4 5 Materials Specs

Qatar General Electricity & Water Corporation
TENDER NO. GTC 177/2007

Head works Construction at Airport, Old Salwa,Doha SW & Messaieed Town
SECTION 5
PIPE MATERIALS AND MAIN LAYING
Appendix-A Section -5
Tender Documents GTC-177/2007 Page 1 of 64 Materials and Main laying
SECTION FIVE –PIPE MATERIALS AND MAIN LAYING
5 PIPE MATERIALS
5-1.1.0 General 7/64
5-1.1.1 Suitability of Materials 7/64
5-1-1.02 Third Party Inspection 8/64
5-1-1.03 List of Approved Manufacturers 9/64
5-1-2.0 Ductile Iron Pipes & Fittings 9/64
5-1-2.01 General 9/64
5-1-2.02 Class of Pipes & Fittings 9/64
5-1-2.03 Joints 9/64
5-1-2.04 Length of Pipes 10/64
5-1-2.05 Markings 10/64
5-1-2.06 Pipes for Cutting on Site 11/64
5-1-2.07 Certification of Tests 11/64

5-1-2.08 Nuts, Blots and Washers 11/64
5-1-2.09 Restrained Joints 11/64
5-1-3.0 Coating of Ductile Iron Pipes & Fitting During Manufacture 12/64
5-1-3.01 General 12/64
5-1-3-02 Lining Material 12/64
5-1-3.03 External Protection To Pipes & Fittings 12/64

5-1-4.0 Slip on Couplings & Flange Adaptors 13/64
5-1-4.01 General 13/64
5-1-4.02 Slip on Couplings 13/64
5-1-4.03 Flanges Adaptors 13/64
5-1-4.04 Step Couplings 14/64
5-1-4.05 Coating of Slip-On Coupling, Step Couplings 14/64
5-1-5.0 Site Applied Corrosion Protection 14/64
5-1-5.01 Protective Wrapping Tape 14/64
5-1-5.02 Joint Moulding Compound 14/64
5-1-6.0 Valves & Flow Meters 14/64
5-1-6.01 Gate Valves 14/64
5-1-6.02 Butterfly Valves 16/64
5-1-6.03 Air Relief Valves 17/64
5-1-6.04 Flow Control Valves 18/64

5-1-6.05 Flow Meters 19/64
5-1-6.06 Flap Valves 21/64
5-1-7.0 Surface Boxes, Access Covers & Frames 22/64
5-1-7.01 General 22/64
5-1-7.02 Surface Boxes for Sluice Valves 22/64
5-1-7.03 Access Covers & Frames 22/64
5-1-8.0 Markings and Miscellaneous 23/64
5-1-8.01 Trench Marker Tape 23/64
5-1-8.02 Valve Chamber Marker Posts 23/64
5-1-8.03 Pipeline Marker Posts 23/64
5-1-8.04 Valve Chamber Name Plates 24/64
5-1-8.05 Geotextile Membranes 24/64
5-1-8.06 Reinforcement 24/64
5-1-8.07 Cement-Bound Granular Material as Trench Backfill 25/64
5-1-8.08 Imported Granular Material for Pipe Surround 27/64
5-2 Main laying 28/64

5-2-1.0 Excavation and Earthworks 28/64
5-2-1.01 Excavation, Generally 28/64
5-2-1.02 Excavation for Main laying Works 28/64
5-2-1.03 Excavation for Mai laying Works Generally 28/64
5-2-1.04 Interference to Public 29/64
5-2-1.05 Surface Grading and Stripping 29/64
5-2-1.06 Existing Services 30/64
5-2-1.07 Work In The Vicinity Of Oil or Gas Lines 31/64
5-2-1.08 Blasting 33/64
5-2-1.09 Support of Excavations 33/64
5-2-1.10 Excavations to Be Kept Dry 34/64
5-2-1.11 Dewatering 34/64
5-2-1.12 Slips & fall & Excess Excavation 35/64
5-2-1.13 Trimming and Leveling 35/64
5-2-1.14 Restricted Working 36/64
5-2-1.15 Backfilling Excavations 36/64
5-2-1.16 Breaking Out & Reinstatement Of Surfaces 36/64
5-2-1.17 Excavation, Backfilling & Reinstatement of Trenches in the Highway

37/64
5-2-1.18 Landscaping 37/64
5-2-1.19 Planting 38/64
5-2-1.20 Boundary Structures 39/64
5-2-2.0 Pipe laying 39/64
5-2-2.01 Setting Out & Pipe Alignment 39/64
5-2-2.02 Storage and Handling of Pipes 40/64
5-2-2.03 Storage of Valves and Fittings 40/64
5-2-2.04 Storage Of Materials Susceptible To Heat And Sunlight 40/64
5-2-2.05 Pipe Wrapping 40/64
5-2-2.06 Joint Protection 41/64
5-2-2.07 Stringing 41/64
5-2-2.08 Laying Pipes 42/64
5-2-2.09 Pipe Jointing 42/64
5-2-2.10 Concrete Protection to Pipelines 43/64
5-2-2.11 Pipelines in Ducts 44/64
5-2-2.12 Backfilling of Road Grossing & Tracks 44/64
5-2-2.13 Laying P.V.C Marker Tape 44/64
5-2-2.14 Geotextile Matress 44/64
5-2-2.15 Repairs to Pipes and Fittings 45/64
5-2-3.0 Chambers and Structures 45/64
5-2-3.01 Concrete Classification 45/64
5-2-3.02 Pipeline Chambers 45/64
5-2-3.03 Building Pipes Through Structures 46/64
5-2-3.04 Drag Blocks and Thrust Blocks 46/64
5-2-3.05 Tanking 41/64
5-2-3.06 Exposed Tanking Protection 42/64
5-2-4.0 Cleaning, Testing & Sterilizing 47/64
5-2-4.01 Pipelines to Be Kept Free From Extraneous Material 47/64
5-2-4.02 Dry Swabbing 48/64
5-2-4.03 Testing General 48/64
5-2-4.04 Testing Pipelines 49/64
5-2-4.05 Water for Testing 50/64
5-2-4.06 Cleaning and Disinfection Pipelines 50/64
5-2-4.07 Connection to the Existing Network 50/64

5-2-4.08 Medical Certification of Contractor’s Workforce 51/64
5-2-5 Survey Of the Pipeline Route 51/59
5-2-6 Soil Investigation 52/59
5-2-6.01 Soil Testing 52/59
5-2-6.02 Receptivity Survey 52/59
5-2-6.03 Interaction Testing 53/64
5-2-7 Pipeline Inside Crossing Tunnel or Sleeve 53/64
5-2-8 Pipelines under Existing Roads 53/64
5-2-9 Thrust Boring 54/64
5-2-9.01 General 54/64
5-2-9.02 Method Statement 55/64
5-2-9.03 Sleeves 55/64
5-2-9.04 Thrust Boring 55/64
5-2-9.05 Pipeline Installation 55/64
5-2-9.06 Grouting 56/64
5-2-10 Epoxy Coatings 56/64
5-2-11 Testing Structures on Pipelines 57/64
5-2-12 Surge Protection 57/64
5-2-12.01 Surge Vessels 58/64
5-2-12-02 Reciprocating Air Compressors 59/64
5-2-12.03 Pipe work and Valves for Compressed Air Systems 60/64
5-2-12.04 Air Receivers 60/64
5-3 Special Clauses 61/64

5-3-1.0 Safe Working In The Vicinity Of Overhead EHV Lines 61/64
5-3-2.0 Step Potential Testing 62/64
5-3-3.0 Interaction Testing 62/64
5-3-4.0 Pipeline Test Pressure 62/64
5-3-5.0 Codes and Standards 62/64
5-3-6.0 Testing Facilities 63/64
5-3-7.0 Reliability Tests 64/64
5.1 PIPE MATERIALS

5-1.1.0 GENERAL
5.1.1-1 SUITABILITY OF MATERIALS
A All materials which are to come into contact with potable water shall comply with the
requirements of BS 6920 and must be certified as being non toxic and suitable for use with
potable water by an internationally recognised testing organisation.
B All materials which are to come into contact with potable water shall be suitable for use with
the range of chemical characteristics of the water detailed as follows:
Anticipated Limiting
Characteristics Characteristics
TDS mg/l 500-560 600 max
Total
Hardness mg/l CaCo3 150 150 min
Total
Alkalinity mg/l CaCo3 88-73 25 min
Sodium mg/l Na 108-134 150 max
Calcium mg/l Ca 36-31
Magnesium mg/l Mg 14-18
Chloride mg/l CL 195-240 250 max
Bicarbonate mg/l HCO3 28-34 30 min
Sulphate mg/l SO4 107-89 250 max
PH 8.0-8.2 6.5-8.5
Langelier
Index + Ve +Ve
Chlorine mg/l CL 0.7-1.0 30*
o
Temperature C 30-50
* during sterilization
C All materials shall be suitable for using and storing in the environmental conditions
detailed in Scope of work.
D The Tenderer shall furnish the Engineer with signed certificates from the proposed
manufacturers confirming the compliance of his materials ith items A and B
compliance.
5.1.1-2 THIRD PARTY INSPECTION

A When called for in the Bills of Quantities the Contractor shall arrange for Third Party
Inspection of the materials listed in part C of this clause. The Third Party Inspector shall
be one approved by KAHRAMAA and the bio-data of the staff to be employed shall be
submitted to the Department for approval.
B If a manufacturer is certified under the ISO System (9001, 9002 or 9003) then the Third
Party Inspector shall witness at least 5% of the tests carried out by the Manufacturer's
Quality Control Department. If a manufacturer is not so certified then the Third Party
Inspector shall witness all tests carried out by the Quality Control Department.
C The following items shall be inspected by the Third Party Inspector:

Straight pipe
Pipe fittings
Gate valves
Butterfly valves and gearboxes
Air valves and mitre gearing where applicable
Control valves
Flow meters
Electrical equipments (switchgears, control panels, instruments, etc.
Mechanical equipments (pumps, motors, etc.)
D The Third Party Inspection report shall be submitted before acceptance of the relevant
materials to site.
E Access to all parts of the Manufacturer's factory shall not be restricted, except for
safety reasons. The Engineer or Third Party Inspection Agency may require access at
any time.
F The Third Party Inspection shall carry out the following minimum tasks:
a. Verify compliance with the specification
b. Examine manufacturer's Quality Control System and ensure that the whole
manufacturing process is covered.
c. Attest the manufacturer's Quality Control Statement.
d. Witness tests carried out by the Quality Control Department. The Third Party
Inspector may require additional tests to be performed by the Quality Control
Department.
e. Review manufacturer's quality control reports on items not actually witnessed.
f. Report on all activities and results.
g. Mark, indelibly, items physically inspected and conforming to Specification.
h. Inspect and certify packing.
i. Issue Release Note to Manufacturer with a copy to Engineer prior to shipping of

materials.
j. If, on arrival at site, materials are found to be defective, then the Third Party Inspector
may be required to attend further inspections with the Engineer's Representative.
5.1.1-3 LIST OF APPROVED MANUFACTURERS
For following materials, the contractors are required to submit three alternative suppliers
during tendering stage. The provided list will be subjected to kahramaa material
department approval:
Ductile iron pipes and fittings
Valves
Flexible couplings and flange adaptors
Wrapping tape putty and primers
Polyethylene sleeving and marker tape
5-1-2.0 DUCTILE IRON PIPES AND FITTINGS

5-1-2.01 GENERAL
A Ductile Iron pipes and fittings shall comply with BS EN 545 or ISO
2531 except where otherwise required herein.
5-1-2.02 CLASS OF PIPES AND FITTINGS
A Ductile iron spigot and socket pipe shall be Class K9.

B Ductile iron flanged pipe shall be Class K12
C Ductile iron fittings shall be Class K12 except for fittings with branches which shall be
Class K14
5-1-2.03 JOINTS
A Spigot and Socket pipes and fittings shall be provided with approved integrally cast
'push-in' type joints, each joint being supplied with an approved jointing ring designed
by the Manufacturer solely for the purpose of sealing the joint.
B All flanged pipes and fittings shall be provided with integrally cast flanges and shall be
rated to PN16 as detailed in BSEN 545, and supplied with approved gaskets from the
same Manufacturer.
C Pipes and fittings with spigot and socket joints shall be capable of the following
minimum deflections without leakage.
Nominal Size (DN) (mm) Deflection Limit (Degrees)
Up to and including 300 5

350 to 600 4
700 to 900 3
1000 to 1600 2
D Rubber joint rings for spigot and socket joints and gaskets for flanged joints shall
comply with the requirements of ISO 4633 and shall be manufactured from Ethylene
Propylene rubber (EPDM) or Styrene Butadiene rubber (SBR) and shall be obtained
from the Manufacturer of the pipes to be jointed.
E Joint lubricants shall have no deleterious effects on either the joint rings or pipes and
shall be unaffected by the liquid to be conveyed. Lubricants to be used for jointing
water mains shall not impart to water taste, colour, or any effect known to be
injurious to health and shall be resistant to bacterial growth.
5-1-2.04 LENGTH OF PIPES

A All pipes shall be supplied in the standard lengths as stated in BSEN 545 except
where otherwise specified.
B Any deviation from the lengths specified shall be approved by the Engineer.
5-1-2.05 MARKINGS
A All pipes and fittings shall be marked in accordance with BSEN 545.
B In addition to that detailed in 5-1.1.03 above, all pipes shall be marked with white
lettering 100 mm high, indicating the nominal diameter of the pipe.
5-1-2.06 PIPES FOR CUTTING ON SITE

Where short make-up lengths are required these shall be cut from pipes specially
purchased for the purpose. The tolerance required on the external diameter to suit the
joint shall apply for the full length of the barrel. The Contractor shall order a
sufficient quantity of pipes for cutting on site which shall be clearly marked for that
purpose. Cut surfaces shall be made good and protected to the approval of the
Engineer.
5-1-2.07 CERTIFICATION OF TESTS

A The Contractor shall supply to the Engineer signed certificates stating the results of
all tests as specified in BSEN 545.
B The Purchaser reserves the right to witness tensile tests on bar test pieces selected on
the basis of not more than one test piece for every batch of 100 pipes.
C Where specified tests are to be witnessed the tests shall be in accordance with the
Manufacturers normal quality control procedure.
D Contractor should note that no pipes will be accepted without the signed certificate
required in part A of this clause.
5-1-2.08 NUTS, BOLTS AND WASHERS

A See QNBS (Sewerage) miscellaneous works
5-1-2.09 RESTRAINED JOINTS

A Where restrained joints are required they shall be fixed strictly in accordance with
the manufacturer's instructions.
B The Contractor shall submit for approval detailed pipe work layout plans showing all
restrained joints and concrete surround for each bend or other location where
restraint is required.
C The Contractor shall confirm with the pipe and joint manufacturer the adequacy of
the proposed pipe and joint combination for each bend or other location where
restraint is required.
D Where space for the required number of restrained joints is restricted concrete
surround shall be used in conjunction with anchored pipes to provide the required
resistance.
E All pipe work with anchored joints shall be backfilled as specified prior to filling the
pipeline.
5-1-3.0 COATINGS OF DUCTILE IRON PIPES AND FITTINGS DURING
MANUFACTURE
5-1-3.01 GENERAL
A All materials used for the lining of ductile iron pipes and fittings shall conform to BSEN
545-" Effect of non-metallic materials on water quality.
B All ductile iron pipes and fittings shall be internally lined with cement mortar in
accordance with BSEN 545.
C The method of lining, lining thickness, curing of lining, mortar cube strength and repair
to lining, if any shall be carried out strictly in accordance with BSEN 545.
5-1-3.02 LINING MATERIAL

A The cement mortar lining to all ductile iron pipes and fittings shall be made using
sulphate resisting cement.
B The Contractor is to supply confirmation from the Manufacturer that the cement lining
to be used is suitable for use with the range of Chemical characteristics of water detailed
in Clause 5-1-1.1.
C The internal section of sockets to pipes and fittings shall not be cement lined and shall
be suitably protected during the lining operation.
D The internal section of sockets of pipes and fittings shall be painted with a two pack
solvent free epoxy not less than 100 micron thick.
E After completion of the curing period for the cement lining, the linings of pipes and
fittings shall be painted with a bitumen seal coat in accordance with BSEN 545. This
seal coat must conform to Clause 5-1-3.01 A of this specification.
5-1-3.03 EXTERNAL PROTECTION TO PIPES AND FITTINGS
A External coatings to pipes and fittings shall be as detailed in Section 3 of BSEN 545
except that an external zinc coating conforming to BSEN 545 shall be applied to pipes
of all sizes.
B The finishing layer to all pipes and fittings shall be a bitumen coating conforming to BS
3416 type 2.
C In addition to the requirements of this Clause the Contractor may, with the written
approval of the Engineer, supply pipes which have a factory applied polyethylene
coating, applied by extrusion methods.
D The polyethylene coating shall be a minimum of 1.25mm thick and blue in colour.
E The Contractor is to supply a detailed specification of any proposed extruded

polyethylene coating for pipes as well as proposals for repairs to external coatings
damaged on site.
5-1-4.0 SLIP-ON COUPLINGS AND FLANGE ADAPTORS

5-1-4.01 GENERAL
A The Tenderer shall submit full details of all the component materials which must comply
in all respects with the current British Standards where applicable.
B All materials must conform to Clause 5-1-1.03 of this Specification.
C The Contractor shall be responsible for checking the outside diameters of pipes to be
joined and for ensuring the suitability of the couplings to be ordered.
D In the case of flange adaptors the Contractor shall be responsible for checking the flange
type for existing pipes and ensuring the suitability of the couplings to be ordered.
5-1-4.02 SLIP-ON COUPLINGS

A Slip on couplings shall be manufactured from either cast iron or rolled steel and shall be
suitable for use with ductile iron pipes to BSEN 545.
B Couplings shall be similar in design to that detailed in BS 8010 section 2.1 'Slip on
couplings'.
5-1-4.03 FLANGE ADAPTORS

A Flange adaptors shall be manufactured from either cast iron or rolled steel and shall be
suitable for use with ductile iron pipes to BSEN 545.
B Flange adaptors shall be suitable for jointing with flanges to PN16 as detailed in BSEN
545.
C Flange adaptors shall be similar in design to that detailed in BS 8010 Section 2.1
"Flange Adaptors".
5-1-4.04 STEP COUPLINGS
A Step couplings shall be manufactured from either cast iron or rolled steel and shall be
suitable for jointing ductile iron pipes to existing mains.
5-1-4.05 COATING OF SLIP-ON COUPLINGS, STEP COUPLINGS AND FLANGE

ADAPTORS DURING MANUFACTURE
A All couplings, step couplings and flange adaptors shall be coated internally and externally
at the factory with 300 micron minimum thickness of fusion bonded epoxy or
thermoplastic polymide nylon. The coating shall be certified as non-toxic by an
internationally recognised testing organisation. The colour shall be blue.
5-1-5.0 SITE APPLIED CORROSION PROTECTION

5-1-5.01 PROTECTIVE WRAPPING TAPE
For details refer to spec. clause 5-1-3.03
5-1-5.02 JOINT MOULDING COMPOUND
A The joint moulding compound used on all types of pipe joints shall be an inert non-toxic
compound.
B The moulding compound shall be suitable for use with the approved PVC/Bituminous
tape wrapping materials. The moulding compound shall be that recommended by the
tape manufacture.
C The moulding compound shall be supplied in 25 kg drums.
5-1-6.0 VALVES AND FLOW METERS

5-1-6.01 GATE VALVES
A Gate Valves shall be of the double flanged wedge gate type and shall comply with BS
5163 type B. The nominal pressure rating shall be PN16.
B Valves shall be inside screw, non-rising stem have metallic seatings with stainless steel
trims and be suitable for use in a closed end test. Flanges shall be to BS 4504 PN 16 and
be of the raised face type.
C Gate valves up to 350mm diameter shall be of the resilient seat type.
D 400mm diameter and larger gate valves shall be fitted with spindle reduction gear
(enclosed type).
E 600mm and larger diameter gate valves shall be fitted with the following:
a. Integral by-pass valve

b. Spindle reduction gear (enclosed type)
c. Lifting eye bolts
d. Pedestal feet
e. Easing screed (for metal faces valves only)
F All gates valves shall be designed for standard direction of operation which shall be
clockwise to close and shall be operated by the use of a removable key through a valve
cap unless otherwise shown on the drawings.
G Where specified sluice valves shall be supplied with cast iron hand-wheels marked 'open'
and 'closed' with arrows in the appropriate directions. These shall be cast on to the hand-
wheel. Their design shall be such that the hand-wheel can be removed when necessary.
H Sluice valves up to and including 300 mm diameter shall have 'O' ring seals which are to
comprise of 'seal' and wiper rings. There shall be a minimum of two wiper rings in
addition to the seal ring.
I Sluice valves above 300mm diameter may have either 'O' ring seals, or stuffing boxes
filled with an approved 'TEFLON' or graphite based packing material.
J Materials for gate valves shall comply with the following minimum standards:
Body/Bonnet/Stuffing Box : Ductile iron BS 2789 Grade 500/7 or DIN
1693 Grade GGG-40 or 50
Wedge Gate : Ductile iron BS 2789 Grade 500/7 or DIN
Stem/Spindle : Stainless Steel BS 970: Part 1Grade 316 S33
Wedge/Body Seating : Stainless Steel BS970: Part 1 Grade 316 S33
Internal Fastening, nuts,
bolts, Washers, etc. : Stainless Steel BS 970: Part 1 Grade 316 S33
K Gate valves shall be coated internally and externally at the factory with 300 micron
minimum thickness of fusion bonded epoxy of thermoplastic polymide nylon. The
coating shall be certified as non-toxic by an internationally recognised testing
organisation. The colour of the coating shall be blue.
L A test certificate shall be provided for each valve confirming that the valves have been
factory tested in accordance with BS 5163 and stating the actual pressures used in the
tests.
M In addition to the marking requirements of BS 5163, gate valves shall also be marked
with the month and year of manufacture.
N Valve keys shall be of the heavy duty, lever type, shall be aluminium alloy and to be
capable of opening valves against their designed working pressure heads.
O Valve keys of standard length shall be supplied in the ratio of 1 key per 20 sluice valves
with a minimum of 2 keys for each size required.
P Extension spindles and support brackets shall be provided to all gate valves in chambers
to allow surface operation and shall be coated with anti corrosive primer.
Q All valves and/or the hand-wheels shall have a locking mechanism to prevent
unauthorised operation.
5-1-6.02 BUTTERFLY VALVES
A Butterfly valves shall be of the double flanged type and comply with BS 5155. (long
pattern). The nominal pressure rating shall be PN 16.
B Valves shall have resilient seatings and be 'drop-tight' at closure. Flanges shall be to BS
4504 PN16 and be of the raised face type.
C The direction of closing shall be clockwise. If a hand-wheel is fitted, the marks for
direction of opening and closing shall be cast on to the wheel. If a hand-wheel is fitted, it
shall also be possible to fit an extension spindle. The valve shall be capable of being
operated manually under an unbalanced pressure in either direction. The disc shall be
able to withstand the maximum pressure differential in either direction. Valves shall be
provided with suitable stops to prevent movement of the spindle beyond the 'full open'
and 'full closed' positions.
D Materials for butterfly valves shall comply with the following minimum standards:
Body and Flanges : Ductile iron 2789 Grade 500/7 or DIN 1693
Grade GGG-40 or 50
Disc : Ductile iron BS 2789 Grade 500/7 or DIN
Rings for sealing, seating : Stainless steel BS 1503 Grade 316S31
or retaining purposes :Stainless Steel BS 970: Part 4 Grade 316
Shaft : S16 Stainless Steel BS 970: Part 1 Grade 316 S33
Internal fastenings, nuts

bolts, washers, etc. : Stainless Steel BS 970: Part 1 Grade 316 S33
Disc Seal : EPDM
Gear Box : Ductile iron BS 2789 Grade 500/7 or DIN
1683 Grade GGG 40 or 50
Gear Box internals : Stainless steel BS 970: Part 1 Grade 316 S33
E Butterfly valves shall be coated internally and externally at the factory with 300 micron
minimum thickness of fusion bonded epoxy or thermoplastic polymide nylon. The
organisation. The colour of the coating shall be blue.
F A test certificate shall be provided for each valve confirming that the valves have been
factory tested in accordance with BS 5155 and stating the actual pressures used in the
tests.
G In addition to the marking requirements of BS 5155, butterfly valves shall also be marked
with the month and year of manufacture.
H Valves for manual operation will be provided with extension spindles and support
brackets to allow surface operation by use of a valve key and shall be coated with an anti
corrosive primer.
I Valves shall be fitted with electric actuators for remote control where indicated on the
drawings or in the Bills of Quantities.
J Valves and/or the hand-wheels shall have a locking mechanism to prevent unauthorised
operation.
5-1-6.03 AIR RELIEF VALVES
A Air relief valves shall be of the double orifice type. The inlet flange shall be of the raised
face type and comply with BS 4504 PN16. Sizes shall be as shown in the Bills of
Quantities.
B The valve design shall incorporate two chambers with guides for the floating balls. One
chamber shall have a small orifice for automatic release of air and the other chamber a
large orifice for passing bulk volumes of air. The floating balls shall be capable of
withstanding a temperature of 60 oC without any adverse effects.
C Air relief valves shall be fitted with an isolating gate valve with extension spindle and
bevel gearing to allow surface operation.
D Air relief valves and associated isolating valves shall be factory tested to 16 bar working
pressure and the Engineer shall be supplied with records of all tests.
E Materials for air relief valves shall comply with the following minimum standards:
Body/Cover : Ductile iron BS 2789 Grade 500/7 or DIN

1693 Grade GGG-40 OR 50
Floating Balls : Brass coated steel covered with EPDM
rubber or approved alternative
Nuts, bolts, washers and
other metalwork :Stainless steel BS 970: Part 1 Grade 316 S33
F Air relief valves shall be coated internally and externally at the factory with 300 micron
minimum thickness of fusion bonded epoxy of thermoplastic polymide nylon. The
organisation. The colour shall be blue.
5-1-6.04 FLOW CONTROL VALVES
A Flow control valves if required shall be specifically designed for that purpose so that flow
regulation is obtained over the major part of the valve stroke and vibration, cavitation,
erosion and scour are minimized.
B The valves shall be double flanged and the nominal pressure rating shall be PN16.
Flanges shall be to BS 4504 PN16 and be of the raised face type.
C Materials for flow control valves shall generally comply with the following minimum
standards:
Body/Cover : Ductile iron BS 2789 Grade 500/7 or DIN 1693

Grade GGG-40 or 50
Sleeves and
Control surfaces : Gunmetal
Spindle : Stainless steel BS 970: Part 1 Grade 316 S33
Bolts, Washers and
Other metal work : Stainless steel BS 970: Part 1 Grade 316 S33
D Flow control valves shall be fitted with electric actuators for remote control.
5-1-6.05 FLOW METERS
A Flow meters shall be of the electromagnetic type, suitable for potable water application.
The meter shall be guaranteed suitable for operation temperatures up to 80oC.
Generally the flowmeter shall be in accordance with the following:
B Flow metering System
a) Each flow metering system shall consist of the primary transducer (sealed to IP68),
earthing rings, the necessary signal converter and power supply unit and all cabling
between the primary transducer and signal converter and power supply unit.
b) Each of the signal converters/power supply unit shall be supplied for remote
mounting and sealed to IP65, unless otherwise specified.
c) The signal converters/power supply units shall be provided with a4-20mA output
signal, linear with flow and suitable for retransmission to remote instrumentation, the
above units shall operate from a 240V 50Hz mains supply. The supply voltage may vary
by + 15% and frequency between 48 and 52 Hz.
The signal converter supply shall have a modulated direct current excitation and inherent
total zero stability.
The Contractor shall provide sufficient suitable cable to allow for the primary transducers
to be situated up to 100 metres from their signal converters.
The Contractor shall provide full details of the cable he proposes to use with his tender.
C Accuracy
The flowmeter accuracy shall be + 0.2% of reading in the velocity range of 10 metres/sec
down to 0.5m/s and +0.05% of reading down to 0.2 m/s. The repeatability of the
flowmeter shall be +0.05% down to 0.5 m/s velocity increasing progressively to + 1% at
0.25 m/s all flowmeters are to be calibrated on NAMAS accredited flow calibration rigs
and calibration certificates are required for each flowmeter. The contractor shall provide
manuals for the flowmeters.
D Signal Output
The following output formats are required and must be isolated from any common
connection to the instrument to prevent common mode interference.
i) Analogue
The signal output shall be a 4-20 mA direct current loop. The output shall be short circuit
protected and capable of supplying a load of up to 1000 ohms.
The Contractor shall state to what limit over-scale currents may be trusted to represent
flow to +5% in the event of pipeline bursts occurring downstream of the meter (i.e. to
what current is the circuit reasonably linear for overscale flows).
ii) Integration
One pulse shall be generated for a specific volume of water passing the meter. This shall
be achieved by the closure of volt-free contacts. This function need only be applied to
forward flows, unless available bi-directionally as a standard feature.
iii) Interference
Electrical noise may occur from sources such as electromagnetic induction, electrostatic
or capacitive coupling and electrical coupling or electrical conduction. The signal to
noise ratio should be sufficiently high to prevent spurious signals affecting the signal
and the instrument and associated cables must be so screened as to operate without
degradation of performance in the following conditions.
Portable or mobile radio
Power 0-25 watts
Frequency 49-150 MHZ, AM and FM
Proximity > 5 meters
iv) The flowmeter shall incorporate electrode (s) to detect when the pipe is not full. The
flowmeter converter shall display the pipe not full signal.
E Electrodes
i) The flowmeter shall be of a type that prevents polarisation of electrodes.
ii)The primary transducer electrodes shall be capable of being removed for cleaning. The
Contractor shall provide details of the working space required to allow the electrodes to
be removed.
F Vibration
The flowmeter shall be able to endure vibration, where in service, without any
degradation in performance.
G Wetted Parts
All wetted parts shall be non-toxic and suitable for use with potable water at temperatures
up to 80oC.
H Plant Labelling and Nameplates

Manufacturer's name.
Serial number
Nominal internal diameter
Maximum operating pressure
Calibration factors
Type of enclosure
Forward flow direction
Weight
Power
I Installation
i) The flowmeter shall be raised face flanged to ISO2531 NP16 Each flowmeter should be
individually pressure tested by the manufacturer to at least 1.5 times its flange pressure
rating. A Certificate of Conformity for pressure testing will be required.
ii) The flowmeter shall be fitted with permanent lifting eyes (minimum 25 mm internal
diameter) and be supplied with all relevant test certificates
iii) The Contractor shall include a dimensioned arrangement drawing showing details of
length, clearance dimensions and any special suppoarrangement. A flange adaptor shall
be incorporated to allow removal of the flowmeter.
iv) The flowmeter head shall be protected from direct sunlight if installed in an exposed
location.
J Calibration
i) The manufacturer shall provide a calibration certificate with each flowmeter supplied.
This calibration shall be traceable to national standards.
5-1-6.06 FLAP VALVES

A Flap valves shall be manufactured from corrosion resistant materials.
B Doors shall be designed to maintain an efficient seal under minimal

seating head conditions.
C The valves shall be capable of operating with flows at high pressure

while in the open position.
5-1-7.0 SURFACE BOXES, ACCESS COVERS AND FRAMES

5-1-7.01 GENERAL
A All surface boxes, access covers and frames shall be manufactured from
ductile iron.
B All surface boxes, access covers and frames shall be coated with a cold
applied black bitumen solution to BS 3416.
C All surface boxes shall be item marked or a certificate of compliance

with the relative standard must be supplied with all deliveries.
D Lifting keys, of malleable cast iron with loop handle, suitable for use
with the surface boxes shall be supplied 1 set per 25 surface boxes.
5-1-7.02 SURFACE BOXES FOR SLUICE VALVES
A Surface boxes for sluice valves shall be heavy duty and shall be
manufactured in accordance with BS 5834 Part2.
B The surface box shall be of the double triangular loose coupled type with
a nominal 150mmx150mm clear opening.
C The covers of the surface box shall have open keyways.
D The covers of the surface box are to have in the casting the letters 'SV'
minimum size 25 mm high.
E The covers of the surface box are to be fitted with security chains.
5-1-7.03 ACCESS COVERS AND FRAMES
A Access covers and frames shall be heavy duty and shall comply with BS 5834 Part3.
B Access covers and frames shall be of the rectangular type with a

nominal 675 X 675 clear opening.
C The covers shall have open key ways.
D Access covers for air valves shall be supplied with vent holes to assist air release.
E Covers shall be marked with the word 'MEW-WATER' in letters 30mm high. The
manufacturers name shall not appear on the cover.
5-1-8.0 MARKINGS AND MISCELLANEOUS

5-1-8.01 TRENCH MARKER TAPE
A The tape shall be manufactured from non-biodegradable low density

polyethylene.
B The tape shall be blue in colour.
C The tape shall be 150mm wide, and of a minimum nominal thickness

200 microns.
D The tape shall be inscribed with the words "CAUTION POTABLE

WATER MAIN BELOW' in both Arabic and English.
E The tape shall be supplied in roles of 500 metres long.
F The tape shall be installed 400mm below finished grade level
5-1-8.02 VALVE CHAMBER MARKER POSTS
A Marker posts to an approved design shall be provided at all buried

sluice valve, air valve, washout and meter chambers. A valve chamber nameplate
shall be fixed to the post.
B Marker posts shall be situated in footpaths or verges against a wall or

property boundary and facing the chamber cover. Their bases shall be
surrounded in Grade SCR 20 concrete below ground level.
5-1-8.03 PIPELINE MARKER POSTS
A Pipeline marker posts shall be provided at all points where the pipelines cross boundaries
or change direction with a maximum distance between markers of 300 metres.
B The marker posts shall be set over the centrelines of the pipelines with their bases
surrounded in Grade SRC 20 mass concrete.
C The posts shall incorporate a description of the pipeline and its service in relief lettering
in both Arabic and English.
5-1-8.04 VALVE CHAMBER NAME PLATES

A Name plates shall be provided at all sluice valve, air valve, washout and meter chambers.
They shall indicate in both Arabic and English the type of chamber, and its reference in a
format to be approved by the Engineer.
B At buried chambers the name plate shall be fixed in an approved manner to the valve
chamber marker post.
C Where chambers are visible above ground the marker plate shall be fixed to the edge of
the chamber roof slab in a visible location near the access cover.
5-1-8.05 GEOTEXTILE MEMBRANES

The membranes shall comprise a high-strength flexible non-biodegradable thermally bonded
non-woven material of polypropylene and polyethylene. The fibres shall be of the continuous
filament type and circular in cross-section.
The fabric shall be resistant to all naturally occurring soils alkalis and acids and shall be
unaffected by bacteria, fungi and UV light.
Fabric for geotextile mattresses shall comply with the following Specification:
Plain Strain Tensile Strength : 15KN/m width

Extension at Failure : 35%
CBR puncture resistance (DIN54307E) :2600N

Porosity : 33 l/m3/sec with 100mm
Head
Pore size distribution D90/D50 : 50/30 microns
5-1-8.06 REINFORCEMENT
Al reinforcing bars, fabric and special steel connections shall be protected against corrosion
with a fusion-bonded epoxy coating applied in accordance with ASTM A775-81 and shall be
supplied from an approved coating factory using approved epoxy resins. All cutting and
bending procedures hall be to the coating factory's recommendations and instructions, as
agreed with the Engineer.
The Contractor shall furnish to the Engineer a certificate of compliance for each delivery of
coated bars. The certificate of compliance shall state that representative samples of the coated
bars have been tested and that the test results comply with the requirements herein specified.
Al chairs, tie-wires or other devices used to connect, support, secure or asten epoxy coated
reinforcement shall be made of, or coated with, a dielectric material such as nylon, epoxy or
plastic.
5-1-8.07 CEMENT-BOUND GRANULAR MATERIAL AS TRENCH

BACKFILL
A The granular material to be used shall consist of crushed, hard, clean, durable rock or
washed sand or a combination thereof. The material shall be sufficiently well-graded
to ensure a well closed surface finish and have a grading within the range given in the
following table:
BS Sieve Size Percentage by mass passing

50 mm 100
37.5mm 95-100
20 mm 94-100
10 mm 35-100
5 mm 25-100
600 micron 8-65
300 micron 5-40
75 micron 0-10
B The granular material shall be mixed with sufficient cement to provide a average crushing
strength not less than 3.5 N/mm2 at an age of 7 days from a batch of 3 test cubes from
samples taken as required by this clause. In addition to the minimum strength
requirement no cube shall differ from the average by more than 25%.
C The material shall be mixed in a paddle or pan type mixer which may be of batch or
continuous type. If batch mixers are used the mixing time shall not be less than one
minute. Sufficient potable water shall be added to the mix to bind it together without
causing segregation.
D Material when mixed shall be removed at once from the mixer, transported directly to the
point where it is to be laid and protected from the weather both during transit from the
mixer to the laying site and whilst awaiting tipping.
E All material shall be placed and spread evenly. Spreading shall be undertaken either
concurrently with placing or without delay. The material shall be spread in one layer so
that after compaction the total hickness does not exceed 150 mm.
F Compaction in trenches shall be carried out using vibrating rollers. Where access for a
roller is not possible (eg. around manholes), the Contractor may be permitted to use
vibrating plate compactors. The number of passes required to give the necessary
compaction shall be generally in accordance with the following table:
Type of Category Number of passes Number of passes
compaction for layers not for layers not

plant greater than greater than
1100mm 150mm
vibrating roller Mass per metre

width of vibrating
roll:
700-1300 kg 16 Unsuitable
1300-1800 kg 6 16
1800-2300 kg 4 6
2300-2900 kg 3 5
2900-3600 kg 3 5
Vibrating plate
compactor
Mass per unit area
of base plate:
1400-1800kg/m2 8 Unsuitable
1800-2100kg/m2 5 8
over 2100 kg/m2 3 5
Compaction shall be completed as soon as possible after the material has been spread.
Special care shall be taken to obtain full compaction in the vicinity of joints with
previous work. Any loose, segregated or poorly compacted materials shall be removed
and replaced with fresh material.
G Any layer of cement-bound material not covered within 2 hours shall, immediately upon
completion, be cured for a period which shall not be less than 3 days. Curing shall be
achieved by covering until the next permanent layer is laid.
H Samples of the cement-bound shall be taken from each layer or such other area as the
Engineer may decide. From each sample a cubical test specimen shall be prepared, cured
and tested using the procedure given in BS 1881.
I If an area or layer or cement-bound material represented by the 3 test cubes has an average
strength less than the specified minimum value, the Engineer may require that the
defective material be replaced by cement-bound material to Specification.
5-1-8.08 IMPORTED GRANULAR MATERIAL FOR PIPE

SURROUND
A Imported granular material for pipe surround shall comprise either of natural dune sand ,
or coarse graded sand or crushed limestone having particles all passing 10mm BS sieve,
as directed by the Engineer's Representative. The sand and/or crushed limestone shall be
obtained from a source approved by the Engineer and shall not
contain particles with sharp edges which could cause damage to the pipes. Sea sand shall
not be used.
B Granular material shall contain no excessive quantities of dust, soft or flaky particles,
shells, congealed lumps, nodules of soft clay, alkali or other contaminations likely to
affect adversely the compaction of the material or to attack the pipes.
C The sulphate content (as SO3) of the material shall not exceed 0.40% by weight and the
chlorides as (Cl) shall not exceed 0.10% by weight.
D Prior to commencement and during progress of works the Contractor shall provide the
Engineer with 8 samples of the granular material he proposes to use in the works along
with their soil test results and shall obtain his written approval for its use. These samples
will be retained by the Engineer for comparison with deliveries to the site during the
works.
E The grading of dune sand when determined by the method described in BS 812 shall lie
within the respective limits specified within the following table:
S.Sieve Size(mm) Percentage Passing by Weight

____________________________________________________
4.76 95 - 100
2.40 70 - 95
1.20 45 - 85
0.60 25 - 60
0.30 5 - 30
0.15 0-10 -
___________________________________________________
F The total quantity of clay and silt in natural sand shall not exceed 4% by weight when
determined by the field settling test described in BS 812 paragraph 15.
5.2 MAINLAYIG
5.2.1.0 EXCAVATION AND EARTHWORKS
5.2-1.01 EXCAVATION, GENERALLY
A The general Specification for Excavation and Earthworks is contained in Section 3 of

this Specification.
5-2-1.02 EXCAVATION FOR MAINLAYING WORKS
A Further particular Specification Clauses for Mainlaying Works are given below. The
following clauses are to be read in conjunction with the general Specification as
described above.
5-2-1-03 EXCAVATION FOR MAINLAYING WORKS GENERALLY
A The Contractor's standard of workmanship in excavation shall be not less than the
appropriate recommendations of B.S 6031- Code of Practice for Earthworks, in
conjunction with such other and further requirements as are contained herein.
B The extent of all trench excavations in open cut shall be the minimum necessary or
practicable for the construction of the works and shall in no case exceed the trench width
restrictions shown on the Drawings.
C In the case of trench excavations made in roads, footpaths, verges, central strips or within
5 metres of buildings, the Contractor shall be required to execute the Works so as to
minimise damage and disturbance. Vertical trench sides will generally require support by
timbering or other suitable means. Under-cutting of trench sides shall not be permitted.
D In the event of any trench for pipelines being excavated with battered or stepped sides
that portion of the trench which extends from the ormation to a point not less than 300
mm above the crown of the pipe shall be formed with vertical sides within the limits
detailed on the Contract Drawings.
E Bulk excavations shall be made to such sizes, depths and inclinations as the Engineer
may direct or as may be necessary to construct the Works.
F Should the trench be excavated to a depth greater than is required, in the opinion of the
Engineer's Representative, the Contractor shall fill in the bottom of the trench to the
required depth with concrete or other such materials as the Engineer's Representative
may direct.
G In areas frequented by the public the maximum length of open trench in any one section
shall not exceed 500 metres. For other areas the maximum length of open trench shall be
subject to the approval of the Engineer's Representative.
H A minimum clear carriageway width of 3 metres shall be left for vehicular traffic
wherever possible at all times. Clearance widths less than 3 metres shall only be allowed
after approval from the Engineer's Representative.
I The Contractor shall in all respects Comply with the procedures and requirements of the
Police and the Authority having charge of the road surfaces.
J The Engineer's Representative reserves the right to direct theContractor as to the lengths
of trench which shall be opened up at any one time.
K Any excavated material stored on site for backfilling or other purposesshall be deposited
compactly alongside the excavation in such a manner that it shall cause no damage and
as little inconvenience as possible.
L Where undertaking excavation works adjacent to tree planted areas and particularly
trench excavation adjacent to and parallel with tree planting in road verges and central
reservations the Contractor shall remove excavated material to a temporary tip for the
duration of excavation and construction operations the Contractor shall also allow for
additional watering where necessary.
5-2-1.04 INTERFERENCE TO PUBLIC
A In the case of excavations in roads , and in other cases which in theopinion of the
Engineer's Representative are liable to cause interference to the public, the Contractor
shall so organise his operations as to reduce to a minimum the interval between opening
up and backfilling excavations.
B The Contractor shall provide and maintain to the satisfaction of the Engineer's
Representative suitable temporary crossings over the pipe trench to permit the passage of
pedestrian, vehicular and other traffic. In addition he shall phase the excavation,
pipelaying, jointing and reinstatement in such a way as to provide reasonable access to
houses, roads, footpaths and all other places requiring access at all times.
5-2-1.05 SURFACE GRADING AND STRIPPING
A The Contractor shall grade the whole of the Site to the levels shown on the drawing prior
to commencement of any other construction.
B Upon completion the Contractor shall re-grade, if necessary, to the specified levels all
areas which are not occupied by the permanent Works and which are not to be
landscaped.
C The definition of grading shall be deemed to include both excavation in any material and
disposal of surplus materials and/or filling with approved materials as may be necessary
in order to achieve the required levels.
D The Contractor shall protect and take all due care not to damage any trees which are on
or adjacent to the site. Where directed by the Engineer's Representative, fencing shall be
erected to protect trees on the site and such fencing shall be to the satisfaction of the
Engineer's Representative and owners concerned.
E No tree roots of diameter greater than 40mm shall be severed and where necessary the
Contractor shall be required to excavate and lay the pipeline under such root system.
F Before any excavations are commenced, all surfacing materials shall be carefully
stripped to the minimum extent necessary for the Construction of the Works and shall be
set aside and kept separate from any other excavated material.
5-2-1.06 EXISTING SERVICES
A The following sub-clauses shall apply to excavation for trench works, over and above the
requirements of Section 1
B The Engineer's Representative will apply to the various Utility Services Departments for
details of existing and proposed services. These details will be provided to the Contractor
in advance of any excavation being undertaken.
C Subject to the Conditions of this Clause and Section 1 the Contractor shall be required to
make all necessary arrangements with .
the various Departments and private land owners regarding the work specified in this
Clause. The contractor shall be responsible for any damage caused as a result of an
omission in this respect on his part or any damage caused by his failure to notify the
Engineer's Representative and the Departments concerned immediately any service is
encountered in the excavation.
D Except as detailed below the Contractor shall be responsible for maintaining all
watercourses, sewers, drains, gas mains, water mains, electricity and telecommunication
cables and all other services structures, trees and plants encountered during the
construction of the Works and for any remedial measures necessary to make good any
damage caused thereto during the construction of the Works all at his own expense. Such
operations being executed either by the Contractor or by the workmen of the Department
concerned as may be directed by that department and all such operations shall be
performed to the satisfaction of the Engineer's Representative and the appropriate
Department.
The Contractor shall to the satisfaction of the Engineer's Representative and the
appropriate Department temporarily support or divert and subsequently reinstate all such
services and structures as herein specified or such operations shall be carried out by the
Department at the Contractor's expense if the Department should so elect. Where
services have to be temporarily supported or diverted and subsequently reinstated and the
appropriate Department decides to execute such works by the agency of its own
employees the Contractor shall on the direction of the Engineer's Representative
reimburse that Department the reasonable charges incurred in performing such work.
E Safety shall always be maintained in all work in the vicinity of existing services in
accordance with particular requirements of Service Authorities or the Engineer's
Representative, and the requirements of Clause 5-2-1.16.
F The Engineer's Representative shall determine whether a service requires to be

permanently diverted or supported.
G Where permanent diversion or support is rendered necessary as the unavoidable result of

the construction of the Works in accordance with the Contract the Engineer will instruct
the Contractor accordingly.
5-2-1.07 WORK IN THE VICINITY OF OIL OR GAS LINES
A In addition to the provisions of clause 5-2-1.06, when carrying out pipelaying

operations in the vicinity of existing gas or oil lines, the following requirements must be
strictly complied with.
a) The minimum clearance between the bottom of the oil or gas line and the top of the
pipeline being constructed is to be 600mm.
b) A hand excavated pilot hole shall be dug to determine the gas or oil line invert level
and position prior to any trench excavation in gas/oil line pipe reservations.
c) The excavation for the pipeline under construction must be carried out by hand up
to 2.0 metres either side of the existing gas/oil line.
d) Jack hammers (manually operated) may be used within 5.0 metres of the buried
pipeline only after completion of item C) above.
e) The use of Mechanical/ Hydraulic rock-breakers shall not be allowed within 5.0
metres of the buried pipeline.
f) Prior to the exposure of any live pipeline the Contractor is to erect a suitable
substantial barrier to prevent any damage to the exposed pipeline.
g) On completion of the concrete surround to the pipelines under construction, the existing
gas/oil line shall be re-bedded with a minimum of 150 mm of naturally occurring soft
dune sand bed and surround. The remaining backfill and bund shall be made up of
selected desert fill with a particle size not exceeding 150 mm which shall be free from
organic matter. The Qatar General Petroleum Corporation (QGPC) (onshore) Engineer
will require to be notified a minimum of 24 hours in advance, to witness the backfilling
operation.
h) Any damage to the external protective wrapping to the gas/oil line shall be notified
promptly to the QGPC (onshore) who will arrange for the damage to be inspected and
repaired in strict accordance with QGPC (onshore) procedures at the Contractor's cost.
i) When the Works reach 15 metres from the existing gas/oil line, contractor should
contract the QGPC. (onshore) Engineering Superintendent (US) Tel : 771521/774235,
who will arrange the necessary permit to work. QGPC (onshore) will require a
minimum of 48 hours notice prior to the commencement of work.
B It should be noted that a QGPC (onshore) permit to work does not in any way make
QGPC (onshore) responsible for any of the Contractor's work, nor does it absolve the
Contractor from his responsibilities for complying with the above, but only allows the
Works to be carried out in accordance with the agreed working methods and
practices. QGPC (onshore) reserve the right to visit the site regularly to observe that
the agreed methods and practices are being adhered to and to stop the work/withdraw
the permits to work should they consider there is adequate justification to do so.
C The requirements of the QGPC (onshore) may vary from and are not necessarily
limited to the aforegoing.
5-2-1.08 BLASTING
A The Contractor shall not use any explosives in the construction of the
Works .
5-2-1.09 SUPPORT OF EXCAVATIONS
A The Contractor shall provide the necessary support of excavations.
B The Contractor shall submit his proposals for supporting the sides of the excavations
at least seven days prior to the commencement of any excavation work. His proposals
shall take into account the nature of ground to be excavated, the water table level at
the site and the closeness of adjacent buildings and roads.
C If in the opinion of the Engineer's Representative the support proposed by the

Contractor is insufficient then the Engineer's Representative will order the provision
of stronger support for the excavations than that proposed by the Contractor and in
this event the Contractor shall adopt and make no charge for adopting the method so
ordered by the Engineer's Representative.
D The Contractor shall not remove temporary works supporting the excavations until in
the opinion of the Engineer's Representative the permanent work is sufficiently
advanced to permit such removal which shall be executed under the personal
supervision of a competent foreman.
E Any advice, permission, approvals or instruction given by the Engineer's

Representative relative to such support or the removal thereof shall not relieve the
contractor from his responsibilities under the Contract.
F All temporary works supporting the excavation shall be removed during backfilling
unless previous approval has been obtained from the Engineer's Representative.
Where temporary supports have been used in the excavation any such support shall be
left in at the expense of the Contractor should he find it impracticable to remove them.
G Should temporary supports need to be left in any excavation owing to the Engineer's
Representative deciding that their permanent installation is necessary for the stability
of an adjacent structure or service the Contractor shall comply and make no charge for
such supports.
H Underpinning, supports and other protective measures for buildings, structures and
apparatus in or adjacent to the excavations shall be provided by the Contractor and
shall be of proper design and sound construction and shall be securely placed to the
satisfaction of the Engineer's Representative but without prejudice to the
responsibility of the Contractor therefore.
I Timbering, steel sheeting, strutting and sheet piling for the support of excavations
where provided shall be fixed by the Contractor in accordance with British Standard
6031.
5-2-1.10 EXCAVATIONS TO BE KEPT DRY
A The Contractor shall keep all excavations free from water, and other liquids whether
affected by tides, floods, storms or otherwise so that the works shall be constructed in dry
conditions.
B The Contractor shall keep the water at a level lower than the bottom of the permanent
work for such a period as the Engineer's Representative shall direct.
C In the event of the Contractor requiring drainage channels or sub-drains the Engineer's
Representative will permit these to be constructed below the level of and within the
width limits of the permanent work provided he has approved the details of the
Contractor's proposals.
D Any sub-drainage that the Contractor constructs below the permanent works shall if left in
place be made to provide support. Ballast filled sub-drains underneath permanent in-situ
concrete shall be covered with a waterproof membrane of building paper.
E No sub-drain pipes shall be left in unless they are filled with concrete Grade SRC 20 or
other approved material.
F The Contractor shall provide all the materials,plant and labour to comply with the
requirements of this Clause. The operations shall be conducted so as not to endanger the
foundations or stability of any adjoining structures, and any damage to the Works caused
by prolonged or excessive pumping and any other damage whatsoever or nuisance
arising out of pumping operations shall be the liability of the Contractor.
5-2-1.11 DEWATERING
A The Contractor shall satisfy himself as to the extent of the water table and make due
allowance in his tender for draining and maintaining in a dry condition all works during
construction. Water removed from excavations must not be allowed to cause nuisance or
damage to traffic or any public or private property or service.
B Generally all dewatering arisings must be pumped to an area approved by the Engineer's
Representative and under no circumstances can they be discharged into any part of the
sewerage system without approval from the Drainage Division, Civil Engineering
Department, Ministry of Municipal Affairs and Agriculture.
C All proposed methods for dewatering excavations must be submitted to the Engineer's
Representative for his approval. The responsibility for dewatering rests with the
contractor for the duration of the Contract. Care must be exercised during dewatering
such that no material in or around the excavations is disturbed as a result of dewatering.
D The Contractor shall take care to avoid undermining any part of the Works or other
properties by pumping but should undermining occur then he shall immediately make
good the same to the satisfaction of the Engineer's Representative.
5-2-1.12 SLIPS AND FALLS AND EXCESS EXCAVATION
A Every precaution shall be taken by the Contractor to prevent slips and falls of earth and
other material in the excavations. In the event of slips or falls occurring or in the event of
excavations being made in excess of the minimum necessary or practicable for the
construction of the Works the voids so formed shall be filled. In all cases where the voids
so formed may in the opinion of the Engineer's Representative affect the stability of the
ground for the support of permanent works or of adjacent structures and services then
such voids shall be filled solid, at the Contractors expense, with concrete GradeSRC 20.
In all other cases the voids shall be packed with selected excavated material thoroughly
compacted and to the satisfaction of the Engineer's Representative.
5-2-1.13 TRIMMING AND LEVELLING
A When any excavation has been taken out and trimmed to the required levels, the
Engineer's Representative shall be informed so that he may inspect the completed
formation, and no excavation shall be filled in or covered with concrete until it has been
so inspected.
B Where shown on the Drawings or instructed by the Engineer, a layer of blinding concrete
to the thickness shown on the Drawings shall be laid in order to protect the formation and
to provide a clean working surface.
C Before placing blinding concrete the formation shall be rammed if in the opinion of the
Engineer's Representative, such ramming would improve the formation.
D If the formation of any excavation deteriorates for any reason prior to the placement of the
blinding concrete or other permanent work, the Contractor shall remove all damaged
ground and replace with approved fill material or blinding concrete as directed by the
Engineer's Representative.
5-2.1.14 RESTRICTED WORKING
A No extra payment shall be made to the Contractor for working in a confined space or if the
position of the Works as set out or ordered shall not allow the use of mechanical
excavators or the storage of excavated material alongside the excavation.
5-2-1.15 BACKFILLING EXCAVATIONS

A Notwithstanding the provisions of Clauses 5-1-1.02 and 5-1-1.03 the following additional
sub-clauses shall apply to backfilling of trenches.
B In refilling trenches, after the Engineer's Representative has approved the permanent
works, the first 300mm above granular or concrete surround shall be covered by hand with
lightly compacted selected excavated material free from clay lumps, large stones or other
material which may cause damage to the permanent works.
C Backfilling of trenches in the highway shall be carried out in accordance with Clause 5-2-
1.17.
5-2-1.16 BREAKING OUT AND REINSTATEMENT OF SURFACES

A Material forming the surfaces and foundations thereto of all lands other than public
highway shall be carefully stripped and set aside to the minimum extent necessary for the
construction of the Works and shall be as far as possible placed in its original position
together with such new material as may be required in order to reinstate the land to a
condition at least equal to that existing before the Contractor first entered thereon.
This reinstatement shall be carried out as soon as practicable after the completion
of the permanent work and of the refilling of the excavation or as may be directed by the
Engineer's Representative and shall be maintained in that condition throughout the
Contract.
B The Contractor will be required to return to the site at regular intervals during the period of
Maintenance to carry out at his own cost works necessary to ensure that surfaces are
reinstated to the condition before the works commenced.
C Where construction works are to be carried out in public grassed areas the turf shall be
neatly cut and stacked clear of the working area. The Doha Municipality Garden Section
shall be advised immediately prior to undertaking this work and will confirm whether they
wish to remove the turf for use elsewhere. The Contractor shall allow for provision of 150
mm sweet soil and reseeding on completion of the Works.
D The Contractor shall reinstate the surface of all storage areas, working areas and access
routes, whether obtained by himself or by the mployer, in accordance with the signed
agreement between the landowner and the Contractor or the Employer, as the case may be,
but in any case to condition not less than equal to that existing before the commencement
of the Works.
5-2-1.17 EXCAVATION, BACKFILLING AND REINSTATEMENT

OF TRENCHES IN THE HIGHWAY
A Excavation, backfilling and reinstatement of trenches in the Highway shall be carried out
in accordance with the Code of Practice and Specification for Road Crossings in the
Highway dated January 1992 and any subsequent revisions thereof, issued by the
Highways Maintenance Section, Civil Engineering Department, Ministry of Municipal
Affairs and Agriculture. A copy of this document may be obtained from the Civil
Engineering Department and the Contractor shall be deemed to be in possession of a copy
and fully conversant with the regulations therein.
B The Contractor shall prepare all RO1 forms and deliver them to the Programmes and
Projects department, MEW (Water Section) for endorsement. The contractor shall be
responsible to, obtain the RO2 forms from all the other services and planning departments.
When all the RO2 forms have been received the Contractor shall be issued with those and
the RO3 form. The Contractor shall be responsible for the liaison with police and all
matters relating to the RO3 forms.
C The Contractor shall obtain Traffic Police approval and submit a copy of this to the
Highway Maintenance Section, Ministry of Municipal Affairs and Agriculture. A copy of
the RO3 endorsed by the Highway Maintenance Section shall be submitted to the
Engineer's Representative prior to commencing any trench work.
D Any Nuclear Density Measurement (NDM) tests undertaken shall be performed only by
persons or companies holding a valid Authorised User Certificate issued by CED
Laboratory. Each NDM device shall have a valid Calibration Certificate, also issued by
CED Laboratory.
E The Contractor is advised that an item has been included in the Bill of Quantities for
carrying out the reinstatement of major roads between existing road joints. The Contractor
is deemed to have included in his programme of works for carrying out this work as
required by the Highways Maintenance Section of the Ministry of Municipal
Affairs & Agriculture.
5-2-1.18 LANDSCAPING
A Where landscaping of the Site is specified this shall usually be undertaken after the
Contractor has completed all the other earthworks on the Site.
B Sweet soil for use on the Site shall be obtained from a source approved by the Engineer's
Representative.
C Animal manure for use on the Site shall be of the first quality and be obtained from an
approved supplier.
D Grass shall be Bermuda Grass- Sinidon Sactilon.
E Seedlings of trees and shrubs shall be young plants free from disease of the types and
sizes, specified in the Bill of Quantities.
F All areas of the Site which are to be planted with grass shall be excavated to a level
400mm below final ground level and all surplus excavated material disposed of off site.
After excavation is complete the area to be planted shall be filled to final ground level with
lightly compacted sweet soil. In this filling the Contractor shall make allowance for any
consolidation and shrinkage which may subsequently occur. Animal manure shall then be
added at a rate of 7.5 kg per square metre. After spreading uniformly on the surface the
manure shall be thoroughly mixed into the top 150 mm of soil.
G Where trees or shrubs are to be planted their location shall be agreed on Site with the
Engineer's Representative. A hole 1000mm by 1000mm deep below final ground level
shall be excavated for each tree or shrub, and the surplus excavated material disposed of
off Site. This hole shall then be filled with sweet soil. 10 kg of animal manure shall be
thoroughly mixed with the soil in each hole.
5-2-1.19 PLANTING
A After the landscaping work has been completed to the satisfaction of the Engineer's
Representative the Contractor shall commence preparation of the Site for planting.
B This preparation work shall involve irrigating the site daily for seven consecutive days to
leach out any remaining traces of salt. During this period irrigation water shall be applied
uniformly over the Site at a rate of not less than 15 litres per square metre per day.
C The water to be used for this leaching and for subsequent irrigation shall be final effluent
obtained from the irrigation pipe network. If a supply is not available from this source then
the Contractor shall provide potable water.
D Planting shall be carried out in the appropriate season and shall commence immediately
following the seven day leaching period. After planting the Contractor shall continue to be
responsible for the irrigation of the Site until such time as satisfactory growth has been
achieved by all plants. At this time the Employer's Representative will assume
responsibility for irrigation.
E Any trees, shrubs or areas of grass which fail to exhibit satisfactory growth shall be
replaced free of charge by the Contractor. The responsibility for the irrigation of these
replacement plants shall remain with the Contractor until such time as these plants exhibit
satisfactory growth.
F In programming the planting work the Contractor shall take due regard of the accepted
seasons for planting. Should the period of the Contract be such that landscaping works are
completed at a time when planting is inadvisable then the Contractor may apply to the
Engineer's Representative for permission to postpone the planting until a more suitable
time of year. Should this delay mean that the planting has to be carried out after the date of
completion of the Works then the Contractor shall give satisfactory undertakings to
complete the outstanding work during the maintenance period.
5-2-1.20 BOUNDARY STRUCTURES
A Where a pipeline passes under, through or over any fence wall or other boundary
structure, the Contractor shall unless otherwise instructed by the Engineer's Representative
carefully dismantle the boundary structure to the minimum extent necessary. The structure
shall be stored and subsequently re-erected by the Contractor to a standard not less than
was existing before it was dismantled.
B The Contractor shall to the satisfaction of the Engineer's Representative replace all
materials damaged during dismantling, storage and re-erection.
C Where access across boundary structures is required and permitted for constructional
plant, the width of the opening in the boundary shall be enlarged as stated to the minimum
extent necessary. Before any opening is made through any fence, wall or boundary
structure, the Contractor shall first obtain the written approval of the Engineer's
Representative.
D Openings through boundary structures shall be temporarily fenced during construction

with chestnut pale fencing or barbed wire fencing as directed by the Engineer's
Representative.
E Where directed by the Engineer's Representative, the pipeline shall be brought across
boundary structures by means of a short heading instead of forming an opening through
the boundary.
5-2-2.0 PIPELAYING
5-2-2.01 SETTING OUT AND PIPE ALIGNMENT
A All pipes and pipelines shall be laid to the lines and depths shown on the Drawings or as
otherwise directed by the Engineer's Representative.
B All pipelines shall be laid accurately to line and gradient so that except where otherwise
specified or ordered by the Engineer's Representative the finished pipeline is in a straight
line in both horizontal and vertical planes. Where shown on the Drawings or otherwise
permitted by the Engineer's Representative, shallow changes of direction shall be achieved
by deflection at joints within the maximum permitted on the drawing and stated elsewhere
in this specification. Where the angle of the bend required is greater than that obtainable
by reasonable multiple joint deflection then manufactured bends of the appropriate degree
shall be used. Manufactured bends shall only be used where shown on the Drawings or
where otherwise permitted by the Engineer's Representative.
C Where pipelines of constant gradient are to be laid, the Contractor shall provide, fix and
maintain properly painted sight rails and boning rods of predetermined measurement for
the boning in of individual pipes to correct alignment . The sight rails shall be situated
vertically over the line of pipes or immediately adjacent thereto and there shall at no time
be less than three sight rails in position on each length of pipeline under construction to
any one gradient.
D If the Contractor wishes to propose an alternative method of controlling pipeline

alignment, he shall submit his proposed method to the Engineer's Representative for
approval.
5-2-2.02 STORAGE AND HANDLING OF PIPES
A Storing and handling including taking delivery, loading, handling, unloading and stringing
of pipes, valves, fittings and other equipment shall be carried out by the Contractor in such
a manner as to avoid breakage, distortion, denting, gouging, grooving, flattening, damage
to pipe ends and other damage to the pipes, coatings, valves, fittings and other equipment.
Stacking of materials shall be done in accordance with the manufacturer's
recommendations in such a manner as to prevent damage to the pipe or coatings to the
satisfaction of the Engineer's Representative.
B Generally, all pipes and specials shall be handled using woven slings not less than 150mm
wide. The use of chains or wire slings will not be permitted.
C Where lifting hooks are permitted by the Engineer's Representative, they shall be of the
type having a plate curved to fit the curvature of the inside of the pipe.
5-2-2.03 STORAGE OF VALVES AND FITTINGS
A All valves and fittings shall be stored under cover on hard standing until required for
fixing. Uncrated valves and fitting shall not be stacked.
B Electrical equipment shall be protected from the damp and the damp-proofing seals shall
remain intact until the electrician is ready to connect up the equipment.
C Air valves are to be stored under cover, in a vertical position with the top of the valve
uppermost. Under no circumstances are air valves to be stored such that the ball is
subjected to sun light. Resilient seated sluice valves are to be stored in the same fashion as
air valves.
5-2-2.04 STORAGE OF MATERIALS SUSCEPTIBLE TO HEAT AND

SUNLIGHT
A Wrapping tape, joint rings, rubber seatings, gaskets, polyethylene film and other anti-
corrosion materials and all other equipment and materials liable to be adversely affected
by the heat and sunlight are all to be stored in cool covered storage to the approval of the
5-2-2.05 PIPE WRAPPING
A Laminate tape system shall be applied by machine in clean, dry conditions using the
following procedure.
B Prior to primer application, all oil, grease, etc. shall be removed with an approved solvent.
Surfaces to be coated shall be cleaned by mechanical brushing to remove loose corrosion
products, welding slag, loose factory applied bituminous paint or any other foreign matter
and achieve a surface finish equivalent to SIS 05 5900 St. 3 on bare surfaces.
C Primer shall be applied to all surfaces to be wrapped immediately following completion of

surface preparation.
D The primer shall be allowed to dry prior to wrapping. Primer application shall be limited
to that amount that can be wrapped during the working day.
E Laminated tape shall be applied in a spiral fashion with a 55mm overlap and with
sufficient tension to give constant adherence, without voids or wrinkles. On completion of
the wrap the surface shall be smoothed to ensure completely sealed overlaps and absence
of air pockets under the tape. The width of tape shall be suitable to conform to the size and
shape of the pipeline being wrapped.
F Spigot ends of pipes shall not be coated over the depth of engagement within the socket or
flexible coupling.
G On completion of the wrapping all tape coatings shall be detected at 15 kV minimum for
'holiday' defects. Any such defects found shall be sealed by over wrapping with tape and
the tape coating retested.
H Bond/adhesion tests shall be carried out on all tape coatings a minimum of 24 hours after
completion of wrapping.
5-2-2.06 JOINT PROTECTION
A After hydraulic testing pipe joints shall be protected by heat shrink tubes coated internally
with thermoplastic adhesive. The profile of the pipe joint shall be smoothed using joint
moulding compound or preformed plastic foam sections taped in position. Heat shrink
sleeves shall be used on pipes with extruded polythene coatings, and in all cases shall be
applied in accordance with the sleeve manufacturer's and pipe coating manufacturer's
instructions.
B Joints within in-situ concrete chambers do not require wrapping or sleeve protection.
C Damaged areas of protective coating or wrapping shall be repaired in a manner to be

approved by the Engineer's Representative.
5-2-2.07 STRINGING
A The Contractor shall take pipes from his storage depots, unload them and string them
along the route of the pipeline. Pipes shall be so strung as to cause the least practicable
interference with the use of the land and at intervals gaps shall be left between pipes to
permit the passage of equipment across the Working Width.
B Pipes shall not be placed on the ground but shall raised on timbers and bedded to the
approval of the Engineer's Representative. The timbers shall in no case be less than
200mm wide.
C After a pipe has been strung and immediately before being laid it shall be brushed out and
examined by the Contractor and the Engineer's Representative, and all damage which is
found to either the coating lining and/or the pipe shall be repaired or the pipe rejected as
the Engineer's Representative may direct.
D The inside of each pipe shall be examined by the Contractor for cleanliness prior to
jointing and all extraneous matter shall be removed.
5-2-2.08 LAYING PIPES
A Each pipe immediately before being laid shall be carefully brushed out and inspected for
defects.
B In trench pipes with flexible joints, except where concrete protection is provided as
specified hereafter, shall be laid on a well compacted bed of granular bedding material
extending for the full width of the trench and with sufficient material at the sides to
permit the pipes being worked into the granular material and firmly supported to true line
and level. Sufficient space should be left to enable the joints to be made, tested and
inspected but the Contractor shall ensure that at least three quarters of the pipe length is
fully supported. After the pipeline has been tested and approved by the Engineer's
Representative the trench shall be carefully filled to 300 mm above the crown of the pipe
with granular material.
5-2-2.09 PIPE JOINTING
A The Contractor shall ensure that all pipe joints are made strictly in accordance with the
manufacturer's recommendations and shall include but not be limited to the following:
B The pipe ends, flange faces, coupling grooves and rubber rings shall be cleaned
immediately before assembly and lubricants shall be used in accordance with the
manufacturer's instructions.
C Except in the case of flanged or restrained joints, joints on ductile iron pipes will be of the
flexible type sealed with an elastomeric rubber ring or gasket. In the case of push-on joints
the spigot end of the pipe shall be checked to ensure circularity and that it is correctly
chamfered. The rubber ring or gasket shall be correctly located in the preformed groove of
the socket. The jointing depths shall be indelibly marked on the spigot after allowance for
the initial jointing allowance has been made. The spigot shall be entered into the socket in
strict alignment and to the correct jointing depths. Any joint deflection required must be
made only after the completion of the joint.
D Pipes less than one full pipe in length shall be cut from gauged pipe.
E Flanged pipes shall be properly aligned before any bolts are tightened.
F When flanged joints are to be made the gasket and bolts shall be inserted and the nuts
turned to finger tightness. Thereafter the final tightening of the nuts shall be effected by
torque spanners in such sequence that diametrically opposite nuts are tightened together.
The pipe manufacturer's instructions in respect of the maximum torque to be applied to
each bolt shall be complied with.
G Restrained joints where shown on the Drawings on ductile iron pipes shall be made strictly
in accordance with the manufacturer's recommendations.
H Pipe deflections at restrained joints shall not normally exceed one degree without the
approval of the Engineer and the manufacturer's tolerance on laying of restrained jointed
pipes shall be adhered to such that the restrained joint is 'pulled home' firm and with any
deviations at the joint within the allowance specified above when full internal pressure is
applied to the pipeline.
I The Contractor shall obtain from the Manufacturer or his Agent the services of a skilled
pipe fitter to demonstrate the correct method of making all proprietary or patented joints.
5-2-2.10 CONCRETE PROTECTION TO PIPELINES
A Where concrete protection to pipelines is specified or ordered by the Engineer's

Representative a 75mm thick Grade SRC 20 concrete layer shall be laid over the full
width of the trench and never less than 150mm wider on each side than the barrel of the
pipe and with its top surface positioned as shown on the drawings.
B This concrete shall be allowed to set and be thoroughly washed down before pipe laying is
started.
C The length of pipeline laid in any one operation before concreting the pipeline shall be that
which in the opinion of the Engineer's Representative permits accurate laying of the
pipeline and proper compaction of the fill.
D Pipes up to 1200mm diameter shall be firmly supported on precast concrete blocks and
separated from them by a 25mm thick saturated softward packing.
E After the pipeline has been tested and approved by the Engineer's Representative the
concrete shall be thoroughly washed down and additional concrete Grade SRC 20 shall be
carefully placed and compacted in layers to avoid disturbing the pipes or joints until the
appropriate profile for the type of protection required has been reached.
F When support of excavation is provided building paper shall be placed against that support
before concreting to facilitate withdrawal of the support.
G In the cases of spigot and socket pipes with flexible joints the concrete protection at each
joint shall be interrupted in a vertical plane at the edge of the socket by a strip of
fibreboard or other material approved by the Engineer's Representative and of the
following thickness:
Up to 300 mm nominal bore - 13mm

Over 300 and up to 600 mm nominal bore - 25 mm
Over 600 and up to 1200 mm nominal bore - 38 mm
5-2-2.11 PIPELINES IN DUCTS
A Where pipelines are to be laid in ducts, the Contractor shall propose for the Engineer's
approval a suitable system of guides, supports and slides to ensure that the pipe is
installed to the required levels as shown on the Drawings.
B The Contractor's installation system shall ensure that no damage occurs to the pipe, linings
or coatings to the pipe, or to the duct.
C After the pipe has been tested the annular space between the external face of the pipe and
the internal face of the duct shall be filled as directed by the Engineer's Representative.
5-2-2.12 BACKFILLING OF ROAD CROSSINGS AND TRACKS
A In the case of the pipe crossing any existing or proposed carriageway or track the lower
portion of the trench shall be backfilled as specified for reinstatement of trenches in the
highway upon which the Contractor shall provide a raft of 200mm (minimum) thickness
of plain concrete class SRC 20 as detailed on the Contract Drawings.
5-2-2.13 LAYING P.V.C MARKER TAPE
A Blue P.V.C marker tape shall be laid directly above the watermain, 300mm below finished
ground level.
B Under carriageways the tape shall be laid on top of the concrete protection to the
watermain or as directed by the Engineer's Representative.
5-2-2.14 GEOTEXTILE MATTRESS
A When instructed by the Engineer's Representative a 300mm thick granular filled geotextile
mattress shall be provided to the underside of the granular bedding. The fabric shall be
laid on the prepared formation and extending up the sides of the trench to produce the top
cover to the mattress, overlaps of the fabric shall be in accordance with the
recommendations of the manufacturer of the fabric but not less than 300mm.
Granular mattress filling material as specified previously shall be placed and
compacted in two layers to a compacted thickness of 300mm. Each layer shall be
compacted by 6 passes of a vibrating roller having a mass per metre width of vibrating roll
over 1800 kg and up to 2300 kg or by means of 8 passes of a vibrating plate compaction
having a mass per unit area of base plate over 1800 kg/m2 and up to 2100 kg/m2 or by
equivalent means approved by the Engineer. The fabric shall be lapped over the granular
material, prior to placing of the pipe bedding material.
5-2-2.15 REPAIRS TO PIPES AND FITTINGS
A Pipes and fittings damaged during handling or storage shall be set aside and the Engineer's
Representative informed. Repair proposals shall be submitted to the Engineer's
Representative in writing for approval. If in the Engineer's Representative's opinion the
damage is such that the pipe or fitting has been permanently impaired it shall not be
incorporated in the works.
B No repairs shall be started without the approval of the Engineer's Representative.
5-2-3.0 CHAMBERS AND STRUCTURES

5-2-3.01 CONCRETE CLASSIFICATION
A The type of concrete to be used for particular classes of work shall be as follows:
CONCRETE GRADE APPLICATION

OPC 35 Special reinforced structural concrete
OPC/SRC 30 Precast concrete, floor screeds
OPC 25 Normal reinforced concrete
SRC 25 Roads and hardstandings ,mass concrete outside the
tanking system
OPC 20 Mass concrete and screed within the tanking system
SRC 20 Blinding
SRC 10 Backfill
B Alternative uses for any type of concrete may be specified by the Engineer where
required.
5-2-3.02 PIPELINE CHAMBERS
A Chambers shall be watertight with external tanking.

B Pipes shall project from the external faces of the chambers by amounts stated for ductile
iron pipes in Clause 5-2-3.03 unless otherwise shown on the Drawings or instructed by the
Engineer.
C Top surfaces of walls supporting cover slabs shall be to true line and level and painted
with two coats of approved bituminous paint as a bond breaker.
D Lifting holes or eyes in precast components are to be provided as shown on the Drawings
or as directed by the Engineer.
E All valve chambers shall be backfilled to crown of pipe level or as directed by the
Engineer with concrete grade SRC 20 against undisturbed ground to resist thrust.
5-2-3.03 BUILDING PIPES THROUGH STRUCTURES
A Where pipes pass through a concrete wall or structure they shall unless otherwise shown
on the Drawings project from the external face of the structure by 300 mm for pipes with
nominal bore of 500mm or less and by 600mm for pipes with nominal bores in excess of
600mm and the surface of such pipes shall be prepared to the approval of the Engineer to
ensure a satisfactory bond between pipes and concrete forming the wall. A puddle or
thrust flange shall be incorporated on each pipe passing through a wall as shown on the
drawings.
B Any excavation beneath the formation line of a pipe trench adjacent to a structure shall be
backfilled to the formation line of the pipe trench with concrete grade SRC 20. The
concrete shall extend at least 500mm beyond the extremities of the pipe on each side.
C The first pipe in open ground leaving a structure shall be a short length of either spigot and
socket or double spigot to suit the flow direction. The length of this pipe shall be one and
half times the nominal bore or 600 mm whichever is the greater or as shown on the
Drawings. A double socket collar shall be used to make the first joint to a spigot outside
the structure as shown on the Drawings unless otherwise directed.
5-2-3.04 DRAG BLOCKS & THRUST BLOCKS
A For all pipelines which are constructed in a manner which permits axial movement at
joints, then at every bend in the pipeline and where otherwise shown on the Drawings or
instructed by the Engineer's Representative, the Contractor shall construct a drag block or
thrust block of concrete Grade SRC 25 to the dimensions shown on the Drawings or as
approved by the Engineer and cast against undisturbed ground.
B The excavation for the drag block or thrust block shall be carried out prior to laying the
pipes except that a trimming margin of not less than 150 mm shall be left to be removed
by hand excavation in order to obtain a firm thrust face against undisturbed ground. This
trimming margin shall only be removed after laying and jointing of the pipes and the
concrete for the drag block shall be placed on the same day as the removal of the trimming
margin. No pressure is to be applied to any drag block or thrust block until the concrete
has matured for at least 7 days.
5-2-3.05 TANKING
A All underground external concrete surfaces shall be tanked, with the tanking extending
150 mm above finished ground level.
B Tanking of all external faces of concrete shall becarried out by wrapping with a preformed
strong impervious self-adhesive laminated bitumen/ polythene membrane which shall be
capable of withstanding cracking of the substrate up to a crack width of 0.6
millimetres and shall be subject to the approval of the Engineer's Representative.
C All surfaces shall be dry and dust free and surfaces painted with a coat of primer as
recommended and supplied by the same manufacturer as the membrane. The membrane
shall have a 75 mm minimum overlap at the joints. The concrete blinding shall be
extended outside the wall line by at least 100 mm to enable overlapping and fixing of the
membrane.
D The tanking membrane shall be applied in two layers and laps shall be staggered from one
layer to the next.
E Horizontal tanking applied over the concrete blinding shall as soon as practicable after
laying be protected from damage by the application overall of a 50mm screed of Concrete
Grade SRC 20.
F Tanking to all other surfaces up to finished ground level shall be protected with a 12mm
minimum thickness of bitumen bonded cork board which shall be subject to the approval
of the Engineer's Representative. The protective board shall be placed against the tanking
and held in position by temporary struts or other means while the backfilling is being
placed care being taken to prevent loose stones damaging the membrane or the protective
board. Tanking above finished ground level shall be protected by an aluminium flashing as
indicated on the drawings.
G All application details for the tanking membrane shall be in accordance with the
membrane manufacturer's details.
H The Engineer's Representative may at his discretion approve alternative methods and
materials for tanking purposes.
5-2-3.06 EXPOSED TANKING PROTECTION
A Exposed tanking shall be protected by flashing fabricated from aluminium alloy at least
1.6 mm thick to BS 1470.
5-2-4.0 CLEANING, TESTING AND STERILISATION

5-2-4.01 PIPELINES TO BE KEPT FREE FROM EXTRANEOUS
MATERIAL
A The pipeline shall at all times be kept free of extraneous material, and when work is not in
progress the open ends of the pipeline shall be securely plugged with an approved
watertight plug or stopper firmly fixed to resist unauthorised removal. During times of
rainfall this plug must be able to resist the water pressure of a flooded excavation and
prevent ingress of water into the pipeline. Claw type plugs or any type liable to damage
the pipe will not be approved.
B All such stoppers, plugs or caps shall be provided with a vent incorporating a valve for the
purpose of testing whether the pipeline is under pressure or vacuum and to enable
pressures to be equalised prior to its removal.
C The Contractor shall clear the inside of each fitting and pipe length immediately prior to
jointing and shall swab all fittings and pipe lengths to remove all dirt, sand or other matter
that may clog the line or contaminate the fluid to be transported in the pipeline.
D After jointing, the interior of the pipes shall be freed from any dirt, stones or other matter
that may have entered them. For this purpose, a dry swab shall be pulled through the pipe
after jointing.
E The entire absence of foreign matter from the completed line shall be a condition
precedent to acceptance.
5-2-4.02 DRY SWABBING
A A foam plastic cylinder swab which meets the approval of the Engineer shall be inserted
into the pipeline at the beginning of pipelaying and pulled through each pipe as it is laid by
means of a rope, thus providing an effective dry swab. The swab shall be replaced at
regular intervals to ensure a tight all round fit.
5-2-4.03 TESTING GENERAL
A Pipelines shall be tested in lengths between valve chambers with lengths not exceeding
one and half kilometre except by agreement with the Engineer's Representative. Testing
shall not be against closed valves, and pipes of different diameters shall not be tested
together in the same test. The arrangements for testing a pipeline shall include provision
for purging the air from the pipeline during the test.
B The joints shall be left open so that they may be inspected during hydraulic testing. Only
the barrels of the pipes shall be backfilled prior to hydraulic testing taking great care to
avoid the joints and leaving sufficient space all around the joints to permit inspection and
to undertake remedial measures should the joint be found to leak under hydraulic testing.
After the successful completion of hydraulic testing, the joints shall, if specified, be
wrapped, coated or sleeved as appropriate, and then backfilled in the manner specified
elsewhere in this specification.
C The final test shall be applied in the presence of the Engineer's Representative.
D The Contractor shall keep a record of all tests in a book which shall be available for
inspection and handed over to the Engineer's Representative on demand. The Contractor
shall complete standard test record sheets which shall be submitted to the Engineer's
Representative for approval.
E The section under test shall be properly sealed off with blank flanges or special stop end
caps held securely in position by adequate temporary anchorages, and filled with lightly
chlorinated water. All peak points of the pipeline shall be adequately vented during the
filling operation using temporary bleed valves. All air valves shall be removed and all
other valves shall be set in the open position.
F Pipe joints, valves and fittings shall also be checked over carefully for loose bolts or
connections which might cause leakage and delay the execution of the tests.
G Should any section fail to pass the tests, the Contractor shall determine the cause of the
failure and shall locate, excavate and repair any damage or leakage sustained by the
pipeline before or during the tests and retest the section. The cost of such repair work,
additional backfilling and reinstatement and the abortive test shall be borne by the
Contractor.
H On completion of testing, the section of pipeline shall be properly sealed to prevent the
intrusion of any extraneous matter, until connected to the pipeline network.
5-2-4.04 TESTING PIPELINES
A All sections of pipeline shall be tested after completion of the pipeline with the exception
of any backfilling not necessary for the stability and safety of the works. Once the pipeline
has been filled with lightly chlorinated water and all air bled off additional water shall be
added via a small capacity high pressure positive displacement pump, drawing from a
suction tank where the volume change can easily be checked and measured. The pipeline
shall be allowed to stand until stable testing conditions are achieved.
B The pipeline shall be tested for a period of at least 24 hours after which the test pressure
shall be restored by pumping and the quantity of water lost during the test measured. The
permissible loss shall not exceed 0.02 litre per day per millimetre of nominal bore per
kilometre of pipeline per bar of pressure.
C If the calculated leakage rate is within the allowable leakage rate, the test water shall be
transferred to the next section of the pipeline to be tested or disposed of as approved by the
D Unless otherwise specified all pipelines shall be tested to a pressure one and a half times
the working pressure or to a pressure of 9 bar whichever is the greater.
E When all sections of similar diameter have been jointed together after completion of
section testing, unless otherwise directed by the Engineer's Representative a test shall be
carried out at the specified pressure on the completed pipeline. All joints between
individual test sections shall be left uncovered during this final test for inspection by the
Contractor and the Engineer's Representative. The final test shall be carried out using the
same procedure as the section tests. On successful completion of the final test, the exposed
joints shall be covered and the trench backfilled as specified in the appropriate Clause of
this Specification.
F The Contractor shall include in his pipelaying rates to supply and install the required
number of flexible couplings to join together all sections of the pipe after testing.
5-2-4.05 WATER FOR TESTING
A The Contractor shall make his own arrangements for the supply and disposal of water used
for testing which shall be provided by the Contractor at his own cost and removed from
the nearest convenient approved source.
5-2-4.06 CLEANING AND DISINFECTING PIPELINES
A Pipelines shall after pressure testing be thoroughly flushed out with clean water using
methods approved by the Engineer.
B After the Engineer has approved the cleaning, the Contractor shall disinfect the main on
receipt of the Engineer's order to do so. Disinfection shall be in accordance with the
requirements of ANSI/AWWA C651. The concentration of chlorine shall be at least 30
mg/l.
C The method used for chlorine injection shall be approved by the Engineer. The length of
pipeline which is being disinfected shall be completely isolated from the existing supply
mains. The chlorine solution shall remain in the pipeline for at least 24 hours during which
period all valves in the treated pipeline shall be operated so as to be thoroughly
disinfected.
D After disinfection the pipeline shall be thoroughly washed out with potable water and,
before being put into service, the pipe shall be filled and allowed to stand for a minimum
of 24 hours. After this period the Contractor shall carry out bacteriological tests on the
water and only an excellent laboratory report will be acceptable. This procedure shall be
repeated to the satisfaction of the Engineer.
E Storage and handling of chemicals shall be to the manufacturer's instructions and the
Engineer's approval. Proper care shall be taken to store chemicals in a safe condition and
place inaccessible to children or unauthorised persons.
F The Engineer's order to disinfect the pipelines will not normally be given until
immediately before commissioning.
5-2-4.07 CONNECTION TO THE EXISTING NETWORK
A When all testing, cleaning and disinfection has been satisfactorily completed the new main
may be connected to the existing network.
B The Contractor shall apply to the Engineer for the necessary shutdown to make the
connection. The Contractor's application shall include a method statement for each
connection to demonstrate his preparedness to undertake the connection. He should allow
a period of 4 weeks for the necessary arrangements to be made and permission to be
granted. The Contractor must comply with the requirements of the Department and ensure
that the work is carried out within the time permitted.
C The Contractor shall not cut any existing main until permission is given by the Engineer.
D The length of time available for each connection to existing mains varies and will be
determined by the relevant authorities.This time will be determined by the Engineer
during the construction time.
5-2-4.08 MEDICAL CERTIFICATION OF CONTRACTOR'S WORKFORCE
A Each member of the Contractor's workforce who will be working on water supply
contracts shall be medically examined to establish his freedom from the carrier state. The
Contractor shall supply all medical certificates to the Engineer as proof.
B The medical certificates shall state that the person has been checked for the following:
a. Salmonella typhi
b. Salmonella Paratyphi A
c. Salamonella Paratyphi B
d Non-specific Salmonella
C The medical examination shall consist of:

a. Blood test
b.Bacteriological examination of stools & urine on a minimum of three occasions at
weekly intervals.
c. X Ray.
D If after the medical examination the person suffers any illness associated with looseness of
the bowels or any illness necessitating his absence from work for more than five days then
he shall be medically examined again to determine if it is safe for him to be employed on
work which could lead to contamination of the water supply system.
5-2-5 Survey of the Pipeline Route

The Contractor shall undertake a survey of the routes of all the pipelines prior to the
commencement of construction work, and shall provide the Engineer with at least two
copies of the results of the survey which shall be in the same format as the tender
drawings, together with the Contractor’s proposals for the pipeline gradient and invert
level, location of air valves, washouts, bends (including co-ordinates),..etc. The survey
shall also show the location, dimensions and level of underground existing services or
obstructions in the pipeline route and shall conform to the following:
a. The length of the route shall be accurately measured. The route thus marked shall be
agreed with Engineer prior to commencement of level surveying.
b. Using a total station or GPS system (accuracy ± 50 mm), ground levels shall be taken
at route and at significant changes in ground level and with spacing not less than 50ms.
c. Levels shall relate to an approved datum, and permanent bench marks shall be
established, well clear of the proposed pipeline, at intervals along the pipeline route.
d. Prior to the survey, the Engineer shall supply the Contractor with a data copy of the
tender drawings. The results of the survey shall be presented as a modified form of the
long section drawings plotted at 1:1000 horizontal and 1:100 vertical scale.
At all times the route surveying shall be at least one month ahead of excavation and
pipe laying to enable agreement to be reached between the Engineer and the Contractor
on the lines, levels and gradients.
The Contractor shall be responsible for locating all services crossing or closely
paralleling to the route of the trench by consultation with the concerned authorities.
The excavation shall done by hand with trail holes in advance to main excavation.
The Contractor shall survey ahead of the pipe laying and copies of the results shall be
submitted to the Engineer without delay.
5-2-6 Soil Investigation
5-2-6.01 Soil Testing
a. The Contractor is required to dig trial pits and carry out in-situ and laboratory soil
tests at intervals along the route of the pipelines located as directed by the Engineer but
not exceeding 500m. The tests shall be carried out at a sufficient distance ahead of
pipelaying that construction is not held up.
b. The Contractor shall carry out laboratory soil tests on selected material removed from
each trial pit to determine its suitability for trench back-fill. The tests shall include
particle size distribution, atterberg limits and dry density moisture content relationship.
c. Where the Engineer considers excavated material to be unsuitable for use as trench
backfill, the Contractor shall carry out soil tests on the material he proposes to import
to determine its suitability. If the Contractor proposes a change in back-fill or fill
material, all tests shall be repeated for the new material.
D. The Contractor shall also prepare a survey of the soil resistivity along each pipeline
route at intervals not exceeding 500m and determined at the depth of the underside of
the pipe and at the depth of the top of the pipe. Soil resistivity values shall be
determined by the Wenner technique as described in 402 of British CP 1013. Results
shall be presented in tabular form in accordance with ANSI A 21.5 (AWW A C 105)
E. Soil samples shall be taken from trial pits at a minimum of 1 Kilometer spacing along
the route of the pipeline as directed by the Engineer. Soil samples shall be tested for
PH -value, redox potential, moisture content, chloride content and sulphide content,
and the results presented in tabular form in accordance .with ANSI A 21.5 (AWWA
C105).
5-2-6.02 Resistivity Survey
Whilst undertaking the conventional survey of the pipeline route the Contractor shall
undertake a resistivity survey in accordance with the requirements of BS 1377 Part 9.
Resistivity measurements shall be carried out at not more than 500 m spacing along the
pipeline route and at all wadi crossings. The results of the resisitvity survey shall be presented
in a tabular report format to be approved by the engineer. As a minimum, the report should list
the following information for each measurement.
¾ Date and time

¾ WGS 84 grid reference
¾ Brief description of location
¾ Resisitivity values at depths of 1.5,2 and 3 m
The resistivity survey report for each section of pipeline shall be presented to the engineer at
the same time as the conventional survey drawings.
5-2-6.03 Interaction Testing
a. The Contractor shall carry out interaction testing in accordance with BS 7;61 Part
1:1991 at all locations where the pipelines cross existing cathodically protected
pipelines.
B. The results of the testing shall be submitted to the Engineer together with proposals
for remedial measures where the positive potential change exceeds 20mV.
c. Testing shall be carried out by qualified persons approved by the Engineer.
5-2-7 Pipeline Inside Crossing Tunnel or Sleeve
Pipes inside crossing tunnels shall be of flanged joints each of length about 3 meters
and shall be supported on wheels to allow the possible pulling of pipeline and
dismantling any piece of pipe to be maintained or replaced, no extra cost shall be paid
for using these flanged pipes.
5-2-8 Pipelines under Existing Roads

The Contractor shall programmed the works to reduce disruption to road traffic to a
minimum and before any work commences in existing road shall:
a. Obtain the full permission and approval of all authorities concerned serving notices
of intent to start work as may be necessary and observing all the local laws and
regulations.
b. Submit details of his proposals, and obtain approval form the Engineer.
Pipelines shall normally cross roads at right angles.
The roadway shall be reinstated using the form of construction and materials as
ordered by the relevant authority.
The bedding and jointing shall be as specified but the trench re-filling shall be carried
out using granular bedding material and compacted at the sides of the pipes to not less
than 95% of the maximum dry density as determined by the compaction test in BS
1377: Part 4 (2.5 kg rammer).
Above this a 250 mm layer of Class 20/20 concrete shall be placed to bring the level
of the backfilling up to 100 mm below the finished road surface. This method of
backfilling shall extend at least 2 m either side of the surfaced road carriageway.
The replacement of the road surfacing shall be carried out as soon as practicable after
backfilling has been completed.
The edges of the trench shall be cut to a uniform line consistent with the varying
width of the trench and the trimming allowances. Any part of the road wearing course
which has been damaged beyond the width of the trench must be cut out and made
good. The Engineer’s prior agreement for such additional work must be obtained
before additional payment can be considered, in cases where the damage was beyond
the Contractor’s control.
A vertical joint shall be formed between the new work and the existing road surface
and shall be painted with hot bitumen, or as approved by the Engineer, and the two
layer wearing course stepped 75 mm.
The finished levels of the completed reinstatement shall conform with the adjoining
carriageway surface.
Reinstatement of wearing courses shall match as nearly as practicable the colour or
other characteristics of the existing surface.
Where the carriageway surface adjoining the trench is of rolled asphalt the Contractor
may, with approval of the relevant authorities and the written approval of the
Engineer, lay a temporary wearing course of Class 20/20 concrete 100 mm thick. At a
later date, to be decided by the Engineer, the Temporary wearing course may be
removed and replaced with 2 layers of rolled asphalt each 50 mm thick.
5-2-9 Thrust Boring

Where open trench excavation crossing of roads is not permitted, and where existing
ducts are not available, pipe laying shall be undertaken by trenchless methods as
described below.
5-2-9.01 General
Thrust boring is the preferred method of trenchless construction although other

suitable alternative methods will be considered by the Engineer.
The work shall only be carried out by a specialist Sub-Contractor with proven
experience in the particular methods of construction proposed.
The Contractor shall carry out the works to the approval of the Engineer and strictly
in accordance with the requirements of the relevant authorities.
The Contractor shall carry out any investigations necessary and shall be fully
responsible for determining the suitability of his proposed methods of construction to
the prevailing ground conditions.
The Contractor shall design the permanent and temporary works to withstand all
anticipated dead loads and traffic loading without damage to the pipeline and to
prevent any adverse effects on the road construction by way of settlement or
otherwise.
5-2-9.02Method Statement
For all activities the Contractor shall submit to the Engineer for approval a fully
detailed method Statement that shall include inter alias all design calculations, details
of manufacture and suppliers of materials, details of vertical and horizontal loadings
and pressures, means of maintaining control of line and level, type and method of
pipe jointing and type methods of grouting.
5-2-9.03 Sleeves
The diameter of the sleeves shall be determined by the Contractor and shall be the
smallest possible size to accommodate the ductile iron pipes and joints and allow free
passage for the in-situ annulus grouting.
The sleeve pipes shall be of welded steel, having a wall thickness determined by the
Contractor.
5-2-9.04 Thrust Boring

Thrust boring shall be undertaken from and to supported excavations.
The Contractor shall provide continuous, experienced supervision of operations in
order to maintain the line and level of the sleeve to a tolerance of ± 75 mm of the true
line and level. Adjustment to the line and / or level should be gradual.
Thrust walls for jacking operations shall be constructed normal to the proposed line
of thrust and shall be adequate for installation of the sleeve. Intermediate jacking
stations may be used where frictional resistance might result in unreasonable high
jacking forces, subject to the approval of the Engineer and the relevant authorities.
Thrust loads shall be imparted to the sleeve through a suitable thrust ring, which shall
be sufficiently rigid to ensure even distribution of the load. Unless otherwise
specified or directed by the Engineer resilient packing material shall be used between
the pipe end and the thrust ring and also at any intermediate jacking stations.
The Contractor shall maintain up-to-date records of thrusting pressures and line and
level measurement for inspection by the Engineer as required.
5-2-9.05 Pipeline Installation

The pipeline shall be installed and maintained in position within the sleeve to the line,
level and gradient shown on the drawings and requirements of Clauses 2.7 and 2.9 of
this Chapter.
Insertion of the pipeline into the sleeve shall be by towing or jacking using suitable
supports and spacers to facilitate installation and to prevent damage to the pipes, shall
be made before insertion into the sleeve.
5-2-9.06 Grouting
Grouting of the annulus between the sleeve and the pipeline shall not commence until
the pipeline has been hydraulically tested to the full specified test pressure and
approved by the Engineer.
Mixing shall be carried out in pans paddle type mixers suitable for the purpose to
produce a grout of adequate workability for pumping. Materials shall be batched by
the whole bag by weight with particular attention paid to the water content. After
mixing the grout shall be transferred to a holding tank before pumping.
Hand mixing of grout will not be allowed.
Grout shall be pumped continuously in one operation until the annulus between the
sleeve and the pipe is completely filled.
The amount of grout to be pumped to completely fill the annulus shall be calculated
taking account an allowance for wastage and the quantity of grout pumped
continually monitored to ensure that the annulus is completely filled.
The Contractor shall provide the Engineer with records of grout pressures and
quantities pumped during the filling operations.
5-2-10 Epoxy Coatings
Where epoxy coating is specified, completed fittings shall be coated on all surfaces,
both internal and external, including inside bolt holes etc, with a 100% solids,
thermosetting, fusion bonded, dry powder epoxy resin.
The metal surface shall be blast cleaned to BS 7079 second quality of surface finish,
the maximum amplitude of surface roughness shall be 0.1 mm. Surfaces shall be
cleaned to remove all traces of oil, grease and loose deposits, etc.
The coating process shall be commenced immediately after the blast cleaning and
surface and cleaning and before the formation of visible oxidation on the metal
surface.
The metal shall be pre-heated in an indirectly fired oven to a temperature not
exceeding 245 degrees centigrade. In the event of any oxidation on the surface the
metal shall be cooled to ambient temperature and re-cleaned before re-commencing
the coating process. The heated metal shall be immersed in a bed of fluidized epoxy
powder until such time as the thickness of the coating is 300 microns.
Alternatively, powder can applied by spraying onto the pre-heated surface until the
required and uniform thickness of coating has been achieved. The spray gun shall
have sufficient capacity to maintain a uniformly dense moderate velocity spray
pattern. The coating shall be applied in a uniform sweeping motion.
The coating shall be cured in accordance with the powder manufacturer’s
recommendations to achieve optimum physical and chemical properties.
The coating shall be tested with a calibrated thickness gauge to ensure a minimum
coating thickness of 300 microns. Spark testing for pin holes, cracks, voids,
contamination and damaged areas shall be carried out using a high voltage spark
generator of 2KV. Faults shall be repaired and cured in accordance with the powder
manufacturer’s instructions.
On delivery to site all pipes and fittings shall be carefully inspected for handling or
transit damage and shall be repaired following the manufacturer’s recommended
procedures.
At all times the Engineer of his Inspecting Authority shall be permitted free access to
the place of coating for the purpose of examining and witnessing the coating process.
5-2-11 Testing Structures on Pipelines
Unless otherwise approved by the Engineer, water-retaining structures on the

pipelines, which are not tested, with the pipelines shall be separately tested in the
presence of the Engineer for water tightness.
The structures shall be filled with water to ground level, the underside of the cover
slab, or to give a head over the pipeline of 2 m whichever is the less. After a period to
the approval of the Engineer to allow for absorption of water by the structure, there
shall be no discernible loss of water over a period of 30 minutes as measured by a
vernier gauge or other approved device.
5-2-12 Surge Protection

The Contractor shall perform a surge analysis as described in scope of work to
confirm the surge protection equipment design requirements. The analysis shall be to
the approval and satisfaction of the Engineer.
The surge analysis carried out shall include analysis and recommendations for surge
protection measures for the ultimate system. The surge protection measures
recommended and provided initially shall be capable of simple expansion, or
extension to meet the ultimate requirements.
The Contractor shall provide if required, air/water interface type surge vessels, surge
tanks, air valves, control valves and other control and surge protection equipment,
complete with isolation valves, fittings and accessories, as determined by the
Contractor's surge analysis.
The supply for the surge vessels shall include (if required) an electrically driven
reciprocating air compressor system arranged to automatically charge the vessel with
oil-free air. The vessels and connecting pipework shall be located with an adequate
access for operation and maintenance. Means shall be provided for draining down
each vessel and connecting pipework for inspection and maintenance purposes.
The Contractor shall undertake surge analyses to determine the extent of surge
pressures or other adverse hydraulic conditions that may occur during the operation
of the pumping facilities.
The Contractor shall undertake the following tasks as an integral part of the surge
analysis for each system:
a) Construct a mathematical model of the system using network fluid flow simulation
computer software.
b) List the steady state condition under which the system will operate.
c) List, with reasons, the most adverse surge conditions under which the system will
operate.
d) Determine maximum and minimum surge pressures along the system that can occur
due to system operation.
e) Identify possible surge suppression options listing their advantages and disadvantages
for the system analysed.
f) Recommend the preferred option giving details of the maximum and minimum
pressures to which the system will be subjected with the surge suppression equipment
installed. Full details of the surge suppression equipment and ancillary equipment
shall be given.
g) Prepare a Surge Analysis Report providing full details of tasks (a) to (f), including
sufficient data sheets, figures and analysis output, etc. from the network fluid flow
simulation software to allow the Engineer to undertake a detailed review of the Surge
Analysis Report.
As a result of the Engineer’s review, where revisions to the Surge Analysis Report are
agreed between the Engineer and Contractor, the Contractor shall incorporate these
into the report and reissue the report.
The format of the Surge Analysis Report shall be agreed with the Engineer after tasks
(b) and (c) have been completed and before analyses are commenced. A summary of
the findings from tasks (b) and (c) shall be presented with the proposed report format.
5-2-12.01 Surge Vessels

● Design and Construction
Vessels shall be designed, constructed and tested in accordance with the design
parameters provided and to BS 5500 and other relevant British Standards as follows:
(i) Mild steel pressure parts BS 1501-151-288A.
(ii) Mild steel non-pressure parts –BS 4360.
(iii) Mild steel forgings – BS 1503
Requirements for connections and fittings, … etc., include:
- Saddle supports for horizontal mounting, or legs for vertical mounting,
complete with holding down bolts.
- Drilled and tapped or flanged facings for the following fittings, together with
the fittings:
a) Pressure relief valve rated for not less than 150 % working pressure and to pass 200 %
maximum gas flow into vessel.
b) Adequate access to afford inspection of the inside of the vessel, in accordance with the
requirements of BS 470.
c) Calibrated level sight glass of the reflective type covering the full range of water level
in the vessel and having top and bottom shut off cocks, hinged safety shutter and
pressure/level calibrations carried on a substantial engraved plate.
d) Air replenishment valve and fittings for connection to an air compressor.
e) Air release valve.
f) 150 mm diameter pressure gauge with gauge isolating cock.
g) Lifting lugs shall be provided to enable handling of the vessel on site without damage
to the painted surfaces.
h) Flanged inlet and outlet branches as required.
Design and manufacture of the vessel shall be subject to approval by an independent
Inspection Authority. The Contractor shall make all arrangements for the Inspection
Authority to approve the design and witness all workshop tests. On satisfactory
completion of the vessel, the supplier shall provide an Inspection Certificate,
endorsed by the Inspection Authority to verify that the vessel meets all the
requirement of BS 5500.
The Contractor shall include in his bid for the cost of an approved Inspection
Authority to carry out the necessary certification and testing at each stage of
manufacture and shall provide final Inspection Certificates for each vessel endorsed
by the Inspection Authority. Copies of certificates of inspection during manufacture
required for insurance shall be given to the Engineer before delivery of the vessel to
site. The Contractor shall make all necessary arrangements with the insurers in
respect of the inspection and testing.
The water level indicator shall incorporate a magnetically coupled level gauge with
control contacts.
5-2-12.02 Reciprocating Air Compressors

In case of the system with Compressors, it shall be rated for continuous operation at
full duty. Compressors shall be of the oil-free single or multi-stage air-cooled
reciprocating type fitted with automatic unloading valves.
Cylinder heads shall be readily removable for inspection. Each cylinder shall be
constructed to provide easy replacement and maximum cooling.
The unit shall consist of:
● two Reciprocating air compressors and squirrel cage induction motor mounted
on a common base plate.
● Receiver mounted pressure switch and controls.
● Air receiver and safety valves.
● Intake silencer and filter unit.
● After cooler.
● Air delivery line including check valve, isolating valve, moisture trap, air filters
and pressure regulator,
● Flexible connection to the air main.
● Outlet pressure gauge.
Compressors shall be tested in accordance with BS 1571.
5-2-12.03 Pipework and Valves for Compressed Air Systems

(i) Pipework:
All air lines shall be of the galvanized heavy gauge steel tubing type, to BS 1387 :
1967. All bends, tees, unions and other fittings shall be of galvanized steel to BS 143
and shall be of the correct size and type for the steel tubing in use. Screwed or flanged
joints may be incorporated. Pipes shall be flanged to BS 4504, PN 10 where required
to make connections with plant items, and shall be designed for a pressure of not less
than 3 x relief valve pressure blow point. Air main velocity shall not exceed 6 m/s.
Pipework shall be installed horizontally and vertically but shall fall in the direction of
air flow to facilitate draining of condensate. Automatic drains shall be fitted to
prevent the accumulation of condensate at low points in the system. the nominal fall
of the pipework shall be 1-in-80.
(ii) Valves:
Pressure relief valves and condensate drain valves shall be provided as required by
the operating system. Isolating valves shall be full bore diaphragm or ball pattern.
5-2-12.04 Air Receivers

The air receiver shall be cylindrical and constructed to BS 5500. The air receiver
volume shall be at least six times the total volume of the air compressed in 1 minute,
at duty pressure, and shall include the following fittings and equipment:
● Air relief Valve.
● Pressure gauge.
● Drain valve.
● Air line connections
● Pressure switch for automatic control of compressor
N.B.:
Vessels with bladder can be accepted upon the approval of the Engineer.
5-3 SPECIAL CLAUSES
5-3-1.0 SAFE WORKING IN THE VICINITY OF OVERHEAD EHV

LINES
A The Contractor should note that large sections of the route are to be constructed
parallel to existing overhead EHV lines.
B Before any work will be permitted in the vicinity of the overhead EHV lines the
Contractor shall submit for approval a Safety Plan containing his proposals for barriers
and safe working methods for the protection of both his employees and the overhead
lines. The approval of both the Engineer's Representative and MEW (Electricity Section)
will be required for these proposals although approval will not relieve the Contractor of
any of his responsibilities for safety under the Contract.
C The Contractor's Safety Plan will be required to include the following minimum
requirements:
1.Erection of continuous warning barriers not less than 2.5m high and 15m from the
pylon centre line along the full working area parallel to the overhead lines.
2.Provision of 'goal posts' with continuous height warning barriers under all overhead
line crossing points required for access or pipelaying.
3. Adoption of working methods and the use of such types of plant as to make
accidental contact with the overhead conductors impossible during normal working
operations, having regard to location, reach and swing areas for all types of plant
employed.
4. The use of warning notices both on the site as a general warning to employees and
in the various items of plant as a specific warning to operators.
5. A detailed description of the above measures together with the names and duties of
the persons responsible for safety on the site.
D At all times work is being carried out in the vicinity of the overhead lines the
Contractor shall have on site a senior person responsible for overall safety approved
by the Engineer's Representative. In addition the Contractor shall have at each and
every location when work is being carried out in the vicinity of overhead lines a
person responsible for safety approved by the Engineer's Representative.
E If the Contractor fails to comply with any of the requirements of this clause or with his
own approved Safety Plan, the Engineer's Representative shall give immediate
instructions to stop the work and any resulting delay or costs shall be entirely the
Contractors' responsibility.
5-3-2.0 STEP POTENTIAL TESTING
A The Contractor shall test all exposed pipeline appurtenances, such as valves, to verify
that within the wayleave of overhead high voltage cables, the touch voltage is less than
15 volts in accordance with CSA Standard C22.3 No 6-M 1991.
B The results of the testing should be submitted to the Engineer together with proposals
for remedial measures should the touch voltage exceed 15 Volts.
C Testing shall be carried out by qualified persons approved by the Engineer.
5-3-3.0 INTERACTION TESTING
A The Contractor shall carry out interaction testing in accordance with BS 7361:
Part 1:1991 at all locations where the pipelines cross existing cathodicall protected
pipelines.
B The results of the testing should be submitted to the Engineer together with proposals
for remedial measures where the positive potential change exceeds 20 mv.
C Testing shall be carried out by qualified persons approved by the Engineer.
5-3-4.0 PIPELINE TEST PRESSURE
A All pipelines shall be tested to a pressure equivalent to 90m above Qatar National
Datum.
5-3-5.0 CODES AND STANDARDS
A Where specified in the Bill of Quantities the Contractor shall provide copies of all
British Standards and other codes standards.(one original and two copies)
B The above documents are to be provided at the commencement of the contract and
prior to commencement of work and submission of material proposals and shall be the
property of the Government.
5-3-6.0 TESTING FACILITIES
Add the following sub-clauses:
D The Contractor shall for the full duration of the contract retain the services of an
independent and approved laboratory complete with all the equipment necessary to
perform the following tests as specified in QNBS or the relevant British or ASTM
standard, and in accordance with test procedures approved by the Ministry of
Municipal Affairs & Agriculture Civil Engineering Department (CED) Materials
Testing Laboratory:
1. Aggregate Grading
2. Flakiness Index
3. Elongation Index
4. 10 minute Immersed Rotational Test
5. Cube Crushing
E Where specifically called for in the Particular Specification the Contractor will comply
with sub clauses F to H below.
F The Contractor will maintain on site for the full duration of the contract the following
equipment in addition to the requirements of Clause 5-4.03.
1. Workability - 2sets, slump and flow
2. Cube making - 24No. 150 mm moulds

- Vibrating table for 6 moulds
3. Cube curing - Thermostatically controlled tank
4. Temperature - 2No. max/min air thermometers

- 2No. digital concrete thermometers
G The Contractor shall provide the services of suitably qualified technician who will be
responsible for the control of site concrete to the satisfaction of the Engineer's
Representative. The technician shall be independently mobile and able to visit off-site
concrete plant, quarries, laboratories etc. as required in order to satisfy the sampling
and testing requirements of the contract.
H The Contractor shall supply original copies of all relevant British, ASTM or other
standards together with the guidelines and recommendations regarding the specified
tests as produced by the CED Materials Testing Laboratory, all of which shall remain
the property of the Engineer.
I The site equipment shall be operational to the approval of the Engineer before
consideration can be given to commencing any trial mixes.
5-3-7.0 RELIABILITY TESTS
After completion of normal testing & commissioning by the contractor, the Reliability
tests shall apply to all the various modes of operation and be conducted exclusively by
operation and Maintenance staffs in a period of one month.
The Reliability tests shall be made under the full responsibility of contractor.
The reliability tests shall last for a period of 31 consecutive days during which the
whole of the plant under test shall operate continuously without any defects. If there is
any defect or fault, then the test shall start again from the time the defect is rectified
and shall extend the whole test period.
The operation & maintenance personnel shall be fully satisfied prior to taking over and
a certificate of substantial completion will only be issued upon their acceptance.

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Qatar General Electricity & Water Corporation

TENDER NO. GTC 177/2007

PIPE MATERIALS AND MAIN LAYING

SECTION FIVE –PIPE MATERIALS AND MAIN LAYING

5-1-2.07 Certification of Tests 11/64

5-1-3.03 External Protection To Pipes & Fittings 12/64

5-1-6.04 Flow Control Valves 18/64

5-2 Main laying 28/64

5-2-1.17 Excavation, Backfilling & Reinstatement of Trenches in the Highway

5-2-4.07 Connection to the Existing Network 50/64

5-3 Special Clauses 61/64

5-3-7.0 Reliability Tests 64/64

5.1 PIPE MATERIALS

5.1.1-2 THIRD PARTY INSPECTION

C The following items shall be inspected by the Third Party Inspector:

i. Issue Release Note to Manufacturer with a copy to Engineer prior to shipping of

5.1.1-3 LIST OF APPROVED MANUFACTURERS

5-1-2.0 DUCTILE IRON PIPES AND FITTINGS

5-1-2.02 CLASS OF PIPES AND FITTINGS

A Ductile iron spigot and socket pipe shall be Class K9.

Nominal Size (DN) (mm) Deflection Limit (Degrees)

Up to and including 300 5

5-1-2.04 LENGTH OF PIPES

5-1-2.06 PIPES FOR CUTTING ON SITE

5-1-2.07 CERTIFICATION OF TESTS

5-1-2.08 NUTS, BOLTS AND WASHERS

5-1-2.09 RESTRAINED JOINTS

5-1-3.02 LINING MATERIAL

5-1-3.03 EXTERNAL PROTECTION TO PIPES AND FITTINGS

E The Contractor is to supply a detailed specification of any proposed extruded

5-1-4.0 SLIP-ON COUPLINGS AND FLANGE ADAPTORS

5-1-4.02 SLIP-ON COUPLINGS

5-1-4.03 FLANGE ADAPTORS

5-1-4.05 COATING OF SLIP-ON COUPLINGS, STEP COUPLINGS AND FLANGE

5-1-5.0 SITE APPLIED CORROSION PROTECTION

For details refer to spec. clause 5-1-3.03

5-1-5.02 JOINT MOULDING COMPOUND

C The moulding compound shall be supplied in 25 kg drums.

5-1-6.0 VALVES AND FLOW METERS

C Gate valves up to 350mm diameter shall be of the resilient seat type.

a. Integral by-pass valve

5-1-6.02 BUTTERFLY VALVES

Shaft : S16 Stainless Steel BS 970: Part 1 Grade 316 S33

Internal fastenings, nuts

5-1-6.03 AIR RELIEF VALVES

Body/Cover : Ductile iron BS 2789 Grade 500/7 or DIN

5-1-6.04 FLOW CONTROL VALVES

Body/Cover : Ductile iron BS 2789 Grade 500/7 or DIN 1693

5-1-6.05 FLOW METERS

i) The flowmeter shall be of a type that prevents polarisation of electrodes.

H Plant Labelling and Nameplates

5-1-6.06 FLAP VALVES

B Doors shall be designed to maintain an efficient seal under minimal

C The valves shall be capable of operating with flows at high pressure

5-1-7.0 SURFACE BOXES, ACCESS COVERS AND FRAMES

C All surface boxes shall be item marked or a certificate of compliance

5-1-7.02 SURFACE BOXES FOR SLUICE VALVES

C The covers of the surface box shall have open keyways.

5-1-7.03 ACCESS COVERS AND FRAMES