the drillhole
locations in such a manner that inspection of the cores can be made easily. The boxes containing
the cores shall be stored under cover and protected from the weather to the satisfaction of the
Engineer.
After completion of a drillhole, the Contractor shall remove the boxes of cores to a temporary
central store on the Site until instructed to transport them off Site. Such store (to be provided by
the Contractor) shall be weatherproof and lockable, and shall be large enough to contain all the
boxes of cores from all the drillholes.
J1.7.21 Transport of core boxes off Site

If required, the Contractor shall transport all boxes containing cores to premises or a destination
named by the Engineer. If the said premises are within the control of the Contractor, he shall
continue to be responsible for the care of those samples.
J1.7.22 Core samples

Lengths of core not less than 300 mm and not more than 600 mm long shall be taken for use as
samples for laboratory testing when directed by the Engineer. Such samples shall be cut from the
core as it is extruded from the core barrel and a spacer bearing the sample number shall be placed
in the core box.
J1.7.23 Waxing core samples

Immediately they are taken core samples shall be coated with microcrystalline wax and
cheesecloth or other similar material approved by the Engineer. The coating shall be built up in
layers to a total thickness of not less than 4mm in order to seal the samples against loss of
moisture by evaporation. The samples shall then be packed with straw or sawdust in wooden
boxes for transport to the Contractor’s laboratory. The wooden boxes shall become the property
of the Employer. The samples shall be stored in the manner prescribed for undisturbed samples.
J1.7.24 Labelling core samples

The top of the sample shall be clearly marked both before it is waxed and on the outside of the
wax. Labels as specified shall be placed inside the wax, outside the wax and on the wooden box.

J1.7.25 Water samples

The Contractor shall take a water sample from all holes in which groundwater is encountered
before the addition of water to the hole unless this is impossible. The method of sampling shall
be to the approval of the Engineer. Samples shall be stored only in approved airtight and
scrupulously clean containers, and shall not be less than 1 litre in volume.
J1.7.26 Transport of samples to Contractor’s laboratories

Unless otherwise instructed, the Contractor shall transport all samples to his laboratories where
they shall be available for inspection by the Engineer and for such Laboratory Testing as he may
direct.
The Contractor shall be responsible for the care and storage of samples.
J1.7.27 Delivery of samples to other destinations

If directed by the Engineer the Contractor shall deliver selected samples from Site or from his
laboratories or store to any destination named by the Engineer, at the cost of the Employer.
J1.8 FIELD TESTING
J1.8.1 Standard penetration tests

Standard penetration tests (SPTs) shall be carried out in accordance with BS 1377 using a split
barrel sampler.
All external and internal faces of the samplers shall be smooth and free from scars. If directed by
the Engineer a cone-ended adaptor with a 30° half-angle shall replace the open-ended driving
shoe for gravelly soils. Every precaution shall be taken to minimise disturbance of the soil to be
tested. If the shell is used with the boring rig it shall be worked gently up and down to avoid
disturbance of the soil by surging. The distance through which the shell is dropped shall be small,
and the shell shall be removed slowly to minimise suction. If possible the casing shall be turned
down through the overlying 300mm of soil but shall not penetrate the soil to be tested. The test
shall be stopped if the total blow count, including the seating drive, reaches 75.
A small disturbed sample and, for cohesive soils, a field moisture content sample shall be taken
from each soil type in the sampler core. The water level in the hole at the time of the test shall
also be recorded.
Where a solid cone is used or where no soil is recovered in the sampler, a disturbed sample shall
be obtained from the position of the test.
Unless otherwise directed by the Engineer the frequency of in situ testing shall be:
• in cohesionless soils: at 1.0m intervals for first 10m then 1.5m thereafter, and
• in weak rocks: between coring runs when core recovery is less than 50%.
J1.8.2 Rock strength testing

A rock strength index shall be obtained on site by using a diametral point load test on cores as
directed by the Engineer, and following the method suggested by the International Society for
Rock Mechanics for determining the point load strength index. Each test will comprise a set of
10 readings.

J1.8.3 Percolation tests in soil (Le Franc tests)

As required, the Contractor shall measure the groundwater level and shall perform permeability
tests to determine the water-bearing characteristics of the overburden. Use of drilling fluid
additives, bentonite, or other substances that may affect the permeability of the overburden will
not be permitted in these holes. The Contractor shall provide an adequate source of clear water, a
means of measuring the rate of flow of water added to the top of the hole, and a means of
measuring the depth of the hole.
The hole shall be advanced by driving casing to the required depth(s) in accordance with
Section J1.3. Only flush joint casing shall be used and the casing shoe or bit shall have the same
outside diameter as the casing. The objective of the driving casing is to obtain as tight a seal as
practical between the casing and the overburden to preclude leakage of water along the outside of
the casing during testing. Drilling and casing techniques shall be oriented towards this goal. All
cuttings shall be cleaned out to the bottom of the casing and the hole flushed with clear water.
Clear water shall be added to the fill the hole to the top of the casing, and the rate of fall of water
level in the casing with time shall be measured as required. Alternatively, clear water shall be
added to the casing at a constant rate of flow, necessary to maintain the water level in the casing
measured as required. The following information shall be recorded.
1. Hole number,
2. Depth of bottom of hole,
3. Depth of bottom of casing,
4. Diameter of hole, inside diameter of casing,
5. Rate of fall of water level in the hole in cm/min, or rate of flow of water added to
hole in litres/min,
6. Date and time of test,
7. Names of person(s) conducting the test.
J1.8.4 Water pressure tests (Lugeon test)

As required, the Contractor shall measure the ground water level and shall perform water
pressure tests to determine the water bearing characteristics of the bedrock mass in the selected
drill holes. Use of drill mud, bentonite, or other substances that may affect the permeability of the
rock will not be permitted in these holes, without the specific approval of the Engineer.
The Contractor shall provide:
1. an adequate source of clear water,
2. pump(s) capable of delivering water at rates up to 2.5 l/s at pressures up to 1Mpa,
3. pneumatically inflatable single packers and/or double packers (N-size) with
separations of from 2 to6 m capable of sealing off portions of the hole under
pressures of up to 1 Mpa,
4. water meter(s) reading to nearest 0.05 litre with an accuracy within 10 percent,
5. gauge(s) for reading water pressures up to 1 Mpa with an accuracy of 10 percent,
6. a stop watch and a water-dip meter (device for measuring water levels in boreholes),
7. valves to allow the regulation of flow pressure, and

8. all piping, hoses, and other equipment necessary to conduct the tests.
All pumping materials used for water pressure testing shall have a minimum inside diameter of
25 mm. All equipment shall be in first class working order and shall be subject to approval at all
times
The Engineer will require proof of recent calibration of the water meter(s) and pressure gauge(s)
and a reasonable amount of testing at the site to demonstrate that the equipment is working
properly and accurately.
The Contractor shall calibrate the packer assembly, piping, and valves for friction loss as
required prior to the start of the testing. Friction loss adjustments shall be applied as needed in
the calculation of water pressure test (lugeon) results.
The hole shall be advanced to the required depth(s) as specified elsewhere for Drilling. Tests will
be conducted in accordance with the method of Houlsby, or equivalent international standards for
lugeon testing in rock that require a series of increasing and then decreasing, step-wise
increments in injection pressure (A. C. Houlsby, 1976. Routine interpretation of the lugeon
water-test, Quarterly knl. Engineering Geol., vol. 9, 1976, pp. 303-313). The hole shall be
flushed with clear water prior to actual pressure tests. Tests may be required either progressively
from the bottom of the hole upward, for the entire portion of the hole in rock, or for isolated
segments of the hole. The following information shall be recorded:
1. Hole number;
2. Depth of bottom of hole;
3. Depth of zone tested;
4. Pressure of water supply;
5. Rate of water take;
6. Depth of casing;
7. Date and time of test, and name of person(s) conducting test.
J1.8.5 Pressuremeter tests

As required the Contractor shall perform in situ pressure meter testing at 2 meter intervals or as
directed by the Engineer, to determine the strength characteristics of the overburden and soft
rock, in accordance with ASTM D4719-87 “Test Method for Pressuremeter testing in Soils”.
J1.8.6 Test pit and test trenches

The Contractor shall excavate the test pits and test trenches as shown on the drawings or as
directed. This work shall include: minor cleaning and grading, excavation and stockpiling of
excavated materials, sheathing, bracing, or timbering with wood or other materials of approved
quality where required, dewatering as may be required, sampling as required, and backfilling.
Test pits will be about 1.5 m by 1.5 m in plan (as practical) and test trenches about 1.5 m wide
(or wider depending up on the equipment used to excavate the trench) by up to 20 m in length or
as determined by the Engineer on site. The depth of test pits and trenches shall be 3 to 5m based
on soil conditions and as instructed by the Engineer. Both test pits and trenches shall be
stockpiled away from the edges of the pits/trenches. The sides of the test pit/trench shall be
sloped or braced or sheathed as required for the stability and the safety. A ladder shall be
provided for access to the test pit/trench. Test pits/trenches shall be dewatered during sampling
operations. Test pits/trenches shall be barricaded, fenced off, covered or otherwise protected to
prevent entry by persons or farm animals when open or unattended. Test pits/trenches shall be

backfilled upon completion of sampling. Excess backfill shall be mounded up over the test
pit/trench and shaped to drain off water.
The Contractor shall collect bulk and jar samples from the sides and bottom of the test
pits/trenches at intervals as required by the Engineer and/or the Contractor’s geologist. At least
one sample will be taken from each stratum encountered during excavation. The Engineer
reserves the right to reject the samples that are non-representative, contaminated by other
materials, or otherwise unsatisfactory for testing purposes and no payment will be made for such
samples.
Bulk samples will be about 20 kg in size. Bulk samples shall be sealed in plastic bags or plastic
pails in accordance with ASTM Standard d 4220, “Standard practices for Preserving and
Transporting Soil Samples”. Plastic bags shall be placed in a sturdy wooden crate or a metal or
plastic pail for shipment to the testing laboratory. Each sample shall be labelled with the Project
Name, test pit number, sample number, sample depth, and date of sampling.
At least one jar sample for moisture content determination shall be taken with each bulk sample,
and otherwise as required. Jar samples shall be placed in glass or plastic jars of at least 250 ml
capacity. The jar shall be sealed with a moisture-tight self –sealing screw top. Each sample shall
be labelled with the Project Name, test pit or trench number, sample number, sample depth, and
date of sampling.
The Contractor shall furnish a sketch plan of each test pit/trench and two vertical sections, one
parallel to the length and one parallel to the width of the each test pit/trench. The plan shall show
the general dimensions of the pit/trench at the ground surface, at any general change in cross-
section, and at bottom, and the location of samples. The section shall be in the form of geologic
logs, showing the shape and dimensions of the pit/trench, the depth to any change in soil strata,
the depth to any water inflows, and the location and depth of samples. Visual soil classification
shall be performed in accordance with ASTM D-2488. The type of bracing and sheathing or
sloping of the sides shall be noted on the plan and sections. The test pit and the test trench logs
shall include the Project Name, test pit/trench number, elevation of the ground surface, date
excavation started, date excavation completed, date backfilled, the type and size of equipment
used to make the excavation, the amounts of any water pumped from the excavation and the
name of the Contractor’s employee in charge of the excavation.
J1.8.7 Records of field tests

Within one working day of completing a field test the Contractor shall supply the Engineer with
two copies of the results of the test.
J1.9 INSTRUMENTATION
Instrumentation materials and installation are covered in Section 2.
J1.10 LABORATORY TESTING
J1.10.1 Approved laboratory

The soil, rock and water samples shall be tested at a local approved laboratory in Oman. The
Engineer shall have access to the laboratories to supervise and check the laboratory testing of the
samples. The laboratory shall work to standards specified in J1.10.5.

J1.10.2 Schedule of laboratory tests

The Engineer will decide the laboratory tests required and will provide the Contractor with one
or more schedules for Laboratory Testing. It may be necessary to specify additional testing after
the results of the original testing are available. Testing schedules will not be prepared until the
Engineer has received the relevant preliminary records as detailed in Clause J1.3.8. Apart from
any additional tests which may be ordered, testing schedules will be provided within 1 week of
receipt by the Engineer of the last of such preliminary records. The Contractor shall inform the
Engineer within three calendar days from the receipt of the testing schedule if the samples are not
adequate for all the tests specified.
J1.10.3 Type of tests

The testing in the laboratory shall comprise, but not limited to, the following tests;
1. Grain Size Analysis
2. Atterberg Limits (LL,PL)
3. Specific Gravity
4. Unconfined Compression Test
1. On soil samples
2. On rock samples
5. Direct Shear test on soil
1. Unconsolidated undrained
2. Consolidated Drained
6. Bulk Dry Density
7. Natural Moisture Content
8. Shrinkage Limit
9. Consolidation with swell potential determination
10. Permeability
11. Triaxial Compression (UU)
12. Sulphate content
1. Soil
2. Water
13. Chloride content of Soil water
14. Ph value of soil / water
15. Organic matter content of Soil water
16. Total Dissolved Salts in Soil / Water
17. Petrographic analyses (Fine and Aggregates)
18. Unit weight
19. Los Angles Abrasion
20. Sodium Sulphate Soundness

21. Water Absorption

22. Porosity
23. Electrical Conductivity of Soil / Water
24. Petrographic Studies for Gypsum content of Soil / Rock
25. Creep & Poisson’s Ratio
26. V.B. Time
27. Modulus of Elasticity
28. Direct & Indirect Tensile Strength
29. Compressive Strength
30. Alkali Aggregate Reactivity
31. Silica Content / Abrasiveness Index
32. Fineness modulus
33. Crushing Behaviour and % Sand
34. Flakiness and Elongation Index
35. Aggregate Crushing Value
36. Crumble Test
37. Double Hydrometer Test
38. Pinhole Test
39. Standard Proctor Optimum Moisture Content & Maximum Dry Unit Weight
J1.10.4 Test results and records

The Contractor shall maintain proper records of all tests and shall send to the Engineer a
preliminary copy (in duplicate) of test results within four working days of the completion of each
test.
J1.10.5 Standards for laboratory tests

Subject to any particular requirements of the Contract or special instructions of the Engineer,
laboratory tests shall be carried out and reported generally in accordance within the relevant
British Standards. Where tests are not covered by British Standards they shall be performed in
accordance with the procedures given in the following references.
1. ‘Manual of Soil Laboratory Testing’ by K H Head (Volumes 1 to 3),
2. Relevant publications by the Transport and Road Research Laboratory (TRRL), the
American Society for Testing Materials (ASTM) and the International Journal of
Rock Mechanics and Mining Science (IJRM).
J1.10.6 Unused material to be retained

When laboratory tests are carried out on only a part of a soil sample, any remaining material in
the sampler or container shall be resealed as soon as possible and retained.

All soil on which laboratory tests have been carried out including that wasted during the
preparation of test specimens, shall be retained in labelled airtight containers until otherwise
directed by the Engineer.
J1.10.7 Use of other laboratories

The Engineer may, at his discretion, order individual samples to be handed over to him for
testing at another laboratory in addition to or as an alternative to tests carried out by the
Contractor. Such tests will not be measured under the Contract and the Contractor shall not be
entitled to any payment.
J1.11 REPORTING
J1.11.1 Reporting on field work

In addition to the records and reports (as specified elsewhere) required to be submitted during the
course of Site Operations, and within two weeks of the completion of Site Operations, the
Contractor shall submit for the Engineer’s approval a draft copy of a field report covering
items (a) to (f) of Clause J1.11.3. Upon receipt of the Engineer’s approval of the draft, or
instructions for any modification, the Contractor shall provide such number of copies of the
approved draft version of the field report as may be stated in the Bill of Quantities.
J1.11.2 The report of the Investigation

The Report of the Investigation shall consist of the draft field report together with such other
items as are requested in the Contract and incorporating such further corrections or modifications
as the Engineer may require. The Report shall be submitted in draft for the Engineer’s approval
within 2 weeks of completion of all Laboratory Testing or, if Laboratory Testing is not required,
within 4 weeks of the completion of Site Operations.
J1.11.3 Contents of the Report

The Report shall be bound and shall be of ISO paper size A4. Drawings larger than A3 size shall
be folded and included in bound wallets.
The Report shall contain the following information:—
1. A general description of the work carried out; the numbers and types of exploratory
holes and field tests, plant and equipment used; time of year and general weather
conditions; a factual summary of general geology and subsurface conditions.
2. A general location plan for the Site.
3. A fully-dimensional site plan showing main topographical features, setting out points
and bench marks used and position of all holes with ground levels related to Datum
and locations related to Site grid. A suitable base plan will be provided by the
Engineer when available.
4. Records and logs of all holes and trial pits correctly drawn to scale including all
information as specified in Clause J1.3.8. Material descriptions shall take into
account any additional information obtained from laboratory tests.
5. Full records of all water-level measurements.
6. Full records of all field tests.

7. Full records of all laboratory tests including any which have been carried out by
nominated or approved sub-contractors. The records shall include a detailed
description of each sample tested.
A summary of the results should be included in the main volume of the Report. If the size of the
Report warrants it, detailed records may be included in separate volume(s) and shall include
graphs of laboratory tests where appropriate.
1. Representative colour print photographs of borehole cores, material and trial holes
when required.
2. Appraisal of ground conditions at each location with recommendations for
foundation design and construction.
J1.11.4 Amendment and submission of final Report

Subject to the Engineer’s approval of the draft Report or after incorporating any corrections or
modifications as the Engineer may require, the Contractor shall submit the final Report. The
number of copies required shall be as specified in the Bill of Quantities.

SECTION J2 EARTHWORKS
J2.1 SCOPE
J2.1.1 General
This Part contains requirements which, where relevant to this Contract, shall apply to site
clearance; general excavation; trench excavation; embankments; topsoiling and landscaping.
J2.1.2 Definitions
The following terms shall have the meanings hereby assigned to them:—
‘Topsoil’ any surface material capable of supporting vegetation and suitable for use
in soiling areas to be grassed or cultivated.
‘Rock’ naturally-occurring material which in the opinion of the Engineer would
normally have to be loosened either by blasting or by the use of pneumatic
tools (other than clay spades) or by other rock quarrying methods or, if
excavated by hand, by the use of wedges and sledge hammers. An isolated
solid boulder or detached piece of rock shall qualify as Rock only if it
exceeds 1.0m³ in volume.
‘Bulk excavation in open cut (excluding Trench Excavation) down to levels
Excavation’ specified in the Drawings or otherwise as being the general levels after
completion of excavation other than Incidental Excavation.
‘Trench excavation, to levels and limits specified in the Drawings or otherwise, of
Excavation’ trenches into which pipes and the like are to be laid.
‘Incidental excavation (generally in small quantities) below or outside the limits of
Excavation’ Bulk Excavation and Trench Excavation, but excluding Excess Excavation.
‘Excess excavation outside the limits specified for Bulk, Trench or Incidental
Excavation’ Excavation.
J2.2 REFERENCE STANDARDS

Reference Standards are referred to in the text of the Specification in abbreviated form (such
as BS 1377). The full titles of some which have relevance to this Part are given below for
convenience:—
Standard
BS 410-1:2000 Test sieves. Technical requirements and testing. Test sieves of metal
wire cloth
BS 410-2:2000 Test sieves. Technical requirements and testing. Test sieves of
perforated metal plate
BS 812 (Various Parts) Testing aggregates.
BS EN 1097-2:1998 Tests for mechanical and physical properties of aggregates. Methods for
the determination of resistance to fragmentation
BS 1377(Various Parts) Methods of test for soils for civil engineering purposes.

BS 3506:1969 Specification for unplasticized PVC pipe for industrial uses.

BS 3882:1994 Specification for top soil.
BS 5607:1998 Code of practice for the safe use of explosives in the construction
industry.
BS 6906(Various Parts) Methods of test for geotextiles.
BS 6187:2000 Code of practice for demolition
BS 6031:1981 Code of practice for earthworks
CIRIA Report 97 Trenching practice– 1992 Edition (Reprint 2001)
J2.3 SUBMISSIONS BY THE CONTRACTOR

Submissions which the Contractor is required to make in relation to earthworks include, where
relevant, the following:
Drawings and survey notes:
• Contractor’s record drawings of the ground level survey prior to the start of any
earthwork;
• information obtained from trial holes ordered by the Engineer;
• Contractor's record drawings of any other level surveys taken for the purposes of
measurement of quantities of excavation or filling, such as Rock level surveys;
• (Survey record drawings as specified above shall be submitted within 7 days of the
completion of the survey work recorded on them.)
• survey notes on depths of Trench Excavation;
• survey notes on Rock levels;
• proposals to excavate with sloping faces without support.
Certificates:
• laboratory tests;
• field tests.
Details of proposed methods:
• proposed methods of excavation, transport of materials, filling and compaction;
• proposed source of free-draining fill and methods of selective excavation or
processing;
• programme for quality control of earthworks and proposals for the use of off-Site
laboratories.
Samples:
• materials proposed for filling and for geotextiles, where specified or where
specifically required by the Engineer.

J2.4 MATERIALS
J2.4.1 Fill material — general

Excavated material (including material excavated from borrow pits) selected by the Contractor
for use as backfilling to excavations, as filling around structures or as filling for embankments
shall be free from clods and lumps and shall be approved by the Engineer.
Should the material selected as filling, while acceptable at the time of selection, become
unacceptable to the Engineer for any reason including exposure to weather conditions, flooding,
contamination by other materials or segregation during the progress of the Works, the Contractor
shall at no extra cost to the Employer remove such damaged, softened or segregated material and
replace it with fresh approved material.
J2.4.2 Free-draining fill

Free-draining fill material shall be formed of hard durable particles and shall be free from clay,
silt and organic matter, and shall comply with any particular requirements specified hereafter.
Material for free-draining fill shall be provided by the Contractor from an approved source. The
Contractor shall submit full details of the proposed source, certified test results and samples for
the approval of the Engineer. The Contractor may use material emanating from excavations
having first processed it so that it complies with the specified requirements for free-draining
materials fill.
J2.4.3 Geotextiles
Geotextiles shall have the mechanical and hydraulic properties of the geotextile types and
manufacture specified or equivalent types approved by the Engineer. The materials shall be
sufficiently durable to last for the design life of the structure, and the Contractor shall provide
evidence of similar applications where the proposed material has been used.
J2.5 WORKMANSHIP
Sub-section 2.5(a): General
J2.5.1 Levels to be recorded

Before the surface of any part of the Site is disturbed or the Works thereon are begun the
Contractor shall take and record levels and dimensions of any such part. The Contractor shall
also take and record such other levels and dimensions as are necessary during the progress of
excavation to allow accurate measurement of the different categories of excavation.
All levels and dimensions shall be taken in the presence of the Engineer and recorded in the
manner specified or as agreed with the Engineer, and such levels when agreed with the Engineer
shall form the basis for measurement.
J2.5.2 Notification of Rock

Any material in the excavations which the Contractor considers may be classified as Rock as
defined herein shall be notified to the Engineer before excavation of the material is begun. The
quantities of Rock or material alleged to be Rock excavated from within the nominal limits of
excavation shall be recorded and the agreed record shall be signed by the Engineer and the

Contractor each day or at such shorter intervals as the Engineer may require. Overbreak (that is,
excavation in Rock outside the nominal limits of excavation) shall be kept to a minimum and
shall be held to be Excess Excavation.
J2.5.3 Explosives and blasting

The Engineer shall have power to regulate, restrict or prohibit blasting if in his opinion it is
necessary to do so for the safety of persons or property or to safeguard the Works. No blasting
shall be carried out in any part of the Works without the permission in writing of the Engineer.
Such permission shall not absolve the Contractor from any of his obligations or liabilities under
the Contract. The Contractor shall take all necessary precautions including the use of blasting
nets to avoid damage, loss or injury to persons and to public or private property.
Excavation within 500mm of the Final Surface shall be completed by rock breaker on an
excavator, wedging, barring, channelling and broaching, or by other approved means. Where the
use of explosives is approved for excavation of foundations, they shall be applied as “controlled
blasting” where explosives shall be of such quantity and moderate power and shall be used in
such locations as will neither open seams nor crack nor damage rock outside the specified Final
Surface of the excavation.
Any work involved in the use of explosives, including storage and handling shall be carried out
in accordance with BS 5607.
The Contractor shall obtain the necessary licences for the storage, transport and handling of
explosives and shall provide a store or stores suitable for explosives in accordance with local
regulations.
The Contractor shall keep the Engineer fully informed at all times when blasting is proposed to
be carried out and of any details the Engineer may require concerning strength of charges and
their positions.
J2.5.4 Excess Excavation (backfilling)

Excess Excavation may normally be backfilled with material emanating therefrom, but where the
Engineer has ordered such material to be removed from Site as being unsuitable the Contractor
shall make good the Excess Excavation with such kind of fill material or in such class of
concrete as may be reasonably required by the Engineer having regard to the circumstances.
J2.5.5 Trial holes

The Engineer may direct that trial holes shall be excavated in advance of other excavation to
such dimensions and depths as he shall order to obtain information required by him.
Any further trial holes required by the Contractor to determine the position of underground
services, sub-soil drains or for any other reason shall be excavated and reinstated at no extra cost
to the Employer.
The Contractor shall arrange for the refilling and reinstatement of trial holes to be carried out
immediately the required information is obtained. The reinstatement of the surfaces of trial holes
shall be carried out to the approval of the Engineer.

J2.5.6 Excavations: support and working space

The Contractor shall provide effective support for the sides and ends of all excavations to prevent
any fall or run from any portion of the ground outside the excavation and to prevent settlement or
damage to structures adjacent to the excavation.
If, for any reason, any portion of the bottoms, sides or ends of any excavations shall give way the
Contractor shall at no extra cost to the Employer take all necessary remedial measures including
the excavation and removal of all the ground thereby disturbed both within and without the
nominal limits of excavation and such extra excavations shall be held to be Excess Excavation.
Where the Contractor proposes to carry out excavations with sloping faces (other than sloping
excavations shown on the Drawings or required as permanent features of the Works) and without
shoring, excavated faces shall be to stable slopes and heights and the resulting extra excavation
shall be held to be Excess Excavation. Full details of the Contractor's proposals shall be
submitted to the Engineer for approval.
The Contractor shall be deemed to have made his own allowance for any working space or
support required, and any excavation outside the specified or nominal payment limits which has
not been ordered by the Engineer, whether it be excavated to suit the Contractor's method of
working or unavoidable overbreak or due to his carelessness or error, shall be held to be Excess
Excavation.
J2.5.7 Fossils and the like found in excavations

No requirement of the Specification regarding the disposal of material arising from Site clearance
or excavation shall override any provision in the Conditions of Contract as to the discovery, or
ownership, of fossils, coins, articles of value or antiquity, or anything of geological or
archaeological interest found on the Site.
J2.5.8 Inspection by the Engineer

When the specified levels or limits of any excavation are reached, the Engineer will inspect the
ground exposed and if he considers that any part of the ground is by its nature unsuitable he may
direct the Contractor to excavate further. Such further excavation shall be refilled to the specified
levels or limits with concrete, selected excavated material or selected imported material as
directed but shall not be held to be Excess Excavation.
Should the material forming the bottom or side of any excavation, while acceptable to the
Engineer at the time of inspection, subsequently become unacceptable due to exposure to
weather conditions or due to flooding or have become puddled, soft or loose during the progress
of the Works, the Contractor shall remove such damaged, softened or loosened material and
excavate further to a sound surface. Such further excavation shall be held to be Excess
Excavation and material emanating therefrom shall be removed from the Site.
Sub-section 2.5(b): Site clearance
J2.5.9 Site clearance

All areas of the Site specified or marked in the Drawings for clearance or from which material is
to be excavated or upon which filling is to be deposited shall be cleared to the extent required by
the Engineer of all buildings, walls, gates, fences and other structures and obstructions and of all
bushes, hedges, trees, stumps, roots and other vegetation except for trees marked for
preservation. Material so cleared shall so far as suitable be reserved and stacked for the

Employer’s use but shall otherwise be burnt to ash or disposed of off the Site as directed by the
Engineer.
J2.5.10 Trees
Where directed by the Engineer trees shall be uprooted or cut down as near to ground level as
possible. Branches and foliage shall be removed and burnt to ash or disposed of off the Site.
Useful timber shall, as between the Employer and the Contractor, be deemed to be the property
of the Employer and shall be cut into suitable lengths and transported a distance not exceeding
5km to a location provided by the Employer where it shall be off-loaded and stacked.
J2.5.11 Stumps
Stumps and roots whether existing or remaining after tree felling shall where directed by the
Engineer be grubbed out and disposed of off the Site. The resulting hole shall be filled with
approved material deposited and compacted in layers to the same dry density as the adjoining
soil.
Sub-section 2.5(c): Excavation (other than for pipe trenches)
J2.5.12 Excavation generally

For the purposes of this sub-section, the term ‘Excavation’ shall include excavation, whether
Bulk or Incidental, required for structures and roadworks and from borrow areas. It shall not
include excavation for pipe trenches and the like except for miscellaneous isolated lengths of
trenches beneath or adjacent to structures, such trenches being deemed to be Incidental
Excavation.
The ground shall be excavated by such methods and to such dimensions and depths as shall allow
for the proper construction of the Works.
J2.5.13 Stripping of top surface

Where ordered by the Engineer the top surface including Topsoil if any shall be stripped, to such
depths and over such areas as he may direct, as a separate operation prior to any further
excavation which may be required.
J2.5.14 Trimming excavations

When excavating to specified levels for the foundation of any structure or to specified limits for
the face of any structures required to abut undisturbed ground the Contractor shall not finally
complete the excavation until immediately before commencing the constructional work, except
where the Engineer shall permit otherwise.
Before commencement of any constructional work all shattered and loose material shall be
removed from the excavations so as to ensure that the work rests on a sound and clean
foundation or where appropriate abuts against undisturbed ground.
J2.5.15 Disposition of excavated material within the Site

Subject to any specific requirements of the Contract, the disposition of excavated material within
the Site shall be at the Contractor’s discretion but shall be so arranged as to suit the overall
requirements for the construction of the Works.

The Contractor shall ensure that no excavated material which is suitable for and is required for
reuse in the Works is disposed of outside the Site.
J2.5.16 Spoil tips on the Site

Only material which is approved by the Engineer shall be placed in the various spoil tips. No tree
trunks stumps roots branches or rubbish of any kind shall be placed in spoil tips.
Temporary spoil tips may be used to store excavated material as required and shall be arranged
by the Contractor subject to the Engineer's approval having regard to any particular requirements
of the Contract. Temporary spoil tips shall be so shaped as to maintain stability and good
drainage at all times. Where directed by the Engineer, Topsoil stripped from the Site shall be
stored in separate spoil tips for use in reinstatement or landscaping.
The limits of permanent spoil tips shall be as shown in the Drawings or as may be ordered by the
Engineer for landscaping purposes. Permanent spoil tips shall be finished to shapes as indicated
on the Drawings or as directed by the Engineer.
J2.5.17 Disposal of excavated material off the Site

Excavated material which is not required for or is unsuitable for re-use in the Works shall be
disposed of off the Site as directed either to locations to be found by the Contractor (Contractor’s
tip) or to locations designated by the Engineer (Engineer’s tip).
Material ordered to be disposed of to Contractor’s tip shall, as between the Employer and the
Contractor, be deemed to be the property of the Contractor and he shall be entirely responsible
for its removal from the Site and ultimate disposal.
Material ordered to be disposed of to Engineer’s tip shall remain the property of the Employer
and shall be transported off the Site and deposited at places designated by the Engineer. Material
so deposited shall be shaped up or spread and levelled as directed by the Engineer. Any necessary
work to provide access to Engineer’s tips or other preliminary work in connection therewith shall
be valued as additional work.
J2.5.18 Field drains

Should any existing sub-soil or field drains be uncovered during excavation the Contractor shall
either carefully replace them when backfilling or, if this is impracticable, shall divert them to
new drains or ditches or otherwise relay them as the Engineer may direct and all work in this
connection shall be valued as additional work.
J2.5.19 Backfilling of excavation

For purposes of this sub-section, the term ‘backfilling’ means replacing material into any part of
the excavations which the Contractor has needed for working space and which is therefore
deemed to be Excess Excavation. Backfilling shall be carried out using material emanating from
the excavations and complying with specified requirements. The backfilling shall be properly
compacted and where necessary the Contractor shall adjust the moisture content of the material
either by drying out or by adding water. After such drying out or adding of water the material
shall be thoroughly mixed until the moisture content is uniform.

J2.5.20 Filling to structures

Filling to structures means filling around or over completed structures (whether within
excavations or not) using such material as may be specified therefor and to the limits shown in
the Drawings. It does NOT include ‘backfilling’ as described in the preceding clause.
Where the Contract requires the placing of different types of fill material in separate layers or
wedges the Contractor shall carry out the work so as to avoid mixing the different types of
material. Should there be any mixing of materials, such mixed materials shall be removed from
the Site and replaced with separate materials, all at no extra cost to the Employer.
J2.5.21 Backfilling not to endanger structures

The Contractor shall arrange the timing and rate of placing of backfilling or of filling to
structures in such a way that no part of the Works is overstressed, weakened, damaged or
endangered. The layers of material shall be so placed as to maintain adequate drainage and to
prevent accumulation of water. In particular, the placing of material around the walls of
basements, reservoirs and tanks shall commence only after the walls and floor have been
completed and have attained their full specified strength. Material behind walls fixed at the top to
the roof shall not be placed until the roof has been completed and, if made of concrete, has
attained its full specified strength and had the temporary supports removed. The material shall be
placed uniformly around the walls of structures in such a manner as to avoid eccentric or
differential loads.
Sub-section 2.5(d): Trench Excavation
J2.5.22 Trench Excavation generally

Trench Excavation means excavation of trenches into which pipes are to be laid and the term
‘pipes’ shall mean pipes of all kinds and for whatever purpose, and shall also include cables
except where the context clearly renders this inapplicable.
The line and level of trenches shall be as shown in the Drawings or as may be directed by the
Engineer. Before commencing Trench Excavation, the route of the trench shall be set out
accurately and the natural ground levels shall be recorded and agreed with the Engineer. Strong
sight rails shall then be fixed and maintained at each change of gradient and at as many
intermediate points as may be necessary. On these rails shall be marked the centre line and the
level to which the excavation is to be carried out, such rails being not more than 40m apart.
Trench Excavation shall be carried out by such methods and to such lines, dimensions and depths
as shall allow for the proper construction of the Works. Except where otherwise specified or
approved, the types of temporary support, their design and the procedures for installing and
withdrawing them shall comply with the requirements and recommendations of CIRIA Report
97.
Any Rock in Trench Excavation shall be so excavated that the clearance between the pipe when
laid and the Rock sides and bottom of the trench is kept to the minimum limits necessary to
provide for the specified thickness of bedding haunching and surround to the pipe. Any
excavation outside these limits whether for working space or due to overbreak shall be held to be
Excess Excavation.
The sides of Trench Excavation shall be vertical unless the Engineer permits otherwise.

Any widening or deepening of Trench Excavations necessary to accommodate curves, joints or

bends in the pipe or to provide extra working space for the construction thereof shall be held to
be Excess Excavation.
No length of Trench Excavation shall be started until the pipes to be laid in that length are
available on the Site.
J2.5.23 Trimming Trench Excavations

When excavating to specified levels for Trench Excavation or to specified limits for the face of
any structure therein required to abut undisturbed ground, the Contractor shall not finally
complete the excavation until immediately before commencing constructional work except where
the Engineer permits otherwise.
Where no bedding material is specified to be laid beneath the pipe the bottom of Trench
Excavation shall be carefully boned in and trimmed true to grade with the aid of a straight-edge
so as to ensure a continuous support for the pipes. The trench bottom shall then be pricked over
with a fork and any stones or flints likely either to cause the pipe to bed unevenly, or to damage
the pipe or its coating, shall be picked out of the pipe bed; any holes so formed shall be filled in
with soft material and trimmed to the correct level.
Where bedding material is specified, all shattered and loose material shall be removed from the
bottom of the Trench Excavation so that the bedding material rests on a sound and clean
foundation.
J2.5.24 Disposition of material from Trench Excavation

Subject to any specific requirements of the Contract, the Contractor shall make his own
arrangements for the temporary storage of any excavated material which is required for use in
refilling Trench Excavations, including any necessary double handling. In this connection the
Contractor shall have regard to the working areas available to him for the construction of the
pipeline, particularly where this is located in roads or in other places to which the public has free
access. Any temporary tips alongside the Trench Excavations shall be to stable slopes and
heights.
Top surface material and Topsoil if any shall be stored separately from other excavated materials.
Where the nature of the excavated material is suitable, the Contractor's temporary storage as
aforesaid shall include for the separate storage as the Engineer may direct of suitable material for
the surface reinstatement of Trench Excavation.
Any excavated material not required for or not suitable for use as refilling as aforesaid or for use
elsewhere in the Works shall, as between the Employer and the Contractor, be deemed to be the
property of the Contractor and he shall be entirely responsible for its removal from the Site and
for its ultimate disposal.
J2.5.25 Trenches not to be left open

Trench Excavation shall be carried out expeditiously and, subject to any specific requirements of
the Contract, the refilling and surface reinstatement of Trench Excavations shall be commenced
and completed as soon as reasonably practicable after the pipes have been laid and jointed.
Pipelaying shall follow closely upon the progress of Trench Excavation, and the Contractor shall
not permit unreasonably long lengths of Trench Excavation to remain open while waiting to test
the pipeline. The Contractor shall take precautions to prevent flotation of pipes in locations

where open Trench Excavations may become flooded, and these precautions may include the
partial refilling of the trench leaving pipe joints exposed while awaiting tests of the joints.
If the Engineer considers that the Contractor is not complying with any of the foregoing
requirements he may prohibit further Trench Excavation until he is satisfied with the progress of
laying and testing of pipes and refilling of Trench Excavation.
J2.5.26 Refilling Trench Excavations

Subject to any particular requirements specified hereafter, Trench Excavations shall be refilled
using suitable materials selected from nearby excavations.
After any specified concrete or granular bed haunch or surround has been placed the refill
material shall be deposited and properly compacted in layers, any coarse or hard material being
placed in the upper layers. Particular care shall be taken to avoid damage to the pipe and any
sheathing or surround.
Where necessary, the Contractor shall adjust the moisture content of the refill material either by
drying out or by adding water to assist the compaction of the material.
Where directed by the Engineer, Trench Excavations shall be refilled with concrete.
J2.5.27 Refill material: special measures

Where, in the opinion of the Engineer, sufficient supplies of material suitable for trench refilling
cannot reasonably be obtained from nearby excavations without resorting to sieving or other
special means then he may order the Contractor:
a) to carry out such work as may be necessary to sieve or otherwise render the material
suitable, or
b) to transport suitable material from excavations elsewhere (‘overhaul’), or
c) to excavate material from suitable borrow areas and transport it to the length of
trench to be refilled, or
d) to import suitable material.
J2.5.28 Crossing watercourses

Where the line of Trench Excavation crosses streams, ditches, culverts and other watercourses
the Contractor shall be deemed to have allowed for all the additional measures necessary for the
proper construction of the Works at these crossings including maintaining the full flow of water.
J2.5.29 Geotextiles
Geotextiles shall be protected at all times against mechanical or chemical damage. Those
geotextiles which are susceptible to damage by light shall be stored under cover.
J2.5.30 Laying of geotextiles

Geotextiles shall be laid and lapped as specified or in accordance with the manufacturer's
recommendations. The layer of material on which the geotextile is to be placed shall not have
protrusions or sharp projections which are likely to damage the geotextile during installation or
in service. The method of installation shall ensure that the geotextile is in continuous contact
with the surface on which it is to be placed and the geotextile shall not be stretched or bridged

over hollows or humps. Operation of construction plant directly on the installed geotextile will
not be permitted. Care shall be taken in placing fill material to avoid damage to the geotextile.
J2.6 TESTING
J2.6.1 Testing by the Contractor

The Contractor shall be responsible for carrying out all field and laboratory tests required for the
proper control of earthworks.
Laboratory tests shall be carried out at the Site or in an off-Site laboratory approved by the
Engineer.
Field density tests shall be performed to ensure that the specified density is being obtained. Tests
shall be in accordance with BS 1377: Part 9. Test results and copies of calculations shall be
submitted to the Engineer.
Tests on geotextiles shall be in accordance with BS 6906, and the Contractor shall be responsible
for carrying out such tests as required by the Engineer.

SECTION J3 CONCRETE WORK
J3.1 SCOPE
This Section contains requirements for the manufacture, transportation, placement, finishing,
repair and curing of concrete; for the detailing, supply and placing of reinforcement; for
formwork; for joints, joint materials, joint treatment and bearing pads; and for all other work
associated with cast-in-place and precast concrete.

Reference Standards are referred to in the text of the Specifications in abbreviated form
(e.g. BS 12). The numbers and subjects are given below for convenience.
STANDARD SUBJECT
American Concrete Institute (ACI)
ACI 211.1 Standard practice for selecting proportions for normal, heavyweight, and mass
concrete
ACI 305R Hot weather concreting
ACI 315 ACI detailing manual
ACI 318 Building code requirements for reinforced concrete
American Society for Testing and Materials (ASTM)
ASTM A36 Specification for structural steel
ASTM A53 Specification for pipe, steel, black and hot-dipped, zinc-coated, welded and
seamless
ASTM A184M Specification for fabricated deformed steel bar mats for concrete reinforcement
ASTM A185 Specification for steel welded wire fabric, plain, for concrete reinforcement
ASTM A416 Specification for steel strand, uncoated seven-wire stress-relieved for prestressed
concrete
ASTM A421 Specification for uncoated stress-relieved wire for prestressed concrete
ASTM A615 Specification for deformed and plain billet-steel bars for concrete reinforcement
ASTM C31 Practices for making and curing concrete test specimens in the field.
ASTM C33 Specification for concrete aggregates
ASTM C39 Test method for compressive strength of cylindrical concrete specimens
ASTM C40 Test method for organic impurities in fine aggregates for concrete
ASTM C42 Methods of obtaining and testing drilled cores and sawed beams of concrete
ASTM C88 Test method for soundness of aggregates by use of sodium sulfate or magnesium
sulfate
ASTM C94 Specification for ready-mixed concrete
ASTM C117 Test method for materials finer than 75 µm (No. 200) sieve in Mineral
Aggregates by washing
ASTM C127 Test method for specific gravity and absorption of coarse aggregate
ASTM C131 Test method for resistance to degradation of small-size coarse aggregate by
abrasion and impact in the Los Angeles machine
ASTM C136 Method for sieve analysis of fine and coarse aggregates
ASTM C142 Test method for clay lumps and friable particles in aggregates
ASTM C143 Test method for slump of Portland cement concrete
ASTM C151 Test method for autoclave expansion of Portland cement

ASTM C172 Standard practice for sampling freshly mixed concrete

ASTM C186 Test method for heat of hydration of hydraulic cement
ASTM C231 Test method for air content of freshly mixed concrete by the pressure method
ASTM C260 Specification for air-entraining admixtures for concrete
ASTM C295 Standard guide for petrographic examination of aggregate for concrete
ASTM C309 Specification for liquid membrane-forming compounds for curing concrete
ASTM C311 Method for sampling and testing fly ash or natural pozzolans for use as a mineral
admixture in Portland cement concrete
ASTM C404 Specifications for aggregate for masonry grout
ASTM C441 Test method for effectiveness of mineral admixtures in preventing excessive
expansion of concrete due to the alkali-aggregate reaction
ASTM C451 Test method for early stiffening of Portland cement (Paste method)
ASTM C494 Specification for chemical admixtures for concrete
ASTM C595 Standard specification for blended hydraulic cements
ASTM C618 Specification for fly ash and raw or calcined natural pozzolan for use as a
mineral admixture in Portland cement concrete
ASTM C989 Specification for ground iron blast-furnace slag for use in concrete and mortars
ASTM C1260 Potential alkali reactivity of aggregates (Mortar bar method)
ASTM D545 Standard test methods for preformed expansion joint fillers for concrete
construction (non-extruding and resilient types)
ASTM D1190 Specification for concrete joint sealer, hot-poured elastic type
ASTM D1751 Preformed expansion joint fillers for concrete paving and structural construction
(Non-extruding and resilient bituminous types)
ASTM D1752 Specification for preformed sponge rubber and cork expansion joint fillers for
concrete paving and structural construction.
ASTM D1850 Specification for concrete joint sealer, cold-application type
ASTM D2419 Test method for sand equivalent value of soils and fine aggregate
British Standards (BS)
BS l2 Specification for ordinary and rapid hardening Portland cement
BS l46: Part 2 Specification for Portland blast-furnace cement (Metric units)
BS 340 Specification for precast concrete kerbs, channels, edgings and quadrants
BS 368 Precast concrete flags
BS 747 Reinforced bitumen sheets for roofing, Specification
BS 812 Grading of aggregates
BS 1200 Building sands from natural sources
BS 2499 Hot applied joint sealant systems for concrete pavements: Specification for joint
sealants
BS 3148 Methods of tests for water for making concrete
BS 3416 Specification for bitumen-based coatings for cold application, suitable for use in
contact with potable water
BS 3940 Adhesives based on bitumen or coal tar
BS 4246 Low heat Portland blast-furnace cement
BS 4254 Specification for two-part polysulphide-based sealants
BS 4871 Approval testing of welders working to approved welding procedures
BS 5135 Metal-arc welding of carbon and carbon manganese steels
BS 5215 Specification for one-part gun grade polysulphide-based sealants
BS 5896 Specification for high tensile steel wire strand for the prestressing of concrete
BS 6073 Specification for precast concrete masonry units
BS 6213 Selection of construction sealants: Guide

BS 6744 Stainless steel bars for the reinforcement of and use in concrete – Requirements
and test methods
BS 6949 Specification for bitumen-based coatings for cold application excluding use in
contact with potable water
BS 8000 Code of practice for water proofing
BS 8007 Code of practice for design of concrete structures for retaining aqueous liquids
BS 8102 Code of Practice for protection of structures against water from the ground
BS ISO 14654 Epoxy-coated steel for the reinforcement of concrete
BS ISO 14656 Epoxy powder and sealing material for the coating of steel for the reinforcement
of concrete
U.S. Army Corps of Engineers (US COE)
CRD C568 Rubber - preparation of pieces for test from other than standard vulcanized sheets
CRD C570 Test for brittleness temperature of plastics and elastomers by impact
CRD C571 Test for stiffness of plastics by means of a cantilever beam
CRD C572 Specifications for polyvinyl chloride waterstop
CRD C573 Test for rubber properties in tension
US Federal Specifications (US)
SS S1614 Sealing compound, jet-fuel resistant, hot-applied, one-component, for Portland
cement and tar concrete pavements
TT C598C Caulking compound oil and resin base type (for building construction)
TT S00227E Sealing compound elastomeric type, multi-component (for caulking, sealing, and
glazing in buildings and other structures)
U.S. Federal Test Method Standard No. 601 for rubber waterstops
J3.3 SUBMISSIONS BY CONTRACTOR
J3.3.1 General
Requirements for submissions by the Contractor in relation to concrete work are described in the
relevant clauses of these Specifications. For convenience, these submissions are summarised
hereunder.
J3.3.2 Certificates and mill test data

The Contractor shall furnish manufacturers' or suppliers' certificates of compliance with relevant
standards for each shipment of all materials and accessories used in the Permanent Works,
including:
- Cement
- Pozzolanic materials and inert mineral admixtures
- Chemical Admixtures
- Curing compound
- Jointing materials, including waterstops
- Membranes and bituminous coatings
- Reinforcing steel, together with fusion bonded epoxy coating
- Mechanical couplings for reinforcing steel

The Contractor shall also submit appropriate mill analysis and laboratory test data of samples
tested by the supplier. Mill analysis and test data shall be representative of materials furnished
for the Permanent Works. The frequency of sampling and testing by the supplier shall conform to
applicable standards.
All materials that may be in contact with water that is or will become part of a potable supply
shall be approved for such contact in accordance with the relevant requirements of Part A of the
Specification.
J3.3.3 Results of tests performed by the Contractor

The Contractor shall furnish:
• Daily reports and monthly summaries of aggregate plant gradation test results on
aggregate produced.
• Monthly calibration certificates for the weighing and dispensing devices on batching
and mixing plants.
• Proposals for concrete laboratory trial mix programmes and reports thereon.
J3.3.4 Samples
The Contractor shall provide samples of all materials, together with manufacturers' technical
information, to be used in the Permanent Works as may be required by the Engineer. Reference
samples shall be kept in suitable containers, properly labelled, and stored on Site.
J3.3.5 Construction plants

The Contractor shall submit location plans, layout drawings, flow diagrams and equipment list
for the aggregate plant(s), refrigeration plant(s), concrete batching and mixing plant(s) and high
pressure water-blasting equipment for cleaning of joints and surface of the old concrete prior to
ordering or erecting these plants. The submittal for each plant shall be accompanied by the
Contractor's detailed written proposal for quality control of the product at the Site. The quality
control plans for ensuring compliance of the products with the specification shall detail sampling
points, methods and frequency of testing and procedures for dealing with non-compliances. The
proposals for the plant and quality control will be reviewed and commented on by the Engineer
with regard to compliance with Specification requirements and the Contractor shall modify his
proposals to the satisfaction of the Engineer. The Engineer will require 6 weeks for review of the
proposals.
J3.3.6 Construction details

The Contractor shall submit his detailed proposals for the following for advance approval by the
Engineer:
- Construction joints where they are not shown on the Drawings.
- Layout of lifts.
- Installation of joint fillers, sealants, waterstops and membranes, including
manufacturer’s requirements for storage, handling and installation.
- Placement of new concrete to the raised levels over the old concrete with details
of cutting of old concrete to the required depth, drilling holes, fixing and grouting
anchors and cleaning surface of old concrete.

- Concrete placement sequences including special measures for dealing with

concreting in hot weather and during nights.
- Precast concrete works.
- All formwork.
- Reinforcing bar details showing bar shapes, embedments and splice lengths.
Work shall not commence before such an approval is received by the Contractor.
J3.3.7 Concreting records

The Contractor shall submit daily returns in respect of all concrete placed during the previous
day, in a form to be agreed with the Engineer.
The returns shall include but not necessarily be restricted to:
in respect of each concrete Class:
- the number of batches mixed,
- the number of batches and the total volume of concrete placed,
- the number of batches wasted or rejected, and
- the weights of all cement, aggregates, water, pozzolanic materials and additives
used;
and in respect of each location in the Permanent Works:
- the position of the placement (e. g. structure or lift reference number),
- the concrete Classes placed, and
- the total volume of concrete placed and the number of batches of each Class used.
In addition, the Contractor shall maintain an accurate and up-to-date record showing dates, times,
weather and temperature conditions when each part of the Permanent Works was concreted. The
record shall be available for inspection by the Engineer at all times.
J3.3.8 Welding of reinforcement

The Contractor shall obtain prior approval of the Engineer for any welding of reinforcement. The
approval shall cover:
- Welding procedures.
- Qualifications of welders to work at Site.
- Methods of inspection of welds.
J3.4 MATERIALS
J3.4.1 Cementitious materials
J3.4.1.1 General
Cementitious materials shall normally consist of Ordinary Portland cement (OPC), Sulphate
Resistant Cement (SRC), or a combination of OPC, or SRC and pozzolanic material (either raw

or calcined natural pozzolan, fly ash or blast-furnace slag). The sources of cement and pozzolanic
material shall be proposed by the Contractor and shall be subject to approval by the Engineer.
J3.4.1.2 Cement
Cement used in the Permanent Works shall conform to ASTM C595, with the additional
requirements that the cement shall:
a) have a reduction of mortar bar expansion greater than 75% at 14 days when tested in
accordance with ASTM C441 and compared to the expansion of mortar bars made
with the cement having a zero slag content,
b) have a heat of hydration of less than 70 calories per gram at 7 days when tested in
accordance with ASTM C186,
c) be non-false setting, defined as having a minimum final penetration of 50% of initial
penetration when tested in accordance with ASTM C451, and
d) have an autoclave expansion or contraction of less than 0.8% when tested in
accordance with ASTM C151.
The Contractor may propose alternatives to the above for the approval of the Engineer including:
e) separate furnishing of slag or other pozzolanic materials and OPC conforming to BS
12 for blending at the Site, provided that the blend conforms with all the above
additional requirements;
f) use of a Portland low alkali cement (having a reactive alkali content not exceeding a
maximum value of 0.6% by mass as Na2O) meeting all the above additional
requirements.
Preference shall be given to the use of cement with a total alkali content, expressed as the sodium
oxide (Na2O) equivalent, not exceeding 0.6%, where: % Na2O equivalent = % Na2O + (0.658 x
% K2O).
Should it not be possible to obtain cement with a total equivalent alkali content as low as 0.6%,
then the potential occurrence of alkali aggregate reaction (both alkali silica and alkali carbonate)
with the specific aggregates to be applied must be investigated through laboratory testing.
J3.4.1.3 Cement supply and storage

Each shipment of cement shall be accompanied with a certificate stating the silo number from
which the cement was taken, slag content as weight percentage, transporting unit number, time of
batching, date shipped and amount transported. The Contractor shall undertake each month two
tests for heat of hydration of cement from each source in use. The tests shall be in accordance
with ASTM C186. The Engineer may order further heat of hydration tests, in which case the cost
of additional tests shall be reimbursed to the Contractor. Before the 14th day of each month, the
Contractor shall submit an updated summary of all tests made on cement supplied to the
Permanent Works including 7 and 28 day compressive strength and heat of hydration. The
Engineer shall have the right to sample and test cement at any time to confirm compliance.
Immediately upon arrival at the Site, cement shall be stored in silos designed for the purpose or
in dry, weather-tight and properly ventilated structures with floors raised 500 mm above ground
level and having adequate provision to prevent absorption of moisture. All storage facilities shall
be subject to approval by the Engineer and shall be such as to permit easy access for inspection
and identification. Each shipment of cement shall be kept separately and the Contractor shall use

the shipments in the order in which they are received. Sufficient cement from a single source
shall be in storage at the Site to complete any lift of concrete started. Adequate storage capacity
shall be furnished to provide sufficient cement to meet the peak needs of the approved
construction schedule.
Cement of different types and from different sources shall be kept in clearly marked separate
storage facilities. Cement delivered to the Site in drums or bags provided by the supplier or
manufacturer shall be stored in the unopened drums or bags until used in the Permanent Works.
Any cement in drums or bags which have been opened on the Site shall be used immediately, or
shall be disposed of. Unless otherwise permitted, cement from not more than three plants shall be
used and, in general, only the product of one plant shall be used in any particular section of the
Permanent Works.
Any cement which is, in the opinion of the Engineer, lumpy or partially set shall be rejected and
the Contractor shall promptly remove such cement from the Site. Cement which has been stored
on the Site for more than 91 days and cement which, in the opinion of the Engineer, is of
doubtful quality shall not be used in the Permanent Works unless it is retested and the test results
show that it complies in all respects with these Specifications. Cement stored on Site for more
than 183 days shall not be used in the Permanent Works and shall be removed promptly from the
Site by the Contractor.
Accurate records of deliveries of cement and its use in the Permanent Works shall be kept by the
Contractor. Copies of these records shall be supplied to the Engineer in such form as he may
require.
J3.4.2 Pozzolanic materials

Raw or calcined natural pozzolan, fly ash and finely-ground granulated iron blast-furnace slag as
described below shall be termed pozzolanic materials.
J3.4.2.1 Raw or calcined natural pozzolan and fly ash

Raw or calcined natural pozzolan shall conform to ASTM C618, Class N or Class F. The
following limits on chemical requirements shall apply for Class N pozzolan:
- Available alkalis, as Na2O, maximum % 1.5
- Magnesium oxide (MgO), maximum % 5.0
For class F pozzolan (fly ash), the following additional limits on physical requirements shall also
apply:
- Moisture content, maximum % 2.0
- Loss on ignition, maximum % 5.0
The source of pozzolan or fly ash shall be approved by the Engineer.
Pozzolan or fly ash shall be sampled and tested in accordance with ASTM C311. The physical
and chemical properties of pozzolan or fly-ash shall be uniform from shipment to shipment. The
results of testing shall be submitted to the Engineer. The Contractor shall supply a certificate of
compliance for each shipment of pozzolan to the Site stating that the pozzolan meets the
requirements of these Specifications. In addition, the certificate shall show the date the shipment
was made, quantity transported, and manufacturer's silo number from which the pozzolan was
taken. The Engineer shall have the right to sample and test the pozzolan at any time to confirm
compliance. If tests prove that pozzolan at the Site is unsatisfactory, the Contractor shall
promptly remove it from the Site.

Pozzolan shall be stored in the manner specified for cement.
J3.4.2.2 Granulated iron blast-furnace slag

Slag shall consist of finely-ground granulated iron blast-furnace slag and shall conform to ASTM
C989, Grade 80 or higher. The physical and chemical properties of ground slag shall be uniform
from shipment to shipment. Each shipment of ground slag shall be sampled and tested prior to
use in the Permanent Works. Adequate storage capacity shall be provided to ensure a sufficient
amount of tested slag to meet demand. If tests prove that a shipment of ground slag at the Site is
unsatisfactory, the Contractor shall promptly remove it from the Site. Slag shall be stored in the
same manner as specified for cement.
J3.4.3 Aggregates
J3.4.3.1 General
Aggregates for concrete shall be processed and shall consist of natural particles or a blend of
natural and manufactured particles. Aggregates shall be produced from suitable material from
required excavations or borrow areas as approved by the Engineer. The approval of any source
from which aggregates are to be produced by the Contractor shall not be construed as
constituting approval or acceptance of all materials taken from the source.
The Contractor shall provide all labour and equipment and shall maintain a testing laboratory for
the quality control of aggregates produced for the Permanent Works. At least once per shift, the
Contractor shall sample and test for grading each coarse aggregate produced during that shift.
The gradation of fine aggregate shall be determined at a minimum frequency of one test per hour
of production unless, in the opinion of the Engineer, the test results show the aggregate grading
to be sufficiently consistent to allow less frequent testing. The Contractor shall also sample and
test aggregates for gradation at various stages in the processing, transporting, stockpiling and
reclaiming as may be required by the Engineer. The Contractor shall submit a daily report to the
Engineer which shall include production quantities and gradation test results.
The Contractor shall promptly correct any excesses or deficiencies in gradation of coarse and fine
aggregates during processing. Rejected or waste material shall be disposed of in approved areas
or re-processed.
J3.4.3.2 Fine Aggregate quality and grading

Fine aggregate for concrete shall conform to the quality requirements of ASTM C33 and shall
consist of natural and/or crushed sand.
In addition to the above, fine aggregate for concrete shall meet the following physical
requirements:
- Fineness modulus (ASTM C33) 2.50 to 3.0
- Sodium sulphate soundness 5 cycles (ASTM C88) maximum 10% loss
- Sand equivalent (ASTM D2419) minimum 80%
- Material passing 75 µm (No. 200) sieve maximum 3% by weight
In addition to compliance with grading requirements, the fine aggregate grading shall be
controlled such that the fineness moduli of at least 9 out of every 10 consecutive test samples do
not vary by more than 0.20 from the average fineness modulus of the 10 test samples.

The maximum percentages of deleterious substances in the fine aggregate, as delivered to the
mixer, shall not exceed the following values:
- Clay lumps and friable particles (ASTM C33) 1% by weight
- Shale 1% by weight
- Total of other deleterious substances (such as mica, 1% by weight
chlorite, coated grains and soft flaky particles)
The sum of the percentages of all deleterious substances shall not exceed 2% by weight.
Aggregates shall be tested in accordance with ASTM C40 for content of organic impurities. Any
aggregate producing a colour darker than the standard shall be rejected.
When tested in accordance with ASTM C136, fine aggregate shall be uniformly graded within
the following gradation requirements:
U.S. Standard Percent Passing
Sieve Size by Weight
9.5 mm (0.375 in.) 100
4.75 mm (No. 4) 95-100
2.36 mm (No. 8) 80-100
1.18 mm (No. 16) 50-85
0.60 mm (No. 30) 25-60
0.30 mm (No. 50) 5-30
0.15 mm (No. 100) 0-10
75 µmm (No. 200) 0-3
J3.4.3.3 Coarse aggregate quality and grading

Coarse aggregate shall conform to the quality requirements of ASTM C33, and shall consist of
gravel, crushed gravel or crushed stone. Coarse aggregate shall be washed and shall be separated
into the nominal size ranges indicated below. The specific gravity and absorption of coarse
aggregates shall be determined in accordance with ASTM C127.
In addition to the above, coarse aggregate for concrete shall meet the following physical
requirements:
- Sodium sulphate soundness 5 cycles (ASTM C88) maximum 12% loss
- Los Angeles abrasion value (ASTM C131) maximum 30% loss
The maximum percentages of deleterious substances in any nominal size range of coarse
aggregate as delivered to the mixer shall not exceed the following values:
- Material passing 75 µm (No. 200) sieve (ASTM C117):
19.0 (3/4 in.) mm to 4.75 (No. 4) mm size range 0.50% by weight
37.5 mm (1½ in. to 19.0 mm (3/4 in.) size range 0.25% by weight
75 mm (3 in.) to 37.5 mm (1½ in.) size range 0.25% by weight
- Shale 1% by weight

- Clay lumps and friable particles (ASTM C142) 2% by weight

- Other deleterious substances 1% by weight
The sum of the percentages of all deleterious substances in any size, as delivered to the mixer,
shall not exceed 2% by weight.
When tested in accordance with ASTM C136, the coarse aggregate nominal size ranges shall
meet the following gradation requirements when delivered to the mixer and shall be uniformly
graded within the limits stated:
19.1 mm 38.1 mm 76.2 mm

Sieve Size
to 4.75 mm to 19.1 mm to 38.1 mm
100 mm (4 in) 100
75 mm (3 in) 90-100
50 mm (2 in) 100 20-55
37.5 mm (1½ in) 90-100 0-15
25.0 mm (1 in) 100 20-55 0-2
19.0 mm (3/4 in) 90-100 0-15
9.5 mm (3/8 in) 10-40 0-2
4.75 mm (No. 4) 0-5
2.36 mm (No. 8) 0-2
J3.4.3.4 Sampling and testing of aggregates

During concrete production, aggregates, as delivered to the mixer, will be sampled and tested in
accordance with ASTM C136 by the Engineer to determine compliance with these
Specifications. The Contractor shall provide samples and such facilities as may be necessary for
the ready procurement of representative test samples. Testing of concrete aggregates by the
Engineer shall not relieve the Contractor of his responsibility to maintain control on production,
stockpiling and handling of both fine and coarse aggregates in accordance with these
Specifications.
J3.4.3.5 Storage of aggregates

The Contractor shall provide means of storing the aggregates such that:
- each nominal size range of coarse aggregate and the fine aggregate shall be kept separated
at all times,
- contamination of the aggregates by the ground or foreign matter shall be effectively
prevented at all times, and
- each heap of aggregate shall be capable of draining freely.
Rock ladders of satisfactory design or other appropriate measures shall be used with conveyor
systems for stockpiling aggregate to prevent segregation and excessive breakage.
The Contractor shall ensure that graded coarse aggregates are tipped, stored and removed from
store in a manner that does not cause segregation. No equipment shall be permitted to operate on
storage piles except with express permission of the Engineer.

Fine aggregate, as delivered to the batching and mixing plant storage bin, shall have a uniform
and stable free-moisture content which shall not exceed 7%. Excessive moisture shall be
removed mechanically or by the 3-pile drainage method.
The Contractor shall protect the piles of fine aggregate against inclement weather. Windbreaks
shall be provided where aggregates might suffer contamination by wind-blown materials.
J3.4.3.6 Aggregates for epoxy concrete and mortar

The aggregate used for epoxy concrete shall be clean, dry, crushed aggregate. Except for
gradation, fine and coarse aggregates shall meet the requirements of ASTM C33. Aggregates for
epoxy concrete shall meet the requirements for gradation specified below.
Gradation for Fine Aggregate for Epoxy Concrete
9.5 mm (3/8 in) 100
4.75 mm (No. 4) 95-100
2.36 mm (No. 8) 80-100
1.19 mm (No. 16) 50-85
0.60 mm (No. 30) 25-60
0.30 mm (No. 50) 10-30
0.15 mm (No. 100) 1-10
75 µm (No. 200) 0-3
Gradation for Coarse Aggregate for Epoxy Concrete
19.0 mm (3/4 in) 100
12.5 mm (1/2 in) 90-100
9.5 mm (3/8 in) 40-70
4.75 mm (No. 4) 0-15
2.36 mm (No. 8) 0-5
The aggregate shall be well graded from coarse to fine.
The fine and coarse aggregates used in the preparation of epoxy resin concrete shall be oven dry
and shall be conditioned to a temperature of 15o to 21oC prior to mixing the epoxy resin binder.
Except for gradation, fine aggregate for use in epoxy mortar shall conform to the requirements of
ASTM C404. The gradation of aggregate for epoxy mortar shall conform to the requirements for
fine aggregates for epoxy concrete. The aggregate used in the preparation of the epoxy mortar
shall be oven dry and shall be conditioned to a temperature of 15o to 21oC prior to mixing the
epoxy resin binder.
J3.4.4 Water
Water for washing aggregates and mixing concrete shall be reasonably clean and free from the
detrimental amount of salts, alkalis, oil, organic matter or other deleterious substances and shall

comply with the recommendations contained in the Appendix to BS 3148. The concentration of
sulphates and chlorides shall be such that the concrete mix as a whole complies with the limits of
salts content also recommended in BS 3148.
River water is suitable for the mixing and curing of concrete. However, during floods, the river
water will contain silt and some ponding to settle out the sediments may be necessary under such
circumstances.
The Contractor shall make arrangements to protect water from direct sun and contamination by
wind-blown materials. The Engineer shall order retesting of water whenever deemed necessary.
J3.4.5 Admixtures
Admixtures shall mean chemical materials added to the concrete materials during mixing for the
purpose of altering the properties of the concrete mix. They shall not contain calcium chloride.
The Contractor shall furnish and use a water-reducing and/or water-reducing set-retarding
admixture as approved by the Engineer. The water-reducing and/or water-reducing set-retarding
admixture shall conform to ASTM C494, Type A or D as appropriate. The amount of admixture
used per batch shall be proposed by the Contractor for the Engineer’s approval following suitable
tests but, in general, the amount will be in accordance with the manufacturer's recommendations.
No admixture shall be considered for approval that has not been used with satisfactory service in
works of similar nature. A manufacturer's technical data sheet and certification of compliance
with ASTM C494, Type A or D as appropriate, shall be submitted at the time of request for
approval. After approval is granted, a manufacturer's certificate of compliance shall be furnished
with each shipment to the Site. Admixtures may be sampled and tested by the Engineer for
compliance with ASTM C494. If tests prove that any admixture which has been delivered is
unsatisfactory, it shall be promptly removed from the Site.
The Contractor shall furnish and use an approved air-entraining admixture in all concrete unless
otherwise approved or instructed by the Engineer. The air-entraining admixture shall be a
neutralised vinsol resin and shall conform to the requirements of ASTM C260.
The admixtures shall each be accurately batched by mechanical batcher and shall be added in a
manner which ensures uniform distribution throughout the batch.
The compatibility of different admixtures used in the same batch shall be established to the
satisfaction of the Engineer.
The amount of air-entraining admixture used in each concrete mix shall be just enough to cause
entrainment of air in the following percentages when concrete is discharged from the mixer:
Nominal maximum size of coarse
Total percent of air by volume
aggregate
75 mm (3 in) 4 to 5*
37.5 mm (1 ½ in) 4 to 6
19.0 mm (3/4 in) 5 to 7
* based on the minus 37.5 mm portion of a sample after sieving through a 37.5 mm sieve.
Field tests on air-entrained mixes shall be made in accordance with ASTM C231. Concrete
produced with air contents exceeding the above limits may be rejected by the Engineer.
Admixtures shall be stored in suitable containers which will maintain them in uniform solution
and will protect them from weather and contamination.

Admixtures which have been in storage for more than 6 months shall not be used unless retest
proves them to be satisfactory. Costs of all such retests shall be borne by the Contractor. Rejected
materials shall be removed immediately from the Site.
J3.4.6 Concrete Classes

The concrete grades required for the Works are as follows. The strength shall be the 28 day
strength unless otherwise noted. The Concrete Class is an arbitrary system referring only to these
Works, and does not refer to any recognised Standard.
Concrete Typical use Minimum Compressive Maximum size of

Class Cylinder Strength aggregate
(Characteristic Strength)
(MPa) (mm)
Structural concrete up to
A1 28 19
300 mm thick
Structural concrete more
A2 28 37.5
than 300 mm thick
Water retaining
B 35 19
structures
C Mass concrete fill 14 37.5
D Blinding 14 19
J3.4.7 Jointing materials and waterstops

Jointing materials include waterstops, fillers, paints, caulking compounds, sealants, adhesives
and other such materials required for the making of joints in concrete and between existing and
new concrete.
Materials for concrete jointing and protection shall be obtained from manufacturers approved by
the Engineer’s Representative. Unless otherwise approved, all materials for concrete jointing and
protection which are in contact with each other or jointed together to form a jointing and/or
protective system shall be obtained from a single manufacturer.
All materials for concrete jointing and protection which may come into contact with one another
shall be compatible with each other. They shall not cause any change in properties of the
materials with which they are in contact which may make them unsuitable for use in concrete
jointing or protection, or which may reduce the working life of joints or protection.
The Contractor shall supply manufacturers' test sheets to certify compliance of all jointing and
protection materials with relevant quality standards. Where there is no relevant quality standard,
the Contractor shall prove by demonstration, tests or otherwise the suitability, adequacy and
performance of the material under Site conditions. Only such materials as have been approved by
the Engineer’s Representative shall be used in the Works. Jointing materials shall be proposed by
the Contractor and approved by the Engineer. They shall be handled, used and stored in
accordance with the manufacturer's recommendations.

Waterstop shall be dense, homogeneous and free of holes or other imperfections. The cross
section shall be uniform along the length and symmetrical transversely so that the thickness at
any given distance from either edge will be uniform. Where not otherwise shown on the
Drawings:
• the width of the waterstop shall be not less than 80% of the thickness of the concrete
section and not less than 230mm;
• the web thickness shall be not less than 9mm in the case of waterstop for use within
the concrete thickness or 5mm in the case of waterstop for use on the outer face;
• all waterstop shall incorporate a solid bulb or major rib at or near each edge;
• waterstop wider than 180mm which is for use on the outer face shall incorporate a
total of at least two major ribs each side of the centreline;
• waterstop at movement joints shall incorporate a central hollow bulb;
• waterstop for use at induced contraction joints shall incorporate a crack inducer;
• waterstop for use within the concrete thickness shall be of rubber.
Rubber waterstop shall be of natural rubber, suitable synthetic rubber, or a blend of the two. PVC
waterstop shall be of an elastomeric plastic compound; no reground material shall be used.
All intersections and junctions in waterstop shall be factory-produced by the manufacturer of the
waterstop, normally as moulded special pieces, so that the only joints remaining to be made at
Site shall be straight butt joints between straight lengths of waterstop of the same section and
material. Jointing materials used in the work shall conform to the following standards:
Material Standard
ASTM D1190 or US SS S1614 Sealer;
Hot-poured joint sealing compound
Hot-poured type for joints in concrete
Cold application type ASTM D1850
Polysulphide-base or
US TT S00227E
polyurethane-base joint sealant
Preformed expansion joint filler ASTM D1751, ASTM D1752 Type II
US TT C598C, Grade 1 or 2, colour as shown
Caulking compound
on the Drawings or as approved
Extruded plasticised polyvinyl US COE Specification CRD C572 for
chloride resin (PVC) waterstop polyvinyl chloride waterstop
PVC waterstop shall be extruded from an elastomeric plastic compound, the basic resin of which
shall be PVC. The compound shall contain such additional resins, plasticizers, stabilisers or other
materials needed to ensure that when the compound is extruded to the shapes and dimensions
shown, it will have the following physical characteristics, when tested by the US Army Corps of
Engineers test method specified below:

Test method
Physical characteristics Requirement
(US COE)
Tensile strength using die III not less than 12 MPa C568
Ultimate elongation using die III not less than 350% C573
Low temperature brittleness, no sign of failure
2° C C570
such as cracking or chipping at
Stiffness in flexure, 12.5 mm span, not less than 2.75 MPa C571
Rubber waterstops shall be of natural rubber, synthetic rubber or a blend of both the rubbers.
When tested in accordance with U.S. Federal Test Method Standard No. 601, rubber waterstops
shall have the following properties:
Physical characteristics Requirement Test method
Tensile strength - not less than 17 MPa 4111
Elongation at break - not less than 450% 4121
Tensile strength at 300% elongation - not less than 6 MPa 4131
Durometer hardness - Shore Type A 60-70 3021
Water immersion, change in weight - maximum 5% 6631
Tensile strength after ageing; percent of tensile
strength before ageing (oxygen bomb method) not 55 7111
less than
Compression set – maximum 30% 3311
Adhesion on 510 grams cotton fabric - not less than 320 grams/mm 8011 and 8021
Where there is no appropriate standard to which reference may be made in respect of any
proprietary jointing material, the Contractor shall prove by demonstration, tests or otherwise the
suitability, adequacy and performance of the material under Site conditions. In other instances
the Contractor shall supply manufacturer's test sheets to certify compliance with relevant quality
standards. Only such materials as have been approved by the Engineer shall be used in the
Permanent Works.
Where bond-breaking coating or bitumen coating for application to concrete surfaces to prevent
bonding of fresh concrete to concrete previously placed is shown on the Drawings it shall be a
bituminous paint or other compound of a type that will adhere to damp surfaces of concrete and
perform its function of breaking bond without any damage to the new concrete. The Contractor
shall furnish detailed specifications and samples of the material he proposes to use for the
approval by the Engineer.
J3.4.8 Formwork
Formwork shall be constructed of timber, sheet metal or other approved material depending on
the class of finish to be obtained. The Contractor shall use only approved material for exposed
surfaces of the same class of finish.

Ties shall be of the rod and cone or other approved proprietary type. Embedded material rods
shall terminate not less than 50 mm inside the formed faces of the concrete. Wire ties shall not be
permitted.
Ties for use in water-retaining structures, which are continuous through the section, shall
incorporate a diaphragm, not less than 50 mm diameter and 4 mm thick, welded normal to the
midpoint of the tie, designed to prevent water passing along the tie.
J3.4.9 Steel reinforcement

Steel for reinforcement bars shall be hot rolled deformed steel bars conforming to ASTM A615,
grade 40 and 60. Fabricated reinforcement mats shall conform to the requirements of the
appropriate ASTM standard.
The Engineer shall have the right to witness routine testing of steel reinforcement at the
manufacturer's workshop.
When required by the Engineer, the Contractor shall take samples from reinforcement delivered
to the Site and shall arrange for the samples to be tested by an approved testing agency. Test
certificates from that agency shall be submitted to the Engineer.
For compliance with ACI 318 the actual yield strength based on mill tests of grade 40 or 60
reinforcement shall not exceed the specified yield strength by more than 120 MPa (retests shall
not exceed this value by more than an additional 20 MPa) and the ratio of the actual ultimate
tensile stress to the actual tensile yield strength shall not be less than 1.25.
Where specified epoxy coating shall be Type A (flexible) to BS ISO 14654
J3.4.10 Accessories
Spacer blocks for maintaining concrete cover to reinforcement shall be of concrete of the same
texture, colour and composition as the in situ concrete. They shall be cast in the form of a
truncated cone or pyramid with the smaller face having a minimum dimension of 50 mm (2 in).
PVC spacer blocks of colour matching with the concrete shall be used where formed surfaces are
designated F3 or F4. The Contractor shall submit samples and manufacturer's technical data to
the Engineer for his approval. They shall not be used for any surface that may be in contact with
water.
Chairs and other accessories for maintaining reinforcement in position shall be of steel and shall
not be placed within the specified minimum cover to steel. Binding wire shall be 2 mm soft iron
wire.
J3.4.11 Joint filler and capping strip

Joint fillers shall be preformed, compressible and resilient and shall comply with all relevant
requirements of this clause, except where alternative requirements are specifically approved by
the Engineer’s Representative.
Bitumen impregnated joint fillers of fibre or cork shall comply with ASTM D 1751.
Resin bonded cork or self expanding cork joint filler shall comply with ASTM D 1752. Sponge
rubber joint fillers shall also comply with ASTM D 1752 except that the load required to
compress the test specimen to 50% of its initial thickness shall not exceed 0.5 N/mm².
Joint fillers of closed-cell polyethylene or polyvinyl foam shall, when tested in accordance with
ASTM D 545, have the following properties:

• the load required to compress the test specimen to 50% of its thickness before test
shall be no less than 0.13 N/mm² or greater than 0.3 N/mm²;
• 10 minutes after release of the compressive load (or 1 hour if the retest provision
applies) the test specimen shall have recovered not less than 80% of its initial
thickness.
Joint filler for use in joints which may be submerged shall be of closed-cell polyethylene or self
expanding cork.
Joint filler for use in joints across which little load needs to be transferred shall be of sponge
rubber, closed-cell polyethylene or polyvinyl foam.
Capping strip to joint filler shall be of grey plasticised PVC, formed to shape and sized for use
with the appropriate thickness of joint filler.
J3.4.12 Joint sealant

Joint sealant shall be one of the following types:
• polysulphide-based sealant complying with BS 4254, having a movement
accommodation factor (as defined) of at least 25% and a minimum service life
expectancy of 15 years;
• polysulphide-based sealant complying with BS 5215, having a movement
accommodation factor of at least 10% and a minimum service life expectancy of
15 years;
• approved proprietary product formulated from chemically resistant elastomeric
polymers, having a movement accommodation factor of at least 20% and a minimum
service life expectancy of 15 years;
• rubber-bitumen compound complying with BS 2499, type A2, having a movement
accommodation factor of at least 10% and a minimum service life expectancy of 10
years;
• approved bituminous putty proprietary product, having a movement accommodation
factor of at least 10% and a minimum life expectancy of 10 years.
Sealant shall be selected in accordance with BS 6213. Definitions included in BS 6213 shall
apply to this Specification.
Sealant shall be non-degradable under the prevailing conditions. Where sealant will be in contact
with sewage, the Contractor shall submit for the Engineer’s Representative's approval evidence
that the proposed product will resist aerobic and anaerobic attack.
J3.4.13 Epoxy seal coat

Where specified the soffit of the roof of reinforced concrete water tanks shall be protected by the
application of an epoxy seal coat. The seal coat material shall be a two part solvent-free epoxy
lining material approved for long term contact with potable water in accordance with Part A of
the Specification. The lining system shall have been proven in service over a number of years
and evidence of this satisfactory use shall be submitted for approval prior to purchase.

J3.4.14 Back-up material, bond breaker and primer

Back-up material inserted in a joint to limit the depth of sealant (where joint filler does not serve
this purpose) shall comprise closed-cell low-density compressible joint filler preformed for the
purpose or such other material as is recommended for this use by the sealant manufacturer and
approved by the Engineer’s Representative.
Bond breaker installed behind joint sealant shall be thin self-adhesive polyethylene tape. Where
the sealant manufacturer recommends the use of primer before the application of sealant, it shall
be provided by the sealant manufacturer for the purpose.
J3.4.15 Slip membrane

Slip membrane for use in a two-layer separating membrane at sliding joints shall consist of
proprietary plastic sheeting not less than 1.5mm thick which shall have a coefficient of friction
not exceeding 0.2 between rubbing surfaces when used in accordance with the manufacturer's
instructions and subjected to a load of 0.27N/m².
J3.4.16 Bituminous paint

Bond breaking paint for use on concrete or steel reinforcement shall be bituminous paint
complying with the relevant provisions of BS 3416 or BS 6949, as appropriate.
J3.4.17 Dowel caps

Where dowels of steel reinforcement are used for expansion joints, the dowel to one side of the
joint shall be painted with 2 coats of bituminous paint and the end of the dowel shall be fitted
with a dowel cap. The cap shall comprise a cardboard or plastic tube which is a free fit on the
dowel and which is filled with joint filler for a part of its length not less than the thickness of the
joint filler in the joint.
J3.4.18 Protective membrane systems (tanking)

Membrane for water proofing concrete either for prevention of water penetration through the
structure or for the protection of concrete from salts present in groundwater shall be flexible self-
adhesive impervious composite sheeting of total thickness not less than 1.5 mm consisting of
either:
• a sheet not less than 0.25 mm thick of cross-laminated polyethylene or PVC, and a
rubber-bitumen compound; or
• a bituminous sheet and a polyester surface film.
Membrane for the exclusion of groundwater or the retaining of an aqueous liquid shall comply
with the recommendations of BS 8102 and shall be flexible self-adhesive impervious composite
sheeting of total thickness not less than 1.5 mm consisting of either:
• a sheet not less than 0.30 mm thick of cross-laminated polyethylene or PVC, and a
rubber-bitumen compound; or
• a polyester-reinforced rubber-bitumen sheet with polyester carrier film or as BS 747:
type 5B.
Primer for membrane and other sundry materials for forming fillets, upstands and chamfers shall
be fully compatible with the membrane material.

Membranes shall be capable of withstanding cracking of the concrete substrate up to a crack

width of 0.6 mm.
J3.4.19 Protective coatings to concrete surface

All concrete in contact with the ground and immediately above the finished ground surface shall
be protected with a bituminous coating.
Coatings to concrete surfaces shall consist of two coats of an approved high build fibre
reinforced bitumen based waterproofing emulsion to give a minimum coverage of 0.9 kg/m2 with
a DFT of 750 micron.
Coatings to concrete faces shall continue above finished ground level by a minimum of 150 mm.
Where exposed above ground two additional coats of an aluminium paint shall be applied or as
many coats as are necessary to ensure bleed of the bitumen system through the top coat does not
occur.
The coatings shall be subject to the approval of the Engineer and preferably be made by a single
manufacturer. They shall be fully compatible with materials used for sealing of joints. They shall
be applied strictly in accordance with the manufacturer's recommendations.
J3.5 EQUIPMENT
J3.5.1 General
Plant and equipment shall be sufficient to meet the requirements of both the Specifications and
the construction programme. Special requirements for plant and equipment for concrete
production are described below.
J3.5.2 Aggregate production plant

The Contractor shall submit the following information before delivery of his plant on site:
• Scheme for developing aggregate sources.
• Plant flow diagram and list of major pieces of equipment.
• Plan showing proposed layout of the plant, including waste disposal areas and
facilities.
• Method of transporting raw materials to the aggregate plant.
• Production capacity per hour of each section of the plant.
• Method and provisions for dust control.
• Proposals for quality control at each stage of the process to ensure satisfactory and
uniform products, including sampling methods and facilities.
The plant shall be capable of stocking the screened aggregate into allocated bins or stockpiles.
The plant shall have means for quick adjustments of the crusher and/or of the screening
equipment operations, as may be necessary, to maintain consistent grading of the aggregate.
All milling to manufacture fine aggregate shall be done in equipment normally used to produce
manufactured sand for concrete. Crushing plant screenings smaller than 9.5 mm sieve size will
not be accepted for any part of the fine aggregate unless the screenings first pass through the fine
aggregate processing equipment. Both fine and coarse aggregates shall be washed.

The aggregate production plant will be required to screen natural material in separate sizes and
crush the oversized down to the required sizes. The whole process will require plant for crushing,
sizing, washing, material handling, transportation equipment, conveyors and feeders.
J3.5.3 Batching and mixing plant for concrete

The Contractor shall provide and maintain a modern and dependable, automatic, interlocked,
computer-controlled batching and mixing plant or plants. All solid materials entering the plant
shall be measured and batched by weight. Liquid materials may be measured and batched by
weight or by volume. All concrete shall be centrally mixed in stationary mixers located with the
batching equipment. The total production capacity of the plant shall be enough to meet the
peak-period concrete demands. Each plant shall be of heavy duty construction that is capable of
withstanding continuous day to day production of 75 mm (3 in) nominal maximum size
aggregate and low-slump concrete mixtures. The equipment shall provide facilities for the
separate measurement and batching of cement, pozzolan, water, ice, fine aggregate, three size
ranges of coarse aggregate and various chemical admixtures. The handling and batching system
for cement and for pozzolan, including storage, screws, elevators, chutes and weighing hoppers
shall be completely independent and separate from each other.
In case the Contractor elects to blend natural sand with manufactured sand in the batching plant,
the Contractor shall provide separate batching bins and weighing systems for each type of sand.
The Contractor shall submit, for approval by the Engineer, drawings showing the general plant
arrangement, specifications, type and main features of the equipment proposed for use prior to
the ordering of the batching and mixing plant. At the same time the Contractor shall also submit
for approval written proposals as to how the Contractor will control and check the operation of
the plant to ensure that each batch of concrete produced will satisfy the mix design requirements
and that there will be no significant variation between different batches made to the same mix
design. Notwithstanding approval of these proposals any failure of the installation, the operation
and performance of the plant and equipment to meet the requirements of the Specification, shall
be the responsibility of the Contractor to rectify.
Each plant shall be equipped with separate screen decks for rewashing and finish screening of
coarse aggregate. All coarse aggregate shall be rewashed on a rinsing screen with spray bars
immediately prior to elevating to the batch plant. The rinsing screens shall be of sufficient length
to remove excess moisture from the coarse aggregate. Coarse aggregate shall be finish screened
on horizontal vibrating screens. The finish screens shall be so mounted that the vibration of the
screens will not be transmitted to, or affect the accuracy of the batching scales. The method and
rate of feed shall be such that the screens will not be overloaded and will operate properly in a
manner that will result in a finished product which consistently meets the grading requirements
of the Specification. Feed to the finish screens shall be a combination or alternation of aggregate
size ranges such that there will be no noticeable accumulation in any bin of material not having
the full range of sizes specified. Aggregates larger than 37.5 mm (1 ½ in) shall be lowered into
the bins by means of rock ladders which shall operate effectively to keep breakage at a minimum.
Material that is removed from the coarse aggregate and passes the 4.75 mm screen (No. 4) as a
result of the finish screening operation shall be wasted.
Aggregates shall be weighed in separate weigh batchers with individual scales or cumulatively in
one weigh batcher on one scale. Weighing hoppers shall be arranged to permit the convenient
addition or removal of material. Aggregate batching equipment shall be constructed and arranged
so that the sequence and time of discharge can be controlled to produce a ribboning and mixing
of the aggregate with the cement and pozzolanic material as the materials are charged into the

mixer. This shall be accomplished by control of the batcher discharge gates. The operation of the
gates shall allow precise cut-off of the aggregate flow such that the exact required quantity is
discharged.
An approved electric resistance device shall be provided in the sand batcher for indicating
moisture content. The electrodes shall extend to within 300 mm of the batcher discharge gates.
The monitoring instrument shall be located in plain view of the plant operator. Plant controls
shall be capable of ready adjustment to compensate for varying moisture contents of aggregate
and for effecting changes in the concrete mix proportions.
The plant shall include suitable devices for the batching of each admixture. Admixtures may be
discharged with the fine aggregate, ice or water but in no case shall admixtures be permitted to
intermix until they enter the mixer. Equipment for admixture batching shall be designed for
visual confirmation of the accuracy of the measurement through a vertical glass cylinder. The
filling mechanism of the device shall be capable of ready adjustment to permit varying the
quantity of admixture. Equipment for admixture batching shall be within full view of the
operator and shall be interlocked with the other measuring mechanisms.
All batching equipment shall be interlocked so that a new weighing cycle cannot be started until
all batchers are completely emptied and the batcher discharge gates and valves are closed; the
batcher discharge gate cannot be opened until the correct weights of materials are in the batching
hoppers and the scales in balance; and the discharge gates can not be closed until all the materials
are entirely discharged from the hopper and the scales return to zero. The filling and discharge
valves for the water batcher shall be interlocked with the other weighing mechanism. The pipe
for delivering water to the mixer shall be such that leakage will not occur when the valve is
closed and the pipe will quickly drain without water trail.
The Contractor shall provide standard test weights and any other auxiliary equipment required
for checking the operating performance of each scale and other measuring device from zero to
full capacity of the scale or device within an accuracy of 0.2%.
The accuracy of the batching equipment in delivery of materials shall be as follows:
Cement: ± 2% of the required weight of material being weighed, or
± 0.3% of scale capacity, whichever is greater;
Pozzolan: same as cement material;
Water (ice): ± 2% of the required weight of material being weighed, or
± 0.3% of scale capacity, whichever is greater, or
± 1% of the required volume of material being batched or ± 5 litres, whichever is
greater
Aggregates: for each aggregate size,
± 3% of the required weight of material being weighed, or
± 0.3% of the scale capacity, whichever is greater.
Admixture: ± 0.3% of the required weight or volume of material being batched.
The plant computer control system shall have a capacity to input and store no less than 20
different mix designs. The proportions for each mix design shall be easily adjustable and shall be
based on aggregate weights in surface dry condition. Actual batch weights shall be automatically
adjusted by input of aggregate moisture contents and shall be readily changed within the system
as the aggregate moisture content changes. The system shall store and output the number and size

of batches of each mix design batched and the cumulative quantity of each material used during
each shift of operation.
All batching and mixing operations shall be automatically operated by the computer on
command. An accurate display shall be in full view of the operator which shall display the target
batch weights based on mix design used and, when batching is completed, the actual batch
weights of each material. The system shall not discharge materials from the batchers until all
materials are within tolerance. A printed record shall be made showing the mix design, target
batch weights, actual batch weights, moisture content of each aggregate, mixing time, placement
to which the batch is designated, date and time of day for each batch. The printed sheet shall be
made in triplicate and the original shall become the property of the Engineer upon completion of
each shift. The print-out shall be readily and conveniently available for review by the Engineer at
any time during concrete production and a copy of the print-out for each batch shall travel with
the concrete to the placement area.
The plant operator's platform shall be closed, air-conditioned, soundproofed, completely
protected from dust and vibration and shall be positioned where the operator can readily observe
the mixing action of concrete in at least one mixer and the discharge of all mixers. Suitable
location of the operator will be required for adequate control of concrete consistency. In addition,
the plant shall include facilities for sampling each aggregate size from under the storage bin
gates.
The plant shall be equipped with one or more batch type tilting drum mixer, vertical shaft pan
mixer, or horizontal shaft pan mixer and a discharge hopper. Each mixer shall be capable of
combining the aggregates, cement, pozzolan, admixtures and water (including ice) into a uniform
mixture, in colour and consistency, and of discharging the mixture without segregation. The
mixers shall be interlocked with the batching plant such that they cannot be charged until empty
or discharged until the required mixing time has elapsed. The Contractor shall be required to
prove the adequacy of his proposed mixing time for each mix to be manufactured. Mixing time
shall start when all solid materials are in the mixer. The timing device for mixing time on each
mixer shall be equipped with a bell or other suitable warning device adjusted to give a clearly
audible signal to the plant operator each time mixing is completed. The mixing plant shall have
means for readily wasting material or concrete that is improperly batched, mixed, or held in the
mixer too long.
The discharge hopper shall be fitted with a suitable device to facilitate obtaining representative
samples of concrete and delivering them to the ground for unit weight and consistency tests. All
necessary platforms, tools, equipment and personnel to assist the Engineer in obtaining samples
shall be furnished by the Contractor.
The Engineer will conduct mixer performance tests in accordance with ASTM C94 to determine
the uniformity of the mix when mixed to the specified or approved mixing time. Should the
mixer performance tests show that operations fail to result in the required uniformity of
composition and consistency of concrete within the mixed batch, the Engineer may require
repairs to the mixing plant or increase in mixing time until satisfactory results are achieved. If the
repairs do not remove the defects from the mixing plant and the necessary increase in the mixing
time could affect the production progress, the Engineer may order immediate removal of the
defective mixing plant or provision of additional mixer capacity.
The mixer shall revolve at a uniform speed and shall not be charged in excess of the capacity
recommended by the manufacturer. Excessive over-mixing, requiring addition of water to
preserve the required consistency, will not be permitted.

Should any mixer at any time produce unsatisfactory results, its use shall be promptly
discontinued until it is repaired or replaced. Mixers shall be maintained in clean and good
working condition at all times.
Each mixer shall have attached in a prominent place a manufacturer's plate showing the capacity
of a drum or pan in terms of volume of mixed concrete and the speed of rotation of the mixing
drum or blades.
The batching and mixing plant shall be maintained free of set concrete or cement and shall be
clean before commencing mixing. The accuracy of calibration of every weighing device, water
measuring device and admixture dispenser, shall be checked by the Contractor in the presence of
the Engineer before carrying out trial mixes, before the first mixing of concrete for inclusion in
the Works, after each service or adjustment to the mixing plant and in any case at least once per
month.
J3.5.4 Vehicles for transporting concrete

Transit mixers or appropriate agitator trucks may be used for transporting mixed concrete,
subject to the requirements of the Specifications and subject to approved measures to ensure that
no water is added to the concrete in the transit mixers or agitator trucks and that concrete is
discharged without segregation.
J3.5.5 Vibrators for concrete compaction

Vibrators for vibrating concrete in structures shall be heavy duty, immersion type vibrators. They
shall operate at frequencies and amplitudes of vibration of not less than six thousand impulses
per minute and 1 mm respectively, for vibrator heads with a diameter greater than 125 mm; and
seven thousand impulses per minute and 0.5 mm amplitude for smaller vibrator heads. Vibrating
equipment shall be fully capable of obtaining satisfactory results and operating reliably and
effectively with all types of specified concrete mixes. The Engineer will test vibrator frequency
and amplitude from time to time for compliance with manufacturer's specifications. Prompt
modification or replacement of vibration equipment will be required if it does not perform
satisfactorily under all operating conditions. The use of surface vibration equipment or form
vibration equipment will not be permitted unless specified or approved in each case by the
Engineer.
J3.5.6 Refrigeration plant

Adequate refrigeration facilities shall be provided to ensure that the temperature of concrete,
when placed in the forms, shall not exceed the values given in Clause J3.6.16.
Before erection of the refrigeration plant, the Contractor shall submit the technical data of the
plant, its layout including arrangements for procurement of water, method of transporting ice into
the concrete mixer, storage of ice and heat-balance calculations and drawings of the plant to the
Engineer for his information.
The Contractor may elect to chill the coarse aggregate as an aid to meeting the specified placing
temperatures. If the Contractor intends to chill coarse aggregate, the Contractor shall submit his
proposals for chilling arrangements to the Engineer for approval.

J3.6 WORKMANSHIP
J3.6.1 Proportioning of concrete
J3.6.1.1 Responsibility of Contractor

The Contractor shall be responsible for developing mix designs for concrete and mortars which
conform to this Specification.
J3.6.1.2 Mix designs

The Contractor shall propose mix designs for the trial mix programme. The procedures used for
mix design shall be in accordance with ACI 211.1, Standard Practice for Selecting Proportions of
Normal, Heavyweight and Mass Concrete.
A report including mix design calculations shall be submitted to the Engineer for approval not
less than 28 days prior to commencement of the trial mix programme.
The mix designs shall include mixes for each Class of concrete given in Clause J3.4.6 as well as
bedding mortars and the like required for execution of the Works.
For the purposes of mix design, the Contactor shall obtain test data defining the relationship
between strength and water /cementitious ratio. The cementitious content is the content of
cement and pozzolanic material. Alternatively, the Contractor may assume a reasonable range of
water/cementitious ratios for a given strength and design trial mixes accordingly. The chosen
water/cementitious ratios in the trial mixes for any one Class of concrete shall be well to each
side of the ratios expected to give the required strengths.
For concrete exposed to air and water the water/cementitious ratio shall not exceed 0.50 unless
the Engineer so expressly permits. No concrete shall have a water/cementitious ratio greater than
0.70.
Water reducing agents may be used if the required workability (slump) cannot be obtained within
the required limiting water/cementitious ratios.
The Contractor shall demonstrate to the satisfaction of the Engineer that the content of cement
and pozzolan is the minimum required to yield the required strength for the concrete and which
will satisfy other criteria set out in this Section of the Specification.
J3.6.1.3 Trial mixes

The Contractor shall submit to the Engineer for approval any laboratory test programme the
Contractor may require for determining the strength relationship with water/cementitious ratio
not less than 4 weeks prior to commencements of any such tests.
The Contractor shall prepare a laboratory test programme for the concrete trial mixes and shall
submit it to the Engineer for approval not less than 4 weeks before commencement of the trials.
The objectives of the programme are to determine mix proportions which will yield the specified
properties for the specified concrete Classes.
The trial mix programme shall be started not less than 6 weeks prior to the scheduled
commencement of concrete placements in permanent works.
The Characteristic Strength for the various concrete Classes is given in Clause J3.4.6. This is the
minimum strength the concrete shall have at a given maturity (time since casting). The strengths

measured on specimens of apparently identical concrete show statistical variations that follow a
Normal Distribution and this variation can be measured as the Coefficient of Variation (standard
deviation / mean strength). A certain proportion of test results can be below the Characteristic
Strength and this proportion is termed the Failure Rate. For each Failure Rate there is a factor
derived from the properties of the Normal Distribution which when multiplied by the Standard
Deviation gives the Margin. This factor is 0.842 for a failure rate of 20%, 1.280 for a Failure
Rate of 10% and 1.645 for a Failure Rate of 5%. The Target Strength is the sum of the
Characteristic Strength and the Margin. The Target Strength shall be the strength used as a basis
for design of the mixtures. At the commencement of the concrete programme the Standard
Deviation will not be known. Coefficients of variation can be estimated on the basis of
characteristics of concrete manufacture, transport, placing and other factors. Until such times as
the strength test data from the concrete mixtures are available and reliable coefficients of
variation calculated, the Coefficient of Variation shall be 30% for a tilting drum mixer
installation and 25% for a twin-shaft batch type pug-mill mixer installation. These coefficients
are based on truck transport between the mixers and the point of placement. The allowable
Failure Rate for all Classes of conventional concrete shall be 10%.
As strength data from production mixes becomes available, the variance (Standard Deviation)
and a revised Target Strength shall be calculated. Based on all the information available, the
Contractor shall propose adjustments to the mix proportions to reflect the revised Target Strength
for the Engineer’s approval. For the purposes of determining the variance (Standard Deviation)
for any one Class of concrete a series of test results from not less than 40 separate batches of
concrete from the same batch plant produced over a period of not less than 5 days but not
exceeding 26 weeks shall form the basis for the determination.
The trial mix programme shall include mixes with a range of mix proportions for each Class of
concrete which will ensure that at least one mixture for each Class of concrete will conform to
this specification in all respects. Any delays caused by failure to produce mixtures which so
conform shall not relieve the Contractor of any of his obligations under the Contract. Under no
circumstances shall concrete of a particular Class be placed in the permanent works until the trial
mix programme has established the mix proportions for that concrete Class to the satisfaction of
the Engineer.
Test cylinders shall be cast from each mixture in sufficient numbers for testing at 3, 7, 14, 28 and
91 days after casting. The test cylinders shall be made and cured in accordance with ASTM C31.
The number of cylinders cast from each mixture and workability shall be not less than 18. The
cylinders shall be tested for compressive strength in accordance with ASTM C39.
The testing shall be carried out at the Contractor’s laboratory. The laboratory shall be furnished
with all equipment, facilities, personnel and materials necessary to perform the trial mix
programme including testing in accordance with the specified Standards.
The Contractor shall produce a report on the trial mix programme at the time of completion of
the manufacture of concrete cylinders, and shall provide all data from testing daily as the tests
proceed. The Contractor shall provide a final report which shall include all test data, description
of test procedures, evaluations of data and proposals for mix proportions to be used in various
Classes of concrete, including maximum allowable water/cementitious ratios, for the approval of
the Engineer. The Engineer will require 2 weeks to evaluate the proposals.
J3.6.2 Concrete properties and requirements

Concrete mixtures shall be composed of cementitious materials, water, fine and coarse aggregate,
and air-entraining admixtures unless otherwise specified. Water reducing agents may be used to

improve workability subject to the approval of the Engineer. Cementitious materials shall consist
of cement and pozzolanic material. Epoxy resin shall be used to produce epoxy concrete/mortar
when so ordered by the Engineer.
The design of the mixtures shall be based on securing a plastic workable mixture both suitable
for the specific conditions at placement and, when properly cured, a product having durability,
impermeability and strength in accordance with the requirements of the structures covered by
these Specifications. For all concrete placements, the Contractor will be required to handle and
place low-slump mixtures in order to achieve high-quality concrete, except for pumped concrete
for which the slump will be appropriate for the application. In the placement of any single
concrete lift, the Contractor may be required to handle and place several different concrete
mixtures containing different maximum size coarse aggregate for producing higher quality, more
durable exterior concrete and for placement in highly reinforced and congested areas. The
mixtures shall contain no more cementitious material than needed to meet the structural design
requirement. The use of pozzolanic material with OPC will result in a slow early rate of gain in
concrete strength, and the Contractor shall have due regard for this when designing his formwork
and planning his programme for form removal.
The Contractor shall keep the fine aggregate content to the minimum that is compatible with
producing a concrete with the maximum possible compacted density for that concrete Class as
well as other specified criteria.
Aggregate shall be a mixture of coarse and fine aggregate. Coarse aggregate shall consist of one
or more of the specified size ranges to produce a well graded aggregate mixture with the required
nominal maximum size aggregate. The nominal maximum size aggregate to be used in the
various parts of the Permanent Works shall be in accordance with the following unless otherwise
directed or approved:
NOMINAL MAXIMUM
GENERAL USE
AGGREGATE SIZE
37.5 mm Walls, columns and slabs – more than 300 mm thick.
Thin walls, slabs, and beams - up to 300 mm thick; heavily
19 mm reinforced concrete, pre-stressed concrete, and blinding layer
concrete.
In no event shall the nominal maximum size aggregate exceed one-fifth of the narrowest
dimension between sides of forms; one-third the depth of slabs; nor three-fourths of the
minimum clear spacing between individual reinforcing bars, bundles of bars, or post-tensioned
cable conduits.
The Contractor shall provide effective means such as pre-cooling of aggregates, refrigerating the
mixing water, adding flake, chip, crushed, tube, or other forms of ice up to the full amount of
added mixing water, or a combination of these or other methods, as necessary to maintain the
temperature of concrete at or below the specified temperature as it is placed. The size of the ice
particles shall be such that the ice is completely melted before the end of the mixing time for
each batch.
J3.6.3 Concrete consistency

The concretes shall have a consistency, as measured by the slump method (ASTM C143),
conforming to the various limits specified below.

SLUMP (mm)
SPECIFIED CONCRETE WORK SPECIFIED SPECIFIED
WORKING
WORKING REJECTION
RANGE
LIMIT LIMIT
Mass concrete and reinforced
concrete walls, slabs and piers 50 25 to 50 75
more than 900 mm thick
Walls, slabs and columns less
75 50 to 75 100
than 300 mm thick
Bedding mortars 150 100 to 150 175
Under no circumstances shall the quantity of water and ice added cause the water/cementitious
ratio to exceed the maxima allowable as determined in the trial mix programme. If these limits
are exceeded in any batch of concrete, the batch will be rejected by the Engineer.
Concrete with a slump equal to or greater than the rejection limit as measured by the Engineer at
the point of placement will be rejected by the Engineer. Concrete consistency shall be uniform
from batch to batch. The Contractor shall vary the quantity of mixing water from batch to batch
if necessary to offset variation in free moisture content or grading of the aggregates. Water shall
not be added to compensate for stiffening of concrete held in the mixer too long or for delays in
placement.
The specified working limit is the permitted upper limit of a range of slumps selected to provide
the required concrete properties including the ability to be readily compacted by the specified
vibration equipment during concrete placement. The slump of concrete as placed shall average
approximately 10 mm less than the specified working limit. The 25 mm margin between the
working limit and the rejection limit is provided for occasional inadvertent batches which may
exceed the working range. Batches of concrete with slumps exceeding the working limit, but
within the inadvertency margin, will be rejected if the frequency of their occurrence is such that
the average of three successive tests exceeds the working limit by more than 12 mm.
Concrete that has been rejected for failure to meet slump limits shall not be used in the
Permanent Works.
J3.6.4 Sampling and testing of concrete

During concrete production, the Contractor under the supervision of the Engineer and to his
satisfaction will routinely test the concrete for compliance with specified requirements. In
general, one set of four cylinders will be made for each 200 m3, or a fraction thereof, of each
Class of concrete placed in a shift or from each day's placement as appropriate. The Contractor
shall provide a suitable device to sample the discharge from each mixer.
Test specimens shall be made by the Contractor in accordance with the requirements of
ASTM C31. Test specimens shall be tested by the Contractor in accordance with the
requirements of ASTM C39 for compressive strength, to develop a comprehensive and historical
record of mixtures, strength development and the degree of quality control achieved. In addition,
the Contractor shall also determine the air content and density of the fresh concrete from which a
set of specimens are cast.

The Contractor shall determine the aggregate grading of fresh concrete by wet sieving at least
once a day when concrete is being placed and at such times and locations as the Engineer may
direct.
Where there is evidence that concrete production and placement has resulted in work that does
not meet the quality requirements of these Specifications, core boring will be ordered by the
Engineer in accordance with ASTM C42. In the event that examination and tests on samples
removed from the structure show that the concrete does not conform to these Specifications,
measures as prescribed by the Engineer shall be taken by the Contractor to correct the deficiency.
The entire cost of testing and corrective action shall be borne by the Contractor.
Concrete samples containing aggregate particles larger than 37.5 mm shall be wet-screened to
remove such particles in accordance with ASTM C172 before making the slump test or casting
150 mm by 300 mm cylindrical compression test specimens.
J3.6.5 Mixes not approved

Approval of a mix may be withheld or withdrawn if (inter alia):
a) the grading of the aggregate changes such that the fraction of aggregate retained on
any sieve differs from the corresponding fraction of aggregate in the approved mix by
more than 2% of the total quantity of fine and coarse aggregate; or
b) the source of supply of aggregate, cement or pozzolan is changed.
If approval of a mix for any class, or grade of concrete is withdrawn for any reason the
Contractor shall carry out such further trials as are necessary to achieve a satisfactory mix for that
class, or grade of concrete.
J3.6.6 Preparing for concreting

Before placing concrete, the Contractor shall ensure that:
- The surface of the previously placed concrete or the foundation is clear of all oil, loose
fragments of rock, earth, mud, timber, pieces of tie-wire or any other foreign material,
running or standing water, dust, etc.
- Excavated surfaces on which concrete is to be placed shall consist of undisturbed in situ
material. They shall be compacted if so directed by the Engineer.
- Where concrete is to be placed on compacted fill, the compacted fill shall be extended
beyond the foundation line by a distance sufficient to ensure that all fill below the
foundation surface is compacted to the specified degree. The fill shall then be trimmed to
the foundation level shown on the Drawings. The surfaces shall be re-compacted if so
- All reinforcement is in its correct place, well tied and fitted with spacer blocks to maintain
correct cover, and is clean.
- All embedded items are securely fixed at the locations shown on the Drawings.
- All formwork is rigid and well supported, made to dimensions shown on the Drawings,
erected to the specified tolerances, cleaned, oiled, inspected and accepted by the
Engineer.
- All necessary tools and plant, e.g. vibrators, and all necessary materials for protection and
curing of concrete are available and in working order.
- All surfaces against which concrete is to be placed are wet, without ponding of water.
- Concrete materials are within specified temperatures.

- Clearance of the Engineer for concreting of the lift has been received.
J3.6.7 Embedded pipes and other item

Pipes and other items designed to be embedded in concrete structures shall, wherever practicable,
be built into the structure as indicated on the Drawings or as directed by the Engineer as work
proceeds, having been installed and connected to the remainder of the system to ensure proper fit
prior to the start of any concreting.
When that procedure cannot be adopted, holes shall be formed or conduits built-in for such items
to allow them to be installed later. Such holes shall be of size and shape sufficient to permit
proper placing and compacting of concrete or grout. The surfaces of the holes shall be treated to
produce a bonded surface where so directed by the Engineer.
All items to be built-in shall be securely supported in their correct position to prevent movement
or damage during building-in. In particular, any pipe with flanged joints shall not be concreted in
until its accurate fit with other pipe-work has been checked and it has been secured in position.
Concrete used for building-in shall be of the same Class as the surrounding concrete, except that
the mix shall also incorporate an approved expanding additive used with due regard to the
manufacturer's instructions. Cement/sand mortar or cement grout, if used, shall also incorporate
an approved expanding additive. Concrete, mortar and grout shall be placed and compacted by
the methods to be approved by the Engineer.
Any air or water lines or other materials to be embedded in structures, as construction
expedients, shall be firmly and securely fastened in place and thoroughly clean and free of oil and
other foreign matter such as loose coatings of rust, paint, scale or mortar prior to embedment.
After embedment and upon completion of their use, they shall be backfilled with concrete or
grout as directed by the Engineer.
No through going members of this kind shall be permitted in water retaining structures.
J3.6.8 Fixing and cover to reinforcement

All reinforcement shall be securely and accurately fixed in the positions shown on the Drawings
using approved spacer blocks or chairs. All intersections of bars shall be secured with soft iron
wire, the ends turned into the body of the concrete. The Contractor shall ensure that all
reinforcement is maintained in correct position at all times, particular care being taken during
placing of the concrete.
Concrete cover to reinforcement, unless shown on the Drawings, shall be maintained in
accordance with the following:-
Concrete Section Minimum cover
(a) Surfaces cast against contact with rock or soil 75 mm
(b) Surfaces in contact with rock or soil 50 mm
(c) Surfaces in contact with water or exposed to weather 50 mm
(d) Soffits of slabs above water (with additional protection of steel 40 mm
reinforcement)
(e) Internal surfaces not exposed to weather or water:-
Beams, columns, walls 40 mm

Concrete Section Minimum cover

Slabs 25 mm
In no case shall the cover be less than 1.5 times the maximum size of the aggregate used in the
concrete, nor 2.5 times the maximum diameter of the steel reinforcement.
Top reinforcement in slabs shall be maintained in position with the use of chairs, sized and
spaced to provide adequate support and fixity for the reinforcement. The reinforcement closest to
the form shall be positioned parallel to the direction of flow in water passages.
No part of the reinforcement shall be used to support formwork, access ways, working platforms,
or the placing equipment or for the conducting of an electric current.
J3.6.9 Welding of reinforcement

No welding of reinforcement whatsoever, including tack welds, shall be permitted unless shown
on the Drawings or authorised in each case by the Engineer. Where shown on the Drawings or
authorised, welding shall be in accordance with the requirements of BS 5135 and the
recommendations of the manufacturer of the steel. The Contractor shall demonstrate by bend and
tensile tests on specimen welds that the strength of the parent metal is not reduced and that the
weld possesses a strength not less than that specified for the parent metal. The welding procedure
established by successful test welds shall be maintained and no departure from this procedure
shall be permitted.
Following the establishment of a satisfactory welding procedure, each welder to be employed on
the Works shall carry out welder performance qualification tests on reinforcing bars of the same
metal and bar sizes as those to be used in the Permanent Works. The requirements of BS 4871
shall be observed.
Details of welding procedure and welder qualification tests shall be submitted to the Engineer for
approval before welding of reinforcement commences.
J3.6.10 Design and layout of formwork

The Contractor shall be responsible for the adequacy of the design and safety of formwork.
However, the type, size, shape, quality and strength of all materials shall be subject to approval
by the Engineer.
On formwork for external faces which will be permanently exposed and where finish F2 or F3 is
designated, care shall be taken to construct the form in such a manner that horizontal and vertical
joints are well matched and are continuous across the entire surface of the structure. Special
attention shall be paid to such places as points of bifurcation in a structure, widening or
narrowing of a structure, where horizontal members meet with vertical members and where the
shape of a structure changes. Joints in formwork shall be sanded or ground to remove
imperfections if necessary. Joints shall be mortar-tight and sufficiently strong to withstand loads
of concrete and equipment. Headed nails shall not be used.
Curved surfaces shall be smooth and construction in chorded lengths shall not be allowed except
when permitted by the Engineer. Forms for warped surfaces shall conform accurately to the
specified curved surfaces, which shall have been dimensioned at several sections. Intermediate
sections shall be interpolated as necessary and the forms shall be constructed so that the
curvature will be continuous between sections. Where necessary to meet requirements for

curvature, the form lumber or plywood shall be built up of laminated splints cut to make tight,
smooth form surfaces.
All exposed joints, edges and external corners shall be chamfered 1 in x 1 in (25 mm x 25 mm)
except when shown otherwise on the Drawings. Internal corners shall be filleted as indicated on
the Drawings or as directed by the Engineer. Forms for external concrete surfaces shall not be
constructed continuous but shall be removed and reset for each placement. Form sheathing shall
not overlap previously placed hardened concrete by less than 1 in (25 mm) and shall be drawn
tight against the hardened concrete so that an offset at the construction joint and loss of mortar
are avoided.
J3.6.11 Erection of formwork

All formwork shall be soundly constructed, true to grade and line, firmly supported, adequately
strutted, braced and tied to withstand the placing and vibrating of concrete and the effects of
weather.
Faces of formwork in contact with concrete shall be free from adhering foreign matter, projecting
nails and the like, splits or other defects, and all formwork shall be clean and free from standing
water, dirt, shavings, chippings, tying wire or other foreign matter. Joints shall be sufficiently
watertight to prevent the escape of mortar or the formation of fins or other blemishes on the face
of the concrete.
Except where the surface is subsequently to be rendered, formwork in contact with the concrete
shall be treated with an approved non-staining form mould oil to prevent adherence of the
concrete. Care shall be taken to prevent the oil from coming in contact with reinforcement or
with concrete at construction joints. Surface retarding agents shall not be used unless specified.
Openings for inspection of the inside of the formwork, for the removal of water used for washing
down and for placing concrete shall be provided and so formed as to be easily closed before or
during placing concrete. Before placing concrete, all bolts, pipes or conduits or any other fixtures
which are to be built-in shall be fixed in their correct positions, and cores and other devices for
forming holes shall be held fast by fixing to the formwork or otherwise.
For all surfaces where quality of finish is of paramount importance, the Contractor shall cast
samples, to actual scale and dimensions or a part thereof as may be decided by the Engineer, to
ensure that the desired quality of finished surface has been achieved. Concreting shall not
commence before approval of the specimen sample.
J3.6.12 Removal of formwork

Formwork shall be so designed as to permit easy removal without resorting to hammering or
levering against the surface of the concrete.
The periods of time elapsing between the placing of the concrete and the striking of the
formwork shall be as approved by the Engineer after consideration of the loads likely to be
imposed on the concrete and shall in any case be not less than the periods shown in the following
table:

Minimum time for removal of formwork

(For Concrete using Ordinary Portland Cement)
NORMAL WEATHER COLD WEATHER
POSITION
(days) (days)
Beam sides, walls
1 2
and columns
Slab and beam soffits 14 21
Minimum times shall be determined by the Engineer when pozzolanic materials are used.
Cold weather is defined as the situation where either or both of the following conditions exist at
the Site:
- The air temperature at the time considered is below 2° C.
- The mean daily air temperature over three or more successive days has dropped below
5° C.
Normal weather is at all other times.
Where soffit formwork is constructed in a manner that allows the removal of the majority of the
formwork and the retention, during and after such removal, of a sufficient number of adequate
supporting props in an undisturbed condition, the Contractor may, with the agreement of the
Engineer, remove the formwork at the earlier times listed above provided that the props are left
in position and are not disturbed during removal of the majority of the formwork.
Notwithstanding the foregoing, the Contractor shall be held responsible for any damage arising
from removal of formwork before the structure is capable of carrying its own weight and any
incidental loading.
J3.6.13 Transporting concrete

Concrete shall be conveyed from mixer to its place on the Permanent Works as rapidly as
possible by ways and means which will prevent segregation or drying out and ensure that the
concrete is of the required consistency at the time of placing.
Buckets, belt conveyors, chutes or other similar equipment will be permitted for conveying
concrete subject to approval of the proposed system by the Engineer.
All conveying equipment and methods shall be designed for and capable of handling concrete of
all specified aggregate sizes and slumps, including low-slump concrete.
Clear indication shall be provided for the identification of different mixes of concrete and their
destination, and each consignment shall be accompanied by a copy of the batching plant printed
record.
J3.6.14 Placing concrete

All concrete shall be placed so as to produce a set concrete that is hard, durable, dense, free from
honeycombing, formwork irregularities and other surface blemishes.
At least 63 days before placing concrete in any major structure, the Contractor shall submit to the
Engineer for his approval details of his proposed construction procedures including a description
of the methods of concrete placement. Approval of construction procedures and methods of

placement will not relieve the Contractor of his responsibility for their adequacy and the
Contractor shall remain solely responsible for satisfactory construction of the Permanent Works.
For each concrete placement, the Contractor shall provide the Engineer with written notice, a
drawing and a pre-placement checkout sheet signed by the Contractor's appropriate supervisory
personnel that demonstrate that foundation preparation, construction joint cleanup, formwork,
installation of reinforcing steel, block-outs and all embedded items for the placement have been
completed according to the Drawings or as specified. Before concrete placement is permitted,
each item on the checkout sheet shall be initialled by the Engineer showing that the item has been
inspected and is ready to receive concrete. Concrete placement will not be permitted when, in the
opinion of the Engineer, conditions prevent proper placement, consolidation, finishing and
curing.
Concrete mixed in stationary mixers and transported by non-agitating equipment shall be placed
within thirty minutes of mixing. When an agitator is used for transporting concrete, the concrete
shall be delivered to the site of the work and discharge shall be completed within 1½ hours after
introduction of cement to the aggregates except that, when the temperature of the concrete
exceeds 21° C, the time shall be reduced to 45 minutes. The concrete shall be placed within
20 minutes after it has been discharged.
Concrete shall be carefully placed in horizontal layers not exceeding 450 mm thick. Concrete
shall not be allowed to slide or flow down sloping surfaces, except in underground galleries, but
shall be placed in its final position from skips, trucks, barrows, down pipes or other placing
machine or device or, if this is impossible, it shall be shovelled into position with care being
taken to avoid separation of the constituent materials. Concrete placed in horizontal slabs from
barrows or other tipping vehicles shall be tipped into the face of the previously placed concrete.
Bedding mortars shall only be used when the Engineer so directs. Where bedding mortars are
directed to be used they shall be spread to the thicknesses and over areas given by the Engineer.
Bedding mortar shall be covered by concrete within 15 minutes of the bedding mortar being
placed. If this period should be exceeded the Engineer may direct the Contractor to remove the
bedding mortar and halt the concrete placement until such time as the area has been prepared for
receiving concrete.
Concrete dropped into place shall be dropped vertically. It shall not strike the formwork between
the point of its discharge and its final place. Concrete shall not be dropped freely through a
height greater than 1.5 m. Chutes and conveyor belts shall be so designed that there is no
segregation or loss of mortar and shall be provided with a vertical tapered down pipe, or other
device, to ensure that concrete is discharged vertically into place.
Where a lift of concrete is built up in a series of layers, each layer shall be properly merged into
the preceding layer before initial set takes place.
When pumps are used, the end of the supply pipe shall be arranged so as to avoid segregation.
Mortar or water used at the beginning or end of a run shall be discharged outside the formwork.
Where concrete abuts against earth or other materials liable to become loose or to slip, the
Contractor shall take steps to prevent any such loose material falling onto the surface of the
concrete.
J3.6.15 Lift height and time between placement

The permissible depth of concrete placed in one lift and the minimum time elapsing between the
placing of successive lifts shall be as follows unless otherwise shown on the Drawings or
directed by the Engineer:

MAXIMUM DEPTH OF MINIMUM TIME ELAPSING

LOCATION CONCRETE PLACED IN BETWEEN PLACING OF
ONE LIFT SUCCESSIVE LIFTS
Concrete in base slabs and in
walls, columns and piers
3m 120 hr
whose thickness does not
exceed 3.0m
All other concrete 4.5 m 120 hr
The elapsed time between adjacent pours shall not be less than 14 days or as otherwise directed
by the Engineer.
When slabs or beams are monolithic with supporting walls or columns, there shall be a
construction joint near the top of the wall or column. The position of the joint shall be subject to
the approval of the Engineer.
When placing concrete directly onto existing concrete or new concrete that is more than 21 days
old the above maximum depths of concrete shall be half that given in the above table.
J3.6.16 Placing temperature of concrete

Unless specified otherwise for particular parts of the Works, the temperature of the concrete
when delivered to the forms shall be as low as practicably can be produced but in no case at a
temperature in excess of the requirements specified below for different types of concrete
sections.
J3.6.16.1 Thin and moderate sections

This type covers sections 3 m and less in thickness when screeded and/or formed on both faces,
and 1.5 m and less in thickness when one face is formed and the other is placed against earth,
rock or concrete. The maximum temperature allowed shall be 30° C.
J3.6.16.2 Heavy sections and mass concrete

This type covers sections with dimensions greater than those given above for thin and moderate
sections. Concrete and mortar for such sections shall have a temperature of not more than 28°C
when placed.
J3.6.17 Placing temperature of epoxy concrete and mortar

Epoxy concrete and mortar shall be placed and repairs shall be made when the atmospheric and
concrete temperatures are above 5° C and below 38° C and remain in this range for a period of at
least 24 hours. If the work is required to be done at temperatures lower or higher than those
specified, approved means as recommended by the manufacturer of the epoxy binder and
approved by the Engineer shall be provided to raise or lower the ambient and concrete
temperatures as required for satisfactory work. Such means will include heating or cooling
equipment and necessary shelters. If temperatures below 5° C are anticipated during the cure-out
or hardening period of the epoxy concrete or mortar, heated enclosures shall be maintained over
the repair area with care taken to avoid localised heating or hot-spots. Circulating air shall be
used to ensure that surface temperatures do not exceed 38° C, during curing.

J3.6.18 Concreting in hot weather

All hot weather concrete shall comply with the requirements of ACI 305R. In hot weather, the
Contractor shall take steps to ensure adequate protection of concrete work. Hot weather is
defined as any combination of high air temperature, low relative humidity and wind velocity
tending to impair the quality of fresh or hardened concrete or otherwise resulting in abnormal
properties. To that end the Contractor shall provide sun shades over stockpiles of aggregates,
batching and mixing plant, cement silos, and mixing water tanks and pipelines; insulate facilities
and, in addition, shall carry out one or more of the following procedures which shall be
submitted to the Engineer for approval:
• Shade and/or wet the outside of the formwork;
• Apply a fine moisture (fog) spray of clean water at a temperature not exceeding 25°C
in order to cool and moisten the surrounding air and the sub-surface, to cool the
formwork and reinforcement, to lessen rapid evaporation from unformed concrete
surfaces and to keep concrete surfaces cool;
• Apply a fog spray to aggregate stockpiles;
• Use a wet-belt conveyor for the delivery of aggregates to the batching plant;
• Refrigerate the mixing water;
• Add chip, crushed, tube, or other forms of ice up to the full amount of added mixing
water.
If, in the opinion of the Engineer, the maximum temperature reached by the concrete during
hydration could nevertheless damage the finished work, the Contractor may order:
• avoiding the placement of concrete during the hottest part of the day, or
• placement only at night, or
• an increase in the minimum period between lifts, or
• a combination of these.
J3.6.19 Concrete placed in water

The Contractor shall not place any concrete in water without prior permission of the Engineer.
Concrete shall not be placed in running water nor shall concrete be allowed to fall through water.
The methods and equipment used shall be subject to the Engineer's prior approval. Use of
concrete buckets will not be permitted for under water placement of concrete.
When approved, concrete shall be placed in water only by means of a bottom opening watertight
box or a tremie of a type approved by the Engineer. Bottom opening boxes shall not be opened
until they are resting on the surface on which the concrete is to be placed and the discharge ends
of tremies shall always be kept buried within freshly placed concrete and the shaft kept full of
concrete to a point above the water surface. Placement shall proceed without interruption until
the concrete has been brought to the required height. The tremie shall not be moved horizontally
during a placing operation, and a sufficient number of tremies shall be provided so that concrete
does not have to flow horizontally a distance of more than 3 m.

J3.6.20 Compaction
All concrete, other than blinding concrete, shall be compacted with power driven, immersion
type vibrators supplemented by hand spading and tamping.
Vibrators shall be inserted into the un-compacted concrete vertically and at regular intervals such
that the radius of action overlaps that of the previously vibrated concrete. A layer shall not be
covered with a succeeding layer until it has been thoroughly vibrated as specified. Where the un-
compacted concrete is in a layer above freshly compacted concrete, the vibrator shall be allowed
to penetrate vertically for about 100 mm (4 in) into the previous layer. In no circumstances shall
vibrators be allowed to come into contact with the formwork or embedded parts, nor shall they
be withdrawn quickly from the mass of concrete, but shall be drawn back slowly so as to leave
no voids. Internal-type vibrators shall not be placed in the concrete in a random or haphazard
manner, nor shall concrete be moved from one part of the work to another by means of the
vibrators. Care shall be taken properly to vibrate concrete placed in contact with previously
placed concrete or embedded parts.
The duration of vibration shall be limited to that required to produce satisfactory compaction,
without causing segregation. Compaction of the concrete by vibration shall be such as to produce
a concrete that has the maximum practicable density, is free from pockets of coarse aggregate
and entrapped air and makes complete contact with the foundation, previously placed hardened
concrete, embedded items and the formwork.
Blinding concrete shall be compacted by hand spading and tamping.
J3.6.21 Attendance of steel fixer and carpenter

The Contractor's arrangements for concreting shall provide for the immediate availability of
competent steel fixers and carpenters during the whole period of any concrete placement.
J3.6.22 Curing of concrete

Concrete shall be cured by approved methods. Means shall be provided for protecting the newly
cast surface from the effects of sunshine, drying winds, frost, rain, running water or mechanical
damage. The Contractor shall submit proposals for the means of curing that he proposes to use to
the Engineer for approval.
The curing shall be maintained for a continuous period of at least 14 days or until covered by the
next lift or as otherwise approved by the Engineer.
If, during the specified minimum period of curing, the surface temperature of the concrete falls
below 10° C, the period of curing shall be extended to allow the concrete to reach sufficient
maturity. The period of extension shall be as approved by the Engineer.
The curing protection shall be applied as soon as practicable after completion of placing and
shall include one or more of the following methods as may best suit the circumstances:
• water sprays in continuous operation;
• covering with hessian or similar absorbent material, or sand, kept constantly wet;
• after thorough wetting, covering with a layer of waterproof fabric kept in contact with
the concrete surface;
• keeping the formwork in position;

• applying an approved non-staining liquid curing membrane conforming to ASTM

C309, Type 2, Class B. The liquid shall be applied to formed surfaces immediately
after stripping the formwork, except to those areas requiring surface repair.
Where the use of a liquid curing membrane is likely to spoil the finished appearance of an
exposed surface, the Contractor shall not use this form of curing. The Engineer may also prohibit
the use of liquid curing membrane where potable water will be stored.
Liquid curing membrane shall be applied in compliance with the instructions of the manufacturer
and on rough surfaces the rate shall be increased as necessary to obtain the required continuous
membrane. Liquid curing membrane shall not be used on concrete where a bond is required.
The underside of deck slabs and surfaces to be backfilled shall be cured with liquid curing
compound.
Care shall be taken to ensure coverage of corners and edges. Equipment for applying liquid
curing membrane shall be of the pressure tank type with provision for continual agitation of the
contents during application. All operations by the Contractor on membrane cured concrete shall
be such as to avoid damage to the membrane for a period of not less than 28 days. Any
membrane that is damaged or that peels from concrete surfaces within 28 days after application
shall be immediately repaired by methods to be approved by the Engineer.
All repairs done by epoxy concrete or epoxy mortar shall be protected from rain or seepage water
for at least 12 hours and from all types of traffic for a period of 24 hours after placement.
J3.6.23 Joints
J3.6.23.1 Construction joints

A construction joint is defined as a joint in the concrete introduced for convenience in
construction or where shown on the Drawings or where directed by the Engineer at which special
measures are taken to achieve subsequent continuity and water-tightness with no provision for
relative movement.
The positions of construction joints and the size of the formwork panels shall be so coordinated
that, where possible, the line of any construction joint coincides with the line of a formwork joint
and that in any case all construction joint lines and formwork joints appear as a regular and
uniform series. For all exposed horizontal joints and purposely inclined joints, a uniform joint
shall be formed with a pattern of approved dimensions to give a straight and neat joint line.
Hardened concrete at a construction joint shall have all laitance, loose or unsound concrete,
coatings, stains or other foreign material removed before placement of fresh concrete. The whole
of the concrete surface forming the joint shall be cleaned by high-pressure water-blasting or by
sand-blasting.
Wet sand-blasting, when employed in the preparation of construction joints, shall be performed
immediately before placing the following lift. The impact pressure of the wet sand will be
regulated by the Contractor so as to achieve the removal of the laitance without undercutting the
edges of the larger aggregate.
High-pressure water-blasting utilising a pressure not less than 20 MPa may be used in lieu of wet
sand-blasting for preparing the joint surfaces. High-pressure water-blasting equipment shall be
rated for pressures up to 50 MPa and shall be equipped with suitable safety devices for
controlling the pressure. It shall include a shut-off switch at the nozzle that will shut off the
pressure if the nozzle is dropped.

The operation employed shall be continued until all unsatisfactory concrete, all laitance, coatings,
stains, debris and other foreign materials are thoroughly removed. Before concreting is resumed,
all loose matter shall be completely removed and the surface shall be clean and slightly wet.
The method used in disposing of waste water employed in cutting, washing and rinsing of
concrete surfaces shall be such that the waste water does not stain or discolour the exposed
surfaces of the structure. Methods of disposal shall be subject to approval by the Engineer.
Should any delay in placement occur so that previously placed concrete begins to stiffen, the
exposed leading edge of the placement shall be thoroughly vibrated to a uniform and stable
slope. The sloping surface shall be treated as a construction joint and shall be properly cleaned
before covering with fresh concrete.
The Contractor shall submit his proposals, which shall be subject to approval by the Engineer,
for all construction joints not shown on the Drawings.
J3.6.23.2 Movement joints

All movement joints (for expansion and/or contraction) shall be constructed according to the
details shown on the Drawings. All jointing materials shall be secured in place before concreting
at the joint begins. Where corrugated metal sheets are used in control joints they shall be lapped
50 mm with adjacent sheets. The concrete cover to sheets shall be not less than 75 mm. Any
projections of the concrete into and around the joint space that are likely to spall under
movement or prevent the proper operation of the joint shall be carefully removed.
J3.6.24 Placing of jointing materials

All jointing materials shall be applied strictly in accordance with the application instructions of
their suppliers. All materials for concrete jointing and protection shall be stored in accordance
with the instructions of the supplier, especially in regard to temperature. Materials shall be used
in order of delivery from the manufacturer and shall not be used after the expiry of any storage
life recommended by the manufacturer.
Joint filler shall be cut from the least practicable number of pieces to fit exactly and completely
cover the areas shown on the Drawings. Loose fitting or open joints between sections of filler or
between filler and forms will not be permitted. When required by the Drawings or directed by the
Engineer, a space adjacent to the preformed expansion joint filler shall be filled with a joint
sealant. Joint sealant shall be placed in strict accordance with the manufacturer's
recommendations.
As far as possible, jointing of waterstops on Site shall be confined to the making of butt joints in
straight runs. Where it is necessary for an intersection, or change of direction, or any joint other
than a butt joint in a straight run, to be made on Site, a preliminary joint, intersection or change
of direction piece shall be made and submitted to such tests as the Engineer may require.
Flexible waterstops shall be fully supported in the formwork, free of nails and clear of
reinforcement and other fixtures. Any waterstop, which after installation is found to be damaged,
shall be removed and replaced. Placing and compacting of concrete in the vicinity of waterstops
shall be carried out with care to ensure that the waterstops do not bend or distort and that no
voids are left below the waterstop.
The surface of set concrete in a joint shall, where a bond breaker is specified on the Drawings, be
painted with two coats of bituminous paint and new concrete shall be placed against it only when
the paint is dry.

Caulking grooves shall be provided as shown on the Drawings. At all joints where a caulking
groove is formed, immediately prior to caulking, the groove shall be sand-blasted or high
pressure water blasted and loose material removed and blown out by compressed air. After the
groove has dried, it shall be primed and caulked with approved caulking compound in strict
accordance with the manufacturer's recommendations.
Swelling waterstop shall be fixed in accordance with the manufacturer’s recommendations.
J3.6.25 Protective membrane (tanking)

Concrete (other than blinding concrete) surfaces which would otherwise be in contact with the
ground or exposed to groundwater or forming a roof structure shall receive a protective
membrane where specified.
All concrete to which protective membrane is to be applied shall have Class U2 or F2 finish, free
from sharp protrusions and hollows. External angles shall be chamfered. All surfaces shall be
clean and dry. Except for horizontal blinding concrete, all concrete to receive membrane shall be
primed in accordance with the membrane manufacturer's instructions.
One complete layer of protective membrane shall be applied in accordance with the
manufacturer's instructions with laps of not less than 150mm at ends and 75mm at sides. All
corners shall receive two layers of membrane either by use of an additional reinforcing strip of
membrane not less than 300mm wide or by carrying each overlapping membrane at least 150mm
beyond the corner to provide an overlap not less than 300mm wide. Internal angles shall have
approved fillets installed to facilitate proper dressing of the protective membrane with the corner.
Chamfers and fillets shall be not smaller than 25 x 25 mm.
Membranes applied to vertical surfaces shall terminate 125mm above ground or finishes level
except where otherwise shown on the Drawings. Above and to a minimum of 150 mm below
finished ground level applied membranes shall be protected with a layer of self adhesive mineral
finished bituminous felt, or other solar protection material supplied by the membrane
manufacturer. Above ground the membranes and the bituminous felt shall be terminated by
turning into a 20 mm by 20 mm rebate which shall subsequently be neatly pointed with a
thixotropic rubber bituminous sealant. The sealant and the protection shall be compatible with
the membrane and with each other. An approved aluminium flashing shall be fixed as shown on
the Drawings to retain the mineral finished bituminous felt.
Where a membrane is applied to horizontal surfaces of an underground structure, a 50 mm layer
of concrete Class C shall be placed as soon as practicable after the completion of laying the
membrane. The limits of the concrete protection shall correspond precisely with the formation
level plan of the structural concrete so as to enable the vertical membrane to be joined to the
horizontal membrane in the manner specified. The top surface of the concrete protection shall be
finished accurately to level with a tamped texture and the concrete shall be allowed to set
thoroughly for at least 48 hours before any subsequent operations on the structure are
commenced.
J3.6.26 Protective coatings

All structural concrete below and adjacent to ground level shall receive protection by the
application of a membrane, applied coating or sacrificial concrete.
Concrete cast against the ground as a specified vertical thrust face shall be provided with two
layers of polythene sheet. All other formed surfaces shall receive two coats of an approved high
duty fibrous bitumen based waterproofing emulsion to give a minimum coverage of 0.9 kg/m2.

The coating shall be continued to at least 150mm above the ground surface. Where exposed
above ground two additional coats of an aluminium paint shall be applied or as many coats as are
necessary to ensure bleed of the bitumen system through the top coat does not occur.
Blinding concrete to 75mm thickness shall be provided beneath all structural concrete. Blinding
to buildings shall be placed over two layers of polythene sheeting to prevent damp rising.
Blinding to water tanks shall omit the polythene sheet to enhance friction resistance.
J3.6.27 Epoxy seal coat

Epoxy seal coats to the internal soffit of tank roofs shall be applied by roller and brush in
accordance with the manufacturer’s instructions as one coat to a dry film thickness of 1.0mm.
The soffit shall have an F3 finish. Prior to application all nibs and projections shall be removed
and pinholes filled. A primer/sealer coat shall be applied prior to the main coat.
J3.6.28 Unformed surfaces - class of finish

Finishes to unformed surfaces of concrete shall be classified as U1, U2, U3, U4, or such other
special finish as may be particularly specified.
Where the class of finish for unformed surfaces is not specified, the concrete shall be finished as
follows:
- surfaces exposed to high velocity flow U4
- surfaces exposed to flowing water other than high velocity flow U3
- building floors not receiving additional finishing U3
- other surfaces except surfaces against which backfill is to be placed U2
- surfaces against which backfill is to be placed U1
Class U1 finish shall be finished to grade and screeded, uniform plain or ridged finish, which
(unless it is being converted to Class U2, U3 or bonded concrete) shall not be disturbed in any
way after the initial set, surplus concrete being struck off immediately after compaction.
Class U2 finish shall be produced by manual or mechanical floating of the concrete surface after
the initial set has taken place when the surface has hardened sufficiently and free water has
disappeared. The concrete shall be worked no more than is necessary to produce a uniform
‘sandpaper' finish free from screed-marks.
Class U3 finish shall be the next stage after Class U2 and shall be a hard, smooth, steel-trowelled
finish. Trowelling shall not commence until the concrete has hardened sufficiently to prevent
excess laitance from being worked into the surface. The surface shall be trowelled under firm
pressure and left free from trowel marks. The addition of dry cement, mortar or water shall not be
permitted.
Class U4 finish shall have a Class U3 finish and in addition all abrupt irregularities shall be
eliminated completely by grinding to a slope of 1 to 50, height to length.
J3.6.29 Sloping surfaces

Where concrete is to be placed on a slope steeper than one vertical to four horizontal and not
shuttered, the Contractor shall use a travelling slip-form screed to hold the concrete in position
temporarily so that it can be fully compacted by internal vibrators ahead of the screed. The screed
shall be weighted and shall have a leading edge that is normal to the finished surface. The width

of form shall be at least 1 m in the direction of movement. The screed shall be drawn up the
slope at a steady and uniform rate which shall be consistent with the rate of concrete placement.
The screed shall ride on guide rails which shall be located outside the placement. The required
finish shall be applied to the concrete emerging from the trailing edge of the form. The slip-form
screed shall be subject to the approval of the Engineer.
J3.6.30 Formed surfaces - class of finish

Finishes to formed surfaces of concrete shall be classified as F1, F2, F3, F4 or such special finish
as may be specified.
Where the class of finish for formed surfaces is not specified, the concrete shall be finished as
follows:
- surfaces exposed to high velocity water flow F4
- surfaces exposed to flowing water other than high velocity flow F3
- other surfaces, except surfaces against which backfill is to be
placed and surfaces receiving additional finishes F2
- surfaces against which backfill is to be placed F1
- surfaces receiving additional finishes F1
Formwork for Class F1 finish shall be constructed of timber, sheet metal or any suitable
materials which will prevent loss of grout when the concrete is vibrated. Surfaces subsequently to
be rendered, plastered or tiled shall be adequately scabbled or roughened as soon as the
formwork is removed to reduce irregularities to not more than half the thickness of such
rendering, plastering or bedding for tiles and to provide a satisfactory key.
Formwork for Class F2 finish shall be faced with tongued and grooved boards or plywood or
metal panels arranged in a uniform approved pattern free from defects likely to detract from the
appearance of the surface.
Formwork for Class F3 finish shall be lined with panels of non-staining material with a smooth
unblemished surface such as sanded plywood or hard compressed fibre board. The panels shall
be as large as possible and shall be arranged in a uniform approved pattern. Un-faced boarding or
standard steel panels shall not be permitted.
Formwork for Class F4 finish shall be used for surfaces subject to high velocity flow as specified
on the Drawings. Such surfaces shall have a F3 finish and in addition, all abrupt irregularities
shall be eliminated by grinding to a slope of 1 to 50, height to length.
J3.6.31 Dimensional tolerances and surface finish of concrete

Concrete surfaces for the various classes of unformed and formed finishes shall be true to the
lines, levels and dimensions shown on the Drawings within the tolerances stated on the Drawings
or, where not so stated, as shown in the Table below.
Surface irregularities shall be classified as "abrupt" and "gradual". Abrupt irregularities include,
but shall not be limited to, offsets and fins caused by displaced or misplaced formwork, loose
knots and other defects in formwork materials, and shall be tested by direct measurement.
Gradual irregularities shall be tested by means of a straight template for plane surfaces or its
suitable equivalent for curved surfaces. The template shall be 1.5 m long.

MAXIMUM TOLERANCE
CLASS OF
FINISH LINE AND ABRUPT GRADUAL CONCRETE
LEVEL IRREGULARITY IRREGULARITY DIMENSION
U1, F1 12 mm 6 mm 12 mm +12 mm –6 mm
U2, F2 6 mm 6 mm 6 mm +12 mm –6 mm
U3, F3 6 mm 3 mm 6 mm +12 mm –6 mm
U4, F4 6 mm 0 6 mm +12 mm –6 mm
J3.6.32 Defects in formed surfaces

Workmanship in formwork and concreting shall be such that concrete shall not normally require
repair, surfaces being fully compacted, smooth and with no irregularities.
Any minor surface blemishes shall be repaired to the satisfaction of the Engineer immediately
after removal of formwork. Remedial measures may include, but shall not be limited to the
following:
- Holes left by formwork supports shall be thoroughly cleaned out to remove all loose
material and the sides shall be roughened, if necessary, to ensure a satisfactory bond. They
shall then be filled with dry-pack mortar.
- Fins, pinholes, bubbles, surface discolouration and minor defects shall be rubbed down with
sacking and cement immediately after the formwork is removed. Excess cement shall be
removed after the concrete has been fully covered by rubbing down with carborundum.
- Abrupt and gradual irregularities shall be rubbed down with carborundum and water after
the concrete has been fully cured.
- Small defects and minor honeycombing shall be chipped out perpendicular to the face of the
concrete to a depth of at least 25 mm and filled with epoxy mortar. Epoxy mortar shall not
be used where the width exceeds the depth of the defects.
Where remedial work is to be carried out using dry-pack mortar, the concrete surrounding the
hole shall be thoroughly soaked, after which the surface shall be dried so as to leave a small
amount of free water on the surface. The surface shall then be dusted lightly with cement by
means of a small dry brush until the whole surface that will come into contact with the dry-pack
mortar has been covered and darkened by absorption of the free water by the cement. Any dry
cement in the hole shall be removed.
Dry-pack mortar shall be mixed and placed as specified in Clause J3.6.33.
Where deeper or more extensive defects occur, the Contractor shall cut out the defective area to a
depth of 25 mm with a diamond saw to give a regular edge to the repair and further chipping to
form a hole free of any loose, broken or cracked concrete or aggregate, with a minimum depth of
75 mm and a dovetail shape to sound concrete. If reinforcing steel is exposed, the concrete shall
be removed to a depth of 25 mm beyond the back side of the reinforcement. The void shall be
refilled with epoxy concrete.
Epoxy mortar and concrete shall be mixed and placed as specified in Clause J3.6.35.
Unsound repairs shall be removed and replaced.

Where, in the opinion of the Engineer, the defect is too extensive to permit satisfactory repair,
either from the point of view of structural integrity or appearance, the concrete containing the
defect shall be broken out and replaced at no cost to the Employer.
J3.6.33 Dry-pack mortar

Dry-pack mortar for filling holes shall be made from one part by weight of cement and three
parts fine aggregate passing a 1.18 mm (No. 16) sieve. The colour of the mortar shall match that
of the surrounding concrete by replacing part of the grey cement with white cement as approved
by the Engineer. The mortar shall be mixed with only sufficient water to make the materials stick
together when being moulded in the hands.
The dry-pack material shall be placed and packed in layers having a thickness not greater than
15 mm. The compaction shall be carried out by use of a hardwood stick and hammer and shall
extend over the full area of the layer, particular care being taken to compact the dry-pack against
the sides of the hole. After compaction the surface of each layer shall be scratched before further
loose material is added. Holes shall not be overfilled and the surface shall be finished by laying a
hardwood block against the dry-pack fill and striking the block several times. Steel finishing
tools shall not be used and water shall not be added to facilitate finishing. All dry-pack fillings
shall be cured in an approved manner.
J3.6.34 Blinding concrete

Where concrete is to be placed on a flat excavated surface or one inclined at not more than 1
Vertical : 1.75 Horizontal, a 75mm layer of blinding concrete shall be placed immediately after
completion of the excavation and cleaning, unless otherwise directed or shown on the Drawings.
The upper surface of the blinding concrete shall not be higher than the required cover below the
lowest layer of the reinforcing steel. The final excavated level shall be calculated to allow for the
thickness of the blinding layer. Where directed by the Engineer, the excavated surface shall be
compacted prior to placing of blinding concrete.
J3.6.35 Epoxy concrete and mortar

Epoxy concrete and/or mortar shall be used for the replacement of faulty concrete or for other
special purposes. Epoxy concrete and epoxy mortar shall be mixed in the proportions by such
methods and with such equipment as are recommended by the manufacturer of the epoxy resin
and approved by the Engineer. The proportions of epoxy mortar and epoxy concrete and the
methods of mixing and placing will be subject to change to meet field requirements. The
individual batch size of epoxy concrete and mortar which may be prepared at one time shall not
exceed the amount that may be mixed, placed and finished in accordance with the manufacturer's
instructions as approved by the Engineer.
J3.6.36 Precast concrete members

Structural and non structural units of precast concrete shall be manufactured to the sizes and
details shown on the Drawings. The concrete shall comply, in every respect, with the provisions
of these Specifications whether such units are manufactured on the Site or obtained from
manufacturers approved by the Engineer.
Non structural concrete products shall, where appropriate, be manufactured in accordance with
the following standards, being hydraulically pressed where possible:

Standard Type Of Unit

BS 340 Kerbs etc.
BS 368 Flags
BS 6073 Masonry units
Where the installation of precast concrete units in any particular structure is such that the faces of
the units are to be left exposed, either internally or externally, the exposed surfaces of the units as
finished shall be uniform in colour and in texture. All cement, aggregates and other materials
used in the manufacture of the units shall be obtained from the same approved sources
throughout the period of manufacture.
Surfaces of precast concrete units shall comply with the requirements for U3 unformed surfaces
and F3 formed surfaces respectively.
The Contractor shall submit full details of his proposed method of carrying out all operations
connected with the manufacture and assembly of precast concrete structural members, including:
a) a schedule of the precast members;
b) a description of the types of casting bed, mould and formwork for the various
members;
c) the procedure for concrete casting and the method of curing the concrete;
d) the procedure for transporting, handling, hoisting and placing of each type of precast
structural member;
e) and particulars of temporary supports as deemed necessary to ensure adequate
stability against the effects of construction loads, wind load or other transient loads
during and after erection.
All units shall be laid, bedded, joined and fixed in accordance with the lines, levels and other
details shown on the Drawings. Mortar for bedding and jointing units shall consist of one part by
volume of OPC and two parts by volume of sand to the grading of Table 2 of BS 1200.
J3.6.37 Dimensional tolerance of precast concrete

Dimensions and shapes of precast concrete structural members shall comply with tolerances
given on the Drawings or, when not so given, with those stated hereunder.
The dimensional tolerances for length shall be as follows:
LENGTH DIMENSION MAXIMUM DIFFERENCE FROM SPECIFIED
less than 3m 6 mm
3 – 4.5m 9 mm
4.5 – 6m 12 mm
additional for every subsequent 6m 3 mm
The dimensional tolerances for cross section shall be as follows:
CROSS SECTION (EACH MAXIMUM DIFFERENCE FROM SPECIFIED
DIRECTION) DIMENSION
less than 450mm 6 mm

additional for every subsequent 300mm 3 mm

The dimensional tolerances for straightness or bow shall be as follows:
STRAIGHTNESS OR BOW DEVIATION FROM INTENDED LINE
less than 3m 6 mm
additional for every subsequent 3m 3 mm
When considering the squareness of a corner, the longer of the two adjacent sides being checked
shall be taken as the baseline, and a line perpendicular to the baseline shall be taken as the check-
line. The distance of the shorter side from the check-line shall be such that the difference
between the greatest and shortest such distances shall not exceed:
LENGTH OF SHORTER SIDE DEVIATION FROM SQUARENESS
not exceeding 1.2m 6 mm

1.2 – 2m 9 mm
exceeding 2m 12 mm
For the purpose of this requirement, any error due to lack of straightness shall be ignored;
squareness shall be measured with respect to the straight lines which are most nearly parallel
with the features being checked. When the nominal angle is other than 90o, the included angle
between the baseline and the check-line shall be varied accordingly.
No corner of a nominally plane surface shall deviate from the plane containing the other three
corners by more than:
SURFACE DIMENSIONS DEVIATION FROM PLANE

not exceeding 0.6m wide and not exceeding 6m long 6 mm
any other size 12 mm
The deviation from a 1.5 m straightedge placed in any position on a nominally plane surface shall
not exceed 6 mm
J3.6.38 Installation of precast concrete members

At all stages and until completion of the Permanent Works, precast members shall be adequately
protected to preserve all permanently exposed surfaces and architectural features. The protection
shall not mark or otherwise disfigure the concrete.
All units shall be laid, bedded, jointed and fixed in accordance with the lines, levels and other
details shown on the Drawings.
Dry pack mortar for joint packing shall conform to Clause J3.6.33.
Any precast concrete member that is found to be cracked, damaged or otherwise unsuitable,
either before or after erection, shall be rejected and replaced at no extra cost to the Employer.

J3.6.39 Reinforcement details

The Construction Drawings furnished to the Contractor will show the amounts of steel
reinforcement to be included in the various parts of the Permanent Works. From the information
given on these drawings, the Contractor shall prepare detailed reinforcement drawings and
schedules for approval. The detailed reinforcement drawings and schedules shall clearly show the
numbers, shapes, lengths, sizes and weights of the bars and the laps and couplings to be used.
The reinforcement detailing shall be in accordance with the recommendations of ACI 318 and
ACI 350.
J3.6.40 Bending of reinforcement

Bars shall be cut and bent in accordance with the provisions of ACI 315. Bending shall be carried
out slowly, at a steady even pressure, and without jerking, impact or heating. The temperature of
the steel at the time of bending shall not be less than 5° C. Bent bars shall not be re-bent unless
permitted by the Engineer.
J3.6.41 Storage of reinforcing bars and fabricated mats

The Contractor shall stack separately and label different types of reinforcement for positive
identification of the manufacturer, size and production run or other number which relates to the
test certificates furnished by the manufacturer.
Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust, mill scale, oil,
grease, dirt, paint or any other material which may impair the bond between the concrete and the
reinforcement.
All reinforcement shall be stored under cover on wooden or concrete supports at least 150 mm
clear of the ground.

SECTION J4 PIPELINES, CABLE DUCTS AND APPURTENANCES
J4.1 GENERAL
J4.1.1 Scope
This Section covers requirements for pipes, valves, fittings, cable ducts and appurtenances.
The main transmission pipelines and fittings shall be either Carbon Steel CS “For 1200mm &
1600mm Diameter pipes or Ductile Iron DI “Pipes smaller than 1000mm” unless otherwise
specified. For CS Pipes welding joints shall be used and joints at valve chambers and above
ground shall be bolted flanges. For DI Pipes joints shall be spigot and socket push in joints.
Joints at fittings shall be flanged, push fit or (bolted gland) mechanical joints. Valves shall have
flanged joints, and adapters for ease of dismantling.
Cable ducts shall be of uPVC or, where installed by trenchless methods, high density
polyethylene (HDPE).
J4.1.2 Definitions
The following terms shall have the meanings hereby assigned to them:
‘Pipes’ Straight pipes, whether whole or cut and their joints
‘Pipeline’ or ‘Pipework’ The whole pipeline inclusive of pipes, fittings, valves and pipeline
appurtenances
‘Fittings’ All components fitted to a pipe for jointing, connecting or changing
the direction or bore of a pipe (including bends, tees, tapers, collars
and couplings)
‘Valves’ Valves installed on the pipeline including isolation valves and air
valves
‘Pipeline appurtenances’ All items additional to pipes and fittings required to complete a
pipeline including but not limited to internal and external
protection systems, supports and anchors, chambers, marker posts
and any apparatus or construction required for testing, cleaning,
disinfecting or operating the pipeline
‘Ducts’ uPVC Pipeline inclusive of all fittings and appurtenances including
drawpits and draw cords
‘Accessories’ Nuts, bolts, gaskets, glands, lubricants and all other items necessary
to lay and joint the pipework

Unless otherwise specified materials and workmanship shall comply with the relevant Reference
Standard as listed below or stated within the specification clauses.
Where pipelines or any parts thereof are outside the range of sizes covered by Reference
Standards, the requirements of the Reference Standards shall still apply where relevant, unless
otherwise specified.

BS EN 545 Ductile iron pipes, fittings accessories and their joints for water
pipelines – Requirements and test methods
AWWA C651-99 Disinfecting water mains.
AWWA M12-02 Simplified Procedures for Water Examination. 5th Edition
BS 1377 Parts 1 to 9 Methods of test for soils for civil engineering purposes.
BS EN 681-1:1996 Elastomeric seals. Material requirements for pipe joint seals used
in water and drainage applications. Vulcanized rubber
in water and drainage applications. Thermoplastic elastomers
in water and drainage applications. Cellular materials of
vulcanized rubber
in water and drainage applications. Cast polyurethane sealing
elements
BS 7874:1998 Method of test for microbiological deterioration of elastomeric
seals for joints in pipework and pipelines
BS 970-1:1996 Specification for wrought steels for mechanical and allied
engineering purposes. General inspection and testing procedures
and specific requirements for carbon, carbon manganese, alloy
and stainless steels
BS EN 10088-1:1995 Stainless steels. List of stainless steels
BS EN 10088-2:1995 Stainless steels. Technical delivery conditions for sheet/plate and
strip for general purposes
BS EN 10088-3:1995 Stainless steels. Technical delivery conditions for semi-finished
products, bars, rods and sections for general purposes
BS EN 22063:1994 Metallic and other inorganic coatings. Thermal spraying. Zinc,
aluminium and their alloys
BS 2569-2:1965 Specification for sprayed metal coatings. Protection of iron and
steel against corrosion and oxidation at elevated temperatures
BS 3251:1976 Specification for indicator plates for fire hydrants and emergency
water supplies.
BS 3927:1986 Specification for rigid phenolic foam (PF) for thermal insulation
in the form of slabs and profiled sections.
BS EN 1295-1:1998 Structural design of buried pipelines under various conditions of
loading
BS 4190:2001 ISO metric black hexagon bolts screws and nuts
BS 4320:1968 Specification for metal washers for general engineering purposes.
Metric series.
BS EN 1092-1:2002 Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated. Steel flanges
BS EN 1092-2:1997 Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated. Cast iron flanges
BS EN 1515-1:2000 Flanges and their joints. Bolting. Selection of bolting

BS EN 1515-2:2001 Flanges and their joints. Bolting. Classification of bolt materials

for steel flanges, PN designated
BS 5292:1980 Jointing materials and compounds for water, low pressure steam
installations, 1st, 2nd and 3rd family gases.
BS 6076:1996 Tubular polyethylene film for use as protective sleeving for
buried iron pipes and fittings.
BS EN ISO 3506-1:1998 Mechanical properties of corrosion-resistant stainless-steel
fasteners. Bolts, screws and studs
fasteners. Nuts
fasteners. Set screws and similar fasteners not under tensile stress
fasteners. Tapping screws
BS 6956-5:1992 Jointing materials and compounds: Jointing compounds for use
with water, low pressure saturated steam, 1st family gases
(excluding coal gas) and 2nd family gases
BS 5292:1980 Specification for jointing materials and compounds for
installations using water, low-pressure steam or 1st, 2nd and 3rd
family gases
BS 6956-1:1988 Jointing materials and compounds. Specification for corrugated
metal joint rings
BS EN 751-2:1997 Sealing materials for metallic threaded joints in contact with 1st,
2nd and 3rd family gases and hot water. Non-hardening jointing
compounds
2nd and 3rd family gases and hot water. Anaerobic jointing
compounds
2nd and 3rd family gases and hot water. Unsintered PTFE tapes
BS EN 14161:2003 Petroleum and natural gas industries. Pipeline transportation
systems
BS 7079-O:1990 Preparation of steel substrates before application of paints and
related products. Introduction
BS EN ISO 8501-1:2001, Preparation of steel substrates before application of paints and
BS 7079-A1:1989 related products. Visual assessment of surface cleanliness. Rust
grades and preparation grades of uncoated steel substrates and of
steel substrates after overall removal of previous coatings
BS EN ISO 8501- Preparation of steel substrates before application of paints and
1:Supplement:2001, BS related products. Visual assessment of surface cleanliness.
7079-A1:Supplement Representative photographic examples of the change of
1:1996 appearance imparted to steel when blast-cleaned with different
abrasives


BS 7079-C1:1989 related products. Surface roughness characteristics of blast-
cleaned steel substrates. Specifications and definitions for ISO
surface profile comparators for the assessment of abrasive blast
cleaned steel substrates. Method for the grading of surface profile
of abrasive blast-cleaned steel. Comparator procedure
cleaned steel substrates. Method for the calibration of ISO
surface profile comparators and for the determination of surface
profile. Focusing microscope procedure
BS EN ISO 4624:2003, Paints and varnishes. Pull-off test for adhesion
BS 3900-E10:2003
BS EN ISO 1518:2001 Paints and varnishes. Scratch test
BS EN ISO 2409:1995, Paints and varnishes. Cross-cut test
BS 3900-E6:1992
BS 5252:1976 Framework for colour co-ordination for building purposes
Swedish Standard SIS 05 Pictorial Surface Preparation Standards for Painting Steel
59 00. Surfaces.
BS 812: Part 103.1:1985 Testing Aggregates. Method for determination of particle-size

distribution. Sieve tests.
BS EN 1514-1:1997 Flanges and their joints – Dimensions of gaskets for PN-
designated flanges. Non-metallic flat gaskets with or without
inserts
Transport Research Simplified Tables of External loads on buried pipelines
Laboratory (UK)
WIS 4-52-01 Specification for polymeric anti-corrosion (barrier) coating.
AWWA C.105-99 American National Standard for Polyethylene Encasement for
Ductile Iron Pipe
AWWA C104/A21.4-03 American National Standard for Cement Mortar Lining for
Ductile Iron Pipe and Fittings for Water.
AWWA C111/A21.11- Rubber Gasket Joints for Ductile Iron Pressure Pipes and
00 Fittings.
AWWA C151/A21.51- American National Standard for Ductile Iron Pipe, Centrifugally
02 Cast, for Water.
BS EN 1563:1997 Founding. Spheroidal graphite cast iron
BS 3416:1991 Specification for bitumen-based coatings for cold application
suitable for use in contact with potable water
BS 4027:1996 Specification for Sulphate-resisting Portland cement.
BS 8010: Code of Practice for pipelines on land: design, construction and
Section 2.1:1987 installation: Ductile iron.
BS EN 22063:1994 Metallic and other inorganic coatings. Thermal spraying. Zinc,
aluminium and their alloys.

BS EN 545:2002 Ductile iron pipes and fittings, accessories and their joints for
water pipelines. Requirements and test methods.
ISO 7005-2:1998 Metallic Flanges: Cast iron flanges
ISO 2531:1998 Ductile iron pipes, fittings and accessories and their joints for
water or gas applications for pressure pipelines.
ISO 8179-1 01:2002 Ductile iron pipes - External zinc coating - Part 1: Metallic zinc
with finishing layer
ISO 8179-2 01:1995 Ductile iron pipes - External zinc coating - Part 2: Zinc rich paint
with finishing layer
AWWA C502-94 Dry-barrel fire hydrants.
AWWA C504-00 Rubber Sealed Butterfly Valves
BS EN 837-1:1998 Pressure gauges. Bourdon tube pressure gauges. Dimensions,
metrology, requirements and testing
BS EN 837-2:1998 Pressure gauges. Selection and installation recommendations for
pressure gauges
BS EN 837-3:1998 Pressure gauges. Diaphragm and capsule pressure gauges.
Dimensions, metrology, requirements and testing
BS 1041 Various Parts Code for temperature measurement
BS 1042 Various Parts Measurement of fluid flow in closed conduits.
BS EN 1982:1999 Copper and copper alloys. Ingots and castings
BS EN 1561:1997 Founding. Grey cast irons
BS EN 12163:1998 Copper and copper alloys. Rod for general purposes
BS EN 12164:1998 Copper and copper alloys. Rod for free machining purposes
BS EN 12167:1998 Copper and copper alloys. Profiles and rectangular bar for
general purposes
BS EN 1171:2002 Industrial valves. Cast iron gate valves
BS 3416:1991 Specification for bitumen-based coatings for cold application,
suitable for use in contact with potable water.
BS 4147:1980 Specification for bitumen-based hot-applied coating materials for
protecting iron and steel, including suitable primers where
required.
BS 4999 Various Parts General requirements for rotating electrical machines.
BS EN 13397:2002 Industrial valves. Diaphragm valves made of metallic materials
BS 5163:1986 Specification for predominantly key-operated cast iron gate
valves for waterworks purposes.
BS 6755-2:1987 Testing of valves. Specification for fire type testing requirements
BS EN 12266-1:2003 Industrial valves. Testing of valves. Pressure tests, test
procedures and acceptance criteria. Mandatory requirements
BS EN 12266-2:2002 Industrial valves. Testing of valves. Tests, test procedures and
acceptance criteria. Supplementary requirements
BS EN 593:2004 Industrial valves. Metallic butterfly valves.
BS EN 558-1:1996 Industrial valves – Face to face and centre to face dimensions of
metal valves for use in flanged pipe systems – PN designated
valves

ISO 8770 01:2003 Plastics piping systems for soil and waste discharge (low and
high temperature) inside buildings - Polyethylene (PE)
ISO 8772 01:1991 High density polyethylene (PE-HD) pipes and fittings for buried
drainage and sewerage systems; specifications
BS EN ISO 1461:1999 Hot dip galvanized coatings on fabricated iron and steel articles.
Specifications and test methods
BS 3643-1:1981 ISO metric screw threads. Principles and basic data
BS 3643-2:1981 ISO metric screw threads. Specification for selected limits of size
BS EN 12334:2001 Industrial valves. Cast iron check valves
ASTM D1000-99 Standard Test Method for Pressure-Sensitive Adhesive-Coated
Tapes Used for Electrical and Electronic Applications
ASTM D638-03 Standard Test Method for Tensile Properties of Plastics
ASTM D1004-03 Standard Test Method for Initial Tear Resistance of Plastic Film
and Sheeting
ASTM G13-89(1996)e1 Standard Test Method for Impact Resistance of Pipeline Coatings
(Limestone Drop Test)
ASTM D570-98 Standard Test Method for Water Absorption of Plastics
ASTM E96-00e1 Standard Test Methods for Water Vapor Transmission of
Materials
BS 4607-1:1984 Non-metallic conduits and fittings for electrical installations.
Specification for fittings and components of insulating material
BS 3505:1986 Specification for unplasticized polyvinyl chloride (PVC-U)
pressure pipes for cold potable water
BS EN 1452-1:2000 Plastics piping systems for water supply. Unplasticized
poly(vinyl chloride) (PVC-U). General
BS EN 1452-2:2000 Plastics piping systems for water supply. Unplasticized
poly(vinyl chloride) (PVC-U). Pipes
BS EN 1452-3:2000 Plastics piping systems for water supply. Unplasticized poly
(vinyl chloride) (PVC-U). Fittings
(vinyl chloride) (PVC-U). Valves and ancillary equipment
(vinyl chloride) (PVC-U). Fitness for purpose of the system
BS 4660:2000 Thermoplastics ancillary fittings of nominal sizes 110 and 160
for below ground gravity drainage and sewerage
BS EN 13598-1:2003 Plastics piping systems for non-pressure underground drainage
and sewerage. Unplasticized poly (vinyl chloride) (PVC-U),
polypropylene (PP) and polyethylene (PE). Specifications for
ancillary fittings including shallow inspection chambers
BS 5481:1977 Specification for unplasticized PVC pipe and fittings for gravity
sewers
BS EN 1401-1:1998 Plastics piping systems for non-pressure underground drainage
and sewerage. Unplasticized poly vinylchloride (PVC-U).
Specifications for pipes, fittings and the system

ASTM B418-01 Standard Specification for Cast and Wrought Galvanic Zinc
Anodes
BS EN 12201-1 Plastics piping systems for water supply Polyethylene (PE), Part
1 – General
1 – Pipes
1 - Fittings
ANSI/ASME B16.9 Factory made wrought butt-welding fittings.
ANSI MSS-SP-97 Integrally reinforced forged branch outlet fittings - socket
welding, threaded and butt welding ends.
ASME B16.11 Forged fittings, socket welding and threaded.
ASME B36.10M Welded and seamless wrought steel pipe.
BS EN 1092-1 Flanges and their joints. Circular flanges for pipes, valves,
fittings and accessories, PN designated. Steel flanges.
BS EN 1514-1 Flanges and their joints.Dimensions of gaskets for PN-designated
flanges. Non-metallic flat gaskets with or without inserts
BS EN 1515-1 Flanges and their joints.Bolting. Selection of bolting
BS EN 1515-2 Flanges and their joints.Bolting.Classification of bolt materials
for steel flanges, PN designated
BS 7361-1 Cathodic protection. Code of practice for land and marine
applications
BS EN 10204 Metallic materials - Types of Inspection Documents.
BS EN 13480-1 Metallic industrial piping. Part 1: General
BS EN 13480-2 Metallic industrial piping. Part 2: Materials.
BS EN 13480-3 Metallic industrial piping. Part 3: Design and calculation.
BS EN 13480-4 Metallic industrial piping. Part 4: Fabrication and installation.
BS EN 13480-5 Metallic industrial piping. Part 5: Inspection and testing.
BS EN 13480-6 Metallic industrial piping: Additional requirements for buried
piping.
BS EN 13480-7 Metallic industrial piping.Guidance on the use of conformity
assessment procedures.
BS EN 13636 Cathodic protection of buried metallic tanks and related piping.
NACE RP0286 Standard Recommended Practice - Electrical Isolation of
Cathodically Protected Pipelines
Welding & Joining
BS/EN 287-1 Approval testing of welders - Fusion welding - Part 1: Steels.
BS/EN 288-2 Specification and approval of welding procedures for metallic
materials - Part 2: Welding procedure specification for arc
welding.
BS/EN 288-3 Specification and approval of welding procedures for metallic
materials - Part 3: Welding procedure tests for arc welding of
steels.
BS/EN- 288-9: 1999 Specification and approval of welding procedures for metallic
materials - Part 3: Welding procedure tests for pipeline welding

on land and offshore site butt welding of transmission pipelines.

BS EN 1011-1 to 3 Welding.Recommendations for welding of metallic materials.
BS EN ISO 3834-1 Quality requirements for fusion welding of metallic
materials.Criteria for the selection of the appropriate level of
quality requirements.
materials.Standard quality requirements.
materials.Elementary quality requirements.
BS EN ISO 5817 Fusion welded joints in steel, nickel, titanium and their alloys
(beam welding excluded). Quality levels for imperfections
BS EN ISO 9692-1 Welding and allied processes: Recommendations for joint
preparation. Manual arc welding, gas-shielded metal-arc welding,
gas welding, TIG welding and beam welding of steels.
BS EN ISO 13920 Welding. General tolerances for welded constructions.Dimensions
for lengths and angles.Shape and position.
Non-destructive examination, testing and post-weld treatment

BS EN 462-3 Non-destructive testing.Image quality of radiographs. Image
quality classes for ferrous metals.
BS EN 473 Non-destructive testing.Qualification and certification of NDT
personnel. General principles
BS EN 571-1 Non-destructive testing.Penetrant testing. General principles
BS EN 970 Non-destructive examination of fusion welds - Visual
examination.
BS EN ISO 1182 Reaction to fire tests for building products. Non-combustibility
test
BS EN 1289 Non-destructive examination of welds.Penetrant testing of welds.
Acceptance levels
BS EN 1290 Non-destructive examination of welds. Magnetic particle
examination of welds
BS EN 1291 Non-destructive testing of welds.Magnetic particle testing of
welds. Acceptance levels
BS EN 1435 Non-destructive examination of welds -Radiographic examination
of welded joints.
BS EN 1712 Non-destructive examination of welds.Ultrasonic examination of
welded joints.Acceptance levels.
BS EN 10256 Non-destructive testing on steel tubes. Qualification and
competence of level 1 and level 2 non-destructive testing
personnel
BS EN 2516 Passivation of corrosion resisting steels and decontamination of
nickel base alloys
BS EN 12517-1 Non-destructive testing of welds.Evaluation of welded joints in
steel, nickel, titanium and their alloys by radiography. Acceptance
levels

Drawings
Submissions by the Contractor shall include but will not be limited to the following:
• Typical drawings of standard items.
• Detail drawings of special items.
• Setting out proposals for achieving curvature by joint deflection.
• Shop drawings for valve chambers and drawpits including:
- Details of pipes and fittings.
- Foundation and support details for pipes, valves and fittings.
- Setting out dimensions.
- Reinforcement details.
- Metalwork and supports.
- Valve spindle details.
- Method of building pipes into structure walls.
• Details of supports to buried services.
• Temporary work details, including temporary supports.
Data
Submissions by the Contractor shall include but will not be limited to the following:
• External protection details;
• Method for control of line and level of pipeline during installation
• Manufacturers’ calculations, catalogues and data sheets;
• Methods for pipe handling, installation and backfill;
Records to be kept
The Contractor shall keep detailed and up-to-date records in a form to be approved by the
Engineer of all pipes, fittings and pipeline appurtenances, the quantities of each type, size and
class which have been:
a) ordered during the course of the Works;
b) delivered during the course of the Works;
c) declared on delivery to be faulty, damaged or deficient;
d) broken, damaged or lost during the course of the Works;
e) repaired;
f) laid or installed.

Each week the Contractor shall provide the Engineer with an up-to-date copy of the above
records.
Certificates of tests
The Contractor shall forward to the Engineer the following certificates, where relevant:
a) works tests on pipes and fittings;
b) material tests;
c) inspections;
d) welder-qualification tests;
e) non-destructive tests on completed welds.
The Contractor shall submit for the approval of the Engineer details of his proposed methods and
programme for pipeline testing, swabbing, and cleaning (including details of test and cleaning
equipment).
J4.4 MATERIALS
J4.4.1 General
Materials shall be manufactured to the requirements specified and shall be provided by the
Contractor. All items shall be of the diameter and/or dimensions detailed in the Drawings and
shall be suitable for the test and working pressures specified or detailed on the Drawings. The
class and pressure rating shall not be less than that specified.
For the pipes and fittings that are offered to be used in the Works the Contractor shall give the
name and address of the factories at which the required material will be manufactured, together
with a complete specification in English language, catalogues, a certified programme of delivery,
and evidence of satisfactory service in similar installations for a period in excess of five years.
The normal temperature of the water in the pipelines will be up to 40ºC. All materials that are
close to or in contact with the water shall be suitable for long-term exposure to such
temperatures.
Before commencing manufacture the Contractor shall supply to the Employer for approval
detailed drawings for all the offered materials complete with all technical information, catalogues
and tabulation showing:
a) The overall dimensions of each type and size of the offered materials.
b) The chemical compositions of the various alloy components and the quality of metal
used for the offered materials.
Materials quoted must comply in every respect with this Specification.
J4.4.2 Handling and storage

The Contractor shall develop the method of stock piling on his transport vehicles and stores and
shall furnish special loading spacers, bolsters and the like, approved by the Supplier, to protect
the pipe during transport.
Coated pipe shall be handled at all times with wide non abrasive or leather belts or other
equipment designed to prevent damage to the coating. All such equipment shall be kept in repair

so as to prevent injury to the coating. The use of tongs, bare pinch bars, chain slings, protruding
rivets, pipe hooks, or any other handling equipment that may be injurious to the coating shall not
be permitted. The coated pipes will be padded while being transported and the Contractor shall
take due account of the likely road condition throughout the year.
The bolster of the trailer shall have a bearing surface not less than 30 mm to give necessary
support to the padding which protects the coating. Sacks partly filled with sand or sawdust
should be placed on the bolster and between the outside bottom pipes and the bolster stakes
The maximum piling heights for various types of coated pipe shall be limited to such heights as
will prevent damage to pipe when nested with regular coated pipe.
J4.4.3 Damage
No pipes, fittings, valves or accessories with significant damage to the internal or external
coatings shall be installed. Where in the opinion of the Engineer damage to the coating is minor,
it shall be repaired as far as possible in accordance with the manufacturer’s recommendations to
the original coating system. Acceptance of repairs will be subject to the satisfaction and approval
of the Engineer
J4.4.4 Pipes, fittings and accessories
J4.4.4.1 General
Carbon Steel & Ductile iron pipes and fittings shall be procured from a supplier acceptable to the
Employer.
J4.4.4.2 Pipes, fittings and accessories (Carbon Steel)
J4.4.4.2.1 Carbon Steel pipes

Carbon Steel pipes shall be mild steel pipe in accordance with ASME B31.10M/ BS EN 10217-
1/ AWWA C200 designed in accordance with AWWA M11. Pipe dimension and wall thickness
shall be calculated as per pressure on the pipes. Pipe wall thickness shall be at least the minimum
thickness listed below.
Pipe DN (mm) Minimum Wall Thickness (mm)

PN16 PN25 PN40
1600 8 12 20
1200 8 12 N.A
Pipes materials shall be selected based on the pressure requirements and conform to an ASTM or
BS EN Standard. Minimum yield point of steel shall be 38,000 psi. Pipe shall be manufactured as
fabricated pipe per AWWA C200 as modified herein.
J4.4.4.2.2 FITTINGS
All fittings shall be in accordance with the drawing and shall conform to ASME B 16.9 or
AWWA C208.

J4.4.4.2.3 FLANGES
Flanges shall be in accordance with ASME 16.47 Series B / BS 4504 rated at PN 16, 25 & 40
depend on the location and specified pipes rating.
J4.4.4.2.4 Other
Pressure retaining fittings which are not made to approved standards, as e.g. ASME B16.9,
ASME B16.5 and BS EN 1092-1, shall be type approved or alternatively design approved.
O’lets shall be designed in accordance with BS EN 13480-3 and “over-sizing” shall be

minimized to the extent practically possible.
The design shall not include partly penetrated welds and all o’lets shall be fully welded. O’lets
shall be type approved or alternatively design approved.
J4.4.4.2.5 Hot formed bends

General
The hot formed bends shall be with radius of curvature R = 5 x DN or R = 10 x DN.
Codes and Standards
ISO 15590-1:2001 Induction bends, fittings and flanges for pipeline transportation systems -
Part 1: Induction bends
Functional requirements and materials
The pipe material shall be compatible with the abutting pipe in accordance with the appropriate
Piping Class as specified.
The bends shall be manufactured by inductive heating and bending.
The bends manufactured from longitudinal welded pipe shall have the weld seam placed in the
tensile zone between 10 and 45 degrees from the neutral axis.
The bends manufactured from spiral welded pipe shall not contain skelp end welds.
The welding ends shall be delivered bevelled to match abutting pipe.
Each end of the bend shall have a straight tangential length not less than the nominal diameter.
The deviation from the stated bend angle shall not exceed 0.5 degree.
The end faces shall be perpendicular to pipe axis.
Minor defects may be removed by grinding provided that the minimum wall thickness is
maintained and the grinding does not exceed 300 mm in any direction.
NDE
The wall thickness shall be verified measured along the longest arc together with any area where
defects have been ground out.
The finished bends shall be examined by magnetic particle or dye penetrant for cracks.

The butt welding ends shall be ultrasonically tested for lamination.
J4.4.4.2.6 Isolating couplings for carbon steel pipes
General
Isolating couplings shall be installed at the interfaces between buried piping and piping
installations in buildings.
Functional requirements and materials
Coupling type
Monolithic with pipe pup-pieces.
Design
The isolating coupling shall be designed in accordance with ASME VIII Div. 1 or PD 5500.
Construction
Bolted or threaded joints are not permitted. The design of welds joining coupling element and
pipe pup-pieces shall permit radiographic examination of joining welds.
Seals shall be made from continuously moulded precision "O" rings of dielectric material.
Bore shall be not less than 90% of abutting pipe internal diameter.
Welding ends shall match abutting pipe
Materials
Materials shall be fully killed fine grain carbon steel conforming to specified standards as
indicated in this Specification.
Pipe pup-pieces may be free issued to the Supplier by the Contractor. If this is not the case, pup-
piece material shall be in accordance with the relevant Piping Class Specification, and shall be
the same diameter and wall thickness as the line into which it will be installed.
Seals and dielectrics shall be inert and resistant to any blend of organic or inorganic corrosion
inhibitors and biocide microbiological growth inhibitors.
The isolating coupling Supplier shall obtain from the Contractor necessary information regarding
inhibitors to ensure appropriate selection of seal and dielectric material.
Surface treatment
The bore of the isolation coupling assemblies shall be lined with a coating as specified or to be
approved by the Engineer, with minimum DFT of 300 microns, having electrical and abrasion

resistance properties to prevent a decrease in electrical resistance across the isolation coupling
such as caused by debris bridging the isolating ring.
The coating shall not bridge the isolating ring.

The coating shall be capable of resisting preheating to 150°C at the place of welding.
Inspection and testing
NDE
All items shall be ultrasonically tested.

All forgings shall be magnetic particle tested over the entire surface.
All welds shall be 100% radiographic / ultrasonic tested.
Welding ends shall be ultrasonic tested to a minimum distance of 50 mm from the bevel end.
Hydrostatic testing
Each coupling shall be hydrostatically pressure tested to 1.5 times the system design pressure.
Initially, each coupling shall be subjected to 3 pressure cycles between 10% and 85% of the test
pressure.
The pressure test is accepted with the full test pressure applied for a minimum 1 hour.
Electrical test
The isolation couplings shall be electrically tested in a fully dried condition.
The strength test shall be by 5000 V AC, 50 Hz shall be applied for a period of not less than one
minute during which no puncture of coating or formation of sparks may occur, and the leak
current differential shall not exceed 2 mA.
The resistance test shall be by application of 500 V DC with a measured electrical resistance
greater than 1 MΩ.
J4.4.4.2.7 Installation and execution
J.4.4.4.2.7.1 Preparation for joining
Marking of piping materials
For piping materials with certificate, the charge number shall be transferred by permanent marker
to the pipe section so as to be able to identify the charge number of the pipe after welding.
These markings shall be removed after completed, approved and documented control of the
system.

Cutting and bevelling
Cutting and bevelling of pipes shall be carried out by mechanical means.
Weld bevels for butt weld of pipes and fittings shall be in accordance with the relevant Welding
Procedure Specification (WPS).
J.4.4.4.2.7.2 Welding requirements
Welding processes
Acceptable welding processes are as specified in BS EN ISO 4063, being:
Metal-arc welding with covered electrode.
Flux-cored wire metal - arc welding without gas shield.
Submerged arc welding.
Tungsten inert gas arc welding (TIG welding) for use in draught-free workshops.
Other welding processes are not acceptable unless agreed with the Engineer prior to fabrication.
Welding consumables
All consumables shall be low hydrogen type with maximum 5 ml hydrogen/100 g weld metal
(mercury method in accordance with BS EN ISO 3690).
Other consumables are not acceptable unless approved by the Engineer prior to qualification of
welding procedures or fabrication.
The chemical composition of the deposited weld metal shall be selected to ensure adequate
resistance to degradation under the intended operating condition.
All welding materials shall be delivered in hermetically sealed containers and stored in a clean,
dry, indoor area until used.
Wet or damaged electrodes, contaminated flux, and rusty filler wire shall be rejected.
Welding Procedure Specification
Before commencing the work, the Contractor shall submit detailed welding procedure
specification (WPS) complying with BS EN 288-2. Specification and approval of welding
procedures for metallic materials - Part 2: "Welding procedure specification for arc welding".
The Contractor shall confirm compliance of each welding procedure according to BS EN 288-3.
"Specification and approval of welding procedures for metallic materials. Part 3: Welding
procedure tests for arc welding of steels" and undertake qualification tests.
The qualification tests shall be performed on the same material as stated in the relevant piping

class specification.
All welding procedures together with qualification documents - Welding Procedure Qualification
Records (WPQR) must be handed to the Engineer for approval.
The documentation for WPQR and production tests shall ensure traceability between material
including welding consumables and the material certificate.
The WPS shall only refer to one WPQR which shall include both the low and high heat input
level.
Welders' Qualification
Prior to the performance of any production welding, welders and welding operators shall qualify
for the relevant welding procedures according to BS EN 287-1. Approval testing of welders -
Fusion welding. Part 1: Steel or alternatively in accordance with ASME IX, BPVC, Welding and
Brazing Qualifications.
The welder's performance qualification shall be carried out in accordance with an approved
qualified welding procedure.
Identification of welders
Welder's Performance Qualification (WPQ) certificates with photograph shall be used unless
otherwise agreed prior to fabrication.
Each qualified welder or operator shall be assigned a symbol, which shall always be visible
during welding.
The welder or operator shall mark his welds with his symbol.
A record shall be kept of the welder's or operator's work during the latest 12 months and be
available for the Engineer at all times.
J4.4.4.2.8 Site welding of steel piping
General
The Contractor shall establish shielding to protect each welding site from rain and wind.
No welding shall be carried out when the surface is damp or wet.
Preparation and welding of materials shall be in accordance with the specifications and qualified
procedures and approved by the Engineer.
All welds shall be marked with a weld number and welder's designation.
These marks may be removed after completion and approval of the weld.

Alternatively, all welds shall be shown with welder's number on a drawing.
Welded connections
Adjacent sections of welded pipe that are joined by butt welding shall have the longitudinal
seams positioned so that they are at least 15 degrees apart.
Wherever possible the longitudinal weld seam shall be positioned so that branch connections
such as couplings, o'lets etc. is clear of the weld seam.
Butt welds between materials of different wall thicknesses shall be tapered by scarping the parent
material at a taper of 1:4.
Arc strikes outside the welding groove are not permitted.
Should the strikes occur, they shall be repaired in accordance with the procedures approved by
Contractor's QA department and Engineer's approved welding repair procedure.
Tack welds
Tack welds shall be of a minimum length of four times the base metal thickness or 50 mm, which
is the lesser, and shall be carried out in accordance with an approved welding procedure.
Tack welds shall have adequate cross section to prevent cracking.
Tack welds that form part of the completed weld shall be ground to a feather edge, and
completely fused with the root run.
Cracked tack welds shall be completely removed by grinding and shall not be incorporated into
the finished weld.
After removal, the parent material shall be examined by magnetic particle or liquid penetrant to
ensure that crack propagation from the tack weld into the parent plate has not occurred.
Weld interruption
Welding shall not be discontinued until 25% of the weld thickness or 3 passes are complete,
whichever is more stringent.
At this stage, the weld profile should be con- cave, particularly at the weld material/parent plate
interface.
Weld repairs
All corrective work consisting of removal of defects and deposition of repair welds shall be
carried out in accordance with the qualified repair welding procedure or, alternatively, the
deposition of repair weld shall be in accordance with a welding procedure qualified for the
original weld.
The removal of defective areas shall be carried out by machining, grinding, chipping or arc/air

gouging followed by grinding.
The resulting cavity shall be clean, free from scale and have a contour to permit ease in repair
welding.
Defect removal shall be assured by magnetic particle or liquid penetrant testing.
Repairs and modifications shall be identified and documented.
Second weld repairs shall require the Engineer's approval.
Production testing of welding
If the Engineer has reasonable doubts of the welding quality, for example if during the periodical
parameter checks it is observed that the welding is not performed in accordance with the relevant
approved WPS, the Engineer may require production tests to be performed.
The production tests shall be taken directly from the production welds when it is technically
possible and the Engineer reserves the right to select the test welds.
All costs related to the production tests shall be to the Contractor’s account.
If the production test does not fulfil the requirements, the cause of failing shall immediately be
established and brought to the attention of the Employer.
The PAEW or his representative may specify further testing or the rejection of the represented
production welding.
J4.4.4.2.9 Additional requirements pertaining to welding of stainless steel
Cleanliness and gas shielding
The importance of cleanliness has been addressed in the context of materials handling and
storage. It is even more important during welding. Further recommendations are contained in BS
EN 1011-3.
Prior to welding, the weld zone and Heat Affected Zone shall be free from oil, grease, other
surface contamination and excessive oxidation.
Contamination of weld zone, particularly by iron, copper, zinc, lead, shall be minimised to extent
possible. Tooling shall chosen and used accordingly, e.g. iron-free slitting wheels and grinding
disk, stainless steel brushes shall be used.
An inert backing gas or mixture shall be used to protect the penetration bead of single-sided, full
penetration welds from oxidation, including tack welds. The shielding shall be maintained for
sufficient duration to ensure that the finished weld surface and HAZ oxidation is contractually
acceptable. These requirements are essential for optimum corrosion performance where there
will be no access for subsequent cleaning of weld surface. Where the use of inert backing gas is
impractical, then a shielding paste or tape may be used as an alternative, after submitting a

suitable qualified procedure and obtaining Engineer's approval. The paste or tape shall be
completely removed after welding. Where access does not permit full removal, then mechanical
joint shall be used instead of welded.
Post-weld cleaning
The slag left by welding must be removed by careful hammering, care being taken to avoid
denting the adjacent metal surface
In order to achieve the optimum corrosion performance of stainless steel welded joints
contamination and discoloration deeper than Sample 4 in accordance with ANSI/AWS 18.2 shall
be removed. The method of removal shall be by mechanical dressing followed by acid pickling
of the joint. Electro polishing or sand blasting may be used as an alternative to acid pickling.
For mechanical cleaning, grinding and polishing, all abrasive media shall be iron-free and wire
brushes shall be made of a suitable grade of stainless steel wire, be stored in clean conditions and
not be used for any other purpose, to avoid contamination.
The physical properties of stainless steels require care during mechanical cleaning to prevent
overheating and associated heat discoloration. This phenomenon occurs when the surface
temperature exceeds 200°C. The pressure exerted by the disk or belt must be adjusted to the
minimum level allowing satisfactory polishing without overheating.
The chemical treatment for removal of oxide film shall be by immersion in pickling bath
followed by abundantly rinsing with chlorine-free water. Alternatively pickling paste or gel can
be employed thus limiting the treatment to the weld zones, followed by rinsing with chlorine-free
water.
After pickling the metal surface is unprotected and new passive layer must be formed to restore
its corrosion resistance. The parts shall be immersed in passivating bath for required period of
time followed by rinsing with chlorine-free water. Alternatively passivating paste/gel shall be
used locally on weld zones followed by brushing and rinsing with chlorine-free water for
complete removal of passivating media.
The chemical treatment, pickling and passivation, shall be performed in accordance with
procedures prior approved by Engineer and samples of welded material, both prior and after
chemical treatment shall be retained through the contract as reference. These procedures may be
stand-alone or be a part of welding procedure.
J4.4.4.2.10 Inspection and Testing
J.4.4.4.2.10.1 Non-Destructive Examination of Steel Piping
Following methods are applied for examination of metallic piping:

• Liquid penetrant examination (PT)
• Magnetic particle examination (MT)
• Radiographic examination (RT)
• Ultrasonic examination (UT)

• Visual examination (VT)

• Eddy current (ET)
Other examination methods may be acceptable upon agreement with the Engineer.
If, for any reasons, the Engineer or other parties have reason to believe that a weld contains
unacceptable defects, the Contractor shall use any of the above or alternative methods to
determine the acceptability of the weld with agreement with Engineer.
Qualification Requirements
The execution of all types of examination methods intended to be employed during fabrication
shall be qualified in accordance with relevant standard.
Examination Organization
The organization performing NDE shall be a manufacturer’s NDE department covered by a

certified quality system according to EN ISO 9000 series or an authorised independent inspection
organization accredited according to EN 45001.
Examinations carried out on behalf of the Employer shall be performed by personnel from an
inspection organization accredited in accordance with EN 45001.
The Engineer shall approve prior to commencing any testing procedures other examination
organizations if so required.
The organization shall employ minimum one level 3 person certified according to BS EN 473.
Examination Personnel
All personnel shall be certified in accordance with BS EN 473 or in accordance with ASME V:
BPVC Section V Nondestructive Examination.
Other qualifications shall be agreed by the Engineer, who reserves the right to require re-
examination or rejection of NDE personnel.
Liquid Penetrant Examination: Level 2 (multi-sectorial).
Magnetic Particle Examination: Level 2 (multi-sectorial).
Radiographic Examination: Level 2 for examination of welds.
Ultrasonic Examination: Level 2 for examination welds.
Eddy Current Examination: Level 2 for examination of welds.
Visual Examination: The personnel performing visual examination shall be qualified based on
participation in relevant courses and practical experience.
Certification of the personnel performing visual examination is not required, but documentation

of qualifications such as CSWIP or equal must be on file.
The visual perceptiveness of the personnel shall be checked annually according to BS EN 473 or
ASME V
Procedures
All NDE shall be performed in accordance with procedures which have been approved by the
responsible Level 3 personnel and the Employer in accordance with the requirements of the
applicable standards.
The procedures shall be referred to in relevant documents such as weld check lists.
Reporting
The Contractor shall document the examinations in reports in accordance with the requirements
of the applicable standard with regard to examination technique and results.
The reports shall include the parameters required for reproducing the examination.
Appendix 3 includes forms, which fulfil the requirements of this Specification.

J.4.4.4.2.10.2Performance of NDE on steel piping
Fabrication
All NDE shall be performed after final post weld heat treatment, if applicable.
Before final NDE, the following resting periods shall have elapsed after welding:
C-Mn steel: 16 hours.
The following procedure can be used as an alternative for C-Mn steel to the 16-hour hold
between completing a weld and performing the final NDE for approval:
• After completion, the welding and its surroundings are heated up to minimum 200°C.
• The 200°C is maintained for 2 hours per 50 mm in thickness, minimum 2 hours.
• The weld is allowed to cool freely.
• NDE is performed after cooling to the temperature required for performance of the
examination.
Sequence of Examination
100% visual examination shall always be performed prior to other examinations.
When examinations for detection of internal as well as external defects are required for the same
weld, the examination for external defects shall be performed prior to the examination for
internal defects.
Surface Conditions
The surface and the adjacent area to be examined shall be clean and free of all dirt, grease, paint,
spatter, heavy oxidation etc. that may interfere with the examination.
The weld shall be prepared by grinding if necessary to assure that the examination can be carried
out thoroughly and that the surface condition of the weld is not causing misleading
interpretations of the results.
NDE shall be performed prior to application of linings and coatings.
Random Examination
Where random examination is required, a complete examination of welds with an accumulated

length or number of welds corresponding to the specified percentage of the welds in the lot shall
be carried out.
The lot is defined as welds for piping for the given system.
The selection of welds to be examined may be at the discretion of the Engineer.

Where practical, the selection shall ensure that the work product of each welder or welding
operator carrying out the production welding is included.
Precautions in Case of Unacceptable Indications
All unacceptable indications shall be removed.
Where welding repair is required, the repair area including 100 mm on either side shall be re-
examined for external defects prior to welding.
Welding repairs (or replaced welds) shall be examined with the methods prescribed for the
original weld.
If NDE carried out at random reveals unacceptable indications, the following precautions shall be
taken:
a) Two additional welds made by the same welder or welding operator and welded in
accordance with the same welding procedure specification (WPS) shall be examined with
the same examination method.
b) If the results of the examination according to a) are acceptable, the defective welds shall
be repaired and re-examined, and all welds in the lot are considered acceptable.
c) If the results of the examination according to a) are unacceptable, all welds made by the
same welder or welding operator and welded in accordance with the same welding
procedure specification (WPS) shall be examined.
If the results of the examination according to c) are acceptable, the defective welds shall be
repaired and re-examined and all welds in the lot are considered acceptable.
If the results of the examination according to c) are unacceptable, all unacceptable welds welded
by the same welder or welding operator in accordance with the same welding procedure
specification (WPS) shall be:
Repaired or replaced and re-examined.
Selection of examination method
The examination methods shall be selected in accordance with Table J4442-1 for detection of
internal defects, which are defects not located at accessible surfaces and Table J4442-2 for
detection of external defects, which are defects located at accessible surfaces.
In case of doubt or suspicion on defects, the Engineer reserves the right to require supplementary
examinations.

Table J4442-1: Selection of examination method for detection of internal defects

Thickness, t (mm) t < 12 12 ≤ t < 30 30 ≤ t < 120
Ferritic butt joints RT RT or UT UT
Ferritic branch joints UT UT UT
Austenitic butt joints RT RT RT or UT
Austenitic branch joints UT UT UT
Note 1: Thickness is the nominal thickness of the thinnest component of the joint.
The term “Branch" includes all types of branched connections.
Note 2: For branched joints the lower limit for UT is 8 mm.
Table J4442-2 : Selection of examination method for detection of external defects

Ferritic steels VT and MT (1, 2)
Austenitic steels VT and PT (2)
Note 1: MT shall preferably be used. PT may be used where MT is not possible.
Note 2: ET shall only be used for in-service examinations.
Liquid Penetrant Examination
Examination technique: BS EN 571-1.
Acceptance level: BS EN 1289 level 2X
Magnetic Particle Examination
Examination Technique: BS EN 1290
Only the wet method shall be used.
If black suspended powder is used, the examination surface shall be covered by a thin layer of
contrast paint.
Acceptance level: BS EN 1291 2X
Radiographic Examination
Examination technique to be in accordance with BS EN 1435 Class B.
γ-radiation sources according to BS EN 1435 Class B may be used.
The Employer shall approve lower thickness prior to examination. Acceptance level: BS EN
12517 Level 1.
Field welds shall be examined in accordance with BS EN 1435

Class A. Acceptance level: BS EN 12517 Level 1.

Ultrasonic Examination
Examination technique: BS EN 1714 Level B
Acceptance level: BS EN 1712 Level 2.
Visual examination
Examination technique: BS EN 970
Acceptance level: BS EN ISO 5817 quality Level B.
Eddy Current Examination
Examination technique: BS EN 1711.
The sensitivity shall be set using a 1-mm deep notch.
Acceptance level: All areas with indications exceeding the signal from a 1 mm deep notch shall
be further investigated with MT or PT
Extent of Examination of Welds
All welds shall be examined visually 100%.
Other examination methods in accordance with Piping Class specifications.
J4.4.4.2.11 Charpy Tests:

a) General: Steel used in production manufacturing of pipe and specials shall be tested for
notch toughness using Charpy V-Notch tests per ASTM A 370. The test acceptance for
full size specimens (10mm by 10mm size) shall be 25 foot-pounds at a test temperature of
30 degrees F; tests shall include three impact specimens an shall be conducted in the
direction transverse to the final direction of rolling. Subsize specimens taken from steel
less than 7/16-inch thickness shall be tested for acceptance at reduced values per Table 6
of ASTM A 370.
b) Plate: Charpy tests shall be conducted on each plate as required in ASTM A20.
c) Coils: Charpy tests shall be conducted on the first 500 tons of steel by testing each coil as
follows:
• Tests shall include representative sampling of all steel thicknesses required for the
Work.
• Each coil shall be tested by taking coupons from the outer, middle, and inner wrap of
the coil. Middle coil coupons may be taken from the ends of full-length pipes that are
closest to the middle of the coil.

• Coils that do not meet the above Charpy acceptance criteria shall not be used in
production of pipe.
• After the initial 500 tons, conduct one test per heat of coil on the outer wrap only.
d) The Contractor shall increase the Charpy testing to include more steel than
indicated above (Le., beyond the first 500 tons and the single coupon per coil
thereafter) if directed by the Engineer.
J4.4.4.2.12 Shop Fit Test:
a) To ensure that lap joints may be fully assembled and that excessive annular space between
spigots and bells does not exist, and that the pipe meets the requirements of AWWA
C200, the pipe fabricator shall perform a shop fit test on a minimum of five joints of
each size. The joints to be tested shall be selected by the Engineer based on pipe
measurements.
b) The shop fit test shall join the pipe ends in the shop with the proposed adjacent pipe end.
c) Record the actual annular space, with the data to include as a minimum:
• Maximum space at any point.

• Minimum space at any point.
• Space at 90-degree intervals-top, bottom, and spring line on both sides.
d) The pipe ends shall be match marked after shop assembly.
J4.4.4.3 General
Ductile iron pipes and fittings shall be procured from a supplier acceptable to the Employer.
J4.4.4.4 Ductile iron pipes

Ductile iron pipes shall comply with ISO 2531 or BS EN 545 and shall have cement mortar
lining to BS EN 545.
Pipes shall be manufactured by the centrifugal casting process with push-in socket and spigot
joints. The joints shall permit pipes to be deflected angularly by up to 2° axially for diameters up
to 900mm and by up to 1.5° axially for diameters over 900mm.
Pipes shall be Class K9 and K11 unless otherwise specified or otherwise required to withstand
the specified pressures. Pressure ratings of pipes and fittings shall be determined in accordance
with BS EN 545. Pipes shall be capable of sustaining the pressures detailed in BS8010 Part 2.1
Where pipes are specified to be “gauged” or “sized” they shall be suitable for cutting on site.
Such pipes shall have the tolerance required on the external diameter to suit the joint applicable
over the full length of the barrel. Such pipes shall be clearly marked “Gauged for cutting on site”.
Spigots shall have marks to ensure the correct register of the spigot in the socket (for example
two white painted lines).

J4.4.4.5 Ductile iron fittings

Ductile iron fittings should comply with ISO 2531 or BS EN 545 and shall be capable of
sustaining the site test pressures specified. Fittings with flange joints shall be capable of
sustaining the site test pressure applicable to the rating of the flange. Fittings shall be clearly
marked with the PEA (allowable site test pressure).
Self-anchored couplings and flange adapters shall not be used for transmission of axial loads.
J4.4.4.6 Thrust flanges

Thrust flanges shall be integral with the pipe and shall be designed to act in either direction and
to transfer into the concrete surrounding the pipe and flange the thrust imposed on a blank flange
fixed to the end of the pipe by an internal hydrostatic pressure equal to the factory test pressure.
J4.4.4.7 Detachable flexible couplings and flange adapters

Detachable flexible couplings or flange adapters shall only be used where shown on the
Drawings or with approval of the Engineer.
Detachable flexible couplings shall be suitable for the angular deflections specified below
without leakage. Flange adapters shall be suitable for half the angular deflection stated.
Nominal pipe diameter (mm) Angular deflection (degrees)

Up to 600 5
601 to 750 4
751 to 900 3
901 to 1200 3
1201 to 1800 2
1801 upwards 1
Flexible couplings for each size of pipe shall also be capable of withstanding the shear force
applied by the weight of a 4m length of pipe of that diameter full of water suspended between
two couplings.
Detachable flexible couplings shall be provided with central registers or location plugs only
where specified or detailed in the Drawings.
Flange adapters shall have flanges as specified for flanged joints.
Bolts, nuts and washers shall comply with the requirements for bolts, nuts and washers for
flanges.
The metal components of detachable flexible couplings and flange adapters shall be protected by
thermoplastic polyamide or fusion-bonded epoxy coatings unless otherwise specified or detailed
in the Drawings.
J4.4.4.8 Cable ducts

Cable ducts in the grounds or through structures shall be of uPVC to BS EN 1452, BS EN 13598
or BS EN 1401 and shall have double spigot glued collar joints.
Cable ducts installed by directional drilling shall be of HDPE.

Draw cords shall be provided in all ducts. The draw cord shall be a polypropylene cord having a
breaking load of not less than 5kN. Joints in the draw cord shall be kept to a minimum; they shall
be at least as strong as the cord and shall be so made as not to cause any jamming in use.
J4.4.4.9 Spigot and socket joints for ductile iron pipes

Push-in socket and spigot joints shall permit pipes to be deflected angularly by up to 2° axially
for diameters up to 900mm and by up to 1.5o axially for diameters over 900mm.
Joint sealing rings shall only be obtained from the manufacturer of the pipe or joint.
Joint sealing rings shall comply with the relevant requirements of BS EN 681 or
AWWA C111/21.11, shall be rubber, suitable for making a long-term flexible seal between the
pipes and shall be suitable for the ambient and climatic conditions in the place of installation, for
water temperature of 50°C and be resistant to mechanical, chemical or bacteriological attack
leading to deterioration of the flexible seal. Rubber for sealing rings shall be ethylene propylene
rubber (EPDM or EPM), acrylonitrile butadiene rubber (nitrile) or styrene butadiene rubber
(SBR) which complies with the above requirements.
Lubricants used during jointing shall have no deleterious effects on either the sealing ring, pipes
or pipe coating and shall be unaffected by the liquid to be conveyed.
J4.4.4.10 Mechanical (bolted gland) joints for ductile iron pipes
Where detailed on the drawings spigot and socket joints to fittings shall be the mechanical
(bolted gland) type supplied with rubber gasket and bolts. Glands should be ductile iron of the
same quality as the fitting and shall be supplied with a bituminous coating of thickness not less
then 100 microns. On a fixed spot on the outside of each gland the manufacturers name or
identification mark, date of manufacture and nominal diameter shall be marked. Bolts for use
with bolted gland joints shall be spheroidal graphite in accordance with BS EN 1563 Grade EN-
GJS-500-7.
J4.4.4.11 Flanges and flanged joints for ductile iron pipes

Flanges shall be ductile iron NP16, NP25 or NP40 to ISO 2531 and drilled to ISO 7005-2.
All supplied flanges shall be compatible.
Back faces of flanges shall be machined.
The Contractor shall ensure that flanges are compatible in all cases, including where connections
are to be made to existing pipe flanges.
Where flanges are coated with paint, fusion bonded epoxy or other materials, the coated surfaces
of mating faces shall, whilst maintaining minimum coating thickness, be prepared as necessary to
ensure suitable regular surfaces for mating. Bolt holes shall be reamed out as necessary to allow
insertion of bolts whilst maintaining minimum coating thickness.
J4.4.4.12 Bolts, nuts and washers for flange joints
Bolts nuts and washers shall be galvanized to BS EN ISO 1461.

Nuts and bolts shall be manufactured to BS 4190 ISO metric black hexagonal bolt screws and
nuts. They shall be threaded in accordance with BS 3643-2 ISO metric series threads.
Each bolt shall be provided with a nut and two 3 mm thick washers.
Each bolt shall be of sufficient length to show two threads past the nut when installed.

J4.4.4.13 Gaskets for flange joints

Gaskets shall be suitable for use with both flanges with raised faces and between flanges with
fully machined faces. Gaskets shall be inside bolt circle type to BS EN 1514-1 of materials
complying with BS EN 681.
Gaskets shall comply with the relevant sections of BS 5292 and their dimensions shall be in
compliance with BS EN 1514-1.
Gaskets shall be one piece EPDM rubber of hardness 80, of minimum thickness 3 mm and of
such physical properties as to be capable of forming permanent watertight joints against
pressures up to the maximum test pressure. The use of jointing paste, adhesive tape or grease on
gaskets will not be permitted.
J4.4.4.14 Puddle and thrust flanges
Where shown on the Drawings ductile iron pipes passing through concrete walls or other similar
structures shall incorporate a puddle flange of the same dimensions as flanges for the size and
class of pipe to which they are attached. A rubber strip or gasket shall be used to seal split puddle
flanges to the pipe if required by the design of puddle flange. Where pipes will be transferring a
thrust from the pipe to the wall an integral thrust flange shall be incorporated in the pipework.
J4.4.4.15 Connections between different pipe classes

Where different types or classes of pipe material are jointed together, the Contractor shall supply
special fittings or stepped couplings designed and manufactured to suit the ends of pipes to be
jointed. Stepped couplings shall comply with the requirements for detachable flexible couplings
and flange adapters where applicable.
J4.4.4.16 High density polyethylene (PE-HD) pipes and fittings

High density polyethylene pipes shall comply with the requirements of BS EN 12201 Part 1, 2
and 3 or other relevant International Standards. All pipe and fittings shall be of PN 16 capability.
J4.4.4.17 PE-HD Joints

Flanged fittings shall not be used unless directed by the engineer. Joints between polyethylene
pipe and metal flanges, such as at valves, shall be by means of metal–PE flange adaptors,
specifically designed for this purpose.
J4.4.5 Pipe coatings and protection
J4.4.5.1 External protection of ductile iron pipes and fittings

Ductile iron pipes and fittings shall be factory coated externally with a layer of metallic zinc of
not less than 130 g/m2, covered by a finishing layer of bituminous paint. The application
materials, methods and testing shall be in accordance with BS EN 545 or ISO 8179. The
covering layer shall have a mean thickness of not less than 70 micron with a local minimum
thickness not less than 50 microns.
Fittings may alternatively be supplied with a fusion bonded epoxy coating applied to all internal
and external surfaces.
All buried ductile iron pipes, fittings and joints shall be double sleeved with site applied
polyethylene sleeving.

Unless otherwise specified, each item shall be checked for holidays over all of the external
surfaces on delivery to the site and when being lowered into the trench.
No pipes with significant damage to the external coating will be accepted. Where, in the opinion
of the Engineer damage to the coating is minor, it shall be repaired in accordance with the
procedures specified by the supplier of the original coating system, subject to the approval of the
Engineer.
J4.4.5.2 Enhanced external protection of ductile iron pipes and fittings

Where specified the external coating and finishing shall be enhanced by a site applied tape wrap.
J4.4.5.3 External protection of ductile iron pipes and fittings by polyurethane coating
Where specified the external zinc coating and finishing shall be replaced by a two part solvent
free urethane coating applied to a minimum 1 mm dry film thickness. Preparation of the pipe
outer surface shall be strictly in accordance with the coating supplier’s specifications.
All other requirements of clause J4.4.5.1 shall remain applicable.
J4.4.5.4 Internal protection of ductile iron pipes and fittings

Pipes and fittings shall be lined in accordance with BS EN 545 with cement mortar lining and a
seal coat. The mortar thickness shall be as specified in BS EN 545, and repeated below. The
cement used shall be Ordinary Portland cement. The seal coat material shall be a two part
solvent-free epoxy lining material approved for long term contact with potable water in
accordance with Part A of the Specification. The seal coat shall be applied strictly in accordance
with the coating supplier’s instructions to a minimum of 200 microns dry film thickness. The
lining system shall have been proven in service over a number of years and evidence of this
satisfactory use shall be submitted for approval prior to purchase.
Fittings may alternatively be supplied with a fusion bonded epoxy coating applied to all internal
and external surfaces.
No pipes or fittings with significant damage to the internal lining will be accepted. Where, in the
opinion of the Engineer damage to the lining is minor, it shall be repaired in accordance with the
procedures specified by the supplier of the original lining system, subject to the approval of the
Engineer.
Pipe diameters Lining thickness (mm) Maximum crack

width and radial
DN (mm) Nominal value Limit deviation* displacement
40 to 300 4 -1.5 0.4
350 to 600 5 -2.0 0.5
700 to 1 200 6 -2.5 0.6
1 400 to 2 000 9 -3.0 0.8
*The lower limit only is given

J4.4.5.5 Protection of spigots and sockets

The internal surfaces of sockets and the external surfaces of spigot ends up to 250 mm from the
end) shall be coated with an approved 2-pack solvent free epoxy resin of thickness not less than
100 microns, applied fully in accordance with the manufacturers instructions.
J4.4.5.6 Protective wrapping tape systems

Where specified the external surface of the pipes and fittings shall be wrapped at site. The
protective wrapping tape for the external protection of pipes and fittings shall comprise a thick
plastic tape coated on one side with a heavy self-adhesive bituminous or butyl rubber compound.
The adhesive compound shall form at least 50 % of the total tape thickness.
The product shall achieve the following minimum performance values when tested as per
methods indicated below:
Performance Value Test Method
Total tape thickness 1.6mm
Compound thickness 0.85mm
PVC thickness 0.75mm
Tensile Strength 12N/mm ASTM D1000
Elongation of non- strengthened tape 250% ASTM D638
Tear Resistance 45N ASTM D1004
Impact Resistance (double layer) 15 (Joules) ASTM G13
Adhesion 2.00N/mm ASTM D1000
Dielectric strength 20Kv
Insulation resistance 1,000,000 Mega ohms/cm2
Operational temperature range -20 to + 800C
Water vapour permeability 0.6g/m2/24hrs ASTM E96
0
Water absorption 0.25% at 23 C/24 hrs ASTM D570
Holiday test voltage 10/15/kV
Note: Elongation for tapes strengthened with approved inert fibres may be reduced to 25%. However all tapes
must be sufficiently deformable to ensure close wrapping of all joints and fittings.
J4.4.5.7 Outer wrap protective tape

The outer wrap to the bituminous protective wrapping tape shall comprise a PVC carrier coated
with a pressure sensitive adhesive. The product shall achieve the following minimum systems
performance values:
Total tape thickness 0.2mm -
Tensile strength 2.6N/mm ASTM D1000
Elongation 180% ASTM D638


Tear Resistance 8N ASTM D1004
Dielectric Strength 10KV -
Operational Temperature range 0 to 75ºC.
All tapes must be sufficiently deformable to ensure close wrapping of all joints and fittings.
J4.4.5.8 Primer
The wrapping system for pipes shall, unless otherwise approved by the Engineer, include a
bituminous based quick drying surface primer which shall be compatible with the wrapping tape
and external pipe coating. The primer shall be as recommended by the tape manufacturer and be
fast drying and suitable for cold application by brushing and spraying and be compatible with the
factory applied pipe coating.
J4.4.5.9 Polyethylene sleeving

Buried ductile iron pipes, fittings and joints shall be double sleeved with site applied
polyethylene sleeving. Factory applied sleeving shall not be used.
Polyethylene shall be in accordance with BS 6076 or 'C' of AWWA C105, except as otherwise
specified. Sleeving shall be black Class C. The minimum thickness shall be 200µm.
Suitable adhesive PVC tape shall be used to secure the sleeving in position and to make joints
between adjacent sections.
J4.4.5.10 Heat-shrink sleeving

Where specified heat-shrink sleeves shall be applied at pipe joints to complete fusion-bonded
epoxy coatings. They shall be manufactured from heavy-duty radiation cross-linked polyolefin
sheet material, coated on one side with high shear strength hot-melt adhesive.
J4.4.5.11 Fusion-bonded epoxy coating

Fusion-bonded epoxy coatings shall consist of a polymeric anti-corrosion barrier applied at a
factory approved by the Engineer.
The coating system requirements, performance testing and factory applied coating requirements
and practice shall be in accordance with the Water Industry Specification (WIS) 4-52-01.
The method of surface preparation and cleaning shall be in accordance with the requirements
specified by the coating material manufacturer and the following requirements:
• The pre-coating surface shall be blast-cleaned to a minimum standard of ISO Sa 2½;
• The surface shall be tested for soluble salts and re-blasted if soluble salts are found to
be present;
• All oil, grease and other contaminants shall be removed;
• All slivers and scabs made visible by blast cleaning and detrimental to the coating
process shall be removed;
• Welds shall be fettled smooth;
• Edges and corners shall be smoothed to a 3.0 mm minimum radius;

• Any pre-treatment prior to coating shall not be permitted without the written approval
of the Engineer
• The shot-blasted surface shall have a roughness RZ between 40µm and 80µm
inclusive.
The minimum and maximum thickness of coatings for pipes and fittings shall be as in the table
below:
Location Minimum Maximum
Pipe walls 300 microns 1.6mm
Fittings including flanges 300 microns 2.0mm
Inside bolt holes 300 microns 2.0mm
All thickness-critical surfaces shall be coated to the thickness specified and within the tolerances
identified. Raised flange faces shall be dressed after coating to remove coating runs.
Unless otherwise specified, each item shall be checked for holidays over all of the coated
surfaces. A fitting with two or more holidays per 3m2 of surface area or a pipe with thirty or more
holidays per pipe length shall be rejected for subsequent stripping and recoating. All holidays
detected shall be repaired and on completion the item shall be re-examined for holidays. After
repair the coating shall be holiday free to Class A.
All coatings on pipes and fittings shall be treated with a UV-inhibitor to prevent chalking or loss
of colour.
External protection to pipes to be surrounded in concrete over part of their length shall extend at
least 150mm within the concrete.
J4.4.5.12 Repairs to Coatings

Materials and instructions shall be supplied for repair of coatings damaged in transit and on site.
Repair materials shall be compatible with the coating in colour and adhesion and shall be suitable
for site application.
In the event of a fusion-bonded epoxy coating being damaged after leaving the factory the item
shall be returned to the factory for repair or, with the consent of the Engineer, be repaired at Site.
Site repairs will not be permitted where the total area of damage to be repaired on a single pipe or
fitting exceeds 6cm2 for pipes and fittings up to and including 600 mm diameter and 12cm2 for
pipes and fittings in excess of 600 mm diameter. Repairs shall be carried out in accordance with
the manufacturer’s recommendations. Notwithstanding such recommendations the repair shall
meet the following minimum requirements:
• Repair materials shall be compatible with the original factory-applied coating
materials and, where applicable, they shall comply with Clause J4.4.5.11;
• The edges of the original factory-applied coating shall be ground off to a taper or
feather edge;
• Exposed metal shall be cleaned and prepared as specified in Clause J4.4.5.11
• The relative humidity of the atmosphere in which the repair is to be effected shall be
maintained (if necessary by the use of hot-air blowers and tenting) at less than 85%, a
wet/dry thermometer being provided during repairs to demonstrate humidity;

• The surface temperature of the exposed metal shall be raised to at least 3oC above
dew point and the coating shall then be applied in stages, as recommended by the
manufacturer, so as to achieve a total thickness in accordance with Clause J4.4.5.11;
• All repairs shall be checked with a holiday detector and any holidays shall be
repaired, after which the repairs shall rechecked.
J4.4.5.13 Painting new ductile iron pipes and fittings installed above ground
All damaged areas of shop applied coatings shall be degreased, wire brushed and painted with
one coat of zinc rich paint and one coat of two part solvent free epoxy or polyurethane as the
original coating.
After 3 days (minimum) the Contractor shall apply three coats of an approved oil based
aluminium paint by airless spray/brush/roller to a minimum dry film thickness of 25 microns per
coat. Over-coating times should be as indicated in the paint manufacturer's instructions. Prior to
over-coating the surfaces shall be sweep blasted to remove surface gloss and obtain an adequate
key to the paint system to be applied.
The aluminium paint should be suitable for application on the epoxy or polyurethane surfaces.
The paint shall have a metallic aluminium coloured finish.
J4.4.6 Valves
J4.4.6.1 General
Valves shall be manufactured to the requirements specified hereunder. All valves shall be
suitable for use with water at the temperatures and pressures specified or detailed on the
Drawings.
Where the Contractor proposes to use dissimilar metals either in contact or close enough for the
gap between them to be bridged by an electrolyte the Contractor’s design shall include provisions
to prevent corrosion.
Gate valves (sluice valves) and butterfly valves shall be suitable for flow in either direction.
Valves shall be suitable for frequent operation as well as for operation after long periods of
idleness in any position.
Rubber used in valves shall be ethylene propylene rubber (EPDM or EPM) or styrene butadiene
rubber (SBR). It shall be suitable for making a long-term flexible seal and be resistant to
mechanical, chemical or bacteriological attack leading to deterioration of the flexible seal.
Valve components shall be of materials not inferior in strength or resistance to corrosion to those
listed below:
Component Material
Bodies, covers, cowls and plungers Spheroidal graphite iron to BS EN 1563 Grade
EN-GJS-500-7 or EN-GJS-450-10
Pistons, sleeves, liners, guides, bushes, Gunmetal to BS EN 1982 Number CC491K
seats, seat rings and seal holders
Hinge bushes and pins Bronze to BS EN 12163 Number CW451K

Component Material
Valve stems, spindles other than extension Stainless steel to BS 970: Part 4, grade 431 S29
spindles and pins or 316S13 (BS EN 10088-1, X19 CrNi 17-2 or
X2-CrNiMo 17-12-2)
Aluminium Bronze to BS EN 12163/12167
Number CW307G
Extension spindles (plain ends) Galvanised mild steel to BS 970: Part 1,
grade 230 MO7 (BS EN 10087, 11 SMn 30)
Except where otherwise specified all valves shall be suitable for continuous use in the range -
0ºC to +50ºC.
The pressure rating of all valves, including gates, bodies and flanges, shall not be less than the
maximum working and test pressure of the pipeline in which the valve is to be installed.
Valves shall be supplied with all necessary accessories such as hand wheel, extension shaft,
couplings, caps, bolts, nuts, washers and 3mm cotton reinforced rubber gaskets for each flange.
Valves shall close clockwise.
All copper alloys which may come into contact with raw, treated or potable water shall contain
not more than 4% zinc.
J4.4.6.2 Painting and protection of valves

Except where otherwise specified and except for stainless steel valve parts, all valves shall be
fusion-bonded epoxy coated externally and internally to a thickness of at least 150 microns.
Fusion-bonded epoxy coatings shall be suitable for application to ductile iron based material
used in contact with fresh water, brackish water or distillate in any soil conditions or in chamber
applications. The coating shall consist of a polymeric anticorrosion barrier.
The coating system requirements, performance testing and factory applied coating requirements
and practice shall be in accordance with the Water Industry Specification (WIS) 4-52-01.
The method of surface preparation and cleaning shall be strictly in accordance with the
requirements specified by the coating material manufacturer and the following requirements:
a) The pre-coating surface shall be blast-cleaned to a minimum standard of Grade B Sa
2½ in accordance with BS 7079: Part A1;
b) The surface shall be tested for soluble salts and re-blasted if soluble salts are found to
be present;
c) All oil, grease and other
d) All oil, grease and other contaminants shall be removed;
e) All slivers and scabs made visible by blast cleaning and detrimental to the coating
process shall be removed;
f) Welds shall be fettled smooth;
g) Edges and corners shall be smoothed to a 3.0mm minimum radius;
h) Any pre-treatment prior to coating shall not be permitted without the written approval
of the Engineer.

The shot-basted surface shall have a roughness RZ between 40µm and 80µm inclusive.
Raised flange faces shall be dressed after coating to remove coating runs.
Unless otherwise specified, each item shall be checked for holidays over all of the coated
surfaces. A valve with two or more holidays per 3m2 of surface area shall be rejected for
subsequent stripping and re-coating. All holidays detected shall be repaired and on completion
the item shall be re-examined for holidays. After repair the coating shall be holiday free to
Class A.
All coatings shall be treated with a UV-inhibitor to prevent chalking or loss of colour.
Materials and instructions shall be supplied for repair of coating damaged in transit and on site.
Repair materials shall be compatible with the coating in colour and adhesion and shall be suitable
for site application.
J4.4.6.3 Marking of valves

Each body will be marked by Cast-on or stamped figures as follows:
• Size of Valve
• Year of Manufacturing
• Working Pressure
• Type of Casting
J4.4.6.4 Tests on valves

Each valve shall be tested according to the standard specification and the Employer shall be
supplied with the records of all tests.
J4.4.6.5 Valve Flanges

Flanges shall be ductile iron NP16, NP25 or NP40 as defined on the Drawings, schedules and
Specification Part B and shall have the dimensions specified in Clause J4.4.4.11.
J4.4.6.6 Bolts, Nuts and Washers
Bolts nuts and washers shall be galvanized to BS EN ISO 1461.

Nuts and bolts shall be manufactured to BS 4190 ISO metric black hexagonal bolt screws and
nuts. They shall be threaded in accordance with BS 3643-2.
Each bolt shall be provided with a nut and two 3mm thick washers.
Each bolt shall be of sufficient length to show two threads past the nut when installed.
J4.4.6.7 Gaskets
Gaskets shall be suitable for use with both flanges with raised faces and between flanges with
fully machined faces. Gaskets shall be inside bolt circle type to BS EN 1514-1 of materials
complying with BS EN 681.
Gaskets shall comply with the relevant sections of BS 5292 and their dimensions shall be in
compliance with BS EN 1514-1.

Gaskets shall be one piece EPDM rubber of hardness 80, of minimum thickness 3mm and of
such physical properties as to be capable of forming permanent watertight joints against
pressures up to the maximum test pressure. The use of jointing paste, adhesive tape or grease on
gaskets will not be permitted.
J4.4.6.8 Operating gear

Valves shall be clockwise closing. Unless otherwise specified, all valves shall be provided with
handwheels and mechanical position indicators. Where practicable, the mechanical position
indicators shall be clearly visible from the operating position. All valves shall incorporate
integral locking devices. Pressure and flow control valves shall be lockable in any position.
All manually-operated valves shall be capable of being opened and closed manually by one
person only. When the specified maximum unbalanced pressure is applied to the valve in use the
force required to open the valve from the closed position shall not exceed 125N at each of two
diametrically-opposite points on the rim of the handwheel or at each end of the tee key.
Handwheels shall be not more than 700mm diameter and shaped to give a safe grip without sharp
projections, clearly marked with the direction of closing and be fitted with integral locking
devices (not padlock and chain). Tee-key operated valves shall be provided with detachable cast
iron spindle caps to take the key. One key shall be supplied for every five valves installed, with a
minimum requirement of two keys in any one size.
Operating gear shall be of the outdoor waterproof type that is watertight under an external head
of 10 m of water. Gearboxes shall be totally-enclosed oil-bath lubricated. Thrust bearings shall
be provided in such a way that the gear case may be opened for inspection or be dismantled
without releasing the stem thrust or taking the valve out of service. Oil and grease-lubricated
gearing, bearings and glands shall be protected against the ingress of dust and moisture.
J4.4.6.9 Spindles (stems) and caps

Operating and extension spindles for valves operated by tee key shall be capped.
Extension spindles shall be circular in section. For valves installed in chambers, extension
spindles shall be provided with suitable bearings rigidly held on brackets spaced no more than
1000 mm apart.
Extension spindle couplings shall be robust and provided with adequate pinning to carry the
shear and prevent pullout.
Spindles including all fixing, mountings and couplings shall be designed for the maximum
operating torque with a factor of safety of two.
J4.4.6.10 Isolation valves

Isolation valves include:
• Line valves (located on the main pipeline)
• Washout valves
• Isolation valves at air valves
Isolation valves will be manually operated and installed in chambers.

Line valves and washout valves shall be installed with extension spindles, spindle caps, spindle
supports, protection tubes and surface boxes to permit operation of the valve from outside of the
chamber. The Contractor shall prepare shop drawings, supply and install suitable extension
spindles for all line and washout valve installations.
J4.4.6.11 Gate valves (sluice valves)

Gate valves up to and including 600 mm nominal diameter shall conform to the requirements of
BS 5163 for copper alloy faced with a solid wedge.
The valves components shall be manufactured from the following materials:
Body, bonnet, stuffing Ductile Cast Iron to BS EN 1563 Grade EN-GJS-450-10 or
box, cap Grade EN-GJS-500-7
Stem Aluminium bronze to BS EN 12163 Grade CW307G
Ductile Cast Iron to BS EN 1563 Grade EN-GJS-450-10 or
Wedge
Grade EN-GJS-500-7
Facing rings Gunmetal to BS EN 1982 Number CC491K
Hand wheel (where
Cast Iron to BS EN 1561 Grade EN-GJL-250 minimum
required)
Valve spindles shall be of the internal non-rising type. The valve spindle seal shall be replaceable
with the valve fully open and the main under pressure.
The valve stem shall be made in one piece and shall be able to withstand without permanent
distortion all stresses, compressive, tensile and torsional, to which it could be subjected. The
stem diameters above and below the collar shall comply with the dimensions given in Table 4 of
BS 5163.
Except where otherwise shown gearbox spindles for hand wheel/tee key or for connecting with
an extension spindle shall be vertical when the valve is installed. Gate valves shall be manually
operated and shall be closed clockwise.
Valves shall not contain any brasses that have more than 5% zinc.
J4.4.6.12 Butterfly valves

Butterfly valves shall comply with BS EN 593 or AWWA C504, except as specified herein.
Valves shall be suitable for mounting in any position and shall be designed to be used as a
regulating valve and closing valve.
Valves shall be mounted with shafts horizontal unless otherwise specified or shown on the
Drawings. Valves over 350 mm bore shall be provided with bevel gearing.
Valves shall be fitted with indicators to show the position of the disc.
The Contractor shall provide details of the materials of manufacture and of the valve design,
including the access route to repair or replace seals and shall provide evidence to show that the
proposed materials and seating designs for the sealing and seating arrangements have given
satisfactory performance in similar conditions to those applying under the Contract.
Flanges and hubs for shaft bearing housings shall be integrally cast with the valve body. All
bearings shall be maintenance-free of a self-lubricating or sealed-for-life type.

Disc edges shall be machined with rounded corners and shall be polished to a smooth finish. The
valve disc shall rotate through an angle of 90 degrees from the fully opened to the fully closed
position and the seat shall be designed so as to close at an angle normal to the axis of the pipe.
Hollow discs and any other castings with voids shall be fitted with watertight threaded plugs.
Discs shall be capable of maintaining their fully open and fully closed positions with the gearbox
removed. Limit stops shall be capable of absorbing full operating torque with a minimum design
safety factor of 5.
Shafts shall be fabricated of stainless steel grade X2-CrNiMo 17-12-2 to BS EN 10088-1. Body-
seats shall be fabricated of stainless steel grade X2-CrNiMo 17-12-2 to BS EN 10088-1 or made
of back-up welded nickel face (nickel weld overlay).
The shaft and disc fixing shall be capable of absorbing the full operating torque with a minimum
design safety factor of 5 and will safely sustained maximum differential pressure across the
closed valve. Shaft seals, when used, shall be of the resilient O-ring type. Packing shall be either
of the resilient 0-ring or of the self-adjusting chevron type.
The sealing ring shall be replaceable without the need to remove the valve body from the
pipework in which it is fitted.
The valve body and disk shall be of ductile cast iron of quality not less than BS EN 1563
Grade EN-GJS-500-7. In general the materials chosen shall be corrosion resistant to the source
water referred to in the Specification. All bolts, nuts and other fixings, which will be in contact
with the flow or with the ground shall be of stainless steel type X2-CrNiMo 17-12-2.
Bolts retaining the removable seal cover and the body seat ring shall be of stainless steel
type X2-CrNiMo 17-12-2.
Valves shall be suitable for submergence below water.
The valves shall be capable of being seated and unseated under the most adverse conditions
appropriate to its rating.
The gearbox spindle for hand wheel/tee key or for connecting with the extension spindle shall be
vertical when the valve is installed.
Valves greater than 600mm diameter shall be provided with suitable support feet.
The face-to-face dimensions of butterfly valves shall be as detailed for Series 14 valves in Table
4 of BS EN 558-1.
Each valve shall be tested in accordance with the requirements of BS EN593, for body test, seat
test and disc strength test. Seat tests shall be carried out in each direction and the valve shall be
drop tight. Disc strength tests shall also be carried out in each direction.
J4.4.6.13 Resilient-seated butterfly valves

Service application for resilient-seated valves shall be “tight shut-off”. The valve seal shall be
EDPM, EPM or SBR, durable and replaceable. The rubber sealing ring shall be made of nitrile
synthetic rubber (or equal) suitable for permanent contact with Fresh or Brackish water at a
permanent temperature of at least 50°C.
The valve seal shall be securely clamped to the edge of the disc by seal-retention members or
other equivalent retention device in such a manner as to prevent leakage of water under the seal
and to hold the seal securely in position during opening and closing of the valve disc. The seal-
retention members shall be of stainless steel and shall be securely fastened to the body or disc
with stainless steel fasteners. Stainless steel shall be X2-CrNiMo 17-12-2.

The seal and its retention members shall be adjustable to ensure water tightness and to minimise
the seating and unseating friction forces. When all the seal retention members are in place the
finished edges of the seal shall fit closely and the surface shall be smooth with all fastenings set
flush in the water passage so as to offer the least resistance possible to the flow of water through
the valve.
Valve seats which extend over the face of the flanges to secure the seat in place, or which require
surface grinding and/or hand fitting of the disc, or designs which require the adjoining pipe
flange to retain the seat in place and resist line pressure, are not acceptable.
J4.4.6.14 Electric actuators for motorised valves

Electric actuators shall operate valves at opening and closing rates that will not impose
unacceptable surge pressures on the pipework.
Actuators shall be rated at not less than 20 percent in excess of the power required to operate the
valve under maximum working conditions.
Actuators shall be suitable for use with a nominal 400 volt 3 phase 50 Hz power supply and shall
incorporate a motor, integral reversing contactor starter local control facilities and terminals for
remote control and indication connection.
The gearbox shall be of the totally enclosed oil bath lubricated type suitable for operation at any
angle.
A handwheel shall be provided for manual operation engaged when the motor is declutched by a
lever.
Actuators shall be provided with open and close torque and/or position limit switches as required
by the type of valve or penstock plus two additional limit switches at each end of travel for
remote indication and interlocking.
The reversing contactor starter and local controls shall be integral with the valve actuator housed
to prevent breathing and condensation build up. The starter shall be suitable for 60 starts per hour
and shall comprise mechanically and electrically interlocked reversing contactors of appropriate
rating to the motor size with coils fed from a 12 volt control transformer of 40 VA minimum
rating.
Local controls shall comprise a switch for open close and stop and a Local/Remote selector
switch.
The actuator enclosure shall be watertight to NEMA 6, IEC 144-IP67.
The actuator starter shall be integrally housed with the actuator in a robustly constructed totally
enclosed weather proof housing. The motor starter shall be capable of starting under the most
severe conditions.
To enable the valve position to be remotely controlled from a telemetry system the actuator shall
be provided complete with equipment such that when “Remote” control is selected the actuator
can control the position of the valve in proportion to a continuous 4-20 mA current signal
(analogue).
For each actuator a control unit shall be provided for installation near to the actuator. The control
unit shall be arranged such that when “Remote” control mode is selected on the actuator then the
actuator may be controlled either from the local control unit or from a telemetry system.

J4.4.6.15 Pressure-reducing valves

Valves shall be capable of maintaining a constant downstream pressure from a higher constant or
variable upstream pressure and they shall be drop-tight under no-flow conditions.
A pressure gauge shall be provided to indicate downstream pressure over the operating range of
the valve.
Pressure control valves shall be capable of long term operation in partly open position without
sticking. Valve response shall be adjustable and sufficient to provide controllability over the
operating pressure range. Valves shall operate without cavitation and excessive noise.
Valve operation shall be controlled by the interaction of the inlet pressure, outlet pressure and an
intermediate pressure produced by a pilot valve or relay system acting on the upper side of the
main valve.
The pilot valve or relay system shall be actuated by a diaphragm connected to the outlet pressure
on its underside and a constant pressure on its upper side, derived either from weights or from a
spring.
Valves shall be flanged and drilled to BS 4504 for the operating pressure required.
Materials for valves shall be as follows:
Component Material
Body and cover Cast iron
Internal valve Gunmetal with bronze liner, cups and facing rings in
leather
Relay valve Bronze with stainless steel shaft and nylon valve face
Diaphragm Reinforced synthetic rubber
Loading spring, Spring steel
If employed
Cylinder & weights, Cast iron
If employed
Lever Steel with gunmetal pins and links
Connecting pipework to Copper
cylinder
Cylinder Mild steel epoxy lined with internal working parts
gunmetal bushed
J4.4.6.16 Automatic air-relief valves

Air valves shall be provided as specified or shown on the Drawings, to achieve the following:-
a) To exhaust air automatically during filling, the air being released fast enough to
prevent back pressure restricting water inflow.
b) To ventilate pipework automatically during emptying, the air inflow being fast
enough to prevent the development of any significant negative pressure.
c) To release air automatically during normal working.

Conditions a) and b) shall be met by using an orifice capable of handling large volumes of air at a
high-flow rate in either direction. Condition c) shall be met by using a small orifice capable of
discharging small volumes of air as they accumulate.
Valves shall have approved screens to prevent the ingress of foreign matter.
Air valves shall be of one of the following types;-
a) Double valves shall combine both large and small orifices in one valve. The large
orifice shall be sealed by a float and the valve shall be designed to avoid premature
closing of the valve by the discharging air. The small orifice shall be sealed by a float
at all pressures above atmospheric, except when air accumulates in the valve body.
b) Single large orifice type for automatic ventilation or exhaust of pipework.
c) Single small orifice type for automatic release of air under normal working pressure.
Large orifice air valves, including those incorporated in double air valves, shall be constructed so
that the air flow holds the valve open during discharge of air at all flows possible in service.
When coupled to their respective isolating valves, they shall be capable of admitting or
exhausting the required quantities of free air without the pressure differential across the
combined air valve and isolating valve exceeding 0.5 bar.
Small orifice air valves, including those incorporated in double air valves, shall be capable of
discharging not less than 0.5 m³/min of free air when the pressure in the pipeline is at the
maximum working pressure.
Balls or floats shall be of ABS, vulcanite, rubber-covered metal, stainless steel, or other approved
materials, and shall operate automatically at all pressures up to the test pressure. Orifices shall be
bronze or stainless steel.
Air valves shall be designed so that each float seats against its orifice or causes the orifice to be
closed without leakage at all pressures between 0.2 bar g. and the specified test pressure. Balls
and seats shall be designed to minimise adhesion of the ball to the seat. They shall be of a type
proven to be suitable for the specified duties.
Each air valve shall be provided with an isolating valve, which shall be an integral lever-operated
isolating ball valve.
Each small orifice or double air valve shall be fitted with a test cock in the valve body for
verification that the small orifice air valve is operating properly.
Body ends shall be flanged with raised faces and drilled to BS 4504 for the nominal pressure
specified.
The materials for valves shall be not inferior to the following:
• body cover and cowl: cast iron;
• small orifice: cast iron with gunmetal seat;
• small orifice ball: rubber-covered or other approved;
• large orifice: cast iron with rubber seat;
• large ball: Vulcanite covered or other approved.
J4.4.6.17 Non-slam air valves
Non-slam air valves shall be double air valves as specified above except that the air valve shall
be fitted with a vented non-return valve or other device which permits air to enter the pipeline
freely on low pressures caused by surges within the pipeline, but which controls the expulsion of

any air drawn into the pipeline under surge conditions in order to minimise ‘slam’ as the air is
finally expelled from the pipe.
The non-slam air release & vacuum break valve shall be of the compact single chamber design
with solid cylindrical HDPE. control floats housed in a tubular stainless steel body with epoxy
powder coated cast iron or steel ends secured by means of stainless steel tie rods. The valve shall
have an integral ‘Anti-Shock’ Orifice mechanism which shall operate automatically to limit
transient pressure rise or shock induced by closure.
J4.4.6.18 Check valves (non-return valves, reflux valves)

Check valves may be of single/multiple door or tilting disc type, suitable for installation in the
required position. Other types of valves may be acceptable, subject to the approval of the
Engineer,
All check valves shall be designed for rapid closing without slamming no later than the moment
of cessation of forward flow.
Single-door swing check valves hall have a single port sealed by means of a gate with hinges
offset outside the area of the port. The gate shall open automatically on start of flow in one
direction and close automatically on flow reversal. Closure of the gate may be assisted by
weights or weighted levers.
Unless otherwise specified, valves shall conform to BS EN 12334 and shall be double-flanged.
Multiple-door check valves are swing check valves except the valves shall have two or more
parallel ports each with separate hinged gates.
Unless otherwise specified, valves shall conform to the general requirements for swing type
valves as specified in BS EN 12334.
J4.4.7 Ancillaries
J4.4.7.1 Marker tape

Marker tape shall be buried 0.3 m below ground level. The tape shall be a minimum of 300mm
wide and 0.1mm nominal thickness coloured polythene or similar approved system boldly
printed in black with the word ‘CAUTION’ in English and Arabic and words to identify the
particular service throughout its entire length at 1 m intervals, in accordance with the following
coding:
Types of service Tape Colour Service Identification Wording

Water supply pipe Blue WATER MAIN BELOW
Instrumentation, telephone & Green CONTROL CABLE BELOW
telemetry cables
J4.4.7.2 Marker plates

In built up areas standard marker plates measuring 300mm x 80mm shall be affixed to walls or
buildings or set into pavements or kerbs. These plates should be coloured in accordance with the
standard colour coding as set out for marker tapes in J4.4.7.1 and should carry wording in
English and Arabic indicating the service type and offset distance from the plate where
applicable.

J4.4.7.3 Marker posts

In open country away from roadways a standard 100 mm diameter vertical tubular steel marker
post shall be installed. The post shall be 950 mm long buried 400 mm in the ground as detailed
on the drawings. Standard marker plates shall be set on to the post.
J4.5 WORKMANSHIP
J4.5.1 Setting out

Pipelines shall be accurately installed to even grades and to the lines and levels shown on the
Drawings so that the barrel of the pipe is continuously supported throughout its length by the
bedding material. The line and level of the pipeline shall be as shown on the Drawings or as
The Contractor shall submit details of the methods he proposes to use for control of the accuracy
of pipe laying. The position of any pipe shall be within ±25 mm of the specified level and within
±100 mm of the horizontal alignment.
Strong sight rails marked the centre line and the level to which the pipeline is to be laid shall be
fixed and maintained at each change of gradient and at as many intermediate points as necessary
not more than 40 m apart. Alternatively the Contractor may use laser techniques.
Horizontal curves and changes in grade of the pipeline shall be carried out smoothly by making
use of the permissible deflection at joints, vertical and horizontal. The Contractor shall prepare
all necessary shop drawings to achieve satisfactory alignment.
J4.5.2 Trial Length of pipeline

At the commencement of the Works the Contractor shall construct a trial 1000 m length of
pipeline and carry out soils testing and a successful pressure test to demonstrate the acceptability
of his proposed construction methods.
The trial length may form part of the permanent works providing that it complies with the
specification.
J4.5.3 Pipelines in the same trench

The minimum clear spacing between barrels of adjacent parallel pipes shall be 500mm. Unless
otherwise shown the crown levels of the pipelines shall be at the same level.
J4.5.4 Pipeline gradients and cover

Pipelines shall be laid to a minimum cover below the natural ground level of 1.00m. The
maximum cover below final ground level shall not exceed 4.0m unless otherwise directed by the
Engineer.
The minimum rising gradient in the direction of flow shall not be less than 0.2% and the
minimum falling gradient in the direction of flow shall not be less than 0.33%.
J4.5.5 Cable duct cover

Cable ducts shall be laid with 0.80m cover

Sub section J4.5 (a) Buried pipes

J4.5.6 General
Trench excavation and backfill shall be co-ordinated with the construction of the pipeline as a
whole so as to ensure expeditious completion of the whole operation.
Flexibly-jointed socket and spigot pipes shall normally be laid with sockets leading. Where the
gradient exceeds 5%, installation shall proceed on an ascending grade with sockets leading. Pipes
shall be installed singly and shall not be jointed until after they have been laid. After laying and
jointing, the level of each pipe shall be checked before the next pipe is laid.
Pipe bores shall be kept clean and free from water, dirt, stones and other foreign matter.
When installation is not proceeding a suitable stopper shall be installed to seal the open ends of
pipes.
The Contractor shall take such precautions as are necessary to prevent pipes from floating.
J4.5.7 Granular bed and surround

All ductile iron pipes with flexible joints except where concrete protection is provided as
specified hereafter shall be laid on a well compacted bed of granular material extending for the
full width of trench and with sufficient material at the side to permit the pipes being worked into
the granular material and firmly supported to true line and level. Granular bedding shall be
compacted to at least 70% relative density and to the correct levels and accurately shaped by
template so that pipes are given full support along the entire barrel length and over the widths
shown in the Contractor's drawings. Recesses shall be formed in the granular bedding to
accommodate joints. The Contractor shall ensure that the pipe is uniformly supported on the
bedding material over its full length and under no circumstances shall large stones, rock
projections or other hard objects be permitted to come into contact with the pipe. Pipes shall not
be supported on timber wedges, pre-cast concrete blocks, or similar materials.
Unless indicated to the contrary on the drawings the minimum thickness of granular bedding
below the barrel of a pipe shall be 200 mm.
The filling shall be placed and thoroughly compacted by hand in successive layers not exceeding
150 mm thickness up to the crown of the pipe. The material shall be placed around both sides of
the pipe simultaneously and shall completely fill the spaces between the pipe and trench wall and
under the haunches of the pipe. The bedding shall be properly compacted around the sides of the
pipe so as to avoid disturbing the pipe or joints.
The final layer of bedding of 300 mm thickness above the crown of pipe shall be carefully
compacted by hand and the Geotextile positioned.
All uPVC ducts shall be laid in the same trench as the ductile iron pipes with the same granular
surround.
Material for granular bedding and surround shall be broken stone or irregular shaped gravel and
shall be inert to the ground water. The Contractor shall determine the required grading(s) and
compaction in accordance with the pipe supplier’s requirements and shall propose these to the
Engineer for approval.
The material shall be tested in accordance with BS 812: Part 111, and shall have a 10% fines
value greater than 50 kN. Material retained on a 7mm sieve shall have an index of flakiness less
than 25% and an index of elongation less than 45%.

J4.5.8 Concrete bed and surround

Where shown on the Drawings or directed by the Engineer concrete bedding, haunches and
surround shall be provided. The concrete shall be un-reinforced Class C. Any formwork required
shall be Class F1.
Each pipe shall be supported on at least two purpose-made pre-cast concrete blocks, which shall
be left in place. In-situ concrete shall be placed after the joints at each end of the pipe have been
completed and the pipeline has been checked and adjusted for alignment. The concrete shall be
placed and carefully worked and compacted beneath and around the pipe. Unformed surfaces
shall be of spade finish. The pipe shall be prevented from floating or otherwise moving during
concreting.
The continuity of concrete bed, haunch or surround to pipes with flexible socket and spigot joints
shall be broken at each flexible joint by 25 mm thick fibreboard, placed against the face of the
socket. The concrete bed, haunch or surround shall be discontinued at detachable flexible
couplings, leaving a clearance of 75 mm each side of the coupling.
Where two or more pipelines are laid in the same trench, the joints shall coincide at the joints in
the largest diameter pipeline where the continuity of the concrete bed, haunch or surround shall
be broken. Any intermediate joints in the smaller diameter pipelines shall be surrounded in
concrete.
J4.5.9 Jointing
Before making any joint the Contractor shall ensure that the interior of each pipe or fitting is
clean and shall prepare the ends for jointing as necessary. All mechanical joints shall have their
coating made good before assembly in accordance with the coating manufacturer’s
recommendations.
Only the proper jointing parts as specified and obtained from the suppliers of pipes or fittings
shall be used.
Joints shall be made in accordance with the manufacturer’s instructions.
Unless otherwise specified or detailed in the Drawings the deflection of a flexible joint shall not
exceed 50% of the maximum value specified by the manufacturer.
Bolts for flanged and other mechanical joints shall show two threads clear of the nut after
tightening.
Stainless steel nuts and bolts shall be lubricated before assembly with an anti-galling lubricant.
Nuts shall be tightened to the torques recommended by the joint manufacturer. Torques shall not
exceed values at which there is risk of galling.
After completing the joint any protective or other coating shall be made good and the joint
protection and sleeving completed without delay.
J4.5.10 Flanged joints

Joint rings for flanged joints may be fastened to the bolts with cotton thread. The use of jointing
paste, adhesive tape or grease will not be permitted.
The bores of abutting pipes or fittings and the joint gasket shall be concentric; no joint material
shall be left protruding into the bore. Nuts shall first be tightened by hand and nuts on opposite
sides of the joint circumference shall then be alternately and progressively tightened with a
spanner so as to ensure even pressure all round the joint.

J4.5.11 Work inside pipelines

The Contractor shall maintain adequate safety and monitoring systems, access, lighting and
ventilation to any part of a pipeline where work is undertaken inside the pipes.
J4.5.12 Cutting of pipes

Pipes shall not be cut until after adjacent pipes have been laid and jointed and accurate
measurement of the length and the required angle and shape of the cut can be made.
The cut shall be neatly performed by an experienced skilled man using tools or machinery
appropriate for the type and diameter of pipe to be cut. The cut ends of the pipes shall be shaped
up and trimmed so as to ensure an accurate joint. Any damage to wrapping, coating or lining
shall be made good.
The unused part of any cut pipe shall be disposed of off the Site unless, with the Engineer's
approval, it can be used elsewhere in the Works.
J4.5.13 Closing lengths

Pipes for closing lengths or for inserting into pipelines already laid shall be cut to allow a gap of
at least 20 mm between adjacent pipe ends. Otherwise, the gap shall be as recommended by the
manufacturer of the coupling. The closing joints in pressure pipelines shall be made with bolted
gland collars unless otherwise shown on the Drawings.
Sub section J4.5 (b) External protection
J4.5.14 Sleeving of pipelines

Double layer polyethylene sleeving to Clause J4.4.5.9 shall be installed so that it is continuous
over all buried ductile iron pipes, joints and fittings in accordance with the following procedure.
Immediately before lowering the pipes into the trench they shall be cleaned of all soil and foreign
matter and any damage made good.
The sleeve shall be slipped over the pipes and secured in place using adhesive PVC tape. The
sleeving shall be pulled tight against the bottom invert of the pipe and the excess girth shall be
gathered at the top of the pipe and folded. The sleeve at the ends of the pipes shall be left loose
until after jointing and any wrapping of the joint. The loose sleeving shall then be carefully
pulled over the joints so that it is continuous. The overlaps shall be secured with PVC tape at not
more than 600 mm centres. Bends, tees and similar fittings shall be protected similarly.
Any sharp edges such as at bolted gland or flanged joints shall be padded with four thicknesses
of sleeving material before the sleeve is pulled over them.
Care shall be exercised during handling, installing and backfilling to prevent damage to the
sleeving. Any minor damage to the sleeving shall be repaired by wrapping a sheet of material cut
from the sleeving material right round the pipe and so that it provides an overlap of at least
200 mm past each side of the puncture; all edges being taped to the sleeving.
Sleeving shall be omitted from the sections of pipes and fittings which are embedded in concrete
chambers. Before placing the concrete, the end of the sleeving shall be folded back clear of the
concreting operations and a run of adhesive PVC tape not less than 50 mm wide shall be affixed
around the pipe barrel so that the centre of the tape is aligned with the eventual position of the
concrete face. After concreting is completed, the sleeving shall be pulled over the pipe up to the

concrete face and secured to the pipe barrel with PVC tape such that the end of the sleeving
overlaps the tape previously placed around the pipe and so that no part of the pipe remains
exposed. The termination of the sleeving shall be completed by placing a further run of adhesive
PVC tape around the pipe, spanning between the end of the sleeving and the face of the concrete.
Sleeving shall be continuous around fittings (bends and tees) at thrust blocks.
A double polyethylene sleeve shall be applied to all ductile iron pipes.
J4.5.15 Tape wrapping with outer wrap for ductile iron pipelines
Pipes shall be tape wrapped at locations shown on the Drawings or as directed by the Engineer.
Buried wrapped pipes shall be additionally protected by polyethylene sleeving to Clause J4.4.5.9.
The Contractor shall submit to the Engineer for his approval the details of the proposed methods
of cleaning, priming, application of mastic putty, tape wrapping and the equipment to be used for
wrapping before commencing work.
Primer, mastic putty and wrapping tapes shall be obtained from the same manufacturer and be
compatible.
Prior to wrapping all surfaces shall be cleaned and primed with primer complying with Clause
J4.4.5.8.
Pipes of 400 mm diameter and above shall be machine wrapped on site with tape complying with
Clause J4.4.5.6 using a wrapping machine supplied by the Contractor. The wrapping tape shall
be applied in a spiral manner under tension to ensure conformability and adhesion to the barrel of
the pipe or fitting. The wrapping shall have a minimum 55% overlap and shall be wrinkle and
bubble free. A length of 200 mm at the spigot shall be left unwrapped until after jointing.
When a new roll of tape is started, the end lap shall be overlapped on the roll a minimum of
150 mm, measured circumferentially and shall be smooth and placed so as to maintain the
continuity of the wrapping.
The Contractor shall prove the wrapping to be holiday free using a holiday detection meter and
voltages to the approval of the Engineer.
On completion of wrapping with protective tape an outer wrap of tape complying with Clause
J4.4.5.7 shall be applied over the protective tape using the same type of mechanical equipment as
used to apply the protective tape. The overlap of the outer wrap shall not coincide with the
overlap of the protective tape. The outer wrap may be applied at the same time as the protective
tape and shall have a minimum 50 mm overlap.
The minimum end lap of two rolls shall be 150 mm measured circumferentially. The outer wrap
shall be applied such as to initially leave 300 mm at the spigot unwrapped.
After the wrapped pipes are laid and jointed mastic putty shall be applied at the joint to smooth
out the external pipeline profile. The putty shall be applied as a fillet with an angle to the pipe
axis not exceeding thirty degrees.
Tape wrapping and outer wrap shall then be made continuous over the joint by hand wrapping.
Prior to backfilling the Contractor shall prove the joint wrapping and exposed pipe wrapping to
be holiday free using a holiday detection meter and voltages to the approval of the Engineer.

J4.5.16 External wrapping of fusion-bonded epoxy coated pipes and fittings

Field joints of fusion-bonded epoxy coated pipes shall be protected by heat-shrink sleeves. The
sleeve shall be pre-cut to size and wrapped around the pipe or fittings before it has cured. The
completed sleeve shall conform to the pipeline shape, show no blisters or sign of air entrainment
and the hot-melt adhesive shall be visible as a flow from all edges.
J4.5.17 Protection of bolted couplings, adapters and flanges

After jointing and testing corrosion protection shall be applied to all buried detachable couplings,
adapters, flange adapters, mechanical (bolted gland) joints and flanged joints incorporating
ferrous metals which are laid in direct contact with the ground. Mastic putty shall be applied at
the joint to smooth out the external pipeline profile. The putty shall be applied as a fillet with an
angle to the pipe axis not exceeding thirty degrees to fill all voids and crevices created by the
bolts, nuts and structure of the fittings. Tape wrapping and outer wrap shall then be made
continuous over the joint by hand wrapping.
Alternatively the Contractor may apply to the Engineer for permission to surround the joints with
solid bitumen instead of adopting the measure described above and if approval is given the
bitumen used shall be suitable for the duties and temperatures involved and shall provide a
minimum of 20 mm of cover around all parts of the joint.
Alternative means of protecting bolted connections may be submitted to the Engineer for his
approval providing they supply a comparable degree of protection to the pipes and fittings.
In addition to the bituminous coatings specified above all buried bolted connections, flexible
couplings, adaptors and valves shall be wrapped to the same specification as for pipes.
All bolts in chambers shall be thoroughly cleaned and wrapped with tropical grade petroleum
jelly impregnated open weave cotton, synthetic fibre or glass fibre tape. The tape shall be suitable
for use in the prevailing climatic and soil conditions and be applied in accordance with the
manufacturer’s instructions. Profiling putty shall be used as required to provide a regular surface
for wrapping. The tape shall extend at least 200 mm over the adjacent pipe barrel.
All bolts shall be re-checked for tightness before wrapping tape is applied.
J4.5.18 Painting above ground new ductile iron pipelines and fittings
All surfaces of exposed ductile iron pipework aboveground shall be painted as follows:
a) Prior to over coating epoxy surfaces shall be sweep blasted so as to remove surface
gloss to obtain an adequate key to the paint system to be applied all to the approval of
the Engineer.
b) All damaged areas of shop applied coatings shall be degreased wire brushed and
painted with one coat of zinc rich paint and one coat of the same top coating material
as shop applied. All areas thus restored shall not be over coated for a minimum
period of 16 hours.
c) 3 coats of an approved oil based aluminium paint shall be applied by airless spray or
brush/roller to a minimum dry film thickness of 25 microns per coat. Over coating
times should be as indicated in the paint manufacturer's instructions. Prior to over
coating epoxy surfaces shall be sweep blasted to remove surface gloss and obtain an
adequate key to the paint system to be applied.

The aluminium paint should be suitable for application on the epoxy surfaces limiting any bleed
through the first finishing coat to a minimum and totally inhibiting bleed through the subsequent
coating. The paint shall have a metallic aluminium coloured finish.
All preparation and painting at works shall be carried out under cover at ambient temperature
controlled between 16°C and 21°C and relative humidity below 85%,
Site painting shall not under any circumstances proceed in an ambient temperature less than 5°C
for epoxy coat applications or on surfaces which are other than completely dry.
All paint shall be obtained from an approved manufacturer and shall be applied strictly in
accordance with this Specification. The Contractor shall issue a copy of this Specification to any
Sub-Contractor involved and also to the manufacturer of the paint.
The paint manufacturer shall spot check the preparation and painting and submit to the
Contractor a written report of his observations for forwarding to the Engineer.
J4.5.19 Connecting to existing pipelines

Before starting any connection into an existing pipeline the Contractor shall verify the exact
dimensions and the materials necessary. The Contractor shall excavate trial pits, prepare designs,
and obtain the Engineer’s approval and liaise with the authority responsible for the operation of
that pipeline.
The Contractor shall prepare a detailed method statement for the completion of the connection,
clearly indicating the period for which it will be necessary for the existing pipeline to be taken
out of service The period of planned shut-down shall be kept to the minimum practicable in the
circumstances.
The statement shall also detail the methods and plant to be employed, standby plant to be made
available and the measures that will be taken to prevent contamination of the existing pipeline.
The statement shall be subject to the approval of the Engineer and of the operating authority.
Unless otherwise agreed in writing the operation of valves necessary to isolate the section of the
existing pipeline and subsequently to restore it to service shall only be undertaken by staff of the
operating authority. If so instructed by the Engineer the Contractor shall assist the authority in
carrying out any activities necessary to facilitate the efficient completion of work on the
connection.
The new pipeline and, where practicable, the existing pipeline at the connection shall be tested
for leakage. Any existing pipe, fitting or joint leaking due to damage occurring during the
connection operation shall be removed and replaced by the Contractor at no extra cost to the
Employer.
Sub section J14.5(c) Ancillaries
J4.5.20 Marker installation

Markers shall be positioned above the main at a minimum of 50 m spacing, and at all bends, tees
and each structure. At bends and structures two markers shall be installed, one immediately
upstream and downstream of the structure. The marker shall be as close as possible to the
structure. At tees three posts shall be provided.

J4.5.21 Cable ducts

Where ducts are detailed as being laid in large radius curves in either the horizontal or vertical
planes these shall normally be not less than 50 m radius, unless a smaller radius is specifically
detailed. In no case shall a curve of less than 25m radius be installed. Ducts shall be laid in
regular curves of the required radius by bending the pipe during installation. Curves shall not be
formed with angular deviations at flexible joints.
A mandrill shall be pulled through the completed ducts
Joints in the draw cord shall be kept to a minimum; they shall be at least as strong as the cord and
shall be so made as not to cause any jamming in use. The draw cords shall be installed with
suitable tying off eyes in the drawpits.
J4.5.22 Anchor and thrust blocks

At every bend and junction on pressure pipelines the Contractor shall construct a thrust or anchor
block of concrete Grade C to the dimensions indicated on the Drawings to resist thrusts
transferred by the required site test pressure. Thrust and anchor blocks shall be of mass concrete.
The additional excavation for thrust and anchor blocks shall generally be made after the pipeline
has been jointed.
Following excavation, construction of the thrust and anchor blocks shall be commenced
immediately and shall proceed to completion as a continuous process.
Below ground surfaces of thrust blocks shall be protected in accordance with the relevant clause
of the Specification.
The bearing face of thrust blocks shall be wrapped in two layers of polyethylene each of
minimum thickness 0.25mm and the edges of the polyethylene sheeting shall be sealed with
approved plastic adhesive tape.
Above ground surfaces of thrust blocks shall be painted in accordance with the relevant clause of
the Specification.
No pressure shall be applied to the thrust and anchor blocks until in the opinion of the Engineer
the concrete has achieved sufficient strength to restrain the loads imposed.
Unless otherwise detailed in the Drawings thrust blocks shall be constructed with the bottom,
thrust and side surfaces bearing against undisturbed ground.
If blinding concrete is required or allowed to be placed beneath any horizontal thrust block shear
keys shall be formed on its upper surface.
The surfaces of concrete thrust blocks not cast against undisturbed ground shall be waterproofed
with two coats of bituminous paint.
J4.5.23 Diaphragm blocks

Where pipeline gradients are greater than 1:50 mass concrete diaphragm blocks shall be
constructed around the pipe as indicated in the drawings. The blocks are to reduce water
movement within the pipe bedding and sidefill. Diaphragm blocks shall be spaced along the
pipeline such that pipe the level difference between blocks shall be not geater than the pipe
diameter. The diaphragm block shall be embedded into the original ground of the bed and walls
of the trench to at least the depth indicated on the Drawings. The class of concrete to be used
shall be Grade C.

J4.5.24 Valve and other chambers

All buried valves butterfly shall be provided with reinforced concrete chambers as shown on the
drawings. The class of concrete to be used shall be Grade A.
The thrust-bearing surfaces of pipeline chambers which are designed to carry thrusts shall be
constructed against undisturbed ground.
If undisturbed ground has not been maintained the gap shall be backfilled with Class C mass
concrete.
Pipes shall project from the external faces of the chambers by the amounts stated for ductile iron
pipes in Clause J4.5.27.1 unless otherwise shown on the Drawings or instructed by the Engineer.
Top surfaces of walls supporting pre-cast concrete cover slabs shall be to true line and level.
Lifting holes or eyes in pre-cast components are to be provided as shown on the Drawings or as
The outer surfaces of concrete chambers shall be waterproofed as detailed on the drawings and
Specified in SECTION J3
The dimensions of the chambers indicated in the drawings are for guidance only. Depending
upon the assembly of pipes, fittings and valves at site the Contractor shall check and modify the
dimensions if required with the approval of the Engineer so that enough working space is
available in the chamber.
The cover slabs for chambers shall be as shown on the drawings and be designed for traffic
loading with 11.5 tonne wheel load.
If precast concrete cover slabs are detailed they shall be placed in position using lifting hooks
provided for the purpose, the slab shall be cast in sections such that the weight of each portion
does not exceed one tonne. The cover joints shall be sealed against ingress of water.
If multiple ducted frames and covers supported on steel cross beams are detailed the beams and
the manhole frames and covers shall be of bolted type and set in the recesses of the chamber
walls such that the whole system can be dismantled and lifted easily. The cover joints shall be
sealed against ingress of water.
Unless otherwise specified the manhole cover size shall be 800mm x 600mm heavy duty ductile
iron. In air valve chambers the manhole covers shall be of the vented type. The manhole cover
position shall be as shown on the drawings and as approved by the Engineer. Manhole covers
outside of fenced site areas shall be of the open frame concrete infill pattern.
A sump shall be provided in the base slab of all chambers. The top of the floor slab shall be
screeded to slope and drain into the sump. A ladder shall be provided in the walls to suit the
manhole opening.
J4.5.25 Installation of valves

Valves shall be installed and commissioned in accordance with the manufacturer’s instructions.
After installation valves shall be cleaned. Gates, discs, seats and other moving parts shall be
closely inspected and all foreign matter removed and the valve shall be checked for ease of
operation. Moving parts shall be lightly greased or otherwise treated as the manufacturer instructs
to bring them into a good operating condition. Valves within chambers or other structures shall
be protected from damage and dirt with suitable approved covering until commissioning.

Butterfly valves shall be fixed with the disc spindle horizontal and installed so that when the
valve is opening the lower portion of the disc moves in the direction of the main or normal flow.
Except where shown otherwise in the Drawings gate valves shall be fixed with their spindles
vertical.
J4.5.26 Drawpits
The Contractor shall submit details for drawpits which shall be either precast or insitu concrete
Class A1, or HDPE. The roof slab shall be precast concrete with lifting hooks to enable it to be
removed.
The cover shall be bedded and sealed against ingress of water.
The external faces of buried concrete walls shall be painted with 2 coats of bitumen paint.
Where ducts are built into the walls the openings shall be sealed and made good.
The drawpits shall incorporate anchor eyes for the pulling of the cables. Drawpits shall be spaced
at no more than 200metres centre to centre.
J4.5.27 Pipelines built into structures
J4.5.27.1 Rocker pipes

Rocker pipes comprising a short length of spigot and socket pipe shall be provided as shown on
the Drawings. Unless otherwise shown the first joint shall be not more than one pipe diameter or
500 mm, whichever is the smaller, from the outside face of the structure and the length of pipe
between the flexible joints shall be equal to two pipe diameters or 1000 mm, whichever is the
greater.
J4.5.27.2 Excess excavation

Any excavation beneath the formation line of a pipe trench adjacent to a structure shall be
backfilled to the formation line with concrete Class C. The concrete shall extend at least 500 mm
beyond the extremities of the pipe on each side.
J4.5.27.3 Thrust flanges

Pipes passing through the walls of chambers shall be provided with thrust flanges where shown
on the Drawings.
J4.5.27.4 Pipeline spacing at structures

Where it is necessary to increase the spacing of pipelines at structures such as chambers and
thrust blocks the deviation shall be made by deflecting the pipe joints. Deflections shall be
limited to 50% of the maximum allowable stated by the manufacturer.
J4.5.27.5 Pipework in chambers

Pipework systems shall be complete and checked for correct position and alignment before being
concreting in.
The Contractor shall ensure that no excessive loads or stresses are imposed upon the pipework or
structure and shall adequately support the pipework during installation until permanent supports
and anchorages are completed

Where pipe fittings are cast into in-situ concrete walls and where a puddle flange is not required
to resist forces rubber sealing rings shall be installed.
J4.5.27.6 Painting of pipes, fittings and valves in chambers

Factory-applied coatings on pipes, fittings and valves in chambers and other exposed areas shall
be made good on completion of construction of the chambers as necessary to return the items to
the appearance on leaving the factory.
Where specified exposed pipes, fittings and valves and their joints shall be over-painted to a
colour to be agreed with the Engineer. Paint systems for over-painting shall be compatible with
any factory coatings including coatings made good on site.
Bitumen coated items shall be primed with two coats of aluminium sealer to a total dry-film
thickness not less than 30 microns. Top coats of approved colour of alkyd chlorinated rubber
finish shall be applied sufficient to give a total over-paint dry-film thickness of 80 microns.
Where shown on the drawings or specified FBE or epoxy-coated items shall be lightly rubbed
down with emery to provide a key and painted with two coats of alkyd or epoxy finish coats of
approved colour.
Sub section J14.5(d) Workmanship for high density polyethylene pipelines
J4.5.28 PE-HD thermofusion welding

Butt fusion welding shall be done using approved proprietary equipment and shall on no account
be made by hand. Joints shall be made in accordance with manufacturer’s instructions, but shall
in any case include the following steps:
(i) The mating surfaces of the components to be jointed shall be square and free
from imperfections. Pipes for cutting shall be cut using appropriate pipe-
cutters designed for the purpose. On no account shall pipes be cut by hand
using improvised methods, e.g. knife, hacksaw etc.
(ii) The surface of the heated plate shall be clean and maintained at 210 °C, or
as otherwise stipulated by the pipe manufacturer. The mating surfaces shall
be pressed constantly against the plate until a small bead of molten material
is formed. Thereafter the pressure shall be reduced to ensure that the bead
does not continue to grow whilst heating is continued.
(iii) The hot plate shall be removed and the heated faces brought together under
pressure. Pressure shall be maintained until the joint area has cooled
sufficiently. The ridge produced inside and outside the pipe, shall have a
height not exceeding a quarter of the wall thickness.
J4.5.29 PE-HD bending

Pipe shall not be heated and stressed to form curves or bends. Gradual curves may be introduced
into the pipe at ambient temperatures to form direction changes. The inside radius of the bend
shall be not less than 20 times the outside diameter of the pipe.

J4.5.30 PE-HD Storage

Pipes shall be stored on flat, clean surfaces free of sharp objects or any other item that may mark
or damage the pipe in any way. Pipes shall not be stored on or against hot surfaces. Blue and
Black polyethylene pipe shall be stored under cover and out of direct sunlight.
Coils may be stored either on edge or stacked flat one on top of the other.
Straight lengths should be stored on horizontal racks giving continuous support to prevent the
pipe taking on a permanent set.
J4.5.31 Installation of buried PE-HD pipes

When laying pipes in hot weather, the trench shall be partially backfilled before making the final
connections and locating anchor blocks.
J4.5.32 Moling PE-HD pipes

Only coiled pipe shall be installed by moling. Moling methods may include pulling pipe through
holes pre-drilled by mole-bore, and mole-ploughing using a proprietary ploughing machine.
The Contractor shall ascertain that ground conditions are suitable for moling before commencing
any such work. The Contractor shall ensure that he has complete knowledge of any services that
may lie along, or in the immediate vicinity of the pipeline route, and has taken appropriate
mitigation in accordance with the Specification, before he commences.
The diameter of the mole should be 1½ to 2 times the outside diameter of the pipe being laid.
The following procedures shall apply when installing pipe:
(i) Any trenches/pits required for launching and receiving moles, pulling pipe,
and making joints, shall be made in advance of the works and clearly
identified. The pits should be planned at intervals slightly shorter than the
length of the coils to be used. Starting and intermediate pits shall be at least
1.5 m long and 0.3 m wide and to the depth it is intended to plough.
(ii) Pipes shall be uncoiled and laid on the ground in the direction of pulling (or
in a wide circle) near the hole at which they will be needed. The ends of the
pipe shall be covered or bunged in order to keep soil from entering the bore.
(iii) Pulled pipes shall be laid individually between pits and pulled by tractor or
winch through to the next pit. Only continuous lengths shall be pulled,
pulling of coupled pipes shall not be permitted. In hard soils the friction may
be reduced by pouring a little water into the hole made by the plough.
(iv) The Contractor shall make adequate allowance for expansion of the pipe due
to pulling or laying by plough. Pipes shall be left overnight following laying
and before making joints, to allow for contraction of the pipe.
J4.5.33 Above ground installation of PE-HD pipes

Pipe fitted above ground shall be black pipe supplied in straight lengths, unless otherwise agreed
by the Engineer. Where pipe is cut from a coil, fixing shall be arranged so that the curvature of
the pipe is corrected by contact with the surface to which it is being fixed. Pipe shall not be
straightened by applying tension.

Pipe clips shall be plastic and shall be correctly aligned to provide a flat smooth surface for
contact with the pipe. No sharp edges shall be present on supports. Valves and other such items
shall be properly supported.
Pipe shall be continuously supported or on fixings such as pipe clips, brackets, etc., which shall
be used at approximately the following spacings. Values are for use in temperatures up to 20 °C.
Spacings shall be reduced by 25% between 20-30°C. Pipes shall be continuously supported
where temperatures are above 40°C.
Nominal Size Spacing(m) Nominal size Spacing(m)
16 0.45 50 0.7
20 0.6 63 0.85
25 0.6 90 0.85
32 0.6 110 0.9
40 0.7 140 1.1
160 1.3
Support distances may be doubled for vertical pipes
J4.5.34 Expansion and contraction of PE-HD pipes

Adequate means shall be provided to account for expansion and contraction. This shall be by
means of bends/changes of direction at appropriate intervals or purpose designed bellows, sliding
gland expansion joints or expansion loops.
J4.6 ROAD CROSSINGS BY TRENCHLESS CONSTRUCTION
J4.6.1 Scope
Where required by the Royal Oman Police and instructed by the Engineer the installation of
pipelines and cable ducts at road crossings shall be by trenchless construction methods.
J4.6.1.1 Pipe jacking

For the water transmission pipeline the work includes the supply of sleeves and/or pipes and their
installation by jacking techniques while excavating behind a remote controlled steering shield.
Ductile iron pipelines are to be installed centrally, within the sleeve and supported by suitable
spacers. The annulus will be grouted.
The Contractor may additionally propose alternative methods of trenchless construction such as
direct installation of proprietary pipes suitable for jacking. Alternative proposals shall be subject
to acceptance by the Engineer.
J4.6.1.2 Directional drilling

For the installation of ducts the work includes the supply of the duct and its installation by
directional drilling techniques.
Directional drilling shall include all work necessary for the installation of 32 mm to 150 mm
nominal diameter high density polyethylene (H.D.P.E.) pipe as shown on the drawings and as
specified herein. Services provided by the Contractor shall be performed in accordance with the
best industry practice and the Contract. The Contractor shall furnish all labour, equipment and
materials necessary to accomplish the work.

The Contractor will at all times provide and maintain instrumentation which will accurately
locate the pilot hole and measure drilling fluid flow discharge rate and pressure. The Engineer
will have access to these instruments and readings at all times.
J4.6.1.3 Design
The Contractor shall design the permanent and temporary works covered by this section of the
Specification.
The design shall comply with the requirements of the Contract and shall be submitted to the
Engineer for his approval. The Contractor shall be responsible for his design and shall obtain all
necessary approvals from the Muscat Municipality, Royal Oman Police and any other relevant
authorities.
J4.6.1.4 Site investigation

The Contractor shall carry out any additional site investigation necessary for the design and
construction of trenchless road crossings.
J4.6.1.5 Reference Standards

The trenchless construction shall comply with all relevant statutory regulations and Reference
Standards, unless otherwise indicated within this Specification. Reference Standards include:
BS 5911-1:2002 Precast concrete pipes, fittings and ancillary products. Specification
for unreinforced and reinforced concrete pipes (including jacking
pipes) and fittings with flexible joints (complementary to BS EN
1916:2002)
BS6164:2001 Code of practice for safety in tunnelling in the construction industry.
ANSI/AWWA C200-97 Steel Water Pipe - 6 in. (150 mm) and Larger
ASTM A53/A53M-02 Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-
Coated
ISO 8770 Plastics piping systems for soil and waste discharge (low and high
temperature) inside buildings - Polyethylene (PE)
ISO 8772 High density polyethylene (PE-HD) pipes and fittings for buried
drainage and sewerage systems; specifications
J4.6.2 Submissions by the Contractor
J4.6.2.1 Pipe Jacking

Submissions which the Contractor shall make in relation to trenchless construction include but
are not limited to the following:
• Design calculations, drawings, material specifications and method statements;
• Calculations of jacking loads;
• Calculations of highway loading, depths of cover and spacing of sleeves;
• Predictions of maximum surface settlement and proposed methods of monitoring
surface deformation;

• Proposed method of pipe installation and support within the sleeve;

• Details of temporary works including jacking and receiving pits, site access and
storage proposals, protection of existing services;
• Details of trenchless construction work which has previously been performed by the
proposed method in similar ground conditions;
• Details of trenchless construction work which has previously been performed under
the control of the proposed supervisor;
• Results of loading tests on pipes;
• Samples of proposed packing materials;
• Results of loading tests on packing;
• Records of line, level and rate of progress;
• Records of bentonite slurry used and pressures measured at the slurry pump;
• Record of jacking forces;
• Records of changes in level of ground surface and structures above and adjacent to
the position of the trench less construction works.
J4.6.2.2 Directional Drilling

Prior to commencing directional drilling, the Contractor shall submit to the Engineer details of
equipment and detailed working drawings describing the proposed method of directional drilling.
This shall include arrangement of equipment, location and size of drilling and receiving pits,
proposed plan and profile of the installation, method of dewatering, method of removing spoils
material, size carrier pipe, method of fusing pipe segments, type wire, carrier pipe end seals,
support segments, and method of abandonment of pilot hole. Sufficient material shall be
submitted to show compliance with the Contract Documents and to show that articles proposed
for use in the work are acceptable.
All drawings, catalogue cuts and other descriptive data covering several related items in the same
system shall be submitted at the same time in order that their complete integrated applicability in
the entire system is adequately reviewed.
The Contractor shall submit product information, material specifications, handling procedures,
special precautions required, and method of mixing and installation details of the
bentonite/drilling mud.
J4.6.2.3 Approvals
The design and construction of road crossings by trenchless construction shall be the sole
responsibility of the Contractor. Approval and/or comments by the Engineer shall not relieve the
Contractor of his obligations and responsibilities to complete the works in a satisfactory manner
to the approval of all concerned authorities.
J4.6.3 Materials for trenchless construction
J4.6.3.1 Sleeves for trenchless construction

Sleeves shall be formed from either:-

a) Concrete pipes which shall be designed to give a reliable service life of at least 60
years. Concrete jacking pipes shall be butt-jointed reinforced concrete with an
external collar and shall comply with BS5911; Part 120. The pipes shall be
manufactured using Sulphate Resisting Portland cement. The 28-day characteristic
cube strength of the concrete shall be not less than 50 N/mm2. Both the internal and
external face of the sleeve shall be protected with two coats of bitumen paint;
or,
b) Polyester Resin Concrete pipes which shall be butt jointed with an external collar.
The minimum design compressive strength of for design purposes relative to design
jacking load shall not be less than 80 N/mm2;
or,
c) Welded steel pipe conforming to the requirements of ASTM A53 Grade B or
AWWA C200, having a minimum yield strength of 250 N/mm2 of minimum
thickness 10 mm for 900 mm diameter and smaller and 15 mm for 1050 mm
diameter and larger.
The strength of the pipes shall be selected to suit the installation loads, imposed loads and the
design life.
Joints which shall be used in conjunction with resilient packing shall be capable of accepting
repeated angular deflections of up to 0.5o without:
- Loss of structural strength;
- The ingress of water or bentonite.
Joint materials shall be suitable for the local ground conditions.
J4.6.3.2 Collars for sleeves for concrete pipes

Collars shall be of steel or GRP and sit in a recess in the pipe barrel such that the external surface
shall be flush with the outer surface of the pipe.
J4.6.3.3 Packing for sleeves for concrete Pipes

The material used for packing shall have, under dry conditions, when subjected to the maximum
permitted bearing pressure:
• A compression of at least 50% of the original thickness
• A re-assertion after 1 hour of at least 65% of the original thickness.
J4.6.3.4 Bentonite
The material used for lubrication of pipe jacked sleeves shall be calcium bentonite or other
approved material stored and mixed in a manner recommended by the supplier.
J4.6.3.5 Ductile iron carrier pipes

Carrier pipes to be inserted within the sleeve shall be ductile iron with spigot and socket type
anchored joints. The pipes shall be tape wrapped, but not be polyethylene sleeved, and shall
comply in all other respects with the Specification.

J4.6.3.6 Pipe Supports in Sleeves

Pipe supports (spiders) for the Ductile Iron carrier pipes shall be proprietary ductile iron supports
or shall be purpose designed and fabricated in steel.
Pipe supports (spiders) for the HDPE carrier pipes shall be purpose designed and fabricated in
steel.
The supports shall be designed to resist the installation forces and shall not cause damage to the
sleeve.
J4.6.3.7 Bulkheads
Bulkheads around the ductile iron carrier pipe at each end of the crossing shall be fabricated from
steel with grout inlet/outlet pipes.
J4.6.3.8 Annulus Grout Material

The grout to surround the annulus between the carrier pipe and the sleeve shall be a mixture of
75% pozzolanic fly ash and 25% cement plus a high grade gel to control bleed and a dispersant
to lower the viscosity for increased pumpability. Coarse sand and/or aggregate shall not be used.
The 28 day compressive strength shall be at least 10 N/mm2. The set grout shall have a high
sulphate resistance. The mixed grout shall have a low slurry viscosity; apparent viscosity shall be
between 500 and 1500 cP at 5 l/sec.
Slurry density of the mixed grout shall be at least 5.8 kg/m3
J4.6.3.9 High Density Polyethylene Ducts

The cable duct to be inserted within the sleeve by horizontal directional drilling shall be HDPE to
ISO 8770/8772. Joints shall be electrofusion welded.
J4.6.4 Workmanship for trenchless construction
J4.6.4.1 Approval
The Contractor shall obtain the approval of all concerned authorities. No construction shall
commence until written approvals have been submitted to the Engineer and the Engineer has
stated in writing that the work may commence.
J4.6.4.2 Method of construction

The Contractor shall select a method of construction which is suitable for the pipes, diameters,
ground conditions and all particular conditions at the respective site.
Before commencing work the Contractor shall submit full details of the method, equipment and
his proposed personnel.
J4.6.4.3 Monitoring
The Contractor shall be responsible for taking all precautions necessary to protect existing
infrastructure and existing utilities and structures and road surfaces from settlement or damage.
Under no account shall settlement be allowed to exceed 9 mm.

The Contractor shall survey all areas that may be affected by the works prior to commencement
and shall monitor surface levels during the progress of the works.
The Contractor shall submit results of surveys to the Engineer within 12 hours of taking the
levels.
The Contractor shall immediately inform the Engineer of any surface settlement that exceeds the
predicted value.
J4.6.4.4 Microtunnel Equipment

Trenchless construction shall be performed using modern state of the art equipment specifically
designed for pipe jacking with particular regard to compactness, low noise emission, cleanliness
and safety.
The equipment shall be of a type where the pipe or sleeve is jacked into place immediately
following the excavation machine such that the excavation is always completely supported.
The system shall have automatic steering control by means of a microprocessor system with line,
level and gradient prediction capability. The system shall produce monitoring information in the
form of print outs giving loads and positions every 100 mm.
A laser guidance system shall be used for the control of the shield alignment.
The laser shall be mounted independently of the thrust wall.
Laser accuracy shall be checked each shift.
J4.6.4.5 Horizontal directional drilling equipment

Horizontal directional drilling shall be performed using modern state of the art equipment
specifically designed for the purpose. The equipment shall incorporate a steering system
J4.6.4.6 Directional tolerance of directional drilling

A pilot hole shall be drilled along the path shown on the plan and profile drawing to the
following tolerances:
a) Elevations- plus or minus 150mm;
b) Alignment- plus or minus 150mm;
c) Curve radius -No curves will be accepted with a radius less than that shown on the
plan and profile drawing.
At the completion of the pilot hole drilling, the Contractor shall provide a tabulation of
coordinates referenced to the drilled entry point which accurately describe the location of the
pilot hole.
J4.6.4.7 Directional drilling ream and pull back

Pre-reaming operations shall be conducted at the discretion of the horizontal drilling contractor.
All provisions of this specification relating to the simultaneous reaming and pulling back
operations shall also pertain to pre-reaming operations.
The maximum allowable tensile load imposed on the pipeline pull section shall not exceed the
following amounts:

Nominal Diameter Allowable Tensile Load

32mm 390Kg
50mm 800Kg
75mm 1,750Kg
100mm 2,900Kg
150mm 6,200Kg
The amount of pull applied to the pipe shall be controlled and limited by devices such as
hydraulic pressure regulator or a load sensor between the pulling equipment and the pipe.
J4.6.4.8 Directional drilling - torsional stress

The amount of pull applied to the pipe shall be controlled and limited by devices such as
hydraulic pressure regulator or a load sensor between the pulling equipment and the pipe.
The pull section shall be supported as it proceeds during pull back so that it moves freely.
A metallic detection wire shall be pulled along with the carrier pipe.
J4.6.4.9 Drilling fluids for directional drilling

No drilling fluid will be utilised that does not comply with all environmental regulations.
Disposal of drilling fluids shall be the responsibility of the Contractor and shall be conducted in
compliance with all relative environmental regulations, right-of-way and work space agreements.
Drilling fluid returns at locations other than the entry and exit points shall be minimised. The
Contractor shall immediately clean up any inadvertent returns.
The Contractor is responsible for transporting and storing any water required for drilling and
hydrostatic testing. Securing permission to use water from any other source is the responsibility
of the Contractor.
Excess drilling fluid may be disposed of at a pre-approved location. The Contractor is
responsible for transporting all excess fluids to the disposal site and paying any disposal costs.
J4.6.4.10 Safe working

The Contractor shall maintain safety equipment including toxic gas monitors at the bottom of all
working shafts.
J4.6.4.11 Settlement
The Contractor shall continuously monitor settlement of the ground surface, adjacent structures
and buried utilities and shall limit settlement to an absolute minimum by controlling the
tunnelling activities such as rate of excavation, progress of jacking, design of bentonite slurry
mixes etc.
All work and any stoppages or modifications to materials, equipment or methods of working to
reduce settlement to the Engineer’s satisfaction shall be at the cost of the Contractor.

J4.6.4.12 Line and level of microtunelling

All microtunelling trenchless construction shall be carried out in an uphill direction unless
otherwise approved by the Engineer.
The pipe or sleeve shall be installed straight at a constant slope. The position of the internal face
of any part of the pipe or sleeve shall not deviate by more than:
Line and level: - +/- 50mm
Maximum lipping between edges of adjacent pipes: - 2.5% of nominal diameter
Angular deflection of joints: - 0.5°
J4.6.4.13 Records of microtunelling

The Contractor shall keep records of the line, level and rate of progress. Copies of the records
shall be submitted daily to the Engineer.
J4.6.4.14 Deviation of microtunelling

If any section of the pipe deviates from the alignment tolerances specified the shield shall be
steered in a manner that ensures a gradual return to the correct alignment to the approval of the
Engineer.
J4.6.4.15 Thrust system for microtunnelling

The jacking rig shall distribute the thrust to the pipes via a thrust ring and packing. The jacks
shall apply the thrust to the thrust ring by means of symmetrical distribution.
Spacer blocks if used shall be true and free from any distortions.
All thrust rigs shall be true and free from any distortions and sufficiently stiff so as to transfer the
load from the jacks uniformly to the packing.
Other than at the shield each group of jacks shall be interconnected to ensure that an evenly
distributed load is applied to the thrust ring. Each jack shall incorporate a load cell.
At the jacking ring automatic thrust recording equipment shall be provided, together with a
pressure-metering device, to monitor load cells incorporated in each jack. Copies of the records
clearly stating the units measured shall be submitted daily to the Engineer.
The jacking force shall not exceed the force agreed between the Contractor and the Engineer,
based on calculations submitted by the Contractor and approved by the Engineer and on
consideration of the behaviour of the pipe joint at the maximum permitted angular deflection of
0.5° with the maximum permissible bearing stress in conjunction with the stress/strain
relationship obtained from the packing compression tests.
J4.6.4.16 Thrust wall for microtunnelling

The thrust wall (jacking ring reaction surface) shall be normal to the proposed line of thrust. The
thrust wall shall be of sufficient capacity to accept repeatedly the maximum permitted jacking
force without any movement. If will not be permissible to thrust off any permanent part of any
shaft of chamber.
The design of the thrust wall and any other associated temporary works shall be such as to
prevent damage to any part of the permanent works.

Any void between the soil face used to provide a reaction to the jacking force and the thrust wall
shall be filled completely with cement based grout.
The Contractor shall take any measures necessary to prevent damage or deterioration of the soil
reaction face during the construction of the temporary and permanent works from whatever
possible cause, such as ingress of water softening a cohesive soil or loss of fines from a granular
soil.
J4.6.4.17 Microtunelling pipelaying records

The following records shall be submitted daily:
a) Date
b) Drive No. or identification
c) Pipe No.
d) Operator
e) Strata record
f) Remarks
and then at each monitoring position (at a maximum spacing of 500 mm or as directed by the
Engineer).
g) Time recorded
h) Distances jacked - (0.500, 1000 etc.)
i) Charging pressure - Kg/cm²
j) Face pressure - Kg/cm²
k) By-pass pressure - Kg/cm²
l) Discharge volume - m³/min
m) Jacking speed - mm/min
n) Jacking force - main - tonne
o) Jacking force:
interjack 1 - tonne
interjack 2 - tonne
p) Cutter torque - percent
q) Cutter rotation - clockwise/anticlockwise
r) Steering:
up - deg
down - deg
left - deg
right - deg
s) Displacement:
X+ - mm

X- - mm
Y+ - mm
Y- - mm
t) Roll:
left - mm
right - mm
u) Lead:
left - mm
right - mm
v) Inclinometer - deg
J4.6.4.18 Grouting of annulus

All grout materials should be dry blended prior to mixing with water. Storage at the job site shall
be as a dry material.
The grout mixer shall be a high shear, high energy colloidal mixer of sufficient rate and capacity
to meet the grout placement requirements without causing delays. A colloidal mixer is necessary
to achieve the best uniform mixture and density.
Grouting shall only be considered complete when grout slurry is ejected from the reception vent
pipe.
J4.6.4.19 Completion of installation

After installation of the duct is complete, drilling pits and receiving pits shall be backfilled as
specified in the Standard Technical Specifications.
J4.6.4.20 Testing of sleeve

Prior to inserting the ductile iron or HDPE carrier pipe the sleeve shall be inspected by CCTV, or
manually in the larger diameter sleeves, to ensure that the sleeve is undamaged and clear of
debris.
J4.6.4.21 Testing of ductile iron pipe

Prior to removal of jacking plant and the reinstatement of the jacking and reception pits the
length of ductile iron pipe constructed by trenchless techniques shall be fully tested to the
specified test pressures as detailed on the Drawings. The test length shall include the first joint
and the connecting length of standard pipe at each end of the pipe installed by trenchless
techniques.
J4.7 TESTING PIPES AND DUCTS
J4.7.1 General
All water pipelines shall be cleaned, pressure tested and disinfected.
Cable ducts shall be cleaned and left stoppered with draw cords.

All chambers and draw pits shall be cleaned of all debris silt and sand, any mortar droppings on
pipework or metalwork shall be removed and any damaged coatings made good. Valves shall be
tested for operation, valve spindles shall be adjusted for correct alignment and chamber covers
shall be cleaned and properly seated.
Records of all cleaning, testing and disinfection operations shall be submitted to the Engineer
weekly.
J4.7.2 Water for testing, cleaning, swabbing and disinfection

The Contractor shall make his own arrangements to provide all water required for testing and
cleaning and disinfection of pipelines.
The Contractor shall provide all necessary temporary connections, pipework and any tankers
necessary to convey water from the point of supply.
The Employer cannot guarantee that water will be available from the Wadi Dayqah reservoir for
pipeline testing.
Waste water shall be discharged only on to sites or into conduits that are suitable. Discharges
shall not cause damage, create a nuisance or health hazard, or interfere with the work of others.
The Contractor shall obtain the consent of the Engineer and relevant authority before discharging
any water to a watercourse.
Water may be re-used in testing or cleaning other parts of the Works.
J4.7.3 Valves
All valves shall be tested on completion of installation. Each installation shall be checked for
water tightness. Valves shall be demonstrated to function satisfactorily under design maximum
differential head conditions.
The Contractor shall carry out a final test and inspection of valves and associated equipment
immediately before pressure testing the pipeline.
Where directed by the Engineer valves shall be internally inspected after testing to verify that the
seals remain in a satisfactory condition.
J4.7.4 Testing pipelines
J4.7.4.1 General
The Contractor shall submit for the approval of the Engineer details of his proposed methods and
programme for pipeline testing, swabbing, disinfection and cleaning (including details of test and
cleaning equipment).
All parts of pipeline systems shall be subjected to hydraulic pressure testing. Pipelines shall be
tested to the piezometric pressure (head) shown on the Drawings.
Testing shall be undertaken in sections as the work proceeds but the whole system shall be
subjected to a final test.
Pipelines at road crossings and in other locations as may be directed by the Engineer shall be
subjected to a hydrostatic pressure test immediately the section has been completed.

For the purposes of this final test, the pipeline system shall be divided into suitable sections as
agreed with the Engineer. The length of pipeline tested at one time shall not exceed 10 km
without the approval of the Engineer.
Testing shall not be carried out against closed valves, other than for testing of limited closure
sections to the working pressure indicated on the Drawings.
All testing shall be witnessed and approved by the Engineer.
J4.7.4.2 Test equipment

The Contractor shall supply water, pressure gauges, pressure recorders, meters, hoses, pumps,
stop ends and all other equipment necessary for carrying out tests.
Pressure gauges shall be minimum diameter 100 mm and shall have a full-scale reading of not
more than twice the maximum pressure being tested. The Contractor shall provide the Engineer
with a recent independent test certificate for each pressure gauge and pressure recorder.
J4.7.4.3 Anchors
The Contractor shall provide and install all necessary stop ends and temporary thrust restraints to
carry out the tests. Pressure tests shall not be made against closed valves.
The Contractor shall satisfy himself and the Engineer that all temporary and permanent structures
and thrust blocks are capable of withstanding the forces exerted from hydraulic tests with a
sufficient factor of safety. Calculations shall be submitted to the Engineer for approval.
Thrusts from hydraulic test pressures shall not be exerted on any permanent structure that is
located in saturated ground where the standing water level is above the lowest level of the
foundation without the approval of the Engineer.
The Contractor shall provide any additional support or kentledge to structures as necessary to
withstand the test pressures.
No loadings from testing shall be imposed on any structure without the approval of the Engineer.
Notwithstanding any approval given by the Engineer, the Contractor shall be fully responsible for
any consequences arising from the testing.
Where more than one pipe is laid in a common trench only one pipeline shall be pressurised at
any one time.
J4.7.4.4 Preparation for site pressure testing pipelines for water supply
Before filling pipelines for pressure testing, the Contractor shall re-check pipes and valves for
cleanliness and shall re-check the operation of all valves.
The ‘open’ ends of the pipeline (or sections thereof) shall be stopped off by blank flanges or cap
ends secured by temporary struts, wedges and thrust blocks.
All permanent thrust blocks and valve chambers shall have been completed and backfilled and
the concrete shall have attained its specified 28-day strength
All pipe straps and other devices intended to prevent the movement of pipes shall be securely
fastened.

J4.7.4.5 Procedure and standards for site pressure testing ductile iron water supply
pipelines
Testing of installed pipelines shall be carried out according to Clause 11.3 of EN 805:2000.
Joints including spigot and socket joints shall be left exposed for inspection during pressure
testing and trenches between pipe joints shall be backfilled to the extent necessary to prevent
movement of the pipeline.
The test section shall be filled with water and all air removed.
As a preliminary test the pipeline shall stand full of water for at least 24 hours at the working
pressure and all joints and restraints shall be inspected for leakage and movements.
The pressure shall then be raised by pumping in water until the specified test pressure is reached.
The pressure shall be maintained at the test pressure by further pumping for a period of not less
than 1 hour during which time the pipeline shall be again inspected for leakage or movement.
Pumping shall then cease and the time (T) for the pressure head to fall by 10 m shall be recorded.
If the pressure head has not fallen by 10m within three hours, then the fall in head at 3 hours shall
be recorded. Pumping from calibrated container(s) shall then be resumed to restore the pipeline
pressure to the test pressure. The quantity of water (Q) pumped into the pipeline shall be
recorded.
The rate of loss shall be calculated as being the quantity (Q) pumped into the pipeline divided by
the time (T).
The allowable rate of loss shall be less than 0.2 litres per 24 hours per mm of nominal internal
bore per kilometre of pipe for each 10 m head of pressure applied.
J4.7.4.6 Procedure and standards for site pressure testing HDPE pipelines
Joints including but welds shall as far as possible be left exposed for inspection during pressure
testing and trenches between pipe joints shall be backfilled to the extent necessary to prevent
movement of the pipeline.
The test section shall be filled with water and all air removed.
As a preliminary phase the pipeline shall stand full of water for at least 24 hours at the working
pressure and all joints and restraints shall be inspected for leakage and movements. The pipeline
shall then be de-pressurised to atmospheric pressure and allowed to stand for one hour, taking
care to avoid any air entry to the pipeline. After one hour quickly and continuously raise the
pressure to the system Test Pressure (STP) in less than 10 minutes. Maintain the pipeline at the
STP for thirty minutes by controlled continuous pumping, or by intermittent pumping. Inspect
the line for leakage during this period. After thirty minutes cease pumping and leave line under
pressure for one hour. Measure the pressure drop from the beginning to the end of this period. If
the pressure drop is less than 30% of the STP value the preliminary phase may be considered
acceptable and the main test may start. If the pressure drop exceeds 30% of the STP, de-
pressurise the line and rectify potential reasons for the drop.
If the preliminary phase was acceptable undertake an integrated pressure drop test to determine
that air content is acceptably low. Reduce rapidly the remaining pressure in the line to produce a
further pressure drop of 10 – 15% of STP by bleeding off water and measuring precisely the
volume withdrawn, ∆V. Calculate the allowable water loss, ∆Vmax from equation:
∆Vmax = 1.2 x V x ∆p x { 1/EW + D/(e x ER )}

Where:
∆Vmax = Allowable loss of water in litres;
V = Volume of test line in litres;
∆p = measured pressure drop in kilopoascals;
EW = bulk modulus of water in kilopascals
D = internal pipe diameter in metres
e = wall thickness of pipe in metres
ER = modulus of elasticity of pipe wall in the circumferential direction in kilopascals
Should ∆V exceed ∆Vmax then further removal of air from the line is necessary before the main
test.
During the 30 minutes immediately following completion of the integrated pressure drop test the
pressures should be monitored closely. If the pressure steadily rises during this period as a result
of pipe contraction following pressure reduction and at no time, falls the test is satisfactory.
In case of doubt from results over the 30 minute period the measurement should continue to a
total of 90 minutes. Should the pressure drop not exceed 25 kilopascals over this period then the
test may be considered satisfactory.
Any repetition of the Main test must be preceded by the test procedure including the full
preliminary phase.
J4.7.4.7 Action following test failures

If the pipeline (or a section thereof) fails to pass the pressure test the Contractor shall locate the
faults and shall uncover, repair, retest and reinstate the pipeline as may be necessary until all
parts of the pipeline shall have passed the pressure test.
J4.7.4.8 Working pressure and site test pressure

The working pressure and test pressures of the different sections of pipeline shall be as shown on
the Drawings or in the Specification. Conversion of piezometric elevation shall be at 10.19
metres is equivalent to 100 kilopascals.
J4.8 CLEANING OF PIPELINES
J4.8.1 Water pipelines

Before commencing pressure testing, the Contractor shall clean out the part of the pipeline to be
tested to the satisfaction of the Engineer.
Materials and equipment necessary for cleaning shall be provided by the Contractor.
After the whole pipeline has been successfully pressure tested (whether as a whole or in sections)
and the Contractor has reconnected any parts temporarily removed from the pipeline, the
Contractor shall finally clean out the whole pipeline and flush it through with clean water.
The Contractor shall be liable to the Employer for any damage caused to the pipeline or to pumps
and other equipment of the Employer as a result of foreign matter of any kind not having been
cleared out of the pipeline.

J4.8.2 Cleaning of cable ducts

Pipes laid as cable ducts shall be kept thoroughly clean and all pipe ends shall be kept stoppered
off with expanding rubber plugs.
Ducts shall be proved by pulling through a train consisting of an approved badger and a circular
rubber squeegee followed by a wooden ball.
The wooden ball shall not be smaller than 25 mm less in diameter than the pipe.
After cleaning ducts they shall be provided with draw cords.
J4.8.3 Swabbing of pipelines for water supply

Water pipelines shall be swabbed after pressure testing and before disinfection by passing a foam
swab through the pipeline.
The swab shall be non-abrasive and shall fit compressed into the pipeline. Swab stiffness shall be
selected to suit the pipe and lining material.
The swab shall be driven at a velocity of between 0.3 m/s and 1.0 m/s by the admission of treated
water.
Sufficient passes of the swab shall be made to produce clear water.
Swabs and debris from the pipe shall be disposed of to suitable locations by the Contractor.
Flushing water shall be disposed of as specified in Clause J4.7.2.
All materials and equipment, including temporary swab insertion and retrieval points and
temporary connections to the source of water shall be provided by the Contractor.
J4.8.4 Disinfection of Water Pipelines

Disinfection of pipelines shall be carried out in accordance with AWWA C65.
The Contractor shall provide all materials and equipment necessary for disinfection.
Liquid chlorine, calcium hypochlorite or sodium hypochlorite may be used for disinfecting.
Liquid chlorine shall be used only in conjunction with proper equipment and under the
supervision of qualified personnel who are familiar with the physiological, chemical and physical
properties of this material and who are properly trained and equipped to handle any emergency
that may arise.
Pipelines shall be disinfected by the continuous feed method. Water entering the pipeline shall be
maintained at a minimum of 20 mg/l available chlorine or such level as may be necessary to
ensure that at the end of 24 hours the treated disinfecting water shall contain not less than 2mg/l
of chlorine at all points in the pipeline being disinfected. The chlorine concentration shall be
measured at regular intervals in accordance with AWWA M12 to ensure that the required
concentration is maintained.
After the required retention period, the heavily-chlorinated water shall be flushed from the main
using potable water until the chlorine concentration in the water leaving the main is no higher
than that generally prevailing in the systems and not exceeding 0.1 mg/l. Chlorine-residual
determinations shall be made to ascertain that the heavily chlorinated water has been removed
from the main.
Dechlorination shall be carried out if necessary and as instructed by the Engineer in order to
achieve an acceptable low level of residual chlorine in the discharge.

After final flushing samples shall be collected from a sampling cock with a copper tube
gooseneck located at the end of the pipeline which is remote from the source of supply and tested
for bacteriological quality. The sampling cock shall remain in place upon completion of the test.
The samples shall show the absence of coliform organisms.
Samples shall be collected directly from the sampling cock in sterile bottles treated with sodium
thiosulphate. No hose or fire hydrant shall be used in the collection of the samples.
If the initial disinfection fails to produce satisfactory samples, disinfection shall be repeated until
satisfactory samples have been obtained.
J4.9 COMMISSIONING
Commissioning, putting into service and the full operation during the specified Contract period
and for the first three months of the Period of Maintenance of the Scheme will be undertaken by
the Contractor. The Contractor shall be fully responsible for all activities required to properly
commission the whole of the Works to transfer and treat water as specified.

SECTION J5 ENGINEERING METALWORK AND GRP
J5.1 SCOPE
This Section covers the supply and installation of engineering metalwork and GRP fabrications.

The following standards are referred to in this Section of the Specification:
BS 497: Part 1 Manholes covers, road gully gratings and frames for drainage purposes: cast iron
and steel.
BS 1247 Manhole steps.
BS 1470 Wrought aluminium and aluminium alloys - plate, sheet and strip.
BS 1471 Wrought aluminium and aluminium alloys - drawn tube.
BS 1474 Wrought aluminium and aluminium alloys - bars, extruded round tubes and
sections.
BS 2903 Higher tensile steel hooks for chains, slings, blocks and general engineering
purposes.
BS 4190 ISO metric black hexagon bolts, screws and nuts.
BS 4360 Weldable structural steels.
BS 4942: Part 2 Short link chain for lifting purposes: grade M(4) non-calibrated chain.
BS 5135 Arc welding of carbon and carbon manganese steels.
BS 5834: Part 2 Surface boxes, guards and underground chambers for gas and waterworks
purposes: small surface boxes.
BS 6180 Barriers in and about buildings.
BS EN 14122: Safety of machinery – Permanent means of access to machinery
Part 1 Choice of fixed means of access between two levels
Part 2 Working platforms and walkways
Part 3 Stairways, stepladders and guard-rails
Part 4 Fixed ladders
BS 4211 Permanently fixed ladders
BS 4592;Part 5 Industrial type metal flooring, walkways and stair treads-Specification for solid
plates in steel, aluminium and glass reinforced plastic
BS 5395 Stairs, ladders and walkways
Part 1 Code of practice for the design, construction and maintenance of straight stairs
and winders
Part 3 Code of Practice for the design of industrial type stirs, permanent ladders and
walkways

J5.3 SUBMISSIONS BY CONTRACTOR

The following submissions are required by this Section of the Specification.
Drawings:
− general arrangements;
− detailed manufacturing drawings.
Certificates:
− material tests.
Data:
− manufacturers’ catalogues (where alternatives are offered for approval);
− manufacturers’ catalogues and test data for proprietary fixing bolts.
J5.4 MATERIALS
J5.4.1 General
The Contractor shall supply and install the items of metalwork and GRP shown in the Drawings
or specified herein, together with all fixings, mounting brackets, locking screws, lifting keys and
other accessories normally required for erection, permanent fixing and operation.
No orders for engineering metalwork and GRP shall be placed by the Contractor until he has
submitted his detailed drawings, and where applicable supporting design calculations, to the
Engineer and received the Engineer’s consent.
Where the Contractor proposes to use dissimilar metals either in contact or close enough for the
gap between them to be bridged by an electrolyte, he shall satisfy the Engineer that adequate anti-
corrosion provision is included in the design.
J5.4.2 Steel items - general

Steel items for which there is no relevant standard shall be fabricated as shown in the Drawings
from steel which is in accordance with BS 4360, Grade 43A, by welding using procedures in
accordance with BS 5135.
Unless otherwise specified or detailed in the Drawings, all steel items shall be galvanised in
accordance with BS 729. Galvanised items shall not be painted except where so specified or
shown in the Drawings. No galvanised metal shall be painted until the Engineer has inspected the
coating.
J5.4.3 Aluminium items - general

Items of aluminium and aluminium alloy shall comply with the relevant provisions of BS 1470,
BS 1471 and BS 1474.
J5.4.4 Steel ladders

Unless otherwise specified or shown in the Drawings, steel ladders shall be generally in
accordance with BS 4211 for Class A ladders with solid steel stringers (stiles) but shall have the
following dimensions:
− minimum thickness of stringer: l2mm

− diameter of rungs: 20mm

− rung spacing: 250mm
− rung length between stringers: 400mm
− minimum clearance to wall or other obstruction: 220mm
− maximum distance between stringer supports: 2.0m
Wherever possible, stringers shall extend 1.0m above the level of the floor or platform at the top
of the ladder and the clear width between stringers shall be increased to 600mm for this length.
The stringers shall be sized to suit the height of ladder and the intervals of the stringer supports.
Stringers shall be drilled to receive the rungs which shall be welded to the stringers on each side
of each stringer. Unless otherwise detailed in the Drawings, the bottom ends of the stringers shall
not be designed for floor fixing, but shall terminate at wall fixing supports at least 150mm above
the floor. All edges of stringers, brackets, splice plates and other components shall be ground
smooth to remove burrs and sharp edges.
Ladders exceeding 3m high shall be provided with safety hoops at intervals not exceeding
900mm, with the lowest hoop 2.5m above the ladder foot unless otherwise specified or shown in
the Drawings. Unless provided otherwise, landings of open mesh flooring and handrails as
specified shall be provided at intervals not greater than 9m. When detailed in the Drawings,
anchorage points shall be provided for attaching safety harnesses instead of the above safety
hoops.
J5.4.5 Steel stairways

Stairways shall be designed for a loading of 5.0kN/m2 of plan area of the stairway. Steel
stairways shall be provided with tubular handrailing and stringers of cross section suitable for the
span and loading. Treads shall be of open-bar gratings, expanded metal grating panels or cold
formed planks as shown in the Drawings and in accordance with Part 1, 2 or 3 respectively of
BS 4592. Except where so shown in the Drawings, treads of pressed-bar construction shall not be
used.
The angle of rise of stairways shall be between 30° and 42°. The rise between treads shall be
uniform and between 155mm and 190mm. Stairways in the same area of the Works and in
similar locations shall have the same angle of rise and the same rise between treads.
The depth of the treads shall be between 250mm and 300mm. The width of the stairways shall be
as shown in the Drawings.
The stringers shall be mounted by means of angle brackets with slotted holes for adjustment of
line and level.
J5.4.6 Manhole steps

Except where otherwise specified or shown in the Drawings, manhole access shall be by GRP
ladder.
J5.4.7 Access covers, road gully gratings and frames

Except where otherwise detailed in the Drawings, access covers, road gully gratings and frames
shall be of ductile iron and shall comply with BS 497: Part 1. Lockable units shall be provided
for the locations specified or detailed in the Drawings.

Covers and frames detailed as sealed shall incorporate suitable neoprene or other approved
synthetic rubber sealing rings, or shall seal by another approved sealing method.
Access covers outside of enclosed sites shall be of a concrete infill pattern.
J5.4.8 Surface boxes

Surface boxes for key operation of valves and sluice gates shall be of grey or ductile iron and
shall comply with the relevant requirements of BS 5834: Part 2. Except where otherwise
specified or shown in the Drawings, they shall be Grade A and coated.
J5.4.9 Metal and GRP flooring and walkways

Metal and GRP flooring and walkways shall comply with BS EN 14122, supported by BS 5395
Parts 1 and 3 as appropriate. Subject to anything specified under Particular Requirements or
shown in the Drawings, metal flooring and walkways:
a) may be of GRP, steel or aluminium;
b) shall be heavy duty; and
c) may be of open-bar gratings, expanded metal grating panels or cold formed planks
but pressed-bar construction shall not be used in places exposed to the weather or in
situations where condensation is likely.
Except where otherwise specified, flooring panels shall be removable and the maximum weight
of each panel shall not exceed 25kg. Where lifting by two people is possible this weight may be
increased to 50kg. Removable sections of flooring shall be provided with holes for lifting keys,
and keys to suit.
Flooring shall be detailed and fabricated so that no cutting is required on site. Supporting
steelwork shall comply with the requirements of SECTION J10 of the Specification (Structural
steelwork). Bolt holes in brackets and mountings shall be slotted to allow for adjustment of line
and level. Cut-outs shall be trimmed with straight or curved bars as appropriate. Angle kerbing
for seating the flooring in concrete shall be provided as shown in the Drawings. Kerbing and
other supporting structures for building into concrete shall have lugs welded on at maximum
spacing of 600mm.
Except where otherwise specified or shown in the Drawings, the width of any access walkway
shall be not less than 750 mm.
All members of assemblies shall be marked at the factory with distinguishing numbers, letters or
marks corresponding to those shown on approved drawings or parts lists.
J5.4.10 Chequer plate

Except where otherwise specified or shown in the Drawings, chequer-plate flooring shall have a
raised pattern without enclosed recesses and shall have a minimum base thickness of 4.5 mm in
the case of steel plate or 8mm in the case of aluminium and GRP. Panels shall be secured to
supports with countersunk screws at maximum spacings of 0.5 m along supports.
J5.4.11 Handrailing
Handrailing shall comply with the relevant recommendations of BS 6180. Except where
otherwise specified or shown in the Drawings, handrailing shall consist of standards at regular
intervals not exceeding 1.5m, and two rails. The upper rail shall be 1.1m above the adjacent

finished floor level, and 0.9m above the nosing line on stairways. The lower rail shall be midway
between floor or nosing line and the upper rail. Rails shall be fabricated from 32mm-bore mild
steel tube and standards from 38mm diameter solid mild steel bar, or pultruded GRP sized to
provide same deflection limits..
Handrailing shall be ball-jointed. Handrailing terminating against a wall shall either have a
suitable wall-fixing flange or shall terminate at a standard or a loop with a gap between the
standard or loop and the wall not exceeding 75mm. Where the shape of the floor or platform
structure does not incorporate an upstand at the edge of walkways, toe plates not less than 5mm
thick and not less than 100mm high shall be fixed to the handrail standards. The bottom edge of
such toe plates shall be not more than 25mm above the surface of the walkway.
The handrail standards for stairways and for landings and walkways of width less than 1.2m shall
have palm fittings for bolting to the sides of the structures. Elsewhere the standards shall be
designed for fixing 100mm (minimum) inside the edge of concrete structures, or at the
supporting edge girder of flooring, or have palm fittings. Standards either side of openings shall
be equipped with eyes for attaching safety chains at top and middle rail level.
Safety chains shall be of mild steel of 10mm nominal size, short link, smooth welded chain in
accordance with BS 4942, Part 2. Each length of chain shall be fitted with a shackle at one end
and a snap fastening at the other.
J5.4.12 Servicing hooks

Servicing hooks shall comply with those provisions of BS 2903 which relate to the appropriate
Type. Each hook, together with any beams and other supporting members, shall be designed
(with an appropriate allowance for dynamic loading) to carry safely the heaviest item of plant
required to be lifted.
The safe working load shall be clearly and permanently displayed alongside each hook so as to be
legible from the normal working level.
J5.4.13 Fixings for metalwork

Bolts for fixing metalwork to concrete, brickwork or blockwork shall be of the following types:
a) For fixing in drilled holes in horizontal, vertical or inclined surfaces, approved
proprietary epoxy resin fixed bolts shall be used. The epoxy resin shall be a quick
setting formulation, supplied in suitable pre-measured sachets to separate the
components until punctured in the hole and mixed by rotation of the fixing bolt. The
resin and bolts shall be used in accordance with the manufacturers’ instructions.
When fixed, the resin shall completely fill the space between the bolt and the hole to
the surface of the concrete, brickwork or blockwork.
b) As an alternative to (a), approved mechanical expansion-type bolts may be used for
fixing to concrete surfaces inside buildings above ground level where the application
proposed by the Contractor is approved by the Engineer. Expansion bolts shall not be
used inside liquid-retaining structures, in chambers, basements and similar locations
below ground level, in exterior locations, nor in any brickwork or blockwork.
c) For fixing to horizontal top surfaces of concrete by grouting with cement-based grout
or mortar, foundation bolts may be used in pre-formed, drilled or cut pockets.
d) Where approved by the Engineer screws and approved fixing plugs.

The Contractor shall submit details of his proposed fixings for the approval of the Engineer.
Where required by the Engineer, the Contractor shall demonstrate the effectiveness of the fixings
by suitable tests.
Other bolts and nuts used in fabrication or erection shall be in accordance with BS 4190.
Bolts, nuts, screws, washers and other fixings shall be stainless galvanised, sherardised or
electro-plated steel. All fixings within water or within damp and splash areas shall be of AISI
316L stainless steel.
J5.4.14 Opening tools

Lifting keys and devices for unfastening locking screws shall be of galvanised mild steel. They
shall be supplied at the rate of one set for each five similar covers, with a minimum of two sets of
each particular type.
J5.4.15 Security doors

Security doors shall be tested by the Loss Prevention Certification Board (LPCB) and certified to
LPS 1175: Issue 4, Security Rating 4 with approved padlocks. They shall have solid chequer
plate fronts, be outward opening with a single piece folded deep flange for security and totally
hidden hinges. Doors shall be fitted with·3 point stainless steel shoot bolts locking with shrouded
hasp and staple to suit LPCB approved padlocks. Doors shall have internal override locking
handles. Doors shall have auto safety stays to maintain 90° opening. The frame shall be multi
point fixing universal frame to suit the adjacent wall construction. Where specified as stainless
steel these doors shall be fabricated from AISI 316L (UNS S 31603) with brushed satin finish.
J5.4.16 Security covers

Security vented access covers on tanks shall be sealed and fully vented, double skin, dry moated,
upstand cover and frame units, tested and certificated to Loss Prevention Certification Board
(LPCB) Security Level 4.
Each assembly shall be hot dip galvanised, after manufacture, to BS EN ISO 1461. The inner and
outer covers shall be hinged with auto safety stays and torsion spring assistance to permit safe
single person operation.
The inner cover shall be sealed with lever down locking and full ventilation to the inner frame.
Ventilation shall be provided by grade 316 stainless steel insect proof mesh panels (designed to
implode under extreme vacuum conditions) having a maximum opening size of 0.4mm and a free
air passage of not less than 46% of the gross area covered. For 900 x 600 mm. c/o access covers
the gross vent opening area of the mesh shall be not less than 0.145m². For 2000 x 900 mm. c/o
access covers the gross vent opening area of the mesh shall be not less than 0.254m². For 500 x
500 mm. c/o access covers the gross vent opening area of the mesh shall be not less than 0.25m².
The outer cover shall be domed for water shedding and have external lifting handle. The outer
cover shall have security enhanced features for locking by a LPCB approved security padlock
and an internal twin shoot-bolt locking system.
All holding down bolts shall be internal for maximum security. Brackets shall be provided within
the frame for the fitting of proximity and vibration alarm systems.
Hinged, ladder style fall protection to be fitted within all access covers greater than 450 x 450
mm clear opening size.

J5.5 WORKMANSHIP
J5.5.1 Tolerances
Metalwork and GRP equivaents shall be constructed and installed within the following
tolerances:
− for work at floor level (such as joints between flooring sections and between steel/GRP
flooring and adjacent concrete):
− difference in level at joints: 3mm
− joint gap: 3mm
− dimensions shown in the Drawings: 5mm
− levels shown in the Drawings: 5mm
J5.5.2 Installation
Where metalworkor GRP equivalent is to be founded on and/or fastened to concrete, the
Contractor shall use one of the following methods:
l. Bolting or screwing the work to plates or angle section having anchors cast into the
concrete structure or set into pockets left in the concrete structure.
2. Setting the metalwork into pockets left in the concrete structure.
3. Bolting the work to anchor bolts (studs) cast into the concrete structure or set into pockets
left in the concrete structure.
4. Bolting the work to anchor bolts (studs) as specified, in holes drilled into concrete
structure.
5. Bedding the work on cement mortar placed on the concrete surface.
Cement mortar of 3 parts of sand to l part of cement shall be used for bedding access covers and
the like and for filling around metalwork or bolts set into pockets smaller than 100mm square or
equivalent. For larger holes, concrete of the same grade as the structure shall be used instead of
mortar. The installation methods permitted for various types of metalwork are specified below.
Metalwork and GRP items Permissible methods of installation
Stairs, ladders and flooring 1, 3 and 4
Step irons, sockets for removable items 2
Handrailing 2, 3 and 4
Access covers, surface boxes and gully 2 and 5
gratings
During installation each item of metalwork shall be temporarily braced as necessary to resist all
forces which are likely to be applied to it during installation, fixing and building in. Any bolted
connections required as part of the installation operation shall be fitted and tightened before
fixing bolts are tightened or pockets are grouted. The nuts of grouted or resin-fixed bolts shall
not be tightened until the grout or resin has fully cured.
Where approved by the Engineer, small or lightly loaded items may be fixed using screws and
plugs set in drilled holes.

SECTION J6 ROADS, PARKING, FOOTPATHS AND DRAINAGE
J6.1 GENERAL
J6.1.1 Scope
This Section includes requirements for the construction of roads, drainage for roads, the
preparation of the sub-grade and the construction of sub-bases, bases and pavements for those
roads (including hardstandings) and footpaths which form part of the Permanent Works. All
clauses pertaining to roadworks shall also be applicable to parking areas.
J6.1.2 Use of site roads by Contractor

Site roads forming part of the Permanent Works shall as a minimum be designed for use by
operating traffic belonging to the Employer and shall be assumed to have been designed for any
more severe use by the Contractor at any stage during construction or after completion.
The Contractor shall take every precaution to prevent damage to roadworks including
strengthening them where necessary to ensure that they can carry the Contractor's traffic. As soon
as practicable after completion of the Works the Contractor shall carry out any remedial work
ordered by the Engineer to bring the roadworks up to the design requirements. All remedial work
shall be carried out by the Contractor without additional payment.
No vehicular traffic having an axle loading greater than 2 tonnes shall run on the finished surface
of a concrete pavement within a period of 14 days of its completion. No vehicle shall run on the
pavement until any temporary or permanent sealing is carried out. Rubber tyred vehicles having
an axle loading of less than 2 tonnes and proceeding at speeds not exceeding 15km/h will be
permitted after a period of 7 days from the completion of a concrete pavement. If the 7 day
strength is below that specified in the concrete specification, the above periods before traffic may
run on the pavement shall be increased at the discretion of the Engineer.
No traffic shall run over lean concrete or any other cement treated roadbase layer within 7 days
of construction.

Unless otherwise specified materials and workmanship shall comply with the relevant Standard
as listed below or stated within the specification clauses.
BS 1377-1:1990 Methods of test for soils for civil engineering purposes. General
requirements and sample preparation
BS 1377-2:1990 Methods of test for soils for civil engineering purposes.
Classification tests
BS 812-111:1990 Testing aggregates. Methods for determination of ten per cent fines
value (TFV)
BS EN 1097-2:1998 Tests for mechanical and physical properties of aggregates. Methods
for the determination of resistance to fragmentation
BS 410-1:2000, ISO Test sieves. Technical requirements and testing. Test sieves of metal
3310-1:2000 wire cloth

BS 410-2:2000, ISO Test sieves. Technical requirements and testing. Test sieves of
3310-2:1999 perforated metal plate
BS 812-105.2:1990 Testing aggregates. Methods for determination of particle shape.
Elongation index of coarse aggregate
BS 5835-1:1980 Recommendations for testing of aggregates. Compactibility test for
graded aggregates
BS 8500-1:2002 Concrete. Complementary British Standard to BS EN 206-1. Method
of specifying and guidance for the specifier
BS EN 12620:2002 Aggregates for concrete
BS 4987-1:2003 Coated macadam (asphalt concrete) for roads and other paved areas.
Specification for constituent materials and for mixtures
BS 4987-2:2003 Coated macadam (asphalt concrete) for roads and other paved areas.
Specification for transport, laying and compaction
BS 434-1:1984 Bitumen road emulsions (anionic and cationic). Specification for
bitumen road emulsions
BS 434-2:1984 Bitumen road emulsions (anionic and cationic). Code of practice for
use of bitumen road emulsions
BS 594-1:2003 Hot rolled asphalt for roads and other paved areas. Specification for
constituent materials and asphalt mixtures
BS 594-2:2003 Hot rolled asphalt for roads and other paved areas. Specification for
transport, laying and compaction of hot rolled asphalt
BS EN ISO 591- Titanium dioxide pigments for paints. Specifications and methods of
1:2000 test
BS 4660:2000 Thermoplastics ancillary fittings of nominal sizes 110 and 160 for
below ground gravity drainage and sewerage
BS EN 13598- Plastics piping systems for non-pressure underground drainage and
1:2003 sewerage. Unplasticized poly vinyl chloride (PVC-U), polypropylene
(PP) and polyethylene (PE). Specifications for ancillary fittings
including shallow inspection chambers
BS 5481:1977 Specification for unplasticized PVC pipe and fittings for gravity
sewers
BS EN 1401-1:1998 Plastics piping systems for non-pressure underground drainage and
sewerage. Unplasticized poly vinyl chloride (PVC-U). Specifications
for pipes, fittings and the system
BS 4962:1989 Specification for plastics pipes and fittings for use as subsoil field
drains
for unreinforced and reinforced concrete manholes and soakaways
(complementary to BS EN 1917:2002)


for road gullies and gully cover slabs
BS EN 1917:2002 Concrete manholes and inspection chambers, unreinforced, steel
fibre and reinforced
BS EN 124:1994 Gully tops and manhole tops for vehicular and pedestrian areas.
Design requirements, type testing, marking, quality control
BS 7263-1:2001 Precast concrete flags, kerbs, channels, edgings and quadrants.
BS 7263-3:2001 Precast, unreinforced concrete paving flags and complementary
fittings. Requirements and test methods
BS 6717:2001 Precast, unreinforced concrete paving blocks. Requirements and test
methods
BS 7533-4:1998 Pavements constructed with clay, natural stone or concrete pavers.
Code of practice for the construction of pavements of precast
concrete flags or natural stone slabs
BS 598 (Various) Sampling and examination of bituminous mixtures for roads and
other paved areas.
BS 1377-4:1990 Methods of test for soils for civil engineering purposes. Compaction-
related tests
BS 2782-11:Method Methods of testing plastics. Thermoplastics pipes, fittings and
1121B:1997, ISO valves. Thermoplastics pipes for the conveyance of fluids. Nominal
161-1:1996 outside diameters and nominal pressures. Metric series
BS ISO 11922- Thermoplastics pipes for the conveyance of fluids. Dimensions and
1:1997 tolerances. Metric series
BS ISO 4065:1996 Thermoplastics pipes. Universal wall thickness table
The roadworks shall comply with all relevant statutory regulations and standards current at date
of Tender, unless otherwise indicated within this Specification. The Ministry specifications for
road and bridge construction shall be taken as the main reference for all roadworks. All other
relevant standards shall be supplementary and complimentary to the Ministry specifications.
Where a standard contradicts the Ministry specification the Ministry specifications shall take
precedence. Where no standard is specified the relevant British Standard or, in the absence of
such standard, the international standard shall apply.

Requirements for submissions by the Contractor in relation to roadworks are described in the
relevant clauses of the Specification. For convenience, they are summarised hereunder.
J6.3.1.1 Design calculations/drawings for:

• Roadworks and footpaths
• Roads
J6.3.1.2 Proposals/samples for:

• Sub-base material

• Road base material

• Bituminous emulsions
• Coated macadam
• Flexible surfacing
• Road marking paint
• Precast concrete paving blocks
• UPVC pipes and ducts
• ABS pipes and ducts
• Precast concrete pipes
• Precast concrete channels kerbs and edgings
• Precast concrete flags
J6.3.1.3 Certificates
• Suppliers' certificates of compliance with specified requirements for the above.
J6.4 MATERIALS
J6.4.1 Materials for roadworks generally

Unless the Specification or Drawings expressly state otherwise, materials for use in connection
with roadworks shall comply with the following requirements.
J6.4.2 Capping material

Material to be used as capping shall be any material, or combination of materials, meeting the
following requirements:
Grading (Clause 9.2 of BS 1377-2) Percentage by mass passing
Sieve size BS 410 (mm)
125 100
90 80-100
75 65-100
37.5 45-100
10 15-60
5 10-45
0.600 0-25
0.063 0-12
Lower Limit Moisture Content to Clause 3.2 of BS 1377-2 shall be Optimum MC minus 2%.
Upper Limit Moisture Content to Clause 3.2 of BS 1377-2 shall be Optimum MC.
10% fines value to BS 812-111 or BS EN 1007-2 shall be 30 kN minimum.

J6.4.3 Sub-base
Material to be used as sub-base shall be Type 1 as specified and shall meet the following
requirements. Type 2 shall not be used for construction of carriageways.
Sub-base Type 1 shall be crushed rock or crushed concrete.
Sub-base Type 2 shall be natural sand or gravel, crushed rock or crushed concrete.
Grading (Clause 9.2 of BS 1377-2) Percentage by mass passing
Sieve size BS 410 (mm) Sub-base Type 1 Sub-base Type 2
75 100 100
37.5 85-100 85-100
10 40-70 45-100
5 22-45 25-85
0.600 8-22 8-45
0.075 0-10 010
10% fines value BS 812-111 50kN minimum 50kN minimum
Plasticity index (material passing 0.425mm Non-plastic 6 maximum
sieve) Clause 5 of BS 1377-2
California bearing ratio(material passing Test not required 30% minimum
20mm sieve) Clause 7 of BS 1377-4
The Contractor shall provide copies of current test certificates for each of the foregoing tests.
J6.4.4 Wet mix macadam roadbase

Wet mix macadam shall consist of crushed rock or gravel complying with BS EN 12620 graded
in accordance with the following table when tested in accordance with Clause 9.2 of BS 1377-2.
Grading Sieve size (mm) to BS 410 Percentage by mass passing
50 100
37.5 95-100
20 60-80
10 40-60
5 25-40
2.36 15-30
0.600 8-22
0.075 0-8
The minimum 10% fines value shall be 50kN when determined in accordance with BS 812-111
or BS EN 1097-2.
The flakiness index shall be less than 35 when determined in accordance with BS 812-105,
Section 105.1.
The moisture content of the wet mix macadam shall be the optimum ±0.5% as determined in
compliance with BS 5835-1.

J6.4.5 Lean concrete roadbase

Concrete shall be GEN1 to BS 8500.
The aggregate shall consist of either coarse and fine aggregate batched separately or an all-in
aggregate, having a maximum nominal size not exceeding 40mm and not less than 20mm.
The overall aggregate grading shall be within the following limits when determined in
accordance with Clause 9.2 of BS 1377-2:
Percentage by mass passing
Grading Sieve size (mm) to BS 410 Nominal Maximum Size
40mm 20mm
75 100 -
37.5 95-100 100
20 45-80 80-100
5 30-40 35-45
0.600 8-30 10-35
0.150 0-5 0-6
J6.4.6 Dense bitumen macadam roadbase

Dense bitumen macadam roadbase shall comply with the requirements of BS 4987-1 and shall be
as specified under the Particular Requirements section of this Specification.
Unless otherwise agreed by the Engineer the material shall be suitable for laying by machine.
The Contractor shall submit for the Engineer's approval details of the source of supply for the
coated macadam.
J6.4.7 Bituminous emulsion

Bituminous road emulsions for sealing and preparing the various layers of the road pavement
between steps in construction shall comply with the relevant clause of BS 434-1.
The types of emulsion to be used shall be as follows:
Use Emulsion type
Sealing and surface dressing of formation, sub-base and K1-60, K1-70
road base
Tack coating K1-40
J6.4.8 Flexible surfacing

Unless otherwise specified or shown on the Drawings, flexible surfacing for roads shall consist
of a coated dense bitumen macadam base course and a hot rolled asphalt wearing course, which
shall comply with the requirements of BS 4987-1, and BS 594 respectively.
Unless otherwise agreed by the Engineer both types of material shall be suitable for laying by
machine.
When hot rolled asphalt is specified for the wearing course, then it shall comply with the relevant
sections of BS 594-1.
The Contractor shall submit for the Engineer's approval details of the source of supply for the
bituminous macadam or H.R.A.

Flexible surfacing for footpaths shall comply with the requirements of BS 4987-1, and shall be as
specified under the Particular Requirements section of this Specification.
J6.4.9 Road marking paint

Road marking paint shall be either one-pack epoxy, or alkyd based, and shall be supplied by an
approved manufacturer. It shall be suitable for applying by brush or mechanical means to
concrete or bituminous pavement and to concrete block paving so as to give a chemically stable
film of uniform thickness.
White paint shall contain not less than 6% by mass of titanium dioxide as a pigment, conforming
to type A (anatase) or type R (rutile) specified in BS EN ISO 591-1. Yellow paint shall be
standard colour BS 381C No 355, and shall contain not less than 6% by mass of a suitable yellow
pigment.
The paint shall be supplied fresh and ready for use in sealed containers.
J6.4.10 Pipes for drainage

Pipes and fittings for site and road drainage shall be of ABS or uPVC and shall comply with the
requirements of BS 4660, BS EN 13598-1, BS 5481 and BS EN 1401-1 and shall be suitable for
heavy duty
Pipes for collecting groundwater shall be perforated ABS or uPVC pipes manufactured to
BS 4962 as specified, or perforated uPVC pipes to BS 4660, BS EN 13598-1, BS 5481 and BS
EN 1401-1.
J6.4.11 Pipes for service ducts

Pipes for service ducts shall be as Clause J6.4.10.
J6.4.12 Manholes and street gullies

Pre-cast concrete chamber rings for SW manholes and inspection chambers and street gullies
shall comply with the requirements of BS 5911-3 and BS EN 1917. Cast iron covers and gully
gratings and frames shall comply with BS EN 124 and be heavy duty.
J6.4.13 Kerbs, channels, edgings and flags

Precast concrete kerbs, channels and edgings shall comply with BS 7263-1 and wherever
possible be hydraulically pressed.
Precast concrete flags shall be 50mm thick and shall comply with BS 7263-1.
J6.4.14 Concrete and reinforcement for roadworks

Concrete and reinforcement shall comply with the relevant requirements of the Specification.
J6.4.15 Precast concrete block pavements

Concrete paving blocks, laying-course material and joint-filling sand shall comply with the
relevant provisions of BS 6717. Unless otherwise specified, blocks shall have a nominal
thickness of not less than 80mm and be of interlocking design. Except where otherwise specified,
permanent road markings, parking or other areas shall be indicated by the use of paving blocks of
different colours.

J6.5 WORKMANSHIP
J6.5.1 Earthworks
Excavations and embankments for roads shall be carried out to the lines and levels shown on the
Drawings or as directed by the Engineer and in accordance with the relevant provisions of the
Specification for Earthworks.
J6.5.2 Drainage and service ducts

Surface water drainage for roads shall be piped only beneath roads. Where practicable, drainage
work under the roadway shall be completed before roadworks are commenced.
Open ditches shall be excavated to trapezoidal cross-section with the sides dressed fair
throughout and the bottoms accurately graded to regular falls. Sides and bottoms shall be lined
with stone pitching or concrete slabs.
French drains shall be filled with free-draining granular material and, shall incorporate porous or
perforated pipes.
Trenches for piped drainage shall be excavated to the minimum dimensions necessary for the
proper construction of the Works, and after pipes have been laid, tested and, where specified,
surrounded with gravel or concrete, the trenches shall be back-filled with selected excavated
material and compacted to a dry density equal to that of the adjacent ground. Surplus excavated
material shall be disposed of to the Contractor's tip.
Pipes shall be laid to line and level with a permitted tolerance of 20mm and, if not incorporating
flexible mechanical joints, shall be jointed by a ring of tarred rope yarn driven into one quarter of
the depth of the socket with 2:1 sand-cement mortar filled into the remainder of the socket and
formed into a fillet round the face of the socket. Where directed by the Engineer pipes shall be
haunched or surrounded with concrete.
The pipe strength and surround for crossings under roads shall be designed to take account of
maximum vehicle loading. The Contractor shall at no extra cost to the Employer take all
necessary precautions to avoid damage occurring to the pipes as a result of construction traffic.
Should any damage occur to the pipes as a result of construction traffic, the Contractor shall at no
extra cost to the Employer replace the damaged pipes to the satisfaction of the Engineer.
Porous or perforated pipes shall be laid dry-jointed and shall be surrounded with gravel.
Where the Contractor is required to lay ducts for Statutory Undertakers draw ropes shall be laid
inside the duct and the Contractor shall adequately record or mark the position of the ducts as
instructed by the Engineer.
Precast concrete manholes and gullies shall be constructed complete with cast iron covers or
gully gratings. No cover or grating shall be set at such a level relative to final pavement level
that, in the opinion of the Engineer, it constitutes a danger to pedestrians or traffic.
J6.5.3 Concrete - general

Where concrete, reinforcement and formwork are to be used in the Works, such use shall
conform to the relevant requirements of the relevant Specifications

J6.5.4 Subgrade, capping and formation

`Subgrade' means the upper part of the soil, natural or constructed, which supports the overlying
road structure (the `pavement').
`Capping' means a layer of granular or treated material at the top of (and forming part of) the
subgrade to provide an improved foundation for the pavement.
`Formation' means the surface of the subgrade (i.e. the interface between subgrade and
pavement).
Where capping is provided, the storage, laying and compaction of capping material shall comply
with the specified requirements.
The formation and subgrade shall be graded and compacted to the levels, falls, cambers and
densities specified. Unless otherwise specified or shown, the formation and subgrade shall be
prepared to a width 1 m greater than the width of the finished pavement between kerb faces.
The subgrade shall be so compacted that the dry density of the upper 150mm of the ground or fill
is nowhere less than 95% of the maximum dry density determined in accordance with Clauses
3.3 and 3.4 of BS 1377-4. Where the subgrade is in natural ground, the compaction shall
whenever possible be carried out at or near the natural moisture content of the ground.
Any irregularities or depressions that develop in the formation during compaction of the
subgrade shall be corrected by loosening the surface of these places and adding, removing or
replacing material and re-compacting so that the surface is smooth and uniform.
Any area of subgrade that becomes muddy, broken-up or loosened due to weather conditions or
is otherwise damaged shall be corrected or prepared again by the Contractor as specified above.
After compaction and before any further construction, the subgrade shall be proof-rolled with a
smooth wheeled roller having a weight not less than 8 tonnes and an effective load of not less
than 50kN per metre of its effective rolling width. If in the opinion of the Engineer any part of
the subgrade surface `moves' during proof-rolling it shall be corrected as specified above and
proof-rolled again. This procedure shall continue until the Engineer is satisfied that there is no
movement on the surface under proof-rolling. Where directed by the Engineer, areas corrected as
specified above shall be retested for density.
Where existing ground conditions are such that direct compaction of the subgrade cannot be
carried out as specified, unsuitable material shall be removed and replaced with granular sub-
base or capping material as instructed.
The formation shall be kept free of standing water at all times and drains shall be provided so
that it will drain quickly and effectively during rain.
After completion of compaction and before commencement of the next operation, the surface of
the subgrade shall comply with the surface tolerances specified.
J6.5.5 Storing material for sub-base and wet mix roadbase

Materials of different grading etc shall, where storage is necessary be stored separately so as to
ensure preservation of their specified quality and fitness for the work. Special care shall be taken
to prevent segregation of the different particle sizes, contamination from soil surrounding the
storage area, and maintenance of correct grading and moisture content. The centres of the storage
areas shall be elevated slightly in relation to the edges so as to provide proper drainage of any
excess moisture. The equipment and methods used for stockpiling the materials and for removing

them from the stockpiles shall be such that no detrimental degradation of the particles will result
and no appreciable amount of foreign material will be incorporated into the materials.
J6.5.6 Laying sub-base

Material for the sub-base shall be laid and compacted at such moisture contents as may be
approved by the Engineer to ensure the specified compaction.
Material for the sub-base shall be laid to the specified thickness in one or more layers within 48
hours of the completion of the road formation and shall be compacted in accordance with the
table at the end of this clause.
Sub-base materials shall be deposited in such a manner that there is no segregation and the
material requires the minimum of blading or spreading.
Each layer of material shall be compacted immediately after spreading.
If any of the subgrade material is worked into the sub-base material during the spreading, blading
or compaction, all the sub-base material in the affected area shall be removed and replaced with
fresh sub-base material.
On completion of compaction, and before commencing the next operation, the specified level of
the sub-base shall comply with the tolerances specified.
Compaction Requirements for Granular Materials
Type of Number of passes for layers not
compaction Category greater than
plant 110mm 150mm 225mm
Smooth-wheeled Mass per metre width of roll:
roller over 2700 kg up to 5400 kg 16 unsuitable unsuitable
over 5400 kg 8 16 unsuitable
Pneumatic-tyred Mass per wheel:
roller over 4000 kg up to 6000 kg 12 unsuitable unsuitable
over 6000 kg up to 8000 kg 12 unsuitable unsuitable
over 8000 kg up to 12000 kg 10 16 unsuitable
over 12000 kg 8 12 unsuitable
Vibrating roller Mass per metre width of vibrating roll:
over 700 kg up to 1300 kg 16 unsuitable unsuitable
over 1800 kg up to 2300 kg 4 6 10
over 2300 kg up to 2900 kg 3 5 9
over 2900 kg up to 3600 kg 3 5 8
over 3600 kg up to 4300 kg 2 4 7
over 4300 kg up to 5000 kg 2 4 6
over 5000 kg 2 3 5
Vibrating plate Mass per unit area of base plate:
compactor over 1400 kg/m2 up to 1800 kg/m2 8 unsuitable unsuitable
over 1800 kg/m2 up to 2100 kg/m2 5 8 unsuitable
over 2100 kg/m2 3 6 10
Vibro-tamper Mass:
over 65 kg up to 75 kg 3 6 10
over 75 kg 2 4 8

Type of Number of passes for layers not

compaction Category greater than
plant 110mm 150mm 225mm
Power rammer Mass:
100 kg - 500 kg 5 8 unsuitable
over 500 kg 5 8 12
J6.5.7 Laying of wet mix macadam roadbase

Wet mix macadam shall be spread evenly on the sub-base and compacted in not more than
200mm thickness at the optimum moisture content ±0.5%.
Spreading shall be undertaken concurrently with placing. Compaction shall be completed as soon
as possible after the material has been spread and carried out in accordance with the compaction
requirements for granular materials.
On completion of compaction, and before commencing the next operation, the specified level
and smoothness of the roadbase shall comply with the tolerances specified.
J6.5.8 Laying of lean concrete roadbase

Lean concrete roadbase shall be spread evenly on the sub-base and laid and compacted in layers
not exceeding 200mm thickness.
Spreading shall be undertaken concurrently with placing. Compaction shall be completed as soon
as possible after the material has been spread and compacted in accordance with the compaction
requirements for granular materials. The maximum period of time between mixing of the
materials and final compacting of any given material shall be 2 hours.
Where practicable joints against hardened material shall be avoided. Where such joints are
unavoidable, the hardened material shall be cut back vertically for the full depth of the layer
before placing any further adjacent material.
Lean concrete shall be cured for a period of not less than 7 days. No vehicular traffic shall be
allowed to run on the base during this time.
J6.5.9 Laying of dense bitumen macadam roadbase

Dense bitumen macadam roadbase shall be laid in continuous strips of as large a length as
possible by a self propelled spreader capable of imparting an initial compaction, and finally
compacted with a smooth wheeled roller. The work, including roller sizes, shall be carried out in
accordance with the recommendations of BS 4987-2, except that the minimum temperature
referred to shall be 2°C.
J6.5.10 Sealing of surfaces

Wherever possible the operations of final trimming of the formation, compaction of the
subgrade, and placing and compaction of the sub-base and roadbase, shall be carried out without
intervening delays.

The Contractor shall be responsible for taking all necessary steps to prevent damage to the
previously completed layer or layers by excessive wetting or drying due to weather conditions or
by traffic or any other cause. If the Contractor considers it advisable or if so ordered by the
Engineer the completed layers shall be sealed using bitumen road emulsions as specified
following the procedure set out in Section 8 of BS 434-2.
If instructed by the Engineer, the completed surface of the roadbase shall be sealed as specified
above immediately it has been completed and checked for compliance with the specified
tolerances.
The Contractor shall ensure that the bituminous emulsion does not come into contact with any
material other than that which is to be sealed.
J6.5.11 Laying flexible base course and wearing course

The surface on which each course is to be laid shall be free from standing water and any loose or
deleterious material and shall be tested for accuracy of formation and smoothness.
Before laying of dense bitumen macadam base course or H.R.A. wearing course commences in
any area, a tack coat of bitumen road emulsion shall be applied to the whole area of the preceding
course, and also to kerbs and other concrete surfaces, manhole covers and gully grating frames,
and any other surfaces with which the coated macadam will be in contact, including the edges of
previously laid strips of coated macadam. The tack coat shall be applied in accordance with
Section 14 of BS 434-2. The emulsion shall be allowed to break completely before the
basecourse or wearing course is laid on it.
The Contractor shall ensure that the bituminous emulsion does not come in to contact with any
material other than that which is to be treated.
The base course and wearing course shall be laid in continuous strips of as large a length as
possible by a self-propelled spreader capable of imparting an initial compaction, and shall be
finally compacted with a smooth wheel roller. The work, including roller sizes shall be carried
out in accordance with the recommendations of BS 4987-2, except that the minimum
temperature referred to shall be 2°C for D.B.M mixes.
The specified level and smoothness of individual layers shall comply with the tolerances
specified.
The transportation, laying and compaction of hot rolled asphalt (HRA) wearing course shall be
carried out in accordance with the relevant Sections of BS 594-2. However, for high stone
content HRA the minimum temperature shall be 2°C and for HRA designed to have rolled-in
chippings the minimum shall be 5°C.
J6.5.12 Concrete pavement

Concrete paved areas shall be constructed as shown on the Drawings and in accordance with the
relevant requirements of the Specifications covering concrete, concrete jointing and protection,
formwork and reinforcement for concrete.
Placing, compacting and finishing of concrete in carriageways shall be carried out in one layer as
rapidly as possible. The work shall be so programmed such that the concrete being poured for
any one complete bay shall be poured, compacted and finished, within a period of time which
from batching to finishing does not exceed two hours.
The concrete shall be compacted using a vibratory beam in addition to any other compactive
devices. The beam shall provide a compactive effort of not less than 0.25kW per metre length.

Once compaction of the concrete is completed the surface shall be regulated by at least 2 passes
of a scraping straight edge with blade length greater than the bay width. If owing to irregularities,
the surface is torn significantly by the straight edge a further pass of the vibratory beam shall be
made and the scraping process shall be repeated.
After the final scraping with the straight edge the surfaces of concrete roads, hardstandings and
the like shall be brushed in a direction at right angles to the normal direction of travel with a wire
broom. The broom shall contain 2 rows of tufts spaced 20mm apart with tufts in each row 10mm
apart. The broom shall be at least 500mm wide and shall produce grooves at least 2mm deep.
Where the texture depth obtained by brushing is unsatisfactory the Engineer may require
mechanical grooving of the surface.
Surface levels and smoothness shall be in accordance with the specified tolerances.
Where the road channel is a drainage channel then the channel shall be steel trowel finished to
form a 250mm wide smooth drainage channel.
J6.5.13 Surface levels: tolerances

The surface at each stage during the construction of the roads shall comply with the requirements
set out below.
`Specified level' shall be the level shown on the Drawings, or deduced by reference to the
finished road levels and minimum layer thicknesses.
`Smoothness' shall be measured as the maximum gap beneath a 3.0m long straight-edge used
longitudinally or beneath a template, to suit the specified camber shape of the road, used
transversely.
Tolerances shall comply with the following table.
Surface - Upper surface of: Tolerance from Specified Smoothness (mm)

Level (mm)
Material immediately below +0 to -50
capping layers
Subgrade (formation) +0 to -50
Sub-base +0 to -50
Road base +5 to -25 25
Base course +5 to -10 10
Wearing course +5 to - 5 5
Immediately before the construction of any layer, the surface on which it is to be laid shall be
tested for accuracy of formation and smoothness, and if any areas are found to be outside the
specified tolerances such areas shall be scarified, reshaped, recompacted, broken out and
replaced, or otherwise treated until the specified smoothness and accuracy are obtained.
Notwithstanding the above requirements, no layer of road construction shall have a thickness less
than the thickness specified and the surface of the wearing course shall have no backfall from any
drainage point.
J6.5.14 Kerb laying

Precast concrete kerbs shall be laid to BS 7533-4, true to line and level and any kerb found to be
more than 3mm out of level or 10mm out of line at either end shall be lifted and relaid.

Kerbs shall be bedded on a layer of 2:1 sand-cement mortar 13mm thick laid on a concrete
foundation and shall be backed with concrete shaped up to the required cross-section, all as
detailed on the Drawings. Specially cast radius kerbs shall be used on curves of 12m radius or
less.
Kerb off-shoots (other than kerb weirs for catch pits) shall be of pre-cast concrete, positioned as
Kerbs shall be jointed with cement mortar except at expansion joints which shall be made with
preformed joint filler 13mm thick. Expansion joints shall be carried through the concrete backing
and foundation.
J6.5.15 Footpaths
The formation and subgrade for footpaths shall be prepared as specified for roads, except that
proof-rolling will not be required.
Edging to footpaths shall be bedded in a concrete foundation.
The sub-base, basecourse and wearing course shall be constructed as shown on the drawings.
Compaction shall be carried out in accordance with the requirements for granular materials.
Where a flexible final surface is specified, the base course shall be sealed with a coat of cold
bituminous emulsion sprayed on at the rate of 1.8l/m2 and shall be covered by a wearing course.
Where concrete flags are specified as the final surface, they shall be bedded on 1:10 cement/sand
mortar 30mm thick, laid on to sub-base. Joints shall be made with 1:3 cement/sand dry mix or
mortar.
J6.5.16 Parking area

Parking areas shall be constructed as specified for roadworks and shall include but not limited to
surface drainage, oil separation, kerbing etc.
J6.5.17 Concrete block pavements

The subgrade, sub-base or roadbase, and laying course required shall be prepared and constructed
Unless otherwise specified or approved by the Engineer, blocks shall be laid in herringbone
pattern.
J6.5.18 Road markings

Markings shall be provided for roads and parking areas as directed by the Engineer and shall
comply with the Ministry of Transport and Communications requirements.
Before the roadmarkings are applied, the road surface shall be thoroughly cleaned and dried to
remove all dust and other deleterious matter. Except where otherwise specified, all lines shall be
100mm wide. All lines shall be premarked with dots at approximately 3m centres on straight
lines and 1m centres on curves. Lines on curves shall not be formed by a series of straight
sections around the curve. The alignment shall not deviate more than 20mm in 25m. The width
of the lines shall not be varied more than plus or minus 6mm from the specified width.
The road markings shall be applied in accordance with the manufacturer's instructions. Lines and
other road markings shall be applied uniformly and shall have sharply defined edges without runs
or spatters.

Road markings shall comply with the Ministry specifications.
J6.5.19 Tying in to existing surfaces

Where it is necessary to tie in to existing paved surfaces, this shall be done so as to minimise
irregularities in level.
If it should be necessary to adjust or reshape existing carriageway surfaces to conform to new
cambers or crossfalls, this shall be done by grinding and planing, using a cold planing machine of
suitable design incorporating efficient dust control and noise suppression equipment.
Immediately after the passage of the planing machine surplus materials shall be disposed of to
the Contractor's tip.
On completion of planing and before any resurfacing is carried out the planed surface shall have
a clean and regular appearance with all loose or damaged materials removed to the satisfaction of
the Engineer.
J6.5.20 Topsoiling, grassing, landscaping and irrigation

Should the Contractor damage any grassed, landscaped or irrigated area outside the limit of the
Works then these shall be made good to the satisfaction of the Engineer at no extra cost to the
Employer.
Topsoiling, grassing, landscaping and irrigation shall be carried out in accordance with the
Specification for Earthworks.
J6.5.21 Inspection and testing

The Contractor shall carry out tests at such intervals as the Engineer may direct to demonstrate
that the materials for the capping, sub-base, road base, block laying course and joint filling sand
comply with the Specification and that the specified density for subgrade is being achieved.
The Contractor shall give the Engineer adequate notice of the time that proof-rolling of the
subgrade is to be carried out and such rolling shall be carried out in the presence of the Engineer.
The Contractor shall inspect and test each area of each layer for compliance with surface level
accuracy.
Coated macadam materials shall be tested by the supplier for compliance with BS 4987-1 and
BS 598 and test certificates shall be submitted to the Engineer. In addition, where directed by the
Engineer, the Contractor shall take samples from material delivered to the Site, and shall arrange
for the samples to be tested, and for test certificates to be provided, by a laboratory approved by
the Engineer.
uPVC pipes, fittings, joints and ducts shall be tested by the supplier for compliance with BS
4660, BS EN 13598-1, BS 5481 and BS EN 1401-1 and test certificates shall be submitted to the
Engineer.
Precast concrete pipes and fittings, inspection chambers and street gullies shall be tested by the
supplier for compliance with the relevant part of BS 5911 and test certificates shall be submitted
to the Engineer.
Sealed joint drains shall be tested in sections immediately prior to backfilling of trenches. Drains
not exceeding 750mm in diameter shall be tested by filling with water under a head of not less
than 1.2m above the crown of the pipe at the high end and not more than 11.0m head at the lower
point of the section. The test shall commence one hour after filling the test section at which time

the level of water at the vertical feed pipe shall be made up to produce the required 1.2m
minimum test head. The loss of water over a 30 minute period shall be measured by adding water
at regular 10 minute intervals to maintain the original water level and recording the amounts so
added. The drain will have passed the test if the volume of water added does not exceed 1l/hr per
30m of drain per 25mm of nominal internal diameter. Drains exceeding 750mm in diameter shall
be tested by means of an air test. The air pressure shall give 100mm head of water on a
manometer tube, and the loss shall not exceed 25mm over a period of five minutes. The drain
shall be tested in convenient lengths and all necessary tester junctions, expanding rubber plugs,
testing equipment etc. shall be provided by the Contractor. Drains failing to pass the test
(whether water or air) shall be retested after all defects have been made good.
Soakaways, where provided, shall be tested by subjecting them to an overflow equivalent in
volume to the design rainfall intensity on the area draining to the soakaway. If the soakaway
backs up under these conditions, it shall have failed the test. In this case the soakaway shall be
retested after all necessary remedial work has been carried out.
The manufacturer of precast concrete paving blocks shall carry out the tests specified in BS
6717-1 and test certificates shall be submitted to the Engineer.
Precast concrete kerbs and edgings shall be tested by the supplier for compliance with BS 7263
and test certificates shall be submitted to the Engineer before the materials are incorporated into
the Works.
Precast concrete flags shall be tested by the supplier for compliance with BS 7263 and test
certificates shall be submitted to the Engineer before the materials are incorporated into the
Works.
In-situ concrete shall be tested in accordance with the Specification for Concrete

SECTION J7 BUILDINGS
J7.1 SCOPE
This Section contains requirements which, where relevant to the Contract, shall apply to building
and associated works.

Some of the relevant Reference Standards are as follows:
BS 5442:1989 Classification of adhesives for construction. Classification of
adhesives for use with flooring materials
BS 6073:1981 Precast concrete masonry units.
BS EN 772 Parts 1-20 Methods of test for masonry units.
BS 5628:1992 Code of practice for use of masonry.
BS 5642:1978 Sills and copings.
BS 1243:1978 Specification for metal ties for cavity wall construction
BS 1199:1976 Specifications for building sands from natural sources
BS 1200:1976 Specifications for building sands from natural sources
BS EN 13139:2002 Aggregates for mortar
BS EN 12878:1999 Pigments for the colouring of building materials based on
cement and/or lime. Specifications and methods of test
BS EN 1052:1999 Methods of test for masonry.
BS 6213:2000 Selection of construction sealants. Guide
BS 5492:1990 Code of practice for internal plastering
BS 1191-1:1973 Specification for gypsum building plasters.
BS 5262:1991 Code of practice for external renderings
BS 8204:2003 Screeds, bases and in-situ floorings.
BS 6431 Various Parts Ceramic floor and wall tiles.
BS EN ISO 10545 Various Parts Ceramic tiles.
BS 4131:1973 Specification for terrazzo tiles
BS 4357:1968 Specification for precast terrazzo units
BS EN 12004:2001 Adhesives for tiles. Definitions and specifications
BS 5385 Parts 1 to 5 Wall and floor tiling. Code of practice for the design and
installation
BS EN 649:1997 Resilient floor coverings. Homogeneous and heterogeneous
polyvinyl chloride floor coverings. Specification
BS EN 651:1997 Resilient floor coverings. Polyvinyl chloride floor coverings
with foam layer. Specification
BS 8203:2001 Code of practice for installation of resilient floor coverings
BS 5325:2001 Installation of textile floor coverings. Code of practice
BS EN 312:2003 Particleboards. Specifications
BS EN 622-2:1997 Fibreboards. Specifications. Requirements for hardboards
BS EN 942:1996 Timber in joinery. General classification of timber quality

BS EN 4381:199 Decorative high-pressure laminates (HPL) sheets based on

thermosetting resins.
CP 151-1:1957 Doors and windows including frames and linings. Wooden
doors
BS 4787-1:1980 Internal and external wood doorsets, door leaves and frames.
Specification for dimensional requirements
BS 459:1988 Specification for matchboarded wooden door leaves for
external use
BS 1245:1975 Specification for metal door frames (steel)
BS 1567:1953 Specification for wood door frames and linings
BS 5368-1:1976, EN 42:1975 Methods of testing windows. Air permeability test
BS 5368-2:1980, EN 86:1980 Methods of testing windows. Watertightness test under static
pressure
BS 5368-3:1978, EN 77:1977 Methods of testing windows. Wind resistance tests
BS 5368-4:1978, EN 78:1977 Methods of testing windows. Form of test report
BS EN 1027:2000 Windows and doors. Watertightness. Test method
BS EN 12211:2000 Windows and doors. Resistance to wind load. Test method
BS 6375-1:1989 Performance of windows.
BS EN 12207:2000 Windows and doors. Air permeability. Classification
BS EN 12208:2000 Windows and doors. Watertightness. Classification
BS EN 12046-1:2003 Operating forces. Test method. Windows
BS 6510:1984 Specification for steel windows, sills, window boards and
doors
BS 4873:2004 Aluminium alloy windows
BS EN 1935:2002 Building hardware. Single-axis hinges. Requirements and test
methods
BS 3621:1998 Specification for thief resistant locks
BS EN 12209:2003 Building hardware. Locks and latches. Mechanically operated
locks, latches and locking plates. Requirements and test
methods
BS 6262:1982 Code of practice for glazing for buildings
BS 5713:1979 Specification for hermetically sealed flat double glazing units
BS 5234-1:1992 Partitions (including matching linings).
BS 8290-1:1991 Suspended ceilings.
BS 4576-1:1989 Unplasticized polyvinyl chloride (PVC-U) rainwater goods
and accessories. Half-round gutters and pipes of circular
cross-section
BS EN 12200-1:2000 Plastics rainwater piping systems for above ground external
use. Unplasticized polyvinyl chloride (PVC-U).
Specifications for pipes, fittings and the system
BS EN 1462:1997 Brackets for eaves gutters. Requirements and testing
BS EN 607:1996 Eaves gutters and fittings made of PVC-U. Definitions,
requirements and testing

BS 6700:1997 Specification for design, installation, testing and maintenance

of services supplying water for domestic use within buildings
and their cartilages
BS EN 1057:1996 Copper and copper alloys. Seamless, round copper tubes for
water and gas in sanitary and heating applications
BS 864-2:1983 Capillary and compression tube fittings of copper and copper
alloy. Specification for capillary and compression fittings for
copper
BS EN 1254:1998 Copper and copper alloys. Plumbing fittings.
BS 1010-2:1973 Specification for draw-off taps and stopvalves for water
services (screw-down pattern). Draw-off taps and above-
ground stopvalves
BS 3505:1986 Specification for unplasticized polyvinyl chloride (PVC-U)
pressure pipes for cold potable water
BS EN 1452-1:2000 Plastics piping systems for water supply. uPVC.
BS 4346-1:1969 Joints and fittings for use with uPVC pressure pipes.
BS 5391: Part 1.1976 Specification for acrylonitrile-butadiene-styrene (ABS)
pressure pipe. Pipe for industrial uses
BS 5392: Part 1. 1976 Specification for acrylonitrile-butadiene-styrene (ABS)
fittings for use with ABS pressure pipe. Fittings for use with
pipe for industrial uses
BS EN 10224:2002 Non-alloy steel tubes and fittings for the conveyance of
aqueous liquids including water for human consumption.
Technical delivery conditions
BS 4213:2004 Cisterns for domestic use. Cold water storage and combined
feed and expansion (thermoplastic) cisterns up to 500 l.
Specification
BS EN 60335-2 -35:1995 Specification for safety of household and similar electrical
appliances.
BS 5505-3:1977 Specification for bidets. Vitreous china bidets over rim
supply only. Quality, workmanship and functional
dimensions other than connecting dimensions
BS EN 997:2003 WC pans and WC suites with integral trap
BS 1125:1987 Specification for WC flushing cisterns (including dual flush
cisterns and flush pipes)
BS 1254:1981 Specification for WC seats (plastics)
BS 1188:1974 Specification for ceramic wash basins and pedestals
BS 1206:1974 Specification for fireclay sinks: dimensions and workmanship
BS EN 13310:2003 Kitchen sinks. Functional requirements and test methods
BS 6340-4:1984 Shower units.
BS 4514:2001 Unplasticized PVC soil and ventilating pipes of 82.4mm
minimum mean outside diameter, and fittings and accessories
of 82.4mm and of other sizes. Specification
BS 5255:1989 Specification for thermoplastics waste pipe and fittings

BS EN 1329-1:2000 Plastics piping systems for soil and waste discharge (low and
high temperature) within the building structure. Unplasticized
polyvinyl chloride (PVC-U). Specifications for pipes, fittings
and the system
BS 1521:1972 Specification for waterproof building papersBS EN
12020:2001 Aluminium and aluminium alloys. Extruded
precision profiles in alloys EN AW-6060 and EN AW-6063.
BS EN 515:1993 Aluminium and aluminium alloys. Wrought products.
Temper designations
BS 6925:1988 Specification for mastic asphalt for building and civil
engineering (limestone aggregate
BS 1282:1999 Wood preservatives. Guidance on choice, use and application
BS 6465:1994 Sanitary installations.
BS EN 12056-2:2000 Gravity drainage systems inside buildings. Sanitary pipework,
layout and calculation
BS 1336:1971 Specification for knotting
BS 1387:1985 Specification for screwed and socketed steel tubes and
tubulars and for plain end steel tubes suitable for welding or
for screwing to BS 21 pipe threads
BS 4987-1:2003 Coated macadam (asphalt concrete) for roads and other paved
areas. Specification for constituent materials and for mixtures

Submissions required from the Contractor in relation to building works shall include the
following where relevant:
• calculations for, and design and layout of blockwork and masonry;
• Typical drawings of standard items;
• Details drawings of special items;
• General arrangement drawings;
• Detail drawings of fixings;
• Types of material and their properties;
• Manufacturers proposals, recommendations, catalogues and colour cards;
• Basis for design loadings including design wind speed and when requested,
calculations;
• Methods and frequency of testing;
• Samples of material as required by the Specification, approved samples shall be
stored on Site, properly labelled and available for reference.
• Certificates of compliance with relevant standards and details of test results as
required by the Specification including the Reference Standards.

J7.4 MATERIALS
J7.4.1 Colours, patterns and textures

The Contractor shall provide a range of samples or colour cards and catalogues for materials
which may be obtained in a range of colours, patterns and textures and shall submit his proposals
for them and for other items such as furniture, paint colours and site-produced materials so that
colours, patterns and textures of all items in each location harmonise, accent and contrast in a
pleasing manner. The Contractor shall provide such further samples as are required by the
Engineer to assist him in visualising and if necessary modifying the proposals before approving
them.
J7.4.2 Adhesives
Unless otherwise specified herein, or recommended by the manufacturer of items to be fixed by
adhesives and approved by the Engineer, adhesives shall be selected in accordance with the
recommendations in BS 5442 where relevant and shall be suitable for high ambient temperatures.
J7.4.3 Bricks and blocks, sills and copings

Clay bricks and blocks, calcium silicate bricks and concrete bricks and blocks shall comply with
the relevant requirements of BS3921, BS187 and BS 6073: Part 1 respectively. The testing of
bricks, blocks, sills and copings shall comply with the relevant parts of BS EN 772 and BS EN
1052. The dimensions of special bricks shall comply with BS 4729.
The quality of bricks or blocks shall be at least equal to that recommended in Table 13 of BS
5628: Part 3 for the location and exposure in which they will be used.
All bricks normally exposed to view externally, shall be facing bricks except where otherwise
specified.
All blocks used in facing work either for exterior or interior application, are to be “selected” and
are to be to the entire satisfaction of the Engineer and in conformity with samples to be approved
by him.
All blocks on fair face surfaces are to be perfect and no cracked blocks or blocks with chipped
arrises will be allowed. All blocks for any continuous section of the Works shall be stacked on
site at one time.
All bricks or blocks intended to present a uniform appearance shall be of an identical type and
quality obtained from one manufacturer and shall be ordered and supplied in a single batch or as
few batches as are practicable.
Samples of each type of brick and block to be used in the Works shall be submitted to the
Engineer for his prior approval.
Bricks and blocks shall where practicable be grooved or keyed where they are to receive
plastering or rendering.
Window sills and wall copings of precast concrete, cast stone, clayware, slate and natural stone
shall comply with BS 5642.
J7.4.4 Natural stone

Natural stone shall be of good, hard, durable quality, uniform in texture, and free from iron
bands, spots, sand holes, flaws, shakes and other imperfections which would adversely affect its

strength or appearance. The dimensions of stones shall be appropriate for proper coursing and
bonding.
J7.4.5 Metal ties etc

Wall ties for cavity walls shall be of the vertical twist type conforming to BS 1243. Other ties,
cramps and hold-fasts embedded at least partially in the mortar joints of brickwork and block
work shall be made of austenitic stainless steel. Ties, dowels and fixings for stone masonry shall
be made of austenitic stainless steel in accordance with BS 5628.
J7.4.6 Materials for mortar

Cement shall be Ordinary Portland Cement. Lime shall be hydrated high calcium lime or
hydrated semi-hydraulic lime to BS EN 459. Sand shall be clean natural sand free from clay or
clay film over the grains or shall be crushed natural stone of approved quality. Both sand and
crushed stone shall be to BS 1200 and BS EN 13139. Water used for mixing mortar shall be from
the same source as water used for concrete.
Any pigment incorporated in the mortar shall conform to BS EN 12878.
Cement mortar shall consist of cement and sand gauged by volume in wrought wooden boxes in
the following proportions:
Proportions of Volume
No. Cement Sand Lime
1 1 2 -
2 1 3 -
3 1 6 1
Unless otherwise specified cement mortar shall be No.2.
J7.4.7 Damp-proof courses and flashings

Damp-proof courses shall consist of material complying with BS 743 or BS 6398. It shall be
provided in strips of various widths each suitable for its particular application. Where not
otherwise specified, and subject to the recommendations of BS 5628: Part 3, Table 12, damp
proof courses shall consist of black polyethylene and comply with BS 6515. Flashings for
brickwork and stone masonry shall comply with the recommendations of BS 5628: Part 3. Where
materials are not specified they shall be proposed to the Engineer for his approval.
J7.4.8 Sealants and mastics

Where not otherwise specified, sealants, mastics, bedding material and backing shall be selected
J7.4.9 Materials for plastering and rendering

Cement shall be ordinary portland cement.
Materials for internal plastering, including cement, lime, aggregates, water, admixtures,
plasterboard and metal lathing, shall comply with BS 5492; unless otherwise specified, final coat
plaster shall be Class B specified in Clause 6.1.1 thereof. Proprietary compounds of plaster may
be used provided that they comply with BS 1191.

Materials for external rendering, including cement, lime, aggregates, water, admixtures, pigments
and reinforcement, shall comply with BS 5262. External rendering to blockwork shall be cement
mortar No.3. An approved plasticiser may be added to the mortar mix to improve its workability.
The plasticiser must be approved by the Engineer and shall be used in the mortar mix strictly in
accordance with the manufacturer's instructions.
J7.4.10 Materials for terrazzo and granolithic concrete

Cement shall be ordinary portland cement.
Materials for terrazzo and granolithic concrete, including cement, aggregates, pigments,
reinforcement and dividing strips, shall comply with BS 8204. Water used for mixing terrazzo
and granolithic concrete shall be from the same source as water used for concrete.
J7.4.11 Tile and slab floors and wall tiles

Except where otherwise specified or agreed by the Engineer, tile and slab flooring and wall tiles
shall meet the following requirements.
Ceramic floor tiles shall be fully vitrified floor tiles complete with coves and other fittings in
accordance with BS 6431 and BS EN ISO 10545.
Quarry tiles and fittings shall be thick, Class 1 floor quarries in accordance with BS 6431.
Terrazzo tiles and slabs shall comply with BS 4131 and BS 4357 respectively. Terrazzo tiles and
slabs for floors and walls shall be ground to a fine grit finish.
Glazed ceramic tiles and fittings for internal walls shall comply with BS 6431.
Other tiling materials, including those for bedding and jointing, shall be in accordance with BS
EN 12004 and the recommendations of BS 5385.
J7.4.12 PVC flooring

PVC sheet flooring and floor tiles shall comply with BS EN 649. PVC flooring with cellular
backing shall comply with BS EN 651. Adhesives and any underlays shall be in accordance with
the recommendations of BS 8203.
Unless otherwise specified, skirtings surrounding PVC flooring shall be terrazzo or ceramic.
Where PVC flooring is to be applied to stairs, aluminium nosings with non-slip inserts shall be
used.
J7.4.13 Wood block flooring

Except where otherwise specified, wood blocks for floors shall comply with BS 1187.
J7.4.14 Textile floor coverings

Where not otherwise specified or approved by the Engineer, textile floor coverings and fixings
shall be as recommended in BS 5325, except that tacks and double sided tape shall be used only
where other fixing methods are impracticable.
Coir door mats shall be not less than 45mm thick and, except where other sizes are specified,
shall be 760mm by 455mm.

J7.4.15 Roof coverings

Except where specified otherwise, materials for built up bitumen felt roof coverings, mastic
asphalt roof coverings and associated work including thermal insulation, vapour barrier and
surface finish shall be as recommended in BS 8218.
J7.4.16 Timber
All timber used for the Permanent Works shall be well seasoned and free from excess of wave or
discoloured sapwood, injurious open shakes, large loose or dead knots, decay and insect attack.
Materials for structural timber shall comply with the recommendations of BS 5268: Parts 2
and 5.
The quality of timber in joinery shall comply with BS EN 942 Class J40 timber or, where a clear
finish is specified, for Class J10 timber.
Tolerances on timber sizes shall be in accordance with BS EN 1313.
J7.4.17 Board and plywood

Building board shall be particleboard 19mm thick of minimum grade P4 in accordance with BS
EN 312
Marine plywood shall comply with BS 1088.
Hardboard shall comply with BS EN 622-2 and unless otherwise specified shall be tempered
hardboard not less than 3.5mm thickness.
J7.4.18 Decorative laminated plastic sheet

Unless otherwise specified or agreed by the Engineer, decorative laminated plastic sheet shall
comply with BS EN 438 and be of the following minimum type:
Location Type
Horizontal work surfaces in laboratories and workshops HDF
Other horizontal work surface HGF
Vertical surfaces and undersides of horizontal surfaces normally
exposed to view VGF
Vertical surfaces not normally exposed to view including inside
faces of cupboards and under sides of horizontal surfaces VLS
J7.4.19 Doors
Except where otherwise specified, wood panelled and flush doors shall be constructed in
accordance with the recommendations of CP 151 to the sizes specified in BS 4787.
Matchboarded doors shall be constructed in accordance with BS 459 and shall be framed, ledged
and braced. Fire doors, steel doors, roller shutter doors, folding doors and the like shall be of
galvanised mild steel and to the approval of the Engineer and full details of their design,
materials, testing and manufacturer's finish shall be submitted by the Contractor including
provisions for dust tightness.

Where steel door frames are specified or approved by the Engineer, they shall comply with BS
1245, otherwise frames and linings to wood doors shall be of wood and shall comply generally
with BS 1567.
J7.4.20 Windows
All windows in external walls shall be double glazed.
Windows for offices, conference rooms and the like shall be double glazed, tinted, horizontal
centre hung with friction hinges and provided with safety stays to limit normal opening to
150mm. For cleaning purposes the windows shall rotate through 180° and be lockable at 180° for
safety while being cleaned. Windows shall be of a size and shape compatible with the building
elevation. Frames shall be to a colour approved by the Engineer and of materials suitable for the
environment. Each window shall be fitted with closeable trickle ventilator, provisions for dust
tightness and with a venetian blind equipped with a rigid manual operating system to raise and/or
tilt the slats.
All other windows shall be of matching size and appearance but shall be fixed.
All windows, when tested in accordance with BS 5368, BS EN 1027 and BS EN 12211, shall
have classifications for weather tightness in accordance with BS 6375 of not less than:
air permeability; 200 Pa
watertightness 100 Pa
wind resistance 1200 Pa
except where other classifications for weather tightness are specified.
In addition, except where otherwise specified, steel windows shall comply with BS 6510 and
aluminium alloy windows shall comply with BS 4873.
Roof lights shall be horizontal fixed lights mounted on an aluminium alloy frame and GRP curb
and provided with means of ventilation as specified on the Drawings. Any ventilation openings
provided shall be fitted with insect screens. The roof lights shall be bedded on butyl-mastic and
screwed down to timber plugs cast into concrete up stands.
J7.4.21 Patent glazing

Patent glazing shall comply with the recommendations of BS 5516. The Contractor shall
determine the information to be provided to the supplier of the patent glazing, confirm the basic
wind speed and ground roughness characteristic data with the Engineer, obtain the supplier's
proposals and submit them for the Engineer's approval.
J7.4.22 Hardware
Hinges for doors shall be selected from types complying with BS EN 1935 and shall be of cast
iron, brass or aluminium except for outward opening exterior doors where the hinges shall be of
steel. Hinges shall be not less than 100mm long. Doors fitted with thief resistant locks shall have
each leaf hung on three hinges.
All locks on entrance doors to buildings and where thief resistant locks are specified shall
conform to BS 3621. Other locks and latches shall be in accordance with BS EN 12209. Letter
plates, where used, shall be to BS EN 13724.
Fire check doors shall be fitted with hydraulic or floor mounted spring door closers.

Door handles, finger plates, window stays and latches shall generally be in similar matching
materials and finish throughout areas of buildings used for the same purpose. These items shall
also match hinges, other hardware, furniture and light fittings. The Contractor shall submit
details of proposed hardware with samples for approval. Where not otherwise specified or
approved, items shall be of either brass with BMA finish or anodised aluminium. Visible screws
and fastenings shall have a matching finish.
J7.4.23 Glazing
Glass, spacing blocks, putty, mastic, fixing clips and the like shall be as recommended in BS
6262 and glass thicknesses shall be selected for wind loadings of 600N/m² or such greater
loadings as are specified or indicated on the Drawings. Before ordering glass, the Contractor
shall submit his calculations of the thickness required to the Engineer for approval and provide
samples of the glass which it is proposed to use.
Double glazing shall either have an air space in excess of 75mm with provision to allow
occasional cleaning of the inner glass faces, or shall consist of hermetically sealed units
complying with BS 5713 and having air spaces of not less than 10mm. In the latter case the
rebate of windows shall be sufficiently large to mask from view the sealing at the edge of the
units.
J7.4.24 Partitions
Except where otherwise specified, non-loadbearing partitioning, including relocatable partitions,
shall comply with the recommendations of BS 5234.
J7.4.25 Suspended ceilings

Except where otherwise specified, suspended ceilings and linings shall comply with the
recommendation of BS 8290.
J7.4.26 Rainwater goods

Except where otherwise specified, rainwater goods, including gutters, heads, flat-roof outlets and
pipes, shall be of uPVC and shall comply with BS 4576: Part 1, BS EN 12200, BS EN 1462 and
BS EN 607.
J7.4.27 Water supply services

Materials for use in water supply services shall comply with local water undertaking byelaws
and, except where otherwise specified, with the relevant standard specifications listed in
Appendix H to BS 6700.
J7.4.28 Water service pipes

Except where otherwise specified, hot water service pipes shall be of copper and shall comply
with BS EN 1057. Fittings shall comply with BS 864: Part 2 and BS EN 1254. Stop valves shall
be of brass and shall comply with BS 1010:Part 2. Cold water supply pipes shall be ABS, uPVC
or galvanised steel. ABS pipes and fittings shall comply with BS 5391 and BS 5392, UPVC
pipes and fittings shall comply with BS 3505, BS 4346 and BS EN 1452. Steel pipes shall
comply with BS 534 and BS EN 10224.

J7.4.29 Storage cisterns

Except where otherwise specified, cold water storage cisterns shall be of polyolefin or olefin
copolymer and shall comply with BS 4213. They shall be fitted with lids.
J7.4.30 Water heaters

Except where otherwise specified:
a) Instantaneous electric water heaters shall comply with BS EN 60335 - 2.35. They
shall be 3 kW wall-mounted heaters with free-discharge swivel spray outlets. They
shall be suitable for the available water pressure and shall incorporate temperature
stabilisers;
b) Small thermal storage electric water heaters shall comply with BS EN 60335 - 2.21.
They shall be 3 kW wall-mounted heaters of not less than 30 litres capacity with free
discharge swivel outlets. They shall be suitable for the available water pressure and
shall incorporate adjustable thermostats;
c) Large thermal storage electric water heaters shall comply with BS EN 60335 - 2.21.
They shall be 3 kW wall-mounted heaters of not less than 80 litres capacity with
outlets suitable for connecting to the service water system. They shall be suitable for
the available water pressure and shall incorporate adjustable thermostats.
J7.4.31 Sanitary fittings

Bidets shall be of vitreous china complying with BS 5505.
WCs shall be vitreous china low level suites complying with BS EN 997, BS 1125 and BS 1254.
Wash basins shall be of vitreous china and shall comply with BS 1188 with ½ inch chromium
plated easy-clean pillar taps to BS 1010: Part 2.
Glazed fireclay sinks shall comply with BS 1206. Stainless steel sinks shall each have a single
integral draining board and shall comply with BS EN 13310. Taps shall be chromium plated
easy-clean taps to BS 1010: Part 2.
Shower heads and controls shall comply with BS 6340: Part 4. Shower trays shall be glazed
ceramic and shall comply with BS 6340: Part 8.
Fittings shall be of a colour from the manufacturer's standard range to be chosen by the Engineer.
J7.4.32 Soil, waste and overflow pipes

Soil and vent pipes and fittings shall be of uPVC and shall comply with BS 4514;
Waste pipes, traps and fittings, also overflow pipes, shall be of ABS and shall comply with
BS 5255 and BS EN 1329 Part 1.
J7.4.33 Waterproof building paper

Waterproof building paper shall be Class B complying with BS 1521.

J7.4.34 Aluminium roof edging

Aluminium roof edging shall be manufactured from HE9-TB or HE9-TF complying with BS EN
12020.
J7.5 WORKMANSHIP
J7.5.1 Colours, patterns and textures

The Contractor shall arrange trial panels incorporating site produced materials such as mortar,
stone, rendering and terrazzo to be available for approval at the same time as samples of
purchased materials intended for the same location.
J7.5.2 Brickwork and blockwork walling

Unless otherwise specified, brick and block work walls shall be constructed in accordance with
the recommendations of BS 5628: Part 3.
Prior to the laying of any facing brickwork, sample panels 900mm by 600mm of each facing
brick shall be built using mortars made with different fine aggregates, white or coloured cements,
or colouring agents as directed by the Engineer. When the required ingredients for the mortar
have been determined and approved by the Engineer they shall be used for all mortar for facing
brickwork and the appropriate test panel shall be retained for reference and shall represent the
standard to which all facing brickwork shall conform.
Storage of blocks shall be arranged so that they are protected at all times. They must not become
heated through being left in directed sunlight nor saturated with rain.
Concrete blocks shall be thoroughly wetted with demineralised water for at least 24 hours before
laying and the tops of partially completed walls shall be well wetted before commencing work.
Calcium Silicate blocks shall be wetted for a period of at least 2 hours before laying or as
otherwise directed by the Engineer.
All blockwork shall be laid in stretcher bond solidly bedded and jointed in mortar. All blockwork
above damp proof course level shall be raked back to a depth of 10mm and shall be pointed up
after completion. The pointing externally shall be of the “bucket handle” type giving a slightly
recessed joint. Internally, the pointing shall be flush. All work below damp course level shall be
finished flush as the work proceeds.
All blockwork shall be carried up evenly and no blockwork shall rise more than one metre above
any adjoining work being executed at the same time.
Cavity blockwork shall be tied with stainless steel ties at 0.6m vertically and 0.5m horizontally.
Alternate course of ties shall be staggered. All openings shall be tied at every 0.6m vertically at a
distance not greater than 0.25m from all returns. All ties shall slope downwards and outwards.
Ties shall also be provided between blockwork and superstructure beams and columns.
During laying blocks an open joint not less than 15mm wide shall be left between the ends of all
concrete lintels, whether precast or cast in situ, and the blocks adjacent to these ends. All such
joints shall be properly filled in before the completion of the work.
Jambs of openings in hollow block walling shall be built in solid block or the cavities next to the
opening may be filled solid with concrete Grade C20.
All newly or partially built walls shall be protected against drying out too rapidly in hot weather.
When the Engineer shall so direct blockwork shall be wetted continuously as the work proceeds

and all newly erected walling shall be kept wet for at least 3 days by methods to be approved by
the Engineer.
All blockwork shall be laid and jointed with cement mortar No.3.
J7.5.3 Mortar for brickwork and blockwork

Lime mortar shall be used for brickwork and block work above the ground level damp proof
course unless otherwise specified or ordered by the Engineer.
Cement and lime shall be stored at the Site in a perfectly dry structure and all consignments shall
be used in order of delivery. Cement and lime affected by dampness shall not be used in the
Works.
Mortar shall be mixed and used in accordance with Clauses 31.2 to 31.4 of BS 5628: Part 3.
Where approved by the Engineer, plasticisers or proprietary masonry cements may be used as an
alternative to lime in the mortar. In this case the proportions of the mix shall be based upon the
manufacturer's instructions but shall be to the Engineer's approval.
All engineering brickwork and brickwork below damp-proof course level shall be built using
cement mortar.
The ingredients shall be mixed in an approved mechanical mixer or shall be mixed together dry
on a clean wooden stage until the mix is homogeneous in colour. Water shall then be added
through a hose in sufficient quantity to give no more than stiff workability. The whole shall then
be turned until perfectly mixed.
Mortar shall be used within 1 hour of mixing and shall not be remixed or worked up again after it
has stiffened. Any mortar that has commenced to set shall be removed from the Works.
J7.5.4 Joints in brickwork and blockwork

Joints shall be broken accurately and the thickness of bed joints shall be not greater than 11.5mm
and not less than 8.5 mm.
Facing brickwork shall be finished with weathered joints 3mm deep formed before the mortar
has set, unless the Engineer directs otherwise.
Brickwork or block work for internal surfaces which are not to be rendered or plastered shall be
fair faced with a flush joint made as work proceeds.
Joints in brickwork or block work which is to be rendered or plastered shall be raked out to a
depth of 5 to 10 mm.
Separation joints shall be formed by inserting approved joint filler 10 mm thick. 60 days after the
bricks have been laid the filler shall be raked out to a depth of 20 mm and the joints shall be
pointed with mortar.
J7.5.5 Stonework
Unless otherwise specified, all masonry of natural stone or cast stone shall be constructed in
accordance with the recommendations of BS 5628.
J7.5.6 Brickwork
Joints in external or internal facing brickwork, shall be pointed with a 5 mm deep square
recessed joint before the mortar has set.

Except where directed otherwise by the Engineer, facing bricks shall start from 225 mm below
final ground level, the remaining brickwork down to the foundations being in common brick.
Brickwork in commons which is not to be rendered, plastered or tiled shall be finished with flush
joints, any surplus mortar being carefully wiped off to leave the brickwork plain and clean.
J7.5.7 Internal plastering

Plastering shall be carried out in accordance with the recommendations of BS 5492.
Proprietary compounds of plaster, where permitted, shall be used strictly in accordance with the
manufacturer's instructions, approved by the Engineer in advance of plastering.
Surfaces shall be prepared and plaster applied as specified for cement rendering.
Plastering except soffit plastering to concrete shall be three coat work.
Undercoats shall consist of one part retarded hemihydrate gypsum plaster to one or two parts
sand as recommended by the manufacturer of the brand of plaster used. Alternatively, cement
mortar No. 2 may be used.
The thickness of each undercoat shall be approximately 6 mm.
The finishing coat shall be neat gypsum plaster and shall be approximately 3 mm thick.
Plastering to soffits shall be one coat 5 mm thick using a bonding plaster or a retarded
hemihydrate plaster (BS 1191 finishing type low expansion).
Galvanised expanded metal angle and casing beads shall be fixed with plaster dabs at not more
than 600 mm centres to suit the finished thickness of the plaster and where possible in one
length. Where jointing is found to be necessary, a dowel of heavy galvanised wire shall be
inserted in the hollow head of each piece to ensure perfect alignment. Plaster stops shall be
provided at openings and abutments.
J7.5.8 External rendering

Except where otherwise specified, rendering shall be carried out in accordance with the
recommendations of BS 5262; the preferred mixes in bold type in Table 2 thereof shall be used.
Rendering shall be applied in two coats. The undercoat shall be an average thickness of 12mm
and finishing coat an average thickness of 8 mm. The total thickness shall be 20 mm.
The surface of blockwork to be rendered shall be thoroughly prepared before the undercoat is
applied by raking out the joints to a depth not less than 10 mm to form an efficient key for the
rendering. All surfaces shall be thoroughly brushed down to clean off all dust and loose material.
The surfaces of blockwork shall be thoroughly wetted with fresh water before rendering is
applied. If allowed to dry out the undercoat shall be thoroughly wetted before applying the
finishing coat and kept damp until it is covered.
The finishing coat shall be trowelled off to a smooth and true surface without polishing, free
from irregularities and blemishes. Arrises shall be rounded and lineable and a hollow fillet shall
be run at internal angles.
Rendering to manhole benching shall consist of cement clean hard and coarse sand and water
followed by the application of a surface hardener.
The sand and cement shall be thoroughly mixed in the proportion by volume of two parts of
cement and five parts of sand. The rendering shall be 25mm thick.

The finished rendering shall be protected and cured as specified for concrete.
J7.5.9 Terrazzo and granolithic concrete

Except where otherwise specified, terrazzo and granolithic concrete work shall be carried out in
J7.5.10 Flooring-general
Before the construction of any floor to which a finish is to be applied, the details of the proposed
finish shall be submitted to the Engineer for approval. Any damp proof course or screed required
for the installation of the floor finish as specified, or as required by the Reference Standards or
the manufacturer or installer of the floor finish, shall be incorporated in the floor in accordance
with the proposals approved by the Engineer.
J7.5.11 Tile and slab floors and wall tiles

Except where otherwise specified, tile and slab flooring and wall tiling shall be carried out in
accordance with the recommendations of BS 5385. The Contractor's proposals for installation of
finishes shall comply with the recommendations of the manufacturers of the products for their
installation, taking into account the service conditions to which they may be exposed and the
long service life desired.
Rectangular tiles shall be applied with joints in line unless otherwise specified.
Floor tiling shall be carried out by an approved specialist sub-contractor who shall use the semi-
dry mix method as described BS 5385.
J7.5.12 PVC flooring

PVC flooring shall be installed in accordance with the recommendations of BS 8203. Joints in
PVC sheet flooring shall be welded where specified or where recommended by the supplier and
approved by the Engineer.
J7.5.13 Wood block flooring

Except where otherwise specified, wood block flooring shall be carried out in accordance with
the recommendations of BS 8201.
J7.5.14 Textile floor coverings

Installation of fixed textile floor coverings shall be carried out as recommended in BS 5325
except where otherwise specified or approved by the Engineer. Tacks and double sided tape shall
be used only where no other methods are practicable.
J7.5.15 Roof coverings

Except where otherwise specified, built-up bitumen felt roof coverings, mastic asphalt roof
coverings and associated work including provision of screed, vapour barrier, thermal insulation
and surface finish shall be applied in accordance with the recommendations of CP 144.

J7.5.16 Roof screeds

Roof screeds shall be formed of an approved no-fines lightweight aggregate concrete or an
approved aerated cement screed. In all cases propriety screeds shall be laid in accordance with
the manufacturer's instructions
Falls formed in the roof screed shall be not less steep than 1 in 80 unless otherwise shown on the
Drawings and the minimum thickness of screed shall be not less than 50 mm. Screeds shall be
drained through purpose-formed openings as directed by the Engineer in the (insulation) vapour
barrier and structural roof. These opening shall be made good at ceiling level with cement
pointing at a time to be determined by the Engineer.
Granular lightweight screeds shall incorporate a top layer of 1:4 cement: sharp sand mortar laid
and floated off smooth immediately after the screed has been tamped off to the required falls and
before the screed has gone off.
J7.5.17 Asphalt roofing

All roof surfaces shall be carefully brushed to remove all grit and debris. An isolating membrane
of black bituminous sheathing felt to BS 747: Type 4A (I) shall be laid loose on the roof; lapped
joints in the membrane shall be at least 75 mm wide.
Mastic asphalt shall comply with BS 6925 and shall be applied in two coats of equal thickness to
a total thickness of 20 mm. As soon as possible after laying, the surface of the asphalt shall be
treated with approved solar reflective aluminium paint, free from material deleterious to mastic
asphalt.
Where shown on the Drawings the aluminium paint shall be omitted and approved light coloured
asbestos cement tiles shall be used. The tiles shall be bonded to the mastic asphalt using hot
bitumen.
Up stands, skirtings etc. shall be applied in three coats to a total thickness of 20 mm. At the
intersection of the two planes forming an internal angle a solid angle fillet of mastic asphalt, not
less than 50 mm wide on its face, shall be formed in two coat work. The asphalt shall be neatly
carried up into tucks, grooves and aluminium edges as shown on the Drawings and shall be
dressed around all pipes and handrail standards.
Where asphalt is laid over lightweight screed, approved ventilators shall be incorporated in the
asphalt and carried through the isolating membrane at 4.5 m intervals in both directions.
J7.5.18 Preservation of timber

Before being incorporated in the Permanent Works, timber shall receive a preservative treatment
selected and applied in accordance with the recommendations of BS 1282 and BS 5268: Part 5.
Preservatives shall be applied by a pressure, vacuum or other process which ensures that the
recommended penetration and retention of preservative are achieved.
All timber which is to be glued, painted or coated, or which will normally be exposed to view
internally, shall receive an organic solvent type preservative.
Pressure creosoting shall be carried out in accordance with BS 913.
Before ordering any timber or board for incorporation in the Permanent Works, the Contractor
shall submit for approval, details of the preservative treatments, the locations where application
is to be carried out and details of the quality control and testing proposed. Untreated timber shall

not be delivered to Site for any purpose unless the Engineer has approved the Contractor's
proposals for ensuring that untreated timber is not incorporated in the Permanent Works.
J7.5.19 Carpentry
Workmanship for carpentry shall be in accordance with the recommendations of BS 5268: Part 2.
Wood chipboard for suspended flooring shall be laid in accordance with BS 5669.
J7.5.20 Joinery
Except as otherwise specified, joinery shall be carried out in accordance with BS 1186: Part 2.
Joinery of softwood shall be knotted, stopped and primed before leaving the joiner's shop. All
exposed faces of joinery shall be wrought and sanded to a standard where no defect is apparent
after the application of any specified finish.
Where timber is fixed with nails or pins which may be exposed to view in normal usage, the nails
or pins shall be punched in and the holes stopped with approved stopping. Where timber is fixed
with screws which may be exposed to view in normal usage, the screws shall be sunk in
countersunk holes covered by matching timber pellets. Where timber usually fixed by screws is
required to be removable, it shall be fixed with countersunk screws set in cups.
J7.5.21 Doors and windows

Doors, door frames and windows shall be stored in the dry, properly racked and protected to
avoid distortion or damage. They shall be installed in accordance with the Reference Standards
and immediately provided with sufficient locks, stays etc to allow opening sections to be secured
against wind action. Each door shall be provided with a plastic backstop secured to the floor by a
secret screw. Damage to any installed items or contact with mud, plaster, cement etc. shall be
avoided as far as is practicable by the exercise of care and the provision or retention of protective
coverings which shall be removed just prior to completion. All items shall be lubricated, adjusted
and checked for correct operation and lack of damage, and any defective items shall be replaced.
J7.5.22 Glazing
Glazing shall be carried out in conformity with BS 6262 and other Reference Standards where
applicable. Glazing of any portion of the Works shall not commence until the calculations of
glass thicknesses have been approved by the Engineer.
Immediately before completion of the Contract, all glass shall be cleaned inside and out, and any
defective, cracked or scratched panes shall be replaced. All glazing shall be watertight on
completion.
J7.5.23 Partitions
Except where otherwise specified, non-loadbearing partitioning including relocatable partitions
shall be erected and installed in accordance with the recommendations of BS 5234.
J7.5.24 Suspended ceilings

Except where otherwise specified, suspended ceilings and linings shall be erected and installed in
Each suspended ceiling shall be erected using the manufacturer's recommended system and in
accordance with his erection instructions.

The Contractor shall submit drawings for the Engineer's approval showing details of the ceiling
supports and any light wells and semi-recessed light fittings to be incorporated.
J7.5.25 Rainwater goods

uPVC rainwater gutters shall be fixed in accordance with the manufacturer's instructions, subject
to the following minimum requirements:
Rainwater goods shall be installed so as to intercept and convey all run-off without spillage,
overflow or leakage;
Support brackets shall be installed at every union and outlet, within 150 mm of every stop-end
and angle, and elsewhere at intervals not exceeding 1000 mm;
Every gutter shall fall towards an outlet at not less than 1 in 500 and the high points shall be tight
under the eaves;
Downpipes shall be supported at each connection, and elsewhere at intervals not exceeding
1800 mm;
Due provision for expansion shall be made at each joint.
J7.5.26 Water supply services

Installation of water supply services shall comply with local water undertaking byelaws and,
except where otherwise specified, with BS 6700.
J7.5.27 Water service pipes

Service water pipes shall be fixed clear of the walls with approved pipe clips at intervals not
exceeding 1200 mm. In each section an air release vent shall be provided at the highest point and
a hose connection draincock at the lowest point. Stop valves shall be installed so that all water
heaters and sanitary fittings can be isolated.
Where the general supply is from a cistern, at least one drinking water tap shall be provided,
connected directly to the main. Stop valves shall be installed adjacent to the cistern ball valve
and outlet.
J7.5.28 Storage cisterns

Plastic cisterns shall be supported on solid bases. They shall be provided with ABS overflow
pipes which shall be sited so as to act as warning pipes.
J7.5.29 Water heaters and sanitary fittings

Water heaters and sanitary fittings shall be installed in accordance with manufacturers’
instructions and with any recommendations on installation contained in BS 6465: Part 1.
J7.5.30 Soil, waste and overflow pipes

uPVC soil and vent pipes and fittings and ABS waste and overflow pipes and fittings shall be
installed in accordance with manufacturers' instructions and with any recommendations on
installation contained in BS EN 12056 Part2.

J7.5.31 Waterproof building paper

Building paper shall be laid with laps of not less than 75 mm
J7.5.32 Aluminium roof edging

Aluminium roof edging shall be securely fixed in accordance with the manufacturer's
instructions.
J7.5.33 Fix and build into concrete and blockwork

Openings left in concrete walls for the subsequent fitting and concreting of pipework and fittings
shall have the soffit of the opening inclined at not less than one in four to the horizontal. The
periphery of the opening shall be formed as specified for construction joints.
After placing the pipe or fitting the remaining void shall be carefully packed with concrete of the
appropriate class every care being taken to produce a watertight joint. The concrete shall be
retained by a shutter which shall be built up as concrete filling proceeds. The Contractor shall
ascertain from the suppliers of prefabricated or manufactured goods any special fixing
instructions and shall refer them to the Engineer for approval.
Where fixing bolts are positioned by means of a template they shall be supported and b-raced to
remain in perfect alignment during the setting of the concrete or grout. Where it is necessary to
drill for fixing the holes shall be to the minimum size necessary and they shall be grouted solid
with cement mortar No.2. Where boxing out for horizontal bolts or fittings is provided, the
boxing out and refilling shall be as specified above for pipes and fittings through walls.
Care must be taken to protect faces and other working parts from mortar and other droppings.
Except where otherwise specified when a metal is fixed to a metal or any other surface, the metal
surface in contact shall be painted on Site with two coats of bituminous paint immediately prior
to fixing.
Under no circumstances shall aluminium be built into wet concrete or be fixed to green concrete.
Where it is necessary to joint aluminium to steel or cast iron the two surfaces shall be separated
by an approved insulation not less than 2 mm thick.
Where aluminium or ferrous structural members are built into block or concrete the contact
surfaces shall be first sealed with two coats of bituminous paint.
Where aluminium surfaces are in contact the jointing compound shall be loaded with zinc
chromate.
J7.5.34 Painting
Surfaces to be painted shall be painted in accordance with the system specified in the “Painting
Schedule” at the end of this clause.
Paints to be used in the Works shall comply with the requirements detailed in the following table
and shall, in so far as it is practicable, be obtained from one manufacturer.

Type Requirements Dry Film Thickness

(Each Coat)
Knotting Varnish BS 1336 -
Pink Primer Containing not less than 40 % white 25 microns
lead in dried film
Alkali-Resistant Commarone / Tung Oil medium 25 microns
Primer
Undercoat Compatible with top coat To give adequate coverage
Alkyd Long oil penta alkyd gloss 25 microns
Emulsion Vinyl Copolymer 40 microns
Stabilising Solution “Blue Circle” or similar approved -
Exterior Textured Medium textured approved resin To give adequate coverage
Paint based
Bituminous “Bowranite” or similar approved 125 microns
Aluminium Sealer (for Based on aluminium flake pigment -
use or Bituminous and shellac varnish
paints to prevent
bleeding)
Zinc Chromate Primer Not less than 40 % Zinc Chromate 25 microns
Pigment in the dried film
Hardboard Primer Paint Manufacturer's recommended 25 microns
product
Before placing any order the Contractor shall obtain the prior approval of the Engineer to the
manufacturer or manufacturers and the brand names or reference numbers of the paints and shall
satisfy the Engineer that they are compatible with each other with the sub-strata and with any
timber preservation or fire proofing treatment which may be required.
Paints shall be used strictly in accordance with the instructions issued by the manufacturer. No
unauthorized thinning or other adulteration shall be made and no additions of driers will be
permitted. When authorised additions are made the correct proportions shall be used and the
mixing conducted in a complete and through fashion.
Successive coats of paint on the same surface shall differ in colour.
The colour on drying of finishing paints shall be solid and match the British Standard shade
specified. There shall be no thinning of undercoats.
The dried films of the specified paints shall be free from bloom, sinkage, sheariness, wrinkling,
sagging, curtaining, discolouration and extraneous matter.
Flat and gloss paints shall not be boxed up together and skinned ullages shall be discarded.
Paint shall be stored in suitable accommodation at temperatures not less than 10°C and not more
than 30° C. Inflammable materials shall be stored in accordance with relevant NFPA guidelines.

Any paint surface which after a reasonable curing period is considered by the Engineer to be
more sensitive to solvent-rub than a standard cured sample of the same material shall be
completely removed and a further coat of paint applied.
The Contractor shall regard the preparation of all surfaces to be painted as work of fundamental
importance and he shall provide surfaces which are sound clean smooth and dry. The preparation
shall have no detrimental effect on the sub-strata to be painted nor shall it be prejudicial to
subsequent operations.
Generally all timber iron and steel will be in a primed condition before delivery to site and will
not require further priming except to make good the damaged areas. Such work shall comprise
the preparation and primary procedures as described herein.
Where surfaces are suspected of being infected with mould they shall be thoroughly washed with
a fungicide.
Prior to the applications of any primer and between subsequent coats the surface shall be clean
dry and free from grease and other deposits.
Any knots or resinous runs in timber shall be scraped down and treated with knotting varnish. All
knotholes shall be plugged with timber. Minor holes cracks and crevices shall be filled with an
approved stopping compound.
Where soldered welded or brazed joints occur care shall be taken to remove fluxing material and
other debris before painting.
Painting shall not be undertaken in unfavourable weather or where the ambient temperature is
less than 5°C or the relative humidity is higher than 80% or when such conditions may arise
before the paint work has dried.
Surfaces shall not be painted when they are or are likely to be exposed to direct hot sunshine.
Where dirt or dust has been trapped in the paint film it shall be removed with fine abrasive paper.
Paint shall be applied uniformly. Adequate time shall be left for drying between successive coats.
Exposure of intermediate coats of paint for periods in excess of a few days shall not be permitted
except in the case of work delivered to site in a primed condition. Any work that has been subject
to deterioration from exposure shall be treated as described for remedial work.
Priming paints shall be applied by brush unless otherwise authorized by the Engineer.
Paints shall be well stirred before and during application. A wet edge to the paint surface shall be
maintained throughout all painting operations.

PAEW Water Transmission Pipeline from the Water Treatment Plant of Wadi Dayqah Dam at Mazari in Wilayat Qurayyat to Deem Reservoir in Muscat Governorate
PAINTING SCHEDULE
SURFACE LOCATION FINISH PARTICULAR PRIMER FINAL COAT

PREPARATION
Softwood primed Interior Gloss Sand down, treat knots 1 coat pink primer Alkyd undercoat
or unprimed Alkyd topcoat
Exterior Gloss Sand down treat knots 1 coat pink primer Alkyd undercoat
Alkyd topcoat(2 coats)
Plaster (including Interior Flat Degrease Sand down Emulsion thinned to 2 coats emulsion
plaster board) manufacturer's instructions
Interior Gloss Ditto 1 coat alkali-resistant Alkyd undercoat
primer Alkyd topcoat
Interior Multi-colour Ditto 1 coat primer Multi-colour wall finish
Blockwork Interior Flat - Emulsion thinned to 2 coats emulsion

manufacturer's instructions
Blockwork Interior Gloss -1 coat alkali-resistant 2 coats approved alkyd masonry paint
Cement rendering primer
Concrete *Exterior Textured Stiff Brush -Stabilising solution
(fair-faced)
Steelwork (Not As specified in

including tanks, Section 4.1
towers or vessels)
Hardboard Interior Flat Zinc chromate spot 1 coat emulsion 2 coats emulsion
primer to screw & nail
Interior Gloss heads 1 coat hardboard primer Alkyd undercoat
Alkyd topcoat

J7.5.35 Galvanising
Where steel or wrought iron is specified to be galvanised the galvanising shall be executed after
all fabrication has been completed. The articles shall be pickled in dilute sulphuric or
hydrochloric acid followed by rinsing in water and pickling in phosphoric acid. They shall be
thoroughly washed stoved and dipped in molten zinc and brushed so that the whole of the metal
shall be evenly covered and the additional weight thereof after dipping shall not be less than
610g/m2 of surface galvanised except in the case of tubes to BS 1387 when it shall be 460g/m2.
Edges shall be clean and surfaces bright.
J7.5.36 Protection to exterior surface of faced concrete blockwork

Exterior surfaces of fair faced concrete blockwork shall be protected with one coat of an
approved silicone based water repellent.
The water repellent shall be suitable for the prevailing climatic conditions and as supplied be of a
consistency suitable for application by brush or spray. It shall not change the appearance of the
treated surface from that of the untreated surface.
Cracks wider than hair cracks and/or other defects shall be made good and surfaces shall be
cleaned down and allowed to dry out before treatment.
J7.5.37 Permanent Access Roads

Formations of roads shall be well cleaned free from mud and slurry and properly shaped and
consolidated by rolling to an even and uniform surface parallel to the required finished surface
before the foundation work is commenced. Minimum compaction shall be 96% as measured by
the American Association of State Highway Officials modified compaction test. Formations shall
be covered by the sub-base or broken stone bottoming within 48 hours of exposure.
Finished surfaces of roads shall be formed to provide adequate falls to and satisfactory run off at
surface water outlets.
Formations shall be covered with a sub-base of clinker or ballast thoroughly compacted by a
suitable roller to give a dense even surface. The compacted thickness of the sub-base shall be
100mm.
The base under asphalt surfaces shall be roadbase laid and rolled to a depth of 210 mm after
compaction.
Asphalt surfaces shall consist of two course work to a total thickness of 100 mm. The base
course shall be to a compacted thickness of 65 mm and the wearing course shall be to a
compacted thickness of 35 mm. Each course shall be compacted true to cross section line and
level with a suitable roller and the wearing course shall be blinded with bituminous grit or fine
cold asphalt to comply with BS 4987.
Precast concrete kerbs shall be bedded on and haunched with concrete Class C. Completed kerb
lines shall be jointed with cement mortar No. 2.
Polypropylene gullies shall be positioned as shown on the Drawings or ordered by the Engineer.
They shall be placed in a hole excavated to the minimum size that the ground conditions will
allow. Gullies shall be set on a layer of concrete Class C not less than 80mm thick and the
remainder of the excavation shall be backfilled with concrete Class C. The grating and frame
shall be fixed flush with the surface and shall be set and bedded in cement mortar No.2 on one
course of concrete blocks which shall be laid on the gullies.

J7.5.38 Marker post /marker plate installation

The Contractor shall provide and install marker plates or posts to mark positions of the concealed
parts of the works. However in certain locations the Engineer may order plates instead. The
general rules guiding the type of mark to be installed are as follows:
a) Marker plates
In built up areas standard marker plates measuring 200mm x 200mm should be affixed to walls
of buildings or set in pavements or kerbs. These plates should be coloured blue and carry
wording indicating the service type, and offset distance from the plate. In addition they shall give
the size of pipe and the depth of cover.
b) Marker posts
In non-built up areas, beside roadways which do not have made up footpaths, standard pre-cast
dome as shown on the drawings shall be installed. Standard marker plates as described above
shall be set into the posts. Posts shall be placed every 200 m or at major changes in direction or
to coincide with any duct crossing markers. The posts shall be set vertical with the lower 500 mm
set in concrete as detailed.
Above and below ground, concrete shall be protected in accordance with the relevant clauses of
the Specification.
The Contractor shall be advised on site by the Engineer of the type(s) of marker to be installed.

SECTION J8 FURNITURE AND FITTINGS
J8.1 SCOPE
This Section contains requirements which, where relevant to this Contract, shall apply to the
provision and installation of furniture, furnishings, hand held fire extinguishers and other fittings.
The work shall include interior design, co-ordination of colours, finishes and materials,
procurement and installation of furnishings.

Unless otherwise specified furniture fittings and fire extinguishers shall comply with the relevant
reference standards listed below:
BS 5459-2:2000 Specification for performance requirements and tests for office

furniture. Office pedestal seating for use by persons weighing up to
150 kg and for use up to 24 hours a day, including type-approval
tests for individual components
BS 5459-3:1983 Specification for performance requirements and tests for office
furniture. Storage furniture
BS EN 527-3:2003 Office furniture. Work tables and desks. Methods of test for the
determination of the stability and the mechanical strength of the
structure
BS EN 527-1:2000 Office furniture. Work tables and desks. Dimensions
BS 6261:1982 Method for evaluating the application of and interaction between
components in upholstered furniture
BS 5852:1990 Methods of test for assessment of the ignitability of upholstered
seating by smouldering and flaming ignition sources
BS 5852-1:1979 Fire tests for furniture. Methods of test for the ignitability by
smokers' materials of upholstered composites for seating
BS 5852-2:1982 Fire tests for furniture. Methods of test for the ignitability of
upholstered composites for seating by flaming sources
BS EN 1335-1:2000 Office furniture. Office work chair. Dimensions. Determination of
dimensions
BS 952-1:1995 Glass for glazing. Classification
BS 952-2:1980 Glass for glazing. Terminology for work on glass
BS 5867-1:2004 Specification for fabrics for curtains and drapes. General
requirements
BS 5867-2:1980 Specification for fabrics for curtains and drapes. Flammability
requirements
BS EN 3-7:2004 Portable fire extinguishers. Characteristics, performance
requirements and test methods

BS 4875-1:2001 Strength and stability of furniture. Requirements for the strength and
durability of the structure of domestic and contract seating
BS 4875-5:2001 Strength and stability of furniture. Requirements for strength,

durability and stability of tables and trolleys for domestic and
contract use
BS 4875-7:1998 Strength and stability of furniture. Methods for determination of

strength and durability of storage furniture
BS 4875-8:1998 Strength and stability of furniture. Methods for determination of

stability of non-domestic storage furniture
The furniture and fittings shall comply with all relevant rules and regulations of the Ministry of
Regional Municipalities and Water Resources and shall be of equal or higher quality to the
furniture with which the Directorate of Dams offices are equipped.

Submissions by the Contractor include, where relevant the following:
J8.3.1 Data
• Complete interior colour schemes;
• Manufacturers' catalogues, data sheets and specifications;
• Colour cards;
J8.3.2 Certificates
• Certificates showing compliance with British Standards.
J8.3.3 Samples
• Full size samples of typical items of furniture;
• Samples of basics.
J8.4 MATERIALS
J8.4.1 General
Office furniture shall comply with BS 5459 and any other seating including lounge chairs or
settees shall have performance ratings to BS 4875 of not less than grade 4. Upholstered seating
shall conform to BS 6261. The design and manufacture of materials used in upholstered furniture
shall be such as will pass the fire tests in BS 5852:1 and 2.
Hardware for furniture shall be resistant to corrosion and be of robust construction.
Unless otherwise specified, desks, worktables and chairs for use therewith shall have dimensions
and other properties in accordance with BS 5940. Furniture shall be selected from manufacturers'

standard lines intended for the high quality range of commercial and institutional use and
designed for the specified purpose. Where furniture in a room, a suite of rooms or a building is to
be used for similar purposes, it shall, wherever practicable, be provided from one design range
from one manufacturer to ensure compatibility of styling and allow future interchange and re-
arrangement. Furniture shall be from a modular range of desks and storage units to assemble
appropriate workstations for the nature of the offices. Furniture supplied shall be of equal or
better quality than the furniture with which the Directorate of Dams offices of the Ministry of
Regional Municipalities and Water Resources are equipped.
Furniture shall be in contemporary style in scale with the size and use of the buildings. Colours
shall be generally in the clear lighter range, with accents applied to smaller surface areas such as
chair seat and backs and draperies. Plastic laminate table and desk tops shall be in wood grain or
solid tone. Steel furniture and frames for work tables shall be finished in baked-on acrylic
enamel. Tubular aluminium frames shall be satin anodized finish. Legs, frames and surface
hardware shall be brushed stainless steel or dull chrome finish. Alternatively wood grained
casework may have blending colour toned hardware.
Colour schemes for furniture and furnishings shall be designed taking into account specified
ceiling, wall and floor finishes, light fittings, door furniture etc, and including details of all
colours and finishes which are not specified. Colour schemes and furniture and furnishing details
shall be submitted as fully developed proposals to the Engineer for approval.
All drawer slides shall be on nylon block or nylon rollers. All filing drawers, including desk
units, shall be equipped with heavy duty full-suspension ball bearing tracks.
All wood core casework, including cabinet assemblies shall be of rigid fabrication and design.
Exposed sides, drawer fronts and tops shall be finished with textured plastic laminate. Natural
wood furniture shall be solid hardwood stock with high temperature and high humidity resistant
glues with dowel or mortise and tenon joints.
Hardwood shall be carefully matched for type and grain and be free from blemish and of even
colour. Timber shall be finished to a high standard in acrylic lacquer clear coat matt finish.
Plastic laminated panels shall have balancing veneer on the reverse side and thick matching
plastic veneer edgings.
Locker units, desks, cupboards and filing cabinets shall be equipped with locks with three keys to
each fitting.
J8.4.2 Items of furniture

Except where other dimensions or features are specified elsewhere, items of furniture shall be as
described below. Minimum sizes are indicated, but shall be increased to suit the chosen modular
range.
Desk Size 1800 mm x 800 mm, provided with three box drawer units.
Low bookcases shall be of size 1500 mm x 270 mm x 850 mm high with plinth,
bottom shelf and two adjustable shelves, and sliding glass doors.
High bookcases shall be of size 1500 mm x 270 mm x 2050 mm high with plinth,
bottom shelf and five adjustable shelves, and with solid hinged
glass doors.
Large size work tables shall be size 1800 mm x 800 mm with.
Medium size work tables shall be size 1500 mm x 800 mm.

Small size work tables shall be size 1200 mm x 800 mm.

Office chairs shall have fully upholstered cloth seats, backs and armrests with a
swivel action on a five castor base, with adjustment facilities for
height.
Visitor chairs shall have fully upholstered cloth seats, backs and armrests on a
fixed base.
Typist chair shall have fully upholstered cloth seat fully adjustable for height
with an adjustable backrest for height and posture. The chairs shall
be swivel mounted on five castor bases.
Filing cabinets shall be steel 4 drawer type to receive 450 mm folders.
Utility shelving shelving units shall be baked enamel steel utility open shelving
480 mm deep by 900 mm wide by 2200 mm high sections, with six
adjustable selves. All units shall be demountable with bolted and
clip connections.
Wastepaper bins shall be 300 mm high in anodised aluminium.
Notice boards shall be the open type with an anodised aluminium frame and a
softboard baize covered board size 1200 mm long x 900 mm high
for wall mounting.
White boards shall be wall mounted, 2000 mm wide x 1000 mm high, complete
with coloured marker pens.
Sofas shall have fully upholstered leather seats and backs with stainless
steel frames and ends.
Occasional tables shall be size 600 mm x 600 mm x 450 mm high.
Lockers personnel lockers shall be baked enamel finished steel of welded
construction 2000mm high. One internal shelf and three coat hooks
shall be provided. Doors shall be ventilated.
Utility chairs shall be of polypropylene body construction moulded in one piece
with anti-static additive, mounted on a baked enamel steel frame.
Mess tables shall be size 1200 mm x 600 mm with a baked enamel steel frame
and a plastic laminate wipe clean surface.
Mirrors shall be manufactured from SSQ quality glass to BS 952, with
copper backs to resist moisture and be framed in an anodised
aluminium frame for wall mounting (Size 450mm x 450mm
overall).
First aid cabinets shall be of the wooden wall type with flap down front and internal
shelf, size 300mm x 200mm down front and internal shelf, size
300 mm x 200mm x 110mm deep complete with an advisory leaflet
and a first aid kit suitable for up to 50 employees.
Litter bins shall be of plastic construction suitable for plastic bin liners with a
swing top lid size 380 mm x 200 mm x 700 mm high x 450 mm
diameter.
Dustbins shall be of the galvanised body type with heavy duty rubber lids,

size 600 mm x 450 mm diameter.

Parts and tools shall be size 2000 mm high x 1000 mm wide x 600 mm deep with
storage cabinets 2 adjustable shelves complete with lock and three keys; finished as
lockers.
Lamps All table lamps shall be utilitarian design, with textured fibreglass
shades and durable stable bases. Desk lamps shall be baked enamel
finished steel, with spring loaded universal arms for mobility.
Drawing storage unit shall be enamelled steel of the vertical hanging pull down front type
suitable for AO size drawings.
Conference table shall be rectangular of a size sufficient for 20 people. It shall be
constructed in solid hardwood. Matching hardwood chairs with
leather upholstery shall be provided.
J8.4.3 Window coverings

Fabrics for curtains and drapes shall comply with BS 5867 and their flammability shall meet the
requirements for Type C. Curtains shall be pleated, traverse type secured by hooks to nylon glide
hangers on anodised aluminium tracks and hand drawn by wand.
Roller blinds shall be of the room darkening type manufactured from medium weight,
impregnated, flame proof fabric and operated to any position by ball chain.
Vertical blinds shall consist of vertical louvers which shall be drawn by cord or ball chain and
remotely rotated through 180°. Louvers shall be woven of cotton/polyester or glass fibre and
impregnated with vinyl resin, they shall be flame proof and individually weighted. Tracks shall
be of aluminium alloy.
J8.4.4 Floor finishes

Hard permanent floor finishes and textile finishes are specified in SECTION J7.
J8.4.5 Marking and packing

All items shall be packed in crates and adequately protected to withstand all conditions likely to
be experienced in transit and storage until placed in location in the Works. Each crate shall
contain a detailed packing list. The outside of the crate shall bear a general description of the
contents and an identification mark relating it to the general detailed packing list.
J8.5 WORKMANSHIP
J8.5.1 Delivery and storage

All items shall be checked against packing lists immediately on delivery to the Site, shall be
inspected for damage and checked for shortages and repacked for subsequent. Until required for
installation they shall be carefully stored in a secure, weatherproof, dry and well ventilated
building. Items shall only be transported, stacked and stored using methods and procedures
which will prevent damage occurring.

J8.5.2 Installation
Furniture and furnishings shall not be placed in position until all construction work has been
completed and thoroughly cleaned and the Permanent Works are ready for final inspection.
Packing shall not be removed until items are finally placed in position.
The Contractor shall place in position all loose furniture in accordance with the schedules. All
wall and soffit mounted fittings shall be adequately mechanically fixed into position with
corrosion resistant fastenings compatible with the background materials and approved by the
Engineer.

SECTION J9 BUILDING MECHANICAL SERVICES
J9.1 SCOPE
This Section includes requirements for building services equipment for use on the Contract
Works.

Unless otherwise specified, materials, products and testing procedures shall comply with the
following Reference Standards where relevant.
BS 1646-1:1979, ISO Symbolic representation for process measurement control functions
3511/I-1977 and instrumentation. Basic requirements
BS 1646-2:1983 Symbolic representation for process measurement control functions
and instrumentation. Specification for additional basic requirements
and instrumentation. Specification for detailed symbols for
instrument interconnection diagrams
and instrumentation. Specification for basic symbols for process
computer, interface and shared display/control functions
BS EN 1151:1999 Pumps. Rotodynamic pumps. Circulation pumps having an electrical
effect not exceeding 200 W for heating installations and domestic hot
water installations. Requirements, testing, marking
BS 4082-1:1969 Specification for external dimensions for vertical in-line centrifugal
pumps. 'I' Type
BS 4082-2:1969 Specification for external dimensions for vertical in-line centrifugal
pumps. 'U' Type
BS 5257:1975 Specification for horizontal end-suction centrifugal pumps (16 bar)
BS EN ISO Rotodynamic pumps. Hydraulic performance acceptance tests.
9906:2000 Grades 1 and 2
BS 5306-2:1990 Fire extinguishing installations and equipment on premises.
Specification for sprinkler systems
BS EN 13480-1:2002 Metallic industrial piping. General
BS 1306:1975 Specification for copper and copper alloy pressure piping systems
BS 476-20:1987 Fire tests on building materials and structures. Method for
determination of the fire resistance of elements of construction
(general principles)
BS 143 and Threaded pipe fittings in malleable cast iron and cast copper alloy
1256:2000

BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations.

Sixteenth edition
BS EN 1092-3:2003 Flanges and their joints. Circular flanges for pipes, valves, fittings
and accessories, PN designated. Copper alloy flanges
BS EN 1514-1:1997 Flanges and their joints. Dimensions of gaskets for PN-designated
flanges. Non-metallic flat gaskets with or without inserts
BS 3063:1965 Specification for dimensions of gaskets for pipe flanges
BS EN 1254-1:1998 Copper and copper alloys. Plumbing fittings. Fittings with ends for
capillary soldering or capillary brazing to copper tubes
BS EN 1254-2:1998 Copper and copper alloys. Plumbing fittings. Fittings with
compression ends for use with copper tubes
BS EN 1254-3:1998 Copper and copper alloys. Plumbing fittings. Fittings with
compression ends for use with plastics pipes
BS EN 1254-4:1998 Copper and copper alloys. Plumbing fittings. Fittings combining
other end connections with capillary or compression ends
BS EN 1254-5:1998 Copper and copper alloys. Plumbing fittings. Fittings with short ends
for capillary brazing to copper tubes
BS 4346-1:1969 Joints and fittings for use with unplasticized PVC pressure pipes.
Injection moulded unplasticized PVC fittings for solvent welding for
use with pressure pipes, including potable water supply
Mechanical joints and fittings, principally of unplasticized PVC
Specification for solvent cement
BS EN 1452-1:2000 Plastics piping systems for water supply. Unplasticized polyvinyl
chloride (PVC-U). General
chloride (PVC-U). Pipes
chloride (PVC-U). Fittings
chloride (PVC-U). Valves and ancillary equipment
chloride (PVC-U). Fitness for purpose of the system
BS 5306-1:1976 Fire extinguishing installations and equipment on premises. Hydrant
systems, hose reels and foam inlets
BS 5306-2:1990 Fire extinguishing installations and equipment on premises.
Specification for sprinkler systems
BS EN 671-1:2001 Fixed fire fighting systems. Hose systems. Hose reels with semi-rigid
hose

BS EN 671-2:2001 Fixed fire fighting systems. Hose systems. Hose systems with lay-flat
hose
BS EN 671-3:2000 Fixed fire fighting systems. Hose systems. Maintenance of hose reels
with semi-rigid hose and hose systems with lay-flat hose
BS 21:1985 Specification for pipe threads for tubes and fittings where pressure-
tight joints are made on the threads (metric dimensions)
BS EN 10226-1:2004 Pipe threads where pressure tight joins are made on the threads.
Taper external threads and parallel internal threads. Dimensions,
tolerances and designation
BS 5292:1980 Specification for jointing materials and compounds for installations
using water, low-pressure steam or 1st, 2nd and 3rd family gases
BS EN 751-2:1997 Sealing materials for metallic threaded joints in contact with 1st, 2nd
and 3rd family gases and hot water. Non-hardening jointing
compounds
BS EN 751-1:1997 Sealing materials for metallic threaded joints in contact with 1st, 2nd
and 3rd family gases and hot water. Anaerobic jointing compounds
BS 6956-1:1988 Jointing materials and compounds. Specification for corrugated metal
joint rings
BS 6956-5:1992 Jointing materials and compounds. Specification for jointing
compounds for use with water, low pressure saturated steam, 1st
family gases (excluding coal gas) and 2nd family gases
BS 143 and 1256 Threaded pipe fittings in malleable cast iron and cast copper alloy
BS 1387:1985 Specification for screwed and socketed steel tubes and tubulars and
for plain end steel tubes suitable for welding or for screwing to BS 21
pipe threads
BS EN 10216-1:2002 Seamless steel tubes for pressure purposes. Technical delivery
conditions. Non-alloy steel tubes with specified room temperature
properties
BS EN 10217-1:2002 Welded steel tubes for pressure purposes. Technical delivery
properties
BS 2971:1991 Specification for class II arc welding of carbon steel pipework for
carrying fluids
BS 2640:1982 Specification for Class II oxy-acetylene welding of carbon steel
pipework for carrying fluids
BS EN 970:1997 Non-destructive examination of fusion welds. Visual examination
BS EN 1044:1999 Brazing. Filler metals
BS 417-2:1987 Specification for galvanized low carbon steel cisterns, cistern lids,
tanks and cylinders. Metric units
BS 4213:2004 Cisterns for domestic use. Cold water storage and combined feed and
expansion (thermoplastic) cisterns up to 500 l. Specification

BS 1212 (Various) Float operated valves.

BS 1968:1953 Specification for floats for ballvalves (copper)
BS 2456:1990 Specification for floats (plastics) for float operated valves for cold
water services
BS 1564:1975 Specification for pressed steel sectional rectangular tanks
BS 6282 (Various) Devices with moving parts for the prevention of contamination of
water by backflow.
BS 6283 (Various) Safety and control devices for use in hot water systems.
BS EN 1171:2002 Industrial valves. Cast iron gate valves
BS 5154:1991 Specification for copper alloy globe, globe stop and check, check and
gate valves
BS EN 12288:2003 Industrial valves. Copper alloy gate valves
BS 5158:1989 Specification for cast iron plug valves
BS 5306 (Various) Fire extinguishing installations and equipment on premises.
BS 7854 (Various) Mechanical vibration. Evaluation of machine vibration by
measurements on non-rotating parts
BS 5345 (Various) Code of practice for the selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmospheres
(other than mining applications or explosive processing and
manufacture)
BS 476 (Various) Fire tests on building materials and structures.
BS 3928:1969 Method for sodium flame test for air filters (other than for air supply
to I.C. engines and compressors)
BS EN 779:2002 Particulate air filters for general ventilation. Determination of the
filtration performance
BS EN ISO Acoustics. Determination of sound power levels of noise from air-
5135:1999 terminal devices, air-terminal units, dampers and valves by
measurement in a reverberation room
BS 4856 (Various) Methods for testing and rating fan coil units, unit heaters and unit
coolers. Thermal and volumetric performance for heating duties;
BS 4954-1:1973 Methods for testing and rating induction units for air distribution
systems. Thermal and aerodynamic performance
BS 4954-2:1978 Methods for testing and rating induction units for air distribution
systems. Acoustic testing and rating
BS 4857-1:1972 Methods for testing and rating terminal reheat units for air
distribution systems. Thermal and aerodynamic performance
BS 4857-2:1978 Methods for testing and rating terminal reheat units for air
distribution systems. Acoustic testing and rating

BS 848 (Various) Fans for general purposes.

BS 3790:1995 Specification for endless wedge belt drives and endless V-belt drives
PD 5304:2000 Safe use of machinery
BS EN 12451:1999 Copper and copper alloys. Seamless, round tubes for heat exchangers
BS EN 10216-1:2002 Seamless steel tubes for pressure purposes. Technical delivery
properties
BS EN 10217-1:2002 Welded steel tubes for pressure purposes. Technical delivery
properties
BS EN 378 (Various) Specification for refrigerating systems and heat pumps
BS EN ISO Acoustics. Laboratory measurement procedures for ducted silencers
7235:2003 and air-terminal units. Insertion loss, flow noise and total pressure
loss
BS EN 13190:2001 Dial thermometers
BS 1704:1985, ISO Specification for solid-stem general purpose thermometers
1770:1981
BS 1041 (Various) Code for temperature measurement.
BS 2765:1969 Specification for dimensions of temperature detecting elements and
corresponding pockets
BS 5422:2001 Method for specifying thermal insulating materials for pipes, tanks,
vessels, ductwork and equipment operating within the temperature
range -40°C to +700°C
BS 5970:2001 Code of practice for thermal insulation of pipework and equipment in
the temperature range of -100°C to +870°C
BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations.
Sixteenth edition
BS 3958 (Various) Thermal insulating materials
BS 3416:1991 Specification for bitumen-based coatings for cold application,
suitable for use in contact with potable water
BS 4800:1989 Schedule of paint colours for building purposes
BS 1710:1984 Specification for identification of pipelines and services
BS 3955:1986 Specification for electrical controls for household and similar general
purposes
BS EN 60529:1992 Specification for degrees of protection provided by enclosures (IP
code)
BS 4999 (Various) General requirements for rotating electrical machines.
BS 5000 (Various) Specification for rotating electrical machines of particular types or for
particular applications

BS EN 60034- Rotating electrical machines. Degrees of protection provided by the

5:2001, IEC 60034- integral design of rotating electrical machines (IP code).
5:2000 Classification
BS 3456-1:1969 Specification for safety of household and similar electrical
appliances. General requirements
BS EN 60335-2- Specification for safety of household and similar electrical
73:1997 appliances. Particular requirements. Fixed immersion heaters
BS EN 60335-1:1995 Specification for safety of household and similar electrical
appliances. General requirements
BS 799-5:1987 Oil burning equipment. Specification for oil storage tanks
BS 2594:1975 Specification for carbon steel welded horizontal cylindrical storage
tanks
BS EN 12285-1:2003 Workshop fabricated steel tanks. Horizontal cylindrical single skin
and double skin tanks for the underground storage of flammable and
non-flammable water polluting liquids
EUROVENT 4/5 – Method of Testing Air Filters Used in General Ventilation
1992
DW144 (1998) Specification for Sheet Metal Ductwork - low, medium and high
pressure/velocity air systems
DW143 (2000) A Practical Guide to Ductwork Leakage Testing

The following shall be provided:
Drawings
• Foundation
• General arrangements
• P&IDs
• SLDs
Data
• Cable Schedules
• Calculations
• I/O Schedules
• Manufacturers' catalogues and data sheets
Certificates
• Test Certificates
• Check Sheets

J9.4 MATERIALS AND WORKMANSHIP
J9.4.1 Environmental conditions
J9.4.1.1 Outdoor and overall conditions

The equipment shall be designed and constructed for continuous operation at full load under the
climatic and environmental conditions at the Site, as given elsewhere in the Specification.
J9.4.1.2 Indoor conditions

For indoor rooms general air conditioning or forced ventilation will be provided. The ambient
temperatures in the various rooms depend on the room classification for air conditioning and
ventilation as shown in the section for air conditioning and ventilation. However, in case of
failure in the air-conditioning or ventilation system, the power supply equipment shall be suitable
for operation under the following conditions:
ambient air temperature max. + 55°C
min. 0°C
relative humidity 85%
J9.4.1.3 Damp conditions

For indoor areas including those listed below with increased environmental conditions such as
water spray and aggressive atmosphere the equipment shall be specially designed as stated in the
detailed specification.
• pumping station
• battery rooms
• chemical buildings
J9.4.2 General requirements

Independent of the location in which it is installed, equipment and materials provided for outdoor
installation shall be resistant to the salt laden climate, sand and sand storms, seismic activities
and solar radiation.
J9.4.3 Fire and smoke barriers

Where fire barriers exist or are to be formed in new works, the Contractor shall make adequate
provision for fire and smoke barriers in and around items installed which pass through all floors,
and through voids, wall, partition, etc., which are identified as a fire barrier.
The Contractor shall ensure that the integrity of any such fire barrier is properly maintained
where pierced by any service.
J9.4.4 Circulating pumps
J9.4.4.1 General
Values of the resistance to fluid flow of items of equipment, pipework and/or the total
distribution system where indicated in the contract documents are approximate. It shall be the

responsibility of the Contractor to verify these values and provide pumps capable of delivering
the required volume when operating against the actual total system resistance.
Pumps shall comply with the requirements of BS EN 1151, BS 4082 - 1 and 2 and BS 5257, as
applicable.
Pumps shall be `type' tested in accordance with the requirements of BS EN ISO 9906 and shall
be selected to give the correct fluid flow rate. Test certificates and performance curves shall be
submitted.
Pumps and their drives shall be segregated such that failure of pump seals shall not result in
damage to drive motors.
J9.4.4.2 Pumps used in DHWS and CWS systems

Horizontal or vertical circulators shall be electrically driven and of the following types:
(a) Centrifugal type, close coupled, or with direct or approved indirect drive and taper
connections where necessary on suction and delivery ports. Directly driven pumps shall
be mounted on a common bed-plate.
(b) In-line pumps with connections of a different size to the main pipework may be used
subject to the Engineer's approval. The Contractor shall then ensure that eccentric
reducers are correctly fitted at suction and delivery ports.
(c) For DHWS (domestic hot water systems) and CWS (cold water service) systems, pumps
shall be as items (a) or (b) above but shall have body castings of gunmetal to BS EN
1982 or stainless steel to BS EN 10084.
Each circulating pump shall be installed with a valve on the inlet and a valve on the outlet
connections.
Shafts shall be corrosion resistant. Dripless mechanical shaft seals shall be limited to system
temperatures below 120oC. Where packed glands are provided hardened steel shaft sleeves shall
be fitted. Where a lantern ring is fitted it shall be non-metallic. Gland packing material and
construction shall be suitable for the operating conditions and shall be approved by the Engineer.
Packed glands shall be provided with separate drip pipes, run to discharge visibly over a tundish
or water sump.
Bearings shall be either sleeve type with oiling ring and reservoir, or ball or roller type with
grease lubricator. The bearings shall be outside the stuffing box and shaft seal.
Each floor-mounted circulating set shall be properly levelled, bolted down and grouted-in, on a
brick or concrete base if required, to provide a minimum height to the underside of the pump of
300mm above floor level. The Contractor shall be responsible for providing all dimensions and
details to enable the bases to be set out. Anti-vibration mountings and flexible connections shall
be provided as necessary. The Contractor shall ensure that the complete unit is efficiently
balanced to eliminate noise and vibration. Belts, where fitted, shall be correctly aligned and
tensioned.
Pressure gauges shall be connected to the main on each side of the circulator. Where duplicate
pumps are provided the gauges shall be connected to the common suction and delivery mains.
The gauges shall be provided with air venting facilities, flanged backs, and shall be mounted at
the same horizontal level.

J9.4.4.3 Fire protection system pumps

Pumps providing a water supply to a sprinkler installation shall comply with the requirements of
BS 5306:2.
J9.4.4.4 Pumps used with humidifiers

The performance of pumps used with humidifying equipment shall cater for the resistance of all
associated pipework and fittings and provide sufficient pressure at the terminals to ensure
satisfactory atomisation of the water.
J9.4.4.5 Pumps used with cooling tower condenser water

The performance of condenser water pumps shall cater for the static lift required to the cooling
tower and all other resistances.
J9.4.5 Service pipework distribution systems
J9.4.5.1 General
Unless otherwise indicated, steel and copper pipework systems shall be in accordance with BS
EN 13480 or BS 1306 as relevant.
Where any of the services referred to in this section require the connection of differently sized
items, the Contractor shall be responsible for providing and installing the necessary adaptors.
Joints shall not be made in the thickness of any wall, floor or ceiling, and pipework shall not be
embedded in the structure of floors unless approved by the Engineer. Where pipework passes
through walls, floors or ceiling, sleeves shall be provided. Pipework passing through floors shall
be provided with approved floor and ceiling plates fastened securely to the pipe. Where a piped
service perforates a structure which is a fire barrier with a designated fire delay characteristic to
BS 476-20, the sleeve shall act as a fire stop complying with the local Building Regulations.
Fittings shall be of the same size as the tubes and pipes to which they are connected.
Exceptionally where a fitting having the required outlet is not of standard manufacture, the
necessary size reduction may be accomplished by the use of one bush for each connection.
Galvanised fittings shall be used only on galvanised pipework.
Pipework shall follow the contours of walls. The clearance between pipework, fittings, lagging or
flanges, and the wall or any other fixtures, shall be not less than 25mm.
Purpose made bends or springs may be used where it is necessary to deviate from a straight run
in un-galvanised pipework. In galvanised pipework deviations shall be formed from standard
fittings.
Bends or springs in tubes of DN50 and above shall be hot pulled and the tubes shall remain
circular after setting.
Eccentric reducing sockets shall be used where changes of bore are made in runs of nominally
horizontal pipework to facilitate air venting and draining.
Before pipework is assembled, the Contractor shall ensure that tubes and tube ends are free from
burrs and cutting dross. Tube ends shall be cleaned thoroughly of deleterious materials such as
rust, scale, paint, oil etc. Open ends left during the progress of work shall be closed temporarily
with purpose made metal, plastics or wood plugs or caps, or blank metal flanges.

Entry and exit holes for pipework services from buildings shall be sealed and plugged. For
service conditions below 60oC the sealant shall be mastic compound; above this temperature
sealants shall be silicone rubber. Where pipework enters a building through a duct or hole which
is considered by the Engineer to be too large for such treatment, a mild steel blanking plate not
less than 6mm thick shall be built into the walls of the duct or hole. The service pipes shall pass
through clearance sockets (not less than 4 diameters in length) welded into the blanking plate,
and the spaces between pipes and sockets shall be sealed and plugged as above.
Return headers, where indicated, shall be welded with flanged connections and ends. Each circuit
isolating valve shall be connected direct to a vertical flanged outlet on the top of the return
header. On the circuit side of the isolating valve a tee shall be fitted with a vertical thermometer
in the top reduced outlet. Each circuit return shall be taken horizontally towards the wall behind
the header to another tee, with a reduced outlet in a downward direction, into which the circuit
emptying pipe shall be connected and extended to a drain cock or valve below the level of the
header. The circuit return shall be connected into the vertical full-bore outlet of this second tee.
Headers shall be horizontal and thermometers, drain valves and circuit isolating valves shall be
arranged at common horizontal levels.
Flow headers where indicated shall be welded with flanged connections and ends, and installed
to prevent undue stresses on the boilers and their connections.
Unless otherwise indicated, both flow and return headers shall be provided with one spare
flanged connection. These connections shall be of sizes not less than the largest circuit
connections to the headers and they shall be sealed with blank flanges.
Metallic pipework systems shall be bonded in accordance with BS 7671 and all pipework
installations shall be electrically continuous.
J9.4.5.2 Tubes and pipes

(i) Tubes and pipes used for DHWS, and cold water services, shall be as indicated in the
Pipework Tables section, unless specifically indicated to the contrary in the Particular
Specification and/or Drawings.
(ii) Steel pipework shall be galvanised.
(iii) Pipework designated as 'concealed' in the Pipework Tables section shall include all
pipework in chases, ducts, service shafts, partitions, ceiling voids, floors etc. It shall not
include short lengths of pipework passing through the building structure.
J9.4.5.3 Pipework joints and fittings - DHWS systems

(i) Pipework joints and fittings on DHWS systems shall be stainless steel, copper, or
galvanised steel with stainless steel or copper dead-legs.
(ii) Joints on galvanised pipework shall be screwed, except at dismantling points where they
shall be flanged.
(iii) Fittings for copper pipework up to and including DN50 shall be of the capillary or
compression type to BS 864-2. Fittings shall be resistant to dezincification where
recommended by the Water Undertaking and as approved by the Engineer. Joints over
DN50 shall be brazed or flanged as item (iv).

(iv) Flanges for copper pipework shall be of composite type complying with BS EN 1092-3
comprising copper alloy inserts brazed to the tube with loose steel rocking rings. Flange
connections shall comply with items (v) and (vi) as appropriate.
(vi) Flanged joints shall be made with gaskets to BS EN 1514-1 or BS 3063 as appropriate.
They shall be of a grade and thickness suitable for the temperature, pressure and
operating conditions.
(vii) Pipework shall be arranged to allow easy dismantling. Dismantling points in copper
pipework up to and including DN50 shall be unions, otherwise they shall be flanged.
(viii) Where cold water services inside buildings do not form part of the Works, the DHWS
system shall terminate within 450mm of each sanitary fitting or range of appliances.
J9.4.5.4 Pipework joints and fittings - cold water systems

(i) Pipework joints and fittings for cold water systems shall be stainless steel, Polyethylene,
PVC, other plastics, or copper as indicated.
(ii) Copper systems shall comply with items (iii) and (iv).
(iii) Fittings for copper pipework up to and including DN50 shall be of the capillary or
compression type to BS 864-2. Fittings shall be resistant to dezincification where
recommended by the Water Undertaking and as approved by the Engineer. Joints over
DN50 shall be brazed or flanged as item (v).
(iv) Pipework shall be arranged to allow easy dismantling. Dismantling points in copper
pipework up to and including DN50 shall be unions, otherwise they shall be flanged.
(v) Flanges for copper pipework shall be of composite type complying with BS EN 1092-
3comprising copper alloy inserts brazed to the tube with loose steel rocking rings.
Flange connections shall comply with items vi and vii as appropriate.
(vi) Flanged joints shall be made with gaskets to BS 4865-1, or BS 3063 as appropriate.
They shall be of a grade and thickness suitable for the temperature, pressure and
operating conditions of the service.
(vii) Stainless steel pipe fittings shall be capillary type to BS 864.
(viii) Polyethylene and PVC, or other approved plastics pipes, shall have compression fittings
to BS EN 1254 or solvent welded fittings to BS EN 1452. Where approved by the
Engineer, mechanical joints to BS EN 1452, or joints suitable for ABS or PB pipework
may be used.
Joints on galvanised pipework shall be screwed, except at dismantling points where they shall be
flanged.
Cleaning and sterilisation of the system shall be carried out.
J9.4.5.5 Pipework joints and fittings - fire protection systems

(i) Fire protection systems shall comply with BS 5306 parts 1 and 2 as appropriate.
(ii) Where screwed joints are used, the male component shall be taper threaded to BS 21
and BS EN 10226-1 and the jointing between them shall be PTFE tape to BS 5292 Type
C and to BS 7786 unless otherwise indicated.
(iii) Threaded fittings shall be malleable cast iron, banded or beaded pattern, manufactured
in accordance with BS 143 and galvanised to match associated piping as necessary.

(iv) Proprietary grooved pipe jointing systems using elastomeric seal rings may be used with
the approval of the Engineer up to a maximum temperature of 95oC and a maximum
pressure of 9.5 bar. They shall be suitable for the temperature, pressure and operating
conditions of the service. Manufacturer's recommendations on pipe wall thickness,
methods of groove forming (cut or rolled), groove dimensions, seal materials and
limiting operational loads shall be followed. Piping ends shall be within the
recommended tolerances and shall be free from burrs and distortion.
J9.4.5.6 Welding
Unless otherwise indicated steel pipework complying with BS 1387 or BS EN 10216 and BS EN
10217 with diameters and wall thicknesses not exceeding DN 200 and 20mm respectively shall
be welded in accordance with a method of working to be submitted by the Contractor and
approved by the Engineer. Steel pipes of larger diameters and greater thicknesses shall be welded
in accordance with BS 2971, BS 2640 or other specifications as indicated or approved by the
Engineer.
Joint designs, welding procedures, welder certification and production weld quality shall comply
with the requirements the Engineer.
Unless otherwise indicated, joint designs, welding procedures and welders' competency tests
shall be submitted by the Contractor and approval by the Engineer. Prior approval shall be
obtained to the installation of gusseted bends.
Welds in fire protection system pipework shall be visually inspected in accordance with the
recommendations of BS EN 970, and copies of the records shall be given to the Engineer. Welds
will be checked by the Engineer at the time the pipework is pressure tested. Where the Engineer
is unsatisfied, the welds shall be subjected to non-destructive testing procedures.
J9.4.5.7 Brazing
Copper pipework up to DN200 with wall thicknesses up to 4.5mm shall be brazed in accordance
with a method of working to be submitted by the Contractor and approved by the Engineer. For
other pipe sizes and thicknesses, brazing shall be carried out in accordance with BS 1723, or
other specification as indicated or approved by the Engineer.
Joint designs, brazing procedures, brazer certification and production joint quality shall comply
with the requirements as interpreted by the Engineer.
Unless otherwise indicated or approved, filler metal shall be AG303 as specified in BS EN 1044.
J9.4.5.8 Pipework supports

Pipework shall be supported adequately in such a manner as to permit free movement due to
thermal expansion and contraction. Pipework supports shall be arranged as near as possible to
joints, and the centre spacings shall not exceed those given in the Pipework Tables section.
Where there are two or more sizes of pipes, the common support spacings shall be those required
by the smallest bore pipework.
Branches from vertical pipework shall not be used as a means of support for risers.
Brackets for mild steel pipework shall be mild steel or malleable iron with ferrous fixings.
Brackets for copper pipework shall be brass or gunmetal with non-ferrous fixings.

J9.4.5.9 Pipework anchors

On mild steel pipework, mild steel anchors capable of resisting the maximum stresses shall be
provided and shall be welded to the pipework. Where it is impracticable to weld the anchors to
the pipework, cast iron chairs with at least two wrought-iron stirrup bolts shall be used, the bolts
being provided with sufficient thread to ensure an effective grip on the pipe. For copper
pipework the anchors shall be provided by wide copper straps secured to the pipework in such a
manner that the pipe is not damaged.
J9.4.5.10 Pipework expansion devices

Provision for movement due to thermal expansion and contraction shall be made by changes in
direction of the pipework, by loops or by special expansion joints approved by the Engineer.
Measures shall be taken to prevent the movement of pipework damaging thermal insulation.
Supports and guides shall be arranged to ensure that movement is taken up in the manner
intended.
J9.4.6 Electrically heated hot water storage vessels

Where an electrical immersion heater is fitted into a storage calorifier or cylinder for the
supplementary heating of domestic hot water, or where electrical heating is used in any vessel for
this purpose, the following items shall be included:
(a) A safety valve on the shell, or on associated pipework immediately adjacent to the shell.
The set pressure shall be in accordance with BS 853.
(b) On installations of two or more vessels each safety vent may be connected into a
common vent pipe through a three-way cock so arranged that no vessel can be isolated
simultaneously from the open vent pipe and the free outlet. Vent pipes shall be
continuously rising and unobstructed by a valve or any other item.
Three way cocks shall have the position of the ports clearly engraved on the square end
of the plug. Each cock shall be provided with a loose key.
(c) A thermostat acting on the power supply to maintain the water temperature within an
adjustable setting between 50°C and 80°C.
(d) An independent high limit cut-out device set to isolate the power supply at a water
temperature 10°C above the thermostat setting. This device shall be arranged for manual
reset.
J9.4.7 Cisterns and cold water tanks

Cisterns and cold water tanks shall be of the following types, as required or as indicated
elsewhere:
(a) Welded or riveted mild steel.
(b) Pressed steel sectional.
(c) Thermo-plastics for cisterns.
(d) Glass reinforced plastics (one piece).
(e) Glass reinforced plastics (sectional).
(f) Aluminium/galvanised steel, lined with a butyl rubber membrane.

Mild steel cisterns shall comply with BS 417 Grade A galvanised after manufacture, sacrificial
anodes being provided where indicated. Pressed steel sectional tanks shall be approved. Thermo-
plastics cisterns shall comply with BS 4213. Glass reinforced plastics and butyl rubber lined
cisterns shall be approved by the Engineer.
Each cistern shall be provided with a loose cover formed in sections not exceeding 2m long and
1m wide. Covers for steel cisterns shall be formed with 1.6 mm thick galvanised mild steel with
flanged edges to the sections. Covers for plastics and butyl rubber lined cisterns and tanks shall
be of the same material as the cistern or tank body. The termination of vent pipes into cisterns
and tanks shall permit the easy removal of the covers.
Pressed steel tanks shall be of the externally flanged type and complete with purpose made
covers and all necessary tie rods. Galvanised mild steel cisterns and pressed steel tanks shall be
painted internally with two coats of an approved bituminous solution.
Each cistern or tank shall be fitted with a ball-float valve. Ball-float valves shall be of the sizes
indicated and suited to the pressure available. The cistern or tank shall be installed in a position
that allows easy access for maintenance of the ball-float valve.
Float operated valves shall be to BS 1212 of a size and type to suit the cistern and duty and those
for use with feed/expansion and spill tanks shall be of the long-arm type arranged to shut off
when the tank contains 150 mm depth of water. Where a water meter, measuring the make-up
water quantity is indicated, the ball-float valve shall be of the delayed action type. The floats of
the valves shall be of heavy copper to BS 1968 Class C, or may be of heavy plastics to BS 2456
for cold water cisterns.
Warning and/or overflow pipes shall be twice the bore of the ball-float valve fitted or 32mm size,
whichever is the greater. Warning and/or overflow pipes shall be run to discharge outside the
building.
Connections to mild steel cisterns and tanks shall be made by means of bosses, screwed flanges
or pads and studs. Connections on mild steel cisterns shall be welded before galvanising.
Openings for connections to other tanks may be cut on site and the connections made with back-
nuts and plastics washers. For thermo-plastics and butyl rubber lined cisterns and tanks,
connections shall be fitted in accordance with the manufacturer's recommendations. Flanged
connections may be used on modular glass reinforced plastics tanks and cisterns.
Cisterns and tanks shall be labelled.
J9.4.8 Cold and chilled water storage vessels

This clause concerns the storage for cold, chilled and condenser water associated with air
conditioning and cooling installations only.
Cisterns and tanks shall be of the following types as required or as indicated elsewhere:
(a) Welded or riveted mild steel, to BS 417 Grade A, galvanised after manufacture;
(b) Pressed steel sectional to BS 1564;
Mild steel cisterns shall comply with BS 417 Grade A galvanised after manufacture, sacrificial
anodes being provided where indicated. Pressed steel sectional tanks shall be approved.
Each cistern shall be provided with a loose cover formed in sections not exceeding 2m long and
1m wide. Covers for steel cisterns shall be formed with 1.6mm thick galvanised mild steel with
flanged edges to the sections. The termination of vent pipes into cisterns and tanks shall permit
the easy removal of the covers.

Pressed steel tanks shall be of the externally flanged type and complete with purpose made
covers and all necessary tie rods. Galvanised mild steel cisterns and pressed steel tanks shall be
painted internally with two coats of an approved bituminous solution.
Each cistern or tank shall be fitted with a ball-float valve. Ball-float valves shall be of the sizes
indicated and suited to the pressure available. The cistern or tank shall be installed in a position
that allows easy access for maintenance of the ball-float valve.
Float operated valves shall be to BS 1212 of a size and type to suit the cistern and duty and those
for use with feed/expansion and spill tanks shall be of the long-arm type arranged to shut off
when the tank contains 150mm depth of water. Where a water meter, measuring the make-up
water quantity is indicated, the ball-float valve shall be of the delayed action type. The floats of
the valves shall be of heavy copper to BS 1968 Class C.
Warning and/or overflow pipes shall be twice the bore of the ball-float valve fitted or 32mm size,
whichever is the greater. Warning and/or overflow pipes shall be run to discharge outside the
building.
Connections to mild steel cisterns and tanks shall be made by means of bosses, screwed flanges
or pads and studs. Connections on mild steel cisterns shall be welded before galvanising.
Openings for connections to other tanks may be cut on site and the connections made with back-
nuts and plastics washers. For thermo-plastics and butyl rubber lined cisterns and tanks,
connections shall be fitted in accordance with the manufacturer's recommendations. Flanged
connections may be used on modular glass reinforced plastics tanks and cisterns.
Cisterns and tanks shall be labelled.
J9.4.9 Valves, taps and cocks
J9.4.9.1 General
Unless otherwise indicated, copper alloy shall mean gun-metal grade CC491K to BS EN 1982.
Gland packing, plug lubricants etc shall be suitable for the application. For potable water
systems, materials shall comply with the requirements of the Water Undertaking. Graphite
packing will not be accepted in valves for hot systems.
Valves shall be easily accessible. Valves fitted in horizontal pipework or to equipment with
horizontal connections, shall be installed with the valve spindle vertically upwards unless
otherwise agreed by the Engineer. Check valves shall be installed in accordance with the
manufacturer's recommendations.
Where indicated, valves or cocks shall be lockable, with purpose made locking devices which do
not impede the fast closure of the valve where that is necessary. The locking device shall remain
attached to the valve in both 'open' and `closed' position.
Where modifications or extensions to existing services are to be carried out, all valves which are
to be removed and re-fixed shall be overhauled thoroughly, with glands and seals renewed, all to
the satisfaction of the Engineer.
Copper alloy valves shall be resistant to dezincification where recommended by the Water
Undertaking and approved by the Engineer.

J9.4.9.2 Safety and relief valves

Safety and relief valves shall meet the requirements of the appropriate BS for the pressure
equipment to which they are connected, and they shall be suitable for the operating conditions of
the system. They shall be of the totally enclosed spring-loaded type with padlock.
Safety and discharge pipework for hot water systems shall be laid with a continuous downward
gradient.
Discharge and waste pipes shall terminate at visible and safe positions to be agreed with the
Engineer.
J9.4.9.3 DHWS and cold water supply systems

Check and anti-vacuum valves to BS 6282 and BS 6283 shall be provided.
Isolating valves shall be gate or plug type to BS EN 1171, BS EN 12288, BS 5154 or BS 5158.
Where a cold water service installation is included in this Contract, the Contractor shall provide
copper or polyethylene tube connections to draw-off points, as indicated.
Urinal cistern inlets shall be controlled by solenoid operated valves serving one or more cisterns
as indicated or other flow control device to the approval of the Engineer. These valves shall be
actuated by means of mains operated clocks arranged to ensure that all cisterns flush at least once
per day except at weekends or other fixed periods as indicated. Flow rates to individual urinal
cisterns shall be regulated by pet-cock or disc fittings.
Where sanitary appliances are to be provided with spray taps, a strainer shall be provided
immediately after the stop valves on the hot and cold water connections adjacent to the fittings or
ranges of fittings. The strainer shall include a stainless steel screen of mesh size as recommended
by the spray tap manufacturer.
Stop valves and drinking water taps shall be labelled.
J9.4.9.4 Fire protection systems

Landing valves on wet and dry rising mains shall comply with the requirements of BS 5306 Part
1.
Stop valves and back pressure valves for sprinkler systems shall comply with the requirements of
BS 5306-2.
Fire protection systems shall be in accordance with the Employer's regulations.
J9.4.10 Fans
J9.4.10.1 General
Values of the resistance to air flow of items of equipment, ductwork and/or the total distribution
system where indicated in the contract documents are approximate. It shall be the responsibility
of the Contractor to verify these values based on the equipment offered and provide fans capable
of delivering the required air volume when operating against the actual total system resistance.
Fans shall be type' tested in accordance with the requirements of BS 848 and shall be selected to
give the air volume flow rate and sound power level specified in the contract documents.
Unless otherwise indicated, the requirements of this Section shall not apply to individual fans
having a duty air flow rate of 0.7m3/s or less.

All fans should be constructed to a fully developed design and shall be capable of withstanding
the pressures and stresses developed during continuous operation at the selected duty.
Additionally, all belt driven fans shall be capable of running continuously at ten per cent in
excess of the selected duty speed.
Fan drives shall be as detailed elsewhere in this Specification.
Fans shall be installed using bolts, nuts and washers with all às cast' bearing surfaces for bolt
heads and washers counter faced. Holding-down bolts for fans and motors shall be provided with
means to prevent the bolts turning when the nuts are tightened. Anti-vibration mountings shall be
as detailed elsewhere in this Specification. Fans heavier than 20kg shall be provided with
eyebolts or other purpose made lifting facilities.
Where indicated or as necessary, fans shall be fitted with variable inlet vanes which shall be
matched to the fan performance to give stable control. Vanes shall be closely interlocked to
ensure movement in unison and operation shall be manual or automatic as indicated. Where
manual control is indicated, the operating device shall facilitate positive locking in at least five
different positions.
Vane blades shall not vibrate or flutter throughout their movement and the construction of the
linkage system shall minimise friction and lost motion.
The shaft and impeller assembly of all centrifugal, axial flow and mixed flow fans shall be
statically and dynamically balanced. All propeller fans shall be statically and dynamically
balanced where the impeller diameter is 750mm or greater. Limits of vibration severity shall be
Fan bearings shall be of a type suitable for the installed attitude of the fan. They shall be grease/
oil ball and/or roller type or alternatively oil lubricated sleeve type. All bearing housings shall be
precision located in position and arranged so that bearings may be replaced without the need for
realignment. Bearing housings shall be protected against the ingress of dust and, where fitted
with greasing points, they shall be designed to prevent damage from over-greasing. For grease
lubricated systems the bearings shall be provided with grease in amount and quality
recommended by the bearing manufacturer. For oil lubricated systems the housings shall provide
an adequate reservoir of oil and shall include a filling plug and be oil tight and dust proof.
Systems other than total loss types shall include an accessible drain plug. All bearing lubricators
shall be located to facilitate maintenance.
J9.4.10.2 Centrifugal Fans

Centrifugal fans for high-velocity high-pressure systems shall be backward bladed type.
Unless otherwise indicated, centrifugal fans consuming more than 7.5kW at the fan shaft shall be
of the backward bladed type having a fan total efficiency not less than 78%.
Fan casings shall be constructed to permit withdrawal of the fan impeller after fan installation.
Fans other than those in air handling units shall be provided with flanged outlet connections and
spigoted inlet connections unless otherwise indicated, except that for negative pressures greater
than 500Pa inlet connections shall be flanged. A plugged drain point shall be fitted at the lowest
point in fan casings. Permanent indication shall be provided to show the correct direction of
rotation of the fan impeller. Fan casings shall be provided with removable access panels which
shall incorporate purpose made air seals. The sizes of access panels shall be such as to facilitate
cleaning and maintenance of the impeller.

Impellers shall be of mild steel or aluminium alloy of riveted, welded or other approved
construction, with spiders or hubs of robust design.
J9.4.10.3 Axial flow fans

Axial flow fan casings shall be rigidly constructed of mild steel or aluminium alloy, stiffened and
braced where necessary to obviate drumming and vibration. Mounting feet shall be provided
where necessary for bolting to a base or to supports. Inlet and outlet ducts shall terminate in
flanges to facilitate removal. For in-duct mounting fans the length of the fan casing shall be
greater than the combined length of the impeller(s) and motor(s) and electrical connections to the
motors shall be through an external terminal box secured to the casing.
Impellers shall be of steel, aluminium or plastics and the blades shall be secured to the hub or the
blades and the hub shall be formed in one piece. The hub shall be keyed to the shaft. Blades shall
be aerofoil section or laminar and capable of pitch adjustment where indicated.
Where axial flow fans are driven by motors external to the casings of the fans the requirements
for drives and guards as mentioned elsewhere in this Specification shall be met. Unless otherwise
indicated, a guard is not required for any part of a drive which is inside the fan casing. An access
panel with purpose made air seal shall be provided in the fan casing; the access panel shall be
sized to facilitate maintenance.
Where axial flow fans of the bifurcated type are indicated, the motors shall be out of the
airstream. Motors may be placed between the two halves of the casing in the external air or may
be placed within the fan casing provided that effective ventilation is given to the motors.
J9.4.10.4 Propeller fans

Propeller fans shall be ring mounted or diaphragm mounted as indicated. Impellers shall be of
steel, aluminium or plastics and the blades shall be secured to the hub or the blades and hub shall
be formed in one piece.
Mixed flow fan casings shall be rigidly constructed of mild steel, or aluminium alloy stiffened
and braced where necessary to obviate drumming and vibration. Mounting feet shall be provided
where necessary for bolting to a base or supports. Inlet and outlet shall terminate in flanges to
facilitate removal. Stator vanes shall be or mild steel or aluminium alloy. The unit shall be
designed to facilitate access to the impeller. Where motors are mounted external to the casing the
requirements for drives and guards as mentioned elsewhere in this Specification shall be met. An
access panel with purpose made air seal shall be provided in the fan casing; the access panel shall
be sized to facilitate maintenance.
J9.4.10.5 Mechanical roof extract units

The fans used in roof extract units shall meet the appropriate requirements of the preceding
clauses relating to fans generally and to particular types of fans. Cowls and bases shall be of
materials which are resistant to the weather, solar radiation and are appropriate to the location of
the fan. Casings shall be formed and sealed in the structure to provide weatherproof fitting to the
building structure. Adequate access to electrical supply terminals and lubrication points shall be
provided by means of hinged cowls or otherwise as appropriate. Back-draught dampers and/or
fire release dampers shall be provided where indicated. Bird guards of not greater than 25mm
mesh shall be provided as an integral part of the unit.

J9.4.10.6 Protectively coated fans and fans for corrosive or hazardous applications
Where fans are required to handle toxic, corrosive, flammable, explosive or high temperature
gases the materials of construction shall be as indicated and all relevant safety regulations shall
apply. Bearings and lubrication arrangements shall be suitable for the conditions. Protectively
coated fans shall meet the appropriate requirements of the preceding clauses relating to fans
generally and to particular types of fans; the form of protection shall be as indicated. Where a
protective coating is required for use with corrosive gases the coating shall cover all parts of the
complete fan, motor and casing assembly which will be in contact with the corrosive gases. No
fan shall be installed if the protective coating has been damaged in any way. Impellers shall be of
coated steel, stainless steel or aluminium or plastics as indicated. Where fans are installed in a
potentially flammable explosive atmosphere requirements are to be as indicated and the electrical
installation and motor shall be suitable for the hazardous area zone classification in which it is
installed in accordance with BS 5345.
J9.4.11 Automatic sand filters
J9.4.11.1 General
Automatic sand filters shall be based upon the principle of inertial separation of sand from air by
virtue of a relatively circuitous flow path for air compared with a straight flow path for sand.
Each sand filter shall consist of housing, bleed air manifold, cell bodies, blade packs, bullnoses,
and inlet screen. All finished components shall be hot dip galvanized finished with a 2 pack
epoxy resin paint.
J9.4.11.2 Housing
Housings shall be constructed of not less than 11 gauge steel. The housing shall be of all welded
construction and equipped with continuous standing flanges around the periphery of both air
entering and air exiting sides. Flanges shall have pre-drilled bolt holes to facilitate field
installation.
J9.4.11.3 Bleed air manifold

Housings shall be equipped with a bleed air manifold constructed of not less than 11 gauge steel,
all welded construction. The recommended 10% bleed air volume shall be achieved by the use of
bleed air fan/s.
J9.4.11.4 Blade packs

Blade packs shall be constructed of not less than 20 gauge steel with arc welded construction.
Blade packs shall be removable to provide for inspection or service.
J9.4.11.5 Bull nose

The bullnose shall be aerodynamically formed to provide proper air entry. One bullnose will be
required for each two blade packs to properly direct air to each tapered cell

J9.4.11.6 Bleed slot

Bleed slots shall be an integral part of each dust bin. The bleed slot/dust bin shall be constructed
to not less than 16 gauge steel. The bleed slot shall have rounded entry configuration to minimise
obstruction or plugging under heavy dust concentrations.
J9.4.11.7 Inlet screen

Inlet screens shall consist of a 26 gauge, four mesh, galvanized hardware cloth integrally
supported by a double layered 16 gauge galvanised steel frame. Inlet screens shall be bolted to
the housing.
J9.4.11.8 Efficiency
The sand filter efficiency shall not be less than 93% at a clean airflow rate of 1700m3/h per single
cell using a bleed rate equalling 10% of inlet flow. Inlet to clean air outlet resistance shall not
exceed 0.30kPa at 1700m3/h clean airflow.
J9.4.12 Air filters
J9.4.12.1 General
Filter assemblies shall operate with at least the efficiencies specified in this Section, or as
indicated elsewhere in the Specification or on the drawings.
Filter material or wetting agent shall not be carried over. Filters shall be complete with robust
purpose made holding frames which shall not distort in operation and all filters shall be arranged
to facilitate access for cleaning, removal and refitting. Purpose made seals shall be provided to
minimise air leakage around filters and the effectiveness of the seals shall not be impaired by
periodic removal and refitting of the filter cells.
A differential pressure gauge of the inclined manometer type shall be provided for each filter
bank and the gauge shall be fixed in such a position, outside the casing that it is accessible and
easily read. The gauge shall incorporate a graduated scale on which the reading of maximum
pressure drop shall occur in not less than 75% of the total scale length.
J9.4.12.2 Fire properties

Where a flameproof filter medium is required, the material shall comply with the requirements of
BS 476.
Where washable type flameproof filters are offered or specified the filter medium shall comply
with the requirements of BS 476 both before and after the washing treatment.
Where flameproof filter medium is indicated, and the filter is built into sheet metal ducting, the
ducting shall not be less than 1.6mm thick for at least 1.8m upstream and 1.8m downstream of
the filter; the immediate frames or cases of the filter elements shall be of a material which is
classified non-combustible when tested in accordance with BS 476-4.
For viscous types of filter the liquid shall have a flash point not less than 180oC.
J9.4.12.3 Dry replaceable medium type filters

Unless otherwise indicated, filters of this type shall be of a grade not less than EU3 in accordance
with Eurovent 4/5 standard. The design air velocity at the face of the filters shall not exceed 2.5

m/s. Bag filters shall inflate fully, shall not sag or flutter or be obstructed by contact with other
filter faces or duct surfaces.
At the design air volume flow rate the initial (clean) resistance shall not exceed 90 Pa for filters
of grade EU3 and 125 Pa for filters of a higher grade.
Sufficient spare filter medium shall be provided to replace the complete filter bank.
Unless otherwise indicated, filters shall be selected from the following range of preferred
nominal sizes:
(a) 600mm x 600mm
(b) 500mm x 500mm
J9.4.12.4 Throw away type panel filters

The filter medium shall be glass, natural or synthetic fibre or fabric. Metal wool filters will not
be accepted. Unless otherwise indicated filters of this type shall be of a grade not less than EU2
in accordance with Eurovent 4/5 standard. The design air velocity at the face of all the filters
shall not exceed 1.75m/s.
At the design air volume flow rate the initial (clean) resistance shall not exceed 50Pa.
J9.4.12.5 Open cell plastic cleanable type filters

The filter medium shall be processed open cell foamed plastics and shall be washable. The
element shall be supported on plastics coated steel wire formers with a metal frame. Filters of
this type shall be of a grade not less than EU3 in accordance with Eurovent 4/5 standard. The
design air velocity at the face of all filters shall not exceed 1.2m/s.
At the design air volume flow rate the initial (clean) resistance shall not exceed 75Pa.
J9.4.12.6 Automatic viscous type filters

The filter shall comprise a frame or enclosure, filter plates, motor, drive and fluid tank. There
shall be access to the tank containing the fluid to facilitate maintenance and the tools and
containers required for the removal of sludge shall be provided. Unless otherwise stated filters of
this type shall be of a grade not less than EU3 in accordance with Eurovent 4/5 standard. The
design air velocity at the face of the filter shall not exceed 2.5m/s and the operating resistance
shall not exceed 125Pa at the design air volume flow rate. To ensure that there is no carry over of
fluid from freshly wetted surfaces the rate of drive shall be suitably adjusted and set or the filter
shall incorporate shielding devices.
J9.4.12.7 Automatic fabric roll type filters

The filter shall comprise the complete assembly of filter frame, motor, drive, pressure differential
sensor and filter medium. The filter shall operate automatically to maintain operating resistance
within a range suited to the filter medium and the required operating efficiency. Provision shall
be made for over-riding manual starting and stopping of the filter movement; automatic
movement shall be controlled by the resistance across the filter, unless otherwise indicated.
Visual or audible warning that the end of the clean filter medium is approaching shall be
provided. Unless otherwise indicated, the driving motor shall be automatically switched off when
the end of the filter medium is reached.

Unless otherwise indicated, the initial (clean) resistance of the filter shall not exceed 65Pa and a
mean of 125Pa under design operating conditions. The air velocity through the filter medium
shall not exceed 2.5m/s unless otherwise indicated. Unless otherwise indicated filters of this type
shall be of a grade not less than EU2 in accordance with Eurovent 4/5 standard.
The motor and drive, the electrical insulation and lubricants shall be suitable for the conditions
indicated. The motor, drive and associated control equipment shall be accessible for maintenance
without disturbing the filter medium or roll. The medium shall be provided with an effective seal
to minimise air leakage around it.
A spare roll of filter medium shall be provided for each unit.
J9.4.12.8 High efficiency particulate air filters

High efficiency particulate air (HEPA) filters shall consist of pleated glass-paper or other
approved medium sealed within a rigidly constructed case.
Filters shall be constructed from a continuous sheet of medium folded over a separator of
aluminium or other approved material to form closely spaced pleats, the whole being sealed into
a casing with hard setting synthetic resin cement.
Alternatively, filters shall be constructed with filter elements in W formation, each element being
from a continuous sheet of filter medium formed into closely arranged pleats. The intersection of
each element shall be protected on the outside by a metal cap and the complete W formation
shall be sealed into a casing with hard setting synthetic resin cement.
The air filter casing, filter medium and sealing gaskets shall be of materials compatible with the
conditions indicated and the casing shall not warp, splinter or corrode. The external air sealing
gaskets shall ensure a positive air seal throughout the life of the filter.
All units shall be individually tested according to the requirements of BS 3928 and BS EN 779
and a test certificate shall be issued.
Completed installations using HEPA filters shall be tested as part of the final commissioning.
The test shall be carried out by the Contractor's specialist staff or by a competent independent
specialist acting for the Contractor.
J9.4.13 Air heaters
J9.4.13.1 General
Casings shall be of galvanised sheet steel not less than 1.2mm thick with angle framing at each
end drilled ready to receive the counter flanges on the connecting ductwork. Heaters shall be
supported so that their weight is not transmitted to ductwork and so that they can be removed
without disturbing adjacent ductwork. Inspection doors shall be provided on both the upstream
and the downstream sides of the heater.
J9.4.13.2 Electric type

Electric air heaters shall consist of a number of heating elements of the enclosed type mounted in
a sheet steel casing. The elements shall be so installed that they can be removed for cleaning or
renewal without dismantling ductwork. The surface temperature of the elements shall not exceed
400oC when measured in an air flow of 2.5 m/s at ambient temperature. A high temperature limit
device with hand reset button shall be incorporated such that the limit device sensor is nearest to
and above the heating elements which are energised by the first control step.

The control of electric air heaters, except for remote boosters, shall be interlocked with the fan
motor starters and an air flow control of the pressure type so that the heaters cannot operate
unless the fan is running.
Electric air heaters which are installed as boosters in branch ducts remote from the fans shall
have an air flow control of the vane or pressure type which shall isolate the heating elements
from the electricity supply in the event of the failure of air flow.
The number of elements in the heater shall be the same as or a multiple of the number of steps in
the controller. All heaters and heater sections of more than 3 kW loading shall be balanced over 3
phases and the complete heater bank shall be arranged for balanced operation on a 3-phase 4-
wire system.
The connections form each element shall be taken to a readily accessible terminal box arranged
for conduit entry. Each heater section shall be separately fused and the neutral point of all 3-
phase star-connected sections shall be brought out to a link in the terminal box. Near hot areas
the wiring insulation shall be of a quality suitable for the maximum temperature.
The total resistance of the heater to air flow shall not exceed 25Pa and the face velocity shall not
exceed 6m/s.
J9.4.14 Split air conditioning units
J9.4.14.1 General
Split air conditioning units shall each comprise an indoor evaporator unit and either a roof-
mounted, air-cooled condensing unit, or an internally mounted centrifugal air-cooled condensing
unit ducted to outside air, together with all interconnecting refrigerant pipework. Split units shall
comply with the requirements of BS EN 378-2.
J9.4.14.2 Roof mounted air-cooled individual room condensing units

Each air-cooled condensing unit shall comprise compressor, condenser coil, and propeller
cooling fans and all internal interconnecting pipework and control equipment. Each unit shall be
housed in a totally enclosed, fabricated steel, floor-mounting cubicle, complete with removable
panels to facilitate access to all component parts for maintenance. The units shall be designed for
outdoor mounting and all component steel parts shall be hot-dip galvanised. The units shall be
mounted on raised anti-vibration mountings.
The condenser shall be copper coil with aluminium fins mechanically bonded to it.
The condenser fans shall be propeller type. Fan blades shall be statically and dynamically
balanced, protected by anodized fan blade guards. Each fan shall be driven directly by an
individual motor.
The compressor shall be hermetically sealed and resiliently mounted
The units shall be suitable for continuous operation in dusty conditions at ambient shade
temperature of up to 50°C.
J9.4.14.3 Internal individual room evaporator unit

Internally mounted room evaporator units shall contain the evaporator, electric heater battery,
centrifugal fan, electrical terminal block, all electrical capacitors and all controls. The units shall
be wall mounted and shall be provided with concealed drains for condensate. Filtration shall be
provided by a washable filter accessible from the front of the unit.

The evaporator shall be a single-pass copper coil with light gauge aluminium fins mechanically
bonded to it and with an automatic thermostat to prevent excessive frosting.
Each unit shall be provided with a wall mounted isolation switch grouped with lighting switches,
together with a hand held remote control. Units shall have facilities for varying the fan speed and
air flow direction. Units shall be capable of thermostatic control to a pre-set temperature between
18 and 26° C
J9.4.14.4 Roof mounted air-cooled condensing units

Each air-cooled condensing unit shall comprise compressor, condenser coil, cooling fans and all
internal interconnecting pipework and control equipment. Each unit shall be housed in a totally
enclosed, fabricated steel, floor-mounting cubicle, complete with removable panels to facilitate
access to all component parts for maintenance. The units shall be designed for outdoor mounting
and all component steel parts shall be hot-dip galvanised. The units shall be mounted on raised
anti-vibration mountings.
The condenser coil shall be constructed of seamless copper tubes, arranged in staggered rows,
mechanically expanded into aluminium fins.
The condenser fans shall be propeller type, providing vertical air discharge. Fan blades shall be
statically and dynamically balanced, protected above by anodized fan blade guards. Each fan
shall be driven directly by an individual motor.
Compressors shall be of the serviceable hermetic type. The compressor and fan motors shall be
suitable for continuous three-phase 50 Hz operation.
All control equipment shall be contained in an integral but fully segregated cubicle compartment
with lockable hinged access doors.
J9.4.14.5 Internally mounted air-cooled condensing units

Internally mounted air-cooled condensing units shall be generally as specified for roof mounted
units except that condenser fans shall be of the centrifugal type suitable for ducting to external
louvers.
J9.4.14.6 Refrigeration plant pipework

Refrigeration pipework external to packaged equipment shall conform to BS EN 1057. Joints
shall be brazed or silver alloyed with each joint purged by nitrogen.
Pipework shall be supported securely, with isolation type hangers installed to prevent the effects
of compressor vibration being transmitted to the pipework. Pipework shall be arranged to avoid
trapping of oil in the evaporator or suction runouts.
A liquid line strainer and drier shall be installed in each refrigerator liquid line to protect the
expansion valve from scale and dirt. The drier shall remove accumulated moisture. The strainer
and drier may be a combined unit. A refrigerant moisture and liquid indicator shall be provided
for each external pipework circuit. After installation, the whole of the refrigeration pipework
shall be pressure tested and checked for leaks and dehydration.
Flexible pipes for individual room split units shall comply with EN 1736.

J9.4.14.7 Individual room wall air conditioning units

Each individual room air conditioning unit of the ‘through the wall’ pattern shall comprise two
sections of indoor and outdoor equipment divided by an insulated steel bulkhead. The indoor
section shall contain the evaporator, electric heater battery, centrifugal fan, electrical terminal
block and all electrical capacitors. The outdoor section shall house the compressor, condenser
and propeller fan. The entire units shall be mounted on slide-out chassis within a weatherproof
cabinet with removable front panel.
The compressor shall be hermetically sealed and resiliently mounted
The evaporator shall be a single-pass copper coil with light gauge aluminium fins mechanically
bonded to it and with an automatic thermostat to prevent excessive frosting.
The condenser shall be copper coil with aluminium fins mechanically bonded to it.
Filtration shall be provided by a washable filter accessible from the front of the indoor section.
The units shall be suitable for continuous operation in dusty conditions at ambient shade
temperature of up to 50°C.
J9.4.15 Air coolers
J9.4.15.1 General
Air cooler casings shall be of galvanised sheet steel not less than 1.2mm thick with flanged ends
drilled to receive counter flanges on connecting ductwork or other associated equipment. The
bottoms of casings shall be made in the form of a watertight drip tray from sheet steel galvanised
after manufacture, or be otherwise equally corrosion resistant. Water shall not be carried over
from a cooler battery into the system and an eliminator section shall be provided, where
indicated, to prevent such carry over. The drip tray serving the cooler shall be extended or a
separate tray shall be provided to collect water from the eliminator. Drip trays shall be sloped
toward a drain connection and pipework shall be installed from each connection to the nearest
sump or gully. The drain pipework shall include a water seal of adequate depth to prevent entry
or exit of air to or from the system. A separate drip tray shall be provided for each 1.2m depth of
coil. Sealing devices shall be provided at tops and bottoms of coils to minimise air bypass and
water carry over.
Particular care shall be taken to avoid the use of dissimilar metals in the construction of tubes
and extended surfaces and to avoid contact between dissimilar metals in the presence of free
moisture.
Sprayed coil tubes and extended surfaces shall always be of the same material. The secondary
extended surfaces shall be in firm and continuous mechanical contact with the primary tubes to
ensure maximum heat transfer.
The resistance to air flow through a cooler battery shall not exceed 125Pa and the face velocity
shall not exceed 2.5m/s.
Air coolers shall be supported such that their weight is not transmitted to ductwork and they can
be removed without disturbing adjacent ductwork. Readily removable access panels with air
seals shall be provided upstream and downstream of the cooler battery. Access panels shall be
sized for the full height of the connecting ductwork but need not exceed 1800mm.
Before leaving the maker's works cooler batteries shall be tested with air under water to 1.5 times
the working pressure or to 700kPa whichever is the greater.

J9.4.15.2 Chilled water air coolers

Coolers shall be arranged in a contra-flow pattern, with the flow of chilled water entering the
leaving air end and leaving at the entering air end. The flow and return connections and headers
shall be so arranged to ensure an equal flow of water through all the tubes. Provision shall be
made for thermal expansion of the tubes, for effective venting of the cooler battery and
connections, and for draining of the cooler battery headers and tubes.
Up to and including 50mm bore connections shall be made using ground-in spherical seated
unions. Pipework 65mm bore and above shall be connected using flanged joints. Isolating valves
shall be provided on flow and return connections, arranged so as to facilitate removal of the
cooler. The isolating valves shall be provided with side pressure tappings.
J9.4.15.3 Refrigerant direct expansion air coolers

Coolers shall be provided with refrigerant distributors, and connections to the tubes shall be
designed to ensure an equal flow of refrigerant to each tube. Return (or suction) connections shall
be arranged to ensure complete drainage of any oil in the cooler. Coolers shall be dehydrated,
charged with an inert gas and sealed after manufacture.
J9.4.16 Air washing & humidifying plant
J9.4.16.1 General
All ductwork enclosing humidifying plant shall be watertight. Ductwork and plant shall be
protected from corrosion either by choice of materials or by an approved protective finish.
Particular care shall be taken in the design of plant and the choice of materials to minimise
electro-chemical corrosion between dissimilar metals.
J9.4.16.2 Sprayed coil units

Sprayed coil units shall comply with the requirements for air coolers and spray type air washers.
J9.4.17 Ductwork
J9.4.17.1.1 General
Ductwork shall comply with the HVCA publications DW/144 and DW/143 with additions or
amendments as required by this specification and elsewhere in the contract documents.
Internal roughness and obstructions to air flow (other than dampers, splitters, vanes etc) will not
be accepted for ductwork constructed from sheet materials. Sharp edges or corners on the outside
of ductwork, fittings and supports will not be accepted. Where the use of other fastenings is
impractical self-tapping screws may be used subject to the approval of the Engineer.
At each point where a duct passes through a roof or external wall a weather cravat or other
purpose made arrangement shall ensure weatherproof fixing.
Duct connections between individual components of an air handling assembly and connections
between an assembly and a ductwork system shall be made with angle flanged joints.

J9.4.17.2 Flexible joints

Flexible joints shall be provided on fan inlet and outlet connections and elsewhere on ductwork
where indicated or required. Joints shall be of the same cross-sectional area as the mating fan
inlet, outlet or duct section. The centre lines of flexible joint connections shall be co-axial.
Flexible joints shall consist of, or be externally protected by, material having a fire penetration
time of at least 15 minutes when tested in accordance with BS 476 Part 8 and shall comply with
BS 476-7, (Class 1: surface of very low flame spread).
J9.4.17.3 Dampers - general

Manually and automatically operated dampers shall include a means for indicating externally the
position of the blades. Manual dampers shall include a device for positioning and locking the
damper blades. The positions of all dampers as set after final regulation shall be indelibly marked
at the adjusting device.
Access openings with readily removable air sealed covers shall be provided adjacent to all
dampers. Subject to limitations of duct size the dimensions of access openings shall not be less
than 300mm x 300mm and they shall be located to afford access for inspection and maintenance.
J9.4.17.4 Self-closing (non-return dampers)

Self-closing dampers shall present a minimum resistance to air flow under running conditions
and take up a stable position in operation. Maximum resistance shall be presented under reverse
air flow conditions. Resilient strips or other purpose made devices shall be provided to prevent
the damper rattling and as an aid to air sealing under reverse flow conditions.
J9.4.17.5 Fire dampers

Fire dampers used singly or in combination shall have an overall fire rating not less than that
indicated. In all cases evidence of fire rating in accordance with BS 476-8 shall be provided by
an independent testing organisation approved by the Engineer.
Fire dampers shall be constructed of either a corrosion resistant material such as stainless steel or
be galvanised or otherwise treated to minimise corrosion. The dampers shall be housed in a
corrosion resistant casing constructed to avoid distortion due to stress in fire conditions.
Provision shall be made to accommodate expansion of the damper blade(s) within the casing in
fire conditions. A fire damper installation frame shall also incorporate provision for expansion
within the surrounding structure together with lugs for building in to the structure.
Fire damper assemblies for installations in corrosive environments shall be fabricated from
materials or be coated with a protective finish resistant to the corrosive substances and conditions
indicated.
Each fire damper casing shall be clearly marked with a permanent indication of the correct fixing
attitude of the damper, the direction of air flow and the side at which the access/maintenance
opening shall be located.
The folded continuous interlocked blade type of damper may be used for vertical or horizontal
duct applications. The closing force for these types of dampers shall be provided by a stainless
steel spring or springs. An automatic locking device shall be provided to ensure that the blades
are held in the closed position after release.

Spring actuated pivoted single blade or multi-bladed dampers may be used for vertical or
horizontal duct applications. Multi-bladed dampers shall be provided with a means to ensure that
all the blades close simultaneously.
Gravity operated multi-bladed fire dampers shall not be used in vertical ducts.
Gravity operated single blade dampers may be used for both vertical and horizontal ducts
providing means are incorporated which ensure reliable and positive closure when operating in
maximum air flow rate conditions.
Where gravity acting off-centre pivoted dampers incorporate spindle bearings long term
corrosion effects shall be minimised by choice of materials and bearings shall be sealed or
capped to exclude dirt and dust. Damper blades shall close to comply with the stability and
integrity requirements of BS 476-8.
For high velocity air systems fire dampers shall be of the type where damper blades, in the open
position, give minimum interference with the air flow.
Unless otherwise indicated, each fire damper shall be held in the open position by a corrosion
resistant retaining device incorporating a fusible element which shall operate at a temperature of
72oC, unless otherwise indicated.
Fire dampers shall be located in such a position and be of types which facilitate periodic manual
release and re-setting for test purposes.
J9.4.18 Air terminal devices
J9.4.18.1 General
The testing and rating of air terminal devices and the definition of terms used concerning such
devices shall be in accordance with BS EN ISO 5135.
The sizes of all air terminal devices shall be based on the dimensions indicated and shall be
suitable for the air volume flow rate, air diffusion and noise rating indicated.
The materials of construction shall be steel, aluminium or plastics as indicated. All items shall be
protected against corrosion and be provided in fully finished condition.
The perimeters of all air terminal devices shall be provided with positive seals with the exception
of those mounted on exposed ductwork.
J9.4.18.2 Grilles and registers

Each supply air grille and register shall have two sets of separately adjustable blades, one set
horizontal and one set vertical. Each supply air register shall, in addition, be provided with an air
flow rate controller which shall be an opposed blade multi-leaf type unless otherwise indicated.
All blades and air flow rate controllers shall be adjustable from the front of the grille or register.
For up to ten grilles or registers one set of any tools required for adjusting shall be provided;
from eleven to twenty-four, two sets; twenty-five and over, three sets.
Each exhaust air grille may have either a single set of blades or bars, either vertical or horizontal,
or a lattice or egg crate front, or shall be as indicated. Each exhaust air register shall, in addition,
be provided with an air flow rate controller which shall be an opposed blade multi-leaf damper
operable from the front of the register.

J9.4.18.3 Diffusers
Diffusers shall be of steel, aluminium or plastics as indicated. Steel diffusers shall be protected
against corrosion and shall be stove enamelled. Diffusers mounted on ceilings shall have anti-
smudge surrounds. Pan type diffusers may be provided except where cone type diffusers are
indicated.
Each diffuser shall be provided with an air flow rate controller. Where a diffuser is directly
connected to a stub duct which has a straight length of less than two diameters or equivalent
diameters then an equalising deflector shall be used.
J9.4.18.4 Fan coil units

Fans, filters, cooling coils, heating coils, motors and thermal and acoustic insulation associated
with fan coil units shall comply with the appropriate Sections of this specification, with the
following exceptions or alternatives:
(a) Fans may be of the forward curved centrifugal or tangential flow types and may be of
mild steel, aluminium, reinforced glass fibre or rigid plastics material.
(b) Air filters may be of nylon fibre, glass fibre or cellular plastics material and shall be of a
grade not less than EU2 in accordance with Eurovent 4/5 standard.
(c) Motors shall be quiet running and have sleeve bearings factory lubricated for life. Motor
windings and electrical components shall be impregnated or protected to avoid trouble
from condensation.
The thermal, volumetric and acoustic performance of fan coil units shall meet the requirements
indicated and testing and rating shall be in accordance with BS 4856.
Casings shall be of sheet steel not thinner than 1.2mm suitably stiffened to minimise drumming
and vibration and shall be protected against corrosion and finished inside and outside with stoved
primer. All corners shall be without sharp edges. Casings shall include space for pipework
connections and valves, and there shall be ready access to the fan and motor, filter, damper, drain
pan, pipework connections and valves, for maintenance purposes.
Cooling coils shall be at least two-row and shall include an air vent cock. All units shall include
an easily removable and replacement air filter capable of treating the total air volume. Drain pans
shall be of sheet steel protected against corrosion. Drain pans shall be large enough to collect all
condensate from the coil, return bends and pipework connections; they shall be removable and
have a slight fall to the drain connection. For units whose loads include a high proportion of
latent cooling the fall to the drain point and the size of the drain connection shall be adequate to
deal with the condensed moisture.
The arrangement of units (e.g. wall, floor or ceiling mounted), the position of inlet and outlet
grilles if any, the need for sheet metal casing etc shall be as indicated on the drawings, in
schedules or elsewhere in this Specification.
Fan coil units shall have a control giving at least two running speeds and an 'OFF' position.
Where indicated they shall have connections for both fresh and recirculated air and shall include
a damper which shall be adjustable to give up to 25% fresh air. Outlet grilles shall be capable of
adjusting the direction of
airflow without affecting pressure loss. On floor mounted units, supply grilles shall be on the top
of the unit.

Casings shall be lined with material to act as both thermal and acoustic insulation. Fan and motor
assemblies shall be complete with anti-vibration mountings. Noise data shall be provided and
shall be based on the tests in accordance with the appropriate British Standard Specification; full
details of the testing technique and procedure shall be given. The data shall include an octave
band analysis of the sound power level of the unit when operating at its design speed.
J9.4.19 Air control devices
J9.4.19.1 General
Testing and rating of terminal units shall meet the requirements of BS 4954 and BS 4857.
J9.4.19.2 Induction units

Filters, cooling coils, heating coils and thermal and acoustic insulation shall comply with the
appropriate sections of this specification, with the following exceptions or alternatives:
(a) Air screens may be of nylon fibre or glass fibre and shall be suitable for collecting lint
from the recirculated air.
(b) Unless otherwise indicated, cooling coils and heating coils shall be formed of copper
primary surface tubes with aluminium secondary surfaces.
Casings shall be of rigid construction and be inherently corrosion resistant. Alternatively, if of
sheet steel they shall be protected against corrosion internally and externally. All corners shall be
without sharp edges. Casings shall include space for pipework connections and air ducting as
necessary, and there shall be ready access to the filter, the primary air nozzles and any valves and
controls.
Primary air plenums shall be treated with thermal and acoustic insulation. Units shall be
complete with a device to regulate primary air pressure and air volume flow rate. Primary air
nozzles shall be arranged to induce an even secondary circulation across the cooling and/or
heating coils. The unit air outlet shall incorporate means of directional control of air supply
where indicated. Induction units shall comply with the sound power level indicated.
Cooling/heating coils shall include an air cock and shall be effectively sealed to prevent air
bypass around the coil. Drain pans shall be of a material which is resistant to corrosion or is
protected against corrosion and shall have a slight fall to a drain connection; drain connections
shall be provided with screwed plugs. Each unit shall include a readily removable and
replaceable air filter.
The arrangement of units (e.g. wall or ceiling mounted), and the need for sheet metal casing shall
be as indicated on drawings, in schedules or elsewhere in this Specification.
J9.4.19.3 Single and dual duct terminal units

Casings shall be of rigid construction and be inherently corrosion resistant. Alternatively, if of
sheet steel they shall be protected against corrosion internally and externally by stoved primer or
plated finish. Units shall incorporate a self acting constant flow rate device. The pressure drop
across the unit at design air volume flow rate shall not exceed 250Pa. Where indicated terminal
units shall incorporate an additional feature to give a variable air flow rate determined by
thermostatic control.
Dual duct terminal units shall incorporate devices for varying the proportions of hot and cold air
and for providing thorough mixing of the air. When the inlet control device or devices are at the

closed positions the air leakage across the device at the indicated pressure shall not exceed 2% of
the maximum air volume flow rate for which the unit is designed. If a flow rate controller is
mounted within a box means shall be provided to facilitate access.
All units shall be supplied to comply with the sound levels indicated. Acoustic lining shall be
securely fixed and shall be proofed against erosion by the airflow.
J9.4.20 Air handling units
J9.4.20.1 General
Individual components forming part of packaged air handling plant shall, in addition to this
section, comply with the appropriate sections contained elsewhere in this Specification.
J9.4.20.2 Construction
Air handling assemblies shall be of rigid construction corrosion resistant and strengthened as
necessary to prevent distortion and drumming in operation. All individual components and
sections shall be assembled using proprietary and approved fastening techniques. Locking
devices shall be used with all fastenings which are subject to vibration. Material thicknesses and
methods of strengthening and fastening shall ensure that air handling assemblies are no less rigid
in operation than the distribution ductwork to which they connect.
Readily removable panels with air seals shall be provided to facilitate access to be made to
upstream and downstream faces and internal parts of all sections in the air handling plant. The
access panels shall be secured with a minimum number of fastenings consistent with effective air
sealing. The access panels shall be sized for the full height of the unit or section but need not
exceed 1800mm.
Sections of packaged units shall be arranged with adequate separation to avoid evaporation of
condensate from the cooler by the heating battery and to generally promote even air distribution
across the face of all components.
Where units incorporate humidifying plant and/or cooler batteries the internal surfaces of the
units liable to be affected by any moisture shall be protected by at least two coats of anti-
corrosion paint or a similar finish. All such units shall have corrosion resistant drain trays of
adequate size to collect water. The drain traps shall be extended, or other means of collection
shall be provided, to drain away any water deposited or condensed in adjacent sections. Trays
collecting cooled water shall be insulated to prevent condensation on the outer surfaces. All trays
shall be inclined toward the drain connection and a water sealed trap of adequate depth shall be
fitted in the rain pipework.
J9.4.20.3 Thermal & acoustic insulation

Thermal insulation shall be securely fixed to all sections handling heated or cooled air and,
where appropriate, a vapour barrier shall be provided. Thermal and/or acoustic insulation
characteristics and fixing shall be in accordance with the sections covering - Noise Insulation,
Thermal Insulation and Vapour Barriers. Particular care shall be taken to ensure surface
protection of internal insulation in areas where free moisture may be present and to avoid damage
in sections having walk-in access. Thermal insulation shall have a thickness not less than 25mm
and a thermal conductivity not greater than 0.04 W/mCo and shall be selected and applied to
prevent surface condensation at design conditions.

J9.4.20.4 Dampers
Dampers used in sections of packaged plant shall be of the multi-leaf type. The damper blades
shall be constructed to ensure rigidity and prevent distortion and jamming in operation. The
blades shall be securely fixed to their operating spindles so that differential movement between
them cannot occur. Spindles shall be carried in non-ferrous, nylon or ball bearings and air seals
shall be provided at all casing penetration points.
Manually and automatically operated dampers shall include a means for indicating externally the
position of damper blades. Manual dampers shall include a device for positioning and locking the
damper blades. The positions of all manual dampers, as set after final regulation, shall be
indelibly marked at the adjusting devices.
Damper actuators shall be kept to an essential minimum number and all actuators shall be
provided with mounting brackets.
Unless otherwise indicated, air leakage through dampers when in the closed position shall not
exceed 5% of maximum design air volume flow rate at the maximum design air total pressure.
J9.4.20.5 Fans
Centrifugal fans shall be backward or forward curved type, as indicated, except for high velocity
high pressure systems where backward curved fans shall be used. Fans for installation within
packaged air handling assemblies shall have fan total efficiencies of not less than 75% and 64%
for backward and forward curved impellers respectively at the operating point of the installation.
The method of testing shall be in accordance with BS 848.
Fan total efficiencies shall not be less than 55% and 45% for packaged assemblies using
backward and forward curved fans respectively. The fan total efficiency shall be related to the
motor drive shaft output power and to the complete fan section within the assembled packaged
air handling unit.
Where a fan and its drive motor are contained within a common casing they shall be mounted on
a frame or support base and the complete assembly shall be isolated from the casing to prevent
the transmission of vibration.
Where the fan and drive motor are directly coupled to the fan section casing, the casing shall be
isolated to prevent the transmission of vibration, and flexible joints shall be provided to couple to
adjacent sections of the complete packaged air handling assembly.
If a drive motor is mounted external to the fan section casing the fan impeller shaft shall extend
through the casing. Flexible joints and vibration isolators shall be used to minimise the
transmission of vibration and noise.
All external drive and mechanical power transmission systems shall be guarded and as detailed
elsewhere in this Specification.
Fan shaft bearings shall be self-aligning, grease lubricated ball/spherical roller type according to
load/speed requirements. Bearings shall be charged with grease and seals shall be provided to
prevent ingress of dust and minimise air leakage.
J9.4.21 Belt drives

Belt drives shall comply with BS 3790 and be capable of transmitting at least the rated power
output of the driving motor with one belt removed. Unless otherwise indicated, not less than two
belts per drive shall be used and all multi-belt drives shall use matched sets. Pulleys shall be

correctly aligned and the Contractor shall ensure that any holding down bolts or fixings he
provides that are positioned by others ensure correct alignment. Provision shall be made for
adjustment of the tension in belt drives and also for their alignment.
J9.4.22 Guards
Guards shall comply with PD 5304. Guards shall be provided at all open intakes and exhausts
from fans, all forms of open power transmission systems including belt drives and drive
couplings, and where indicated.
Fixed guards shall be used and they shall be installed to prevent access to dangerous parts of
machinery. Construction and installation of guards shall ensure strength and rigidity and it shall
not be possible to remove any guard or access panel without the aid of a tool.
For fans, the guards shall be manufactured by the fan maker or be to the fan makers approval and
they shall be constructed from galvanised steel wire.
For belt drives, the guards shall be of galvanised steel wire not less than 2.5mm diameter
attached to a rigid galvanised steel rod or angle framework. The mesh size and/or the location of
the guard shall prevent finger contact with any enclosed danger point. Alternative construction
may be from galvanised sheet steel not less than 0.8mm thick stiffened as necessary to ensure a
rigid enclosure. Removable access panels shall be provided in guards to allow tachometer
readings to be taken on both driving and driven shafts and also belt tension to be tested. The sizes
of guards including the dimensions and locations of access panels shall allow for the limits of
motor position.
Where duplicate motors are provided and fixed, the spare motor shall be complete with its
adjusting device to ensure belt tensioning and be in all respects ready for operation. The centre to
centre dimensions between the common driven pulley and the duplicate driving pulleys shall be
the same. The guard provided shall be either a double guard or single unit which can be arranged
to protect both drives. All fixings and mountings for both positions shall be supplied and
installed to facilitate change over of the drive and guard.
J9.4.23 Fan drive pulleys

Belt driven fans shall be fitted with pulleys suitable for the belt drive used. Pulleys may use split
taper bushings of an approved type for drives up to 30kW. Alternatively, and in any case above
30kW output, pulleys shall be secured to the fan and motor shafts by keys fitted into machined
keyways. Pulleys shall be keyed to the fan shaft in the overhung position. Keys shall be easily
accessible so that they can be withdrawn or tightened and they shall be accurately fitted. Where
gib head keys are used they shall not protrude beyond the end of the shaft. When keys without
gib heads are used they shall be drilled and tapped to accept an extractor bolt.
J9.4.24 Refrigeration plant
J9.4.24.1 General
The refrigeration plant shall be of the mechanical, vapour compression type using halogenated
hydrocarbon (halocarbon) refrigerants. The requirements of this section are not intended to apply
to through-the-wall and free standing (unitary or split system) room air conditioning units.
The refrigeration compressors may be of the reciprocating, centrifugal or screw type. The plant
shall include any accessories necessary to ensure continuous and reliable automatic operation.
The design maximum cooling rate shall be achieved at the maximum ambient conditions

indicated. Each unit shall be capable of running continuously at the lowest step of cooling
capacity provided without any adverse effect. The necessary charge of refrigerant and lubricating
oil shall be supplied by the Contractor.
J9.4.24.2 Compressors - reciprocating type

All open, semi-hermetic and hermetic units shall comply with the following requirements.
Hermetic compressors will be acceptable only up to and including 7.5kW input power
and where either:
(a) The entire refrigeration system is completed and charged with refrigerant at the
manufacturer's works or
(b) The condensing unit incorporating the hermetic compressor has a holding charge of
refrigerant or inert gas on arrival at site.
Crankshafts or eccentric shafts of all open or semi-hermetic compressors shall be balanced and,
if having an input power greater than 2.25kW, run in replaceable bearings.
Pistons greater than 50mm diameter shall be fitted with either:
(a) Compression and/or oil control ring(s) or
(b) A combination of compression ring(s) and a piston specially shaped to act as an oil
scraper.
All open and semi-hermetic compressors having an input power in excess of 25kW shall have:
(a) Removable cylinder liners
(b) Side or end covers which will enable servicing or repair of the unit to be carried out 'in
situ.'
Open type compressors shall have a rotary mechanical seal fitted to the driving shaft which
effectively prevents leakage of refrigerant or oil. Direct coupled type units shall be driven
through a flexible coupling which on units with an input power greater than 25.0kW shall be of a
type which will enable the shaft seal to be removed without moving compressor or motor.
Open and semi-hermetic compressors shall have:
(a) A crankshaft driven oil pump used to force feed lubricant via a strainer to the main and
big end bearings and the shaft seal (6.0kW input power and above only).
(b) An oil pressure relief valve or bleed device provided between the oil pump discharge
and the crankcase (6.0kW input power and above only).
(c) Provision for draining oil from the suction manifold into the crankcase and for venting
refrigerant gas (but not oil) in the opposite direction (6.0kW input power and above
only).
(d) A crankcase heater arranged to operate while the compressor is at rest.
All types of compressor, with the exception of hermetic units on factory sealed systems, shall
have the following fittings provided and connected:
(a) Stop valves on refrigerant suction and discharge connections.
(b) Refrigerant pressure gauges, not less than 75mm diameter and fitted with means of
isolation, on suction and discharge. Gauges shall have pressure and saturation
temperature scales for the refrigerant being used. Alternatively, gauges with pressure

scale only may be used in conjunction with a pressure/saturation temperature conversion

table fixed nearby.
(c) Oil pressure gauge, not less than 75mm diameter, with means of isolation (compressors
with oil pump only).
(d) Crankcase oil level sight glass (hermetic compressors excepted).
(e) High and low refrigerant pressure safety cut-outs with adjustable differential and
setpoint. The high pressure section shall have hand reset.
(f) Low oil pressure safety cut-out with hand reset (compressors with oil pump only).
(g) Suction refrigerant gas strainer.
Semi-hermetic and hermetic compressors shall include the following features:
(a) All parts of refrigerant gas cooled motors shall be proof against long term contact with
halocarbon refrigerants and compressor lubricating oil. The motor of a semi-hermetic
unit which is refrigerant gas cooled shall have in-built protection against inadequate
cooling.
(b) The oil pump of three-phase units shall either operate equally well under each direction
of rotation or special arrangements shall be made to prevent reverse rotation.
All compressors having a refrigeration duty in excess of 35 kW shall have capacity control by
means of cylinder unloading. Compressors shall be arranged so that they start unloaded. Unless
otherwise indicated, the hot gas by-pass or injection system of capacity control will not be
accepted.
J9.4.24.3 Compressors - centrifugal type

Open type centrifugal compressors shall have a rotary seal fitted to the driving shaft which
effectively prevents leakage of refrigerant or oil. Open compressors shall be driven through a
flexible coupling of a type which enables the shaft seal to be removed without moving
compressor or motor.
The lubrication system shall be arranged with an interlock to ensure adequate oil pressure at all
bearings before the compressor starts and during the 'coast down' period. A replaceable or
cleanable filter shall be positioned in the oil delivery pipe. Where an oil cooler is used it shall be
thermostatically controlled. A hand reset pressure or flow switch shall stop the compressor on a
lubrication system failure. The oil sump shall have a thermostatically controlled electric heater
which operates while the compressor is at rest.
The compressor shall have automatic capacity regulation which will control at any point from
10% to 100% of full duty without inducing a surge condition. The compressor shall always start
in the unloaded condition. Unless otherwise indicated, the hot gas by-pass or injection system of
capacity control will not be accepted.
The motor of a semi-hermetic compressor which is refrigerant gas cooled shall have in-built
protection against inadequate cooling.
The following fittings shall be provided and connected:
(a) Refrigerant pressure gauges, not less than 75mm diameter and fitted with means of

scale only may be used in conjunction with a pressure/saturation temperature

conversation table fixed nearby.
(b) Oil pressure gauge, not less than 75mm diameter, with means of isolation (compressors
(c) High and low refrigerant pressure safety cut-outs with adjustable differential and
(d) Oil sump or reserve level sight glass.
(e) Low oil pressure or flow switch with hand reset.
(f) High oil temperature cut-out with hand reset.
J9.4.24.4 Compressors - screw type

Screw compressors shall be of the oil injection type. Open compressors shall have a rotary seal
fitted to the driving shaft which effectively prevents leakage of refrigerant or oil. Open
compressors shall be driven through a flexible coupling of a type which enables the shaft seal to
be removed without moving compressor or motor.
A device shall be fitted to prevent the pressure differential across the compressor causing
backward rotation at a normal or emergency stop.
The lubrication system shall be arranged with an interlock to ensure adequate oil pressure at all
bearings before the compressor starts. A hand reset pressure or flow switch is to stop the
compressor on a lubrication system failure. An oil pressure relief valve is to be fitted from the oil
pump delivery pipe to the oil sump. A replaceable or cleanable filter shall be positioned in the oil
delivery pipe. A thermostatically controlled oil cooler shall be used to remove the heat gained by
the oil in the rotor chamber. The oil sump shall have a thermostatically controlled electric heater
which operates while the compressor is at reset.
The compressor shall have automatic capacity control equipment which will control at any point
between 10% and 100% of full duty. The compressor shall be fitted with a device which ensures
that it cannot start unless in the fully unloaded condition. Except where indicated, the hot gas by-
pass or injection system of capacity control will not be accepted.
The motor of a semi-hermetic compressor which is refrigerant gas cooled shall have in-built
protection against inadequate cooling.
The following fittings shall be provided and connected:
(a) Refrigerant pressure gauges, not less than 75mm diameter and fitted with means of
scale only may be used in conjunction with a pressure/saturation temperature conversion
table fixed nearby.
(b) Oil pressure gauge, not less than 75mm diameter, with means of isolation (compressors
(c) High and low refrigerant pressure safety cut-outs with adjustable differential and
(d) Stop valves on refrigerant suction and discharge connections.
(e) Oil sump or reservoir level sight glass.

(f) Low oil pressure or flow switch with hand reset.

(g) High oil temperature cut-out with hand reset.
J9.4.24.5 Evaporators - air cooling

Air coolers using the direct expansion of primary refrigerant shall be provided with refrigerant
distributors, and connections to the tubes shall be designed to ensure an equal flow of refrigerant
to each tube. Return (or suction) connections shall be arranged to ensure complete drainage of
any oil in the cooler. Coolers shall be dehydrated, charged with an inert gas and sealed after
manufacture.
The flow of refrigerant to a multiple circuit dry expansion evaporator shall be controlled by an
externally equalised thermostatic expansion valve which shall not 'hunt' at any step of
compressor unloading. The design of the refrigerant passages in direct expansion type
evaporators shall be such that any oil present is always carried back to the compressor at the
lowest stage of capacity reduction.
The refrigerant side of the evaporators shall be pressure tested at the manufacturer's works in
accordance with the Pressure Testing section.
J9.4.25 Condensers
J9.4.25.1.1 Air cooled

Air cooled condensers shall have copper tubes with aluminium or electro-tinned copper fins, as
indicated. Fins with minor damage shall be combed straight. Units with extensive damage to fins
will not be accepted. Provision shall be made for the purging of non-condensables from the
condenser.
Air cooled condensers mounted outside buildings shall have weather-proof motors. The units
shall discharge air vertically upwards unless they are protected by an integral wind deflector or
purpose made baffle. The structure and casing of units shall be constructed of material which is
either corrosion resistant or proofed against corrosion after manufacture.
Unless otherwise indicated, automatic control of the condensing pressure shall be incorporated.
Where modulation of the outlet dampers only is used the fan motor shall be selected for this
application and arranged so that it is de-energised on complete closure of the dampers.
Fans shall be as specified elsewhere in this Specification, particular attention being given to
limitations on permitted noise levels indicated.
The completed condenser coil shall be pressure tested at the manufacturer's works in accordance
with the Pressure Testing section.
J9.4.25.2 Evaporative
The condenser coils shall be of plain steel (galvanised after manufacture) or copper pipe. Each
condenser shall be complete with water circulating pump (as specified elsewhere in this
Specification) pump suction strainer, water tank complete with make-up connection, ball float
valve, overflow, drain and bleed connections, a cleanable water distribution system and a water
drift eliminator section. Any part of the distribution system open to atmosphere must be fitted
with a leaf or rubbish grid. The structure and casing of the unit shall be either constructed of
material which is corrosion resistant or proofed against corrosion after manufacture. Any pre-
galvanised steel sheet used shall have all cut edges sealed. The tank interior shall be coated with

bituminous or other corrosion resistant paint. The fan bearings and motor, the water pump and
motor, the water strainer and the ball float make-up valve shall all be readily accessible. Where
indicated, a thermostat controlled water sump heater shall be provided. Provision shall be made
for the purging of non-condensables from the condenser.
Fans shall be as specified elsewhere in this Specification, particular attention being given to
limitations on permitted noise levels indicated. Fan motors of induced draught condensers shall
have a suitable protective treatment if mounted in the moist air stream. Fan casings and impellers
shall be made either of corrosion resistant materials or proofed against corrosion after
manufacture.
Unless otherwise indicated, automatic control of the condensing pressure above a pre-determined
minimum shall be incorporated.
Where dampers are used, each fan motor shall be selected for the application and arranged so that
it is de-energised on complete closure of the dampers.
The condenser coil block shall be pressure tested after completion at the manufacturer's works in
J9.4.25.3 Shell and tube

Condensers shall be of the manually cleanable type capable of being re-tubed 'in situ.' The
condenser shell and tubeplates shall be of steel and the water boxes/end covers shall be of steel
or cast iron. The tubes shall be of copper, aluminium brass or cupro-nickel unless otherwise
indicated. Unless otherwise indicated, the design fouling factor on the water side of the tubes
shall be 0.00018m2 deg C/W.
End covers shall be removable, and allow easy access for cleaning and tubes. Means shall be
provided for venting and draining of the water side of the unit.
The positioning of the condenser shall be such that removal or maintenance of the tubes is not
obstructed by pipework, valves etc.
Means shall be provided for the controlled venting of non-condensables from the refrigerant side
of the condenser. For Refrigerants 12, 22 and 502 this may be manually controlled. For
Refrigerants 11, 113 and 114 an automatic purge plant shall be connected to the condenser, a
visual signal being fitted to indicate excessive purge cycles.
Unless otherwise indicated, automatic control of the condensing pressure, shall be incorporated.
The refrigerant and water spaces shall be pressure tested at the manufacturer's works in
J9.4.26 Pressure testing

The units previously mentioned shall have a strength and leakage pressure test after manufacture.
The test pressure to be applied to the water side of units shall be not less than one and a half
times the maximum working pressure indicated.
A pressure test equal to the low side test pressure quoted for the refrigerant being used, shall be
applied to the refrigerant system after all piping has been fitted. This test shall be in addition to
the pressure test on each unit at completion of manufacture.

J9.4.27 Refrigerant pipework

Pipework for refrigerant systems shall be of copper or steel. Copper pipe shall be of refrigeration
quality to BS EN 12451, fully annealed (up to and including 22mm OD only) and internally
degreased and cleaned.
Steel pipe shall be to BS EN 10216 Grade P235TR1 or of equal or higher quality.
Joints in copper pipe shall be flanged, flared (up to 3/4" OD only), or braced (with or without
capillary fittings). Brazing shall be carried out to the requirements of the Heating & Ventilation
Contractors Association (HVAC) Code of Practice - Brazing and Bronze Welding of Copper
Pipe and Sheet.
Joints in steel pipe shall be flanged or welded. Mitred or segmented bends will not be accepted.
Screwed joints will not be accepted in refrigerant pipes except on the equipment accessories. In
such cases the threads shall either be of taper form and used in conjunction with PTFE tape or an
anaerobic sealant, or of parallel form associated with machined joint faces and a suitable joint.
Compression fittings will not be accepted on refrigerant pipework except as detailed above and
on the equipment accessories using Refrigerant 11, 113 or 114.
Refrigerant pipework shall not be arranged for running compressors in parallel (i.e. with common
suction and/or discharge pipes). The use of a number of compressors each having an independent
refrigerant circuit in a common evaporator will be permitted provided pressure tests between
adjacent refrigerant circuits in the evaporator are carried out during manufacture.
The pipework shall be designed so that oil in the refrigerant leaving the compressor (and passing
any oil separator fitted) shall be carried through the system and back to the compressor at the
lowest stage of capacity unloading.
Pipework shall be firmly supported and secured to minimise vibration. Vibration eliminators
shall be fitted to the compressor suction and discharge pipes to minimise transmission of
vibration or noise. Where indicated, a gas pulsation damper shall be fitted in the refrigerant
discharge pipe, in the plant room, as close as possible to the refrigeration compressor.
After completion the refrigerant pipework shall be pressure tested as detailed in the Pressure
Testing section.
J9.4.28 Refrigeration plant accessories and controls

Every refrigeration system shall be protected by a pressure relief device unless it is so
constructed that pressure due to fire conditions would be safely relieved. The equipment
provided shall comply with BS EN 378 and the outlet piped to discharge outside the building.
A liquid receiver shall be fitted to any system using an air cooled or evaporative condenser. For
systems 70kW and above, having a water cooled condenser with insufficient capacity to take the
complete refrigerant charge, a liquid receiver shall be provided to make up the deficiency.
Systems using a thermostatic expansion valve shall have the following items preceding it in the
refrigerant liquid pipe:
(a) A solenoid valve
(b) A sight glass
(c) A refrigerant drier (replaceable)
(d) A refrigerant strainer

(e) A capped refrigerant charging valve.

An evaporator pressure regulating valve where fitted shall be protected by a strainer, and an
evaporator pressure gauge shall be provided, upstream of the valve, fitted with means of
isolation.
Compressors for use in tropical latitudes that may be required to start on an exceptionally heavy
load condition shall either have sufficient motor power available to meet this condition or be
fitted with a device or system which limits the maximum suction pressure.
Units having a direct expansion evaporator at a higher level than the compressor shall operate on
a pump down cycle. On water chilling installations, the chilled water pump shall be kept running
during this process.
Refrigerant stop valves which incorporate a spindle gland shall be of the back seat type. The
spindle gland shall be serviceable with the valve 'in situ.'
A flow switch shall be provided in the chilled water pipeline to each shell and tube evaporator to
prevent the compressor starting or continuing to run if the water flow is below the minimum
stipulated by the evaporator manufacturer.
A low temperature thermostat with hand reset shall be provided for each shell and tube
evaporator to stop the compressor(s) if the chilled water flow temperature falls below +3°C.
J9.4.29 Vibration isolation

All dynamic machinery shall be isolated from the building structure by vibration isolators and/or
vibration isolation materials which shall be purpose designed and selected to suit the machinery.
Where mat type isolation materials are used the Contractor shall supply the materials and be
responsible for their correct location; all other vibration isolators shall be supplied and installed
by the Contractor. Transmissibility of vibration isolators and isolation materials shall be not
greater than indicated.
For fans and air distribution systems, flexible joints shall be provided to minimise the
transmission of vibration. For pumps and water distribution systems, purpose-designed flexible
connections shall be provided as indicated to minimise the transmission of vibration. The
connections shall be compatible with the tube materials and methods of jointing and the fluid(s)
handled in the system.
J9.4.30 Noise insulation

Care shall be taken in the selection and installation of plant and equipment to ensure that the
noise level in the spaces served, in any adjacent buildings and within plant rooms does not
exceed the indicated maximum acceptable noise rating (NR).
Noise level information for compressors, fans, air control and air terminal devices, fan coil units,
condensers and cooling towers, based on octave band analysis, shall be provided by the
Contractor. The reference level and the testing technique shall be stated by the Contractor.
Purpose-made silencers and sound absorbent material shall be designed and installed to give the
indicated acoustic performance and offer minimal resistance to air flow. Acoustic insulation
materials shall be applied to the internal surfaces of ductwork only where indicated. Material
characteristics, including fire properties, for purpose-made silencers and duct lining materials
shall be in accordance with the Thermal Insulation - Materials and Finish section.

Methods of application for duct lining materials shall be in accordance with the Thermal
Insulation - Method of Application section.
All materials used shall have adequate strength and cohesion to resist erosion and shall not
produce dust.
Purpose-made silencers shall be tested in accordance with BS EN ISO 7235and the insertion loss
and generated noise level for each octave band and the pressure loss of the silencers shall be
provided by the Contractor.
J9.4.31 Miscellaneous equipment
J9.4.31.1 General
The instruments, gauges and devices detailed in this Section shall be provided in addition to
those associated with specific items of plant and indicated elsewhere. All instruments, gauges
and devices which have indicating scales shall be mounted such that they are accessible and can
be easily read without the need for portable or temporary means of access.
Scale ranges shall be appropriate within the extremes which will be indicated when the plant is
running and at rest. The design maximum operating condition shall be indicated at not less than
75% of the total scale length. Unless otherwise indicated, pressure gauges and dial thermometers
shall be accurate to 1% of total scale reading
J9.4.31.2 Thermometers - general

Dial type thermometers shall be mercury in steel unless otherwise indicated and comply with the
requirements of BS EN 13190. Liquid in glass thermometers shall comply with the requirements
of BS 1704 or BS 1041, as appropriate.
Direct (local) mounting thermometers shall have rigid stems either vertical, right angle, or
horizontal pattern.
Right angle or horizontal thermometers shall be provided for fitting to vertical pipes or vertical
faces of cylinders, etc.
Thermometers fitted more than 2m above the floor shall be of the dial type.
A thermometer for air temperature reading shall be supplied and fixed securely in a shaded
position outside each major plant room, as directed by the Engineer. These thermometers shall be
stem pattern mercury-in-glass or alcohol-in-glass or dial type as indicated and shall comply with
the following:
(a) The mercury-in-glass or alcohol-in-glass types shall be mounted on enamelled brass
scales graduated to cover the range -20oC to 50oC with wood backings approximately
250mm long and brass guards over the bulbs. They shall be wholly protected by brass
wire mesh semi-cylindrical grid covers.
(b) Dial thermometers shall be generally as specified previously but with a scale graduated
to cover the range -20oC to 50oC. The outdoor bulbs shall be enclosed in louvered boxes
which shall be lockable to prevent unauthorised access and shall be so designed that the
bulbs are fully open to the external air.
Thermometer pockets shall comply generally with the requirements of BS 2765 and be inserted,
and so positioned in the waterways, that they offer minimum resistance to water flow. Pockets

shall be of steel except for copper installations where they shall be brass. Pockets shall be filled
with an approved heat-conducting medium.
J9.4.31.3 Thermometers - air conditioning systems air immersion

Where the system supply air volume flow rate is less than 5m3/s, one liquid in glass type
thermometer complying with the requirements of BS 1704 or BS 1041, as appropriate, shall be
provided and installed in each of the following places (except where thermometers are fitted
more than 2m above the floor when dial type shall be used, as detailed later in this section):
(a) The fresh air connection
(b) The recirculation air duct
(c) Before and after an air heater
(d) Before and after an air cooler
(e) Before and after a humidifying device
Where thermometers cannot be positioned so that they are unaffected by thermal radiation due to
heaters or coolers, shielded thermometers shall be provided.
At each point where a change in system moisture content occurs a second thermometer shall be
provided adjacent to those listed above to enable coincident wet and dry bulb temperatures to be
measured. Wet bulb thermometers shall be provided with a fabric sleeve.
Where the system supplied air volume flow rate is 5m3/s or more, a duct mounted thermometer
shall be provided and installed at each position listed previously. Thermometers may be either
the vapour pressure or the mercury-in-steel type. They shall be approved metal or moulded
plastics cased instruments, complete with mild steel, or stainless steel pressure proof, screwed,
separable pockets. Metal cases shall be finished in enamel, with chromium plated bezels.
Dials shall be white, not less than 100mm diameter with black figured scales graduated
appropriately.
Where instruments cannot be mounted so that they can be read easily remote reading
thermometers shall be installed in lieu of local thermometers. Remote reading thermometers shall
be grouped together and mounted in an accessible position and each instrument shall have its
function clearly labelled. They shall be vapour pressure, mercury-in-steel or electrically energised
single or multi-point indicating type. Instruments shall be installed complete with all accessories
and ready for operation. Capillary tube or wiring between sensors and indicators shall be neatly
run and clipped where appropriate to support surfaces. Temperature sensors shall be located to
avoid the effects of thermal radiation due to heaters or coolers or be fitted with suitable shields.
A plugged 12mm diameter test hole shall be provided adjacent to each fixed thermometer or
temperature sensor. All wiring shall conform to the requirements of the instrument manufacturer.
Air conditioning systems with a total design cooling capacity (not including stand-by) of 200kW
or greater shall be provided with a multi-point remote reading thermometer. This shall be
installed in the main control panel to indicate, as appropriate, the following temperatures:
(a) Fresh air, supply air and return air
(b) Air before and after a cooler and a washer
(c) Air before and after a heater
(d) Main chilled liquid flow and return

(e) Main condenser flow and return

A plugged 12mm test hole or thermometer pocket, as appropriate, shall be provided adjacent to
each sensing point.
J9.4.31.4 System static pressure gauges

System static pressure gauges shall be provided for all fan systems (not including cooling towers
and evaporative or air cooled condensers) where the main fan power exceed 3.75kW. The gauges
shall be single limb inclined manometer type. Two gauges shall be provided for each fan and
arranged to indicate system static pressure on the suction and delivery side.
The gauges shall be connected into the system at points in the plant room where the static
pressures are steady and, on completion of commissioning, the suction and delivery static
pressures indicated by the gauges shall be indelibly marked adjacent to them to serve as system
reference points.
J9.4.31.5 Pressure tappings

For each air conditioning installation with a total design cooling capacity in excess of 30kW and
for each shell and tube evaporator, condenser and cooling tower of duty in excess of 70kW
valved pressure tappings suitable for connection of a pressure gauge shall be fitted to the flow
and return connections. A pair of pressure gauges suitable for use with the tappings shall be
provided by the Contractor. Alternatively, where indicated, isolating valves with side pressure
tappings may be provided.
J9.4.31.6 Self sealing test points

Where indicated or required, self-sealing test plugs suitable for temperature and/or pressure
testing shall be provided. One thermometer and one pressure gauge for each range of
temperatures and pressures, suitable for use with the test plugs, shall be provided by the
Contractor together with an adequate supply of any necessary insertion lubricant. Plugs shall be
fitted with captive caps for sealing them when not in use and the plugs shall have internal self-
sealing devices. The plugs and probes shall be of materials suitable for the application.
J9.4.31.7 Hot and cold water mixing valves and fittings

Thermostatically operated mixing valves shall be of gunmetal or brass construction with
chromium-plated finish. Each mixing valve shall be equipped with a backplate for wall fixing.
Alternative bodies in thermoplastic material will be considered. Each mixing valve shall have a
control thermostat capable of providing a constant mixed water temperature under the available
hot and cold water pressures and of closing down the hot water inlet within 5 seconds in the
event of the cold water failing. The capacity of each individual shower mixing valve shall be a
minimum of 4.5l/m. Each mixing valve shall be provided with a temperature regulating handle or
knob permitting regulation of the mixed water temperature up to a maximum of 45oC.
Means shall be provided for varying the maximum settings and these shall be tamper proof. The
valves shall also have provision for controlling the maximum rate of outlet flow.
Thermostatically operated mixing valves serving groups of showers shall be capable of providing
a minimum of 4.5l/m simultaneously to each shower. These mixing valves shall be provided with
means of locking the regulating handle to prevent unauthorised interference and the water inlets
shall be provided with chromium-plated non-return valves.

An isolating valve and strainer shall be provided on the hot and on the cold supply to each
mixing valve.
Each shower shall be provided with an isolating valve on the riser pipe of type as indicated. Each
shower or group of showers shall be provided with an automatic drain valve which empties the
system when flow is turned off.
Manually operated mixing valves where indicated shall incorporate anti-scald devices and be
suitable for the working conditions.
Unless otherwise indicated, showers shall be stainless, robust and vandal resistant installations
with fixed spray nozzle terminals.
J9.4.31.8 Thermal insulation - general

Thermal insulation and methods of application shall comply with the requirements of BS 5422
and BS 5970.
The thermal insulation materials, adhesives and finishes shall be suitable in all respects for
continuous use without degradation throughout the range of operating temperatures and within
the environment indicated. They shall be designed to provide proof against rotting, mould, fungal
growth and attack by vermin.
Insulating materials for external application shall be such that if subjected to repeated wetting
they shall:
(a) Retain adequate strength;
(b) Not permanently deteriorate in terms of strength and thermal resistance;
(c) Continue to be chemically inert to adjacent metalwork.
Unless otherwise indicated, or as excepted by other Clauses in this Specification, any thermal
insulating materials used within any building shall, when tested in accordance with BS 476 Part
4, be classified non-combustible. Insulation facing materials may be combustible provided they
are not more than 0.8mm thick and they have a surface spread of flame property to Class 1 when
tested in accordance with BS 476 Part 7. When requested by the Engineer evidence of fire
classification, obtained from an approved testing laboratory, shall be provided by the Contractor.
Insulating materials and their finishes whose surface classification complies with Class 0, as
defined by the Building Regulations, may be used within those sealed parts of building structures
which, in the event of fire, would isolate smoke, noxious or toxic fumes from habitable spaces.
Class 0 materials shall not be used in ceiling voids without prior approval.
J9.4.31.9 Thermal insulation to heating & piped water services

Unless otherwise indicated, the thicknesses of insulating materials used within buildings for
pipework carrying hot fluids, and for frost protection of cold water pipework shall be determined
from the Thermal Insulation Tables section. Insulation thicknesses given in the tables shall be
increased by one standard size, or as indicated, when such pipework is used externally to
buildings.
Insulation for protection from condensation shall be provided as indicated.
The thickness of insulation applied to vessels and tanks shall be as indicated in the Thermal
Insulation Tables section for flat surfaces.

J9.4.31.10 Types of insulant to heating and piped water services - within buildings
Thermal insulation shall be applied to:
(a) All pipework flanges and valves carrying fluids at temperatures above 50oC and other
pipework as indicated;
(b) Cold water cisterns, feed and expansion cisterns and vent pipework as indicated.
The insulation referred to in item (a) above shall be preformed rigid sections and/or an approved
pre-insulated pipework system as indicated. Valves and flanges shall be insulated as specified
elsewhere in this Specification.
The insulation referred to in item (a) above shall be as indicated.
J9.4.31.11 Types of insulant to heating and piped water services - external to buildings
Preformed insulation shall be applied to:
(a) Cold water pipework run above ground external to buildings and run in ducts, chases,
roof spaces and as indicated;
(b) Expansion devices, as indicated.
The insulation referred to in item (b) above shall be as indicated on drawings, or elsewhere in
this Specification.
J9.4.31.12 Thermal insulation to heating and piped water services - application

Thermal insulation shall fit closely to the pipework and other surfaces without gaps between
joints.
Each section of preformed insulation shall be secured to the pipe by one of the following means:
(a) Circumferential tie-wires, each formed from one turn of galvanised wire not less than
1.5mm thick, spaced not more than 450mm apart.
(b) Circumferential bands, spaced not more than 450mm apart, of galvanised or non-ferrous
metal (not less than 20mm wide and 0.5mm thick), plastic fabric (not less than 50mm
wide) or adhesive tape.
(c) In the case of preformed flexible insulation the manufacturer's recommended method of
attachment shall be used.
J9.4.31.13 Thermal insulation finishes to piped water services -general

The outside surface of preformed insulation shall be smooth, unbroken, uniform and firm. Outer
coverings shall be continuous through support joints.
Where insulating materials are finished with metallic cladding, the cladding shall be bonded in
accordance with the BS 7671.
J9.4.31.14 Thermal insulation finishes to piped water services in buildings

For concealed pipework the finishes on the thermal insulation shall be as follows:
(a) In roof spaces, foil faced finishing materials, factory applied to preformed sections and
secured on site with adhesive, sealing tape and bands where suitable. Alternatively the finish may
be site applied to the satisfaction of the Engineer. The finish shall be left unpainted.

(b) Within sealed parts of the building structure which, in the event of fire, would isolate
smoke, noxious or toxic fumes from habitable spaces. Glass cloth facings applied to the
insulation and secured on site with adhesive and bands, or finishing material as item (a) above or
approved pre-insulated and clad as indicated. The finish shall be left unpainted.
(c) In all accessible ducts, voids, chases, false ceilings etc, finishing material shall be as item
(a) above with fabricated aluminium or galvanised steel or plastic casings applied to the
insulation at access points which could be subjected to mechanical damage, or approved pre-
insulated and clad pipework systems as indicated.
For visible pipework the finishes shall be in accordance with the following as indicated:
(a) Cotton canvas not less than 100g/m2 to BS 3958 Part 4, factory applied to preformed
sections, lapped and sealed on site with adhesive, and additionally secured with bands
and painted;
(b) Bends and tees shall be finished with preformed fittings.
(c) White lacquered aluminium foil/kraft paper laminate, factory applied to preformed pipe
insulation, overlaps to be sealed with adhesive and circumferential joints to be sealed
with 100mm wide matching tape.
J9.4.31.15 Thermal insulation finishes to heating & piped water services - external to
buildings in open air or in ducts
The outer covering to the insulation shall be a weatherproof finish which passes continuously
without being punctured through pipework supports and over flanges, expansion joints and
anchor points.
The weatherproof finish to the insulation of pipework carrying fluids at temperatures above
ambient shall be one of the following as indicated:
(a) Waterproof vapour permeable plastic coating systems, brush or spray applied and
reinforced with canvas or glass fibre cloth;
(b) Roofing felt, sealed with adhesive with overlaps of at least 50mm wrapped with 25mm
mesh by 1mm thick galvanised wire netting, laced with 1mm thick galvanised wire and
painted two coats of bituminous paint to BS 3416 Type 1 Class A.
(c) Bitumen impregnated fabric systems sealed by the application of heat or by cold
welding;
(d) Other proprietary weatherproof finishes of the type as indicated;
(e) Pre-insulated pipework systems, of the type as indicated.
The finishes specified in items (b) and (c) above shall be perforated on the underside of all
horizontal runs with 6mm diameter holes at approximately 150mm centres. The horizontally
lapped joints shall lie to one side of the bottom centre line exposed edge downwards, so that the
perforations are made in one thickness of the material, with the underlying preformed insulation
open to atmosphere at these points.
The weatherproof finish to the insulation of cold water pipework shall be as items (b), (c), (d) or
(e) above without the requirement for perforation on the underside as indicated.
Thermal insulation to air distribution ductwork and air handling plant
Thermal insulation shall be applied to air distribution ductwork and to components within
distribution systems such as fans, heater and cooler casings which convey conditioned air within

plant rooms and to ductwork (including recirculation air ductwork) conveying warmed or chilled
air through unconditioned spaces or the open air. Unless otherwise indicated, distribution
systems conveying conditioned, warmed or chilled air through conditioned spaces shall not be
insulated. Distribution systems conveying fresh air and exhaust air shall be insulated where
indicated.
The thicknesses of insulation for air distribution services shall be determined from the Thermal
Insulation Tables section.
J9.4.31.16 Thermal insulation to ductwork & air handling plant - materials & finish
All thermal insulating materials and finishes shall be subject to the requirements of fire
properties and vapour barriers mentioned elsewhere in the Specification. The vapour permeance
shall not exceed 0.05g/(sMN) unless otherwise indicated. Thermal insulation applied to packaged
air handling units shall be in accordance with Clause 2.19 of this Specification.
Within buildings, services concealed from view and not readily accessible; the following shall be
provided as indicated:
(a) Preformed slab (or flexible material having a bulk density at least 1 kg/m3) with a facing
of factory-applied aluminium foil or plastics film; secured by adhesive and piercing
fasteners or enclosed within galvanised wire netting of 25mm mesh.
(b) Preformed slab material, secured by adhesive and piercing fasteners, enclosed in
aluminium foil with all laps sealed with matching self-adhesive tape.
(c) As item (b) above but enclosure to be polyisobutylene sheet adhered to the insulating
material and bonded to itself at all laps.
(d) Preformed slab material secured by adhesive and piercing fasteners, covered or enclosed
in 136 g/m2 cotton fabric adhered to the insulating material; painted two coats of
appropriate vapour sealing compound.
Within buildings, services exposed to view but not readily accessible; the following shall be
provided as indicated:
(a) As items (b), (c) or (d) but painted to match decoration of surroundings.
Services in plant rooms and elsewhere, where indicated, to avoid possible damage; the following
shall be provided as indicated:
(i) As items (a) or (b) above but enclosed in 0.8mm thick aluminium sheet or 0.5mm
galvanised steel sheet.
(ii) Preformed slab material, covered with galvanised wire-netting of 25mm mesh, and
supercoated with 10mm thickness of self-setting cement primed and finally painted.
Outside buildings, services exposed to the weather; the following shall be provided as indicated:
(i) As items (a), (b) or (c) above but enclosed in 0.8mm thick aluminium sheet with all
joints sealed and arranged to shed water.
(ii) As items (a) or (b) above but covered in roofing felt and galvanised wire netting of
25 mm mesh and finally treated with two coats of bituminous weatherproofing
compound.
(iii) As items (a) or (b) above but enclosure to be polyisobutylene sheet bonded to itself at all
laps.

J9.4.31.17 Thermal insulation to ductwork and air handling plant - application

Fixing methods for insulation shall provide a minimum of direct metal paths which thermally
bridge the insulation, particularly when the insulation is metal faced. The full insulating effect
shall be maintained at connections and access openings and panels including the edges of such
openings. Thermal insulation shall cover all forms of flanged joints, fasteners and stiffeners
either by means of purpose made boxes or by increasing the general thickness of the insulation to
give at least 6mm cover. Where insulation is applied in layers all joints in all layers shall be
staggered.
At all points of support, the insulation and outer covering and vapour seal shall be continuous
and shall not be pierced or fouled by the supports. The insulation at supports shall be material of
sufficient compressive strength to take the loads transmitted to the supports.
Preformed slab insulation shall be applied with adjacent sides lapped to maintain a uniform
thickness at corners. The insulation shall be fixed securely with adhesive and by impaling on
fasteners which may be rustproof metal studs, split prongs, plastics studs or other approved
devices fixed to the duct surfaces. Fastenings shall be suitable for the thickness and weight of the
insulating materials and finishes to be applied and shall be spaced at approximately 300mm
centres. Fastenings shall be finished flush with the surface of the insulation to which they are
applied. Adhesives shall be compatible with the insulation and in their dry state be non-
flammable. In no circumstances shall adhesive be used which attacks or dissolves the ductwork
or insulation.
Aluminium foil or plastics faced preformed slab insulating materials shall be placed on the
outside of ductwork with adjacent sides lapped to maintain a uniform thickness at corners. All
joints shall be sealed with tape of the same material as the facing and held in place with contact
adhesive. The adhesive shall be suitable for the range of ambient temperature and humidity
encountered.
Reinforcement of self-setting cement shall be 25 mm mesh, 1 mm thick, galvanised wire netting.
Cement finishes applied to thermal insulation shall always be completely dry before the
application of any sealing primer and final decorative coating. Cement application shall be
planned and executed in sections to avoid joints between wet cement and cement already dried.
Where thermal insulation is protected against the effects of weather by plastic sheet or roofing
felt, particular care shall be taken to ensure a watertight seal at all joints. The sheet material shall
be adhered to the external surface of the insulation and all joins shall be lapped, secured and
sealed by adhesive or solvent welding. All jointing and sealing materials and methods of
application shall be to the recommendations of the sheet supplier. Polyisobutylene sheet shall be
not less than 0.8mm thick and have a tensile strength not less than 3.4MN/m2.
Where an insulated duct passes through an external building element adequate precautions shall
be taken to prevent the entry of rainwater into the building.
Flexible insulation shall have all circumferential and longitudinal joints sealed with tape of the
same material as the insulation facing. The external surface of the insulation shall be wrapped
with galvanised wire netting of 25 mm mesh, 1 mm thick, and the netting joints shall be secured
with a lacing of 1mm galvanised wire. Care shall be taken to ensure that the insulation material is
not crushed during application.
Thermal insulation and acoustic insulation materials shall be applied to the inside of ductwork
only where indicated. The insulation material shall be cut to accurately fit the internal duct
surfaces. The insulation shall be fastened to the duct using adhesive spread over the entire
surface in combination with piercing fasteners finished flush with the insulation surface.

Particular care shall be taken to ensure that the edges of all internal insulating materials, whether
exposed or butted against similar edges, are sealed and secured to the internal surfaces of the
duct. They shall be protected with channel sheet metal of not less than 0.8mm thickness and
13mm width or be provided with other approved means of protection to prevent erosion and
peeling. All materials shall have adequate strength and cohesion to resist erosion at the maximum
design air velocity and shall not produce dust.
J9.4.31.18 Thermal insulation - vapour barriers

Where thermal insulation is applied to the outside of piped and ducted services, equipment and
plant used to convey, store or generate fluids or gases at temperatures lower than the design
ambient dew point temperature indicated, a water vapour barrier shall be provided. The vapour
barrier shall be applied such that it is continuous and gives protection to the whole surface of the
insulation which it protects. It shall not be pierced or otherwise damaged by supports or by the
application of external cladding. At points of support means of load distribution shall be
provided as necessary.
Unless otherwise indicated, the vapour barrier shall have a permeance value not exceeding
0.05g/(sMN).
The material chosen for the vapour barrier and its method of application shall be compatible with
the thermal insulation which it is to protect. The following may be used (subject to the Thermal
Insulation -General section.)
(a) Wet-applied vapour barriers of the cut-back bitumen type, bitumen emulsions with or
without elastomer latex, vinyl emulsions and solvent based polymers.
(b) Elastomer sheets with all joints adequately overlapped and continuously sealed.
(c) Polyvinyl chloride, polyethylene, polyisobutylene or other plastics tapes or sheets.
(d) Epoxide and polyester resins.
(e) Sheet metal with all joints adequately overlapped and continuously sealed to a vapour-
tight condition.
(f) Metal foil used alone or laminated to building paper, building sheet or plastics film with
all joints adequately lapped and continuously vapour sealed.
J9.4.31.19 Thermal insulation - painting and identification

Thermal insulation exposed to view (including that within plant rooms) shall be painted except
where the insulation is protected by aluminium foil or sheet, plastics film or a weatherproof
finish. An undercoat and not less than two finishing coats shall be applied. Absorbent surfaces
shall also receive an initial coat of priming paint. All paints shall be compatible with the surfaces
to which they are applied.
The colour(s) of paint(s) shall be to the instructions of the Engineer and shall be selected from
the range contained in BS 4800.
All distribution services shall be colour coded and provided with symbols for identification
purposes. Identification coding for ductwork, including thermal insulation, shall be in accordance
with DW/144. For pipework, including thermal insulation, the basic colour and colour coding
shall be in accordance with BS 1710.
Un-insulated pipework or ductwork and thermal insulation which is painted or unpainted shall be
identified by bands at least 25mm wide or colour triangles of at least 150mm side. The bands or

triangles shall be spaced and located to permit ready identification of the services particularly
adjacent to equipment positions, at service junctions and wall penetrations.
In addition to colour bands or triangles all pipework and ductwork in plant rooms and service
areas, whether insulated or not, shall be legibly marked with black or white letters and triangles
to show the type of service and the direction of fluid flow. The letters F and R shall be added to
piped distribution to show flow and return respectively.
J9.4.31.20 Automatic controls - general

Automatic control systems shall be as required to ensure the safe, reliable and efficient operation
of the plant and systems, and as indicated on the drawings, in schedules or elsewhere in this
Specification and may be self-acting, electro-mechanical, electronic, pneumatic or hydraulic. The
installation may be a single system or a combination of systems.
All items of control equipment shall be compatible within any system, between systems and with
controlled equipment.
The siting of items of control equipment shall always be such that access for adjustment and
maintenance purposes is not impeded. However, where items of control equipment are mounted
in accessible positions within normally occupied areas the control items shall be provided with
means to discourage unauthorised interference.
Control systems shall be arranged such that, in the event of electrical power failure or other
abnormal operating condition, inherent fail-safe features prevent potentially hazardous conditions
arising.
Unless otherwise agreed by the Engineer, the Contractor shall arrange for the control
manufacturer or specialist to supervise installation of the systems, to commission them, and to
provide the related As Installed drawings.
Control systems shall be provided complete with handbooks giving full setting up instructions,
and fault finding and locating information. Simple operating instructions shall be recorded
permanently inside the lid or cover of each unit where appropriate.
Controls shall be electric, pneumatic or self acting as indicated. The term 'motorised' is not meant
to imply that only electrical controls are acceptable.
Electrical connections between internal components shall be soldered but units and individual
items such as clocks shall preferably be of the 'plug-in' type with contacts of not less than 10
ampere rating.
Controls shall conform to the requirements of Ministry of Housing and Public Works.
J9.4.31.21 Time programme control

Time control of the heating and air conditioning systems shall be by the following methods as
required or as indicated on the drawings or elsewhere in this Specification.
(a) On/off time-clock control.
(b) Optimum start control.
(c) Optimum start and optimum off control.
Daily and weekly programme facilities shall be adjustable to suit the plant and building response.
Facilities shall be provided to allow pumps to run on after boilers are switched off to allow for
heat dissipation.

Where indicated a programmable facility shall be provided to allow extensions or reductions to

any daily heating or cooling period and deletions for holidays.
Controllers shall be programmable to provide two independent heating or cooling periods during
any part of a 24 hour period.
Clocks shall be driven by synchronous motors or electronic timers with a self maintaining
mechanical or electrical reserve of not less than 72 hours. Clocks shall incorporate facilities for
omitting days on a seven day programme.
Frost and condensation protection for the buildings shall be provided and monitored by external
and internal temperature detectors respectively during 'heating-off' periods. The external
detectors shall control the heating pumps, air heater batteries etc and the internal detectors shall
control the heat sources and fans.
(a) On/off time control:
Where indicated on the drawings or elsewhere in this Specification clocks used on
weather-compensated circuits shall be provided with additional contacts to provide a
boost to reduce the building pre-heat period. Boost shall be achieved by fully opening
the compensated circuit mixing valve unless otherwise indicated. Boost termination
shall be activated when internal temperature reaches set-point.
(b) Optimum start control:
These controllers shall provide optimum start of heating plant taking into account the
thermal capacity and response of the buildings, and the external and internal
temperatures as appropriate. They shall provide boost during building pre-heat periods
and early start facilities after prolonged shutdown of plant. Boost termination shall be
activated by the internal temperature detectors.
Unless otherwise indicated:
(i) External temperature detectors shall be mounted on the north sides of buildings at
roof level and be shielded from direct solar radiation. The detectors shall be
sensitive to night sky radiation and shall be capable of measuring external air
temperature independently of wind direction.
(ii) Internal temperature detectors shall be located in representative rooms having
thermal performances typical of the buildings or zones to be controlled or as
indicated.
(c) Optimum start and optimum off control:
Where indicated on the drawings or elsewhere on this Specification optimum start
controllers shall be provided with optimum off facilities, which override the day
controls when there is sufficient residual heat for the buildings not to drop below a
minimum temperature by the end of the working day. They shall control the heat
sources, circulating pumps and control valves as appropriate.
The set point for the minimum temperature at the end of the working day shall be
adjustable.
J9.4.31.22 Space temperature control

Internal temperature control shall be provided by one of the following systems as required or as
indicated on the drawings or elsewhere in this Specification.

(a) On/off control;

(b) Modulating control;
(c) Weather-compensated control with internal correction.
(d) Thermostatic radiator valves or other direct acting controller.
(a & b) On/Off and modulating control:
This shall be achieved by the use of space thermostats controlling two or three port
motorised valves.
(c) Weather-compensated control with internal correction:
Weather-compensated control with internal correction shall be achieved by the use of
space thermostats arranged to modify the weather compensated control schedule
dependent on internal temperature.
Set point internal temperature shall be adjustable. The influence of internal temperature
variation on the weather compensated control schedule shall be adjustable.
J9.4.31.23 Room thermostats and temperature detectors

Room thermostats for space heating temperature control shall comply with BS 3955.
Where adjustable thermostats are used a clearly visible indicator and calibrated numerical scale
clearly marked in oC shall be provided for temperature adjustment without the use of tools.
Covers shall prevent unauthorised tampering with the temperature settings.
Where non-adjustable thermostats are used they shall have no external means for changing the
switching temperature.
Room thermostats passing a load current of less than 12 amps through their contacts during
normal operation shall be fitted with accelerator heaters, shunt connected across the supply.
Where the load current exceeds the rating of the thermostat contacts, separate contactors shall be
provided.
Room thermostats and temperature detectors shall be mounted in a position representative of the
zone or space heated by the emitting system or appliance to be controlled. They shall not be
mounted on external walls, in direct sunlight, draughts or be subject to heating from any other
equipment. Wall mounting height shall be 1.5m from the floor.
J9.4.31.24 Duct air thermostats and temperature detectors

Elements sensing the temperature of air in a duct shall be positioned so that:
(a) The element is not subject to radiation;
(b) Account is taken of temperature stratification, (i.e. positioning for frost sensing,
positioning for high temperature limit sensing, positioning for average temperature
sensing);
(c) If of the capillary averaging type, it is installed on a suitable framework and is suitably
arranged for servicing;
(d) If used for determining the dew point, the air adjacent to the element is known to be
saturated within acceptable limits and the construction and material of the element shall
be compatible for use in moist air.

J9.4.31.25 Humidistats and humidity detectors

Humidity sensing element positions shall be:
(a) Representative of the space in which the humidity is being measured;
(b) Such that the air velocity is within the range required by the sensing element;
(c) Arranged to ensure that the air reaching the element is free from airborne contaminants;
(d) Arranged to give convenient access for servicing the element.
J9.4.31.26 Automatic controls - electric air heaters

Electric air heaters shall be energised in three phase balanced stages not exceeding 6kW per three
phase stage except that stages of not more than 3kW may be single phase. There shall be a time
lag of not less than five seconds between successive stages. Arrangements shall be made to
ensure that in the event of electrical supply failure, or after normal shut down, the control system
will recycle to the 'OFF' position upon resumption of supply and before starting to reconnect the
heater load.
J9.4.32 Controllers
J9.4.32.1 Types and construction

Controllers shall be of the following types:
(a) On/off;
(b) Proportional;
(c) Integral;
(d) Proportional plus integral.
Controllers shall be contained within a metal case to BS EN 60529 IP 54 with a lockable cover
suitable for wall, frame or panel mounting as indicated.
Basic adjustments (such as slope characteristics, sensitivity, and anti-hunting adjustments) shall
be concealed and tamper-proof, the panels being lockable. The remaining control functions shall
be accessible and protected by means of lockable and tamper-proof covers.
J9.4.32.2 On/Off Controllers

Differentials shall be adjustable over the entire ranges of the controllers. Temperature scales shall
be numerical and clearly marked.
J9.4.32.3 Integral Controllers

The set points and integral action times shall be adjustable.
J9.4.32.4 Proportional Plus Integral Controllers

The set points, proportional bands and integral action times shall be adjustable as appropriate.
The controllers shall be able to accept signal inputs from either single or numbers of detectors
working together as indicated.

J9.4.33 Control cubicles and panels - construction

As far as is practicable all controls, indicator lamps and instruments shall be grouped and
mounted together in a cubicle or on a floor or wall-mounted panel.
The control panel construction shall be fully compliant with all relevant clauses of the general
material and workmanship standards.
Where duplicate plant is provided the starters for each plant shall be housed in a separate
compartment of a panel. Where more than one refrigeration compressor is provided the
compressor motor starters shall be housed in separate cubicles. For refrigeration plant or
completely packaged water chilling units the compressor motor starters may, at the discretion of
the Engineer, be housed separately from the main starter and control panel but provision shall be
made for any electrical interlocking which may be required between the compressor motor
switchgear and the starters for the remainder of the plant. Each standby (installed spare) electric
motor shall be provided with its own control gear and starting equipment and be connected to a
separate final sub-circuit.
For the control of electrical equipment which is not interlocked an ÒN/OFF' rotary snap switch
shall be fitted on the front of the panel for each item of plant. Where interlocks are required an
ÒN/OFF' switch shall be fitted for the master item and a `HAND/OFF/AUTO' switch shall be
fitted for each item of dependent plant. The switch positions shall be clearly indicated and each
switch shall be clearly labelled to show which item of plant it controls.
With a `HAND/OFF/AUTO' switch in the ÀUTO' position the dependent item of plant shall
start automatically when the master item is switched ÒN' and shall operate automatically under
the dictates of any controlling device. The operation of the switch to the `HAND' position shall
override any controlling devices except those which are necessary for the safe operation of the
plant. Similarly, the operation of a master switch to 'OFF' with dependent plant at ÀUTO' shall
cause all plant to stop, in sequence where necessary (e.g. allowing a fan to run on to remove heat
from electric heaters or chilled water pump to run on until refrigeration pump-down is
completed, to avoid freezing up) and with due regard for all safety controls.
For each electric air heater battery a 'HAND' 'OFF' 'AUTO' switch, an indicator lamp and an
ammeter shall be provided. Associated with the 'HAND' setting of the switch there shall be a
second rotary switch giving manual control of the heating steps independently of automatic
control.
For each electric motor of 7.5kW and above, an ammeter shall be provided on the panel.
For cooling and air conditioning plants the master item shall be the main air supply fan and/or
the chilled water pump(s) as appropriate. For systems with direct expansion air coolers the
starting of the main air supply fan shall, under automatic working conditions, cause all other
plant to start in sequence and as required by the automatic controls. Similarly, for chilled water
systems the master item shall be the chilled water pumps and their operation shall, under
automatic working, allow the refrigeration plant etc to start. Where there are both air and water
systems the main air supply fan shall be the master item for the air handling plant and the air
temperature and humidity controls; the chilled water pump shall be the master item for the water
handling plant, the refrigeration plant and the water temperature controls and water flow switch.
Refrigeration plant shall energise in sequence (i.e. the condenser water pump or evaporative
condenser pump or air cooled condenser fan shall start first), followed by the cooling tower fan
(or evaporative condenser fan) where required and then the compressor. Where more than one
compressor is installed they shall be arranged to start in time delayed sequence and as required
by temperature control (or in some cases refrigerant pressure control); a switch shall be provided

to enable the leading machine to be selected manually (e.g. in sequence 1-2-3, 2-3-1 or 3-1-2).
For each compressor of more than 35kW capacity an hours-run meter shall be provided.
Sequence control shall be provided for boiler plant where relevant.
J9.4.34 Automatic controls - motorised dampers

Motorised dampers, which for the purpose of this specification shall mean dampers operated
automatically by all forms of actuators, shall be of the multi-leaf type. The damper frame and
blades shall be constructed to ensure rigidity and prevent distortion and jamming in operation.
The blades shall be securely fixed to their operating spindles so that differential movement
between them cannot occur. Spindles shall be carried in non-ferrous or nylon plain bearings or in
ball bearings. All dampers shall be provided with blade position indicators. A rigid mounting
bracket shall be provided for each damper actuator.
J9.4.35 Electrical equipment and wiring
J9.4.35.1 General
Unless otherwise indicated the Contractor shall provide and install all electrical equipment
necessary for the complete installation and carry out all wiring from point(s) of supply as
required or as indicated on the drawings or elsewhere in this Specification.
The Contractor shall be responsible for the accuracy of all wiring diagrams provided by him and
for the correct internal wiring of all pre-wired equipment supplied for the contract.
Unless otherwise indicated all electrical equipment shall be suitable for use in ambient
temperatures up to 40oC and relative humidities up to 90%.
The electrical cabling and wiring installation for the air conditioning and ventilation systems
shall be combatable with and fully integrated with other cabling and wiring systems within the
buildings and shall fully comply with the Section 4.5 of the Specification.
J9.4.35.2 Electrical motors

Unless otherwise specified motors shall be three phase squirrel cage induction type fully
complying with BS 4999, BS EN 60034 and BS 5000 as appropriate for the application
specified. They shall be capable of withstanding without damage an overload equivalent to 150%
of full load torque for 15 seconds.
The motor rating shall be at least 110% of the maximum power demand of the driven plant when
operating in its normal range. For motors above 15 kW, output power factor over its normal
operating range shall not fall below 0.85 lagging.
If used with a variable speed motor controller, the motor shall be rated for continuous running
under all load conditions throughout the specified range.
The motor terminal box shall allow adequate clearance for an air termination of the specified
cable, cable lugs and glands.
Motors of 15kW and above shall be fitted with anti-condensation heaters. The heaters shall be
separately fused and energised when the contactor is open and the starter isolator is closed.
The motor rating plate shall contain as a minimum the following information: maker's name,
rating, duty current, voltage, frequency, duty power factor, duty speed, connections, class of

insulation, class of temperature rise maximum number of starts per hour, type and serial number
of motor.
Unless otherwise specified the motors shall be capable of starting at least 5 times, equally
disposed in any one hour at maximum ambient temperature. Motor insulation shall be rated to
thermal class F and temperature rise shall not exceed the limits of class B.
The degree of protection of the motor enclosure as described by BS EN 60034-5 shall be as
follows:
- outdoors IPW 55
- indoors where hosing down may take place IP 55
- indoors general locations IP 54
All motors shall be provided with a frame earth terminal of sufficient size to take full fault
current.
All motors rated over 11kW or operated on variable speed controls shall have their stator
windings equipped with six embedded thermistor temperature detectors (3 for use, 3 spare) wired
to a motor mounted auxiliary terminal box. Connections shall be taken to a thermistor control
unit to BS 4999 part III external device to monitor continuously three temperature detectors in a
particular motor. The monitoring units shall be complete with trip contacts which shall operate
when any single detector exceeds prescribed limits.
Each motor circuit shall be provided with an isolator or switch or circuit breaker in the motor
starter.
Where a motor is not visible from the motor starter position, or where the Engineer decides it is
otherwise necessary to prevent danger, an isolator or switch or push-button shall be provided
adjacent to or mounted on the motor.
Motors arranged for automatic starting shall have a label of durable material fixed permanently
to them in a prominent position and, having, in clearly inscribed black characters on a yellow
background, the legend:
DANGER THIS MOTOR IS AUTOMATICALLY CONTROLLED AND MAY START

WITHOUT WARNING. ISOLATE BEFORE INSPECTION.
J9.4.35.3 Immersion heaters for hot water

Electric immersion heaters shall be of the ratings indicated.
Elements shall be of the metal sheathed rod type with the resistor embedded in refractory
material. They shall be manufactured from materials recommended by the local electricity
authority for the water supply of the particular area.
Elements shall be firmly brazed to brass or gunmetal heads. Soft soldering will not be accepted.
Heads shall be octagonal and screwed 2.25 BSP medium fit, and provided with a jointing washer
and sweating flange.
Heads shall be complete with connection chambers with removable covers, having line, neutral
and earth terminals and bushed cable entries or screwed entries for conduit, as required.
Heaters shall comply with BS 3456-1, BS EN 60335-1 and BS EN 60335-2-73, except as
modified by this specification.

Each single-phase heater shall incorporate an adjustable thermostat having a range of adjustment
between 50oC and 80oC.
Each poly-phase immersion heater shall be controlled by an adjustable thermostat having a range
of adjustment between 50oC and 80oC installed in an immersed pocket and operating through an
electrical contactor.
J9.4.35.4 Bonding
The Contractor shall ensure that all the metallic installations he provides which constitute
'Extraneous conductive paths' shall be electrically bonded in accordance with BS 7671.
Metallic gas pipework shall be electrically continuous. Flanged, grooved or compression type
fittings in gas pipes shall be electrically bonded. Gas pipework shall be electrically bonded to the
electrical earth terminal in accordance with BS 7671.
J9.4.36 Testing
J9.4.36.1 General
All mechanical services plant and the complete installations shall be subject to Off - Site and On
- Site inspection and testing and commissioning.
The Contractor’s obligations and the requirements for inspection and testing and testing
procedures shall fully comply with the requirements of Section 4.1.
Additional specific requirements pertaining to the mechanical services installations are as
follows:
J9.4.36.2 Tanks for water

Every tank for water storage for cooling, make-up and similar applications for water shall be
individually pressure tested off-Site in accordance with BS 799-5 or BS 2594 and BS EN 12285-
1, as appropriate, the test pressure to be maintained for one hour.
Every tank shall be individually pressure tested on-Site, repeating the off-Site test procedure.
J9.4.36.3 Completed pipework systems other than cold water

Completed DHWS and refrigeration systems shall be subjected to hydraulic pressure tests on-
Site after cleaning. The systems shall sustain at least 1.5 times working pressure for not less than
30 minutes. Items of equipment such as safety valves and bursting discs set to operate below test
pressure shall be isolated during testing. After satisfactory tests, systems shall be drained, dried,
filled with preserving solution or filled with treated water as necessary.
J9.4.36.4 Completed cold water pipework system

After being cleaned cold water systems shall be recharged with clean water and tested on-Site as
follows. Storage cisterns and distributing pipework shall be watertight under working conditions
of pressure with all draw-off taps closed. Water mains and service pipework shall be subjected to
a hydraulic test pressure of 9 bar of 1.5 times the maximum working pressure, whichever is the
greater. This pressure shall be maintained without measurable loss for at least 30 minutes.

J9.4.36.5 Ductwork systems

All ductwork systems including associated equipment shall be tested on-Site for air leakage.
Installations, or sections thereof, which will be embedded in the structure or concealed shall, in
addition to the above specified tests, be individually tested as they are laid and prior to being
embedded or concealed.
Pressure tests on completed systems shall preferably be carried out before the application of
thermal insulation. With the Engineer's approval however sub-sections or sub-systems may be
tested before system completion to facilitate the insulation work. These advance tests shall be
witnessed by the Engineer and certified, if appropriate. This shall not relieve the Contractor of
the responsibility to pressure test the completed system and show a satisfactory result.

SECTION J10 STRUCTURAL STEELWORK
J10.1 SCOPE
This Section covers the requirements for the design, supply and erection of structural steelwork.

Unless otherwise specified structural steelwork shall comply with the relevant Reference
Standards listed below:
BS 4-1:1993 Structural steel sections. Specification for hot-rolled sections
Specification for the use of structural steel in building. Metric
BS 449-2:1969
units
Welding consumables. Covered electrodes for manual metal arc
BS EN 499:1995
welding of non alloy and fine grain steels. Classification
Specification for the design and testing of steel overhead runway
BS 2853:1957
beams
BS 4190:2001 ISO metric black hexagon bolts, screws and nuts. Specification
BS EN ISO Welding and allied processes. Determination of hydrogen content
3690:2001 in ferritic steel arc weld metal
Specification for metal washers for general engineering purposes.
BS 4320:1968
Metric series
Plates and wide flats made of high yield strength structural steels
BS EN 10137
in the quenched and tempered or precipitation hardened
(Various)
conditions.
Weldable structural steels. Hot finished structural hollow sections
BS 7668:2004
in weather resistant steels. Specification
Specification for tolerances on dimensions, shape and mass for hot
BS EN 10029:1991
rolled steel plates 3 mm thick or above
BS EN 10113
Hot-rolled products in weldable fine grain structural steels.
(Various)
Structural steels with improved atmospheric corrosion resistance.
BS EN 10155:1993
Technical delivery conditions
Hot finished structural hollow sections of non-alloy and fine grain
BS EN 10210-1:1994
structural steels. Technical delivery requirements
Specification for structural steel equal and unequal angles.
BS EN 10056-1:1999
Dimensions
Specification for structural steel equal and unequal angles.
BS EN 10056-2:1993
Tolerances on shape and dimensions
Specification for high strength friction grip bolts and associated
BS 4395-1:1969
nuts and washers for structural engineering. General grade
Specification for high strength friction grip bolts and associated
BS 4395-2:1969 nuts and washers for structural engineering. Higher grade bolts and
nuts and general grade washers
Specification for the use of high strength friction grip bolts in
BS 4604-1:1970
structural steelwork. Metric series. General grade
Specification for the use of high strength friction grip bolts in
BS 4604-2:1970
structural steelwork. Metric series. Higher grade (parallel shank)


BS EN 10210-1:1994
structural steels. Technical delivery requirements
BS EN 10210-2:1997
structural steels. Tolerances, dimensions and sectional properties
BS EN ISO 15614 Specification and qualification of welding procedures for metallic
(Various) materials. Welding procedure test
Specification for approval testing of welders working to approved
BS 4871-3:1985 welding procedures. Arc welding of tube to tube-plate joints in
metallic materials
BS EN 287-1:2004 Qualification test of welders. Fusion welding. Steels
BS EN 1011 (Various) Welding. Recommendations for welding of metallic materials.
PD 5500:2003 Specification for unfired fusion welded pressure vessels
BS 5531:1988 Code of practice for safety in erecting structural frames
BS 5950 (Various) Structural use of steelwork in building
Hot rolled products of non-alloy structural steels. Technical
BS EN 10025:1993
delivery conditions
Specification and qualification of welding procedures for metallic
BS EN ISO 15614-
materials. Welding procedure test. Arc and gas welding of steels
1:2004
and arc welding of nickel and nickel alloys
J10.3.1 General
The Contractor shall submit the following:
J10.3.2 Design Calculations

• structural design;
• member size;
• calculations for connection details;
• welding procedure sheets.
J10.3.3 Drawings
• general arrangements;
• general assembly, detailed shop and erection drawings;
• detailed manufacturing drawings.
J10.3.4 Certificates
• material tests;
• Inspection certificates;
• qualification certificates.

J10.4 DESIGN
J10.4.1 General principles

Calculations by the Contractor for the design of any steel structure shall be prefaced by a
statement explaining the principles of design and the type of analysis adopted. The statement
shall also indicate the codes of practice and specifications upon which the design is based.
Any computer programs used in the design process shall be fully described, and details of input
and printout shall be presented in an easily understandable form. Program manuals and any
instructions to program users shall be available to the Engineer upon request. Where any such
program cannot be demonstrated to have been fully checked or where the Engineer considers it
necessary, the Contractor shall run such test examples as the Engineer may choose in order to
verify the completeness and accuracy of the program.
J10.4.2 Codes and standards

Structural steelwork shall be designed in accordance with the following:
BS 449-2:1969 Specification for the use of structural steel in building. Metric units
BS 5950 (Various) Structural use of steelwork in building
BS 5400 (Various) Steel, concrete and composite bridges
BS 2853:1957 Specification for the design and testing of steel overhead runway
beams
Structures which are considered by the Engineer to be beyond the scope of BS 449 or BS 5950
shall be designed in accordance with BS 5400 or such other standards as may be consented to by
the Engineer.
Runway beams and the longitudinal support beams of underslung cranes shall be designed in
accordance with BS 2853.
Where the Contractor requires to use a standard of code of practice different to those specified,
he shall first obtain the consent of the Engineer. After having obtained such consent, the
Contractor shall use the standard in its entirety for the whole structure. The Contractor may use
isolated parts of other standards that are considered relevant, but he shall obtain the Engineer's
consent before doing so. The Engineer may exclude such a process on grounds of incompatibility
with the main standard.
J10.4.3 General principles

The structural steelwork shall be designed for a 50 year life.
Structures may be designed either by the working stress approach using unfactored loads against
a working stress (generally limited to 0.7 x yield stress) as specified in the relevant standard, or
by the limit state method. Structures designed to the limit state method shall be designed by
considering the limit states at which they would become unfit for the use for which they are
considered and applying appropriate safety factors to provide an adequate degree of safety and
serviceability.
The overall design concept shall give due regard to the fact that the structure as a whole will be
required to behave as one three-dimensional entity. The layout of its constituent parts, including

the steel members, the other structural elements, the foundations and the connections between
each component, shall be such as to produce a strong and stable structure.
The structure shall be checked for the effects of all possible vertical and horizontal loads, acting
both in conjunction and separately as appropriate, using factored loads when checking strength
and stability to a limit state analysis and unfactored loads when checking deflections or strength
and stability using a working stress approach.
The structures shall be designed to be capable of accepting without overstress 10% extra loading
due to any cause including extra services, heavier cladding, or other appurtenances that may
reasonably be added during the life of the structure.
Structures shall be designed such that undue reliance is not placed on 'key' elements (a key
element is one whose removal tends to prejudice the ability of the whole structure to survive).
The removal or damage of such elements shall not entail collapse of more than a limited part of
the structure. The design of structures will not be considered to be adequate if an accident could
cause damage to the structure out of proportion to the magnitude of the event.
The design shall take account of the need for stability of both the framework and the individual
elements at all stages of erection. Where temporary bracing is required it shall be checked for the
effects of all loadings that may arise during erection including those due to erection equipment
and its operation. Such bracing shall be clearly indicated on the drawings together with clear
instructions as to the appropriate stage of removal.
The design of crane beams shall take due account of all factors relevant to the provision of
effective support to the crane under all conditions of loading including but not limited to:
(a) Underslung cranes and monorail runway beams:
(i) combined flange stresses resulting from overall bending and local flange bending
due to wheel loads causing transverse stresses;
(ii) lateral instability;
(iii) torsional restraint;
(iv) deflection limitations;
(v) joints, particularly local force concentrations due to loads passing across joints.
(b) Overhead, over slung cranes and gantry girders:
(i) as above but related to coincident lifting, slewing, traversing actions of the crane.
All crane-supporting structures shall be designed for the worst combination of all other design
loads with the crane under test.
J10.4.4 Design loadings

Design loadings shall be as for structural concrete design. Seismic design shall be for a vertical
and horizontal acceleration of 0.1g. Wind loading shall be 40m/min for a 3 second gust to BS
6399-2.
J10.4.5 Deflection limits

When checking the deflections of a structure, the most adverse realistic combination and
arrangement of unfactored loads shall be assumed.
The deflection of a building or part of a building shall be limited so as not to impair the strength
or efficiency of the building or of its contents, nor be unsightly or cause damage to the finish or
inconvenience to the occupants.

Deflections of members listed in the table below shall not exceed the tabulated limits, unless the
Contractor can demonstrate to the Engineer's satisfaction that greater values would not be
detrimental to the performance of the structure.
A. Beams Deflection due to imposed road

Cantilevers Length/180
Beams carrying plaster finish Span/400
Roof beams not carrying plaster finish Span/350
Purlins and sheeting rails To suit the characteristics of the sheeting
B. Columns Horizontal deflection
Each storey, top of column, brick or plaster Height/300
cladding
Single storey portal framed structures, with Height/90
metal
cladding
C. Crane Girder Deflection at point of maximum span
moment
Vertical deflection static wheel loads Span/700
Horizontal deflection (calculated on properties Span/500
of top or bottom flange alone as applicable)
The relative lateral deflection of adjacent frames (including the end frames) of sheeting clad
structure shall be limited generally to frame centres/250 unless greater values can be shown to
have no detrimental effect on the structural performance of the sheeting.
J10.5 MATERIALS
J10.5.1 Structural steelwork generally

Rolled structural steel sections shall be of Grade S275 mild steel conforming to BS EN 10025
and subject to the additional requirements of BS 5950. The dimensions, tolerances and
properties of the structural sections shall conform to BS 4 or BS EN 10210 and BS EN 10056.
Where the use of proprietary designs of prefabricated building frames is proposed, the standards
to which they are manufactured shall be no less rigorous than those stated above.
J10.5.2 Bolts and nuts

Steel bolts and nuts shall be high-strength friction-grip bolts conforming to BS 4395 or black
bolts conforming to BS 4190. Washers shall conform to BS 4320.
High-strength friction-grip bolts shall be used in conjunction with approved proprietary load-
indicating washers.

J10.5.3 Welding consumables

All welding consumables (electrodes, wire, filler rods, flux, shielding gas and the like) shall
comply with the requirements of BS EN 1011.
In addition, weld electrodes for metal-arc welding shall conform with BS EN 499 and BS EN
ISO 3690 and to the requirements of the appropriate weld procedure.
J10.6 WORKMANSHIP
J10.6.1 Detailing
The detailing and fabrication of structural steelwork shall be such as to minimise the need for site
welding. Structures and components such as trusses, combined columns and beams shall be shop
fabricated so as to form sub-assemblies of the largest practical size suitable for transportation,
handling and erection. Connections between members at the erection stage shall generally be
bolted.
Structural steelwork shall be so detailed and fabricated as to minimise the formation of pockets
to hold condensation, water or dirt. Where such pockets are unavoidable, suitable drainage shall
be provided.
Detailing shall be in accordance with BS 5950.
J10.6.2 Detail drawings and welding procedure sheets

The Contractor shall prepare detailed shop and erection drawings and welding procedure sheets
for all structural steelwork and these shall be submitted to the Engineer for approval before
fabrication commences. The sequence of submissions shall match the order of fabrication and
erection.
Shop drawings for fabrication shall show full details of the type of steel, member sizes and
dimensions, weld details, welding sequences and any requirements for weld stress relieving.
Welding procedure sheets shall show all details of the welds including:
• welding method;
• current type, voltage and amperage;
• welding positions;
• preparation angles and methods;
• number of runs and their welding positions;
• type, size and class of electrode;
• shielding gas type and flow rate (where applicable);
• non-destructive testing methods and extent of coverage;
• pre-heat, post-heat and stress-relief methods, temperatures and the like.
Where substitution of alternative structural steel sections or modifications to the design or details
is proposed, the Contractor shall prepare revised drawings, and supporting calculations if
required, for consideration by the Engineer. Any such proposals by the Contractor shall not be
put into effect unless the Engineer has given his approval.

Erection drawings shall detail all connections, showing bolt types and sizes and site weld details
as applicable.
Shop and erection drawings shall show all marks necessary to facilitate erection and the marks
shown in the drawings shall be identical with those shown on the fabrications.
J10.6.3 Welding
All welding carried out during fabrication or erection shall be in accordance with the
requirements of BS 5135 and as shown in the approved detail drawings. Details of the proposed
weld procedures shall be submitted to the Engineer for approval at the same time as the detail
drawings. All connections shall be welded in such a manner as to make the finished connections
neat and smooth in appearance and suitable for painting. All slag shall be removed and any sharp
projections shall be ground smooth.
Before welding is commenced either in the fabrication shop or on Site, weld procedure tests shall
be carried out in accordance with BS EN 1011 where directed by the Engineer.
All welders employed either in the fabrication shop or on Site shall pass qualification tests
relevant to the weld procedures in use in accordance with BS 4871. Welders shall have
satisfactory evidence of having been engaged in welding for at least 9 months in the preceding
12-month period. If the work of any welders employed on the Contract is unsatisfactory, the
Contractor shall carry out such further welder qualification tests as are necessary to demonstrate
that the welders are proficient.
Welds shall be subjected to non-destructive testing by processes which may include but shall not
necessarily be limited to radiographic, ultrasonic, magnetic-particle or dye-penetrant methods,
depending on the type of weld and its position in the structure. The standards of acceptance shall
be as defined in PD 5500: Table 5.7, unless otherwise agreed with the Engineer.
If any work shows defects or fails to comply with the requirements of the Drawings or
Specification for any reason it shall be repaired or rejected, even though it may have been carried
out by qualified welders using approved procedures.
J10.6.4 Fabrication tolerances

The general tolerance on all dimensions shall be 2mm. Holes shall be aligned such that fasteners
can be freely inserted through the members at right angles to the contact face. Where holes in
members cannot be aligned without damaging or distorting the structure or (unless the Engineer
shall permit) reaming the holes, the member or members shall be rejected.
A structural member shall not deviate from straightness (or from the specified shape) by more
than:
• 1/1000 of the length between lateral restraints in the case of compression members and
beams, or
• 1/500 of the overall length (maximum 25m) in the case of other members.
A structural member shall not deviate from its intended length by more than:
• 1mm in the case of compression members faced at both ends for bearing, or
• +0mm to -4mm in the case of other members.
Lengths of components shall be such that cumulative variations do not prejudice the accurate
alignment of the completed structure.

Where two steel surfaces are required to be in contact to effect a bearing or frictional contact, the
surfaces shall be prepared so that at least 90% of the area is touching before any clamping force
is applied.
J10.6.5 Dissimilar metals

Where metals dissimilar to those specified in Clause 2 are used in close proximity to structural
steel members or their connections, contact between such metals and the steel shall be avoided
unless the Contractor can demonstrate to the satisfaction of the Engineer that contact between the
dissimilar metals will not lead to galvanic corrosion.
Contact between aluminium or aluminium alloy and galvanised mild steel will be permitted. For
fixing aluminium to steel structures, bolts, nuts, washers and screws shall be galvanised.
Where galvanised parts might otherwise become sacrificial anodes to the main structure, or
where the electrolytic potential difference exceeds 250mV, the parts shall be separated by an
insulating medium of adequate strength.
J10.6.6 Identification of members

All members of assemblies shall be marked at the factory with distinguishing numbers, letters or
marks corresponding to those on approved drawings or parts lists. Such marks, if impressed
before painting, shall be clearly readable afterwards.
Any temporary bolts for field erection shall be clearly marked as such to distinguish them from
high-strength bolts for permanent connections.
J10.6.7 Marking of overhead runway beams

The Contractor shall ensure that the safe working load, identification number and any limiting
operating conditions are plainly and permanently marked on overhead runway beams so as to be
clearly visible to the operator.
J10.6.8 Storage
All structural elements and other materials shall be stored (whether at the place of fabrication or
on Site) clear of the ground and shall be protected against deterioration from any cause. The
Contractor shall agree the storage areas on the Site with the Engineer before any structural
steelwork is delivered.
J10.6.9 Erection
All erection processes shall be carried out in accordance with the recommendations of BS 5531.
The plant used for handling and erection shall be suitable and safe. The Contractor shall supply,
maintain and afterwards remove temporary protection to workmen and materials below any
structural steel under erection and shall provide walkways and ladders so that inspection of any
part of the completed structure may be safely carried out.
Anchor bolts shall be properly located by the use of templates or other approved method. After
building in the anchor bolts, a sufficient time shall be allowed for concrete strength to develop
before finally pulling down to shims and grouting.
Every part of the structural steelwork shall be positioned accurately in accordance with the
dimensions on the approved drawings with a maximum tolerance of !5 mm except where the

steelwork supports metal flooring, when the finished tolerances shall be such that differences in
level between adjacent flooring sections or between flooring sections and adjacent building
floors do not exceed 3 mm. Gaps between flooring sections shall not exceed 3 mm.
Where structural steelwork is to be grouted on or against a concrete or other similar surface and
the design requires a uniform contact area under the base plate, or where directed by the
Engineer, the Contractor shall remove all steel shims or wedges and replace these with grout of
the same constituents and consistency as the main grout. Such steel shims shall be initially
positioned so as to aid removal. In the case of baseplates with large overhangs or with heavy
bearing loads the positions of shims shall be agreed with the Engineer before the structure is
erected on them.
During erection, the work shall be securely bolted or otherwise fastened, and if necessary
temporarily braced, so as to make adequate provision for all erection stresses and conditions,
including those due to erection plant and its operation. No permanent bolting shall be done until
proper alignment has been achieved.
The Contractor shall immediately report to the Engineer any errors in shop fabrication, and any
deformations resulting from handling or transportation, which prevent proper assembly and
fitting of parts. Methods to be used to correct such errors or deformations shall be agreed with
the Engineer prior to beginning of any corrections.
The Contractor may use drift pins to bring several parts together but shall not use them in such a
way as to cause distortion or damage.
J10.6.10 Bolted connections

When assembled, all joint surfaces, including those adjacent to bolt heads, nuts and washers,
shall be free from burrs, dirt or other deleterious matter or defects preventing proper seating of
the parts.
The Contractor shall make bolted connections in accordance with the details shown in the shop
or erection drawings and with BS 449. The bolts used shall be either high-strength friction-grip
bolts in accordance with BS 4395 or mild steel black bolts in accordance with BS 4190, as
detailed in the Drawings. Where necessary, washers shall be tapered or otherwise suitably shaped
to give the nuts and heads of bolts a satisfactory bearing. The bolt length shall be such that each
bolt shall project through the nut not less than one thread and not more than five threads when
fully tightened; the length of the threaded portion shall be such that there shall be at least two
threads under the nut after tightening.
The Contractor shall ensure that the faying surfaces (meaning those surfaces required to transmit
friction in conjunction with high-strength friction-grip bolts) are kept free of contamination by
grease, rust, moisture, dust and the like. If the surfaces are primed after fabrication, the primer
shall be suitable for use in such connections and shall be protected from damage during transit or
erection. If contamination should occur, it shall be remedied by appropriate means, such as:
• on coated surfaces, with a degreasing agent followed by washing and drying;
• on uncoated surfaces, as above or by blast cleaning or wire brushing to clean steel.
These remedial measures shall be taken immediately before the surfaces are bolted together.
High-strength friction-grip bolts shall be used in accordance with BS 4604, using approved load-
indicating washers to check bolt tension. They shall be tightened in accordance with the
manufacturers’ recommendations and the tension shall be re-checked not less than three hours

after first tightening. The bolts shall then be re-tightened to the initial load, all to the approval of
the Engineer.
J10.7 INSPECTION AND TESTING

The Engineer may inspect structural steelwork during fabrication and witness testing at the
fabrication works. The Contractor shall give the Engineer adequate notice of such operations in
order that the necessary arrangements may be made.
The Contractor shall arrange for the Engineer to have access to the fabrication works at all
reasonable times and to be provided with all the necessary facilities and test equipment to carry
out such inspections.
Before any steel overhead runway beam is taken into use for the first time, the Contractor shall
submit to the Engineer a signed certificate from the manufacturer in accordance with Clause 10
of BS 2853.
J10.8 PROTECTIVE COATINGS
J10.8.1 Surface preparation for coating

Steel surfaces shall be blast cleaned prior to painting
Surfaces to be blast cleaned shall be prepared by thoroughly removing all dirt, oil, grease and
other contaminants by one of the methods recommended by CP 3012, using an approved
emulsion cleaner which shall be changed regularly.
Blast cleaning shall be carried out to surface grade SA2½ in SIS 05–5900.
Blast cleaning shall be carried out only when the ambient temperature is above 5°C and the
relative humidity is below 85%. Blast cleaning shall be carried out in conditions under which no
protective coatings can fall onto or condense on the surfaces during or immediately after
cleaning. Special attention shall be paid to the cleaning of any ends, re-entrant corners and edges
which will not be cut off or welded after blasting.
After blast cleaning, dust and blasting grit particles shall be removed from the surfaces, where
possible by vacuum cleaning. Any lamination or other defects in the surfaces exposed by blast
cleaning, which could form a corrosion centre under subsequent protective treatment cover (but
which is not otherwise a cause for rejection of the item), shall be marked clearly for later
remedial work.
Blast cleaning shall be followed within four hours by the application of a blast-primer or the
priming coat of the protective coating system.
J10.8.2 Paints
Primer shall be a shop applied zinc rich mix to 100 micron Dry Film Thickness (DFT). Paint
coating shall be three coats of catalyst-cured straight epoxy to 450 micron total DFT.
J10.8.3 Application
Paint shall be applied only when the ambient temperature is above 5°C, and when the relative
humidity is below 90%. Surfaces to which the paint is applied shall be dry and shall remain free
from moisture until the coating has dried or cured sufficiently to avoid effects harmful to the
subsequent appearance or satisfactory protective behaviour of the paint.

All paints shall be prepared and applied in accordance with the manufacturer’s instructions.
Copies of appropriate data sheets and of the relevant parts of this Specification shall be issued to
all the supervisors and foremen concerned with surface preparation and coating. Where a
manufacturer’s instructions conflict with this Specification, a ruling shall be sought from the
Engineer.
No thinners or cleaners shall be employed other than those recommended by the paint
manufacturer.
Except where otherwise specified or approved by the Engineer all priming paints shall be applied
by brush.
Exposure of intermediate coats of paint for periods in excess of a few days shall not be permitted
except in the case of work delivered to Site in a primed condition.
The dried films of the specified paints shall be free from bloom, sinkage, sheeriness, wrinkling,
sagging, curtaining, discolouration and extraneous matter.
No exterior or exposed paintwork shall be carried out under adverse weather conditions.
Painting shall insofar as is practicable be shaded from direct sunlight to prevent wrinkling and
blistering. Whenever possible, exterior painting during the day shall be so programmed as to be
carried out in shadow.
Painting of surfaces shall not be carried out when the relative humidity of the atmosphere is such
that condensation is present on such surfaces or the application and/or drying of the paints is
likely in the opinion of the Engineer to be affected.
J10.8.4 Repairs
Areas of paint on steelwork which have been damaged shall be cleaned to sound material and the
edges of the undamaged paint shall be smoothed with sandpaper to a gentle bevel. The specified
paint system shall then be applied to bring the damaged area up to the same state of protection as
the surrounding paintwork, with each coat of new paint overlapping the corresponding existing
coat of paint by at least 50mm.
J10.8.5 Inspection
The following tests shall be carried out:-
(a) Checking wet-film thickness:
Wet-film thickness gauges of an approved type shall be provided for each painter to
check the rate of paint application.
(b) Checking dry-film thickness:
The thickness of the built-up dry film after each paint coat applied to steel or other
magnetic surfaces shall be measured systematically, with a dry-film thickness gauge.
(c) Holiday detection on steel and iron surfaces:
The Contractor shall use a suitable method of detecting pinholes in the coating system
after trials on test plates. The sweep voltage on high-voltage direct-current equipment
shall not exceed half the voltage required to spark through the complete paint system
specified.
Any coating which does not meet specified requirements shall be removed and re-applied at no
extra cost to the Employer.

Water Transmission Pipeline Specifications

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Water Transmission Pipeline Specifications

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PAEW Water Transmission Pipeline from the Water Treatment Plant of Wadi Dayqah Dam

at Mazari in Wilayat Qurayyat to Deem Reservoir in Muscat Governorate

WATER TRANSMISSION PIPELINE FROM THE WATER TREATMENT

STANDARD TECHNICAL SPECIFICATIONS

PART J – CIVIL WORKS

Specification Part J October 2012

STANDARD TECHNICAL SPECIFICATIONS

PART J – CIVIL WORKS

SECTION J1 SITE INVESTIGATION 1

Specification Part J J-i October 2012

J1.5.6 Casing in drillholes 11

J1.10 LABORATORY TESTING.......................................................................................... 21

Specification Part J J - ii October 2012

J1.10.4 Test results and records 23

J2.3 SUBMISSIONS BY THE CONTRACTOR ............................................................... 27

J2.4 MATERIALS ................................................................................................................. 28

Specification Part J J - iii October 2012

J2.5.24 Disposition of material from Trench Excavation 34

SECTION J3 CONCRETE WORK 37

J3.2 REFERENCE STANDARDS ....................................................................................... 37

J3.3 SUBMISSIONS BY CONTRACTOR ......................................................................... 39

Specification Part J J - iv October 2012

J3.5.6 Refrigeration plant 59

SECTION J4 PIPELINES, CABLE DUCTS AND APPURTENANCES 83

J4.3 SUBMISSIONS BY THE CONTRACTOR ............................................................... 91

Specification Part J J-v October 2012

J4.4 MATERIALS ................................................................................................................. 92

Specification Part J J - vi October 2012

J4.6.4 Workmanship for trenchless construction 142

SECTION J5 ENGINEERING METALWORK AND GRP 154

J5.2 REFERENCE STANDARDS ..................................................................................... 154

J5.3 SUBMISSIONS BY CONTRACTOR ....................................................................... 155

J5.4 MATERIALS ............................................................................................................... 155

SECTION J6 ROADS, PARKING, FOOTPATHS AND DRAINAGE 161

J6.3 SUBMISSIONS BY THE CONTRACTOR ............................................................. 163

Specification Part J J - vii October 2012

J6.4 MATERIALS ............................................................................................................... 164

SECTION J7 BUILDINGS 177

J7.2 REFERENCE STANDARDS ..................................................................................... 177

J7.3 SUBMISSIONS BY THE CONTRACTOR ............................................................. 180

J7.4 MATERIALS ............................................................................................................... 181

Specification Part J J - viii October 2012

J7.4.5 Metal ties etc 182

Specification Part J J - ix October 2012

J7.5.22 Glazing 193

SECTION J8 FURNITURE AND FITTINGS 201

J8.2 REFERENCE STANDARDS ..................................................................................... 201

J8.3 SUBMISSIONS BY THE CONTRACTOR ............................................................. 202

SECTION J9 BUILDING MECHANICAL SERVICES 207

J9.2 REFERENCE STANDARDS ..................................................................................... 207

J9.3 SUBMISSIONS BY THE CONTRACTOR ............................................................. 212

J9.4 MATERIALS AND WORKMANSHIP.................................................................... 213

Specification Part J J-x October 2012

J9.4.6 Electrically heated hot water storage vessels 219

SECTION J10 STRUCTURAL STEELWORK 265

J10.2 REFERENCE STANDARDS ..................................................................................... 265

J10.3 SUBMISSIONS BY THE CONTRACTOR ............................................................. 266

Specification Part J J - xi October 2012

J10.5.3 Welding consumables 270

J10.8 PROTECTIVE COATINGS ...................................................................................... 274

Specification Part J J - xii October 2012

SECTION J1 SITE INVESTIGATION