Book VI - Infrastructure & Networks

EMPLOYER ARCHITECT / ENGINEER
design at world scale
Mohammed Bin Rashid Al Maktoum City

District One - Phase 3B Villas
Dubai - UAE
ISSUED FOR CONSTRUCTION

REVISION 1
VOLUME II - SPECIFICATIONS
BOOK VI - INFRASTRUCTURE & NETWORKS
20 June 2022 AE7 Project No.20010400

MOHAMMED BIN RASHID AL MAKTOUM CITY
DISTRICT ONE – PHASE 3B - 3B EXTENSION AND 3C
DUBAI - UAE
OT: Outline Specs based on 100% SD Drawings

Revision B: FL Specs based on 100% DD Drawings
Revision C: Based on Drawings Revision C (if required)
Revision 0: FL Specs correspond to Tender Drawings / Construction Documents
AE7 Morse Architecture & Engineering Consultants Revision 0.1: Amended Sections in Tender Specs (in different dates)
Revision 1: FL Specs correspond to Issued for Construction
Revision 1.1: Changed Sections in Issued for Construction (in different dates)
Revision 2: FL Specs correspond to Issued for Construction
SPECIFICATION REGISTER AND TABLE OF CONTENTS (TOC) REVISION DATE
PROJECT NAME: Mohammed Bin Rashid Al Maktoum City - District One – Phase 3B Villas Day 04 21 16
AE7 PROJECT NUMBER: 20010410 Month Nov Dec June
WORK PACKAGE: Issued For Construction Year 2021 2021 2022
EMPLOYER: District One-FZ
REVISION PREPARATORS
PROJECT DESCRIPTION: Phase 3B - 3B Extension and 3C
PROJECT LOCATION: MBRAMC, Dubai Written By: M. K M. K M. K
SUBSTANTIAL DESIGN: Dubai Municipality Edited By: M. K M. K M. K
COPIES: Hard and PDF Reviewed By: R. H R. H R,H
PM: M. S M. S M. S
BOOK - INFRASTRUCTURE OT B C 0 0.1 1 1.1 Remarks
DIVISIONS SECTION TITLE ISSUED SECTIONS
SPECIFICATION REGISTER & TOC Δ □ ■ • •• Ψ ΨΨ
VOLUME 2
PART I GENERAL SPECIFICATIONS • •• Ψ
PART II PARTICULAR SPECIFICATIONS • Ψ
PART III DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE SPECIFICATIONS • Ψ
PART IV APPENDIX TO DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE SPECIFICATIONS • Ψ
PART V PARTICULAR SPECIFICATIONS FOR IRRIGATION WORKS • Ψ
PART VI PARTICULAR SPECIFICATIONS FOR FIREFIGHTING WORKS • Ψ
PART VII BUILDING GENERAL SPECIFICATIONS – CIVIL & ARCHITECTURAL • Ψ
PART VIII BUILDING GENERAL SPECIFICATIONS MEPF • Ψ
PART IX DEWA – PEW TECHNICAL SPECIFICATIONS

• Ψ
AE7 PROJECT NO. 20010410 REV 1 – ISSUED FOR CONSTRUCTION

SPECIFICATIONS REGISTER AND TOC - GR Page 1 of 1 DATE OF ISSUE: 16 JUNE, 2022
Design at world scale

ROADS AND UTILITIES
ISSUED FOR CONSTRUCTION DOCUMENTS

VOLUME 2 – PART 1
GENERAL SPECIFICATIONS
CONSULTANT PROJECT NO.

20010410
JUNE 2022
DUBAI – UAE
Project:20010410
District One – Phase 3B - 3B Extension and 3C
Roads and Utilities
GENERAL INDEX
Volume 1 Construction & Contract Conditions
Volume 2 – Part I General Specifications
Volume 2 – Part II Particular Specifications
Volume 2 – Part III Dubai Municipality Sewerage and Drainage

Specifications
Volume 2 – Part IV Appendix to Dubai Municipality Sewerage and

Drainage Specifications
Volume 2 – Part V Particular Specifications for Irrigation Works
Volume 2 – Part VI Particular Specifications for Fire Fighting Works
Volume 2 – Part VII Building General Specifications – Civil &

Architectural
Volume 2 – Part VIII Building General Specifications - MEPF
Volume 2 – Part IX DEWA – PEW Technical Specifications
Volume 3 Bill of Quantities
Volume 4 Tender Drawings
Volume 5 Soil Investigation Report and Project Environmental and

Health & Safety Requirement
AE7 PROJECT NO. 20010410 iii REV 1 – ISSUED FOR CONSTRUCTION

VOLUME 2 – PART I DATE OF ISSUE: 16 JUNE, 2022
DUBAI – UAE
MEYDAN GROUP LLC
Project: 20010410
Roads and Utilities
Issued For Construction Documents
Volume 2 – Part I
CONTENTS
SECTION 1 - GENERAL ...........................................................................................................1

1/1 SITE ESTABLISHMENT ............................................................................................................. 1
1/2 SITE OFFICE FOR THE ENGINEER........................................................................................ 1
1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR ...................................................... 2
1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR ........................... 2
1/5 CONTRACTOR’S SITE ORGANISATION .............................................................................. 3
1/6 SURVEYING EQUIPMENT ......................................................................................................... 3
1/7 LABORATORY TESTING ........................................................................................................... 4
1/8 PROGRAMME OF WORKS ....................................................................................................... 6
1/9 K SITE, SETTING OUT AND CROSS-SECTIONS ................................................................... 6
1/10 PROJECT SIGN BOARDS ..................................................................................................... 8
1/11 PROJECT PHOTOGRAPHS .................................................................................................. 8
1/12 QUALITY OF MATERIALS AND SUPPLY ......................................................................... 9
1/13 APPROVAL BY THE ENGINEER ....................................................................................... 11
1/14 EXISTING SERVICES AND SERVICE DIVERSIONS .................................................... 12
AE7 PROJECT NO. 20010410 iv REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND

PROPERTIES .......................................................................................................................................... 15
1/16 TRAFFIC MANAGEMENT, SAFETY AND CONTROL .................................................. 15
1/17 TEMPORARY DIVERSION OF TRAFFIC ......................................................................... 16
1/18 FIRE PRECAUTIONS ............................................................................................................ 16
1/19 SAFETY OFFICERS .............................................................................................................. 17
1/20 CONTRACT DRAWINGS AND DOCUMENTS ................................................................ 17
1/21 SHOP DRAWINGS, WORKING DRAWINGS, OPERATIONS AND MAINTENANCE
INSTRUCTIONS...................................................................................................................................... 17
1/22 RECORD DRAWINGS ........................................................................................................... 18
1/23 ACCOMMODATION WORKS .............................................................................................. 18
1/24 PUBLICITY ............................................................................................................................... 19
1/25 TIDYING AND CLEARING THE SITE ................................................................................ 19
1/26 SOIL INVESTIGATION .......................................................................................................... 19
1/27 WORKS FREE FROM WATER ........................................................................................... 19
1/28 OTHER CONTRACTORS ON SITE.................................................................................... 19
1/29 MAJOR EQUIPMENT AND PLANT ................................................................................... 20
1/30 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI ....... 31
SECTION 2 - SITE CLEARANCE AND EARTHWORKS .......................................................33
2/1 SITE CLEARANCE DESCRIPTION ....................................................................................... 33
2/2 SURVEY BEFORE COMMENCEMENT ................................................................................ 33
2/3 DEMOLITION REQUIREMENTS............................................................................................. 33
2/4 GENERAL SITE CLEARANCE ............................................................................................... 34
2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS .......... 34
2/6 ROAD SIGNS............................................................................................................................... 35
2/7 DISPOSAL OF HISTORICAL ARTEFACTS......................................................................... 35
2/8 DISPOSAL OF SURPLUS MATERIAL.................................................................................. 35
2/9 EXCAVATION FOR ROAD CONSTRUCTION .................................................................... 36
2/10 CLASSIFICATION OF EXCAVATION ............................................................................... 36
2/11 EXCAVATION REQUIREMENTS ....................................................................................... 37
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DUBAI – UAE
2/12 BORROW PIT SITE................................................................................................................ 38

2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS
MATERIALS ............................................................................................................................................ 39
2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION ................................................ 41
2/15 EMBANKMENT CONSTRUCTION ..................................................................................... 41
2/16 EMBANKMENT FOUNDATION .......................................................................................... 42
2/17 PLACING AND COMPACTION REQUIREMENTS ......................................................... 43
2/18 MOISTURE CONTROL REQUIREMENTS ....................................................................... 43
2/19 TESTING METHODS ............................................................................................................. 44
2/20 MINIMUM TEST REQUIREMENTS .................................................................................... 44
2/21 STABILISING CRUSHED MATERIAL ............................................................................... 45
2/22 GEOTEXTILE FABRIC .......................................................................................................... 46
2/23 EXCAVATION FOR STRUCTURES................................................................................... 47
SECTION 3 - PAVEMENT CONSTRUCTION .........................................................................51
3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS ..................................................... 51
3/2 TESTING OF AGGREGATES.................................................................................................. 52
3/3 APPROVAL AND INSPECTION OF AGGREGATES ........................................................ 52
3/4 STORAGE OF AGGREGATES ............................................................................................... 53
3/5 TIDYING-UP OF QUARRY AREA .......................................................................................... 53
3/6 GRANULAR SUB-BASE .......................................................................................................... 53
3/7 AGGREGATE ROADBASE DESCRIPTION ........................................................................ 55
3/8 AGGREGATE ROADBASE MATERIAL ............................................................................... 55
3/9 SPREADING AGGREGATE ROADBASE ............................................................................ 56
3/10 COMPACTION OF AGGREGATE ROADBASE.............................................................. 57
3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE........................................... 57
3/12 FINISHING OF AGGREGATE ROADBASE ..................................................................... 58
3/13 MINIMUM TEST REQUIREMENT FOR AGGREGATE ROADBASE ......................... 58
3/14 WET-MIX MACADAM ROADBASE, DESCRIPTION ..................................................... 58
3/15 WET-MIX MACADAM ROADBASE MATERIAL ............................................................. 58
3/16 TRANSPORT AND SPREADING WET-MIX MACADAM ROADBASE ..................... 60
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DUBAI – UAE
3/17 COMPACTION TRIALS OF WET-MIX MACADAM ROADBASE ............................... 60

3/18 COMPACTION OF WET-MIX MACADAM ROADBASE ............................................... 60
3/19 FINISHING OF WET-MIX MACADAM ROADBASE ....................................................... 61
3/20 MINIMUM TEST REQUIREMENTS FOR WET-MIX MACADAM ROADBASE ........ 61
3/21 BITUMINOUS PAVING COURSES, DESCRIPTION ...................................................... 62
3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE ............................ 62
3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE ....................................... 63
3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE .......................................... 63
3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES........................ 64
3/26 BITUMEN BINDER ................................................................................................................. 67
3/27 JOB MIX FOR BITUMINOUS PAVING COURSES......................................................... 68
3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS .......................................... 72
3/29 PREPARATION OF BITUMEN BINDER ........................................................................... 72
3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX ................... 72
3/31 PREPARATION OF BITUMINOUS MIX ............................................................................ 73
3/32 SURFACE PREPARATION .................................................................................................. 73
3/33 PLACING OF THE MIX.......................................................................................................... 74
3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE ....................................... 75
3/35 BITUMINOUS LEVELLING COURSE ................................................................................ 76
3/36 THICKNESS CORES ............................................................................................................. 77
3/37 COMPACTION OF BITUMINOUS LAYERS ..................................................................... 77
3/39 CONTACT SURFACES ......................................................................................................... 79
3/40 JOINTS IN BITUMINOUS PAVING..................................................................................... 79
3/41 PROTECTION OF COMPACTED LAYER ........................................................................ 79
3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES .............................................. 80
3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES ............................................ 80
3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS ................................................. 81
3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES ............. 83
3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS.............................................. 83
3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES .......................... 83
AE7 PROJECT NO. 20010410 vii REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
3/48 BITUMINOUS PRIME COAT ................................................................................................ 84

3/49 BITUMINOUS TACK COAT ................................................................................................. 85
3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT .................... 88
3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION .......................... 88
3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT ...................... 88
3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT ..................... 90
3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE
TREATMENT ........................................................................................................................................... 90
3/55 APPLICATION OF DOUBLE BITUMINOUS SURFACE TREATMENT ..................... 90
3/56 PROTECTION OF ADJACENT STRUCTURES FROM BITUMEN SPLASHING .... 94
SECTION 4 - CONCRETE WORKS ..........................................................................................95
4/1 CEMENT ...................................................................................................................................... 95
4/2 AGGREGATES GENERAL REQUIREMENTS .................................................................... 96
4/3 FINE AGGREGATES ............................................................................................................... 101
4/4 COARSE AGGREGATE FOR CONCRETE ....................................................................... 101
4/5 COMBINED AGGREGATE..................................................................................................... 102
4/6 WATER FOR CONCRETE ..................................................................................................... 102
4/7 APPLICABLE TESTS AND CODES .................................................................................... 103
4/8 REINFORCEMENT BARS ...................................................................................................... 105
4/9 BAR SCHEDULES AND SHOP DRAWINGS .................................................................... 105
4/10 BAR CUTTING AND BENDING ........................................................................................ 106
4/11 PLACING AND FIXING REINFORCEMENT .................................................................. 106
4/12 WELDED WIRE FABRIC .................................................................................................... 107
4/13 SPACER BLOCKS ............................................................................................................... 107
4/14 ADMIXTURES ....................................................................................................................... 107
4/15 CONCRETE MIX SPECIFICATION .................................................................................. 107
4/16 CONCRETE MIX DESIGN .................................................................................................. 110
4/17 QUALITY CONTROL ........................................................................................................... 112
4/18 CONCRETE DESIGN LIMITS ............................................................................................ 114
4/19 CONSISTENCY OF CONCRETE ...................................................................................... 114
AE7 PROJECT NO. 20010410 viii REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS ........................................... 114

4/21 ASSEMBLY AND HANDLING MATERIALS Assembly ............................................. 115
4/22 MIXING CONCRETE ............................................................................................................ 116
4/23 READY MIXED CONCRETE .............................................................................................. 117
4/24 TRANSPORT AND PLACING ........................................................................................... 118
4/25 COMPACTION OF CONCRETE ....................................................................................... 119
4/26 CONSTRUCTION JOINTS.................................................................................................. 120
4/27 CURING CONCRETE .......................................................................................................... 121
4/28 EARLY LOADING................................................................................................................. 121
4/29 CONCRETING AT NIGHT .................................................................................................. 122
4/30 CONCRETING IN HOT WEATHER .................................................................................. 122
4/31 MINIMUM TEST REQUIREMENT FOR CONCRETE ................................................... 123
4/32 FORMWORK Construction ............................................................................................... 123
4/34 MORTAR................................................................................................................................. 128
4/35 EXTENT OF POURS ............................................................................................................ 128
SECTION 5 - ANCILLARY WORKS ..................................................................................... 129
5/1 PAVING DESCRIPTION.......................................................................................................... 129
5/2 PAVING BLOCKS .................................................................................................................... 129
5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS.................................................... 129
5/4 BLOCK LAYING REQUIREMENTS Laying Course........................................................ 129
5/5 KERBS DESCRIPTION ........................................................................................................... 130
5/6 MATERIALS AND MANUFACTURE OF KERBS ............................................................. 131
5/7 KERB LAYING .......................................................................................................................... 132
5/8 PAVEMENT MARKING DESCRIPTION .............................................................................. 133
5/9 MATERIALS FOR PAVEMENT MARKINGS ..................................................................... 133
5/10 APPLICATION OF THERMOPLASTIC ........................................................................... 134
5/11 PERFORMANCE REQUIREMENTS AND TESTING ................................................... 135
5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS ............... 135
5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..) .............................. 135
5/14 ROAD SIGNS, DESCRIPTION .......................................................................................... 136
AE7 PROJECT NO. 20010410 ix REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS ...................................................... 136

5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS .......................................... 136
5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR ................................................. 136
5/18 PAVEMENT REPAIRS ........................................................................................................ 136
5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS .......................................... 137
5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS ................. 139
5/21 METAL BEAM GUARD RAIL SAFETY FENCING ....................................................... 139
5/22 HEAVY DUTY CAT’S EYES (REFLECTIVE STUDS) .................................................. 140
5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS ..................................................... 140
5/24 REFLECTIVE STUDS MINIMUM MECHANICAL AND PHYSICAL PROPERTIES
140
5/25 REFLECTIVITY ..................................................................................................................... 140
5/26 INSTALLATION OF REFLECTIVE STUDS .................................................................... 140
5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION ........................................ 141
5/28 MATERIALS FOR STONE PITCHING ............................................................................. 141
5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING.................................. 141
5/30 GABIONS DESCRIPTION .................................................................................................. 142
5/31 CHAIN LINK FENCING ....................................................................................................... 142
5/32 STEEL AND METAL WORK .............................................................................................. 143
5/33 ALUMINIUM FOR PARAPETS .......................................................................................... 144
5/34 FASTENINGS FOR ALUMINIUM PARAPETS .............................................................. 144
5/35 PAINT AND OTHER PROTECTIVE COATINGS .......................................................... 144
5/36 WATERPROOFING MEMBRANES FOR STRUCTURES Waterproofing Bridge
Deck Slab - Type 1 .............................................................................................................................. 145
5/37 RUBBERISED BITUMEN EMULSION ............................................................................. 147
5/38 WATERSTOPS...................................................................................................................... 147
5/39 PREFORMED JOINT FILLERS ......................................................................................... 148
5/40 COLD APPLIED JOINT SEALANT .................................................................................. 148
5/41 BRIDGE DECK EXPANSION JOINT ............................................................................... 148
5/42 LOCKABLE MEDIAN BOLLARD ..................................................................................... 149
AE7 PROJECT NO. 20010410 x REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED

CONCRETE SURFACES .................................................................................................................... 149
5/44 GEOGRIDS ............................................................................................................................ 151
5/45 LITTER BIN ............................................................................................................................ 152
SECTION 6 - WORKS IN CONNECTION WITH SERVICES ................................................ 152
6/1 GENERAL REQUIREMENTS ................................................................................................ 152
6/2 EXCAVATION FOR EXISTING SERVICES ........................................................................ 155
6/3 SERVICES DUCTS .................................................................................................................. 156
6/4 EXCAVATION FOR DUCTS................................................................................................... 156
6/5 BEDDING AND LAYING OF DUCTS ................................................................................... 157
6/6 BACKFILLING OF TRENCHES ............................................................................................ 157
6/7 TESTING DUCTS ..................................................................................................................... 158
6/8 MARKING AND RECORDING OF DUCTS......................................................................... 158
6/9 ELECTRICITY WORKS - GENERAL ................................................................................... 159
6/10 ELECTRICITY WORKS - SUPPLY OF CABLES AND ACCESSORIES ................. 159
6/11 ELECTRICITY WORKS - INSTALLATION OF CABLES ............................................ 160
6/12 WATER WORKS - GENERAL ........................................................................................... 161
6/13 WATER WORKS - MATERIALS TO BE FURNISHED BY THE CONTRACTOR .. 161
6/14 WATER WORKS - STANDARDS ..................................................................................... 162
6/15 WATER WORKS - PIPES General ................................................................................... 162
6/16 WATER WORKS - GRP FITTINGS .................................................................................. 164
6/17 WATER WORKS - PHYSICAL AND CHEMICALREQUIREMENTS OF GRP
FITTINGS Chemical Requirements ................................................................................................ 165
6/18 WATER WORKS - VALVES ............................................................................................... 169
6/19 WATER WORK - MANHOLE COVERS AND FRAMES .............................................. 170
6/20 WATER WORKS - HANDLING AND STORAGE OF PIPES ...................................... 170
6/21 WATER WORKS - EXCAVATION LAYING AND JOINTING OF PIPES ................. 171
6/22 WORKS - PIPE ANCHOR AND THRUST BLOCKS .................................................... 173
6/23 WATER WORKS - CLEANING OF PIPELINES ............................................................ 173
6/24 WATER WORKS - TESTING PIPELINES ....................................................................... 174
AE7 PROJECT NO. 20010410 xi REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
6/25 WATER WORKS - FINAL CLEANING AND STERILISATION .................................. 175

6/26 WATER WORKS - CONNECTIONS TO EXISTING PIPELINE .................................. 175
6/27 WORKS FOR ETISALAT - GENERAL ............................................................................ 175
6/28 MATERIAL SUPPLIED BY ETISALAT ............................................................................ 176
6/29 INSTALLATION OF PVC DUCT........................................................................................ 176
6/30 WORKS FOR DUBAI MUNICIPALITY DRAINAGE DEPT. ........................................ 179
6/31 SETTING OUT ....................................................................................................................... 180
6/32 EXCAVATION FOR DRAINAGE PIPELINE ................................................................... 180
6/33 STORAGE AND HANDLING OF PIPES ......................................................................... 181
6/34 GRP (GLASS REINFORCED THERMOSETTING RESIN PIPES) ............................ 182
6/35 UPVC (THERMOPLASTIC PIPES) ................................................................................... 184
6/36 TRENCH WIDTHS FOR PIPELINES ................................................................................ 186
6/37 PIPELINES IN WIDE TRENCHES .................................................................................... 186
6/38 PIPELAYING .......................................................................................................................... 187
6/39 PIPELINE BEDDED ON TRENCH BOTTOM ................................................................. 188
6/40 PIPELINES IN CONCRETE CRADLES AND SURROUNDS ..................................... 188
6/41 PIPELINES ON GRANULAR BEDS ................................................................................. 189
6/42 PLACING SURROUNDS TO PIPELINES Group A Pipe Materials ......................... 191
6/43 COMPACTION OF PIPE SURROUNDS.......................................................................... 191
6/44 PIPELINES BELOW PERMANENT GROUND WATER LEVEL ................................ 192
6/45 BACKFILLING TRENCHES ............................................................................................... 192
6/46 DEFLECTION MEASUREMENTS ON GROUP B AND GROUP C PIPELINES .... 193
6/47 STANKS TO PIPELINES IN GRANULAR BEDDING .................................................. 194
6/48 THRUST AND ANCHOR BLOCKS TO PRESSURE PIPELINES ............................. 194
6/49 PIPES PROTRUDING FROM STRUCTURES, CONCRETE SURROUNDS AND
ANCHOR BLOCKS .............................................................................................................................. 195
6/50 PROTECTION OF PIPELINE COMPONENTS............................................................... 196
6/51 INDICATOR POSTS TO PRESSURE MAINS ................................................................ 197
6/52 ENCLOSING GRANULAR OR STONE SURROUND WITH FILTER FABRIC ...... 197
6/53 GROUTING OF PIPELINES ............................................................................................... 198
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DUBAI – UAE
6/54 PIPEWORK WITHIN STRUCTURES ............................................................................... 198

6/55 MANHOLES, CATCHPITS AND CHAMBERS .............................................................. 199
6/56 CATCHPIT/MANHOLE LININGS COVERS AND FRAMES ....................................... 201
6/57 GULLIES AND CONNECTIONS ....................................................................................... 205
6/58 HOUSE CONNECTION LATERALS ................................................................................ 205
6/59 TESTING AND CLEANING OF GRAVITY DRAINS ..................................................... 206
6/60 IRRIGATION WORKS - ASBESTOS CEMENT PRESSURE PIPE ........................... 207
6/61 IRRIGATION WORKS - GLASS REINFORCED PLASTIC (GRP) FITTINGS ........ 209
6/62 IRRIGATION WORKS - VALVES...................................................................................... 214
6/63 IRRIGATION WORKS - DISMANTLING JOINT AND FLANGE ADAPTOR ........... 217
6/64 IRRIGATION WORKS - DUCTILE IRON FITTINGS ..................................................... 218
6/65 IRRIGATION WORKS - HYDRAULIC TEST .................................................................. 218
6/66 IRRIGATION WORKS - DIELECTRIC COUPLINGS .................................................... 219
6/67 IRRIGATION WORKS - BOLTS, PIPE HANGERS AND SUPPORTS ..................... 219
6/68 IRRIGATION WORKS - NON-DISRUPTIVE ROAD CROSSING............................... 219
SECTION 7 – STREET LIGHTING ....................................................................................... 222
7/1 GENERAL .................................................................................................................................. 222
7/2 CABLES...................................................................................................................................... 224
7/2.1 Distribution Cables ......................................................................................................... 224
7/2.1.1 Construction........................................................................................................................ 224
7/2.1.2 Testing of Cables ............................................................................................................... 225
7/2.2 Earth Cable ........................................................................................................................ 225
7/2.2.1 Construction........................................................................................................................ 225
7/2.3 Cable Installation............................................................................................................. 227
7/2.3.1 General .................................................................................................................................. 227
7/2.3.2 Cables Laid Directly In The Ground ............................................................................. 227
7/2.3.2 Cables Laid In Ducts ......................................................................................................... 227
7/2.3.4 Cables Fixed To Steel Work Or Concrete Walls ....................................................... 228
7/2.3.5 Cables In Saddles .............................................................................................................. 228
7/2.3.6 Cable Support Spacing .................................................................................................... 228
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7/2.4 Termination of Cables ................................................................................................... 228

7/3 EARTHING ................................................................................................................................. 229
7/3.1 Earthing System .............................................................................................................. 229
7/3.2 Earth Electrode Terminations ..................................................................................... 229
7/4 TESTING AFTER INSTALLATION ....................................................................................... 230
7/4.1 Continuity of Conductors ............................................................................................. 230
7/4.2 Insulation Resistance Test ........................................................................................... 230
7/4.3 Earth Resistance Test .................................................................................................... 230
7/5 CONCRETE FOUNDATIONS FOR MASTS ....................................................................... 231
7/6 EXISTING STREET LIGHTING FACILITY .......................................................................... 231
7/7 SPECIFICATIONS FOR CONVENTIONAL (up to 16 Meters) ROAD LIGHTING
POLES (COLUMNS) & BRACKETS. ............................................................................................... 231
7/7.1 General: .............................................................................................................................. 231
7/7.2 Specific ............................................................................................................................... 231
7/7.3 Miscellaneous Requirements: ..................................................................................... 233
7/7.4 Design Information ......................................................................................................... 234
7/8 STREET LIGHTING LUMINARIES AND FLOOD LIGHTS ............................................. 234
7.8.1 General ............................................................................................................................... 234
7/8.2 Construction ..................................................................................................................... 235
7/8.3 Mechanical Requirements ............................................................................................ 236
7/8.4 Electrical Requirements ................................................................................................ 237
7/8.5 Photometrical Requirements: ..................................................................................... 238
7/8.6 Photometrical Performance Requirement ............................................................... 238
7/8.7 Documents to be submitted with the offer .............................................................. 239
7/8.8 Materials to be submitted with the offer .................................................................. 240
7/9 SPECIFICATIONS: ................................................................................................................... 240
LOW VOLTAGE FLEXIBLE POWER CABLES FOR CONVENTIONAL LIGHTING
COLUMNS & LUMINARIES ............................................................................................................... 240
7/9.1 General: .............................................................................................................................. 240
7/9.2 Conductors: ...................................................................................................................... 240
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7/9.3 Insulation ........................................................................................................................... 241

7/9.4 Sheath ................................................................................................................................. 241
7/10 SPECIFICATION FOR MID-HINGED HIGH MAST ....................................................... 241
7/10.1 Mid-Hinged Mast ................................................................................................................ 241
7/10.2 Luminaries Specification................................................................................................. 243
7/11 LOW VOLTAGE FLEXIBLE POWER CABLE FOR MID-HINGED HIGH MASTS. 243
7/11.1 General .................................................................................................................................. 243
7/11.2 Conductors .......................................................................................................................... 243
7/11.3 Insulation .............................................................................................................................. 244
7/11.4 Fillers & Binders ................................................................................................................ 244
7/11.5 Oversheath .......................................................................................................................... 244
7/11.6 Testing:.................................................................................................................................. 244
7/11.7 Cable Identification:........................................................................................................... 244
7/12 CROWN HIGH MAST .......................................................................................................... 244
7/12.1 Lighting Requirements .................................................................................................... 244
7/12.2 Flood Lighting Masts ........................................................................................................ 245
7/12.4 Electrical Equipment ....................................................................................................... 249
7/12.5 Warning Labels................................................................................................................... 249
7/12.6 Miscellaneous Requirements......................................................................................... 249
7/12.7 Design Information ............................................................................................................ 249
7/12.8 Test Certificate ................................................................................................................... 250
7/12.9 Important Note .................................................................................................................... 250
7/12.10 Flood Light Luminaries Specification................................................................... 251
7/13 AVIATION LIGHT ................................................................................................................. 251
7/14 LIGHTING BENEATH OVER-BRIDGES ......................................................................... 251
7/15 GANTRY SIGNS ILLUMINATION ..................................................................................... 251
7/15.1 Luminaries and Conduits ................................................................................................ 252
7/15.2 Control of Gantry Sign Luminaries .............................................................................. 252
7/15.3 Gantry Sign Lighting Requirements ............................................................................ 252
7/16 LAMPS .................................................................................................................................... 253
AE7 PROJECT NO. 20010410 xv REV 1 – ISSUED FOR CONSTRUCTION

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7/17 SPECIFICATION FOR STREET LIGHTING SERVICE CUTOUT .............................. 253

7/17.1 Application ........................................................................................................................... 253
7/17.2 Rating .................................................................................................................................... 254
7/17.3 Standard ............................................................................................................................... 254
7/17.4 Construction ....................................................................................................................... 254
7/18 FEEDER PILLAR SPECIFICATION ................................................................................. 255
7/18.1 General .................................................................................................................................. 255
7/18.2 Equipment Housing .......................................................................................................... 256
7/18.4 Contactor/AC.3 ................................................................................................................... 258
7/18.5 Circuit Breaker (Incoming MCCB) ................................................................................ 258
7/18.6 Wiring and Cabling ............................................................................................................ 259
7/18.7 Fuse and Fuse Base ......................................................................................................... 260
7/18.8 Cable Glands ....................................................................................................................... 260
7/18.9 Control System ................................................................................................................... 260
7/18.11 Testing ............................................................................................................................ 262
7/18.12 General ........................................................................................................................... 262
7/18.13 Specifications for Loop Detectors ......................................................................... 262
7/19 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI ..... 264
7/20 LIGHTING REQUIREMENT................................................................................................ 265
7/21 Tunnel / Under Bridge Lighting System ............................................................................. 266
SECTION 8 - CONCRETE PILE FOUNDATIONS ................................................................ 267
8/1 DESCRIPTION .......................................................................................................................... 267
8/2 MATERIALS............................................................................................................................... 267
8/3 GROUND CONDITIONS ......................................................................................................... 267
8/4 TOLERANCES .......................................................................................................................... 267
8/5 PILING METHOD AND PROGRAMME ............................................................................... 268
8/6 PILING RECORDS ................................................................................................................... 268
8/7 DAMAGE TO ADJACENT SERVICES AND STRUCTURES ......................................... 269
8/8 CONCRETE FOR PILES ......................................................................................................... 269
8/9 REINFORCEMENT FOR PILES ............................................................................................ 270
AE7 PROJECT NO. 20010410 xvi REV 1 – ISSUED FOR CONSTRUCTION

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8/10 BORING FOR PILES ........................................................................................................... 271

8/11 DRILLING FLUID .................................................................................................................. 273
8/12 PLACING CONCRETE ........................................................................................................ 274
8/13 EXTRACTION OF CASING ................................................................................................ 277
8/14 TEMPORARY BACKFILLING ........................................................................................... 279
8/15 DISPOSAL OF EXCAVATED MATERIAL ...................................................................... 279
8/16 CUTTING OFF PILE HEADS ............................................................................................. 279
8/17 INTEGRITY TESTING OF PILES ...................................................................................... 279
8/18 LOADING TESTS ................................................................................................................. 280
8/19 FAILURE OF PILE ................................................................................................................ 281
8/20 RECTIFICATION OF FAILURE ......................................................................................... 282
8/21 PROTECTION OF PILING FROM CHEMICAL ATTACK ............................................ 282
8/22 CLEARANCE OF WORKS ................................................................................................. 282
APPENDIX “A” .......................................................................................................................... 283
APPENDIX “A1” ........................................................................................................................ 284
CONTINUATION OF APPENDIX “A1” ....................................................................................... 286
APPENDIX “A2” ........................................................................................................................ 288
LABORATORY TESTS WHICH MAY BE CARRIED OUT BY INDEPENDENT
LABORATORIES ...................................................................................................................... 289
APPENDIX C 291
EQUIPMENT FOR THE ENGINEER’S OFFICE ....................................................................... 291
MISCELLANEOUS TESTING EQUIPMENT TO BE PROVIDED FOR THE USE OF THE
ENGINEER 292
AE7 PROJECT NO. 20010410 xvii REV 1 – ISSUED FOR CONSTRUCTION

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SECTION 1 - GENERAL
1/1 SITE ESTABLISHMENT
1/1.1 The Contractor shall provide sites for the plant and workshops necessary for the
construction of the Works and shall pay any rents, easements and license fees
levied in connection therewith. Client / Owner formal approval to the site for the
Contractor’s plant and workshop must be received prior to occupying the
proposed site.
1/1.2 Client / Owner will not provide any area of land free of charge for the erection of
the offices for the Engineer and the Contractor. Site offices and compound, etc
for the Engineer and the Contractor shall be erected on a site provided by the
Contractor at his own cost. The area of the land shall be approved by the
Engineer with consent of the Employer prior of the erection of the Engineer’s
offices. No Contractors plant and workshops will be permitted within this
compound. It is the Contractor’s responsibility to obtain all necessary No
Objection Certificate for the occupation of the sites.
1/1.3 The Contractor shall construct suitable entry and exit roads to and within the
compound and provide a covered parking area as specified in sections 015000
and 015200 of Part A-General Requirements Volume. The Contractor shall take
all necessary precautions to avoid stormwater flooding within the compound
and accesses.
1/1.4 The Engineer’s office shall be erected and fully equipped to the satisfaction of the
Engineer.
1/1.5 Within one month after the Completion of the Whole of the Works and in
accordance with the provisions of Clause 1/2.1 the whole area of the compound
shall be reinstated to its original condition and all rubbish and refuse removed.
1/1.6 The Contractor’s proposed access routes to and within the site shall be provided
and maintained as agreed with the Engineer. The Engineer may at any time
withdraw his approval for the use of any route and may order such widening,
strengthening or repair work as he considers necessary.
1/1.7 The Contractor shall provide a watchman and other services to engineer on its
own cost.
1/2 SITE OFFICE FOR THE ENGINEER
1/2.1 The site offices for the Engineer shall comply with the requirements included in
sections 015200 of Part A-General Requirements Volume. The offices shall be
available in full working order to the satisfaction of the Engineer within the period
stipulated to commence the works in the Tender (Clause 4) and remain so until
one month after the Completion of the Whole of the Works.
1/2.2 The Contractor shall retain on site for the exclusive use of the Engineer all codes
and standards referred to in the Specification which shall remain in the custody of
the Engineer for his exclusive use until completion of the whole of the works but
shall remain the property of the Contractor.
AE7 PROJECT NO. 20010410 1
VOLUME 2 – PART I REV 1 – ISSUED FOR CONSTRUCTION
GENERAL SPECIFICATIONS DATE OF ISSUE: 16 JUNE, 2022
DUBAI – UAE
1/2.3 All Keys for the Engineer’s site offices shall be held by the Engineer until such
offices are removed.
1/2.4 The Contractor shall provide the Engineer and his staff with daily cleaning
attendance and one full time for serving refreshments, car cleaning etc.
The Contractor shall provide a watchman and other services to engineer on its
own cost.
1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR
1/3.1 The Contractor shall make provision for installation, maintenance and removal at
the completion of the works, of his offices, sheds, and shelters. He shall provide
and maintain at his own cost sanitary facilities on site, first aid and fire fighting
equipment, drinking water facilities, electricity and telephone for the duration of
the Contract.
1/3.2 The Contractor shall be responsible for the security of the site and the safety of
public and adjoining property and shall be liable for any claims arising from loss
or damage suffered. He shall employ watchmen for this purpose.
1/3.3 All temporary accommodation shall be maintained in an efficient condition during

the period of the Contract and shall be available for inspection by the
Government Medical Officer of Health. The Contractor must comply immediately
with any instruction given by the Medical Officer for cleaning, disinfestations and
maintenance of any building to a hygienic and sanitary condition.
1/3.4 The Contractor shall confine his apparatus, the storage of materials and the
operations of his workmen to the limits indicated by law, ordinances, permits or
direction of the Engineer. The Contractor shall erect temporary fences as
required by the Engineer. The site boundary lines shall be to the approval of the
Engineer.
1/3.5 The Contractor shall provide and maintain water, electricity and power required
for the works including that required by the Sub-Contractors. Pay all charges and
bear all costs for the necessary temporary installation including pipework, pumps,
water tankers, storage tanks, generating equipment, etc. and remove on
completion and make good all work disturbed.
1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR
1/4.1 The Contractor shall make provision for the installation, maintenance up to the
completion of the works and removal of fully equipped workshops and stores.
The Contractor shall also provide all necessary construction plant, equipment
and tools necessary for the proper execution of the works. Plant shall include,
but not be limited to, concrete and asphalt manufacturing plant, mobile plant and
sundry equipment required for any particular trade necessary for the execution
and completion of the works. All plant and equipment required for the Contract is
subject to the approval of the Engineer.

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1/5 CONTRACTOR’S SITE ORGANISATION
1/5.1 The Contractor shall perform the setting out of the works as described in the
Drawings and Specification.
1/5.2 The Contractor shall provide the Engineer with all necessary assistance in
checking the setting out of the works and interpreting any information used by the
Contractor for this purpose including the supply of a minimum 2 chainmen as and
when required by the Engineer.
1/5.3 The Contractor shall also provide the Engineer with similar assistance in carrying
out additional surveying works should these be found necessary for the proper
execution of the works.
1/5.4 The Contractor shall also provide all assistance as required by the Engineer for
the measurement of the works for monthly valuation and monthly progress report
for the final payment certificate and also for recording the progress of the works.
1/5.5 The Contractor shall be responsible for all follow up and co-ordination with all
service authorities (Electricity, Water, Drainage, Street Lighting, Telephone,
Horticulture, etc.).
1/5.6 The Contractor shall provide subject to the approval of the Engineer, qualified
and sufficient number of the Engineers, Quantity Surveyors, Supervisors,
Employees and skilled and non-skilled workmen for his supervision of the works
and site administration.
1/5.7 The Contractor shall provide all unskilled labour and all necessary tools as
directed by the Engineer.
1/5.8 If at any time before the commencement or during the progress of the work, the
Engineer decides that for the proper execution of a specified part of the works,
shop drawings are necessary, these drawings shall be prepared by the
Contractor and submitted to the Engineer for approval according to sub-section
1/21. Such drawings must be provided at least 14 days prior to the
commencement of the relevant work on site.
The Contractor shall not proceed with the above mentioned work until these shop
drawings are approved by the Engineer. The Contractor shall not be entitled to
any extra payment or extension of time for the preparation of the shop drawings.
1/6 SURVEYING EQUIPMENT
1/6.1 The Contractor shall supply and maintain in full working order during the progress
of the works the surveying equipment specified in Appendix-C herein, and the
supply of expendable surveying material as required from time to time in
connection with the works. All equipment specified shall be new and shall remain
in the custody of the Engineer for his exclusive use until Completion of the Whole
of the Works but shall remain the property of the Contractor.

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1/7 LABORATORY TESTING
1/7.1 Appendix “A1”
Laboratory Testing
Testing of all materials and completed work shall be carried out in accordance with the
attached appendices and clauses:-
1/7.1.1. Dubai Municipality (DM) – Dubai Central Laboratory Department

(DCLD) in accordance with Appendix “A1”.
1/7.1.2. Independent Laboratory in accordance with Appendix “A2”.
1/7.1.3. Any materials and products which required mandatory certification

as per DM and RTA regulations shall not be used certified by DM
DCL or any accredited certification body approved by Dubai
MunIcipality – DCL or DAC.
Testing at Dubai Municipality (DM) –

Dubai Central Laboratory Department (DCLD)
1/7.1.4. All transport of personnel and materials on site and to/from the
DCL shall be borne by the Contractor. Suitable approved transport
with driver shall be maintained for this specific use by the
Contractor.
1/7.1.5. The contractor shall pay for all the tests carried out by the DCL.
1/7.1.6. Any testing, which is required under the contract, that cannot be
carried out by DCL shall be carried out at Contractor’s expense at
an Independent Laboratory in accordance with Appendix “A2”.
Copy of such sampling and testing reports shall be forwarded to
the DCL and RTA on monthly basis.
1/7.1.7. The testing of the works by the DCL shall in no way absolves the
Contractor from his responsibilities to carry out his own job control
testing of the quality of his work and materials used.
1/7.1.8. Authorized representative of the Consultant and Contractor shall

be permitted to witness the testing carried out by DCL.
1/7.1.9. DCL will not be held liable for interpreting test data, since this will be the
responsibility of the Consultant.
1/7.1.10. All Sampling for such test shall be carried out by the Consultant’s
Representative and labeled as per relevant standard sampling
requirements and submitted by the Consultant to DCL.
1/7.1.11. The Consultant shall submit to DCL Monthly Laboratory Testing

Programs. The program shall details the specific test requirement
for the coming month which includes the type, number and
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approximate date that testing will required.
1/7.1.12. The contractor must make due allowance for the time required for
any testing within his planning and program.
1/7.1.13. Minimum twenty four (24) hours notice shall be given to DCL
before any test are scheduled to be carried out.
1/7.1.14. The consultant shall inform DCL and DM Department concerned

of all failed test results along with his course of action included in
the monthly and final material report.
1/7.2 Appendix “A2”
Testing at an Independent Laboratory
1/7.2.1. Any testing which I required under the contract and cannot be
carried out at DCL, may be conducted at the Contractor’s expense
at an approved Independent Laboratory, provided this laboratory
meets the following requirements:
1/7.2.2. Independent laboratories that operate in Dubai Emirate shall meet

all the requirements of DM rules, regulations, and DAC
accreditation requirements.
1/7.2.3. Independent laboratories that operate outside Dubai Emirate shall

be accredited to one of the National Accreditation Systems for
laboratories such as DAC, NAMAS, NATA, etc. The Contractor
shall forward a copy of the accreditation certificate to DCL for
approval prior to approaching such laboratories for testing
services.
1/7.2.4. All sampling for such test shall be carried out by the Consultant’s
Representative and labeled as per relevant standard sampling
requirements and submitted by the Consultant to the independent
laboratory along with sampling reports.
1/7.2.5. Representatives of the Consultant and the Contractor shall be

permitted to witness the testing carried out by the independent
laboratory.
1/7.2.6. The testing of the works by the independent laboratory shall in no

way absolves the Contractor from his responsibilities to carry out
his won job control testing of the quality of his work and the
materials used according to the contractor specifications.
1/7.2.7. The Consultant shall inform DCL and RTA of all failed test results
along with his course of action included in monthly and final
material reports.

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1/8 PROGRAMME OF WORKS
1/8.1 The Contractor shall submit to the Engineer for approval a Critical Path
Programme and other supporting documentation of the works within the time
stipulated in the Conditions of Contract together with details of equipment,
procedures and method of work which the Contractor intends to utilize and to
follow. Due allowance must be made within the Programme for: (I) Traffic detour
planning and phasing (ii) Maintenance of accesses to all the residential,
recreational, business and institutional premises affected by the works. (iii) Any
restraints and restrictions imposed by Service Authorities or the Police. (vi)
Activities of other Contractors (v) The pavement wearing course and road
marking to be laid at such a time to avoid damage by other construction activities.
1/8.2 The Contractor shall in accordance with the Conditions of Contract, submit a
comprehensive plant schedule which shall include the proposed dates of arrival or
establishment on site for each major item. Plant shall not be brought to or removed
from site without prior approval of the Engineer.
1/8.3 In addition to the Critical Path Programme, the Contractor shall if required by the
Engineer provide a detailed bar chart schedule to be used by the Engineer for
monitoring the progress of works.
Furthermore, the contractor shall submit to the Engineer a daily work programme
showing the activities to be undertaken for the day including laboratory tests and
survey checks at least 18 hours in advance.
1/8.4 A monthly progress report shall be submitted to DCL through RTA Roads
Department.
1/8.5 The materials report shall contain monthly summaries on testing, test results,
statistical summary of test results and list of failed tests of the tested materials.
In addition, it shall contain list of failed test and action taken on non compliance
results.
1/8.6 The frequency of tests details shall also be provided against required frequency.
1/9 K SITE, SETTING OUT AND CROSS-SECTIONS
1/9.1 Areas will be handed over to the contractor in parts to comply with the priority to suit
the construction program and the contractor has to take the phasing of the work into
consideration without any additional entitlement whatsoever.
1/9.2 The Contractor is responsible for all the setting out of line and levels of the Works and
shall employ adequate qualified staff to carry this out.
1/9.3 Before the commencement of the Works the Contractor will be supplied with the
information necessary to establish the lines and levels of the Works. The

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Engineer has shown on the Drawings all the survey markers established but can
give no warranty for their existence at the start of the Contract nor will accept
responsibility for replacing any survey markers found to be missing. Where
survey markers have been established by the Engineer the Contractor shall
check the accuracy of their position and level and shall immediately notify the
Engineer of any discrepancies.
1/9.4 All setting out throughout the Works must be related to the Dubai Municipality Datum
Levels and Survey Stations and values of Dubai Municipality Bench Marks and
survey stations will be handed over by the Engineer and the Roads & Transport
Authority to the Contractor. Any Temporary Bench Mark (T.B.M.) to be fixed on
the site shall be tied into the Dubai Municipality Datum.
1/9.5 The Contractor shall, as soon as practicable, supply the Engineer with records in
approved form relating to all reference pegs and bench marks and shall keep
such records up to date by formal notice to the Engineer.
1/9.6 All survey reference pegs shall be carefully preserved except where construction
requires their removal, and before such removal the approval of the Engineer
shall be obtained.
1/9.7 Before commencing work on any section of the Works, the Contractor shall
survey and level the original ground surface and shall prepare plans and cross-
sections accordingly. These shall, when finally agreed, be signed by the
Engineer and Contractor as truly representing the configuration of the areas in
question before the commencement of the Work. The preparation of the cross-
section drawings shall comply with Clause 1/21.
1/9.8 All setting out shall be approved in writing by the Engineer before work may
commence. The centrelines are to be checked by the Dubai Municipality Survey
Section and approved by the Engineer.
1/9.9 When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of certain
work. The templates will be in accordance with the specifications and drawings
where such are provided. All templates must be approved and shall be
maintained in good order to provide the section required for the entire works.
Templates may be checked from time and any deficiencies noted shall be
rectified immediately. The Contractor shall also supply straight edges and lines
when required to control the work.
1/9.10 The Engineer will, if he deems it necessary, revise the line or grade and will
require the Contractor to adjust the stake-out accordingly.
1/9.11 Where directed by the Engineer, the Contractor shall take such levels and
dimensions as may be required for the purpose of measurement prior to
disturbance of the ground. These shall be agreed between the Contractor and
the Engineer before any surface is disturbed or covered up.
1/9.12 Any change of the ground elevation resulting from compaction or other works
provided for in the Contract Documents shall be deemed included in such works
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and paid for within the tender prices listed in the Bill of Quantities. The
Contractor shall consequently in no way be entitled to any additional payment or
claim whatsoever.
1/10 PROJECT SIGN BOARDS
1/10.1 The Contractor shall provide and erect, in the location to be approved by the
Roads & Transport Authority and the Engineer, the number of Project Sign
boards as described in the Contract.
1/10.2 They shall be signwritten by a skilled signwriter to show the details described in
the Contract plus any other relevant details to the approval of the Roads &
Transport Authority and the Engineer.
1/10.3 Within one month of completion of the Works the Project Sign Boards shall be
dismantled and removed by the Contractor.
1/11 PROJECT PHOTOGRAPHS
1/11.1 The Contractor shall arrange to have monthly record photographs of the Works
taken. These photographs shall cover such extent of the Works as the Engineer
shall direct. The days upon which the photographs are taken shall be decided by
the Engineer.
1/11.2 The Contractor shall provide the Engineer with one set of the monthly progress
photographs with dates imprinted on it.
One set shall comprise the following:-
- One colour negative of each photograph for an anticipated average

maximum of fifty exposures per month.
- Eight colour prints (294 x 210 mm) off each of a maximum of twenty of the
negatives as selected by the Engineer.
1/11.3 The prints are to be processed by an approved professional and shall be in

colour on heavy weight paper with matt finish. A label giving a brief description
shall be affixed in the bottom right-hand corner of each photograph. Each
photograph shall be provided in an approved clear plastic cover for binding.
1/11.4 The Copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of exposure.
The photographs shall not be used for any other purpose whatsoever without the
Employer’s approval.
1/11.5 Monthly Progress Report as well as the Final Materials Report both containing
the prescribed Summary of Testing Frequency Forms shall be submitted to DCL
for review in accordance with Memo Numbers 8/2004 dated 22/02/2004 issued
by the Directorate of Roads Department and 812/02/02/1/630 dated 09/06/2004
issued by the Directorate of the DCLD.

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1/12 QUALITY OF MATERIALS AND SUPPLY
1.12.1 If such specified materials or equipment is not available from Dubai Emirates
market then, any other alternative suitable source can be submitted by the
contractor for the engineer and RTA approval.
1/12.2 Any materials and product which required mandatory certification as per DM and
RTA regulations shall not be use unless certified by DM – DCL or any accredited
certification body approved by Dubai Municipality – DCL or DAC.
1/12.3 Materials delivered to the Site for the purpose of the Works, shall be
accompanied by a ‘Certificate of Guarantee” signed by the authorised
representative of the manufacturer. Such Certificate shall state that the materials
specifications and test results are in compliance with the specified requirement of
the pertinent designations of the most recent edition of ASTM or any other
approved equivalent National Standard unless otherwise directed. Falsification
of such Certificates, Materials, Specifications or Test Results shall be just cause
for the rejection of the materials.
1/12.4 The borrow pit location if not designated in the Contract Documents shall be
approved by the Roads & Transport Authority. The Contractor shall exercise a
continuous quality control upon the extracted material to confirm its suitability for
use.
No material shall be supplied to the site before the Engineer’s approval of the
type of equipment which the Contractor intends to use in the borrow pit, and for
the method of work.
1/12.5 The Contractor shall select rock quarries and shall submit laboratory tested and
accepted samples, within sufficient time before their use, in order for the
Engineer to determine their conformity with the related specifications. The
Contractor shall exercise a continuous quality control upon the extracted material
to confirm its continued suitability for use.
No material shall be supplied on the site before the Engineer’s approval of the
type of equipment which the Contractor intends to use in the quarry, and for the
method of work.
1/12.6 The Engineer’s acceptance of the materials does not relieve the Contractor of his
total responsibility to carry on with additional investigations in order to obtain and
supply during the progress of the works uniform material conforming to the
Specifications.
1/12.7 The Contractor shall be responsible for payment of royalties, if any, arising due to
obtaining of materials for use in the Works. No separate payment will be made
by the Employer as a royalty for materials for use in the Works.
1/12.8 Wherever in the Specifications tests on materials, tests on completed work and
construction control tests are called for or implied, they shall be carried out
according to, and the materials shall comply with, the requirements of the
Specifications (latest edition) with the priority of latest edition of standard shall be
as follows:-

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a. UAE & DM Standards

b. International Standard such as ISO
c. National Standard such as BSI & DIN
d. Others as stated in this Specification such as ASTM, etc.
The Contractor shall provide for the exclusive use of the Engineer copies of each
and any codes of practice, international standards, test methods etc. relevant to
the works.
In addition the Contractor shall retain on site for the use of the Engineer all
manufacturers literature relating to all the products to be used in the works,
current BSI Handbook No. 3 and the Manufacturers installations instructions for
all relevant products, materials components and installations.
1/12.9 Where specific material or equipment is referred to in the Contract, it is intended

only to indicate the acceptable standard. The Contractor may offer alternative
materials or equipment of an equal standard. The Contractor must submit a
statement listing proposed alternatives together with such information and
samples as the Engineer may require to satisfy himself that the alternatives
offered are of equal quality to the items specified. The cost of submitting such
samples will be borne by the Contractor.
1/12.10 The Contractor will be required to produce documentary evidence that all
materials which are not available in the local market and which have to be
imported have been ordered sufficiently in advance to ensure that no delay to the
works occur. As soon as orders have been placed, copies of such orders shall
be submitted to the Engineer. The Contractor shall be responsible for delays as
a consequence of late ordering.
1/12.11 Should the Engineer discover in the Works any materials other than those
approved, he may order their removal from the site and replacement with
approved materials at no cost to the Employer and in compliance with Standard
Specifications.
1/12.12 All specified materials incorporated in the Works shall be fixed or applied strictly
in accordance with the manufacturer’s printed instructions.
1/12.13 The Bills of Quantities shall NOT be used only as a basis for ordering materials,
preparing the program of works and the Contractor is entirely responsible for
assessing the quantities of materials.
1/12.14 All materials or manufactured items shall be carefully loaded, transported,

unloaded and stored in an approved manner, protected from damage and
exposure to weather or dampness during transit and after delivery to the Site.
Damaged material or manufactured items damaged during and after fixing in
position shall be removed, repaired or replaced by and at the Contractor’s
expense.
1/12.15 The Contractor shall erect and maintain ample temporary and weather proof
sheds for proper storage and protection of his own and sub-contractor’s
materials. Cement and other perishable material shall have floors raised 150mm
off the ground. The Contractor shall clear away on completion and make good all
areas disturbed.

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1/12.16 Prior to ordering or delivering any material or manufactured items to the site, the
name and address of the supplier(s) and, where required by the Engineer,
adequate samples, sample schedules and manufacturer’s certificates of all the
materials and goods to be used in the Works shall be submitted to the Engineer
for approval and in the case of rejection further samples shall be submitted until
such are approved. The cost of submitting all such samples shall be borne by
the Contractor. All products/materials shall have approved National Certificate of
conformance similar to B.S.I. Quality Kite Mark or National Agreement Certificate
such as BBA for non-standard products and systems to be approved by the
Engineer and shall be verified by DCLD.
1/12.17 If judged necessary by the Engineer, the samples shall be tested for compliance
at DCL in accordance with Appendix A1 or in a laboratory accredited in
accordance with Appendix A2 of this Specification and Dubai Municipality
Administrative Decision No. 160:2000.
1/12.18 All materials and equipment specified in the Contract Documents which are to
be incorporated into the Works must be obtained from or through a Dubai
Emirate Supplier and or Manufacturer who must be registered and licensed by
the Dubai Municipality. If such specified materials or equipment is not available
from the Dubai Emirate then any source is acceptable.
1/12.19 Approval of a source does not mean that all the materials in the source is
approved. No source of supply shall be changed without Engineer's prior
approval.
Approved samples shall be retained on site for comparison with products and
materials used in the works and shall be removed when no longer required by the
Engineer.
1/12.20 Any materials and products which required mandatory certification as per DM
and RTA regulations shall not be used unless certified by Dubai Municipality -
Dubai Central Laboratory or any accredited certification body approved by DM-
DCL or DAC.
1/13 APPROVAL BY THE ENGINEER
1/13.1 The Contractor shall give adequate notice in writing to the Engineer requesting
inspection and approval of various stages of construction of the Works. Unless
stated otherwise in the Contract a notice period of not less than four hours of
normal working time shall be given before the work is ready for final inspection.
The Contractor shall supply printed forms for this purpose. Further stages of
work shall not proceed until the Contractor has received the written approval of
the Engineer.
1/13.2 The Contractor shall give the Engineer details of the source of materials to be
incorporated into the Works. Reasonable notice must be given by the Contractor
to allow the Engineer to carry out such tests and enquiries as may be appropriate
before giving approval.
1/13.3 When items to be incorporated into the Works are to be manufactured or

fabricated off-site the Contractor shall give the Engineer not less than seven days
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notice in writing of the commencement of such work.
1/13.4 Where the approval of the Engineer is required under this specification, such
approval shall not in any way relieve the Contractor of his duties or
responsibilities under the Contract.
1/14 EXISTING SERVICES AND SERVICE DIVERSIONS
1/14.1 The positions of all public and privately owned services shown on the drawings
have been based on the records of various utilities and Public Authorities and
must be regarded as approximate. The Contractor must verify this information
and satisfy himself as to the exact nature and position of all such apparatus. The
Engineer does not guarantee the accuracy of the information given on the
drawings and no warranty is given or implied.
1/14.2 The Contractor shall take into account the current laws regarding the safety of
service lines, together with any amendment or additions thereto. The Contractor
shall include in his tender for anything in these laws considered to have a
monetary value.
1/14.3 The cost of locating or verifying the location of existing services, liaison with the
various Service Authorities and complying with the above shall be borne by the
Contractor unless provided for elsewhere in the Contract.
1/14.4 Before opening the ground for any purpose, the Contractor must notify all
concerned parties by issue of formal “Notice of intent” and must obtain
information by Formal Notice regarding the location of all services. The
Complete responsibility for obtaining this information rests with the Contractor.
1/14.5 “Notice of Intent” shall be circulated to all concerned parties including the
following:-
Roads & Transport Authority Roads Department
Dubai Electricity and Water Authority
Emirates Telecommunication Corporation
Roads & Transport Authority Street Lighting Section
Dubai Municipality Drainage and Irrigation Department
Roads & Transport Authority Horticulture Section
Consultants for Water, Electricity and Drainage Departments.
1/14.6 Drawings and notices shall be sent in duplicate one of which shall be retained by
the addressee and the other returned to the sender duly marked to show
underground services. “Notice of Intent” will be given 14 (fourteen) days in
advance of the proposed Works. In the event that the work is not started within 8
(eight) weeks of the date of the “Notice of Intent”, it will be deemed to have
lapsed. A further Notice of Intent will then be submitted.
1/14.7 The Contractor shall furnish copies of the above Notices of Intent to the
Engineer. The Contractor shall acquaint himself with the position of all existing
services and must obtain clearance from the relevant authority before
commencing any work in a particular area. Written evidence of such clearance
shall be provided to the Engineer by the Contractor. If any underground service
is encountered unexpectedly, excavation shall cease, and the Engineer’s
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Representative shall be notified immediately. Emergency work, as necessary,

shall be put in hand without delay and without prejudice to the indemnity of the
Employer.
1/14.8 The Contractor shall prepare records and CADD drawings showing position,
levels and types of each existing service including manholes, joint boxes and
inspection chambers etc. All record drawings shall be prepared using a Computer
Aided Drafting program approved by the Engineer.
Diskettes containing the drawings data to be supplied to the Engineer in the

approved digital format for incorporation in the final record drawings.
1/14.9 The Contractor shall take any and all measures reasonably required by any
public or concerned Authority for the support and full protection of all mains,
pipes, cables and other apparatus during the progress of the Works, and shall
construct and provide to the satisfaction of the Authority concerned, all works
necessary for the prevention of damage or interruption of services.
If in the execution of the Works, by reason of any subsidence caused by, or any
act of neglect or default of the Contractor, any damage to any apparatus or any
interruption of, or delay to the provision of any service is caused, the Contractor
shall report it to the Engineer immediately and bear and pay the cost reasonably
incurred by the Authority concerned in making good such damage and shall
make full compensation to the Authority for any loss, sustained by reason of such
interruption or delay.
1/14.10The Contractor shall familiarise himself and all his employees with the dangers of
working in or near live sewers and at sewage treatment works; in particular the
risks of physical injury from the exposure to poisonous gases, of bacterial
infection from contact with sewage and of exposure to poisonous gases, which
may be given off by the sewage. Hydrogen sulphide and methane are prevalent
in the sewers in Dubai, and can exist in excavations where septic sewage from
collection tanks is allowed to seep into groundwaters. In the context of this
clause the term sewer includes irrigation mains and drains carrying ground water
and/or stormwater.
1/14.11The Contractor shall, at all times during the progress of the Works, afford
facilities to properly accredited agents of any Public or Utility Authority for access
to all or any of their apparatus situated in or under the site, as may be necessary
for inspecting, reporting, maintaining, removing, renewing or altering such
apparatus in connection with the construction of the Works or any other purpose
whatsoever.
1/14.12The Contractor will be fully responsible for ensuring observance of the above
regulations of his sub-contractors.
1/14.13Where any utility or service works are to be constructed under a separate

contract by the Employer within the Site and concurrent with the execution of the
Works, the Contractor shall cooperate with the other Contractor and shall
coordinate his construction operations to avoid interference with the other
Contractor’s operations.

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1/14.14The Contractor shall prepare and furnish all necessary shop drawings of the
works required to complete the adjustment of apparatus to finished grade or
specified level. The drawings must be approved by the concerned Utility
Authorities and the Engineer prior to commencement of any work at the site.
Measurement shall be for each utility facility adjusted to finish grade or level
approved by the Engineer.
The Contractor must allow in his rates for services installations for the production
of combined service drawings covering the whole of the Contract area. The
drawings must show both existing services located by trial pits and coordinated
by survey and all proposed new services. The drawings are to identify interface
problems prior to production of working drawings.
Drawings must be prepared using a Computer Aided Drafting program approved

by the Engineer, Diskettes containing the drawing data of the original service
locations and those containing the drawing data of the relocated original services
and of the new service locations together with their protection area to be supplied
to the Engineer for incorporation in the final record drawings in the approved
digital format.
1/14.15The Contractor shall prepare CADD shop drawings for utility protection work and
obtain the approval of the appropriate Authority and Engineer before
commencing with construction.
1/14.16The Contractor shall relocate certain utilities to service reservation areas as

specified in the Contract. This work may only include the construction of
necessary protective housing (e.g. box culverts, slabs, concrete encased sleeves
etc.) in the service reservation areas for utility lines to be relocated. Or this work
may include necessary protective housing as described above and, in addition
the relocation of specific utility lines to the service reservation areas. In both
cases the Contractor shall complete the necessary survey to establish the lines
and levels, prepare shop drawings and submit them to the Engineer for his
review and approval. The Contractor shall obtain approval from the concerned
Authority before commencing this work.
1/14.17Any public or private service for water, electricity, drainage, etc. affected by the
Works shall not be interrupted without the written permission of the Engineer.
Such permission will be withheld until suitable approved permanent or temporary
alternative service have been provided by the Contractor or by the owner of the
utility or his agents.
1/14.18For temporary traffic diversions as may be required for the construction of road
crossings, full liaison with the Roads & Transport Authority and Dubai Police shall
be required and the requirements of Clause 1/16 and 1/17 complied with.
1/14.19Due allowance must be given by the Contractor when preparing the Programme
of Works to comply with this Clause 1/14.

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1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND PROPERTIES
1/15.1 The Contractor shall take all necessary precautions to protect buildings, fences,
roads, passages, culverts and other apparatus if found and he shall not demolish
or remove any of these works except according to specific instructions by the
Engineer. In the case of existence of buildings, ditches, excavations or any other
work adjacent to the Site, the Contractor shall make necessary arrangements
and take precautions for their support and protection at his own expense.
1/15.2 The responsibility lies with the Contractor for the repair and return to the previous
condition of items to which the Contractor’s works have caused damage.
1/15.3 The Contractor shall not be permitted to use earth works of already executed
roads.
1/15.4 It is the Contractor’s responsibility to ensure that continuous access is maintained

to all properties adjacent to the works throughout the Contract period to the
Engineer’s satisfaction.
1/15.5 In pursuance of his obligations under the Conditions of Contract, the Contractor
shall whenever required or directed by the Engineer cover up and protect the
works from weather and from damage by his own or other workmen performing
subsequent operations. He shall provide all necessary dust sheets, hoardings,
barriers and guard rails, waterways, etc. and clear away same at completion.
The Contractor shall take all reasonable and proper steps for the protection of all
places on or about the works which may be dangerous to his workmen or any
other persons or to traffic. The Contractor shall provide and maintain warning
signs, warning lamps and barricades as necessary in all such places.
1/15.6 The Contractor shall furnish and place fresh or brackish water at his own
expense for dust control when and where construction operations require it and
at locations where specifically directed by the Engineer due to conditions created
by the Contractor or his construction operations.
1/15.7 Existing roads, accesses to houses, buildings, etc., and any new roads, whether
part of the Works or not, which are being used by the Contractor’s constructional
traffic shall be kept clean and clear of all dirt, mud and material dropped from
vehicles or from tyres and any damage caused shall be repaired at the
Contractor’s expense. The Contractor shall provide, maintain and use as
directed by the Engineer, suitable equipment including mechanical road
sweepers solely for this purpose throughout the course of the works.
1/16 TRAFFIC MANAGEMENT, SAFETY AND CONTROL
1/16.1 The Contractor shall provide, erect and maintain such traffic signs, lamps,
barriers, traffic control signals, lighting units, road markings and other such
measures as may be necessary for the construction of the works.
1/16.2 The Contractor shall, after consultation with Dubai Police Traffic Department,
prepare a scheme of traffic management for carrying out the works. Such
proposals shall be submitted to the Engineer for his written approval not less than
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30 days before the planned implementation of each proposal. Prior to

commencing any individual diversion or traffic control the Contractor shall provide
to the Engineer details of his overall scheme of traffic control or diversions for the
entire project giving his programme of diversions etc. All diversions must be
approved by the Traffic Police and Roads & Transport Authority Roads
Department prior to implementation.
1/16.3 The Contractor shall not commence any work which affects the public highway
until all approved traffic safety measures conforming to DM Standards are fully
operational to the satisfaction of the Engineer.
1/16.4 Temporary traffic signs conforming to DM Standards and approved by Roads &
Transport Authority Roads Department shall be of good design and sound
construction using reflective sign face material. They shall have a minimum face
dimension of 900mm.
1/16.5 The Contractor shall maintain all signs, lamps, barriers, traffic control signals and
road markings in a clean and legible condition and shall position, re-position,
cover or remove them as required by the progress of the works.
1/16.6 The Contractor shall be entirely responsible for complying with the requirements
of and coordinating with the Dubai Police Traffic Department and Roads &
Transport Authority Roads Department in relation to the above.
1/17 TEMPORARY DIVERSION OF TRAFFIC
1/17.1 The Contractor shall construct temporary diversion ways wherever the
construction of the works will interrupt existing public or private roads or rights of
way.
1/17.2 Diversions must be constructed in advance of any interference with the existing
right of way and the subsequent traffic management, safety and control must be
in accordance with Clause 1/16 and as directed by the Engineer.
1/18 FIRE PRECAUTIONS
1/18.1 Adequate precautions shall be taken against fire throughout all the Contract’s
and Sub-Contractor’s operations. Quantities of flammable materials on site shall
be kept to an absolute minimum, and shall be properly handled and stored.
Gasoline and other flammable liquids as well as pressurised gas tanks shall be
stored in and dispensed from safety containers; however, storage of such
containers shall not be within the offices building. Except as otherwise provided
herein, the Contractor shall not permit fires to be built or open type heating
devices to be used in any part of the work.
1/18.2 Construction practices, including cutting and welding, and protection of adjacent
materials during construction shall be in accordance with good standard practices
for such work. The Contractor shall provide a sufficient number of approved
portable fire extinguishers distributed around the buildings and construction site.

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1/18.3 The Contractor shall make arrangements for periodic inspection by the local fire
authority and shall co-operate with said authority to promptly carry out their
recommendations at his own expense.
1/19 SAFETY OFFICERS
1/19.1 The Contractor shall inform the Engineer in writing within two weeks of the start
of works the names of responsible persons resident on the Site who will be
undertaking the duties of Safety Officers and Safety Supervisors on Site. A
Safety Officer shall be in continuous attendance on site 24 hours a day
throughout the Contract period.
1/20 CONTRACT DRAWINGS AND DOCUMENTS
1/20.1 The Works shall be executed in accordance with the Drawings and other such
information as may be issued or approved by the Engineer. The Contractor will
be furnished with one set of transparencies of the original drawings, free of
charge.
1/21 SHOP DRAWINGS, WORKING DRAWINGS, OPERATIONS AND MAINTENANCE

INSTRUCTIONS
1/21.1 For any work or part thereof as requested, the Contractor shall supply four(4)
copies of shop/working drawings for approval by the Engineer. All working
drawings shall be A1 size folded to A4 size.
1/21.2 For all above mentioned drawings, the Engineer shall return to the Contractor
one (1) copy with any necessary corrections for resubmittal or marked with
approval.
1/21.3 At the end of the Project, the Contractor shall submit to the Engineer the original
negatives of all drawings previously approved with 2 (two) sets of prints of the
same.
Monthly Progress Report as well as Final Materials Report both containing the
prescribed Summary of Testing Frequency Forms shall be submitted to DCL for
review in accordance with Circular No. 8/2004 (Ref. # 812/02//02//1/4063/678
dated 22/2/2004 issued by the Director of Roads Department and the fax
message No. 812/02/02/1/630 dated 09/06/2004 issued by the Director of DCLD.
1/21.4 In additions the Contractor shall provide the Engineer with all information, scale
drawings and every assistance so that the Engineer can prepare drawings of
work as executed to form a complete record of the finished work.
All drawings must be prepared using a Computer Aided Drafting system

Drawings shall be plotted by the Contractor as required by the Specification.
Diskettes containing the drawings data are to be supplied to the Engineer in the
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approved digital format.
1/21.5 The Contractor shall record the exact location of all services apparatus
excavated during the works and shall submit drawings to the Engineer showing
such information for incorporation by the Engineer into the Record Drawings.
1/21.6 The cost related to the production of the drawings, either during construction or at
the time of delivery of the final account (for which 1 negative + 3 copies of all
attachments are necessary), shall be borne directly by the Contractor, and no
separate payment shall be in anyway considered.
1/21.7 Within sixty (60) days of the date of field staking, the Contractor shall submit to
the Engineer for his approval the plotting of the original and final earthwork cross-
sections, together with the area and volumetric earthwork computations. The
Contractor’s cross-section shall be on transparent cross-section sheets for print
reproduction.
On final approval of the Contractor’s cross-sections, the Contractor shall give the
Engineer the original transparent tracings and three (3) prints of the same along
with approved volumetric earthwork computations (in A4 size and bound). If the
Contractor fails or refuses to submit cross-sections within the specified time, the
Engineer may withhold payment for all or any part of the earthwork quantities
involved. All cross-sections shall be plotted on A1 size Drawing folded to A4
size.
1/22 RECORD DRAWINGS
1/22.1 The Contractor shall provide the Engineer every possible assistance with the
preparation of accurate record drawings showing works as executed complete
with existing and finished levels (top invert and formation levels plans cross and
longitudinal sections locations of all junctions manholes inlets, extent of concrete
bed and structures and all things necessary to form a complete pictorial record of
the finished work). Also to be shown are the exact locations with dimensions of
existing and new service ducts, cables, pipes, etc. All negatives of record
drawings so prepared by the Engineer shall be dated and signed by the
Contractor and the Engineer as being a true record of the Works ‘as-built”.
1/23 ACCOMMODATION WORKS
1/23.1 The Contractor will be responsible for making all necessary arrangements with
owners and occupiers for carrying out accommodation works, including, where
necessary, access onto or across private land.
1/23.2 Where, in the opinion of the Engineer, the convenience or amenity of an owner or
occupier or of the public generally is affected by the Works, the Engineer may
order the Contractor to complete any accommodation work, or part of an
accommodation work, with the utmost expediency and irrespective of the
Contractor’s overall programme for the Works.

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1/24 PUBLICITY
1/24.1 The Contractor or any agents or servants in his employ shall not give any
information concerning Works for publication in the press or on radio, television
or cinema screen or elsewhere without the written approval of the Engineer.
1/24.2 No advertisements shall be erected within the Site by the Contractor or any sub-
contractor without written approval of the Employer. Should any advertisement
be erected within the site without such prior approval the Engineer may instruct
the Contractor to remove it forthwith. Should such an instruction fail to be carried
out within 24 hours, the Engineer may remove the advertisement and charge the
cost to the Contractor.
1/24.3 All advertisement within the site shall be removed within one month of the date of
Certificate of Substantial Completion of the Works, unless the Employer agrees
in writing for any advertisement to remain for a further period.
1/25 TIDYING AND CLEARING THE SITE
1/25.1 The Contractor shall maintain the Site in a clean and orderly condition free from
accumulation of waste materials and rubbish during the entire construction period
to the satisfaction of the Engineer.
1/25.2 On completion the entire site within the Right of Way are to be cleared of all
construction materials and temporary buildings, etc. to the satisfaction of the
Engineer.
1/26 SOIL INVESTIGATION
1/26.1 Any information given about soils investigations carried out is for the Contractor’s
assistance only. It is the Contractor’s responsibility to check and confirm the
existing ground conditions and in particular the likelihood of encountering water
during the course of sub-surface construction.
1/27 WORKS FREE FROM WATER
1/27.1 Except where in the opinion of the Engineer, the route of the work necessitates
underwater construction, the Contractor shall execute all works in the dry, and
shall construct any temporary drains, water courses, pumping and other works
that may be necessary for the purpose. The Contractor shall have included for
the cost of all operations necessary to comply with this Clause within his tender.
1/28 OTHER CONTRACTORS ON SITE
1/28.1 The Contractor must extent full cooperation by way of liaison and coordination
with other Contractors who may be operating within the site of the works
engaged in essential work for the Government of Dubai.

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1/29 MAJOR EQUIPMENT AND PLANT
1/29.1 GENERAL
Equipment shall mean, where mentioned in these Specifications, all machines,

tools, equipment and all necessary parts for its operation and maintenance.
Also, the laboratory tools and instruments and/or equipment necessary for the
proper construction of the road and the proper completion of all the works.
The Contractor, shall submit, as stipulated in the “Instructions to Tenderer” a

detailed list of plant equipment which he shall undertake to bring to the site to
carry out the work. The list shall include for each piece of equipment, the type,
size, quantity, manufacturer, model, identification number and year of
manufacture. The Contractor shall supply all plant and equipment necessary for
the construction of each phase of the work and it must be on the site, inspected
and approved by the Engineer prior to the commencement of the particular phase
of work. Any plant or equipment of portion thereof, which becomes worn or
defective shall be immediately repaired or replaced to the satisfaction of the
Engineer.
1/29.2 COMPACTING EQUIPMENT
The compaction equipment for earthwork may be towed or self-propelled and

shall include a suitable combination of tamping rollers, grid rollers, segmented
pad rollers, vibrating rollers, pneumatic rollers and other compaction equipment
that can satisfactorily and uniformly obtain the required compaction.
i Tamping or Sheepfoot Rollers: Tamping or sheepfoot rollers shall consist

of metal rollers, drums, or shells surrounded by metal studs with tamping
feet projecting not less than sixteen and one-half (16.5) centimetres from
the surface of the roller, drum or shell. Tamping feet shall be spaced not
less than fifteen (15) centimetres or more than thirty (30) centimetres
measured diagonally centre to centre and the cross section area of each
tamper foot, measured perpendicularly to the axis of the stud, shall be not
less than twenty-five and eight-tenths (25.8) square centimetres. The
weight of tamping rollers shall be such that when fully loaded, the load on
each tamper foot will be determined by dividing the total weight of the roller
(loaded) by the number of tamper feet in one (1) row parallel to the axis of
the roller.
ii) Pull-Type Steel Rollers: Pull-type steel rollers shall have not less than one
and two-tenths (1.2) metre effective width of roller and shall be designed
and constructed so that the weight per linear centimetre of roller can be
varied from thirty five and seven-tenths (35.7) kilograms to at least fifty-
three and six-tenths (53.6) kilograms.
iii) Self-Propelled Steel Rollers: The power mechanism shall be capable of

propelling the roller smoothly and without jerking when starting, stopping, or
reversing directions free from backlash, loose link motion, faulty steering
mechanism and worn king bolts. The steering mechanism shall have no
lost motion, shall operate readily and permit the roller to be directed on the
alignment desired. The faces of all rollers shall be smooth and free from
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defects which mark the finished road surface. Rollers shall be equipped
with water tanks and sprinkling devices which shall be used for wetting the
roller to prevent adherence of the placed material.
Two-axle tandem steel rollers shall weigh not less than eight (8) tones or
more than twelve (12) tones and shall have a weight per centimetre width of
roll between 35 Kg and 70 Kg.
Three axle tandem steel rollers shall weigh not less than eleven (11) tons.
Three axle tandem roller shall be so constructed that the roller, when locked
in position for all treads to be in one plane, are held with a rigidity which will
satisfy the following test under full load; with the weight of the roller
supported on the central roller, the tread of the central roller shall not be
more than three (3) millimetres above the plane tangent to the tread of the
end roller. With the weight of the roller supported on the end rollers, the
tread of the central roller shall not be more than six (6) millimetres below
the plane tangent to the treads of the end roller.
iv) Trench Rollers: The trench roller shall be of an approved type and shall
weigh not less than fifty-three and six tenth (53.6) kilograms per centimetre
of width and shall be equipped with water and sprinkling device that shall be
used for wetting the roller to prevent adherence of the placed material.
v) Pneumatic-Tyred Rollers: The tyres on the front and rear axles shall have
wide smooth treads and shall be staggered to provide complete coverage of
the entire area which the roller travels. The tyres shall be inflated to a
pressure that has been approved by the Engineer and the pressure shall be
reasonably uniform in all tyres. The Contractor shall provide a suitable

guage for determining air pressure in the tyre.
Light self-propelled pneumatic-tyred rollers shall be so constructed so that
they may be loaded to provide a gross weight of at least forty (40) kilograms
per centimetre of width of tyre tread.
Heavy self-propelled pneumatic-tyred rollers shall be constructed so that

they can be loaded to provide a gross weight of not less than twenty five
(25) tones and they shall have tyre pressures of 6-6.3 Kg/Cm2.
vi) Vibration Compactors: Equipment using principle of vibration as a tamping

force shall be in good mechanical condition and shall be capable of
transmitting forceful vibrations or impacts to the various materials placed in
construction. The equipment may be the roller or pad type or a combination
of roller and pad type. Vibrating compactors shall be of the type and force
1/29.3 HAULING AND WEIGHING EQUIPMENT
i) Hauling Equipment: Hauling equipment for aggregate shall consist of

vehicles having dump bodies suitable for dumping materials in a windrow or
in spreader boxes. The bodies shall be so constructed that their volume
measurement can be accurately determined. They shall be so constructed
and maintained to prevent loss of materials during hauling operations.

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The equipment shall be provided with dump controls that can be operated
from the driver’s seat. The bodies of hauling equipment using public roads
shall be fitted with tarpaulins to prevent the nuisance of spillage.
ii) Weighing Equipment: Weighing equipment for truck-hauled material shall

consist of accurate and reliable platform scales and they shall be accurate
to one percent throughout the range of use. The scale shall have a
platform of adequate length to weigh the longest truck or truck-trailer
combination which is in use on the Project, in one operation. Scales shall
be inspected and sealed or certified by an approved scale company, as
often as the Engineer deems necessary to ensure their accuracy. The seal
or certification shall show the date of the inspection. Where no approved
scale company exists or at the option of the Engineer, the Contractor shall
check and adjust the scale in the presence of the Engineer in the method
recommended by the manufacturer and/or approved by the Engineer. It is
the Contractor’s responsibility to have sufficient standard test weights for
each scale on the Site.
The Engineer, as often as he deems it is necessary, shall direct the

Contractor to check and adjust any scale on site to ensure its accuracy.
The Contractor, shall when directed by the Engineer, make weight

comparisons with other permanently located scale that met with the
approval of the Engineer. These weight comparisons shall be for the
purpose of providing information on the performance of the Contractor’s
scale and will not be used as a basis for adjusting the scale.
The approaches to the scale platform shall be maintained by the Contractor

The Contractor shall furnish a suitable weathertight building to enclose the

indicating mechanism and shall have adequate lighting for the scale
operator’s use.
The Contractor shall on hand not less than ten (10) twenty-five (25)
kilogram weights for testing the scale.
iii) Controlled Water Distribution Equipment: Equipment for distribution of water

shall consist of distributors or tanks equipped with spray bars and, when
required, pumps to operate under pressure. The pumps shall be of
sufficient capacity to provide uniform and adequate distribution. They shall
be mounted on pneumatic-tyred trailers pulled by pneumatic-tyred
equipment. The minimum capacity of any tank shall be four (4) cubic
metres where applicable.
The distributor equipment shall be constructed to permit accurate and

uniform distribution of the desired quantities of water per unit of surface
area. The control valves shall be constructed to permit full closing and to
prevent leakage. The water control valves shall be constructed to operate
from the driver’s seat or provisions made for an additional operator to
operate the control valve while the equipment is traveling at the proper
speed for distribution.

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1/29.4 MAIN PLANT FOR BITUMINOUS PAVING WORKS
i) Equipment for Heating Bituminous Materials: Equipment for heating

bituminous materials shall be of adequate capacity to heat the material
properly by circulating the bituminous material around the system of heated
coils or pipes, or by circulating the bituminous material through a system of
coils or pipes enclosed in a heated jacket or other approved means.
The heating device shall be constructed so that it will prevent the direct
flame from a burner from striking the surface of the coils, pipes or jackets
through which the bituminous material is circulated. The heating device
shall not be operated in a manner that will injure the bituminous material.
Tankers or trucks received on the work which have defective coils, or from
which the coils have been removed, will be rejected by the Engineer unless
some satisfactory auxiliary means can be provided by the Contractor for the
heating of the bituminous material without the introduction or moisture.
The use of any equipment for the agitation of bituminous material to aid in
heating will be prohibited if it injures or in any way changes the
characteristics of the bituminous material or introduces free steam or
moisture into the tank containing the bituminous material.
Tanker or truck connections for transferring bituminous material from

tankers to distributors, supply tanks, or storage tanks shall be constructed
so that they cannot be used for any other purpose. The use of a tanker or
truck connection or any other equipment by means of which free steam can
be introduced directly into the bituminous materials as a means of agitation
or auxiliary heating will be prohibited.
ii) Bitumen Distributor Equipment: Equipment for the distribution of

bituminous materials shall be equipped with the following appliances or
devices:-
- Tachometers
- Pressure Gauge
- Adjustable Length Spray Bars
- Separate Power Unit & Pump on distributing System
- Heating Coils and Burner
- Thermometer well and Accurate Thermometer
- Measuring Sticks
- Quick Opening Gate in dome
All distributors and supply tanks shall be mounted on dependable motor

trucks or trailers equipped with pneumatic tyres. The units shall be so
designed to ensure that no rutting or other injury to the road surface will
result. The distributor shall have pneumatic tyres of such width and number
that the load produced on the road surface shall not exceed one hundred
and ten (110) kilograms per linear centimetre of the width. They will be
sufficiently powered to maintain the desired speed of the equipment during
operation.
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The manometer designating the speed of the truck shall be a separate

operating unit attached to the truck equipped with a larger gauge
approximately fourteen (14) centimetres in diameter and graduated in units
so that the speed of the trucks can be determined within limits of
approximately three (3) metres per minute or equivalent thereto. The
gauge shall be so located that it can be easily read at all times by the driver
of the distributor.
The distributor shall be equipped with either a tachometer, calibrated to

indicate revolutions per minute, attached to the pump shaft or a pressure
gauge, calibrated to indicate kilograms per square centimetre placed in the
distributing system, by which the flow of bitumen may be regulated.
The spray bars shall be constructed to permit adjustment for length in

increments of thirty (30) centimetres for any length up to seven (7) metres,
to permit vertical adjustment of all nozzles to the desired height above the
road surface conforming to the roadway crown, and to permit lateral shifting
of the entire spray bar during operation. The spray bars and nozzles shall
be constructed to prevent clogging of the nozzle during the
intermittent operation and to provide positive and immediate cut-off when

distribution of oil ceases, thus preventing dripping of oil from the bar.
The power unit and pump distribution systems shall have a capacity of not
less than nine hundred fifty (950) litres per minute, shall be equipped with a
by-pass into the supply tank and shall be capable of distributing a uniform
and constant flow of bituminous material through all nozzles at a pressure
between one and one quarter (1.25) and three and one-half (3.5) kilograms
per square centimetre.
The entire distributor assembly shall be so constructed and operated to

ensure accurate distribution of bituminous material at rates of from two-
tenths (0.2) to seven and five tenths (7.5) litres per square metre with
uniform pressure, and with an allowable variation from any specified rate
not to exceed one tenth (0.1) litres per square metre. Minimum capacity of
the distributor shall be four thousand (4,000) litres.
iii) Calibration and Check of Distributors: All distributors shall be calibrated and
checked before being used on the work. The calibration of the tank will be
done by the Contractor in the presence of the Engineer by the method
prescribed by the manufacturer and/or directed by the Engineer.
The operation of the distributor will be checked by the Engineer the first
time it is used and as often as he deems it necessary thereafter, and when
the operation is found to be satisfactory, a new certificate will be issued.
iv) Stationary Mixing Plants: Stationary mixing plants shall consist of

measuring and proportioning equipment and mixing equipment. They shall
also include dryers when aggregates are furnished that contain moisture in
excess of the amounts permitted for mixing. The measuring and
proportioning equipment shall consist of a system of hoppers and scales
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designed for proportioning and measuring by batch weights or of

continuous flow equipment so designed and operated that the flow of
materials can be accurately and continuously regulated and so arranged to
permit easy and accurate checking of the rate of flow on a weight basis.
For continuous flow mixing the proportioning equipment may be at the
stockpile site so that the individual aggregate may be blended prior to
entering the drier.
The drier shall be capable of drying and heating the mineral aggregates to
specification requirements.
The proportioning devices for the bituminous materials and aggregates

shall be so synchronised that proper proportioning will be obtained at all
times.
The design of the mixing chambers shall provide adjustment to permit a

mixing period of sufficient duration to produce a thorough and uniform mix.
The approval of and continued use of a stationary plant shall be contingent
upon its ability to proportion and mix satisfactorily the several materials in
adequate quantity for the proper progress of the work.
v) Hot Mix Plant: All equipment shall meet the approval of the Engineer, shall
be kept in good working condition, shall meet the requirements herein
specified and shall be of sufficient capacity to produce and process not less
than eighty (80) tons of mixed material per hour. All plants used by the
Contractor for the preparation of bituminous mixes and (Plant Mix) prepared
mixes shall conform to all the requirements of these Specifications except
that scale requirements shall apply only where weight proportioning is used,
and in addition batch mixing plants and continuous plants shall conform to
the special requirements of these specifications.
vi) Requirements of all Plant
Uniformity: The plants shall be so designed, co-ordinated and operated to

produce a uniform mixture.
Scale: Scales for any weight box or hopper may be of either the beam or
springless dial type and shall be of a standard make and design, accurate
to one (1) percent of the maximum load that may be required.
When scales are of the beam type, there shall be a separate beam for each
size of aggregate. There shall be provided a “Tell-tale Dial” that will start to
function when the load being applied is within fifty (50) kilograms of that
desired. Sufficient vertical movement shall be provided for the beams to
permit the tell-tale dial to function properly. Each beam shall have a
locking device so designed and located that the beam can easily be
suspended or thrown into action.
Dial scales shall be springless, of a standard make, and of such size that
the numeral on the dial can be read at a distance of at least (8) metres.
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The dial shall be of a compounding type having full complement of index.

Pointers so placed as to give excessive parallax errors shall not be used.
The scales shall be substantially constructed, and those that easily get out
of adjustment shall be replaced with other makes when so ordered. All
dials shall be so located as to be plainly visible to the operator at all times.
Scales shall be inspected and sealed or certified as often as the Engineer

may deem necessary to ensure their continued accuracy. The initial
inspection shall be done by an approved scale company, or by the
Contractor in the presence of the Engineer by the method prescribed by the
manufacturer and/or as directed by the Engineer. The Contractor shall
have on hand not less than ten (10), twenty-five (25) kilograms weights for
testing the scales.
Equipment for Preparation of Bituminous Material: Tanks for the storage of

bituminous material shall be equipped to heat and hold the material at the
required temperature. The heating shall be accomplished by steam coils,
electricity, hot coils, or other approved means so that the flame shall be in
contact with the tank.
The circulating system for the bituminous material shall be designed to

ensure proper and continuous circulation during the operating period.
Provision shall be made for measuring and sampling storage tanks.

Storage tanks shall have sufficient capacity to provide for continuous
operation. The storage tanks shall be calibrated and equipped with a
device whereby the Engineer may determine the amount of asphalt on hand
at any time.
Feeder for Drier: The plant shall be provided with accurate mechanical
means for uniformly feeding the aggregate into the drier so that uniform
production and uniform temperature will be obtained. A separate
mechanical feeder equipped with an adjustable gate opening shall be
provided for each individual aggregate being combined to produce the total
aggregate. The feeders and gate shall be so constructed and equipped
that a continuous and uniform flow of each material will be ensured. They
shall also be installed in such a manner as to be readily accessible for
calibrating at all times.
Drier: The plant shall include a drier or driers which continuously agitate
the aggregate during the heating and drying process. The drier shall be
capable of drying and heating the mineral aggregate to specification
requirements. The burners shall be of such capacity, and they shall be so
constructed and operated that complete combustion of the fuel is obtained.
Screens: Plant screens, capable of screening all aggregates to the

specified sizes and proportions and having normal capacities in excess of
the full capacity of the mixer, shall be provided.
Bins: The plant shall include storage bins (cold & hot) of sufficient capacity
to supply the mixer when it is operating at full capacity. Bins shall be
arranged to ensure separate and adequate storage of appropriate fractions
of the mineral aggregates. Separate dry storage shall be provided for
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Portland Cement, hydrated lime, or other similar material when used and
the plant shall be equipped to feed such material into the mixer.
Each bin shall be provided with overflow pipes, of such size and at such
location as to prevent backing up of material into other compartments or
bins. Each compartment shall be provided with its individual outlet gate,
constructed so that when closed there shall be no leakage. The gate shall
cut off quickly and completely. Bins shall be so constructed that samples
can be readily obtained. Bins shall be equipped with adequate tell-tale
devices to indicate the position of the aggregates in the bins at the lower
quarter point.
The minimum number of bins shall include at least one bin for each different
stockpile of material being used. Intermixing of material from different
stockpiles in one bin or on the ground shall not be permitted.
Bituminous Control Unit: Satisfactory means, either by weighing or metering

shall be provided to obtain the proper amount of bituminous material in the
mix within the tolerance specified. Means shall be provided for checking
the quantity or rate of flow of bituminous material into the mixer. Suitable
means shall be provided for maintaining the specified temperature of the
bituminous material in the pipelines, metres, weight buckets, and spray
bars.
Thermometric Equipment: An armoured thermometer of adequate range in

temperature reading shall be fixed in the bituminous feed line at a suitable
location near the charging valve at the mixer unit.
The plant shall also be equipped with either an approved dial-scale

mercury-actuated thermometer, an electric pyrometer, or other approved
thermometric instrument so placed at the discharge chute of the drier as to
register automatically or indicate the temperature of the heated aggregates.
All plants whether continuous or batch type shall be equipped with two
recording thermometers. These instruments shall be provided with dust-
proof cases, long leads, and automatic recording mechanism capable of
recording the desired temperature for a period of twenty-four (24) hours on
a chart not less than twenty (20) centimetres in diameter, or on a
continuous sheet. The chart for either type shall be graduated in hours,
minutes, and degrees of temperature. The maximum time graduation shall
be fifteen (15) minutes and the maximum temperature graduation shall be
five (5) degrees centigrade. Hours on the chart shall be designated as a.m
or p.m.
The temperature recording thermometers shoulde be installed on points or

a framework, separate from plant, to eliminate plant vibration.
They shall be located in a manner to provide easy access to the case and
chart. The bulb of one instrument shall be installed in the hot asphalt line
as close as is practicable to the spray bar discharge, the bulb of the second
recording thermometer shall be installed in the hot aggregate bin which
contains the fine aggregate. The bulb shall be located where the hot
materials will flow over it during the proportioning operation and shall not be
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located near the corners of the bin or at locations where the material will
collect or pack around it.
The Engineer reserves the right to pass judgment upon the efficiency of
thermometric instruments.
Control of Mixing Time: The plant shall be equipped with positive means to
govern the time of mixing and to maintain a constant time unless changed
by order of the Engineer.
Dust Collectors: The plant shall be equipped with a dust collector

constructed to waste or return uniformly to the hot elevator all or any part of
the material collected as desired.
Safety Requirements: Adequate and safe stairways to the mixer platform

and sampling points shall be provided and guarded ladders to other points
shall be placed at all points where accessibility to plant operations is
required. Accessibility to the top of truck bodies shall be provided by a
platform or other suitable device to enable the Engineer to obtain sampling
and mixture temperature data. A hoist or pulley system shall be provided to
raise scale calibration equipment, sampling equipment and other similar
equipment from the ground to the mixer platform.
All gears, pulleys, chains, sprockets, and other dangerous moving parts
shall be thoroughly guarded and protected. Ample and unobstructed space
shall be provided on the mixing platform. A clear and unobstructed
passage shall be maintained at all times in and around the truck loading
area. The area shall be kept free from dropping from the mixing platform.
vii) Specification Requirements for Batching Plants Weigh Box or Hopper
The equipment shall include a means for accurately weighing each size of
aggregate in a weigh box or hopper suspended on scales and of ample size
to hold a full batch without hand raking or running over. The gate shall
close tightly so that no material is allowed to leak into the mixer while batch
is being weighed. Asphalt plants shall meet requirements in accordance
with ASTMD995 & ASTMD290.
Bituminous Control: The equipment used to measure the bituminous

material shall be accurate to plus minus five- tenths (0.5) percent. The
bituminous material bucket shall be a nontilting type with a loose sheet
metal cover. The length of the discharge opening or spray bar shall be not
less than three-fourths (3/4) the length of the mixer and it shall discharge
directly into the mixer. The bituminous material bucket, its discharge valve
or valves and spray bar shall be adequately heated. Steam jackets, if used,
shall be efficiently drained and all connections shall be so constructed that
they will not interfere with the efficient operation of the bituminous scales.
The capacity of the bituminous material bucket shall be at least fifteen (15)
percent in excess of the weight of bituminous material required in any
batch. The plant shall have an adequately heated quick-acting, nondrip,
charging valve located directly over the bituminous material bucket.

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The indicator dial shall have a capacity of at least fifteen (15) percent in
excess of the quantity of bituminous material used in a batch.
The dial shall be in full view of the mixer operator. The flow of bituminous
material shall be automatically controlled so that it will begin when the dry
mixing period is over and all of the bituminous material required for one
batch will be discharged in not more than fifteen (15) seconds after the flow
has started. The section of the bituminous line between the charging valve
and the spray bar shall be provided with a valve and outlet for checking the
metering device.
Mixer: The batch mixer shall be an approved type capable of producing

uniform mixture.
If not enclosed, the mixer box shall be equipped with a dust hood to prevent
loss of dust.
The clearance of blades from all fixed and moving parts shall not exceed
two and one-half (2.5) centimetres unless the maximum diameter of the
aggregate in the mix exceeds three (3) centimetres, in which case the
clearance shall not exceed three and eight-tengths (3.8) centimetres.
Control of Mixing Time: The mixer shall be equipped with an accurate time
lock to control the operations of a complete mixing cycle. It shall lock the
weigh box gate after the charging of the mixer until the closing of the mixer
at the completion of the cycle. It shall lock the bituminous material bucket
throughout the dry mixing period and shall lock the mixer gate throughout
the dry and wet mixing periods. The dry mixing period is defined as the
interval of the time between the opening of the weigh box gate and the start
of introduction of bituminous material. The wet mixing period is the interval

of time between the start of introduction of bituminous material and the
opening of the mixer gate.
The control of the timing shall be flexible and capable of being set at
intervals as necessary for mixing time throughout the total mixing cycle. A
mechanical batch counter shall be installed as a part of the timing device
and shall be so designed as to register only completely mixed batches.
Automation and Recording of Bituminous Concrete Plants.

The plants shall be equipped with an automatic mass measuring cycling
and monitoring systems approved by the Engineer. Recording equipment
shall monitor the batching sequence of each component of the mixture and
produce a printed record of these operations. For each day's production the
Engineer shall be provided a clear, legible copy of the recording. There
should be provisions so that scales may not be manually manipulated
during the printing process.
viii) Special Requirements for Continuous Mixing Plants Aggregate

Proportioning:
Continuous Mixing Plants are not recommended for Roads & Transport
Authority Projects.
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Weight Calibration of Aggregate Feed: The plant shall include a means for
calibration of gate opening by weighing test samples. Provisions shall be
made so that materials fed out of individual orifices may be bypassed to
individual test boxes. The plant shall be equipped to conveniently handle
individual test samples weighing not less than one hundred (100) kilograms.
Accurate scales shall be provided by the Contractor to weigh test samples.
Weight Calibration of Bituminous Material: The bituminous discharge line

shall be equipped with suitable valves and a bypass so that the asphalt
pump of meter may be readily calibrated. For each change of stockpiles,
the plant shall be recalibrated.
Synchronisation of Aggregate Feed and Bituminous Material Feed:

Satisfactory means shall be provided to afford positive interlocking control
between the flow of aggregate from the bins and the flow of bituminous
material from the meter or other proportioning device. This control shall be
accomplished by interlocking mechanical means or by any other positive
method satisfactory to the Engineer.
Mixer: The plant shall include a continuous mixer of an approved type,

adequately heated and capable of producing a uniform mixture. It shall be
equipped with a discharge hopper with dump gates which will permit rapid
and complete discharge of the mixture. The paddles shall be adjustable for
angular position on the shaft and reversible to retard the flow of the mix.
The mixer shall have a manufacturer’s plate giving the net volumetric
contents of the mixer at the several heights inscribed on a permanent
gauge. Charts shall be provided showing the rate of feed of the aggregate
per minute for the aggregate being used.
Bituminous-mix Paver: Bituminous-mix pavers shall be self-contained,

power propelled units, provided with automatically controlled activated
screed or strike-off assembly, heated if necessary, and capable of
spreading and finishing courses of bituminous plant mix material in lane
widths applicable to the specified typical section and thickness shown on
the plans. Pavers used for shoulders and similar construction shall be
capable of spreading and finishing courses of bituminous plant mix material
in widths on the plans. Pavers shall be capable of laying one hundred (100)
tons per hour.
The machines shall employ mechanical devices such as equalising runners,

straight-edge runners, evener arms, or other compensating devices to
adjust the grade and confine the edges of the mixer to true lines without the
use of stationary side forms.
The paver shall be equipped with a distribution system to place the mixer
uniformly in front of the screed.
The screed or strike-off assembly shall effectively produce a finished

surface of a required evenness and texture without tearing, shoving or
gouging the mixture.

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The paver shall be capable of being operated, when laying mixture, at

forward speed consistent with satisfactory laying of the mixture.
The automatic controls for the paver shall be automatic linkage

arrangement so that through the process of automatically adjusting the
screed, the thickness of asphaltic mixtures can be placed and finished to
predetermined grade and a uniform crown or cross-section.
Manually controlled bituminous-mix pavers may be used only with the

written consent of the Engineer. A manually controlled bituminous-mix
paver shall be of the self-propelled type with spread and strike-off facilities
designed to spread the mixture in such a manner that no supplemental
shaping will be required.
It shall be capable of spreading the mixture evenly, with uniform density,

without segregation and shall strike off true to the cross-section. Screeds
must be constructed so as not to follow minor irregularities in the base and
must be readily adjustable to control accurately the depth spread.
No manually operated bituminous-mix paver shall be delivered to the site

prior to its approval by the Engineer.
Self-Propelled Aggregate Spreader: Self-propelled aggregate spreader

shall be approved design supported by at least four (4) wheels equipped
with pneumatic tyres on two (2) axles. The aggregate spreader shall be
equipped with a means of applying the larger cover coat material to the
surface ahead of the smaller cover coat material and with positive control
so that the required amount of material will be deposited uniformly over the
full width of the bituminous material. Other types of aggregate spreaders
may be used provided they accomplish equivalent results and are approved
by the Engineer.
1/30 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI
The average prevailing local conditions at Dubai City shall be assumed as

follows:
Max. Ambient Temperature 55 deg.C

Min. Ambient Temperature 1 deg.C
Design Ambient Temperature 50 deg.C

Max, Metal Temperature under sun 85 deg.C
Min. Barometric Pressure 998 mb
Average Barometric Pressure 1015 mb
Max. Ambient Humidity 100%
Min. Ambient Humidity 20%
Design Ambient Humidity 80%
Max. Design Wind Velocity 160 Km/hr.
Average Yearly Rainfall 80 mm - 150 mm
The climate of Dubai is relatively mild from November to April, and hot from May

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to October with high relative humidity.
Under certain combinations of the above climatic conditions, considerable

consideration may take place.
Particular attention should be given to the prevailing corrosion conditions.
Distribution of rainfall is irregular and the precipitation amounts are normally of no

significance but attention should be given to the fact that sudden heavy rain falls
in a very short period of time can occur.
The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr, the sand storms and
dust storms occur in summer months.

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SECTION 2 - SITE CLEARANCE AND EARTHWORKS
2/1 SITE CLEARANCE DESCRIPTION
2/1.1 This work shall consist of the removal, wholly or in part, and satisfactory disposal
of all buildings, fences, structures, abandoned pipelines, and any other
obstruction which are not designed or permitted to remain. It shall also include
the salvaging of designated materials and backfilling the resulting trenches, holes
and pits. Site clearance areas shall be based upon Engineer’s approval.
2/2 SURVEY BEFORE COMMENCEMENT
2/2.1 Prior to starting the site clearance, the Contractor shall carry out a thorough
survey of buildings, structures, fences trees, etc. that are to be removed. The
Engineer shall be fully informed of the results of this survey and the amount and
extent of the demolition and site clearance shall then be agreed with the
Engineer.
2/3 DEMOLITION REQUIREMENTS
2/3.1 The Contractor shall in a careful manner, raze, remove and dispose of all
buildings and foundation structures, fences and other obstructions or any
portions of which are within the right-of-way, except utilities and those for
which other provisions have been made for removal. All designated
salvageable material shall be removed, without unnecessary damage, in sections
or pieces which may be readily transported, and shall be stored by the Contractor
at specified places within the project limits or at designated storage areas as
directed by the Engineer. All such salvageable material shall be deemed the
property of the Employer
2/3.2 Foundations of building structures shall generally be removed to a depth of 1m

below ground level or more if considered necessary by the Engineer.
2/3.3 Where shown on the drawings or where directed by the Engineer, underground
structures, culverts, chambers and foundations other than building foundations
shall be removed to such a level as may be indicated on the drawings or directed
by the Engineer.
2/3.4 Where directed by the Engineer, the Contractor shall excavate in trench and
break out redundant pipe ducts and surrounds. Where pipes are to be removed
and either salvaged or relaid they shall be carefully removed and every
precaution taken to avoid breaking or damaging the pipe. The pipes shall be
stored when necessary so that there will be no loss or damage before relaying.
The Contractor will be required to replace sections lost from storage or damage
by negligence or by the use of improper methods in their removal.
2/3.5 Trenches and pits resulting from demolition and site clearance below ground
level shall be properly cleaned out (including pumping) and filled with suitable
material and compacted in accordance with the relevant Specifications up to
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subgrade level or as otherwise directed by the Engineer.
2/3.6 Where required, the Contractor shall be responsible, prior to demolition, for the
disconnection of all services and clearance from the Dubai Municipality and all
Service Authorities.
2/4 GENERAL SITE CLEARANCE
2/4.1 Before commencing any excavation or fill, the area shall be cleared of all trees,
stumps, roots, bushes, vegetation, debris, materials or other obstructions.
2/4.2 Before removal of any trees or shrubs the Contractor shall obtain written consent
from Dubai Municipality Horticultural Section at least two weeks in advance of the
planned removal.
2/4.3 The Engineer’s approval of any removal of trees and undergrowth must be
obtained before commencement of work. Where directed all bushes,
undergrowth, etc. shall be grubbed up and burnt or otherwise disposed of in tips
off site (Sub section 2/8). Holes left by stumps or roots shall, within one week, be
filled with a suitable material, compacted to the Engineer’s satisfaction in
accordance with Specification Clause 2/17.
2/4.4 GHAF TREES
2/4.4.1 Ghaf Trees are a protected species in the United Arab Emirates they are to be
pruned or moved under the complete supervision and written approval of Dubai
Municipality Horticulture Section.
2/4.4.2 Trees may only be moved if they represent an absolute obstruction to the works
and no diversion of services or the road alignment is possible.
2/4.4.3 Attendance on the Horticulture Section is the responsibility of the Contractor and
is included, at least the following plant:
i) Mobile crane of sufficient capacity with slinges etc. to enable the lifting of
the particular tree/trees in question.
ii) Excavator to carry out pre-tree removal works.
iii) Low Bed trailer and tractor or similar to transport the removed tree/trees
to either Mushrif Park or the Dubai terminal of the Dubai to Al Ain Road,
whichever is the nearer to the site.
2/4.4.4 The above plant will be required at both the original and new tree sites. The
Horticulture Department may also require the provision of a supply of potable
water for irrigation of the tree prior to its removal.
2/4.5 The contractor shall provide a watchman and other services to engineer on its
own cost.
2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS
2/5.1 Attention is directed to the Contractor’s obligations under law and under this
Contract with regard to damage, particularly with regard to protection of property,
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plants and landscape and to responsibility for damage claims.
2/5.2 Existing highways, improvements, facilities, adjacent property, services , and

trees and plants designated for preservation shall be protected from injury or
damage which could result from the Contractor’s operations.
2/5.3 The form of protection for vegetation within the site shall be of a type and
standard approved by the Dubai Municipality Horticultural Section.
2/6 ROAD SIGNS
2/6.1 All existing road signs, street name plates and the like affected by the works are
to be carefully taken down and stored. Signs to be re-erected shall be cleaned,
provided with new fixings where necessary and the posts re-painted in
accordance with the Specifications. Redundant signs shall be transported to the
stores or depots of relevant Authorities. Any sign, street name plate or the like
damaged by the Contractor during his operation shall be repaired or replaced at
the Contractor’s cost.
2/7 DISPOSAL OF HISTORICAL ARTEFACTS
2/7.1 Where specified, certain materials arising from the site clearance and excavation
are to remain the property of the Employer. All fossils, antiquities and other
objects of interest or value which may be found or uncovered on the site shall
remain or become the property of the Employer and upon discovery of such an
object the Contractor shall forthwith:
a) Use his best endeavours not to disturb or damage the object;

b) Cease work which would endanger the object or prevent or impede its
removal;
c) Inform the Engineer of the discovery and precise location of the object;
2/7.2 The Engineer will issue instructions on the procedure to be adopted which may
include conditions to permit the examination, excavation or removal of the object
by a third party.
2/8 DISPOSAL OF SURPLUS MATERIAL
2/8.1 Subject to the provision of Clause 27.1of the Conditions of Contract Part 1 and of
the Specification, all materials arising from site clearance which are surplus to or
unsuitable for use in the Works as per Clause 2/13.3 shall become the property
of the Contractor and shall be disposed of by him either off the Site to an
approved tip or if directed or otherwise agreed by the Engineer on the Site in an
approved manner.
*2/8.2 Following consultation with Dubai Municipality Public Health Department the
Contractor shall propose two sites for disposal of unsuitable or surplus material,
one of which shall be specified as having priority and which must be filled before
the second is used, together with a separate location where hard debris, such as
concrete, building rubble, kerbing, road pavement, etc. shall be disposed of. The
Contractor shall seek approval for all the proposed sites from the Dubai
Municipality before work commences and disposal at such sites shall be at no
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extra cost to the Employer.
2/9 EXCAVATION FOR ROAD CONSTRUCTION
2/9.1 This work shall consist of excavating the roadway and borrow pits, removing and
satisfactorily disposing of all materials taken from within the limits of the Work. It
shall include all dewatering, excavation, shaping and sloping as necessary for the
construction, preparation and completion of all embankments, cutting, subgrade,
shoulders, slopes, gutters, intersections, approaches and private entrances, as
directed, and in conformity to the alignment, grades, and cross-sections shown
on the plans or established by the Engineer.
2/10 CLASSIFICATION OF EXCAVATION
2/10.1 Excavated material shall be classified as:-
- Roadway Excavation
- Borrow Excavation
2/10.2 Roadway Excavation: includes all material of whatsoever nature, suitable or

unsuitable, excavated within the limits of the Right of Way for the preparation of
the road bed. All such material after deduction for material declared unsuitable
by the Engineer, shall be considered to be available for use at locations requiring
fill. Roadway excavation shall be sub-classified as Common Excavation and
Rock Excavation.
2/10.3 Authority to identify and define the physical characteristics which determine the
classifications as “Common Excavation” and “Rock Excavation” in accordance
with the intent of the following provisions shall be vested in the Engineer.
2/10.4 Common Excavation:- shall consist of the excavation and satisfactory disposal
(subject to Clause 2/15.3) of all soils, certain strata and rock boulders less than
one (1) cubic metre in volume. Strata which are altered and weathered and are
in place, but which are not firm enough, or in the opinion of the Engineer are not
rigid enough to have all the characteristics of rock excavation shall be classified
as common excavation.
2/10.5 Rock Excavation:- shall consist of the excavation and satisfactory disposal
(subject to Clause 2.15/3) of all unaltered and unweathered firm and rigid
igneous, metamorphic and sedimentary solid rock that in the opinion of the
Engineer is impracticable to remove by heavy mechanical excavating equipment
(e.g. Cat.D8) or heavy duty hydraulic ripper, or by approved pneumatic tools.
These type of rocks would normally be removed by blasting with explosives, or by
heavy duty hydraulic breakers or by drilling and broaching with wedges and
sledge hammers if removed by hand. Also individual boulders or detached pieces
of rock exceeding one cubic meter in size in trenches or excavations
necessitating blasting or breaking as above.
2/10.6 Borrow Excavation:- If the demand for fill material exceeds the quantity of
suitable material obtained from the necessary roadway excavation then suitable
material shall be imported to the worksite from an approved borrow pit. The
excavation, haulage and discharge of material in its final place from a borrow pit
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shall be classified as Borrow Excavation.
2/11 EXCAVATION REQUIREMENTS
2/11.1 All materials removed from an excavation shall be used in the formation of the
embankment, shoulders and at such other places as directed, unless it is
declared unsuitable and ordered to be sent to tip by the Engineer. No excavated
material shall be wasted without written permission from the Engineer, and when
such material is to be wasted, it shall hauled to the approved tip (Clause 2/8) or
as otherwise directed by the Engineer.
Material suitable for top soil, base material, mineral aggregate or other specified
purpose, encountered in excavation, shall be reserved, if so directed, until it can
be placed in its proper position in the roadway. When specified or designated,
top soil shall be used as cover on embankment slopes to aid the regrowth of
vegetation or other purposes.
2/11.2 Excavated materials wasted by the Contractor without written permission of the
Engineer shall be replaced by the Contractor at his own expense.
2/11.3 During the construction of the roadway, the prepared formation shall be
maintained in such condition that it will be well drained at all times.
2/11.4 Rock, shale and other unsuitable material encountered in cuts shall be excavated
to the lateral limits and depth indicated on the plans or as otherwise directed.
Any overbreakage below the depth shown on the plans or as otherwise directed
will not be paid for. Backfill of the overbreakage shall be approved suitable
material and shall have the same density requirements as specified by the
Contract and shall be at the expense of the Contractor. If the backfill of the
overbreakage area designated by the Engineer is to be a crushed aggregate
concrete or other special aggregate the entire cost of the backfill of the
overbreakage shall be at the expense of the Contractor. Undrained pockets shall
not be left in the surface of the rock, but they shall be treated as directed by the
Engineer.
2/11.5 All slopes, except in solid rock or other material which, in the judgement of the
Engineer, require a modified slope, shall be trimmed accurately to the slopes
shown on the cross-section drawings, and care must be exercised that no
material shall be loosened beyond the required slopes. Side ditches if required
shall be excavated in conformity to line, grade, and cross-section as shown on
the Drawings or as directed by the Engineer.
2/11.6 In cut areas, excavation shall be for the full construction width down to
‘earthworks formation level’. For a further depth of 15 cm the existing material
shall be scarified, watered as necessary, mixed and compacted to not less than
95% of maximum dry density as determined by BS 1377 Part 4 (Method 3.5 or
3.6). Field density shall be determined by BS 1377 Part 9 (Method 2.1 or 2.2).
2/11.7 The ‘improved subgrade layer’, using specified imported material, shall then be
placed and compacted to not less than 95% maximum dry density as determined
by BS 1377 Part 4 (Method 3.5 or 3.6) to bring the embankment level up to ‘top of
improved subgrade level’. Field density shall be determined by BS 1377 Part 9
(Method 2.1 or 2.2)
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2/11.8 For cutting 1.5 metres or more in depth the technical requirements, of the
Specification for ‘Excavation for Structures” (Sub-Section 2/23) shall be complied
with.
2/11.9 Where excavation to the finished graded section, that is ‘earthworks formation
level’, results in a formation or slopes of unsuitable soil, the Engineer may require
the Contractor to remove the unsuitable material to a depth directed and backfill
to the finished graded section with approved material compacted in accordance
with specified requirements for embankment construction. The Contractor shall
conduct his operations in such a way that the necessary cross-sectional
measurements can be taken and agreed with the Engineer before the backfill is
placed.
2/11.10 When the Contractor is required or directed to excavate unsuitable material in fill
areas, following general clearance of the area (see Specification sub-Section
2/16 ‘Embankment Foundation”), the depth to which these unsuitable materials
are to be removed will be determined by the Engineer. The Contractor shall so
schedule the work so that authorised cross-sections can be taken before and
after the material has been removed.
2/11.11 All slopes, lines and grades shall be true, correct, and accurate and according to
those on the drawings or otherwise directed and approved by the Engineer. The
‘earthworks formation level’ in cuts shall be accurate to the authorised profile
grade to plus or minus two (2) centimetres and, for ‘top of improved subgrade’
level, plus or minus one (1) centimetre. Where discrepancies are found in the
Work the Contractor shall make necessary corrections.
2/11.12 The Engineer will check all or any part of the Work, as he deems necessary, to
determine conformance to the lines, grades, elevations and cross-sections.
2/12 BORROW PIT SITE
2/12.1 The Contractor shall obtain approval from the Employer for the location of the
borrow pit site. The Contractor shall be responsible to determine the quantities
and quality of the available material in the approved borrow site to meet the
requirements of the Contract. When required the borrow area shall be cleared
and grubbed in accordance with the requirements of Section 2/1
2/12.2 The Employer may at any time revoke approval of a borrow site where the
Contractor is obtaining borrow material for the Works. Upon receiving such
notice from the Employer, the Contractor shall immediately cease removing
material from said borrow site. In the event the Employer revokes approval of the
borrow site, the Contractor shall locate a new borrow pit site as specified above.
2/12.3 The Contractor shall not claim any additional payment for any costs by reason of
the necessity of changing borrow site locations due either to the shortage of the
supply of borrow material available from the borrow pit site approved by the
Employer, or due to the Employer’s decision to revoke approval of the borrow site
where the Contractor is obtaining borrow material for the Works.
2/12.4 The Contractor shall leave borrow pits in a condition acceptable to the Employer

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and to the Engineer.
2/12.5 The Contractor will be solely responsible for ascertaining the location of such
approved borrow areas during the tender preparation stage. Locations,
distances to the work site and haulage from such approved borrow areas shall be
taken into consideration when preparing the unit tender price for Borrow
Excavation.
2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS

MATERIALS
The following definitions of earthwork materials shall apply
2/13.1 Top Soil shall be fertile, friable soil obtained from well drained arable land and
shall be free draining, non toxic and capable of sustaining healthy plant growth.
2/13.2 Suitable Material shall comprise all material that is acceptable in accordance
with the Contract for use in the Works. Suitable material for earthworks shall be
approved soil with a plasticity index not exceeding 6 (liquid limit shall not exceed
40% when tested according to BS 1377: Part 2: 1990: Test 4.5) obtained from
excavations within the works or from borrow pits approved by the Engineer. It
shall not contain an excess of fines (not more than 20% passing Sieve Size
0.063mm determined by BS 1377: Part 2: 1990 Clause 9.2 "Determination of
particle size distribution by wet seiving") or in excess of 2% organic material (BS
1377 Part 3). Suitable material for earthworks shall have a soaked CBR value at
95% of maximum dry density not less than 15% when tested according to BS
1377 Part 4 (method 7). The maximum particle size shall not exceed 63 mm. See
the table below for the details of chemical requirements for existing materials.
Chemical Analysis Requirements

Existing Material – Soil (Suitable for Filing)
Test Method Specifications

Acid soluble Chloride BS 1377:P 3:1990:M 7.3 2% max.
Acid soluble Sulphate BS 1377:P 3:1990:M 5.5 2% max
Organic matter content BS 1377:P 3:1990 M 3 2% max
Water soluble Chloride BS 1377:P 3:1990: M 7.2
Water soluble Sulphate BS 1377:P 3:1990:M 5.5 AMD Total 5% max
9028-1996
PH of the Soil BS 1377: P 3:1990: M9 7-9
2/13.3 The condition for Unsuitable Materials chemical analysis shall be mentioned as
follows.

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Chemical Analysis Requirements

Existing Material – Soil (Unsuitable for Filing)
Test Method Specifications

Acid soluble Chloride BS 1377:P3:1990:M7.3 >2%.
Acid soluble Sulphate BS 1377:P3:1990:M5.5 >2%
Organic matter content BS 1377:P3:1990 M3 >2%
Water soluble Chloride BS 1377:P3:1990: M7.2
Water soluble Sulphate BS 1377:P3:1990:M5.5 AMD Total >5%
9028-1996
Carbonate content of BS 1377:P3:1990:M6.3 AMD Not less than 30
the soil 9028-1996 and greater than
40% (<30
or >40)%
PH of the Soil BS 1377: P3:1990: M9 <7 or >9
2/13.4 Material for Improved Subgrade layer shall meet the following requirements:-
- Not more than 20% by weight passing Sieve Size 0.063mm determined
by BS1377: Part 2 : 1990 Clause 9.2 “Determination of particle size
distribution by wet sieving”.
Soaked CBR value at 95% maximum dry density (soaked) BS 1377 Part 4
(Method 7) not less than 30% MDD/OMC tested according to BS 1377
Part 4 (method 3.5 or 3.6).
A chemical analysis of the proposed material shall be carried out to satisfy the
following requirements:-
- The material shall be shown to have an acid soluble sulphate content of

2% or less and a chloride content in the form of acid soluble chloride of
2% or less by dry weight. The applicable Test methods should be in
accordance with BS 1377 Part 3 (method 5) and BS 1377 Part 3 (Method
7) respectively.
When approved by the Engineer a sulphate content greater than that specified
may be acceptable when the carbonate content is in the region of 30-40% (BS
1377 Part 3 (method 6)).
Higher chloride contents may be tolerated provided that the ratio of (carbonate +
sulphate) to chloride contents is maintained at approximately 15:1.
The moisture content of the material before compaction shall not vary by more
than +/- 2% of the optimum moisture content when tested in accordance with BS
1377 : Part 2 Test 3.2.
The material shall possess satisfactory binding characteristics to enable it to be

compacted to give a smooth well knit surface as judged by the Engineer.

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2/13.5 No excavated suitable material shall be removed from the Site without the
Engineer’s written permission. Should the Contractor be permitted to remove
suitable material from the site to suit his operational requirements, then he shall
make good any consequent deficit or filling arising there from at his own
expense.
2/13.6 If dune sand used, it shall not contain more than 2% organic matter while tested
as per BS 1377:P 3:1990 M 3 AMD 9028: 1996.
2/13.7 Layers of dune sand between layer of granular materials shall not be allowed.
2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION
2/14.1 The Contractor shall employ only that plant which is suited to the soils to be
handled. He shall not at any time use plant which damages or reduces the
natural strength of the soil either in its in-situ state or during handling and placing
or in its final compacted state. Unsuitable or faulty plant shall be removed from
the work site and borrow pits at the order of the Engineer.
2/14.2 The Plant and equipment used for earthworks construction shall be maintained in
good working condition for the duration of the works. The Contractor shall apply
adequate quantities of plant and equipment necessary for the proper execution of
the works in an expeditious manner.
2/14.3 Main plant and equipment shall meet the requirements outlined in Clause 1/29 of
these Specifications.
2/15 EMBANKMENT CONSTRUCTION
2/15/1 This work shall consist of constructing roadway embankment with suitable
material, including the preparation of the areas upon which they are to be placed
and the placing and compacting of approved material within roadway areas
where unsuitable material has been removed. All operations will be performed in
accordance with the Specifications and in conformity with the lines, grades,
thickness and typical cross-sections shown on the drawings or as established by
the Engineer.
2/15.2 Compaction equipment shall conform to the number and type outlined in the
Contractor’s detailed programme of work as approved by the Engineer and
satisfactory performance shall be the basis for such approval.
2/15.3 All materials derived from excavation shall be used in the embankment unless
otherwise declare unsuitable by the Engineer.
2/15.4 Prior to the commencement of embankment the Contractor shall construct trial
compaction lengths as directed by the Engineer. The soils used in the trials shall
be those encountered along the line of the road as approved by the Engineer
and/or those originating from the approved borrow pit. The object of the trials is
to determine the Field Compactibility of the material with the plant and
compaction equipment available with the Contractor. The Engineer may order
additional compaction trials when he deems them necessary.
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2/15.5 During the construction of embankments the Contractor shall control and direct
construction traffic uniformly over the full width of the embankment. Damage to
compacted layers by construction traffic shall be made good by the Contractor at
his own expense.
2/15.6 The Contractor shall be responsible for the stability of all embankments and shall
replace all sections which, in the opinion of the Engineer, have been damaged or
displaced due to carelessness or neglect on the part of the Contractor, or due to
natural causes, such as storms, and not attributable to the unavoidable
movement of the natural ground upon which the embankment is made. During
construction, the roadway shall be kept shaped and drained at all times. When
unsuitable material has been placed in the embankment, its removal shall be at
the expense of the Contractor. Throughout the duration of the Contract all
damage to completed earthworks attributable to rain and rainfall run-off or to any
other cause shall be made good by the Contractor without delay and whenever
possible within 24 hours of such damage occurring.
2/16 EMBANKMENT FOUNDATION
2/16.1 All debris, unsuitable material and vegetable matter shall be removed from the
surface upon which the embankment is to be placed and cleared surface shall be
completely broken up by ploughing, scarifying or stepping to a minimum depth of
twenty (20) centimetres.
2/16.2 The foundation material shall be adjusted to a moisture content within the
moisture range of +/- 3% of the optimum moisture content and compacted to not
less than ninety-five (95) percent of the Maximum Dry Density as determined by
BS 1377 Part 4 AMD 13925:2002 (method 3.5 or 3.6) where the embankment is
less than one and half (1.5m) metres below subgrade; and compacted to not less
than ninety (90) percent where the embankment is more than one and half (1.5m)
metres below the subgrade when tested in accordance with BS 1377 Part 9
(Method 2.1 or 2.2).
2/16.3 If the original surface upon which the embankment is to be placed is an old
roadbed, the surface shall be ploughed scarified or broken up, regardless of the
height of the embankment to be placed and compacted to a density as
determined by the Engineer. All aggregate particles shall be reduced to a
maximum size of 63mm.A well-mixed and uniform layer surface shall be
produced. The embankment layers shall be compacted according to sub section
2/16 requirements.
2/16.4 Where an embankment is to be placed on appreciably sloping ground, this

surface shall be benched in steps or trenched in accordance with the Engineer’s
instructions, including if necessary any under-training of the affected part of the
site.
2/16.5 In circumstances where backfill has to be deposited below standing water. In

such cases the Contractor shall use only an approved granular material of
maximum size not greater than 37.5 mm and which when tested in accordance
with BS 1377 Part 2 Test 9.2 or 9.3 or BS 812 Part 103 Section 103.1 (cl.7.2 or
7.3) complies with the requirements of Table 1 below. Such material shall have a

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‘ten percent fines” value of not less than 5 tonnes when tested in accordance with
B.S. 812 Part 111 and may be deposited below water without the associated use
of compaction plant
Table-1 Free Draining Material
B.S. Sieve Size % By Weight Passing

20 mm 80 to 100
10 mm Up to 100
5 mm Not more than 85
0.600 mm Not more than 45
0.075 mm Not more than 5
2/17 PLACING AND COMPACTION REQUIREMENTS
2/17.1 Only approved materials shall be used in the construction of embankments.
2/17.2 In the formation of the embankment it is strictly forbidden to push the excavated
materials from the side of the road to the embankment by means of bull dozers.
2/17.3 The fill material shall be delivered and spread in layers not exceeding 25 cm
compacted thickness. The layers of fill shall be graded, levelled, pulverised and
mixed, with water added as necessary, to ensure homogeneous conditions
through the full depth of the uncompacted layer. For field density testing refer to
specification sub-section 2/19.
2/17.4 The compacted density of the fill shall be equal to or greater than 95 (ninety-five)
percent of the Maximum Dry Density as determined by BS 1377 Part 4 (method
3.5 or 3.6).
2/17.5 The material to be imported for the “improved subgrade layer” to be constructed
above “earthworks formation level” up to “top of improved subgrade” level as
shown on the drawings shall conform to the Specification Sub-Section 2/13
Paragraph 4.
2/17.6 All slopes, lines and grades shall be true, correct, and accurate and according to
those shown on the Drawings or otherwise directed and approved by the
Engineer. The “earthworks formation level” in embankments shall be accurate to
the authorised profile grade to plus one (1) cm or minus two (2) centimetres and,
the ‘top of improved subgrade’ level, plus or minus one (1) centimetre for 3
locations maximum each 100 m interval. Selected material shall be placed
wherever required. Where discrepancies are found in the work the Contractor
shall make necessary corrections in a manner approved by the Engineer.
2/18 MOISTURE CONTROL REQUIREMENTS
2/18.1 When the moisture content of the embankment soil does not fall within +/- 3% of
the optimum moisture content, water shall be added and thoroughly mixed into
the soil, by approved methods or the material shall be aerated, wherever is
needed to adjust the soil to the proper moisture content.

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2/18.2 The amount of water to be added shall be only that amount that will, as
determined by the Engineer by field tests, provide a moisture content in the soil
within the required range plus a reasonable amount to compensate for
evaporation and other unavoidable losses. Water added in excess of this

amount shall be considered as excess water and must be removed by aeration or
other suitable means as directed by the Engineer. Satisfactory methods and
sufficient equipment shall be used for the furnishing and handling of the water so
that there will be no undue loss due to evaporation or waste. If water is added to
cut areas or borrow pits, the surface of the areas or pits shall be maintained in
such a manner that will prevent undue loss of moisture and segregation.
2/18.3 Use of saline water for earthworks will only be permitted if the percentage of
water soluble salts in the compacted fill does not exceed 5% by weight of dry soil
when tested in accordance with B.S. 1377 Part 3. Test No. 5 & 7 for (SO3 + Cl).
2/18.4 For subgrade material moisture range refer to sub-clause 2/13.4
2/19 TESTING METHODS
2/19.1 A dry density/moisture content relationship in accordance with BS 1377 Part 4

(method 3.5 or 3.6) will be made for each type of soil to be used in the
construction of the work to determine the Maximum Dry Density, the Optimum
Moisture Content and the Moisture Range required of the soil for satisfactory
compaction. In Situ density of soil shall be determined accordance with BS
1377:1990 Part 9 : AMD017229: 2007.
2/20 MINIMUM TEST REQUIREMENTS
2/20.1 For the Contractor’s general guidance, the following tests will be required prior to
use, and during the construction of the embankment and of the subgrade.
EMBANKMENT
2/20.2 Soil samples for Soil classification according to BS 1377 : Part 1, Part 2 and Part
4, laboratory moisture/density relationship tests and California Bearing Ratio shall
be taken prior to use, from any proposed source of material. Each sample shall
represent not more than 5,000 Cu.m. or part of as directed by the Engineer.
Sampling shall be in accordance with ASTM D75 : 2003, Or BS 5930 : 1999. For
minimum test requirements and frequencies please refer to “Table 1-4 in Vol.2
Part 2 – Specifications”.
2/20.3 For every completed layer of fill at least three field density tests shall be
performed for every unit of carriageway. (One unit being 2250 sq.m)
2/20.4 The Contractor shall carry out any additional compaction tests as ordered by the
Engineer at no additional cost.
IMPROVED SUBGRADE
2/20.5 Samples for Soil classification, laboratory moisture density relationship tests and
CBR tests shall be taken prior to use, from any proposed source of material.
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Each sample shall represent not more than 3,000 Cu.m or as directed by the
Engineer.
2/20.6 For every completed layer of subgrade, three field density tests shall be
performed on each unit of carriageway. (One unit being 1500 sq.m.)
2/20.7 The frequency of field compaction tests on the shoulders shall be three every unit
constructed or as directed by the Engineer. (One unit being 1500 sq.m.)
ROCKFILL
2/20.8 Where embankments to be compacted are formed of material consisting
predominantly of rock fragments of such size that the material cannot be placed
in layers of the thickness prescribed without crushing, pulverising or further
breaking down the pieces resulting from normal excavation methods, the material
may be placed in the embankment in layers not exceeding a thickness twice the
average size of the larger rocks, except that no layer shall exceed 600 mm of
loose measurement.
Materials shall be carefully placed so that all large stones will be well distributed
and the voids completely filled with smaller earth, sand or gravel to form a solid
embankment. Each layer shall be bladed or levelled with motor grader, bull
dozer or similar equipment capable of shifting and forming the layer into a neat
the orderly condition. No rocks larger than eighty (80) mm in any dimension shall
be placed in the top one hundred and fifty (150) mm of the embankment unless
otherwise noted on the drawings. Conformance to these provisions and
compaction in a manner and to a point of consolidation approved by the Engineer
will be considered as fulfilment of the requirements for the type of compaction
shown on the drawings. Normally, compaction tests will not be performed in
these areas but the Engineer reserves the right to test compaction in some other
manner if he deems a test necessary to ensure consolidation. Each layer must
be approved by the Engineer before the next layer is placed.
Embankments, which are formed of materials that contain rock but also sufficient
compatible material other than rock or other hard material to make rolling
feasible, shall be placed and compacted in the manner and to the point of
consolidation approved by the Engineer. Moisture shall be added as directed by
the Engineer. Compaction tests will be made wherever the Engineer determines
they are feasible and necessary. Each layer must be approved by the Engineer
before the next layer is placed.
2/21 STABILISING CRUSHED MATERIAL
2/21.1 In the event the foundation on which the embankment or the subgrade materials
will be laid is saturated by water and unstable, the Engineer may decide to lay
crushed granular material to stabilise the foundation. Stabilising crushed material

shall not be laid directly on ground soil but it shall always be laid on geotextile
fabric covering the area to be stabilised as shown on the drawings or directed by
the Engineer.
2/21.2 Such stabilising crushed material when tested in accordance with BS 812: Part
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103: Section 103.1: (cl.7.2 or 7.3), Or BS 1377 P.2 method 9.2 or 9.3, 1985 and
1989 shall have the following gradation:-
BS TEST % PASSING
Sieve (mm)
50.0 100
25.0 80 - 100
14.0 60 - 85
5.0 40 - 70
2.0 20 - 50
0.85 5 - 25
0.425 0 - 10
0.180 0-2
2/21.3 The stabilising crushed material shall have the following characteristics:-
- Los Angeles Abrasion - Not more than 30% loss

(ASTM C-131 or
ASTM c-535)
- BulkSpecific Gravity - Not less than 2.65
(ASTM C-127 and C-128)
- Absorbtion - Not more than 2.0%
(ASTM C-127 and C-128)
2/21.4 The stabilizing crushed material will be laid in layers of 15 cm and compacted
until the foundation is fully stabilized such that the total thickness of the stabilizing
layer shall not be less than 30 cm. Only after inspection and approval by the
Engineer the Contractor may be allowed to continue the construction of the
embankment with other layers of embankment material and/or subgrade material.
The Engineer may decide, after having taken the levels of the existing water
table in the area, and keeping in consideration the finished roads levels, to
excavate portions of the foundation saturated by water, disposing of the
excavated materials, and replacing it with stabilizing crushed material.
2/21.5 Before starting any stabilizing of the foundation of the Engineer will instruct the
Contractor specifying the areas to be stabilized and the final levels to be reached
with the stabilizing crushed material.
2/22 GEOTEXTILE FABRIC
2/22.1 In areas where the Engineer deems the use of geotextile fabric necessary, the
Contractor shall furnish the place geotextile fabric as specified and as directed by
the Engineer.
2/22.2 The geotextile fabric furnished by the Contractor shall be of an approved grade
suitable for placement over fine sand. The geotextile fabric shall be a woven or
non-woven fabric consisting only of long chain polymeric filaments or yarns
formed into a stable network such that the filaments or yarns retain their relative
position to each other. The fabric shall be stabilised against ultra violet light, inert
to commonly uncounted chemicals and chemicals properties of the in-situ soil
and water, and it shall conform to the following minimum requirements:

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Weight ASTM, D 5261 - 135g/m2

Thickness under load (2KN/sq.m) ASTM D 5261 - 0.7mm
Tensile Strength (200mm width) ASTM D1682 - 1.6KN
Puncture Resilience (DIN 54307) - 1.5KN
Permeability BS 6906 Part 3 - 50 L/sq.m/s.
Ultraviolet Stability ASTM D 4335 - 50%after750hrs exposure
Burst Test ASTM D 4632 & 3786 - 2.1 kN
2/22.3 The surface to receive the geotextile fabric shall be prepared to a relatively
smooth condition free of obtrusions, depressions, and debris. The geotextile
fabric shall not be laid in a stretched condition, but shall be laid loosely with the
long dimension parallel to the centreline of the roadway. In the event that the
width of the proposed area for fabric requires more than one panel width of
fabric, the panels shall be overlapped a minimum 15 percent of the panel width.
Longitudinal joints in the fabric shall have an overlap of 50cm. To prevent
slippage of the overlapping fabric, the areas of overlap shall be stabilised as
approved by the Engineer with pins, anchor blocks, or aggregate piles. In the
event construction machinery is used to place the fabric, the working platform for
the machinery shall be the soil and not the previously laid fabric.
2/22.4 Prior to placement of the granular material (Stabilising crushed material) the
Contractor shall spread a layer of sand over the geotextile fabric as directed by
the Engineer. The aggregate material shall not be dumped directly on the fabric,
nor shall haul trucks be run on the fabric. The aggregate shall be spread by a
wheeled front-end loader.
The blade or bucket shall be kept sufficiently high so that the aggregate is not
being pulled over the fabric, but being dropped at a minimum height to the
satisfaction of the Engineer.
2/22.5 Fabric damaged or displaced before or during installation or during placement of

overlaying aggregate material shall be replaced or repaired to the satisfaction of
the Engineer at the Contractor’s expense.
2/23 EXCAVATION FOR STRUCTURES
2/23.1 This work shall consist of all excavation for structures, culverts, headwalls, catch
basins, manholes, inlets, and retaining walls and shall include all necessary
clearing and grubbing, all necessary bailing, drainage, pumping, sheeting,
strutting and the construction of coffer dams or cribs, if found necessary, and
their subsequent removal; also the disposal of all material obtained from such
excavation and backfilling to the level of the original ground; it shall include the
removal of that portion of existing structures below the ground which is
necessitated by the construction of the new structure.
2/23.2 Prior to commencing any structural excavation work 1.5 metres or more in depth,
the Contractor shall design and submit to the Engineer for review and approval,
within a minimum period of 1 week before the intended commencement date,
detailed working drawings of the structural excavation support member materials,
sizes, spacing and engineering calculations to validate their design, including the
maximum theoretical deflections of the support members. The system shall be
designed in such a manner that no raker struts or any other support members
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extend through surfaces exposed in the finished construction, and no shoring or

bracing is placed under permanent structures.
2/23.3 The engineering calculations shall show lateral earth pressure for the full
excavation depths, forces at various stages of support during installation and
removal and concrete placement, the anticipated equipment loads, surcharge
loads of any description, the maximum design loads to be carried by various
members of the support system and strut preload forces.
2/23.4 If the structure support system proposed includes tieback anchors, the
Contractor’s submittal drawings shall show the profile of the soil in which each
anchor is to be installed, the design load for the full depth of the excavation, the
maximum design and proof loads, surcharge loads of any description; equipment
loads, forces at various stages, support during installation and removal, and the
criteria proposed for deformation under proof loads. Where a proposed system
of tieback anchors projects beyond the vertical projection of the Contract limit
lines shown on the Drawings on to the adjoining property, the permission of the
owner shall be obtained in writing and such permission submitted to the Engineer
at the time the shop drawings of the support systems are submitted.
2/23.5 At locations where the excavation extends below the ground water table, a
dewatering system shall be provided which will effectively reduce the hydrostatic
pressure and lower the ground water levels below excavation levels, as required
for the safe and proper execution of the work and which will result in obtaining a
stable, dry subgrade for the execution of subsequent operations. The Contractor
shall design dewatering methods and settling basins so that no critical amounts
of soil, sand or silt are removed during either the initial operations or the
construction operations. Complete working drawings showing the type of
dewatering and ground water control system proposed shall be submitted to the
Engineer for his review.
2/23.6 The Contractor’s submittal drawings shall show the arrangement, location and
depths of the proposed dewatering system if required. A complete description of
the equipment and materials to be used and the procedures to be followed shall
be shown, together with the standby equipment, standby power supply and the
proposed location or locations of points of discharge of water. Any required
dewatering system design shall also include the measures taken to prevent
damage due to settlement of pavement, utilities, sewers, buildings and other
structures outside the excavation but within the area affected by the procedures.
2/23.7 The designs of the structure excavation support system and the dewatering
systems specified above shall be prepared by and signed by a Professional
Engineer approved by the Engineer specializing in this type of design work.
Approval of the designs and shop drawings shall not relieve the Contractor of the
adequacy and performance of these temporary works.
2/23.8 Pre-Construction Inspection-prior to the beginning of construction, the Contractor

and the Engineer shall make a detailed inspection of all adjacent buildings,
pavements, wells and other structures in order to determine its pre-construction
condition and the Contractor shall prepare, for the Engineer’s approval, a typed
Inspection report of the findings.
2/23.9 The Report shall include photographs, drawings and sketches with levels and
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dimensions illustrating the structures condition, noting in particular any existing

damage or structural inadequacy. Deficiencies and damage shall be suitably
marked on the structure such that it is not permanently defaced.
2/23.10 Three copies of the Report shall be submitted for the approval of the Engineer.
Once approved, five additional copies shall be supplied to the Engineer.
2/23.11 The Contractor shall notify the Engineer sufficiently in advance of the beginning
of any excavation so that cross-sectional elevations and measurements may be
taken of the undisturbed ground. The natural ground adjacent to the structure
shall not be disturbed without the permission of the Engineer.
2/23.12 Trenches or foundation pits for structures or structure footings shall be

excavated to the lines and grades or elevations shown on the drawings, or as
ordered by the Engineer. They shall be of sufficient size to permit the placing of
structures or structure footings of the full width and length shown. The elevations
of the bottoms of footings, as shown on the Drawing shall be considered as
approximate only and the Engineer may order, in writing, such changes in
dimensions of elevations of footings as may be deemed necessary, to ensure a
satisfactory foundation.
2/23.13 Unless otherwise provided for in the Drawings or Contract Documents or

directed by the Engineer structural excavation shall be carried out for a width of
at least 500mm beyond the horizontal outside limits of the foundation, footing,
box culvert or structural member to which the excavation relates. Concrete
blinding or sub-foundations are not to be considered as structure for the purpose
of defining such excavation.
2/23.14 If during the progress of the work, loose or improperly compacted soil is
encountered below the structural foundation levels, or adjacent thereof, which is
the result of prior removal of utilities or structures, such material shall be
completely removed within the limits as directed by the Engineer, backfilled with
suitable material and compacted to not less than 95% of the maximum dry
density as determined by BS 1377 Part 4 (method 3.5 or 3.6). Any previous
excavations encountered which would in the opinion of the Engineer be
detrimental to load distribution of new foundations to the underlaying soil, shall be
excavated and backfilled with Class 25 concrete (Clause 4/15).
2/23.15 After each excavation is completed, the Contractor shall notify the Engineer, for
approval of the depth of excavation and the character of the material, prior to
further structural works. Any over excavation shall be backfilled with Class 25
concrete (Clause 4/15) at the Contractors expense.
2/23.16 All rock or other hard foundation material shall be cleaned of all loose material
and cut to a firm surface, either level, stepped, or serrated as directed by the
Engineer. All seams or crevices shall be cleaned and grouted. All loose and
disintegrated rock and thin strata shall be removed.
When the footing is to rest on material other than rock, excavation to final grade
shall not be made until just before the footing is to be placed and special care
shall be taken not to disturb the excavation.
When the foundation material is soft or otherwise unsuitable as determined by

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the Engineer, the Contractor shall remove the unsuitable material and backfill
with approved granular material. This foundation fill shall be placed and
compacted in 150mm layers up to the foundation elevation and compacted to not
less than 95% of the maximum dry density as determined by BS 1377 Part 4
(method 3.5 or 3.6)
The placing of concrete shall follow as closely as practicable the structural

excavation.
2/23.17 Control of Ground Water: Prior to the commencement of construction at any

particular location, the Contractor shall install and maintain a system of
standpipes and other devices to monitor ground water level in any area which in
the opinion of the Engineer is likely to be affected by the dewatering. The
number, location and depth of all standpipes shall be to the satisfaction of the
Engineer.
- The Contractor shall check ground water levels at weekly or where
instructed by the Engineer, more frequent intervals and submit within 24
hours written reports to the Engineer in a form to be agreed.
- In the case of uncontrolled flow of water into any excavation, the Engineer
reserves the right to order an immediate cessation of work and to order
the Contractor to take immediate action to control the inflow of water.
Such actions and remedial works shall be to the Engineer’s approval.
2/23.18 Notification of Damage: The Contractor shall notify the Engineer immediately
of any movement or any damage not noted in the pre-construction report, to any
structure. The Contractor shall immediately cease his construction operations in
the vicinity and shall take immediate action to prevent further movement or
damage. The Contractor shall keep the Engineer fully informed of such action.
2/23.19 Remedial and Preventive Works: Should remedial works be necessary due to
damage caused to the structure or should the Engineer direct the Contractor to
carry out any works necessary to prevent damage to the structure due to the
Contractor’s construction works, the Contractor will present, without delay,
detailed drawings and specifications, as necessary, showing his proposed
remedial or preventive works for the Engineer’s approval.
In either case the Contractor will suspend all construction activities in the vicinity
of the structure until such time as the remedial or preventive works are carried
out to the Engineer’s satisfaction at the Contractor’s expense.
2/23.20 Post Construction Inspection: On completion of, but prior to final acceptance
of the works, the Contractor and the Engineer shall re-examine the structure to
determine any change from the original conditions. The Contractor shall supply
to the Engineer for approval five copies of a report describing measures he
proposes to take to correct any damage which resulted from the construction of
the works. The approved corrective measures shall be carried out by the
Contractor at his expense, to the Engineer’s satisfaction before final acceptance
of the works.
2/23.21 Utilization of Excavated Materials: All excavated material determined as

suitable by the Engineer, shall be utilised as backfill or roadway fill. The surplus
material, shall be disposed of as specified in sub-section 2/8 para 2. Excavated
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material shall not be deposited, at any time, so as to endanger the partly finished
structure or cause an obstruction of any kind. All unsuitable material shall be
disposed of to approved tips.
2/23.22 Backfill: Excavated areas around structures shall be backfilled with excavated
materials or imported granular material approved by the Engineer. Backfill
materials shall be placed in horizontal layers not exceeding 150mm in depth after
compaction to not less than 95% of the maximum dry density as determined by
BS 1377 Part 4 (Method 3.5 or 3.6). The field density shall be determined by BS
1377 1990 Part 9 (Method 2.1 or 2.2). Each layer of material shall be moistened
or dried as required to enable thorough compaction as specified. Backfill shall be
placed to the original ground level or as indicated on the drawings.
2/23.23 Backfill or embankment shall not be placed behind the walls of concrete
structures or rigid frame structures until the top slab is placed and cured. Backfill
and embankment behind abutments when held at the top of the superstructure
shall be carried up simultaneously behind opposite abutments. Backfill shall be
carried up equally on either sides of box culverts.
2/23.24 For frequency of testing of backfill material refer to sub-section 2/20.
SECTION 3 - PAVEMENT CONSTRUCTION
3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS
3/1.1 All aggregates for use in the construction of the Pavement Layers shall be
obtained only from sources approved by the Engineer.
3.1.2 The Contractor shall have determined the location, suitability and quantity of
material available before tendering as well as the cost and the amount of work
required to extract, crush, screen and clean the material and the length of haul to
the job site.
3/1.3 The Contractor shall provide the Engineer, within thirty (30) days prior to the
scheduled beginning of the crushing and screening operations, with a complete
report on the origin and composition of all stone and/or gravel aggregates to be
used in the Work (Aggregate Resources Report). All materials shall comply with
the specified requirements for the various aggregates.
3/1.4 The source and manufacture of the aggregates which will meet the requirements
of the Specification is the sole responsibility of the Contractor. It is also the
Contractor’s sole responsibility to manufacture such aggregates at the rates and
in the quantities required to complete the work within the specified Contract
Period.
3/1.5 The approval of the Contractor’s crushing and screening plant equipment by the
Engineer shall in no way relieve the Contractor of the responsibility of producing
aggregates which meet the Specifications and in the quantities required for the
completion of the work within the specified Contract Period.
3/1.6 No aggregate producing equipment shall be put into operation prior to the
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approval of the equipment by the Engineer. If after the equipment is put into
operation it fails to perform as proposed, the Contractor shall provide additional
equipment or replace the original equipment with more suitable equipment, as
may be directed by the Engineer.
3/1.7 The Contractor shall commence crushing and screening of aggregate

immediately after the Contractor receives approval of his aggregate sources.
3/2 TESTING OF AGGREGATES
3/2.1 Testing to ascertain the properties of all aggregate materials shall be carried out
in accordance with Clause 1/7.
3/3 APPROVAL AND INSPECTION OF AGGREGATES
3/3.1 All sources of aggregates shall be approved by the Engineer prior to the
processing of material from such sources. An individual source of aggregate is
deemed to be a particular location within a quarry or borrow pit where material of a
constant specific gravity is obtained (with possible variation due to minor changes
in characteristics of rock). Test certificates obtained by the Contractor or test
performed by the Contractor at his expense are intended to assist him in his
estimate of the location, extent and quantities which will comply with the
Specifications, when properly processed, and will in no way obviate the need for
future testing by the Engineer.
3/3.2 Only materials from approved sources shall be processed for incorporation into
the work. Approval of specific sources of materials shall not be considered as
final approval and acceptance of materials from such sources. The presence of
weathered materials discovered in the quarry areas shall be a cause of rejection
of the source of materials.
3/3.3 After having received approval of specific sources of material the Contractor
cannot change these without prior written approval of the Engineer.
3/3.4 All processed materials shall be tested and approved before being stored on the
site or incorporated in the works and may be inspected and tested at any time
during the progress of their preparation and use. Questionable materials,
pending laboratory testing and subsequent approval shall not be unloaded and
incorporated with materials previously approved and accepted.
3/3.5 If the grading and quality of the material delivered to the site does not conform to
the grading and quality as previously inspected and tested, or does not comply
with the Specifications, the Engineer reserves the right to reject such material at
the site of the work.
3/3.6 Samples must meet all test requirements as specified under the Specifications.
The Contractor shall permit the Engineer to inspect any and all material used or
to be used, at any time during or after its preparation, or while being used during
the process of the work or after the work has been completed. All such materials
not complying with the required specifications, whether in place or not, shall be
rejected and shall be removed promptly from the work. The Contractor shall
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supply or arrange with any producers or manufacturers to supply, all necessary

material, labour, tools and equipment for such inspection.
3/4 STORAGE OF AGGREGATES
3/4.1 The stockpile site shall be prepared by clearing and smoothing and must be
approved by the Engineer. Prior to any stockpiling of aggregates, cross-sections
of the stockpile site shall be taken and control points established for use in
determining the quantity of subsequently stockpiled material.
3/4.2 The equipment and methods used for stockpiling aggregates and for removing
aggregates from the stockpiles must be approved by the Engineer and shall be
such that no segregation of the aggregate will result and no foreign material will
contaminate the aggregate.
3/4.3 Material shall be stored in a manner that will ensure preservation of their
specified quality and fitness for the work. They shall be placed on hard, clean
surfaces and, when required by the Engineer they shall be placed under cover.
Stored materials shall be located in such a manner to facilitate prompt inspection
and control. Private property shall not be used for storage purposes without
written consent of the owner or lessee and payment to him, if necessary, at the
Contractor’s expense.
3/4.4 The centre of the storage area shall be elevated and sloped to the sides in order
to provide proper drainage of excess moisture. The material shall be stored in
such a way to prevent segregation and to allow proper control of moisture.
Aggregate stockpiles shall be built up in layers not exceeding one (1) metre. The
height of each stockpile, shall be limited to a maximum of five (5) metres.
3/4.5 Sufficient material must be stored in stockpiles to allow for testing and approval
of such materials prior to use in the works.
3/5 TIDYING-UP OF QUARRY AREA
3/5.1 The Contractor shall tidy-up the quarry areas on completion and ensure that side-
slopes are not steeper than 1 to 2 and in a condition acceptable to the Employer
and to the Engineer.
3/6 GRANULAR SUB-BASE
3/6.1 Description: Granular sub-base shall consist of furnishing, spreading, and

compacting sub-base in accordance with the details shown on drawings and
these Specifications.
3/6.2 Materials: Granular sub-base material for Road sub-base shall consist of hard,
durable natural/screened gravel or crushed stone, and shall be free from clay
balls or other deleterious substances. Granular sub-base shall be well graded
and lie within the grading envelope stated below when tested in accordance with
BS 1377:Part 2:1990 :Test 9.2. The material should have a minimum C.B.R of
30% at 95% of maximum dry density and should comply with Clause 3/6.4.
Organic matters (BS 1377 Part 3: 1990 Method 3) shall not exceed 0.2%.

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SIEVE SIZE PERCENTAGE

PASSING
63 mm 100
37.5 mm 85 - 100
9.5 mm 40 - 85
4.75 mm 25 - 45
0.6 mm 8 - 25
0.063 mm 0 - 10
3/6.3 Construction: Road sub-base material shall be delivered to the roadbed as

uniform mixture and shall be spread in layers or windrows. Segregation shall be
avoided and the sub-base shall be free from pockets of coarse or fine materials.
Each road sub-base layer shall be spread by finisher and/or grader or any
approved mechanical methods, watered, shaped and compacted to the required
grade and cross-section not exceeding to thickness of 150 mm.
The compaction procedure and plant shall be to the satisfaction of the Engineer.
At the time of compaction the moisture content of the laid material shall not vary
by more than +2% from the optimum moisture content.
The granular sub-base shall be compacted to not less than 95% of the maximum
density determined in accordance with BS 1377 Part 4 Method 3.6. Particle size
analysis of soils for sieve analysis of fine and coarse aggregate shall be carried
out in accordance with BS 1377 : Part 2 : Test 9.2. The surface on completion of
compaction shall be well closed, free from movement under compaction plant
and free from ridges cracks or loose material. The finished surfaces of the road
sub-base shall not vary at any point more than 10 mm above or below the grade
established by the Engineer. The road sub-base shall be maintained in a
condition satisfactory to receive any subsequent base or surfacing material. Sub-
base which does not conform to the above requirements shall be reshaped or
reworked, watered and thoroughly recompacted to conform to the specified
requirements.
3/6.4 Relevant Test and Standards: The following tests should be carried out and
the material shall conform with the requirements stated:
TEST STANDARD LIMIT
Sampling ASTM D75-2003 ---

Los Angeles Abrasion ASTM C-131 or C-535 30% max.
Soundness (Magnesium ASTM C-88 12% max.
Sulphate Solution) 5 cycles
Liquid Limit BS 1377:Part 2: 1990 Test 35% max.
4
Plasticity Index BS 1377:Part 2: 1990 Test 6 max.
5
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Max Dry Density and BS 1377 Part 4 Method 3.6 2.10 Mg/m3
optimum moisture content min.
C.B.R at 95% of Max. Dry
Density by BS 1377 Part 4 BS 1377 Part 4 Test 7 30% min.
(method 3.6) (96 hour
soaked)
Field Density BS 1377:Part 9 Test 2.2 95% min.
MDD
Linear Shrinkage BS 1377:Part 2 Method 6.5 3% max.
Sulphate Content BS 812: Part 118 0.5% max.
(Acid Soluble)
Chloride Content BS 812 1% max.
(Acid Soluble) Part 117
Compaction Test (Modified BS 1377: Part 4:1990 2000mg/m3
Proctor) Method 3.6 min
3/6.5 Minimum Test Requirements
One sample every 3,000 cu.m or part of as directed by the Engineer shall be
tested for Grading, Plasticity Index, Maximum Dry Density, CBR and Loss by
Abrasion. Three in-situ Density test shall be made every unit of granular sub-
base laid (One unit being 1,500 sq.m.) or as directed by the Engineer. For
3/7 AGGREGATE ROADBASE DESCRIPTION
3/7.1 This work shall consist of furnishing and placing one or more courses of
aggregate, including binder soil if required, on a prepared subgrade or sub-base
in accordance with sub-section 3/8 to 3/13 of the Specifications, in conformity
with the lines, grades, thickness and typical cross-sections shown on the
drawings or established by the Engineer.
3/8 AGGREGATE ROADBASE MATERIAL
3/8.1 All aggregate roadbase material shall be free from dirt, shale or other deleterious
matter and shall be of such quality that it will bind readily to form a stable
aggregate roadbase.
Aggregate roadbase shall consist of uniform mixtures of gravel and/or crushed

gravel with sand, silt and clay, conforming to the specified gradation limits.
3/8.2 The standards listed in these specifications shall be the latest version at time of
use. The latest version may differ from the version at time of use. The latest
version may differ from the version listed at the time of writing of these. The
requirements for aggregate roadbase are:-
Liquid Limit BS 1377 : Part 2 : Test 4.5 25% maximum

Plasticity Index BS 1377 : Part 2 : Test 5 6 maximum
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Sand Equivalent ASTM D-2419 40 minimum

Loss by Abrasion ASTM C-131 or C-535 30% maximum
Flakiness Index (BS812 Part 105 Section105.1) 35 maximum
(Coarse Aggregate)
Elongation Index (BS812 Part 105 Section 105.2) 35 maximum
(Coarse Aggregate)
Soundness (ASTM C-88) (Magnesium Sulphate 5 cycles) 12% maximum
Organic matter content (BS1377 Part 3 Method 3) 0.2% maximum
Acid Soluble Chlorides (BS812 Part 117) 1% maximum
(Combined Aggregate)
Acid Soluble Sulphate (BS EN 1744-1 : 1998) 0.5% maximum
(Combined Aggregate)
Maximum Dry Density 2.20 Mg/m3 minimum
BS 1377 : Part 4 : Test 3.6
CBR on Remoulded Samples after 4 days soaking 80% minimum
at 100% of the maximum dry density (BS 1377 : Part 4 : Test 7)
Soaked CBR at 98% MDD 1990 – Test 7: BS:1377 Part 4 80% minimum
Aggregate Crushing Valve: BS 812 – p110-1990 Sampling 30% max
method to be in accordance with ASTM D75-2003.
3/8.3 The gradation limits when tested in accordance with BS 1377 : Part 2 : Test 9.2
shall be as follows:-
50 mm 100
37.5 mm 70 – 100
28 mm 55 – 85
20 mm 50 – 80
10 mm 40 – 70
5 mm 30 – 60
2.36 mm 20 – 50
0.425 mm 10 – 30
0.063 mm 5 – 15
Aggregate road base shall consist of uniform mixtures of gravel and/or crushed
Gravel with sand, silt and clay, conforming to specified gradation limits.
3/9 SPREADING AGGREGATE ROADBASE
3/9.1 Aggregate roadbase shall be spread on subgrade or sub-base which has been
approved by the Engineer. Aggregate roadbase which has been placed on a
subgrade or sub-base not approved by the Engineer shall be removed at the
Contractor’s expense.
The material shall be spread using a paving machine or spread box operated
with a mechanism which levels off the material at an even depth and without
delay. If necessary, the material may be a spread with the grader as and when
approved the Engineer.
3/9.2 Aggregate roadbase shall be spread on the approved subgrade in layers not
exceeding fifteen (15) centimeters in compacted depth.
3/9.3 The material shall be handled in a manner which avoids segregation.

Segregated materials shall be remixed until uniform. Suitable precautions shall

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be taken to prevent rutting of the subgrade or sub-base during the spreading of

aggregate road base materials. No hauling or placement of material will be
permitted when, in the judgment of the Engineer, the weather or road conditions
are such that the hauling operations will cause cutting or rutting of the subgrade
or cause contamination of aggregate roadbase material.
3/10 COMPACTION OF AGGREGATE ROADBASE
3/10.1 The moisture content of the aggregate roadbase material shall be adjusted prior
to compaction, by watering with approved sprinkler trucks or by drying out, as
directed by the Engineer, to that required to obtain the specified density for
aggregate roadbase. Aggregate roadbase shall be compacted to not less than
Ninety Eight (98%) percent of the maximum dry density, as determined according
to BS 1377 : Part 4 : Test 3.6 at a moisture content between + 2.0% of the
O.M.C. The field density and actual moisture content shall be determined
according to BS 1377 : Part 9 : Test 2.2. Water used in mixing and compacting
road base material shall contain not more than 500 ppm of chloride expressed as
CL. when tested in accordance with ASTM D-512.
3/10.2 The aggregate roadbase shall be compacted by means of approved compaction

equipment progressing gradually from the outside of the road towards the centre
with each succeeding pass uniformly overlapping the previous pass. Rolling
shall continue until the entire thickness of each layer is thoroughly and uniformly
compacted to the specified density. Rolling shall be accompanied by sufficient
blading in a manner approved by the Engineer, to ensure a smooth surface free
from ruts or ridges and having the proper section and crown.
3/10.3 The surface of the material shall on completion of compaction be well closed,
free from movement under the compaction plant and free from compaction
planes, ridges, cracks, or loose material.
3/10.4 Any areas inaccessible to normal compaction equipment shall be compacted by

means of mechanical tampers until satisfactory compaction is obtained.
3/10.5 The Contractor shall program his operations to avoid the drying out of the sub-
base during construction. If any layer of aggregate roadbase material, or part
thereof, is permitted to dry out after compaction, or does not conform to the
required density or finish, the Contractor shall, at his own expense, rework, water
and recompact the material, as directed by the Engineer, to the density specified,
before the next layer of aggregate roadbase or subsequent pavement layers is
placed.
3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE
3/11.1 If directed by the Engineer, prior to the commencement of the aggregate

roadbase operations, the Contractor shall construct trial lengths not to exceed
250 metres. The materials used in the trials shall be those approved for use as
aggregate roadbase, and the equipment used shall be that according to the
Contractor’s approved detailed program of work.
3/11.2 Trial lengths may not form part of the permanent works but may be permitted in
the construction of temporary detours of sufficient length.
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3/11.3 The object of these trials is to determine the adequacy of the Contractor’s
equipment, the loose depth measurements necessary to result in the specified
compact layers depths, the field moisture content, and the relationship between
the number of compaction passes and the resulting density of the material.
3/11.4 The Contractor may proceed with the aggregate roadbase work only after the
methods and procedures established in the compaction trials have been
3/12 FINISHING OF AGGREGATE ROADBASE
3/12.1 Immediately prior to the placing of the first layer of the next pavement course on
to the aggregate roadbase the final layer of aggregate roadbase shall be at the
specified density and to the required grade and section. In order to maintain
these requirements while placing the next course it may be necessary
mechanically sweep or cleaned with compressed air to remove the loose material
and if necessary to water and reshape the surface of the aggregate roadbase.
This work shall be at the Contractor’s expense.
3/12.2 The surface of the finished aggregate roadbase will be tested with a three (3)
metre straightedge by the Engineer at selected locations. The variations of the
surface from the testing edge of the straight edge between any two (2) contacts
with the surface shall at no point exceed twelve (12) millimeters when placed on
or parallel to the centreline, or twelve (12) millimeters when placed perpendicular
to the centreline of the roadway. The aggregate cross section as shown on the
drawings and shall not vary by more than ten (10) millimeters from the required
elevation. All humps and depressions and thickness deficiencies exceeding the
specified tolerance shall be corrected by removing the defective work or by
adding new material as directed by the Engineer. Skin/shallow patching of an
area without scarifying the surface to permit proper bonding of the added material
will not be permitted.
3/13 MINIMUM TEST REQUIREMENT FOR AGGREGATE ROADBASE
3/13.1 One sample every 1,000 cu.m or part of as directed by the Engineer shall be
tested for Grading Plasticity Index, Sand Equivalent, Maximum Dry Density,
C.B.R and Loss by Abrasion. Three in-situ Density tests shall be made per unit
(900 sq.m) of aggregate road base laid or as directed by the Engineer. For
3/14 WET-MIX MACADAM ROADBASE, DESCRIPTION
3/14.1 This work shall consist of furnishing and placing one or more courses of high
quality crushed aggregate, bound by means of carefully controlled moisture
content, on the prepared subgrade or sub-base in conformity to the line, level and
thickness shown on the drawings or as directed by the Engineer.
3/15 WET-MIX MACADAM ROADBASE MATERIAL

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3/15.1 The coarse aggregate shall consist of crushed rock (each particle shall have a
minimum of one crushed face – DCL Test Method DM 8:2001 and the fine
aggregate shall be crushed rock or naturally occurring material. The aggregate
shall conform to the following gradation:
SIEVE SIZE (BS) PERCENT PASSING
50 mm 100
37.5 mm 95 – 100
20 mm 60 – 80
10 mm 40 – 60
5 mm 25 – 40
2.36 mm 15 – 30
0.6 mm 8 – 22
0.063 mm 2–8
The particle size shall be determined in accordance with the requirements of BS

1377 Part 2 (Method 9.2 or 9.3).
3.15.2 The gradation shall be adjusted as required or as directed by the Engineer within
the above limits to ensure the mix has adequate binding properties.
3/15.3 Wet-mix road-base material as a combined aggregate mix shall have physical
properties which do not exceed the following values;
Liquid Limit BS 1377 : Part 2 : Test 4.5 25%

Linear Shrinkage (BS 1377 Part 2 Method 6.5) 3%
Plasticity Index BS 1377 : Part 2 : Test 5 6
Aggregate Crushing Value (BS 812 Part 110) 25%
Water Absorption (ASTM C128/C127) 2.0% max.
Flakiness Index (BS 812 Part 105 Section 105.1) 30
Elongation Index (BS 812 Part 105 Section 105.2) 30
Los Angeles Abrasion Loss 30%
(ASTM C-131 or C-535)
Soundness Loss (ASTM C88) 5 cycles 12%
(Magnesium Sulphate)
Organic matter content (BS 1377 Part 3 Method 3) 0.2%
Chloride Content (Acid Soluble) 1% max.
BS 812 Part 117
Sulphate Content (Acid Soluble) BS EN 1744-1 : 1998 0.5% max.
Dry density/moisture content relationship as per
BS 1377: Part 4 : Test 3.7 2.30Mg/m3 minimum
CBR 80%
The sand equivalent shall not be less than 45 (ASTM D-2419).

For water absorption test shall be ASTM C128 and ASTM C127.
Sampling shall be in accordance with ASTM D75-2003.
When CBR on Remolded Samples after 4 days soaking at 100% of the maximum
dry density (BS 1377: Part 4 : 1990: Test 7)
3/15.4 The moisture content of the wet-mix macadam at the time of laying shall be the
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optimum +/- 1%. Water required to achieve this moisture content shall be added
at the mixing plant. Moisture determination shall be in accordance with BS 1377:
Part 2 : Test 3.2.
3/16 TRANSPORT AND SPREADING WET-MIX MACADAM ROADBASE
3/16.1 Transport vehicles carrying the plant mixed material shall have a capacity suited
to the output of the mixing plant and the site conditions and be capable of
discharging cleanly. 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.
3/16.2 The material shall be placed and spread evenly. The material shall be spread
using a paving machine or spreader box operated with a mechanism which levels
off the material at an even depth and without delay. Except where otherwise
specified, the material shall be laid and compacted in layers of maximum
thickness of 150 mm.
3/17 COMPACTION TRIALS OF WET-MIX MACADAM ROADBASE
3/17.1 If directed by the Engineer, prior to the commencement of the Wet-mix Macadam
Roadbase operations, the contractor shall construct trial lengths, not to exceed
250 metres. The materials used in the trials shall be those approved for use as
Wet-mix Macadam Roadbase and the equipment used shall be that according to
the Contractor’s approved detailed programme of work.
3/17.2 Trial lengths may not form part of the permanent works but may be permitted in
the construction of temporary detours of sufficient length.
3/17.3 The objective of these trials is to determine the adequacy of the Contractor’s
compacted layer depths, the field moisture content, and the relationship between
the number of compaction passes and the resulting density of the material.
3/17.4 The Contractor may proceed with the Wet-mix Macadam Roadbase work only
after the methods and procedures established in the compaction trials have been
3/18 COMPACTION OF WET-MIX MACADAM ROADBASE
3/18.1 The material shall be compacted to a field density equal to or greater than 100%
of maximum dry density value obtained when tested in accordance with BS 1377:
Part 4 : Test 3.7 : 1990 and shall have a minimum 4 days soaked CBR of 80% at
100% (BS1377 : Part 4 : Test 7 : 1990). Field density tests shall be carried out in
accordance with BS 1377 : Part 9 : Test 2.2.
3/18.2 Compaction shall be completed as soon as possible after the material has been
spread.
3/18.3 Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.

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3/18.4 The surface of any layer of material shall on completion of compaction be well
closed free from movement under compaction plant and free from compaction
planes, ridges, cracks or loose material. All loose, segregated or otherwise
defective areas shall be made good to the full thickness of layer and
recompacted.
3/18.5 Where directed by the Engineer a Sieve analysis shall be carried out on the
material recovered from 5 consecutive field density tests. Where this sieve
analysis shows oversize material content of 10% or greater the area of
construction will be removed and the source of the material rejected until further
notice. Where considered necessary other areas of work which were carried on
using material from the same source shall be tested in a similar manner.
3/19 FINISHING OF WET-MIX MACADAM ROADBASE
3/19.1 Immediately prior to the placing of the first layer of the next pavement course on
to the Wet-mix Macadam Roadbase the final layer of Wet-mix Macadam
Roadbase shall be at the specified density and to the required grade and section.
In order to maintain these requirements while placing the next course it may be
necessary to water and reshape the surface of the Wet-mix Macadam Roadbase.
This work shall be at the Contractor’s expense.
3/19.2 The surface of the finished Wet-mix Macadam Roadbase will be tested with a
three (3) metre straight edge by the Engineer at selected locations. The
variations of the surface from the testing edge between any two (2) contacts with
the surface shall at no point exceed ten (10) millimeters when placed on or
parallel to the centreline, or ten (10) millimeters when placed perpendicular to the
centreline of the roadway. The Wet-mix Macadam Roadbase shall be compacted
to the thickness and cross sections as shown on the drawings and shall not vary
by more than ten (10) millimeters from the required elevation. All humps and
depressions and thickness deficiencies exceeding the specified tolerance shall
be corrected by removing the defective work or by adding new material as
directed by the Engineer
3/19.3 Before placing the next construction layer or applying prime coat, the wet-mix
roadbase shall be mechanically swept then cleaned with compressed air to
remove loose material. As soon as possible after cleaning of the surface, the
wet-mix roadbase shall be sealed by the application of a prime coat as specified.
Should the surface of the material be allowed to dry out before the seal is
applied, it shall be lightly watered and re-compacted immediately prior to spraying
with prime-coat. In the event of a section of wet mix roadbase failing to comply,
either by level or degree of compaction, and where the full depth of the layer has
been allowed to dry out, it shall be removed and replaced at the Contractor’s
expense, with fresh material. Watering and re-mixing in place will not be
permitted.
3/20 MINIMUM TEST REQUIREMENTS FOR WET-MIX MACADAM ROADBASE
3/20.1 One sample every 1,000 cu.m. or part of as directed by the Engineer shall be
tested for Grading Plasticity Index, Sand Equivalent value, maximum Dry Density,
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C.B.R. and Loss by Abrasion.
3/20.2 Three in-situ density tests shall be made per unit (750 sq.m.) of each layer
carriageway and three in-situ density tests per unit (450 lin. m.) of shoulder or as
3/20.3 Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.
3/21 BITUMINOUS PAVING COURSES, DESCRIPTION
3/21.1 This work shall consist of the construction of the following hot-mix bituminous
courses which shall be either Asphaltic Concrete or Dense Bitumen Macadam as
shown on the drawings.
Bitumen Paving Courses shall consist of coarse aggregates, fine aggregates,

filler material, and bitumen binder.
3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE
3/22.1 Coarse aggregate, which is the material retained on a 4.75mm, shall consist of
crushed rock or crushed gravel. It shall be clean, hard tough, durable and sound,
and shall be of uniform quality and free from decomposed stone, shale, clay,
lumps and other deleterious substances. Sampling of coarse aggregate shall be
in accordance with ASTM D75.
3/22.2 Crushed gravel for use as coarse aggregate shall consist of the product obtained
by crushing material that has first been screened in such a manner that not less
than ninety (90) percent of the material to be crushed is retained on an ASTM
3/8’ sieve.
3/22.3 Percentage of partially crushed faces with minimum one crushed face shall be
100% by weight of each (stockpile) of aggregate. In addition, at least 85% by
weight of each separate stockpile of aggregate shall have all faces crushed. This
85% value may be reduced to 50% for certain categories of road where indicated
on the drawings.
Crushed face determination shall be as per Dubai Municipality Central Laboratory

Test Method DMS 7 and DMS 8.
3/22.4 Each and every stockpile of coarse aggregate shall have properties which
comply with the following values:-
Los Angeles Abrasion Loss (ASTM C-131 or C-535)

Base Course and Binder Course 30% max.
Wearing Course 25% max.
Aggregate Crushing Value (BS 812 Part 110)

Base Course and Binder Course 25% max.
Wearing Course 20% max.
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Soundness Loss (ASTM C88) 10% max.

Magnesium Sulphate (5 cycles)
Acid soluble chlorides (BS812 Part 117) 1.0% max.
Acid soluble Sulphates (BS EN 1744-1 : 1998) 0.5% max.
Flakiness Index (BS 812 Part 105 Section 105.1)

Base Course and Binder Course 30 max.
Wearing Course 25 max.
Elongation Index (BS 812 Part 105 Section 105.2)

Base course and Binder Course 30 max.
Wearing Course 25 max.
Water Absorption (ASTM C127) 2.0% max.
Stripping Test (ASTM D1664) Non Stripped Area 95% min.
3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE
3/23.1 Fine aggregate shall consist of the material passing a 4.75 mm sieve for
asphaltic concrete and a 3.35mm sieve for DBM mixes.
3/23.2 Fine aggregate including filler shall be obtained from 100% crushed gravel or
crushed rock pre-screened to exclude natural uncrushed fine material or
weathered unsound fines. The use of dune sand shall not be permitted.
3/23.3 Fine aggregate shall have properties which comply with the following values:-
Soundness Loss (ASTM C-88) 10% max.

Magnesium Sulphate (5 cycles)
Plasticity Index Non-Plastic

(BS 1377:Part 2 : Test 5)
Acid Soluble Chlorides 1.0% max.

(BS 812 Part 117)
Acid Soluble Sulphates 0.5% max.

(BS EN 1744-1 :1998)
Water Absorption (ASTM C128) 2.3% max.
Sampling of find aggregate shall be in accordance with ASTM D75.
3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE
3/24.1 When the combined grading of the coarse and fine aggregates is deficient in
material passing the ASTM No. 200 sieve, mineral filler shall be added as
approved by the Engineer at the Contractor’s expense.

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3/24.2 Mineral filler shall consist of finely ground particles of limestone or cement in
accordance with ASTM D-242. It shall be thoroughly dry and free from organic
substances and clay and meet the grading requirements following:
MINERAL FILLER
B.S. SIEVE ASTM SIEVE SIZE PERCENTAGE BY MASS
PASSING
600 micron No. 30 100
300 micron No. 50 95 - 100
150 micron No. 100 90 - 100
75 micron No. 200 70 - 100
Grading should be in accordance with ASTM D546. Relative density test as per,
as per BS812: Part 2: T 5.7.
3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES
3/25.1 The combined mineral aggregate shall meet the following physical requirements:-
Sand Equivalent (ASTM D-2419) determined
after all processing except for addition of asphalt binder 65 minimum
Plasticity Index(BS 1377:Part 2:Test 5) Non Plastic
3/25.2 When tested according to ASTM C-117 and ASTM C-136, the combined mineral
aggregate shall conform to Table 1 for Asphaltic Concrete and Tables 2, 3 and 4
for Dense Bitumen Macadam.
Table 1 - Aggregate Grading for Asphaltic Concrete
SIEVE SIZE
SQUAREOPENIN TOTAL PASSING (BY WEIGHT)
GS
BASE BINDER WEARING
ASTM COURSE COURSE COURSE
37.5 mm 100
25 mm 80 - 100 100 100
19 mm 62 - 92 80 - 100 86 - 100
12.5 mm -- 63 - 85 69 - 87
9.5 mm 45 - 75 57 - 77 58 - 78
4.75 mm 30 - 55 40 - 60 40 - 60
2.36 mm 20 - 40 25 - 45 25 - 45
0.85 mm 15 - 30 15 - 30 15 - 30
0.425 mm 10 - 22 10 - 22 10 - 22

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0.18 mm 6 - 15 6 - 15 6 - 15
0.075 mm 2-8 2-8 2-8
Table 2 - Aggregate Gradation for Dense Bitumen Macadam Roadbase
B.S. TEST SIEVE AGGREGATE, CRUSHED ROCK OR

mm GRAVEL
Percentage by mass passing
50 100
37.5 95 - 100
28 70 - 94
14 56 - 76
6.3 44 - 60
3.35 32 - 46
0.300 7 - 21
0.075 2-8
Note: The aggregate shall be in a surface dry condition prior to mixing.
Table 3 - Aggregate Gradation for Dense Bitumen Macadam Basecourse
AGGREGATE, CRUSHED ROCK OR

B.S. TEST SIEVE GRAVEL
Percentage by mass Passing for Finished
Thickness of Base Course
mm mm mm mm
65 - 80 50 - 60 35 - 45
50 100 -- --
37.5 95 - 100 100 ---
28 70 - 94 90 - 100 100
20 --- 71 - 95 95 - 100
14 56 - 76 58 - 82 65 - 85
10 --- --- 52 - 72
6.3 44 - 60 44 - 60 39 - 55
3.35 32 - 46 32 - 46 32 - 46
0.300 7 - 21 7 - 21 7 - 21
0.075 2-8 2-8 2-8
Table - 4 - Aggregate Gradation for Dense Bitumen Macadam Wearing

Course

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AGGREGATE, CRUSHED ROCK OR GRAVEL

B.S. TEST Percentage by mass Passing for Finished
SIEVE Thickness of Wearing Course
mm mm mm mm
35 - 50 25 - 30 20
28 100 --- ---
20 95 - 100 100 ---
14 70 - 90 95 - 100 100
10 55 - 75 70 - 90 95 - 100
6.3 40 - 60 45 - 65 55 - 75
3.35 25 - 40 30 - 45 30 - 45
1.18 15 - 30 15 - 30 15 - 30
0.075 2-6 2-6 2-6
3/25.3 The gradings given in Tables 1,2,3 and 4 represent the extreme limits which shall
determine suitability of aggregate for use from all sources of supply. The
aggregate as finally selected for use in the work shall have a grading within the
limits designated in Tables 1, 2, 3 and 4 as appropriate and for Table 1 may with
the Engineer’s agreement.
3/25.4 The coarse aggregate, shall show no detrimental amount of stripping when
tested in accordance with ASTM D-1664. The minimum value of non stripped
area shall be 95%. If stripping occurs, the aggregate shall be rejected and an
approved method of treatment specified to change the material from a hydrophilic

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to a hydrophobic state as directed by the Engineer, or an approved additive shall

be used with the bituminous binder.
3/25.5 When necessary to improve the coating of aggregate by bitumen, additives of

approved type will be added to the bituminous material in such percentage as
required to obtain satisfactory results in the affinity with bitumen test performed in
accordance with ASTM D1664. The approved additive will be used in
accordance with Technical Specifications issued by the manufacturer and
approved by the Engineer after appropriate testing.
3/25.6 No extra payment will be made for required anti-stripping additives.
3/26 BITUMEN BINDER
3/26.1 Bitumen Binder for the “Bituminous Paving Courses” shall be Bitumen Binder
penetration grade 60 - 70 unless otherwise specified as 40 - 50.
3/26.2 The bitumen shall be prepared by refining crude petroleum by suitable methods
and shall be homogeneous, free from water and shall not foam when heated to
175 degrees C (347F).
3/26.3 Bitumen penetration grade 60 - 70 and 40 - 50 shall conform to the requirements

of Table 5. Sampling shall be in accordance with ASTM D140.
Table 5 - Bitumen Penetration Grade 60 - 70 & 40 – 50
60 - 70 PEN 40 - 50 PEN
TEST ASTM MIN. MAX. MIN. MAX
.
Penetration at 25 deg.C D5 60 70 40 50
100g, 5 sec., (0.1MM)
Flash Point, Cleveland D92 232 -- 232 --

Open Cup, deg.C.
Ductility at 25 deg.C, cm D113 100 -- 100 --
Solubility D2042 99 -- 99 --
trichloroethylene, %
Rolling Thin film oven D1754 -- 1.00 -- 1.00

test, loss on heating as
per ASTM D 2872
Penetration of residue D5 52 -- 55 --
% of original
Ductility of residue at D113 50 -- -- --

25 deg.C, 5 cm/min.cm

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Kinematic Viscosity D2170 240 -- 280 --
(Centistokes) at 135 deg.

C
Softening Point D36 48 52 51 55

Ring & Ball apparatus
3/26.4 A sample of the bitumen that the Contractor proposes to use in the work,
together with a statement as to its source and properties shall be submitted to
and approved by the Engineer at least 45 days before the asphalt work begins.
3/26.5 No bitumen other than that representated by the approved sample shall be used
by the Contractor except with the written consent of the Engineer. Blending of
bitumen from different refineries will not be permitted.
3/26.6 For Asphaltic Concrete the percentage range of bitumen by weight of total mix to
be added to the aggregate shall be as prescribed in Table 6: For Dense Bitumen
Macadam the range shall be as prescribed in Table 9.
Table 6: Bitumen Content for Asphaltic Concrete
PAVEMENT BITUMEN PERCENTAGE BY WEIGHT

COURSE OF TOTAL MIX INCLUSIVE OF
TOLERANCE
Base 3.2 to 4.4

Binder 3.4 to 4.4
Wearing 3.4 to 4.4
3/27 JOB MIX FOR BITUMINOUS PAVING COURSES
3/27.1 The mix approved for use in the works shall be designed using Marshall tests in
accordance with ASTM D6926: 2004 for Marshall Preparation and ASTM D6927:
2005 for Marshall Testing, and field trials with the following recommendations
taken into account::
- For base course the Marshall shall be modified by substituting all

aggregate sizes over 25 mm with an equal weight of aggregate sizes in
the next lower grading sizes as specified in Tables 1, 2, 3 and 4.
- The combined aggregate gradation should be adjusted within the

allowable limits to achieve maximum stability whilst not going below the
minimum requirement for void content.
- The minimum bitumen binder content according to the results of the

Marshall Method of Mix design should be used provided that it will still
satisfy the durability, the stability and the void content requirements.

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- Prior to final approval, the proposed job mix, but with a bituminous content
at the upper percentage limits shall be compacted to refusal, (400 to 600
blows) and the resulting voids in the mix shall not be less than 2% for
asphaltic concrete or 3% for DBM.
- The final job mix must display the Marshall characteristics specified in
Table 8 for Asphaltic Concrete and Table 9 for Dense Bitumen Macadam.
3/27.2 Determination of VIM, VMA, VFB shall be in accordance with DMS 9.
3/27.3 At least thirty (30) days prior to the date he intends to begin production of plant-
mix “Bituminous Paving Course” Mixes, and after receiving approval of the
aggregates and bitumen from the Engineer the Contractor shall make a written
request for the approval of the job-mix formula from the Engineer. The job-mix
formula will be prepared by the Contractor under the supervision of the Engineer
in the Laboratory. The job-mix design and binder calibration factor shall be
checked at the Dubai Municipality Central Laboratory.
3/27.4 The laboratory job mix formula shall fix a single definite percentage of aggregate
passing each required sieve size, a single definite percentage of bitumen binder
to be added to the aggregate, at a temperature with tolerance as per the viscosity
temperature chart at which the mix is to be emptied from the mixer, and at a
temperature with tolerance as per the viscosity temperature chart at which the
mix is to be delivered to the work site. For tolerance limits applicable refer to
Table 7.
3/27.5 The laboratory job mix formula shall be used for the basis of approval of the job
standard mixture.
3/27.6 Trials areas having lengths of at least 30 m and to the specified layer thickness
shall be laid outside the area of the permanent work by the Contractor for the
Engineer’s approval, before the start of the permanent work. At least two
samples of non-compacted material from the trial area shall be taken in
accordance with ASTM D-979 and shall be analysed at Dubai Central Laboratory
to determine the aggregate grading and binder content. Stability, flow, Marshall
density and voids shall be determined for Marshall Specimens which are made
from plant and site samples. The results shall be submitted to the Engineer and
shall be approved by him before further mixing or laying is carried out. A method
statement regarding laying trial to be forwarded to the Engineer for approval prior
to the trial.
3/27.6.1 In the event, any bituminous mix that is currently being used in another running
DM project, is proposed by the Contractor for approval of using that mix in this
contract, then prior to the approval of otherwise, the Engineer will ensure that:
1) All copies of test reports pertaining to the proposed mix submitted by the
Contractor comply with the specification requirements as stated in this
Contract and
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2) The proposed mix complies with Clause 3/27 of this Contract by verifying it at
DCI.
Note: Any mix that is obsolete and currently not in use shall not be accepted at all
for re-approval.
3/27.7 Trial areas may form part of a temporary traffic detour subject to the approval of
the Engineer. The compaction trials according to sub-section 3/42 should be
performed on the trial mixes. If the trial areas form part of the temporary traffic
detour they shall not be paid for under the relevant Bill item.
3/27.8 Should the laboratory job mix formula after passing the mixing plant and laid and
compacted with approved plant fail to produce a satisfactory trial area, the mix
proportions may be modified by agreement with the Engineer, as necessary and
within the requirements of Table 7, 8 and 9 as applicable to produce a mix of
satisfactory workability and acceptable surface finish subject to the mix being
rechecked in accordance with the preceding Clauses of 3/27. After approval of
the trial area by the Engineer this mix shall be designated the ‘Job Standard Mix’
and shall thereafter be the approved mix.
3/27.9 All mixes produced shall conform to the Job Standard Mix approved by the
Engineer, within the ranges of tolerance specified in Table 7 (within the limits of
Table 1, 6 and 8 for Asphaltic Concrete and Tables 2, 3, 4 and 9 for Dense
Bitumen Macadam). Each day the Engineer shall take as many samples of the
materials and mix as he considers necessary and minimum of one sample for
every 300 tons laid or part thereof for checking their required characteristics.
When unsatisfactory results or changed conditions make it necessary, the
Engineer shall instruct the Contractor to establish a new job-standard following
approval of the new mix design in accordance with the preceding Clauses of
3/27.
3/27.10Should a change in a material be encountered or should a change in a source of

material be made, a new Job-Standard Mix shall be submitted by the Contractor
in accordance with the preceding Clause of 3/27 and approved by the Engineer
before the mix containing the new material is delivered. Job materials will be
rejected if they are found not to have the characteristics required by the approved
Job Standard Mix.
Table 7 - Job Mix Tolerance
Aggregate retained on 4.75 mm sieve or larger +/- 5%

Aggregate passing 4.75 mm sieve and retained on 0.85 mm sieve +/- 4%
Aggregate passing 0.85 mm sieve and retained on 0.075 mm sieve +/- 2%
Aggregate passing 0.075 mm sieve +/- 1.0%
Bitumen Binder +/- 0.2%
Temperature of mixing and placing +/- 100C

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Table 8 - Properties of Mix for Asphaltic Concrete
BITUMINOUS BITUMINOUS BITUMINOUS

PROPERTIES BASE BINDER WEARING
COURSE COURSE COURSE
Number of Compaction blow at
each end of specimen 75 75 75
Stability (Marshall) Minimum N 9800 9800 9800
Flow (0.25 mm) 8- 16 8- 16 8- 16
Minimum Stiffness N/0.25mm) 1225 1225 1225
Percent air voids 4-8 4-8 4-8
Percent voids in mineral
aggregate, minimum % 13 14 15
(V.M.A)
Percent voids filled with
50 – 65 50 - 70 50 - 70
bitumen (V.F.B)
Loss of Marshall Stability in
Max. 25% Max. 25% Max. 25%
accordance with DMS 10
Filler/Bitumen Ratio 0.6 - 1.5 0.6 - 1.5 0.6 - 1.4
Table 9 - Properties of Mix for Dense Bitumen Macadam
BASE COURSE WEARING

DESCRIPTION ROAD BASE COURSE
MIN. MAX. MIN. MAX.
Marshall specimens No.
of Comp. blow each end 75 --
75 --
of specimen
Voids in Mix (%) 7 11 6 9
Voids in Mineral
14 20 14 20
Aggregate (%)
Stability (Marshall)
7350 -- 9800 --
Minimum (N)
Flow (0.25mm) 8 16 8 16
Minimum stiffness
N/0.25mm) 919 -- 1225 --
Bitumen Content (% of
total mix) 3.2 4.0 3.5 4.1
Voids filled with Bitumen
(%) 48 60 48 60
Loss of Marshall Stability
in accordance with DMS
10 - 25% - 25%
3/27.11Samples of bituminous paving course mixes shall be taken from the mixing plant
and/or behind the paver prior to compaction, as per ASTM D979, check
compliance with the approved job mix requirements including Tables 1, 6, 7 and
8 for asphaltic concrete and Tables 2, 3, 4, 7 and 9 for Dense Bitumen Macadam.
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3/27.12The density of the compacted mixes shall be related to the daily Marshall Density
which shall be determined by making four Standard Marshall specimens from
samples of the mix taken from the mixing plant or paver. The density of each
sample shall be determined and compared with the mean value. Any individual
result which varies from the mean by more than 0.015 gm/cc shall be rejected.
Marshall tests shall be repeated on a daily basis to establish the daily Marshall
Density for that particular day’s production. The daily Marshall Density shall not
vary from the Job Mix Design Density by more than + 1.0%.
3/27.13The assistance of the Engineer in the preparation of the job standard mix in no
way relieves the Contractor of the responsibility of producing a bituminous mix
meeting the requirements of the Specifications.
3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS
3/28.1 Method statement and equipment list shall be according to the type and number
outlined in the Contractor’s detailed Programme of Work, as approved by the
Engineer. Requirements for major plant are outlined in Clause 1/29 of these
Specifications.
3/28.2 In addition to the above requirements, trucks used for hauling bituminous mix
shall have tight, clean, smooth metal beds which have been thinly coated with a
minimal amount of paraffin oil, lime solution, or other approved material to
prevent the mix from adhering to the beds. When required by the Engineer, each
vehicle shall be equipped with a canvas cover or other suitable material of such
size as to protect the mix from the weather.
3/28.3 Rolling equipment shall be self-propelled. The wheels on the rollers shall be
equipped with adjustable scrapers and the rollers shall have water tanks and
sprinkling apparatus, which shall be used to keep the wheel wet and prevent the
surface material from sticking.
3/29 PREPARATION OF BITUMEN BINDER
3/29.1 The heating of the bitumen binder for mixing and compacting shall be in
accordance with ASTM D6926:2005.
3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX
3/30.1 i) Coarse and fine aggregate shall be stored at the asphalt plant in such a
manner that the separate stockpiles will not become intermixed. The
stockpiles shall be of sufficient size to provide a minimum quantity of one
week’s continuous production of asphalt mix. Taken into consideration
the frequency of aggregate testings as mentioned in Clause 3/47.2
aggregates brought to the asphalt plant to supplement stocks should be
tested and approved prior to placing in the existing approved stockpiles.
ii) The cold bins shall be calibrated with the materials to be used and the
setting shall be such as to produce a combined gradation in accordance
with the job mix formula. The proportioning shall be such that surpluses
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and shortages in the hot bins will not cause breaks in the continuous
operations. All the above shall be as approved by the Engineer.
iii) The materials shall be thoroughly dried and heated so that their
temperature is within +/- 8 deg.C of the temperature needed to satisfy the
viscosity requirements of the asphalt cement. The moisture content of the
heated and dried materials shall not exceed 0.5 per cent. The quantity of
materials fed through the drier shall in all cases be held to an amount
which can be thoroughly dried and heated within the limits specified.
3/30.2 Immediately after heating, the aggregate or aggregates shall be screened into at
least five (5) sizes and conveyed into separate bins ready for batching and
mixing with bituminous material. When the aggregates supplied are of such size
and grading that separating into five (5) bins is impractical, the number of
required separations may be reduced to four (4) or to three (3) with the approval
of the Engineer. The efficiency of the screening operations shall be sufficient to
produce, at plant operating capacity, gradations in each of the sizes of heated
and dried aggregates which are reasonably uniform and result in the production
of a mix complying with the limits specified for the aggregate gradation.
3/31 PREPARATION OF BITUMINOUS MIX
3/31.1 Dried aggregate as specified and prepared as prescribed above shall be

combined in the plant conforming to ASTM D995 - 88 in the approved
proportions. The bitumen binder shall be introduced into the mix in the proportion
specified by the job-mix formula.
3/31.2 The initial mixing time will be designated by the Engineer. Mixing time may be
increased by the Engineer if additional time is necessary to obtain a
homogeneous mix and satisfactory coating.
3/31.3 The batch plants, timing shall begin at the start of the introduction of the bitumen
into the pugmill.
3/31.4 The length of mixing time for continuous plants will be determined by the
following formula or other approved methods:-
Pugmill dead load capacity in Kg

Mixing time in seconds = --------------------------------------------
Pugmill output in Kg/second
3/31.5 The temperature of the aggregate immediately prior to mixing shall be within +/- 8
deg.C of the temperature of the asphalt cement and the temperature of the
aggregate and asphalt prior to mixing shall be approximately that of the
completed mix as defined in the job mix formula approved by the Engineer. The
mix temperature shall be within the limits set out in the job mix formula when
emptied from the mixer.
3/32 SURFACE PREPARATION
3/32.1 When the Bituminous Mix is placed on a prepared roadbase and whether or not a
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prime coat is designated on the Drawings, the Granular Roadbase shall be even
and firm and within the construction tolerance specified for the roadbase to the
3/32.2 When the paving layer is constructed on an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust. In
addition any loose, broken or shattered bituminous material along the edges of
the existing surface shall be removed, and the exposed subgrade and a sufficient
width of the shoulder adjacent to the edge of the existing surface to receive the
new bituminous mix shall be shaped, bladed, compacted and broomed and
primed to provide a uniform firm subgrade for the new surface course.
3/32.3 The existing bituminous surface, base, or subgrade shall be removed if broken,
shattered, or unstable. The areas shall be excavated to a depth as directed by
the Engineer, and refilled with the Bituminous Mix according to the Specifications.
3/32.4 Prior to the placing of the mix, when designated on the Drawings or directed by
the Engineer, a prime coat or tack coat shall be applied to the roadbase or
surface in accordance with the Specification for Prime Coat or Tack Coat.
3/33 PLACING OF THE MIX
3/33.1 All bituminous mixes shall be introduced to the paver at a temperature not less
than 135 deg.C and not more than 163 deg.C. Mixes outside this temperature
range shall be discarded.
3/33.2 The bituminous mix shall be spread and finished to crown and grade by
automatically controlled bituminous paver. Bituminous mix may be spread and
finished by hand methods only where machine methods are impractical as
determined by the Engineer.
3/33.3 The automatically controlled paver shall lay the bituminous mix without tearing
the surface and shall strike a finish that is smooth, true to cross-section, uniform
in density and texture, free from hollows, transverse corrugations and other
irregularities.
3/33.4 The paver shall be operated at a speed which will give the best results for the
type of paver being used and which co-ordinates satisfactorily with the rate of
delivery of the mix to the paver, to provide a uniform rate of placement without
intermittent operations of the paver.
3/33.5 The mix shall be delivered to the paver in time to permit completion of spreading,
finishing and compaction of the mix during daylight hours.
3/33.6 The longitudinal joints in successive layers shall be offset not less than fifteen
(15) centimetres. The width of surface or top course placements shall conform to
traffic lane edges as shown on the Drawings.
3/33.7 The leading half of half roadway paving shall not get ahead of the trailing half of
the pavement by more than one (1) average full-day of paving and, in no case,
shall the leading half be more than one half (1/2) kilometre ahead of the trailing
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half without the written permission of the Engineer. If the Contractor fails to
comply with this requirement, the Engineer may suspend paving on the leading
half until such time, as the Contractor shall pave the trailing half to a point
approximately even with the leading half.
3/33.8 Unless otherwise directed by the Engineer, where successive layers are to be
placed, the surface of the existing layer shall be swept clean with a power broom,
or by other means as approved by the Engineer, and a tack coat applied. Tack
coat may not be required where the delay between courses laying is less than 48
hours and when the surface is fresh and clean and at the discretion of the
Engineer. The rate of application of tack coat to be between 0.2 to 0.6 L/m2.
3/33.9 Asphaltic concrete mixes, except levelling courses shall be laid in an

uncompacted thickness such that, after rolling the thickness of the compacted
layer shall be:-
Base Course : Min. 6 cm Max. 10 cm

Binder Course : Min. 5 cm Max. 8 cm
Wearing Course: Min. 4 cm Max. 6 cm.
However, DBM thicknesses shall be as specified in tables 3 and 4.
3/33.10The maximum thickness for layers may be increased slightly when such increase
is more adaptable to total pavement thickness and when in the opinion of the
Engineer it is not detrimental to placement and rolling conditions.
3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE
3/34.1 The Contractor shall make the necessary survey required for the reference
grade. When the survey is approved by the Engineer, the Contractor shall erect
and maintain an approved reference string line and operate the paver to conform
to the reference string line for the initial layer and/or any other layers as directed.
Elevation control points stakes for the first layer of bituminous paving course shall
be set at a maximum spacing of twenty (20) metres. For subsequent layers,
control points shall be set at ten (10) metres maximum spacing. The Contractor
shall furnish and maintain an approved mobile string line for all layers not laid
with the erected string line. The string line shall be erected parallel to the
reference grade, and the bituminous mix shall be spread at a constant elevation
above, below or at the string line elevations as directed.
3/34.2 The use of the automatically controlled bituminous paver, to provide both
longitudinal and traverse control, shall include the furnishing and maintaining of a
string line, fixed or mobile, by the Contractor. The longitudinal and traverse
controls shall operate independently of each other, to the extent that the surface
of the bituminous mix will conform to the string line and will be uniform in cross-
section and crown.
3/34.3 The Contractor shall establish the centre-line points and shall maintain the
location of the points until the completion of the surfacing or as directed. When
directed by the Engineer, the Contractor shall erect a string line, to be used as a
guide for the finishing machine, in order to maintain a uniform edge alignment. If
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any other method is proposed by the Contractor, it shall first be approved by the
Engineer.
3/35 BITUMINOUS LEVELLING COURSE

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3/35.1 A levelling course, consisting of a layer of bituminous material of variable

thickness may be used to eleminate irregularities in existing surfaces or based
and to vary existing cross-section elements of roadways.
3/35.2 In areas where levelling courses are required, as shown in the Drawings or
determined by the Engineer, the Contractor shall make a survey of existing
surface or base. When the survey is approved, the Engineer will determine and
inform the Contractor of the precise locations and thickness of levelling course to
obtain the smoothest possible riding surface. Upon receipt of the locations and
thickness from the Engineer, the Contractor shall proceed with the placement of
the Levelling Course.
3/36 THICKNESS CORES
3/36.1 The depth of each bituminous paving course shall be measured by cored
samples. The Contractor shall furnish and operate an approved core drill for
cutting samples from the compacted mix on the road. The equipment shall be
capable of cutting the mix without shattering the edges of the specimen or
otherwise disturbing the density of the specimen. The nominal size of Cored
samples shall be ten (10) centimetres in diameter for binder course and wearing
course and fifteen (15) centimetres in diameter for base course and road base.
Cores shall be obtained in accordance with ASTM D979 in sets of two (2) from
same location of the road.
3/36.2 Cores extracted for thickness measurement may be used for density
determination and density samples may be used for thickness measurements.
Determination of thickness and density of core samples shall be determined in
accordance with ASTM D3549 & ASTM D1188 or ASTM D2726 respectively and
as required by Engineer.
3/37 COMPACTION OF BITUMINOUS LAYERS
3/37.1 After spreading and strike off, and as soon as the mix conditions permit the
rolling to be performed without excessive shoving or tearing, the mixture shall be
thoroughly and uniformly compacted. Rolling will not be prolonged to an extent
that cracks appear.
3/37.2 Rollers shall be of the steel-wheel and pneumatic tyre type and shall be in good
condition, capable of reversing without backlash, and shall be operated at speeds
slow enough to avoid displacement of the bituminous mix. The number and
weight of rollers shall be sufficient to compact the mix to the required density
while it is still in a workable condition. The use of equipment which results in
excessive crushing of the aggregate will not be permitted. A minimum of three
(3) rollers, one (1) steel-wheel and two (2) pneumatic-tyre type, shall be used
with each spreading operation for each lane.
3/37.3 The Contractor shall provide adequate back-up equipment for use in the event of
mechanical failure, all to the satisfaction of the Engineer.
3/37.4 Initial or breakdown rolling shall be done by means of either a tandem power
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steel roller or three-wheel roller followed by a pneumatic-tyre roller or as agreed

by the Engineer. Rolling shall begin as soon as the mix will bear the roller
without undue displacement. Rolling shall be longitudinal, beginning at the low

side of the spread of material and proceeding toward the high side, overlapping
on successive passes by at least one half (1/2) the width of the near wheels.
Alternate passes of the roller shall be of slightly different lengths.
3/37.5 The motion of the roller shall at all times be slow enough to avoid displacement of
the mix. To prevent adhesion of the mix to the rollers, the wheels of the rollers
shall be kept properly moistened with water, but an excessive of water will not be
permitted. Under no circumstances shall the use of diesel fuel or any other
asphalt stripping agent be used for preventing adhesion of the asphalt to the
roller wheels.
3/37.6 Final compaction and finish rolling shall be done by means of a tandem power
steel roller, unless otherwise directed. When the specified density is not
obtained, changes in the size and/or number of rollers shall be made as
corrective measures, to satisfy the density requirements.
3/37.7 Rollers shall be operated by competent and experienced roller men and shall be
kept in operation continuously if necessary, so that all parts of the pavement will
receive substantially equal compaction at the time desired. The Engineer will
order the mixing plant to cease operation at any time proper rolling is not being
performed.
3/37.8 The road density requirements shall be equal to or greater than ninety eight (98)
percent of the average Marshall density of each day’s production for wearing
course and ninety seven (97) percent of the average Marshall density of each
day’s production for asphaltic road base and binder course mixes. However,
densities in excess of 101.8% shall not be permitted.
3/37.9 Any mix that becomes loose, broken, mixed with foreign material, or which is in
any way defective in finish or density, or which does not comply in other respects
with the requirements of the Specification shall be removed, replaced with new
materials, and finished in accordance with the Specifications.
3/37.10Coring to be done after 24 hours of completion of the compaction.
3/38 RE-ROLLING OF BITUMINOUS COURSES
3/38.1 Should any bituminous course fail to achieve the specified density, at the
discretion of the Engineer rerolling may be allowed subject to the following
conditions:-
a) The densification to be achieved shall be 1% or less.

b) Only PTR’s to be used weighing no greater than 18 tons.
c) Re-rolling to take place within 72 hours from the time of the initial rolling of the
asphalt.
d) Re-rolling to take place at the time of the day when the asphalt has attained
its maximum natural temperature.
e) Re-rolling to be applied for a maximum of two hours.
f) Re-rolling to be carried out in the presence of the Engineer’s Representative.
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g) The section of the works in question shall be cored for density determination
immediately after the completion of re-rolling.
h) If after re-testing, the density achieved is 0.5% below the specified density,
the asphaltic material will be accepted in the works subject to a 20%
reduction to the billed rates. If, on the other hand, the density is greater than
0.5% below the specified density, the asphaltic material shall be removed and
new material to the specification laid at the Contractor’s cost.
3/39 CONTACT SURFACES
3/39.1 Contact surfaces between the bituminous paving and of kerbing, gutters,
manholes, and other appurtenances shall be painted with a thin uniform coating
of tack coat as approved by the Engineer.
3/40 JOINTS IN BITUMINOUS PAVING
3/40.1 Joints between old and new pavement or between successive day’s work shall
be made, to ensure thorough and continuous bonding between the two. All
construction joints in previously laid material shall be constructed by cutting the
material back vertically for its full depth to expose a fresh surface.
3/40.2 Before placing the fresh mix against a cut joint or against old joint or against old
pavement, the contact surface shall be sprayed or painted with a thin uniform
coat of tack coat. Where a finishing machine is used the longitudinal joint shall
be made by overlapping the screed on the previously laid material for a width of
at least three (3) centimetres and depositing a sufficient amount of mix so that
the joint formed will be smooth and tight.
Where a reinforcement fabric is specified for use on longitudinal joints, yhe

reinforcement fabric shall meet the following criteria:
Raw material: Polyester

Coating: Bituminous or as per manufacturer’s
recommendation
Weight of Fabric (g/mm2) 240
Mesh size (mm) 30 X 30
Ultimate strength BS6906 P1 (kN) 50 longitudinal, 50 transverse
Elongation at break BS6906 P1 (%) 12 longitudinal, 14 transverse
Strength at 3% elongation BS6906 P1: 12 longitudinal, 10 transverse
The application requirements of the reinforcement geogrid shall be strictly in

accordance with the manufacturer’s recommendations. It shall include for the
application of suitable tack coat to the surface prior to installation. In addition, it
shall be tensioned and fixed in place with an approved pinning bolt system
specifically manufactured for the purpose. Longitudinal and transverse
3/41 PROTECTION OF COMPACTED LAYER
3/41.1 The Contractor shall protect all sections of newly compacted pavement from
traffic until they have hardened sufficiently to the approval of the Engineer. On
heavily trafficked roads during the summer months a minimum period of 7 days
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must elapse before the newly compacted pavement is trafficked.
3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES
3/42.1 Prior to the commencement of the bituminous paving operations, the Contractor
shall construct trial lengths, of at least 30 metres. The materials used in the trials
shall be those approved for use in the bituminous paving courses and the
equipment used shall be that according to the Contractor’s approved detailed
Method Statement and equipment list and the programme of work.
3/42.2 The object of these trials is to determine the adequacy of the Contractor’s
compacted layer depths, and the relationship between the number of compaction
passes and the resulting density of the material.
3/42.3 The Contractor may proceed with the bituminous paving operations only after the
method and procedures established by the Compaction trials have been
3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES
3/43.1 At final compaction the finished surfaces of the individual layers shall fall within
the following maximum tolerances, measured with a 3 m straightedge laid in any
direction
- Base Course 6 mm
- Binder Course 6 mm
- Wearing Course 4 mm
3/43.2 i) The rideability of the finished wearing course when tested with a Laser
Road Surface Testing Machine shall have an IRI (International
Roughness Index) not exceeding the following values:
Average value over a 400 metre section  0.90
Peak value over a 25 metre section  1.5

(Not more than 2 values per 400 metres)
ii) The amplitude of the longitudinal profile of the road, filtered between (a) 1
metre and 3.3 metres and (b) 3.3 metres and 13 metres shall not exceed
the following values:
1m - 3.3 m  1.8 mm
3.3 m - 13 m  3.5 mm
3/43.3 All humps and depressions exceeding the specified tolerance shall be corrected
by removing the defective work and replacing it with new material as directed by
the Engineer at the Contractors cost.
3/43.4 Tolerance on finished surface levels shall be:-

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Road surface +/- 6 mm

Base courses +/- 6 mm
3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS
3/44.1 The thickness of the bituminous paving courses shall be determined in

accordance with ASTM D3549.
3/44.2 For the purpose of establishing an adjusted unit rate for bituminous paving
courses, units to be considered separately are defined as three hundred (300)
linear metres in each traffic lane. The last unit in each lane shall be three
hundred (300) linear metres plus the fractional part of three hundred (300) metres
remaining. At least three cores (in sets of two (2)) shall be taken at random from
each unit being sampled.
3/44.3 Other areas such as intersections, entrances, crossovers, ramps, etc. will be
considered as one unit and the thickness of each unit shall be determined
separately. Small irregular unit areas may be included as part of another unit. At
such point as the Engineer may select in each unit, three cores shall be taken for
each unit of bituminous paving course. One unit shall represent an area of not
more than 1125 sq.m.
3/44.4 If the core so taken is not deficient by more than three (3) millimetres from the
specified thickness, full payment will be made. If the core is deficient in thickness
by more than three (3) millimetres, from the specified thickness, two (2) additional
cores shall be taken from the area represented and if the average of the three (3)
cores is not deficient by more than three (3) millimetres from the specified
thickness, full payment will be made.
If the average thickness of three (3) cores is deficient by more than three (3)
millimetres, but not more than ten (10) millimetres, or fifteen (15) percent
(whichever is less), from the specified thickness, an adjusted unit price as
provided in the Bill of Quantities will be paid for the area represented by these
cores.
3/44.5 In calculating the average thickness of each bituminous paving course,

measurements which are in excess of the specified thickness by more than three
(3) millimetres will be considered as the specified thickness plus three (3)
millimetres, and measurements which are less than specified thickness by more
than ten (10) millimetres or fifteen (15) percent (whichever is less), will not be
included in the average.
3/44.6 When the measurement of any core sample/s (set of two (2)) is less than
specified thickness by more than ten (10) millimetres, or fifteen percent
(whichever is less), the actual thickness of the bituminous paving course in this
area will be determined by taking additional cores at not less than three (3) metre
intervals parallel to the centre-line in each direction from the affected location
until, in each direction, a core is found which is not deficient by more than ten
(10) millimetres, or fifteen (15) percent (whichever is less). Asphalt areas which
are deficient by more than ten (10) mm or 15% (whichever is less) shall be
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removed and replaced at the Contractor’s expense. Exploratory cores for

deficient thickness may be used in average for adjusted unit price. (Refer to the
Bill of Quantities - Preambles for Pavement Construction for price adjustments).

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3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES
3/45.1 The density of the mix as placed and compacted on the road shall be determined
from cores cut from the compacted courses on the road at locations specified by
the Engineer. Samples shall be obtained in accordance with ASTM D979 in sets
of two (2) from the same location on the road. The frequency of testing shall be
three (3) sets of samples per traffic lane per three hundred (300) linear metres
per layer or a minimum of one (1) set per day for shorter runs, or as directed by
the Engineer and such additional tests to determine limits of area deficient in
density, or for recheck. The density of these samples will be referred to as “Road
Density”. Unit area is equal to 1125 m2 or less. Recheck samples shall be cored
from the previous core holes not more than 40cm for the base course layer and
not more than 30cm for the wearing course.
3/45.2 The Contractor shall cut the samples with an approved core drill in the presence
of the Engineer. The equipment shall be capable of cutting the material without
shattering the edges of the specimen. The nominal size of samples shall be ten
(10) centimetres in diameter for binder course and wearing course and fifteen
(15) centimetres in diameter for base course and road base.
3/45.3 All test holes shall be filled and made good with approved material by the
Contractor at his expense.
3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS
3/46.1 Hot bituminous mix shall be placed when the air temperature is eight (8) degrees
C or above, and when the weather is not dusty, foggy or rainy and when the
existing surface is free from moisture. Bituminous mix shall not be placed during
sand storms.
3/46.2 No paving operations shall be started if rain is imminent.
3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES
3/47.1 Bitumen Material: One sample shall be tested for penetration and softening point
ring ball test every 80 tonnes or part thereof. Other tests specified in Clause
3/26.3 Table 5, shall be determined at the time of source approval or whether
there is a change in the source of supply and the Engineer, will, if he deems it
necessary.
3/47.2 Aggregate: Initially one sample for each stockpile every 1000m3 or part thereof
shall be taken and all the required tests shall be performed.
3/47.3 Bituminous mix: One sample of mix shall be obtained from at least every 300
tonnes or part thereof and tested for bitumen content ASTM D6307-2005 (ignition
method) for determination of binder content. grading (ASTM D5444 for gradation
of extracted aggregate.) Density in accordance with ASTM D-1188 or D-2726 and
as required by the Engineer. Stability in accordance with ASTM D 6926:2004
and voidage contents in accordance with DMS 9 shall be determined on Marshall
Specimens.
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3/47.4 Loss of Marshall stability shall be in accordance with DMS 10.
3/47.5 Thickness cores and compaction cores shall be taken as specified in Clause 3/44
and 3/45 respectively.
3/48 BITUMINOUS PRIME COAT
3/48.1 Bituminous Prime Coat shall consist of supplying and applying liquid asphalt to a
previously prepared and approved subgrade, subbase, aggregate base course or
wet mix road-base in accordance with this Specification.
3/48.2 Material for Prime Coat shall be:-
Liquid Asphalt: for prime coat shall be medium curing cut back asphalt MC-70 to
the requirements of ASTM D-2027 as modified by Table 10 or as directed by the
Engineer. Sampling shall be in accordance with ASTM D140. Viscosity test shall
be conducted in accordance with ASTM D140 for every 5 tonnes or part thereof:
other tests specified in Table 10 shall be determined at the time of source
approval or whenever there is a change in the source of supply and the Engineer
will, if he deems necessary.
Table 10 - Medium Curing Liquid.
TEST ASTM MIN MAX.

REF.
*Saybolt Furol Viscosity at 50 deg. D88 60 120

C. sec.
*Flash Point, Tag open Cup, deg.C D3143 38 --
*Distillation D402
- Distillate (% of total distillation

to 360 deg.C)
To 225 deg. C - 20
To 260 deg.C 20 60
*To 316 deg.C 65 90
Residue from distillation to 360 55

deg. C, percent by volume
difference.
Tests on residue from distillation:
- Penetration 25 deg. C, 100g 5 D5 120 250

sec.
- Ductility 25 deg. C, cm D113 100 --
- Solubility in trichloro ethylen % D2042 99 --
Water percent D95 - 0.2

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3/48.3 Prime coat shall be applied at a rate of not less than 0.7 litres per square metre
and not more than 1.5 litres per square metre.
3/48.4 The exact rate of application, which may be varied to suit field conditions, will be
determined by the Engineer following trials to be carried out by the Contractor.
3/48.5 The surface to be prime coated shall be uniformly smooth and firm and true to the
grades and cross-sections shown on the drawings within specified tolerances,
and so maintained throughout prime coating. Prime coat shall not be placed on a
soft, uneven base. Any holes, depressions or irregularities shall be repaired by
the removal of loose and unsuitable material and its replacement with suitable
material compacted to produce a dense, even surface of uniform texture. When
required, the surface to be primed shall be lightly bladed and compacted and the
Engineer may instruct a light application of water to facilitate penetration.
Priming will not be permitted when the surface is wet.
3/48.6 Prime coat shall not be applied when the ambient temperature is less than 13
deg. C or during rain, fog, dust storms or other unsuitable weather. The
application temperature for MC-70 liquid asphalt shall be between 50 deg. C and
80 deg. C as approved by the Engineer. It shall be applied to one lane of the
carriageway width at a time. When applied in two or more lanes there shall be a
slight overlap along adjoining edges. Overlapping will not be permitted at
transverse joints and thick paper shall be used to protect the previous
application.
3/48.7 Traffic shall be kept off the prime coat until it has penetrated the subgrade or
roadbase and fully cured. It should be left undisturbed for a period of 48 hours or
as otherwise directed by the Engineer.
3/48.8 The Contractor shall furnish and spread at his cost sufficient clean fine sand, of
an approved quality, to blot up areas which show an excess of prime coat.
3/48.9 The primed surface shall be maintained in a good, clean condition at all times
until the next course is placed. Any surface irregularities or holes in the primed
surface, however caused, shall be repaired and corrected to the Engineer’s
satisfaction.
3/49 BITUMINOUS TACK COAT
3/49.1 Bituminous tack coat shall consist of supplying and applying emulsified asphalt
diluted with an equal quality of water (1:1) to a previously prepared bituminous
base course or binder course or to an existing bituminous surface, in accordance
with this specification.
3/49.2 The materials for bituminous tack coat shall be slow setting emulsified asphalt,
grade SS-1h (anionic) conforming to the requirements of ASTM D977. Sampling
shall be in accordance with ASTM D140. Viscosity test shall be conducted in
accordance with ASTM D 244:2004 for every 5 tonnes or part thereof. Other tests
tests specified in Table 10A shall be determined at the time of source approval or
whenever there is a change in the source of supply and the Engineer will, if he
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deems necessary.

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Table 10A – Bituminous Tack Coat SS1-H.
TEST UNIT MIN MAX.
Density at 15 deg. C. Kg/L - -
Saybolt Furol Viscosity sfs 20 100
Storage Stability Test 2 hrs. %Wt - 1 max
Distillation
Residue from Distillation to 260 %Vol 57 -
deg. C
Test of Residue from Distillation

Penetration 25 deg. C,( 100gm) 5 mm 40 90
sec.
Solubility of Trichloro Ethylen %Wt 97.5 -
Ductility at 2 deg. Cm/min 5cm cm 40 min. -
The Sample shall meet the requirements of SS1-H grade specification as per
ASTM D-977 with respect to the above tests. Tests shall be conducted as per
ASTM D244:2004.
3/49.3 The tack coat (diluted emulsion) shall be applied in quantities of not less than 0.3
litres per square metre and not more than 0.6 litres per square metre.
3/49.4 Immediately before applying the tack coat, all loose material, dirt, clay or other
objectionable material, shall be removed from the surface with a power broom or
blower supplemented with hand brooms, as directed by the Engineer. After the
cleaning operation, and prior to the application of the tack coat, an inspection of
the area to be coated will be made by the Engineer.
3/49.5 The application temperature for the tack coat shall be between 10 deg. C and 60
deg. C as directed by the Engineer. The material should not be applied when the
ambient temperature is less than 13 deg. C or during rain, fog, dust storms or
other unsuitable weather.
3/49.6 After application the surface shall be allowed to dry to the proper condition of
tackiness to receive the following pavement course. Tack coat shall be applied
only so far in advance to pavement course to obtain the proper condition of
tackiness and the Contractor shall protect the tack coat from damage during this
period.
3/49.7 If the completed tack coat is damaged by rain or dust, it shall be allowed to dry,
cleaned by power broom or blower and, if required by the Engineer, an additional
light application of tack coat shall be applied. No additional payment shall be
made for this work.

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3/49.8 Where, in the opinion of the Engineer, a tack coat is not necessary, the
Contractor shall clean, at his expense the existing surface free of dust and other
deleterious material as paragraph 4 above.
3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT
3/50.1 A self-powered pressure distributor should be used for applying asphalt mixture.
The distributor shall have pneumatic tyres of such width and number that the load
produced on the base surface shall not exceed 110 Kg per centimetre of tyre
width, and shall be so designed and equipped as to distribute the bituminous
material uniformly at even heat on variable width of surface at readily determined
and controlled rates from 0.2 to 7.5 litres per sq.m. with a pressure range of 1.25
Kg to 5.2 Kg per sq.m. and with an allowable variation from any specified rate not
exceeding 5 percent. Distributors and booster tanks shall be so maintained at all
times that no dripping of bituminous material will occur from any part of the
equipment.
3/50.2 Distribution equipment shall include an independently operated bitumen pump,

technometer pressure gauges, volume measuring devices, a thermometer for
reading the temperature of tank contents, and a hose attachment for applying
bituminous material to spots unavoidably missed by the distributor. The
distributor shall be equipped for circulation and agitation of the bituminous
material during the heating process.
3/50.3 The equipment for heating shall consist of steam coils and equipment for
producing steam, so designed that steam will not be introduced into the material.
In the event of storage tanks being used, an armoured thermometer with a range
from 10 deg. C to 150 deg. C shall be fixed to the tank so that the temperature of
the bituminous material may be determined at all times.
3/50.4 Other heating facilities may be used subject to the approval of the Engineer.
3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION
3/51.1 This work shall consider of a wearing surface composed of a bituminous prime
followed by two (2) applications of bituminous seal coats with each seal coat
receiving an application of cover material in accordance with the Specifications
and in conformity with the lines shown on the drawings or established by the
Engineer.
3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/52.1 Prime Coat: The prime coat shall be medium curing cut-back asphalt grade MC-
70. The rate of application shall be between 1.00 to 1.75 litres per square metre
as specified by the Engineer.
3/52.2 Seal Coat: The seal coat shall be 85/100 as per ASTM D946 penetration grade
bitumen. The bitumen may be cut back with up to 2% by weight of kerosene to
improve adhesion to the stone. When subjected to five (5) cycles of magnesium
suplhate soundness testing, as determined by ASTM C 88, it shall have a weight
loss not greater than ten (10) percent and the aggregate flakiness of not greater
than 30 (BS 812: Part 105: Section 105.1) and ACV OF 20 % (BS 812). The
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characteristics of the bitumen are shown in the following table:-
85-100 AS PER ASTM D946 PENETRATION GRADE BITUMEN

TEST METHOD OF TESTING MIN. MAX.
(ASTM)
Penetration at 25 deg. C D-5 85 100
100 g, 5 sec.
Flash Point, Cleveland D-92 232 --
Open Cup, deg.C
Ductility at 25 deg. C,cm D-113 100 --
Solubility in trichoro D-2042 99 --
ethylene, %
Rolling Thin film oven D-1754 1.0
test, loss on heating as
per ASTM D 2872
*Penetration of residue D-5 47 --
percent of original
*Ductility of residue at 25 D-113 75 --
deg. C 5 cm/min cm
3/52.3 Cover Material: Aggregate for cover material shall be screenings of crushed
stone which are clean, tough, durable and free from dirt and other objectionable
matter. The percentages of wear shall not be more than thirty (30) as determined
by ASTM C-131. When subjected to five (5) cycles of magnesium sulphate
soundness testing, as determined by ASTM C-88, it shall have a weight loss not
greater than ten (10) percent and the aggregate flakiness index of not greater
than 30 (BS 812: Part 105: Section 105.1) and ACV of 20% (BS 812 Part 110).
Elongation Index not greater than 30 (BS812:P105;Sec105.2)No less than sixty
(60) percent by weight of crushed stone shall consist of crushed pieces having
two or more faces produced by fracture when tested by DM standard test method
DMS 8. Aggregate shall conform to the following gradations and shall be
DOUBLE BITUMINOUS SURFACE TREATMENT

3/4” 1/2” 3/8” 1/4” No.4 No.10 No.30 No.200
First

DUBAI – UAE
Course100 70-90 0-15 -- 0-2 -- -- --

Second
Course-- -- 100 90-100 60-85 0-25 0-5 0-2
3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/53.1 The equipment used by the Contractor shall include a power broom or a power
blower, or both; a self propelled, pneumatic-tyred roller, or steel-wheeled tandem
roller (4 to 8 tons) or both; self-propelled aggregate spreading equipment that can
be adjusted to spread accurately the specified amount per square metre; a
bitumen distributor and equipment for heating the asphaltic materials.
3/53.2 Other equipment may be used in addition to the specified equipment when
approved or requested by the Engineer.
3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/54.1 HEATING OF BITUMINOUS MATERIALS shall be with equipment as specified.

The use of any method or agitation or heating that introduces free steam or
moisture into the bituminous material is prohibited. Materials heated to
temperatures above twenty eight (28) degrees C higher than the maximum
application temperature specified shall be considered as overheated and shall be
rejected until the material can be resampled and retested. The reacceptance or
final rejection will be made by the Engineer on the same requirements under
which the material was originally tested.
3/54.2 If aggregates are deemed by the Engineer to be dusty or dirty they shall be
washed after which their use shall not be permitted until all free water has
evaporated or been drained.
3/55 APPLICATION OF DOUBLE BITUMINOUS SURFACE TREATMENT
3/55.1 After the prime coat has been applied and has thoroughly penetrated the surface
and cured as specified, the Contractor shall apply 85/100 penetration bitumen
and shall apply the cover material and roll and manipulate the surface, all in
accordance with the requirements specified hereinafter. The material shall be
uniformly applied at the rate designated to the surface being sealed.
3/55.2 Bituminous material shall be applied by means of a pressure distributor in a

uniform, continuous speed over the section to be treated and within the
temperature range specified. The quantity of bituminous material to be used per
square metre shall be within the limits hereinafter specified and as directed by
the Engineer.
3/55.3 A strip of building paper, at least one (1) metre in width and with a length equal to
that of the spray bar of the distributor plus thirty (30) centimetres, shall be used at
the beginning of each spread. The paper shall be removed and disposed of in an
approved manner. The distributor shall be moving forward at proper application
speed at the time the spray bar is opened. Any skipped areas or deficiencies
shall be corrected in an approved manner. Junctions of spreads shall be
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carefully made to ensure a smooth riding surface.
3/55.4 The length of spread of bituminous materials shall not be in excess of that which
trucks loaded with cover coat material can immediately cover.
3/55.5 The spread of bituminous material shall not be more than fifteen (15) centimetres
wider than the width covered by the cover coat material from the spreading
device. Under no circumstances shall operations proceed in such a manner that
bituminous material will be allowed to chill, set up, dry or otherwise impair
retention of the cover coat.
3/55.6 The distributor, when not spreading, shall be so designed that the spray bar or
mechanism will not drip bituminous material on the surface of the travelled way.
3/55.7 Distribution of the bituminous material shall be so regulated and sufficient

bituminous material must remain in the distributor at the end of each application
so that there will be a uniform distribution of bituminous material. In no case shall
the distributor be allowed to expel air with the bituminous material thereby
causing uneven coverage.
3/55.8 The angle of the spray nozzles and the height of the spray bar shall be so
adjusted and frequently checked so that uniform distribution is ensured. If the
raise of the spray bar as the load is excessive and contributes to drilling and
streaking of the seal course, the frame of the distributor shall be blocked or
snubbed to the axle of the truck to maintain a constant height of the spray bar
above the road surface. The distribution shall cease immediately upon any
clogging or interference of any nozzle and corrective measures shall be taken
before distribution is resumed.
3/55.9 Application of Aggregate: Immediately following the application of the bituminous

material, cover material shall be spread with an approved aggregate spreader in
quantities as specified by the Engineer and within the limits specified herein.
Spreading shall be accomplished in such a manner that the tyres of the trucks or
aggregate spreader at no time contact the uncovered and newly applied
bituminous material.
3/55.10The operations of distributing bituminous material shall not be in excess of one

hundred (100) linear metres ahead of the spreading of the aggregate.
3/55.11Procedures of starting, stopping or turning of any piece of equipment which

results in displacement of the cover material or damage to the seal courses shall
be prohibited.
3/55.12The spreading equipment shall be of such width and arrangement that as the
aggregate is placed, complete coverage will be obtained. No brooming, dragging
or blading of the cover material shall be permitted prior to initial rolling. Any
rearrangement of the cover material shall be done by hand methods.
Overlapping the applications of cover material shall be avoided and all spillage
shall be removed from the surface. Before rolling, the bituminous material shall
be uniformly covered.
3/55.13The rates of application for bituminous material and aggregate for “Double
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Bituminous Surface Treatment” shall be within the following limits:
RATES OF APPLICATION OF ASPHALT AND AGGREGATE FOR DOUBLE

BITUMINOUS SURFACE TREATMENT
85/100 PENETRATION AGGREGATE KG/SQ.M

KG/SQ.M
MAX
MIN. MAX. MIN.
.
First
15.0
application 0.70 1.10 12.5
0
(Course)
Second
application 0.70 0.90 6.5 8.5
(Course)

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3/55.14 Manipulation:
Immediately after the application of bituminous material and aggregate to the

road surface and after the aggregate has been rearranged as may be necessary
to provide uniform and complete coverage, the surface shall be sufficiently rolled
with an approved pneumatic-tyred roller to embed the aggregate thoroughly into
the bituminous material. Sufficient rollers shall be provided such that the initial
rolling consisting of a single pass of a 10-12 ton tandem steel wheel roller
followed by at least two (2) complete coverages with the pneumatic-tyred roller
shall be completed with thirty (30) minutes after the cover material is applied.
The rollers shall be operated on each coverage so that each succeeding trip of
the roller will overlap at least fifty (50) percent of the width of the previous trip.
No blading or dragging of the aggregate will be permitted for the first seal coat.
Any rearrangement of the cover material before or during the initial rolling shall
be done by approved hand methods. Rolling shall be continued after the rolling
specified above is completed until a maximum amount of the aggregate is
satisfactorily embedded in the bituminous material. Pneumatic-tyred rollers shall
be operated at a maximum speed of eight (8) kilometres per hour.
3/55.15 Second Seal Coat:
Unless otherwise designated on the drawings, or directed by the Engineer, the

second seal coat shall not be applied for 48 hours after the application of the first
seal coat.
3/55.16 Immediately prior to the second application of bituminous material for sealing,
the surface shall be cleaned in an approved manner for all dust and excess cover
material which is not embedded in the first application of bituminous material for
sealing. Care shall be exercised not to dislodge any cover material which is
embedded in the bituminous material. The second seal coat shall be applied as
previously specified. Brooms or drag brooms shall not be used to shift the cover
material until the initial rolling with the pneumatic-tyred roller is completed and
until the bituminous material has cooled and set up sufficiently to hold the cover
material, preferably not earlier than the day following the application of the
second seal coat. Any rearrangement of the cover material during the initial
rolling shall be done by approved hand methods.
3/55.17 The rolling shall be longitudinal and shall commence at the outer edge of the
shoulder and then progress towards the inner edge. Rolling shall continue until
the entire surface has been completely covered at least three (3) times with a
pneumatic tyred roller. Maximum speed of rollers shall be as previously
specified.
3/55.18 Additional Manipulation of Completed Surfaces:
The Contractor shall manipulate the surface for a period of five (5) days after the
second seal coat has been applied. The manipulation shall consist of the
application of additional aggregate or additional dragging and rolling or all of
these operations to portions of the surface that, as determined by the Engineer,
require such additional treatment. The manipulation shall also include the
dragging and one (1) complete rolling over the entire surface each day from the
time the surface is completed until and including the fifth (5th) day after. A light
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blade equipped with a broom drag shall be operated immediately ahead of the
roller throughout all rolling during the manipulation period. The daily dragging
and rolling under manipulation may be omitted, if in the opinion of the Engineer,
the weather and roadbed conditions are such that the dragging and rolling would
not be beneficial to the surface.
3/55.19 Aggregate and additional manipulation ordered by the Engineer, in this work, will
not be paid for separately but will be considered subsidiary to the item of ‘Double
Bituminous Surface Treatment” included in the “Bill of Quantities”.
3/55.20 Except for times when it is necessary for hauling equipment and/or pilot trucks to
travel on the newly applied seal coat, traffic of all types shall be kept off the seal
coat until it has had time to set properly. The minimum traffic free period shall be
24 hours.
3/55.21 Weather Limitations:
Surface treatment operations shall be carried on only when the surface is dry,
when the atmospheric temperature is above fifteen (15) degrees C, and when the
weather is not dusty, foggy or rainy. The above requirements may be waived, but
only when so directed and in writing by the Engineer.
3/56 PROTECTION OF ADJACENT STRUCTURES FROM BITUMEN SPLASHING
3/56.1 When bituminous materials are being applied the surface of all structures, wheel
guards, guard rail, kerbs and gutters, and other roadway appurtenances shall be
protected in an approved manner to prevent them from being splattered with
bituminous material or marred by equipment operation. In the event that any
appurtenances become splattered or marred, the Contractor shall at his own
expense, remove all traces of bituminous materials, and repair all damage, and
leave the appurtenances in an approved condition.

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SECTION 4 - CONCRETE WORKS
Concrete work shall consist of furnishing all materials and constructing structures of the forms,
shapes and dimensions shown on the Drawings or as directed in accordance with the details
shown on the Drawings and these Specifications.
4/1 CEMENT
Sulphate Resisting Cement
4/1.1 Sulphate Resisting Cement shall comply with BS 4027 or ASTM C150 Type 5. In
addition the cement shall comply with the following:-
- The acid soluble alkali level measured as (Na20+0.658 K20) shall not
exceed 0.6% by weight determined in accordance with BS EN-196 Part
2:1995.
- The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested
in accordance with BS 4550 : Part 3 Section 3.8.
- The maximum limit for Tricalcium Aluminates content is 3.5% when tested
according to BS EN 196 : Part 2 : 1995.
- The specific surface shall be not greater than 375 m2/kg and not less
than 280 m2/kg when tested in accordance with BS EN 196-Part 6.
- Cement strength generally shall be class 42.5N or other classes in
accordance with BS 4027 and Engineer’s requirements.
Ordinary Portland Cement
4/1.2 Ordinary Portland Cement shall conform to the requirements of BS 12 or ASTM

C150 Type 1 with the following amendments:-
- The acid soluble alkali level measured as Na2 0+0.658 K20 shall not
exceed 0.6% by weight determined by the test method described in BS
EN 196 Part 21.
- The specific surface (fineness) shall be not greater than 375 m2/kg and
not less than 280 m2/kg when tested as described in BS EN 196 :Part 6.
- Ordinary Portland Cement shall contain not less than 4% and not more
than 13% of Tricalcium Aluminates by weight.
- Cement. Composition, specifications and conformity criteria for common
cements.
Moderate Sulphate Resisting Portland Cement
4/1.3 Moderate sulphate resisting Portland cement shall comply with ASTM C150 Type
2 but containing not less than 4% and not more than 8% proportion by weight of
tricalcium aluminates with the following amendments. In either case the cement
shall not contain more than 2.5% proportion by weight of sulphur trioxide.

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- The acid soluble alkali level measured as Na20+0.658 K20 shall not
EN196-21.
- The specific surface (fineness) shall not be greater than 375 sq.m/Kg and
not less than 280 sq.m/Kg when tested as described in BS EN 196 : Part
6.
4/1.4 Each cement batch shall bear manufacturer’s name and batch number. Type of
cement shall be the same as mentioned in the approved analysis report. Each
separate consignment of cement shall be tested by the manufacturer before
delivery and certified copies of such tests shall be supplied to the Engineer
before any part of the consignment is used in the works. The Engineer reserves
the right to order a re-test of cement at any time. Approval of cement does not
relieve the Contractor of the responsibility to produce concrete of the specified
strength.
4/1.5 Cement shall be delivered to site in bulk, or with the Engineer’s approval, may be
supplied in sealed bags, which shall bear the manufacturer’s name and the date
of manufacture. Each consignment shall be accompanied by a copy of the
manufacturer’s batch test certificate and certificate of guarantee.
4/1.6 Each consignment of cement shall be kept separate, identified and used in order
of delivery.
4/1.7 Any consignment not used within 2 months from the date of manufacture will not
be allowed to be used in the works.
4/1.8 One brand only of cement as approved by the Engineer shall be used throughout
the works unless otherwise authorized by the Engineer in writing.
4/2 AGGREGATES GENERAL REQUIREMENTS
4/2.1 Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS 882 “Concrete aggregates
from natural sources” and the fine aggregate shall also comply with Dubai
Municipality Administrative Order No. 143/91.
4/2.2 The aggregates used in the permanent works shall be naturally occurring or
crushed materials obtained only from approved sources.
4/2.3 Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.
4/2.4 The results of these tests, etc. shall be submitted to the Engineer and his
approval shall be obtained before any of the material is used in the works. Part
of each sample will be required for concrete trial mixes and part shall be retained
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for comparison with subsequent deliveries.

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4/2.5 Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812 Part 102.
4/2.6 The maximum size of the aggregate shall not be larger than 1/5 of the narrowest
dimension between sides of the number for which the concrete is to be used and
not larger than 3/4 of the maximum clear distance between reinforcing bars.
4/2.7 Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
4/2.8 Coarse aggregate shall be crushed aggregate obtained from a quarry approved
by the Engineer.
4/2.9 Unless otherwise authorized by the Engineer coarse aggregate shall be delivered
to site in separate sizes according to the maximum specified aggregate size for
each grade of concrete.
4/2.10 Each and every stockpile of aggregate shall meet the requirements of Table 4.1.
4/2.11 The frequency of testing of aggregates shall be in accordance with Table 4.2.
or as directed by the Engineer.
Table 4.1 - Limits for Physical, Chemical and Mechanical Properties of Aggregates
for Concrete
TEST
SR. KIND OF REQUIREMENT PERMISSIBLE LIMITS
METHODS
BS 812 :
No. FINES COARSE
ASTM:
BS EN 933-
1. Grading Standard Standard
1-1997
BS EN 933-
Material finer than 0.075 mm
1-1997 or max. 3% Max. 1%
2. Natural, uncrushed/crushed
ASTM max. 7% Max. 1%
Crushed rock
C117:2004
Clay lumps and friable
3. C142 max. 1% max. 1%
particles
max.
4. Light weight pieces C123 max. 0.5%
0.5%
The colour of the
Organic impurities for fine supernatant liquid is
5. C40
aggregate lighter than standard
colour solution
max.
6. Water absorption C128/C127 max. 2.0%
2.3%
min.
7. Specific Gravity (apparent) C128/C127 min. 2.60
2.60
Shell content in aggregates
Part 106
8. Coarser than 10 mm max. 5%
Between 5mm & 10mm max. 15%

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Particle shape Part 105.1 max. 25*

9.
Flakiness index Part 105.2 max. 25*
TEST
SR. KIND OF REQUIREMENT PERMISSIBLE LIMITS
METHODS
BS 812 :
No. FINES COARSE
ASTM:
Elongation index
DMS 8
Partially crushed faces of
Aggregate (100% with at
least one crushed face)
* The index shall be 25 for combined aggregates and should not exceed more than 30
for individual sizes.
Table 4.1 - Limits for Physical, Chemical and Mechanical Properties of Aggregates for
Concrete (Con't)
SR. TEST
KIND OF REQUIREMENT PERMISSIBLE LIMITS
No. METHODS
BS 812 :
FINES COARSE
ASTM:
Acid soluble Chlorides, CL. Part 117,
Appendix C
max.
For reinforced concrete made
0.03%
with SRPC cements
max. max.0.01%
OPC & MSRPC cements
0.03% max 0.02%
10.
For mass concrete
made with
max.0.03% max 0.02%
SRPC cements
max.0.03% max.0.04%
OPC & MSRPC cements
max.
For prestressed concrete &
0.03% max 0.01%
steam structural concrete
BS EN max. 0.3% max. 0.3%
11. Acid soluble sulphate, S03 1744-
1:1998
C88 max. 12% max. 12%

12. Soundness, MgS04 (5 cycles)
Mechanical Strength Part 111 min.

10% fines value Part 112 100KN
13.
or Impact value C131/C535 max. 30%
Los Angeles Abrasion
max. 30%
Part 120 max.

14. Drying Shrinkage
0.05%
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Potential Reactivity
15. Note 2 C289 Innocuous Innocuous
Of Aggregates,
SR. TEST
KIND OF REQUIREMENT PERMISSIBLE LIMITS
No. METHODS
BS 812 :
FINES COARSE
ASTM:
Chemical Method
Of Cement-Aggregate C227 6 month expansion
Combination 0.10% max.
Note 1: There is no requirement of shell content in sands passing 5mm sieve size.
Note 2: Aggregates may initially be assessed for its reactivity in accordance with ASTM
C289 and if potential reactivity is indicated, then mortar bar tests in accordance
with ASTM C227 shall be carried out.
Table 4.2 - Frequency of Routine Tests on Aggregates
SR.NO. KIND OF REQUIREMENT - TEST TEST FREQUENCY RATE

METHOD
Each 2 weeks or per 500 m3
1. Grading – BS EN 933-1-97
whichever is more frequent.
Material finer than 0.075 mm
2. - do -
- BS EN 933-1-97 or ASTM C 117
Clay lumps and Friable Particles
3. - do -
-ASTM C142
4. Organic impurities ASTM C40 - do -
Water absorption - ASTM
5. - do -
C128/C127
6. Specific Gravity - ASTM C128/C127 - do -
7. Shell content – BS EN 933-7:1998 - do -
Particle shape BS812 : Part 105
8. Section 105.1 ; BS812: Part 105 - do -
Section 105.2
Acid soluble chlorides, CL
Qualitative - BS812 : Part 117-
9. - do -
Appendix-C
Appendices A/B & C
Acid soluble sulphates,
10. - do -
S03 – BS EN 1744-1:1998
Soundness, Mg S04 (5 cycles)
11. - do -
ASTM C88
Mechanical Strength
10% Fines or impact value - do -
12 -BS812 : Parts 111, 112
Los Angeles abrasion - - do -
ASTM C131/C535
AE7 PROJECT NO. 20010410 100

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Moisture variation in sand - by

13. Twice daily
Moisture Meters
At the start of the project and
Drying Shrinkage
14. whenever there is a change
BS812 : Part 120
in the source of supply
Table 4.2 - Frequency of Routine Tests on Aggregates (Cont'd)

METHOD
Potential Reactivity:
of aggregates (ASTM C295, C289)

At the start of the project and
15. wherever there is a change in
of Carbonate (ASTM C586) the source of supply
of Cement aggregate combination

(ASTM P214 and C227)
Frequency of testing may be amended by the Engineer based on previous test

results
Note : Drying Shrinkage and potential reactivity of aggregates shall be

determined initially at the start of the project or whenever there is a
change in the source of supply.
Frequency of testing shall be accordance to Table 4.2
4/3 FINE AGGREGATES
4/3.1 The gradation of fine aggregate shall be in accordance with BS 882 latest edition.
4/3.2 Each batch of aggregate delivered to site shall be kept separate from previous
batches and shall be stored for at least 3 (three) working days before use to allow
inspection and tests to be carried out.
4/3.3 Fine Aggregate shall be clean sharp natural and/or crushed sand and shall
comply with BS 882.
4/3.4 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.
4/4 COARSE AGGREGATE FOR CONCRETE
4/4.1 Coarse aggregate shall be prepared as single sized aggregate and blended to
produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS882.
4/4.2 Aggregates that are deleteriously reactive with the alkalis in the cement in an
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amount sufficient to cause excessive expansion of concrete shall not be used.
4/4.3 The Contractor shall mechanically wash aggregate to remove salts and other
4/5 COMBINED AGGREGATE
4/5.1 Approved coarse aggregate and fine aggregate in each batch shall be combined
in proportions as specified in BS 882 and as approved by the Engineer.
However, in no case shall materials passing the 0.075mm, sieve exceed three (3)
percent by weight of the combined aggregate.
4/5.2 The combined aggregate gradation used in the work shall be as specified, except
when otherwise approved or directed by the Engineer. Changes from gradation
to another shall not be made during progress of the work unless approved by the
Engineer.
4/6 WATER FOR CONCRETE
4/6.1 The Contractor shall make his own arrangement and obtain approval for the
supply of water.
4/6.2 The mixing water should be clear, apparently clean and free from matter harmful
to concrete in its fresh or hardened state. Potable water can be used. Water of
questionable quality should comply with the physical tests of Table 4.3 and
chemical limitation listed in Table 4.4. Water shall also meet the requirement of
BS EN 1008.
4/6.3 The temperature of water for concrete should not be less than 5 degree celsius
nor more 25 degree celsius. Water may be cooled to not less than 5 degree
celsius by the gradual addition of chilled water or ice but on mixing, no ice
particles should be present in the mix. Alternatively, flaked ice may be used.
The ice to be used should be crushed and should be the product of frozen water,
which complies, with acceptance criteria of Tables 4.3 and 4.4.
4/6.4 Water for curing concrete shall not contain impurities in sufficient amounts to
cause discoloration of the concrete. Sources of Water shall be maintained at
such depth and the water shall be withdrawn in such a manner as to exclude silt,
mud, grass and other foreign matter.
Table 4.3 - Acceptance Criteria and Physical Tests for Mixing Water
Limits ASTM
Test
Compressive strength, 90 C109

min.%
control at 7 days
Setting time, deviation from from 1:00 C191

control, h:min. early to 1:30
later
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Table 4.4 - Chemical Limitations for Mixing Water
SL.No Max. Concentration Limit, ppm Test Method

.
1. Chloride as Cl 250 ASTM D512
2. Sulphates as SO4 350 ASTM D516
3. Alkali carbonates and 500 ASTM D513
bicarbonates
4. Total dissolved solids, 2000 BS1377 :
including 1, 2 & 3 above Part 3 : Test
8
5. PH min.7/max.9 ASTM
D1293
4/7 APPLICABLE TESTS AND CODES
4/7.1 All concrete, aggregate, cement and water shall be sampled and tested during
construction as frequently as deemed necessary by the Engineer. All test
samples shall be supplied by the Contractor at his expense. Samples shall be
obtained in accordance with BS 812, BS 3148, BS 1881 and BS EN196. Testing
shall be at the frequencies stated in the Specifications or relevant standards. All
sampling shall be carried out by the Engineer.
4/7.2 Workability: Workability shall be assessed by the following tests the

requirements for which shall be as specified elsewhere in the documents.
Slump test shall be performed according to BS 1881 Part 102

Compaction factor shall be performed according to BS 1881 Part 103.
Vebe time shall be performed according to BS 1881 Part 104.
Flow test shall be performed according to BS 1881 Part 105.
4/7.3 Compression Test: The Compression tests shall be performed on cubes 150 x
150 x 150 mm as described in BS 1881 Part 116. Sampling, making test cubes
and curing of cubes shall be in accordance with BS 1881 Parts 101, 108 and 111
respectively.
Frequency of cement, steel and concrete Testing:
Sampling Test
ITEM Test Frequency Rate
Method Method
a. Cement - as per BS EN BS EN BS EN-196 Each 250 ton
196 196-7
b. Steel
1. Deformed S. Bar as BS BS Each size 100 ton
per BS 4449:2005 4449:2005 4449:2005
2. Strand as per BS 5896 BS 5896 - As per Clause 23.3 of
BS 5896:1980 if APPENDIX BS 5896
needed A
c. Concrete
1. Air content, as per BS BSEN BSEN Once at the time of mix
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Sampling Test
ITEM Test Frequency Rate
Method Method
EN 123501-7:2000 12350-1 12350-7 design of concrete or as
2. Flexural strength of BSEN BSEN Once at the time of mix
Prism as per BS EN 12350-1 12390-5 design of concrete or as
12390-5 directed by the Engineer.
3. Bleeding as per BS EN C 232 One at the time of mix
ASTM C232 12350- design of concrete or as
1:2000 directed by the Engineer.
4. Splitting Tensile of BS EN C-496 One at the time of mix
Conc. Cylinder as per 12350- design of concrete or as
ASTM C-496:1996 & 1:2000 directed by the Engineer.
others
5. Depth of Water BSEN BS EN Each 2000m3 of a
Penetration (BS EN 12350- 12390-8 particular grade of
12390 P-8:2000) 1:2000 structural concrete or as
6. ISAT as per BS 1881- BS EN BS 1881 - Each 2000m3 of a
p-208:1996 12350- 208:1996 particular grade of
1:2000 structural concrete or as
7. Water absorption of BS EN BS 1881- Each 2000m3 of a
Hardened Conc. As 12350- 122:1983 particular grade of
per BS 1881 P122 1:2000 structural concrete or as
8. Rapid chloride BS EN ASTM C Each 2000m3 of a
permeability 12350-1 1202 particular grade of
:2000 structural concrete or as
9. Slump test - as per BS EN BS EN From each transit mixture

BS EN 12350-2:2000 12350-1 12350-2 load arrived at site
10. Concrete Mix Design All mixes are to be
(Mixing and Sampling designed once for
in the lab) as per BS verification and approval or
1881 P125 & In Site any changes in the
(Sampling) as per BS ingredients.
EN 12350-1:2000
11. Kerbs-as per BS 7263 BS EN BS EN Sample to be taken from
1339:2003 1339:2003 each batch of up to 1000
kerbs in whole
consignment
d. Water BS EN BS EN For DEWA WD no test is
1008:2002 1008-:2002 required or other than
DEWA twice a week or as
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4/8 REINFORCEMENT BARS
4/8.1 All reinforcement bars shall be of a deformed type in accordance with BS 4449-
1997, except that plain bars may be used where specifically indicated on the
Drawings. Hot rolled plain round bars shall be in accordance with Grade 250 of
BS4449-1997.
4/8.2 All steel reinforcement shall conform to the requirements of the Specifications for
Deformed High Yield Steel Bars grade 460 to 500 N/mm2 Type 2, unless
otherwise shown on the Drawings or specified by the Engineer.
4/8.3 Certification: Three (3) copies of a mill test report shall be furnished to the
Engineer for each lot of steel reinforcement bars proposed for use on the project.
4/8.4 Identification: The bars in each lot shall be legibly tagged by the manufacturer
and/or fabricator before being offered for inspection. The tag shall show the
manufacturer’s test number and lot number and other applicable data such as
Heat number that will identify the material with the certificate issued for that lot of
steel.
4/8.5 The fabricator shall furnish three (3) copies of a certification which shows the
heat number or numbers from which each size of bar in the shipment was
fabricated.
4/8.6 The Engineer reserves the right to sample and inspect all reinforcement steel
upon its arrival at the work site. The Contractor shall provide a certificate
confirming that samples taken from the bars delivered to the works comply with
BS 4449. The frequency of sampling and testing shall be in accordance with BS
4449.
4/8.7 All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust,
paint, grease, oil or other foreign substance, fins, or tears. There shall be no
evidence of visual flaws in the bars, test specimens or on the sheared ends of the
bars.
4/8.8 Uncoated reinforcement shall be grit-blasted before use to remove rust, oil,
grease, salt and other deleterious materials and where pitting has occurred the
causes and products thereof. Repeated blasting may be required when the
reinforcement is in position, or partially cast in. Partially set concrete adhering to
exposed bars during concreting operations shall be removed.
4/8.9 The minimum thickness of concrete cover to reinforcement shall be as shown on

the drawings. Only approved concrete spacers shall be used. The concrete
shall be of similar grade to the main concrete and shall have non-metallic ties.
4/8.10 The Bond strength and surface geometry requirements as per clause no. 7.4 of
BS EN 4449:2005.
4/9 BAR SCHEDULES AND SHOP DRAWINGS
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4/9.1 Before ordering reinforcing steel, the Contractor shall check the bar schedules
and adjust them if necessary to the approval of the Engineer. Bar schedules
shall show the weight of each bar, the total weight of each bar size and the total
weight of bars, and bending diagrams for bars in accordance with BS 4466.
4/9.2 The Contractor shall provide and submit to the Engineer for approval any working
drawings additional to the Contract Drawings, which may be found necessary for
the production of, revised bar schedules or for the completion of the works.
4/9.3 The approval of working drawings, or revised bar schedules by the Engineer shall
in no way relieve the Contractor of responsibility for the correctness of such
drawings or schedules.
4/10 BAR CUTTING AND BENDING
4/10.1 Reinforcement shall be cut and bent in accordance with BS 4466. Cutting or
bending by the application of heat is not permitted. Welding of reinforcement
shall only be permitted when approved in writing by the Engineer. If such
approval is given then the workmanship shall be in accordance with BS 5135.
The Contractor shall submit full technical details of his proposed procedures prior
to seeking approval.
4/10.2 Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than
four times the nominal size of the bar.
4/10.3 Bond strength and strength and surface geometry requirements as per clause no.
7.4 of BS EN 4449:2005.
4/11 PLACING AND FIXING REINFORCEMENT
4/11.1 Reinforcement shall be placed and maintained in the position shown in the
Contract Drawings. Unless otherwise permitted by the Engineer, all bar
intersections shall be tied together using 1.2mm diameter steel wire or No. 18
gauge stainless steel wire as indicated on the drawings and the ends of the tying
wire shall be turned into the main body of the concrete.
4/11.2 Metal supports, approved by the Engineer, shall be provided and used to retain
the reinforcement at proper distances from the forms. Supports under horizontal
bars at the bottom of base slabs shall be spaced at not more than eighty (80)
diameters of the bar. All reinforcement shall be so rigidly supported and fastened
that displacement will not occur during construction. Reinforcing steel shall be
inspected in place and must be approved by the Engineer before any concrete is
deposited.
4/11.3 No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.
4/11.4 Reinforcement temporarily left projecting from the concrete at construction or

other joints shall not be bent out of position during the periods in which
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concreting is suspended, except with the approval of the Engineer.
4/12 WELDED WIRE FABRIC
4/12.1 Welded wire fabric to be used for the reinforcement of concrete shall conform to
the following requirements:
- Dimensions: Welded steel wire fabric shall conform to the size and
dimensions shown on the Drawings.
- Properties: Wire fabric furnished under this specification shall conform to

the requirements for “Welded Steel Wire Fabric for Concrete
Reinforcement” AASHTO M55-81 or to BS4483.
4/13 SPACER BLOCKS
4/13.1 Spacers as approved by the Engineer shall be of such material and design as will
be durable, not lead to corrosion of the reinforcement and not cause spalling of
the concrete cover.
4/13.2 Spacer blocks made from cement, sand and small aggregate shall match the mix
proportions of the surrounding concrete so far as is practicable with a view to
being comparable in strength, durability and appearance.
4/14 ADMIXTURES
4/14.1 Unless agreed by the Engineer neither admixtures nor cements containing
additives shall be used.
4/14.2 Where the use of admixture had been agreed by the Engineer, they shall conform
to the requirements of Type A, Type D, Type F or Type G as specified in ASTM
C494 and shall be used in strict accordance with the manufacturer’s instructions.
Primary tests of cube strength and other tests shall be carried out using the
combination of aggregates cements and admixtures proposed for use.
4/14.3 The Contractor shall be entirely responsible for the use of any approved
admixtures.
4/14.4 Approved methods and equipment shall be used for dispensing and incorporating
the admixture into the concrete. The dispensing unit shall be designed so that
the discharge of the admixture is visible.
4/15 CONCRETE MIX SPECIFICATION
4/15.1 Concrete shall be as shown in the Table of 4.5. The number of mixes may
require to be increased.
The criteria given in the Table are designed to produce concrete of the required
strength and durability.
If the maximum aggregate size is 10mm then the cement content stipulated for
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the class of concrete given in table 4.5 shall be increased by 40 Kg per m3.
Table 4.5 Table of Mixes without any Admixture or Additive
Concrete Max. Min. Max. Free Characteristic Cube

Class Size Qty. of Water / Strength
Agg. Cement Cement CCS
Ratio
7-day 28-day
mm. Kg.per N/mm2 N/mm2
m3
45/20 20/40 400 0.425 33 45

40/20 20/40 370 0.475 30 40
37/20 20 350 0.50 26 37
35/20 20 330 0.525 25 35
30/20 20 310 0.55 20 30
25/20 20 275 0.60 16 25
15/20 20 250 0.65 10 15
The CCSs are for concrete which has been cured at a temperature of 23 degrees
C +/- 2 degree C, and are the values below which no more than 5% of the test
results fall. The 7-day strengths shall be used only as a guide.
4/15.2 Concrete shall comply with BS 8110 except where BS 8007 or this specification
differs. Sampling for test purposes shall comply with BS 1881 Part 101 (on site)
& Part 125 (in laboratory)
If the air-entertainment is specified the average air content at the time of placing
measured in accordance with BS 1881 Part 106 shall be:
Concrete containing 20mm
Maximum size aggregate 5% + 1%
Concrete for water-retaining shall be watertight and shall comply with the
recommendations of BS 8007.
Concrete for paving or precast units shall be tested to BS EN 12390-5 and shall
have a minimum flexural beam strength of 3.5 N/mm2 at 28 days. If the concrete
has a specified CCS of 40N/mm2 or greater, then the minimum flexural strength
shall be 4N/mm2.
If concrete specimens are cured at higher temperatures or for longer periods than
BS 1881 Part 111 requires, the adjusted CCS shall be calculated as follows:
100f’/f = A+B log {24D(T+12)/1000}
f’ = adjusted CCS
f = specified CCS
T = curing temperature
D = age at testing in days
A&B = are coefficients given in the following table
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The above equation applies only to OPC, MSRPC and SRPC.
Recorded Cube Strength N/mm2 A B

Less than 15 10.0 67.5
15 - 35 20.0 60.0
Greater than 35 30.0 52.5
This calculation may be applied for curing at temperatures up to 27 deg.C.
Before placing concrete the Contractor shall obtain approval of the mixes
proposed for each class of concrete and the average target strengths. The mixes
shall be designed to achieve the minimum workability for the Contractor to place
and compact the concrete with the equipment proposed for use.
The mean strength shall exceed the CCS by a margin of 1.64 times the standard
deviation expected from the concreting plant, except that no standard deviation
less than 3.5 N/mm2 shall be used as a basis for designing a mix. Unless
otherwise approved a standard deviation of 7 N/mm2 shall be used for initial
mixes.
4/15.3 The ultimate compressive strength of the concrete shall be determined on test
specimens obtained and prepared in accordance with BS 1881. Part 108. BS
5328 Part IV to be referred in case of marginal failures to attain the minimum
specified strength.
4/15.4 Mixes for structural concrete shall be designed by the Contractor. The class of
concrete (shown on the drawings) is denoted by the 28 day characteristic cube
strength and the maximum size of aggregate.
4/15.5 The chloride and sulphate levels in the concrete mix shall comply with the
following requirements:-
Maximum Limits of acid soluble Chloride and Sulphate content as a percentage

by Weight of Cement in the Mix.
Sl. Type of Concrete Chlorides as Cl Sulphates as SO3

No (Clause 10.2, (Clause 10.3,
. BS1881, Part 124) BS1881, Part 124)
a. For reinforced concrete 0.30 3.70
if made with OPC/MSRPC 0.06 3.70
if made with SRPC
b. Prestressed concrete & 0.10 3.70
Heat-cured reinforced
concrete
c. For mass concrete 0.60 3.70
if made with OPC/MSRPC 0.12 3.70
if made with SRPC
Note: The OPC and MSRPC cements can also contain chlorides, the relevant
standard BS 12 allows upto 0.1% Cl. Therefore any chloride content present in
the cement has to be taken into account while computing total C1 in the mix. In
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case the cement contains the maximum limit of 0.1%, then the aggregates, water
and admixtures used for prestressed concrete or heat cured reinforced concrete
should be absolutely free of chlorides.
4/16 CONCRETE MIX DESIGN
4/16.1 Concrete Mix Design and Trial Mixes shall be verified by DM-DCL.
Preliminary laboratory tests shall be carried out to determine the mixes to satisfy
the specification with the approved materials.
Trial mixes shall be tested to determine the following properties of mixes

proposed for initial field tests:
a) Bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed

0.5%.
b) Drying shrinkage in accordance with BS 1881 Part 5.
c) Air content if applicable BS EN 12350 Part 7.
d) Free water/cement ratio
e) Workability BS 1881 Part 102.
f) Fresh and hardened concrete densities BS 1881 Parts 107 and 114
respectively.
g) Compressive strength BS 1881 Part 116.
h) Water depth of penetration BS EN 12390 Part 8.
(maximum 10mm at 28 days)
i) Chloride permeability to ASTM C1202 (maximum 2000 coulomb at 28
days).
j) Initial Surface Absorption Test (ISAT) of concrete shall be as per BS 1881
Part 208.
k) Water absorption of hardened concrete – BS 1881:P-122:1983
If the values obtained are unacceptable, the mixes shall be re-designed.
4/16.2 At least 35 days before commencement of concreting trial mixes shall be

prepared under full-scale site conditions and tested in accordance with BS 1881.
Samples of concrete incorporating the reinforcing details to be used shall be cast

and examined, before hardening using hand tools, and after hardening by coring
to assess the mixes. Cores shall be taken in accordance with BS EN 12204-
1:2009 Cored specimen-Taking examining and testing compression. The flexural
strength of concrete prism as per BS EN 12390, part 5 and splitting tensile
strength of concrete cylinder accordance with ASTM C 496.
Trial mixes shall be made on each of three days; the workability shall equate to
the designed target value. Six cubes from each mix shall be taken, three for test
at 28 days.
Further trial mixes shall be made if the range (the maximum minus the minimum
of the three cube results in any batch) exceeds 15% of the average of that batch,
or if the range of the three batch averages exceeds 20% of the overall average of
the batches.
The mixes shall be tested to determine the following properties:
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a) Bleeding in accordance with ASTM C232.

b) Air content if applicable BS EN 12350 Part 7.
c) Free water/cement ratio.
d) Tensile strength in accordance with BS EN 12390 – 5 and ASTM C 496.
The average 28-day CCS of the three trial mixes shall not be less than the
designed mean strength, and the results of the above tests shall be acceptable
before the mix is approved. Otherwise the mix shall be re-designed.
4/16.3 The Engineer will review the Contractor’s trial-mixes and crush the test cubes at
seven (7) and twenty-eight (28) days. The Engineer will then determine which of
the trial mixes shall be used. If none of the trial mixes for a class of concrete
meets the Specifications, the Engineer will direct the Contractor to prepare
additional trial-mixes. No class of concrete shall be prepared or placed until its
job-mix proportions have been approved by the Engineer.
4/16.4 The approval of the job-mix proportions by the Engineer or his assistance to the
Contractor in establishing those proportions, in no way relieves the Contractor of
the responsibility of producing concrete which meets the requirements of these
Specifications.
4/16.5 The Engineer may also require practical tests to be made on the Site by filling
trial moulds to confirm the suitability of the mix for the works, the type of plant
used for mixing, the method of compaction used and the formwork face intended
for use in the works.
4/16.6 All costs connected with the preparations of trial-mixes and the design of the job-
mixes shall be borne by the Contractor.
4/16.7 In the event, any Concrete mix that is currently being used in another running
RTA project, is proposed by the contractor for used in this contract, then prior to
according approval, the Engineer will ensure that,
contractor comply with Specification requirements as stated in this
contract and
2) The mix proposed complies with clause 4/16 of this contract by verifying it at
DCL.
3) The engineer has to make sure that all constituents of concrete are tested
and meeting the standard specified requirements. In case there are changes
in results, which may affect the properties of concrete, the mix design
verification shall be done at DCL.
Note: Any mix that is obsolete and currently not in use shall be accepted
at all for re-approval.
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4/17 QUALITY CONTROL
4/17.1 Test Cubes
Cubes shall be manufactured in an on-site laboratory, specially equipped for the

purpose, in controlled conditions. They shall be made, cured, stored, transported
and tested to BS 1881 : Part 108, 111 and 116. The method of compacting
cubes shall be as approved and shall be means of vibrating table in the
laboratory or 25mm vibrating poker on site.
4/17.2 Sampling Cubes Cylinders
A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each day.
The standard deviation shall be calculated from at least 40 individual cube results
each representing separate batches of similar concrete produced by the same
plant under the same supervision. The current margin for the plant shall be thus
established as 1.64 times the standard deviation.
Thereafter one sample shall be taken at random for each class of concrete in
accordance with Clause 4/31 of the Specification.
In addition to the above requirements, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of a
single pour.
From each sample three cubes shall be made for testing at 28 days and three for
testing at 7 days for control purposes.
Six cylinder samples shall also be taken to determine the split tensile strength of
the concrete 3 at 7 days and 3 at 28 days, in accordance with ASTM C 496.
These samples shall be taken from every 100 batches, but at least once a week
during concreting operations, and shall coincide with samples taken for test
cubes.
The frequency of sampling may be required to be varied if directed by the

Engineer.
The procedures shall be repeated when materials or design mixes are changed.
4/17.3 Cube Strength Results
The results will be acceptable if:
i) The average strength determined at the age of 28 days from a sample of

three of more cube test results exceed the specified CCS by 0.5 times the
current margin
ii) No individual result of the sample is less than that (Specified CCS minus
3 N/mm2),
iii) Number of individual results in the sample below specified CCS is not
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more than one.
If any of the above criteria is not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate:
i) Cutting and testing cores from placed concrete
ii) Non-destructive testing of placed concrete

iii) Load-testing relevant structural units
iv) Cutting-out and replacing defective concrete
If the range of individual cube strengths made from the same sample exceeds
15% of the mean then the method of making, curing and testing cubes shall be
checked. In the event of a sample having a range exceeding 20% then the result
shall be unacceptable and the Engineer may order any of the following actions.
i) Changing the mix

ii) Improving quality control
iii) Cutting and testing cores from placed concrete
iv) Non-destructive testing of placed concrete
In the event cutting and testing of cores are required, the Contractor shall cut
cores from approved locations and test them to BS 1881 as modified by BS 6089.
BS EN 12204-1:2009 Cored specimen – Taking examining and testing
compression.
4/17.4 Durability Tests
Concrete shall be tested for durability properties by undertaking absorption and

permeability tests where appropriate, or directed by the Engineer, as directed
below:
Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out between
28 and 32 days in accordance with BS 1881 Part 122. The upper acceptable
limit for absorption after 30 minutes shall be 2%.
Tests in accordance with the method described in Depth of Water Penetration –

BS EN 12390; Part 8 shall be carried out. The maximum acceptable penetration
at seven days shall be 15 mm. The maximum acceptable penetration at 28 days
shall be 10 mm.
Initial surface absorption test as per BS 1881: 208: :1996 shall be carried out.
4/17.5 Other Tests:
When instructed by the Engineer concrete shall be tested for drying shrinkage
and wetting expansion, for which 75 x 75 mm prisms shall be prepared and
tested in accordance with Test 5 of BS 1881 (1970) Part 5 or BS 6073 Part 1
Appendix D. The maximum acceptable limits shall be:
Drying Shrinkage : 0.05%

Wetting Expansion : 0.03%
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Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.
The air content of air-entrained concrete shall be determined (ASTM C231) for
each batch produced until consistency has been achieved, when batches may be
tested. The maximum value shall not exceed 2%.
Compaction factor, slump, vebe or other workability tests shall be carried out as
required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree of workability shall be as for
the trial mixes; permitted tolerance shall be in accordance with BS 5328.
4/18 CONCRETE DESIGN LIMITS
4/18.1 The following will be designated by the Engineer within the limits of the
Specifications.
a) The minimum cement content in kg. per cubic metre of concrete

b) The maximum allowable water/cement ratio including surface moisture,
but excluding water absorbed by the aggregates.
c) Slump or Slumps designated at the point of delivery.
d) Changes requested by the Contractor in mix proportioning previously
approved shall be made only with the agreement of the Engineer.
e) When, in the opinion of the Engineer, cement is being lost due to windy
conditions, the Contractor shall add additional amounts of cement as
directed by the Engineer. No additional payment shall be made for the
added cement.
f) Failure of the mixed concrete to meet specifications as determined by the
Engineer will be grounds for the Engineer to reject the concrete.
g) Bleeding limitations when tested in accordance with ASTM C232.
4/19 CONSISTENCY OF CONCRETE
4/19.1 The Consistency of concrete shall be determined in the field by the Slump Test.
The consistency of concrete at the time of delivery will be designated by the
Engineer and shall not vary by more than 25 mm from the designated
consistency.
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS
4/20.1 Cement
In the case of bagged cement it shall be measured as packed by the

manufacturer; a sack of cement shall weigh fifty (50) kilograms.
Measurement for proportioning all cement shall be accurate to within two (2)
percent throughout the range of use. Only full bags, undamaged or unbroken will
be permitted.
4/20.2 Water
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The mixing water shall be measured by weight or by volume. In either case the
measurement shall be accurate to within one (1) percent throughout the range of
use.
4/20.3 Aggregate
The aggregates shall be measured by weight to an accuracy within two (2)

percent through-out the range of use.
4/21 ASSEMBLY AND HANDLING MATERIALS Assembly

4/21.1 Aggregates shall be assembled in such quantities that sufficient material
approved by the Engineer is available to complete any continuous pour
necessary for any element. The batching site shall be of adequate size to permit
the stockpiling of sufficient, unsegregated materials, having proper and uniform
moisture content, to ensure continuous and uniform operation. Aggregates shall
enter the mixer in a manner approved by the Engineer and in such a manner to
ensure that no matter foreign to the concrete or matter capable of changing the
desired proportions is included. In the event two (2) or more sizes or types of
coarse or fine aggregates are used on the same project, only one (1) size or type
of each aggregate may be used on one continuous concrete pour.
Stockpiling of Aggregates
4/21.2 All aggregates shall be stockpiled before use in order to prevent segregation of
material, to ensure a uniform moisture content and to provide uniform conditions
for proportioning plant control.
4/21.3 The use of equipment or methods of handling aggregates which result in the
degradation and contamination of the aggregates is strictly prohibited.
Bulldozers with metal tracks shall not be used on coarse aggregate stockpiles.
All equipment used for handling aggregates shall be approved by the Engineer.
4/21.4 Stockpiling of aggregates shall be in the manner approved by the Engineer, and
in addition, every precaution shall be taken to prevent segregation. Segregation
shall be prevented by making no layer higher than one and one-half (1.5) meters
and if two (2) or more layers are required, each successive layer shall not be
allowed to ‘cone’ down over the next lower layer.
4/21.5 Aggregates shall not be stockpiled against the supports of proportioning hoppers
and weighing devices.
Segregation
4/21.6 Segregated aggregates shall not be used until they have been thoroughly
remixed and the resultant pile is of uniform and acceptable gradation at any point
from which a representative sample is taken. The Contractor shall re-mix
aggregate piles when ordered by the Engineer.
Transporting of Aggregates
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4/21.7 If aggregates are to be transported from a central proportioning plant to the mixer
in batch-boxes or dump trucks, such equipment shall be of sufficient capacity to
carry the full volume of materials for each batch of concrete. Partitions
separating batches shall be approved by the Engineer and shall be adequate and
effective to prevent spilling from one compartment to another whilst in transit or
being dumped.
Cement
4/21.8 Cement shall be stored in a dry weather-proof shed with a raised wooden floor or
in a silo and shall be delivered in quantities sufficient to ensure that there is no
suspension or interruption of the work of concreting at any time. If stored in
sheds, each consignment shall be kept separate and distinct.
4/22 MIXING CONCRETE
4/22.1 The weighing and water-dispensing mechanisms shall be maintained in good

order. The accuracy shall be maintained within the tolerances described in BS
1305 and checked against accurate weights and volumes when required by the
Engineer.
4/22.2 The mass of cement and of aggregate indicated by the mechanism employed
shall be within a tolerance of 2% of the respective mass per batch agreed by the
Engineer. The mass of the fine and coarse aggregates shall be adjusted to allow
for the free water contained in them. The water to be added to the mix shall be
reduced by the quantity of free water contained in the fine and coarse
aggregates, which shall be determined by the Contractor by a method approved
by the Engineer immediately before mixing begins and further as the Engineer
requires.
4/22.3 Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch
type mixer manufactured in accordance with BS 1305. Where appropriate the
batch capacity, method of loading, mixing time and drum speed shall conform to
the details furnished in accordance with the requirements of BS 3963 for the mix
which corresponds most closely to the mix proportions being used. The mixing
blades of pan mixers shall be maintained within the tolerance specified by the
manufacturer of the mixer and the blades shall be replaced when it is no longer
possible to maintain the tolerance by adjustment. The period of mixing, judged
from the time that all the ingredients including water are in the mixing drum shall
be as ordered by the Engineer’s representative but shall not be less than 2
minutes or 20 revolutions of the drum whichever is the longer.
All plants shall be equipped with an approved automatic cycling and monitoring
system installed as part of the batching equipment. The system shall include
equipment for accurately proportioniting the various components of the mixture
by mass. Admixtures may be measured volumetrically. The automatic
proportioning system shall be capable of consistently delivering each constituent
within the tolerances specified. All records of batches shall show the batch
weights, the batch number, the day, the month, the year and the time of day to
the nearest minute for each batch. This information shall be imprinted on the
record so that each batch may be permanently identified. The Engineer will be
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provided with a clear and legible copy of all batch records for concrete supplied
for the project.
4/22.4 Mixers which have been out of use for more than 30 minutes shall be thoroughly
cleaned before any fresh concrete is mixed.
4/22.5 The method of discharge from the mixer shall be such as to cause no
segregation whether partial or otherwise of the concrete materials.
4/22.6 The Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between its
discharge from the mixer and compaction in its final position. Precautions shall
include the shading of aggregate stockpiles and the use of chilled water.
4/23 READY MIXED CONCRETE
4/23.1 Ready mixed concrete as defined in BS 5328, batched off the site, may be used
only with the agreement of the Engineer and shall comply with all requirements of
the Contract.
4/23.2 The Concrete shall be carried in purpose-made agitators, operating continuously,

or truck mixers. The concrete shall be compacted and in its final position within 1
hour of the introduction of cement to the aggregates, unless a longer time is
agreed by the Engineer. The time of such introduction shall be recorded on the
delivery note together with the weight of the constituents of each mix.
4/23.3 When truck mixed concrete is used, water shall be added under the supervision,
either at the Site or at the central batching plant as agreed by the Engineer but in
no circumstances shall water be added in transit.
4/23.4 Unless otherwise agreed by the Engineer, truck mixer units and their mixing and
discharge performance shall comply with the requirements of BS 4251. Mixing
shall continue for the number and rate of revolutions recommended in
accordance with Item 9 in Appendix B of BS 4251 or, in the absence of the
manufacturer’s instructions, mixing shall continue for not less than 100
revolutions at a rate of not less than 7 revolutions per minute.
4/23.5 Pumping concrete through delivery pipes may be permitted but only with the prior
approval of the Engineer.
4/23.6 Re-mixing of concrete which has commenced to set shall not be allowed and in
no case shall such concrete be used in the Works.
4/23.7 Coarse aggregate shall be kept in identified stockpiles from which samples can
be collected and tested as specified.
4/23.8 The concrete supplier is required to certify that the C1 content in the mix being
delivered is within the limits specified in Clause 4/15.5. The C1 and SO3 content
shall be checked at frequent intervals.
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4/24 TRANSPORT AND PLACING
4/24.1 The method of transport and placing concrete shall be to the approval of the
Engineer. Concrete shall be so transported and placed that contamination,
segregation or loss of the constituent materials does not occur.
4/24.2 All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.
No concrete work shall be stopped or temporarily discontinued within forty-five

(45) centimeters of the top of any finished surface, unless such work is finished
with a coping having a thickness less than forty-five (45) centimeters in which
case the joint shall be made at the under edge of the coping.
Concrete in simple slab spans shall be placed in one (1) continuous operation for
each span, unless otherwise indicated on the drawings or approved by the
Engineer.
4/24.3 Prior to placing any concrete on natural surfaces a blinding layer of Class 15
concrete shall be laid to a minimum of 75mm thickness unless otherwise
specified on the drawings. The blinding shall be suitably cured prior to
subsequent concrete placement. The blinding shall be clean and free from any
dust or impurities prior to subsequent concrete placement.
4/24.4 No concrete shall be placed in a foundation until the extent of excavation and the
character of bearing material have been approved and no concrete shall be
placed in any structure until the placement of reinforcing steel and the adequacy
of the forms and falsework have been approved.
4/24.5 Concrete shall not be placed in any part of the Works until the Engineer’s
approval has been given. If concrete has not started within 24 hours of such
approval being given, approval shall again be requested. Concreting shall then
proceed continuously over the area between construction joints. Fresh concrete
shall not be placed against in-situ concrete, which has been in position for more
than 30 minutes unless a construction joint is formed in accordance with the
Specification. When the concrete has been in place for 4 hours, or less as
directed by the Engineer, further concrete shall not be placed against it for a
further 20 hours.
4/24.6 Concrete when deposited shall have a temperature of not more than 32 deg.C
unless otherwise specified. Concrete shall be compacted in its final position
within 30 minutes of discharge from the mixer unless carried in purpose made
agitators operating continuously, when the time shall be within 1 hours of the
introduction of cement to the mix and within 30 minutes of discharge from the
agitator.
4/24.7 Except where otherwise agreed by the Engineer, concrete shall be deposited in
horizontal layers to a compacted depth not exceeding 400mm where internal
vibrators are used or 300mm in all other cases.
4/24.8 Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 2m. When trunking or chutes are used they shall
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be kept clean and used in such a way as to avoid segregation. Where steep
slopes are required for placing concrete with chutes, the chutes shall be
equipped with baffle boards or be in short lengths that reverse the direction of the
movement. Chutes and the use of chutes must be approved by the Engineer. All
chutes shall be kept clean and free from coating of hardened concrete by
thoroughly flushing with water after each run. The water used for flushing shall
be discharged clear of the concrete already in place.
4/24.9 No concrete shall be placed in flowing water. Underwater concrete shall be

placed in position by tremies, or by pipeline from the mixer.
4/24.10 Full details of the method proposed shall be submitted in advance to the
Engineer and his approval obtained before placing begins. Where the concrete
is placed by the tremie, its size and method of operation shall be in accordance
with BS 8004. During and after concreting under water, pumping or dewatering
operations in the immediate vicinity shall be suspended until the Engineer
permits them to the continued.
4/24.11Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement
against which concrete is to be placed shall be shielded against the direct rays of
the sun and shall be sprayed with water to prevent excessive absorption by the
surface of water from the fresh concrete.
4/24.12A complete record shall be kept of the date, time, temperature and conditions of
placing the concrete in each portion of the work and shall be available for
inspection by the Engineer at any time.
4/24.13Unless otherwise shown on the drawings all concrete placed below ground level
shall have a minimum protection to its outside faces as follows:
Underside - Protected by the laying of a grade 1000 approved polyethylene

sheeting on the blinding concrete. The sheeting shall be returned up the outside
faces of the concrete and suitably sealed.
Sides - Coated with 3 coats of an approved bitumen rubber latex emulsion

flexible damp and vapour-proof liquid membrane conforming to BRE Digest No.
54.
4/25 COMPACTION OF CONCRETE
4/25.1 All concrete shall be compacted to produce a dense homogeneous mass.

Unless otherwise agreed by the Engineer, it shall be compacted with the
assistance of vibrators. Sufficient vibrators in serviceable condition shall be on
site so that spare equipment is available in the event of breakdown. A 50mm
diameter internal vibrator shall be deemed capable of compacting 20 Cu.m/hr.
Internal vibrators shall be capable of producing not less than 10,000 cycles per
minutes.
4/25.2 Vibration shall not be applied by way of the reinforcement. Where immersion
vibrators are used, contact with reinforcement and all inserts shall be avoided.
4/25.3 Concrete shall not be subject to vibration between 4 and 24 hours after placing.
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4/25.4 Vibrators shall be so manipulated as to work the concrete thoroughly around the
reinforcement and embedded fixtures and into corners and angles of the forms.
Vibrators shall not be used as a means to cause concrete to flow or its position in
lieu of placing. The vibration at any point shall be of sufficient duration to
accomplish compaction. After initial set of the concrete, the forms shall not be
jarred and no strain shall be placed on the ends of projecting reinforcement.
4/26 CONSTRUCTION JOINTS
4/26.1 The position and detail of any construction joints not described in the Contract
shall be subject to the approval of the Engineer and shall be so arranged to
minimize the formation of shrinkage cracks.
4/26.2 The timetable for the depositing of concrete between construction joints should
be so arranged that no face of concrete shall be left for more than 20 minutes
before fresh concrete is deposited against it. Pauses for meals, servicing of
machines, changes of shift, etc. and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully
organized to ensure that the above mentioned interval shall not be exceeded.
4/26.3 When the continuous placement of concrete in any structural member is

interrupted or delayed, for any reason, for a period long enough for the previously
partially placed concrete to take its initial set, the Engineer shall declare such
joint a cold joint and the Contractor shall immediately remove the previously
partially placed concrete from the forms. No extra payment will be made for the
initial placement or the removal of concrete which is wasted because of a cold
joint.
The Engineer may suspend all or any part of subsequent concrete work until he
deems the Contractor has corrected the cause for the cold joint occurrence.
4/26.4 Where dowels, reinforcing bars or other adequate ties are not required by the
drawings, keys shall be as made by embedding water soaked beveled timbers in
soft concrete. The key shall be sized as shown on the details, or as directed by
the Engineer, which shall be removed when the concrete has set. In resuming
work the surface of the concrete previously placed shall be thoroughly cleaned of
dirt, scum, laitance or other soft material with stiff wire brushes, and if deemed
necessary by the Engineer, shall be roughened with a steel tool. The surface
shall then be thoroughly washed with clean water and painted with a thick coat of
neat cement mortar, after which the concreting may proceed.
4/26.5 Expansion joints shall be constructed at the locations, of the materials and to the
dimensions shown on the drawings.
4/26.6 The upper surface of lifts of concrete walls and columns shall be horizontal and if
the formwork extends above the joint on the exposed face, it shall be cleaned of
adhering concrete before the next lift is placed. The concrete placed immediately
above a horizontal construction joint shall not be the first batch through the mixer
and shall be thoroughly compacted and worked against the existing concrete.
4/26.7 In the case of vertical surfaces, a 1:1 slurry of cement and concreting sand shall,
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wherever possible, be well worked into them immediately before the fresh
concrete is placed.
4/26.8 Where sections of the work are carried out in lifts the reinforcement projecting
above the lift being cast shall be adequately supported to prevent movement of
the bars during the casting and setting of the concrete.
4/26.9 Wherever possible laitance and all loose material shall be removed while the
concrete is still green and no further roughening shall then be required. Where
this is not possible, it shall be removed by mechanical means provided the
concrete has been in position for more than 24 hours. The roughened surface
shall then be washed with clean water.
4/27 CURING CONCRETE
4/27.1 Immediately after compaction and for 14 days thereafter, concrete shall be
protected from the harmful effects of weather, including rain and rapid
temperature changes, and from drying out. The methods of protection shall be
subject to the Engineer’s approval. The Engineer’s approval will be conditional
upon the proposed curing method proving to be satisfactory on site. Only water
curing shall be allowed for bridges and retaining walls, which shall be
continuously cured for a minimum of 14 days.
4/27.2 The method of curing used shall minimize the loss of moisture from the concrete.
On concrete surfaces which are to be water-proofed, and for bridge
superstructures including piers, abutments, retaining walls and culverts curing
membranes shall not be used. Details of all curing methods to be used shall be
4/27.3 For the bridges retaining walls and culverts exposed and stripped concrete
surfaces shall be kept damp using soaked hessian sheeting. Polythene sheet
covering shall be used where directed by the Engineer to minimize evaporation.
The hessian sheeting shall be maintained continuously damp for a minimum
period of 14 days after casting. The water used for this purpose shall be of the
same quality as that allowed in mixing the concrete.
4/27.4 Whenever approved by the Engineer, membrane curing of concrete with an

approved liquid may be used as an alternative to curing with water except that
membrane curing liquid shall not be applied to surfaces of concrete from which
the shuttering has been stuck, until the concrete has been inspected and
approved by the Engineer’s representative.
4/27.5 Concrete curing compound shall be of an approved type which shall be readily
distinguishable upon the concrete surface for at least four hours after application.
The colour, if any, shall become inconspicuous within seven days after
application.
4/28 EARLY LOADING
4/28.1 Concrete shall at no time be subject to loading, including its own weight, which
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will induce a compressive stress in it exceeding 0.25 of its compressive strength

at the time of loading or of the specified 28 day strength whichever is lower.
4/28.2 For the purpose of this Clause, the assessment, of the strength of the concrete
and the stresses produced by the loads shall be subject to the agreement of the
Engineer.
4/28.3 No superstructure load shall be placed upon finished piers or abutments until the
Engineer so permits, but in no case shall any load of any kind be placed until the
curing has been completed. The Contractor shall not place any temporary loads
on deck slabs. Bridge deck slabs shall be opened to traffic or construction
equipment only when so permitted by the Engineer.
4/29 CONCRETING AT NIGHT
4/29.1 No concrete shall be mixed or placed when the light is insufficient, unless an
adequate and approved artificial lighting system is operated and such night work
is approved by the Engineer.
4/30 CONCRETING IN HOT WEATHER
4/30.1 When the rate of evaporation of surface moisture from concrete is expected to
approach 1 Kg/m2 per hour (estimated from following chart) or when the shade
air temperature is 35 deg.C and rising, precautions shall be taken, including the
following:-
a. Dampening the forms.

b. Reducing the concrete temperature to the lowest practical level by
procedures such as:-
i) Shading the aggregate

ii) Cooling the mixing water before use
iii) Screening the mixing plant and transporting vehicles from wind,
rain and sun
c. Erecting windbreaks and sunshades at the concrete placing location.

d. Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.
e. Minimizing evaporation (particularly during the first few hours subsequent
to placing the concrete) by suitable means such as applying moisture by
fog spraying.
4/30.2 All precautions to be taken shall be subject to the Engineer’s approval and the
Contractor shall demonstrate that all approved precautions are available for use
prior to the Engineer granting approval to any concreting operation.
4/30.3 The temperature of the concrete when placed shall not exceed 32 deg.C nor
shall concrete be mixed or placed when the shade air temperature is 40 deg.C or
above, or is expected to reach such a level during concreting, without special
permission from the Engineer.
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4/31 MINIMUM TEST REQUIREMENT FOR CONCRETE
4/31.1 Any one set of 6 cubes for each class of concrete and for each particular
application represent a maximum quantity of concrete as shown in Table 4.6.
The point of sampling of fresh concrete shall be at delivery into the construction
unless otherwise directed by the Engineer. Each set of cubes shall be made
from a separate batch.
4/31.2 Portland Cement : Sampling shall be as BS EN 196-7.
4/31.3 Water : One (1) - gallon sample shall be obtained prior to use from each source
and at least once every week for quality testing.
Table 4.6 - Sampling Rates
Sl.No Type of Structure Sampling to

. Represent A Volume
of M3 *
1. Critical structures e.g. masts, 10

cantilevers, columns
2. Intermediate structures e.g. 50

beams, slabs, bridge decks
3. Heavy concrete construction e.g. 100

breakwaters, solid rafts
For concrete pours for more than 500m3 this Table shall be modified as agreed
by the Engineer
4/32 FORMWORK Construction

4/32.1 Formwork shall include all temporary or permanent forms required for forming the
concrete, together with all temporary constructions required for their support.
4/32.2 All formwork shall be of such quality and strength as will ensure rigidity
throughout the placing, ramming, vibration and setting of the concrete without
visible deflection.
4/32.3 All formwork shall be so constructed that there shall be no loss of material from
the concrete. After setting, the concrete shall be in the position and of the shape
and dimensions prescribed. The finished surface of exposed concrete shall be of
a quality specified on the drawings and approved by the Engineer.
4/32.4 Unless otherwise provided on the drawings or directed by the Engineer, all
exposed edges shall be beveled by using dressed, mill-cut, triangular molding,
having twenty (20) millimeters sides.
All carved surfaces shall be formed with approved plywood or steel.
The Contractor shall in all cases request the approval of the formwork by the
Engineer’s representative in sufficient time to allow an inspection to be made and
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shall not commence concreting until such approval is obtained. The period
between the Contractor’s request for approval and his intention to commence
concreting shall not less than one clear normal working day and the Engineer’s
representative may require a longer period if, in his opinion, the formwork is of
such complexity as to require it.
Such approval shall not absolve the Contractor of his responsibilities under the
Contract.
4/32.5 Where internal metal ties are permitted, they or their removable parts shall be
extracted without damage to the concrete and the remaining holes filled with
mortar. No permanently embedded metal part shall have less than 40mm cover
to the finished concrete surface or the specified cover to the reinforcement
whichever is the greater.
4/32.6 The Contractor shall submit to the Engineer for his approval strength and
deflection calculations and drawings of the formwork he proposes to use. The
Contractor shall ensure that adequate time is given to enable the Engineer to
examine the calculations and drawings and also to inspect the formwork before
concrete is placed within it.
Falsework
4/32.7 Detailed drawings for falsework and centering shall be prepared by the
Contractor and submitted to the Engineer for approval. The drawings must be
approved by the Engineer before the work is started.
4/32.8 The Contractor shall submit to the Engineer for approval at least one (1) month
before commencing work, details of his proposed system of falsework, including
detailed drawings and calculations. Falsework shall be capable of
accommodating temperature changes without causing damage to the concrete.
4/32.9 Falsework and centering shall be designed and constructed to provide the
necessary rigidity to support all loads placed upon it without appreciable
settlement or deformation. Falsework columns shall be supported on wood or
metal bases to support all falsework that cannot be founded on rock, shale or
thick deposits of other compact material in their natural beds. Falsework shall
not be supported on any part of the structure, except the footings, without the
written permission of the Engineer. The number and spacing of falsework
columns, the adequacy of sills, caps and stringers and the amount of bracing in
the falsework framing shall be subject to approval of the Engineer.
4/32.10 All timber shall be of sound wood, in good condition and free from defects that
might impair its strength. If the vertical members are of insufficient length to cap
at the desired elevation for the horizontal members, they shall preferably be
capped and frames constructed to the proper elevation. Ends of the vertical
members shall be cut square for full bearing to preclude the use of wedges. If
vertical splices are necessary, the abutting members shall be of the same
approximate size, the ends shall be cut square for full bearing, and the splices
shall be scabbled in a manner approved by the Engineer.
4/32.11 All steel members shall be in good condition, free from damage, kinks, corrosion
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or any other defect, which might impair their strength.
4/32.12 The Contractor shall compute the form settlement and deflection required for
bridges so that when the final settlement is complete, the structure will conform to
the required camber, section and grade as shown on the drawings.
4/32.13 The Engineer will check and approve the Contractor’s computations. Long,
tapered hardwood wedges or screw jacks shall be used in all falsework
construction and shall be so placed that they can be adjusted to give proper form
alignment. The Contractor shall, if required by the Engineer, provide means of
adjusting forms to offset any excessive settlement, if screw jacks are used, they
shall be adequately braced and secured in such a manner that will prevent
tipping of the jacks in any direction.
4/32.14 The Contractor shall provide means for accurately measuring settlement in
falsework during placement of concrete, and shall provide a competent observer
to observe and correct the settlement.
4/32.15 In designing forms and centering, concrete shall be regarded as a liquid. In

computing vertical loads, a weight of twenty four hundred (2,400) kilograms per
cubic metre shall be assumed, and not less than thirteen hundred and sixty
(1,360) kilograms per cubic metre shall be assumed in computing horizontal
pressure.
4/32.16 The Engineer may refuse permission to proceed with other phases of the work if
he deems the falsework unsafe or inadequate to support properly the loads to
which it will be subjected.
4/32.17 The review or approval of falsework drawings by the Engineer or permission to

proceed with the work shall not relieve the Contractor of the responsibility for
successful erection or satisfactory results.
Tolerance
4/32.18 The formwork shall be set to such lines and levels as to ensure that the following
tolerances are not exceeded in the structures as cast.
For all buried concrete +25mm - 12mm
In addition, concrete surfaces that are to be waterproofed, abrupt irregularities in

the surface finish shall not exceed 3mm.
- For soffit edge beams and +/- 3mm but not more sides of
parapet plinths than 3mm in 3.5m.
- For all other concrete +/- 6mm but not more than 3mm in
3.5m.
Preparation OF Formwork Before Concreting
4/32.19 The inside surfaces of forms shall, except for permanent formwork, or unless
otherwise agreed by the Engineer, be coated with a release agent approved by
the Engineer. Release agents shall be applied strictly in accordance with the
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manufacturer’s instructions and shall not come into contact with the
reinforcement. Different release agents shall not be used in formwork to
concrete which will be visible in the finished works. A panel shall be constructed
utilizing the proposed release agent for the Engineer’s approval. The surface of
the panel shall not exhibit discoloration or any significant retard of the surface
mortar strength.
4/32.20 Immediately before concreting all forms shall be thoroughly cleaned out. All
formwork shall be inspected and approved by the Engineer before any concrete
is placed in it but such approval shall not relieve the Contractor of his
responsibilities for the safety, accuracy or efficiency of the work.
Removal of Formwork
4/32.21 The Engineer shall be informed in advance when the Contractor intends to strike
any formwork.
4/32.22 At the time of striking any formwork, the concrete shall be of sufficient age and
strength for it to withstand the effects of striking, including the effect of thermal
shock or the loss of surface durability upon premature exposure, and to be able
to withstand the resulting stresses without adverse effects.
4/32.23 The time at which the formwork is struck shall be the Contractor’s responsibility
but the minimum periods between completion of placing concrete in a section of
the works and the removal of forms shall be as follows:-
Sides of beams, walls and columns 2 days

Soffits of beams and slabs (props left in) 7 days
Removal of props (beams and slabs) 14 days
Soffits of precast beams 7 days
4/32.24 Formwork shall be constructed so that the side forms of members can be
removed without disturbing the soffit forms and, if props are to be left in place
when the soffits forms are removed, these props shall not be disturbed during the
striking.
4/32.25 Formwork shall be removed without damage to the concrete.
4/32.26 Where it is intended to re-use formwork it shall be thoroughly cleaned and made
good to the satisfaction of the Engineer.
4/33 CLASSES OF FINISH
Formed Surfaces
4/33.1 The class of finish of formed surfaces shall be as shown on the drawings.
4/33.2 Class F1 : As struck.
4/33.3 Class F2: The irregularities in the finish shall be no greater than those obtained
from the use of wrought thicknessed square edged boards arranged in a uniform
pattern. The finish is intended to be left as struck but imperfections such as fins
and surface discoloration shall, if required, be made good by methods approved
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by the Engineer.
4/33.4 Class F3: The formwork shall be lined with a material approved by the Engineer
to provide a smooth finish of uniform texture and appearance. This material shall
leave no stain on the concrete and shall be so joined and fixed to it’s backing that
it imparts no blemishes. It shall be of the same style and obtained from only one
source throughout.
4/33.5 The Contractor shall make good any imperfections in the finish as required by the
Engineer. Internal ties and embedded metal parts will not be allowed.
4/33.6 Class F4: The requirements for Class F4 are as for class F4 except that internal
ties and embedded metal parts will be permitted. The ties shall be positions as
described in the Contract or as agreed by the Engineer.
4/33.7 Permanently exposed concrete surface to Classes F4, F3 and F2 finish shall be
protected from rust and stains of all kinds.
4/33.8 Unless otherwise described in the Contract, all formwork joints for exposed
surfaces of concrete to Class F2, F3 and F4 finish shall form a regular pattern
with horizontal and vertical lines continuous throughout each structure and all
construction and movement joints shall coincide with these horizontal or vertical
lines.
4/33.9 Remedial Treatment of Surfaces
An inspection of the concrete surface shall be carried out immediately after

removing the formwork, and any remedial treatment to surfaces proposed by the
Contractor shall be submitted to the Engineer for approval and shall be carried
out without delay. Portions of the structure which can not be finished or properly
repaired to the satisfaction of the Engineer shall be removed.
4/33.10 Any concrete, the surface of which has been treated before being inspected by
the Engineer, shall be rejected.
Unformed Surfaces
4/33.11 Class U1 Finish. The concrete shall be uniformly leveled and screeded to
produce a plain surface as described in the Contract. No further work shall be
applied to the surface unless it is used as a first stage for a Class U3 finish.
4/33.12 Class U2 Finish. After the concrete has hardened sufficiently to prevent laitance
from being worked to the surface, a Class U1 finish shall be floated by hand or
machine sufficiently to produce a uniform surface free from screed marks.
4/33.13 Class U3 Finish. When moisture has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, a
Class U1 finish shall be steel-trowelled under firm pressure to produce a dense,
smooth uniform surface free from trowel marks.
4/33.14 Class U4 Finish. This finish is for bridge decks that are to receive approved
waterproofing systems. The concrete shall be uniformly leveled and screeded to
produce a plain surface. When the concrete has sufficiently hardened to prevent
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laitance being worked to the surface it shall be floated to produce a uniform

surface free from screed marks and exposed aggregate. Finally the surface shall
be textured by brushing or otherwise to the waterproofing manufacturer’s
requirements as agreed by the Engineer. The accuracy of the finished surface
shall be such that it does not deviate from the required profile by more than +/-
5mm over a 3m gauge length or have any abrupt irregularities more than 3mm.
Special Finishes
4/33.15 Where special finishes are specified in the drawings or in a particular

specification the Contractor shall make trial panels for the formed finishes
specified for inspection and approval by the Engineer.
4/34 MORTAR
4/34.1 Mortar shall be mixed by approved mechanical mixers. Mortars containing

plasticisers shall not be over mixed. Mixers shall be kept clean at all times.
4/34.2 Mortar shall be used within thirty minutes after mixing. Hardened mortar shall not
be used in the work and shall be removed immediately from the site. Mortar shall
be prepared in the following proportions with the addition of a minimum quantity
of water for workability.
4/34.3 Mortar (3:1)
Sand/Cement mortar (3:1) shall be composed for one part of cement to three
parts of sand by volume. This type of mortar shall be used in block work where
high strength is required
4/34.4 Mortar (4:1)
Sand/Cement with plasticiser mortar (4:1) shall be composed of one part of

cement to four parts of sand with a mixture of an approved plasticising agent,
added in accordance with the manufacturer’s instructions.
4/34.5 The sand used in mortar must be dry when proportioning. Allowance for bulking
shall be made when gauging by volume. The mean compressive strength at 28
days for each mortar shall conform to BS 5628 : Part 1.
4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both as
specified in BS 1200.
4/35 EXTENT OF POURS
4/35.1 The limit of individual pours and the height of lifts shall be as approved. The
sequence of pours shall be arranged to minimize thermal and shrinkage strains.
4/35.2 For walls, the length of panel placed at one time shall not exceed 6m, adjacent
panels shall not be placed within 2 days, but shall be placed as soon as
practicable thereafter. Subsequent vertical lifts shall not be poured within 2 days.
4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved
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sequence of panels. ‘Chequerboard” placing shall be avoided. Adjacent panels

shall not be placed within 3 days, and then only provided that the concrete in the
first pour has cooled down to below 38 degrees centigrade or ambient
temperature. Placing of adjacent panels shall take place as soon as practicable
after the above criteria have been satisfied. Panels shall be 5m x 5m and any
pour exceeding 25 m2 will only be considered for approval of substantiated by
calculations.
SECTION 5 - ANCILLARY WORKS
5/1 PAVING DESCRIPTION
5/1.1 This work shall consist of covering certain areas (footpaths, parking areas, etc.)
with paving blocks in accordance with the Specifications, the Drawings and the
Engineer’s instructions.
5/2 PAVING BLOCKS
5/2.1 Paving blocks shall be concrete blocks, colored where specified, laid on a sand
laying course. Their thickness shall be 6 cm on sidewalks and 8 cm on parking
areas unless otherwise shown on the Drawings or instructed by the Engineer.
5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS
5/3.1 The materials, dimensions and tolerances, test for compressive strength, test for
water absorption and certificate of compliance for paving blocks shall conform to
the requirements of Local Order No. 44/90. Water absorption and abrasion
resistance shall be carried out in accordance with the requirements of the
particular specification.
5/4 BLOCK LAYING REQUIREMENTS Laying Course

5/4.1 The laying course shall consist of sharp black sand containing not more than 3%
silt and clay by weight and not more than 10% retained on 4 mm. sieve. The sand
shall be obtained from a single source, allowed to drain before use and shall be
covered with suitable sheeting to minimize moisture changes. Permissible
sulphate and chloride content shall not exceed 0.3% and 0.5% respectively
(expressed as a percentage by weight). Chloride content test : BS 812, Part 117,
Sulphate content: test: BS 812, Part 118.
5/4.2 The profile of the laying course before compaction shall be similar to that of the
finished surface. During laying the sand shall be uniform in moisture content and
shall be carefully, screened to form a smooth compacted surface to receive the
paving blocks. The maximum deviation from the design levels shall be 5 mm.
5/4.3 The edge restraints to the paved area shall be laid in advance of the laying
course and all permanent obstacles within the area, such as manhole covers,
shall be adjusted to the correct finished levels.
Surface Course
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5/4.4 The paving blocks shall be laid on the sand laying course in such manner as not
to disturb the blocks already laid. Each block shall be placed firmly against its
neighbour so that they fit closely together. The joints between blocks shall not
exceed 3 mm. Laying of the paving blocks shall commence at right angles to the
main pavement axis starting at one end of the area. The paving blocks shall be
laid in a herringbone pattern unless otherwise shown on the drawings or

instructed by the Engineer at 450 to the main pavement axis.
5/4.5 Where blocks do not fit the edge restraints or other obstructions such as
manholes or upstands the gaps shall be filled using cut blocks.
5/4.6 Blocks shall be cut using only a mechanical block splitter.
5/4.7 Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall
be checked after laying the first three rows of blocks and thereafter at regular
intervals. If joints begin to open the blocks shall be knocked together using a
hide mallet.
5/4.8 After each 20 sq.m. or such area that has been agreed with the Engineer, has
been laid the blocks shall be compacted to the required levels using a plate
vibrator.
5/4.9 The plate vibrator shall have a plate area of 0.20 to 0.35 sq.m. and have a
compaction force of 12-24 Kn and a frequency of approximately 75 to 100 Hz.
5/4.10 A minimum of two passes of the plate vibrator shall be made in each direction,
i.e. at 90 degrees to each other. Vibration shall continue until no further
compaction of the sand layer is apparent. The laying course shall have a
compacted thickness of 50 mm. Fine dry sand with a particle size of 0.3 mm
shall then be brushed over the paving, and further passes of the plate vibrator
made in each direction, until the said is no longer absorbed into the joints.
5/4.11 The plate vibrator shall not pass closer than 1 m to a temporarily unrestrained
edge during laying.
5/4.12 No paving shall be left uncompacted overnight except for the 1 m strip at the
temporarily unrestrained edge.
5/4.13 On completion, the finished surface level, shall be within 5 mm of the design level
and the maximum deviation within the compacted surface, measured by a 3 m
straight edge shall not exceed 3 mm. The level of any two adjacent blocks shall
not differ by more than 1 mm. Any areas of paving which do not comply with
these tolerances shall be removed, the sand laying course adjusted and the
paving blocks re-laid to the correct levels.
5/5 KERBS DESCRIPTION
5/5.1 This work shall consist of the construction of kerbs in accordance with the
Specifications and in conformity with the lines, grades and typical sections shown
on the Drawings or established by the Engineer. These Specifications refer to
the following types of precast kerbs to be constructed. Non-Mountable Kerbs,
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Dropped Kerb, Heel Kerb, Quadrants and Flush Kerb. All kerbs and edgings
shall be hydraulically pressed and shall comply with the requirements of BS 7263
Part 1. They shall be uniform in colour, free from cracks, flaws or other defects
and they shall have well defined arises.
5/6 MATERIALS AND MANUFACTURE OF KERBS
5/6.1 Materials shall conform to the requirements specified in Part 4 “Concrete” of the
Specifications and as specified herein.
5/6.2 Kerbs shall be prepared with a concrete mixture containing not less than 400
Kg/m3 of Sulphate Resisting Portland Cement. The aggregate shall meet the
requirements of the General Specifications for concrete work except grading of
aggregates.
5/6.3 The 28 day characteristics cube strength of the concrete shall be 40 N/mm2
determined on cubes specimens, and not less than 75% of this figure after 7
days.
5/6.4 Non-Mountable Kerb, Dropped Kerb, Flush Kerb and Heel Kerb elements shall
only be precast from concrete produced in a fully automatic batching plant.
5/6.5.1 Sampling shall be carried out as per BS 7263 Part 1.
5/6.5.2 Tests shall be carried out on the concrete mix prior to commencement of
manufacture to ascertain the strength and surface finish requirements can be
met. If the required strength and surface finish is not obtained, then the Engineer
may order revisions to be made in order to achieve the specified requirements.
Mix design changes and any other work considered necessary to meet
requirements shall be subsidiary to the pay item.
5/6.6 The Consultant shall collect samples as per standard sampling method and
submit them for testing. All results shall pass before commencing this work.
5/6.7 Elements shall be manufactured to the dimensions shown on the Drawings.
5/6.8 Non-Mountable and Dropped Precast Kerbs shall be formed by elements 900
mm long where required to be laid in straight lines but may be reduced to 250
mm long or curve kerbs may be used where required to be laid to curves
depending on the radii of the curves.
5/6.9 The finished products shall be of solid appearance with clean planar faces, be
free of segregation, honeycombing, pits, broken corners or other defects and
there shall be no evidence of external rendering.
5/6.10 Bull noses and curved faces shall be of constant radius with a smooth change
from radius to plain face.
5/6.11 Tolerances of manufacture shall be three (3) millimeters in any one dimension
and end faces shall be truly perpendicular to the base.
5/6.12 Transverse strength and water absorption requirements shall be in accordance

with BS 7263 Part 1.
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5/7 KERB LAYING
5/7.1 Elements shall be set to the lines and grades shown on the Drawings. Under no
circumstances will it be permitted for levels to be set by direct measurement from
pavement layers.
5/7.2 Unless otherwise indicated, elements shall be laid either directly onto a wet
concrete base or on to a sand/cement (3:1) mortar bedding, two and half (2.5)
centimeters thick, on a previously laid concrete base on approved subgrade. The
dimensions of the base shall be as shown on the Drawings. The concrete base
shall be constructed of Concrete Class 25/20.
5/7.3 No pavement layers shall be laid against kerbing until such time as the backing is
complete, back filled and approved by the Engineer.
5/7.5 Joints between radius kerbs, shall have a clear width of four (4) millimeters and
be filled with a sand/cement (3:1) mortar with one fifth (1/5) part hydrated lime
and sufficient water to make the mixture plastic and easily smoothed. A grooving
tool shall be used to produce a smooth, circular section groove not more than
three (3) millimeters deep in all joints. Grouted joints shall be cured by an
approved method to the Engineer’s satisfaction. Joints between straight kerbs
shall not be filled.
5/7.6 Immediately after any concrete is in place and for 7 days thereafter the kerbs,
base backing and mortared joints shall be fully cured and protected from drying
out and against the harmful effects of weather, including rain and rapid
temperature changes. The method of protection shall be subject to the
Engineer’s approval. The use of colored curing membranes will not be permitted.
Concrete not properly cured and protected will be rejected and shall be removed
from the works.
5/7.7 At each 9 meters or as directed by the Engineer or shown on the Drawings, the
joint between kerbs shall be filled with an approved joint filler 10 mm thick to form
an expansion joint. The filler shall extent through the kerb, bed, backing and
channel, and shall be trimmed to the finished shape of the kerb and channel.
5/7.8 At access points the kerbs, including the bed backing shall be dropped to show a
face of 75 m or as otherwise shown on the Drawings.
5/7.9 At the end of any kerb run, the end kerb section shall be sloped down to ground
level, if applicable, and angled away from the road at 30 degrees.
5/7.10 All kerbs shall be thoroughly cleaned of all extraneous material prior to approval.
5/7.11 Kerbs shall be laid within a tolerance of plus or minus three (3) millimeters, at
each end of an element, to the lines and grades given on the Drawings.
5/7.12 All kerbs shall be painted unless otherwise directed by the Engineer. (Refer to
Sub-section 5/13 or paint).
5/7.13 Any excavated surface for the concrete bedding shall be watered and compacted
to a minimum of 95% maximum Dry Density (BS1377 : Part 9 Method 2.1 or 2.2)
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5/8 PAVEMENT MARKING DESCRIPTION
5/8.1 This work shall consist of supplying thermoplastic road marking material for
marking of the pavement as outlined herein. It shall include the marking of the
centreline, the shoulder strip or edge, the barrier lines, the cross walks and any
other markings required on the pavement for the control and direction of the
traffic. Refer to the Dubai Municipality "Dubai Traffic Control Devices Manual".
5/8.2 The pavement markings shall be painted on the road to the dimensions and in
the location as shown on the Drawings or as directed by the Engineer.
5/8.3 The Contractor shall set out the markings and obtain the Engineer’s approval
before commencing the work.
5/9 MATERIALS FOR PAVEMENT MARKINGS
5/9.1 The materials used shall conform to the B.S. (British Standard) Specification for
Road Marking Materials (Superimposed type) BS 3262, (Part 1) & where
modified in this Specification. Glass Beads shall be in accordance with BS 6088.
5/9.2 The road marking material shall consist of light colored aggregate, pigment &
extender, bound together with hard wearing resins, plasticised with oil as
necessary.
5/9.3 The grading of various ingredients shall be such that the final product, when in a
molten state, can be sprayed on the surface in accordance with BS 3262 Part 3.
5/9.4 The aggregate shall consist of light colored silica sand, calcite, calcined flint or
quartz, in accordance with paragraph 3 of BS 3262 (Part 1)
5/9.5 Glass Beads incorporated in the mixture shall be minimum 70% of spherical, &
free from flaws and not less than 80 percent shall be transparent glass. The
grading of the Glass Beads shall be as stated in BS 6088 (Class).
5/9.6 The pigment material shall be titanium dioxide (in accordance with Clause 4 of
BS 3262 (Part 1) and shall be not less than 10 % by weight of the mix for white
pigment. The lead chromate content of the road marking material shall not
exceed 5% by mass. A suitable yellow pigment should be substituted for all or
part of the titanium dioxide where yellow pigment material specified.
5/9.7 The extender shall be whiting power added to assist the dispersion the pigment
and impart body to the mixture (in accordance with paragraph 2.3 of BS 3262
Part 1).
5/9.8 The binder shall not contain more than 5 percent of resin or other acidic material,
it shall consist mainly of hydrocarbon resins plasticised with mineral oil.
5/9.9 The viscosity of the melted binder at the spraying temperature must be such as to
produce a thermoplastic mix of the required spraying properties.
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5/9.10 The composition and proportion of constituents of the laid material as found on
analysis shall comply with the requirements of Table 1 of BS 3262 (Part 1),
reproduced below :
Percentage by mass of total mixture

Constituent(s) Minimum Maximum
Binder (resin & oil) 18 22
Aggregate, pigment and

Extender and Glass 78 82
Beads
20 --
Solid Glass Beads
5/9.11 The grading of the combined aggregate, pigment extender and where specified
Solid glass beads sampled in accordance with paragraph 7 of BS 3262 Part 1
shall be as follows:
a – 100% by mass passes a 2.8 mm BS 410 test sieve

b - 65% to 95% by mass passes a 0.600 mm BS 410 test sieve.
5/9.12 The capacity of each container shall be not less than 20 Kg or not more than 110
Kg.
5/9.13 Each container shall be clearly marked with the manufacturer’s name, batch
number and date of manufacture (Refer to Clause 10 of BS 3262 Part 1).
5/9.14 Container shall be made of a material which does not contaminate the contents &
will protect the contents from contamination.
5/10 APPLICATION OF THERMOPLASTIC
5/10.1 Application shall be by mobile sprayer, either hand propelled or self-propelled.
5/10.2 The road surface shall be dry, and free from loose, detritus, mud, or other
extraneous matter. Where old paint or thermoplastic material are present, the
manufacturer shall be consulted as to whether or not the surface is suitable.
5/10.3 A tack coat should not be necessary when the thermoplastic is applied to
carriageways. Where it is considered necessary to use a tack coat, this shall be
rubberized type recommended by the manufacturer of the thermoplastic material.
5/10.4 In addition to the glass beads included in the mix, an additional quantity of glass
beads (Class B) shall be sprayed on the thermoplastic line at the time of
application. The rate of application shall be at the rate of about 0.5 Kg/m2.
5/10.5 The thermoplastic material shall be applied in intermittent or continuous lines of

thickness 1.2 ± 0.3mm. For special lettering, arrows or symbols the material shall
be applied by hand methods. The finished lines shall be free from raggedness at
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all edges and be true in place with the road surface. The upper surface shall be
level uniform and free from streaks, blisters, lumps and other defects.
5/10.6 Application of thermoplastic material to new pavement construction should be

preceded by wire brushing to remove bitumen rich surface mortar. Sufficient
compatible mineral oil plasticiser should be incorporated in the thermoplastic
material to reduce levels of early shrinkage in the material and subsequent
cracking of the asphalted pavement structure.
5/11 PERFORMANCE REQUIREMENTS AND TESTING
5/11.1 The thermoplastic material shall meet the performance requirements of the
following table.
THERMOPLASTIC MATERIAL
Property Minimum Maximum
Relative Density BS 3262 : P3 2.0 --

(approx)
Softening Point C BS 2000 : P 58 95 --
Luminance BS 3262 : P1 (White as 70 --
delivered) 65
(White as re- 50
melted) 45
(Yellow as
delivered)
(Yellow as re-
melted)
Heat Stability (White) 65
(BS 3262 : P1) (Yellow) 45
Flow Resistance after 48 hours BS 3262 -- 25
:P1
Skid Resistance BS 3262 : P1 45 --
5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS
5/12.1 The Contractor shall control the traffic in such a manner as to protect the freshly
marked surface from damage. The traffic control shall be so arranged as to give
minimum interference to the travelling public. Signs, barricades, flagmen and
control devices shall be supplied by the Contractor & a system of spaced warning
flags or blocks shall be used to protect the fresh marking until it has dried as
required. Any lines, stripes or marking which become blurred or smeared by the
traffic shall be corrected by the Contractor at his own expense.
5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..)
5/13.1 Road marking paint shall be by an approved manufacturer. It shall be suitable for
applying by brush or mechanical means to cement concrete or bituminous
pavement to give a chemically stable film of uniform thickness and shall be either
chlorinated rubber, epoxy or alkyd based.
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5/13.2 White paint shall contain not less than 6% by mass of titanium dioxide as a
pigment, conforming to Type A (anatase) or Type R (rutile) as specified in BS
1851.
5/13.3 Yellow paint shall be standard colour BS 381C No. 355, except where an
alternative shade has been specified in the Contract, and obtain not less than 6%
by mass of a suitable yellow pigment.
5/13.4 The paint shall be supplied fresh and ready for use in sealed containers and
stored in accordance with the manufacturer’s instructions. The paint shall be
applied without the use of thinners or other additives.
5/13.5 Paint shall be applied at a covering rate recommended by the manufacturer and
5/13.6 Where markings are to be reflectorised with ballotini it shall be sprayed uniformly
on to the wet paint film at the rate of 400-500 g/sq.m. Ballotini shall comply with
the requirements of BS 3262 Clause 15.
5/13.7 Road marking materials shall only be applied to surfaces which are clean and
dry. Markings shall be free from raggedness at their edges and shall be uniform
and free from streaks. Carriageway lane and edge lines shall be laid by
approved mechanical means to a regular alignment.
5/14 ROAD SIGNS, DESCRIPTION
(Refer to Dubai Municipality “Dubai Traffic Control Devices Manual”

Chapter 5 All Clauses)
5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS

5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS

5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR

5/18 PAVEMENT REPAIRS
5/18.1 This work shall consist of the various types of repairs to existing pavement
described herein, necessary to correct structural failures, grade elevations, and
deterioration and/or to prepare the existing pavement surface prior to placing
bituminous pavement overlays. The Engineer on site shall investigate and find
out causes of failure and he shall instruct the Contractor on the type of repair.
The Contractor shall provide assistance in such investigation as instructed by the
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Engineer.
5/18.2 The materials required for the various pavement repair items shall be as
specified and shall be in accordance with the requirements of Section 3 of these
Specifications.
5/18.3 The Contractor shall be responsible for the supply of all the equipment and
labour necessary to perform the work described for the various types of
pavement repair items in accordance with these Specifications and as directed

by the Engineer.
5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS
Repair of Potholes (Isolated Holes In The Pavement of

Less Than One Square Metre)
5/19.1 The Contractor shall cut the failed pavement back to solid material with
pneumatic asphalt cutting tools. Make the cut square or rectangular with faces
straight and vertical. One pair of faces shall be at right angles to the direction of
traffic.
5/19.2 Remove the cut pavement and loose unsuitable material from the hole and cart
away and dispose at a location designated by the Engineer.
5/19.3 If soil is removed, fill the excavation with granular road-base material which has
been premixed to optimum moisture content. Place the material in 150 mm
layers and compact each layer to not less than 98% of the maximum dry density
as determined according to BS 1377 Part 9 Method 2.1/2.2 with mechanical
compactors. The same treatment is to be applied on subsoil before filling the
excavation with granular roadbase material.
5/19.4 Wire broom clean the cut edges of the pavement and paint with tack coat.
5/19.5 Prime the compacted soil or the upper surface of the roadbase layer with a light
coating of prime coat as directed by the Engineer.
5/19.6 Fill the hole with Bituminous Base Course and/or Wearing Course as appropriate
and compact in lifts not exceeding 5 cm to the same level as the adjacent
surface. Vibratory compactors shall be used to compact the hot-mix bituminous
layer.
5/19.7 Check levels of the patch with a straight edge and make corrections as directed
by the Engineer
Repair To Failed Pavement
5/19.8 The Contractor shall cut the failed pavement to solid material with pneumatic
asphalt cutting tools. Make the cut square or rectangular with faces straight and
vertical. One pair of faces shall be at right angles to the direction of traffic.
Vertical faces may be stepped where instructed by the Engineer.
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5/19.9 Remove the cut pavement and excavate the underlying soil to a depth of not less
than 300 mm. The Engineer may, when deemed necessary order substantially
greater depths of excavation payable as common excavation. Cart away and
dispose all cut pavement and excavated soil at a location designated by the
Engineer.
5/19.10 Thoroughly compact the subsoil with mechanical compactors to 98% of

Maximum Dry Density in accordance with the standard test methods given in
Section 2 of the Specification.
5/19.11 Fill the excavation to the bottom of the pavement with granular roadbase
material which has been premixed to the optimum moisture content. Place the
materials in 150 mm layers and compact each layer to 98% Maximum Dry
Density with mechanical compactors in accordance with the standard test
methods given in Section 2 of the Specification.
5/19.12 Wire broom clean the edges of the pavement and paint with tack coat.
5/19.13 Lightly prime the compacted roadbase layer with prime coat as directed by the
Engineer.
5/19.14 Place and compact wearing course or base course as applicable in the
excavation in 50 mm layers to the same level as the adjacent surface. The lower
layer shall be compacted with a vibratory compactor and the top layer shall be
compacted with a steel wheel roller by first compacting the hot-mix bituminous
layer 150mm from the two traffic edges and then by rolling in the direction of
traffic. The drive wheel of the roller shall be in a forward position. Use of asphalt
pavement finisher will depend on the size of the area being patched.
5/19.15 Check levels of the repair with a straight edge and make corrections as required.
Repair of Depressed Pavement
In case where the pavement has depressed but the asphalt has not fractured and
the pavement appears stable, the Contractor shall:
5/19.16 Cold plane and remove the supper 5 cm of the pavement starting just back from
the depression. Cart away and dispose of the removed pavement at a location
designated by the Engineer.
5/19.17 Wire broom clean the surface and lightly tack the surface and the edges with
tack coat (do not exceed 0.23 litres per square metre of tack coat).
5/19.18 Fill the cut with bituminous base course or wearing course as applicable and
compact with a steel wheeled roller by first compacting the hot asphaltic concrete
150 mm from the two traffic edges and then by rolling in the direction of traffic.
The drive wheel of the roller shall be in the forward position.
5/19.19 Check the level of the repair with a straight edge and make corrections as
required.
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5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS
5/20.1 The Contractor shall barricade the immediate work site to protect workmen and
motorists without closing the entire carriageway width to traffic. A single lane
should be closed for such operations.
5/20.2 Cut and remove sufficient asphalt pavement, if any, and concrete from the
manhole to permit removal of the cover and frame without damaging the
reinforcing steel, cart away and dispose of the rubble at a site designated by the
Engineer. Raising or lowering of manhole cover will be executed as per details
shown on the drawings or as otherwise specified.
5/20.3 Before starting any adjustment activity the Contractor shall obtain approval from
the concerned Authority to which the manhole belongs.
5/20.4 The Contractor shall submit to the Engineer for approval shop drawings for each
manhole affected by the work showing existing and new levels and a statement
of the methodology that will be followed.
5/20.5 Payment will be made upon receipt by the Engineer of a certificate issued by the
concerned Authority stating their approval of the works.
5/21 METAL BEAM GUARD RAIL SAFETY FENCING
5/21.1 Safety fencing shall comprise untensioned corrugated rails, channel-section,

posts, blocking-out pieces, nuts, bolts and washers for fixings, and end
anchorages.
5/21.2 Steelwork shall be mild steel Grade 43A to BS 4360, and shall be hot-dip
galvanized after fabricating in accordance with BS 729 to the thickness shown on
the Drawings.
5/21.3 Fencing shall be erected to the dimensions and tolerances shown on the
drawings to produce a flowing alignment. The Contractor shall adjust the
elevation of any rail as required.
5/21.4 The rail section shall be such that when freely supported over a 3 m clear span,
with the road face uppermost, and centrally loaded with a point load of 1000 Kg,
the deflection measured at the centre of the span shall not exceed 40 mm.
5/21.5 Adjacent rails shall be connected by bolted lap of joints made in the relevant
direction to prevent vehicles striking rail ends.
5/21.6 Guardrail posts may be driven into the ground as detailed on the drawings
provided that:-
i) The accuracy of placing will permit the rail mounting to be erected to

present a flowing alignment.
ii) A representative sampling of driven posts selected by the Engineer shall
satisfactorily withstand a test load of 10 KN applied horizontally at the
level of the centre of the rail with a deflection at that level not exceeding
200 mm. Where the previous cannot be met all posts shall be set into
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Class 25/20 concrete or as detailed on the drawings.

iii) Driven posts shall have a protective coating of bituminous paint over the
length which is to penetrate the ground and extend 75mm above the
finished ground level. The bituminous paint shall be of high quality with
excellent adhesion properties. A sample of the paint together with the
manufacturers specifications shall be submitted to the Engineer for
approval prior to use.
5/21.7 The ends of safety fences shall terminate with a mitred end rail and anchorage
flared away from the line of fence.
5/21.8 Site drilling or cutting of beams and posts shall not be permitted without approval.
Flame cutting shall not be permitted.
5/21.9 Minor surface damage to steel components shall be repaired by cleaning with a
wire brush to remove all corrosion products, the application of two coats of rust
inhibiting paint, and two coats of approved cold galvanizing paint or similar over
the damaged area.
5/21.10The horizontal alignment of fences shall not depart from the road alignment by
more than 30 mm overall, and the relative deviation shall not be more than 10
mm in any two successive rail lengths.
5/21.11The height of the uppermost edge of the rail shall not depart from the dimensions
shown on the drawing by more than 30 mm, nor shall the relative deviation from
this line be more than 5 mm in any two successive rail lengths.
5/22 HEAVY DUTY CAT’S EYES (REFLECTIVE STUDS)

5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS

5/24 REFLECTIVE STUDS MINIMUM MECHANICAL AND PHYSICAL PROPERTIES

5/25 REFLECTIVITY

5/26 INSTALLATION OF REFLECTIVE STUDS

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5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION
5/27.1 This work shall consist of the placement of stone pitching on mortar bedding on
slopes at the locations shown on the plans, or as ordered by the Engineer, in
accordance with these Specifications and in conformity with the lines, grades,
thickness and typical cross-section shown on the plans or established by the
Engineer.
5/28 MATERIALS FOR STONE PITCHING
5/28.1 Stone for pitching shall be hard, sound, durable, stones as approved by the
Engineer. Samples of the stone to be used shall be submitted to and approved
by the Engineer before any stone is placed. 5/28.2 Tests for specific gravity and
absorption, shall be determined in accordance with ASTM C-127. The minimum apparent specific
gravity shall be two and seven- tenths (2.7) and the maximum absorption shall be two (2) percent.
The stone shall not have an abrasion loss greater than thirty five (35) percent when tested in a Los
Angeles Abrasion Machine in accordance with ASTM C535.
5/28.3 The size and shape of the stones shall be such to allow for proper placement.
The widths of the stone shall not be less than one and one-half (1-1/2) times their
respective thickness and lengths of not less than (2) times their respective
widths. The minimum width shall be 100 mm.
5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING
5/29.1 The bed upon which the stones are to be placed shall be excavated to the
required grades and lines as shown on the plans or as directed and approved by
the Engineer. A footing trench shall be excavated along the toe of the slope as
shown on the plans or as directed by the Engineer. All footings trenches and
excavations shall be approved by the Engineer prior to placement of stones or
concrete. Subgrade or base should be firm and well compacted as approved by
the Engineer. Stones shall not be placed on a mortar bed as detailed on the
Drawings.
5/29.2 Stones shall be arranged in such a way that the largest stones are at the bottom
of the slope. The surfaces of the stone shall be cleaned of adhering dirt and clay
and shall be moistened immediately prior to grouting.
5/29.3 The space between stones of stone pitching shall be filled with grout consisting of
one (1) part Portland Cement and three (3) parts of fine aggregate, and one-fifth
(1/5) part of hydrated lime with sufficient water to produce a plastic mix as
approved by the Engineer. Immediately after pouring, the grout shall be spaded
and rodded into place with suitable spades, trowels or other approved method,
and broomed into the spaces until the voids are completely filled. The exposed
surface of the rocks shall project not less than 40 mm and not more than 80 mm
above the grout surface. The grouted stone pitching shall be cured by an
approved method for a minimum period of four (4) days. Immediately after the
expiration of the curing period, the exposed surface shall be cleared of all curing
mediums.
5/29.4 Joints as detailed on the drawings will be provided at a maximum interval of 12

meters.
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5/30 GABIONS DESCRIPTION

5/30.1 Gabions shall consist of furnishing and placing wire mesh boxes rectangular in
shape filled with clean and uniform rocks larger than the mesh openings in
accordance with the drawings, and these Specifications.
Gabions shall be of approved quality.
Materials
5/30.2 Wire mesh shall consist of galvanized steel fabricated in double twist woven
hexagonal shape and with the following requirements:-
Wire Diameter Mesh Size

Boxes 2.7 mm 8 cm x 10 cm
Mattresses 2.2 mm 6 cm x 8 cm
5/30.3 The rocks shall consist of clean solid rock non-friable and resistant to weathering
and frost action meeting the following requirements:-
Bulk Specific Gravity (ASTM C128/C127) Not Less than 2.70.

Absorption (ASTM C128/C127) Max. 2%
Soundness by Magnesium Sulphate Max 12%
(ASTM C88).
5/30.4 The rock shall be greater than 150 mm in size.
5/30.5 Excavation required for the placement of gabions shall be made in accordance
with the dimensions as shown on the drawings or as directed. Gabions shall be
constructed in units to the dimensions indicated on the drawings.
5/30.6 The sides, ends, and diaphragms shall be lifted into a vertical position, and
located together with binding wire to form the base.
5/30.7 The binding shall be carried out in a continuous lacing operation, the wire being
passed through each mesh and around both selvedges which must be tied
together with two round of turns after every second mesh.
5/30.8 Assembled gabions may be placed in position for filling singly, or wired together
in groups suitable for man-handling. The baskets shall be securely wired
together at all corners and edges in the same manner as described above.
Where there are more than one course of gabions, the one in the upper course
must be laced to those below. Gabions shall be slightly over-filled to allow for
subsequent settlement.
5/31 CHAIN LINK FENCING
5/31.1 The chain link fencing shall be PVC coated and erected according to the lines
shown on the drawings or as otherwise directed by the Engineer. The fencing
components shall have a five year corrosion warranty from the manufacturer.
5/31.2 The Contractor shall supply shop drawings showing all fixing and erection details,
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for approval prior to erection.
5/31.3 Steel posts, mesh, braces and struts shall conform to the requirements of BS
1722 Part 1 and they shall be hot-dipped galvanized in accordance with BS 729
and then polyester coated to a minimum thickness of 60 microns.
5/31.4 Polyester coating shall conform to the requirements of BS 6496 and BS 6497.
Mechanical Tests
Flexibility (Conical Mandrel) Pass 3 mm

Adhesion (2 mm Crosshatch) BS 3900 - E6. Pass GTO
Erichsen Cupping BS 3900 - E4 Pass > 7 mm
Hardness (400 gms) BS 3900 - E2 Pass - No
Penetration
to substrate
Impact Resistance BS 6496 Clause 16 Pass 2.3J

direct and
reverse
Chemical and Durability Tests
Salt spray ASTM B 117 @ 35 deg. C) Pass at 1000 hrs.

Acetic Acid/Salt spray BS 6496 Clause 15) No corrosion area
more than 2 mm from scribe
Cyclic Humidity BS 3900 - F2 Pass at 1000 hrs

no blistering or
loss of gloss
Distilled Water Immersion Pass - no blistering
BS 3900-G5 or loss of glass
after 24 hours.
Sulphur Dioxide BS 3900 - F8 Pass - no blistering

loss of gloss, or
discoloration
after 240 hours.
Exterior Durability BS 6496 Excellent Performance.

Clause 4.0 Slight even loss of
12 months Florida 40 deg.South gloss, no checking,
cracking or flaking.
- Chalking None in excess of minimum

in ASTM D659:1980.
5/32 STEEL AND METAL WORK
5/32.1 Steel for the fabrication of bridge parapets and signs gantries shall comply with
the requirements of BS 4, Part 1, BS 5400, BS 4360 and BS 4848 as appropriate.
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5/32.2 Fixing bolts and accessories complying with BS 5400, BS 4190 and BS 4320 as
appropriate.
5/33 ALUMINIUM FOR PARAPETS
5/33.1 Extruded sections shall conform to the following requirements:-
Posts Alloy 6082 TE to BS 1474

Other Locations Alloy 6082 TF to BS 1474.
5/33.2 Casting shall be in alloy LM6M to BS 1490.
5/34 FASTENINGS FOR ALUMINIUM PARAPETS
5/34.1 Holding down bolts shall be of stainless steel A4-80 to BS 6105.
5/34.2 Aluminum parapets in contact with concrete shall have bearing pads of
rubber/fabric, new and unvulcanised.
5/34.3 All other fastening shall be of stainless steel 315S16 quality to BS 970 Part 4.
5/35 PAINT AND OTHER PROTECTIVE COATINGS
5/35.1 All paints forming any one painting system shall be obtained from one
manufacturer and, unless otherwise agreed by the Engineer, the source of supply
shall not be changed after the Engineer’s approval has been given. Paint shall
be supplied in sealed containers of not more than 5 litres capacity and these shall
be used in strict order of delivery.
5/35.2 The Contractor shall obtain from the paint manufacturer paint ready for the use
specified under the contract. The paints shall be adequate in all respects for the
purpose intended.
5/35.3 The system of protection for all non-galvanized steel work shall be as follows:-
- Prime Coat: Inter zinc QHA 027/028 (or equivalent) minimum dry film
thickness 65 microns.
- Second Coat: Intergard EBA 070/EBA 100 JB (or equivalent) natural
M.I.O. minimum dry filter thickness 100 microns.
- Third Coat: Intergard EBA 070/EBA 100 JB (or equivalent) silver grey
M.I.O minimum dry film thickness 100 microns.
- Fourth Coat: Intergard EFK 724 (or equivalent) epoxy finish grey minimum
dry film thickness 50 microns.
Total dry film thickness - 315 microns (minimum)
The coating shall have a minimum adherence to the steel work of 2.5 Mpa when
tested with an adhesive tester.
5/35.4 Prior to painting the steel work shall be grit blasted to SA 2-1/2 Swedish Standard
055900 or by other approved method to equivalent standard. Before the steel
surface shows signs of flash rusting the first coat of zinc primer shall be applied.
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If the steel does flash rust then the cleaning process is to be repeated.
5/35.5 Steel work specified as galvanized shall be hot-dipped galvanized to the standard
required by BS 729.
5/36 WATERPROOFING MEMBRANES FOR STRUCTURES Waterproofing Bridge Deck Slab -
Type 1
General
Type 1
5/36.1 Deck waterproofing shall be composed of a proprietary membrane of a polyester

reinforced, SBS (Styrene-Butadiene Styrene) polymer modified bitumen sheet
sprayed or torched applied to primed concrete deck as detailed on the drawings.
Materials
5/36.2 Membranes shall comply with the requirements of Technical Memorandum BE 27

(Bridges) Waterproofing and Surfacing of Bridge Decks and the system shall be
certified by the British Board of Agreement. A service performance guarantee
shall be submitted by the Contractor in respect of materials and application for all
waterproofing works. Materials shall have the following physical properties.
- Minimum thickness 1.5 mm

- Flexibility Over 20 m dia. Mandrel -20 deg.C
- Longitudinal Elongation at Constant
temperature (20 deg.C, 100 mm/min.) 54%
- Longitudinal Elongation with Thermal
shock (20 deg.C., 100 mm/min.) 57%
(-10 deg.C., 10 mm/min.) 42%
- Longitudinal Tear Resistance at
Constant Temperature (20 deg.C.,
100 mm/min.) 180 N/mm.
- Adhesion to Concrete at 20 deg.C > .40 Mpa
- Adhesive Softening Point
When tested to ASTM D36 1000C Minimum
- Puncture Resistance at 20 deg.C.,
500 mm/min. > 800N
Preparation of Surface
5/36.3 All concrete surfaces to be waterproofed shall be smooth and free from
projections or holes which might cause puncture of the membrane. The surface
shall be dry and immediately before the application of primer or membrane, the
surface shall be thoroughly cleaned of dust and loose materials.
5/36.4 Immediately after cleaning and drying of surface, priming should be applied in
strict compliance with manufacturer’s instructions. Primer coat shall be allowed
to cure completely before membrane application. Membrane shall be laid parallel
to traffic direction and tangent to the bridge curve in such a manner that overlaps
are never less than the specified width. In all cases, waterproofing shall begin at
the low point of the surface to be waterproofed. End laps should be staggered
one metre so that at no point are there more than three thicknesses of
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membrane. It shall be installed with 100 mm side laps and 150 mm staggered
endlaps.
Application Details
5/36.5 At the edges of the membrane and at any point where it is punctured by
appurtenances such as drains or pipes, suitable provision shall be made to
prevent water from getting between the waterproofing and the waterproofed
surface, as recommended by the manufacturer.
5/36.6 Precautions must be taken to prevent injury to the finished membrane by any
cause.
5/36.7 The bituminous wearing course should be laid as soon as possible after a
minimum period of four hours has elapsed from completion of the membrane.
Waterproofing Bridge Deck Slab - Type 2
General
5/36.8 Type 2 deck waterproofing membrane shall consist of a two part rapid curing
liquid applied system based on methacrylate resins. The complete system shall
comprise of a primer to ensure good adhesion to the substrate; the membrane
and a tack coat to ensure good adhesion to the bituminous road surfacing. The
system must be suitable for use in Dubai. The temperature of the bituminous
surfacing at the time of laying onto the waterproofing membrane must be
according to Clause 3/33.
Certification
5/36.9 The Type 2 waterproofing membrane system must hold a British Board of
Agreement Certificate.
Application
5/36.10 Application shall be strictly in accordance with the manufacturer’s instructions.
Waterproofing Other Surfaces
5/36.11 Waterproofing membranes for structures other than top of bridge deck slab, shall
consist of an impervious laminate comprising a 0.3 mm PVC sheet and 1.5 mm of
flexible self adhesive rubber/bitumen compound. The laminate shall withstand
cracking of the substrate up to a crack width of 0.6 mm and shall have a tear
resistance (ASTM D1004) of 340 N/mm longitudinally and 310 N/mm
transversely, an elongation film (ASTM D638) of 210% longitudinally and 160%
transversely and a backing sheet tensile strength (ASTM D638) of 4.2 N/mm2
longitudinally and 4.8 N/mm2 transversely. Rubberised mastic and primer for use
with waterproofing membranes shall be special compounds provided by the
manufacturer of the membrane and formulated for its intended use.
5/36.12 Vertical and horizontal faces shall be made smooth, dry and free from nails or
concrete projections. It shall immediately be primed and allowed to completely
dry before installation of membrane. Installation procedures shall be strictly in
accordance with manufacturer’s instructions.
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5/36.13 Joints between sheets shall be lapped with end laps of at least 150 mm and side
laps of at least 100 mm. If the work must be left partially complete temporarily,
the exposed edges of outside strips of the membrane shall be finished with a
trowelled bead of mastic.
5/36.14 Waterproofed surfaces to be backfilled or otherwise exposed to possible

damage by plant or other construction operations shall be protected by
proprietary protection boards specifically designed for this purpose and installed
strictly in accordance with the manufacturer recommendations. As an alternative
to the waterproof membrane plus protection boards a composite membrane
consisting of a rubberised bitumen compound and integral geotextile layer (min.
400 g/sq.m) shall be permitted. The protection boards shall be a minimum of 6
mm thick.
5/37 RUBBERISED BITUMEN EMULSION
5/37.1 Rubberized bitumen for application to buried concrete surface as detailed on the
drawings shall comply with DM 500 and consist of a water bound emulsion
containing not less than 65% of bitumen with fine particles of rubber dispensed in
the bitumen, the consistency being such that it can be applied to the surface by
brush at normal air temperature. The rubber content of the dried film shall not be
less than 10%.
5/37.2 The Contractor shall submit to the Engineer for approval three samples in one
litre containers of the rubber bitumen emulsion. The Contractor shall also submit
to the Engineer certificates that the material complies with the requirements of
the specification, and is suitable for the intended purpose.
5/38 WATERSTOPS
5/38.1 Alternatives from those indicated on the drawings will be accepted only if the
Engineer is satisfied that their material and their performance are not inferior.
The waterstop, used must be installed strictly in accordance with the
manufacturer instructions.
5/38.2 Waterstops shall be manufactured either from rubber or from polyvinyl-chloride

(PVC), at the discretion of the Contractor subject to the approval of the Engineer.
PVC waterstops when tested in accordance with BS 2571, the PVC compound
shall exhibit the following properties:-
- Tensile Strength 13.78 N/sq.mm

- Elongation at Break 300%
- BS Softness 45
- Specific Gravity 1.3
For rubber waterstops the rubber compound shall comply required standard
except ASTM D395-52 for compression and ASTM D2240-75 for hardness.
5/38.3 No splices will be permitted in straight strips. Strips and special connection
pieces shall be well cured in a manner such that cross section shall be dense,
homogeneous and free from all porosity. All junctions in the special connection
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pieces shall be full moulded. During welding or vulcanizing periods the joints
shall be securely held by suitable clamps. The materials at the splices shall be
dense and homogeneous throughout the cross section.
5/38.4 If, after placing concrete, waterstops are materially out of position or shape or if
voids are found, the surrounding concrete shall be removed, the waterstop reset,
and the concrete replaced, all tat the Contractor’s expense.
5/39 PREFORMED JOINT FILLERS
5/39.1 Joint fillers in expansion joints for structures shall consist of a compressive non-
extruding board manufactured from bitumen impregnated fibres.
5/39.2 The physical properties of the materials shall conform to the requirement of
ASTM D-1751.
5/40 COLD APPLIED JOINT SEALANT
5/40.1 Cold applied joint sealant shall be a multi-component, gun applied material of a
grade suitable for the hot climate with a service temperature of up to 70 degrees
centigrade and high resistance to ultra-violet exposure.
5/40.2 The compound shall comply with the relevant standard and approval by the
Engineer.
5/40.3 The sealant must be suitable for the particular application whether the joint to be
sealed is horizontal or vertical and with the ability to accommodate any
movement at the joint without rupturing or losing adhesion.
5/40.4 The hardness of the joint sealant shall be no less than 20 on the “Shore A” scale.
5/40.5 The Contractor shall supply samples together with the manufacturers literature
relevant to any sealant for any application for the Engineer’s approval prior to
use. Only high quality products with demonstrable resilience to the local climate
conditions shall be approved. If a polysulphide based sealant is proposed for
locations exposed to biological attack or wet conditions then it should have a
minimum 40% polymer content. All polysulphide based sealant must utilize a
manganese dioxide curing system.
5/40.6 The mixing, application and curing of the approved sealant shall be strictly in
accordance with the manufacturers recommendations.
5/40.7 The approved sealants shall be delivered to site in sealed containers showing
date of manufacture, batch number and shelf life.
5/41 BRIDGE DECK EXPANSION JOINT
5/41.1 General
Expansion joint assembly shall be as shown on the drawing.
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Full details of the proposed suppliers with their technical specifications,

maintenance manual, design calculations, covering materials, dimensions and
sizes shall be submitted to the Engineer for approval before the Contractor
places an order.
All expansion joints shall be guaranteed by the manufacturer against any defect
in material and workmanship for a period of ten years.
The Contractor shall submit the detailed shop drawings and obtain the Engineer’s
approval before manufacture is commenced.
During placing and hardening of concrete or mortar under the expansion joint
components, relative movement between them and the supports to which they
are fixed shall be prevented.
Installation details shall be as shown on the drawings and as otherwise

recommended by the manufacturer and approved by the Engineer.
5/41.2 All anchoring steel plates, bolts and sockets shall be protected against corrosion.
5/41.3 Joint installation shall be carried out strictly in accordance with manufacturer’s
recommendations and in the presence of the manufacturers representatives.
5/42 LOCKABLE MEDIAN BOLLARD
5/42.1 Lockable median bollards shall be as shown on the drawings.
5/42.2 Movable bollard and locking mechanism shall be galvanized steel to BS 729
standard and treated with anti-corrosion paint.
5/42.3 Post sleeve shall be 4 mm thick PVC pipe.
5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED CONCRETE

SURFACES
General
5/43.1 The coating system shall be an elastomeric system of single component

products, a weather resistant top coat used in conjunction with a penetrating
primer. The coating shall have the ability to provide in-depth protection for
reinforced concrete structures against corrosion associated with the ingress of
chloride and sulphate ions, carbon dioxide and other air-borne acid gases, and
shall have the ability to allow water vapour to escape from the structure.
The Coating thickness of every layer shall be specified either in mm or micron
and shall be verified by DCL.
Primer
5/43.2 The primer shall be a low viscosity reactive silane-siloxane/acrylic blend

dissolved in a penetrating organic carrier. The primer shall have the capability to
penetrate and produce a chemically bound hydrophobic barrier to prevent the
passage of chloride and sulphate icons. The primer should also be film forming
to condition and stabilize the substrate prior to the application of the topcoat. The
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primer should be applied in full accordance with the manufacturers instructions.
Top Coat
5/43.3 The top coat shall be a pure aliphatic acrylic resin, decorative, high performance
water based, pigmented coating. It shall have resistance to water, carbon
dioxide and other air-borne acids and have the ability to allow the passage of
water vapour from within the structure.
5/43.4 The top coat shall have elastomeric and flexural capabilities and should be
applied in strict accordance with the manufacturer’s instructions.
5/43.5 The system will, during trials, display the following properties when applied in
accordance with the manufacturer’s specification to samples obtained from
concrete made without additives.
Reduction in Water Absorption 82% minimum at 28 days

(measured against a control
concrete sample in accordance
with ASTM C642)
Reduction in Chloride Ion 90% minimum at 28 days

Penetration
Water Vapour Transmission > 13g/m2/day
Carbon Dioxide Diffusion Equivalent to 500 mm

Resistance of 30 N/mm2 concrete.
Trial Panels
5/43.6 Prior to applying the system in the works, trial applications shall be carried out on
trial panels made by the Contractor under Clause 4/33. The trials will
demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating. Representatives of the
coating manufacturers shall be present at the trials and the surface preparation
and application of the coating shall be carried out under their direction. The
Contractor shall at his own expense surface coat as many panels as required by
the Engineer until a trial panel has been accepted by the Engineer as
satisfactory. The coated panel, when accepted will form the standard against
which the corresponding coating in the works will be judged. No application of
the coating in the works shall be undertaken until trials have been completed to
the Engineer’s satisfaction.
Inspection of Concrete
5/43.7 The Contractor shall not proceed with the surface finish or making good of
concrete surface until he has received the Engineer’s Representative’s
permission to do so and he shall not apply cement slurry or mortar or any other
coating to the concrete surfaces from which the shuttering has been struck until
the concrete has been inspected and approved by the Engineer’s
Representative.
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Faulty Concrete Work
5/43.8 The Contractor shall on the written instruction of the Engineer remove and
reconstruct any such portion of the work which in the opinion of the Engineer is
unsatisfactory as regards quality of concrete, incorrect dimension of the cast
portion, badly placed or insufficient reinforcement, honeycombing or other such
cause as shall render the construction not up to the standard required and which
in the opinion of the Engineer may prejudicially affect the strength or durability of
the construction.
Approval Prior To Coating Application In The Works
5/43.9 The Engineer’s approval must be obtained prior to applying the coating system
in the works. Before approval is given the Engineer will need to be satisfied as to
the following:-
a) All construction work in the immediate vicinity of the structure to be coated

has been completed.
b) The surface preparation of the structure has been completed.
c) The whole of the structure can be coated in a continuous operation.
d) Adequate measures have been taken to protect the property of third parties,
including vehicles, from coating splatters.
e) The weather conditions accord with the coating manufacturer’s direction for
coating application.
5/44 GEOGRIDS
5/44.1 The Quality Control Strength of the geogrid shall be 30 kN/m with peak strains of
around 11% (longitudinal) and 10% (transverse). The loads at 2% and 5% strain
shall be 10.5 kN/m and 21kN/m respectively in both the longitudinal and
transverse directions.
Tested in accordance with BS 6906 and expressed as the lower 95% confidence
limit in accordance with ISO 2602-1980 (BS 2846 Part 2, 1981).
5/44.2 The ribs of the geogrid shall be of rectangular cross section in both the
longitudinal and transverse directions with a minimum edge thickness of 1.35
mm.
The geogrid aperture size shall be approximately 37 mm x 37 mm.
5/44.3 The geogrid shall be manufactured from polypropylene sheet oriented in two
directions so that the resulting ribs shall have a high degree of molecular
orientation which continues through the area of the integral node.
5/44.4 The geogrid shall be inert to all chemicals naturally found in soils and shall have
no solvents at ambient temperature. It shall not be susceptible to hydrolysis shall
be resistant to aqueous solutions of salts, acids and alkalis, and shall be non-
biodegradable.
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5/44.5 The geogrid shall have a minimum of 2% finely divided carbon black, as
determined by BS 2782 Part 4, Method 452B:1978, well dispersed in the polymer
matrix to inhibit attack by ultra violet light.
5/44.6 The typical strength of the nodes between the longitudinal and transverse ribs, as
determined by the Geosynthetics Research Institute. Drexel University, U.S.A,
Test Method GG2-87, shall be > 90% of the Quality Control Strength in both
longitudinal and transverse directions.
5/44.7 The geogrid shall be manufactured in accordance with the Quality Assurance
requirements ISO 9002 - 1987 (EN 29002/BS 5750, Part 2, 1987). If required by
the Engineer, the Contractor shall provide evidence that the manufacturer’s
Quality Assurance System has been certified to conform with ISO 9002 (EN
29002/BS 5750) by an external authenticating authority.
5/45 LITTER BIN
5/45.1 Litter Bin dimensions shall be 610 mm. diameter by 975mm. height.
5/45.2 Slats shall be made from teakwood and treated with three coats of sadolin. The
total number of slats shall be 22 (twenty two) with slat size being 66 mm. by
32 mm.
5/45.3 Top shall be made from structural plastic foam molded consisting of one piece
molded dome with a spring loaded hinged flap.
5/45.4 Ashtray shall be made from 18 gauge galvanized steel and shall be coated with
baked on polyester powder coating.
5/45.5 Liner shall be fire retardant GRP.
SECTION 6 - WORKS IN CONNECTION WITH SERVICES
6/1 GENERAL REQUIREMENTS
6/1.1 This work consists of the provision of new services and/or the searching,
protection, diversion and relocation of the existing services for the following
authorities:
- Dubai Electricity and Water Authority

- Emirates Telecommunications Corporation Ltd.
- Roads & Transport Authority Roads Lighting Section
- Dubai Municipality Drainage & Irrigation Dept.
- Roads & Transport Authority Roads Department.
- DUSUP
- JAFZA
- LIMITLESS
6/1.2 The full scope of the new works required for the protection, diversion and
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relocation of services cannot be determined at the tender stage and the

Contractor shall allow in his rates for any variation in quantities and for the non
continuous and interrupted nature of the work.
6/1.3 The Contractor’s attention is particularly drawn to the procedures to be followed

concerning existing services and service diversions laid down in Section 1 of the
specifications and all current Administrative orders.
6/1.4 The service ducts shown on the Drawings or as directed by the Engineer are to
be provided so that future services can pass through them without disturbing the
road construction.
6/1.5 Position, types of ducts, pipes, cables, manholes etc. and constructional details
are shown on the Drawings but final locations will be determined on site by the
Engineer after having consulted with the concerned authorities.
6/1.6 The Contractor shall verify the position of services by digging trial trenches and
pits and if ducts, pipes, cables and manholes which are not marked on the
Drawings are found, the Engineer and the concerned Authority will then instruct
on the action to be taken, if any.
6/1.7 All protected services, existing ducts found or newly laid ducts shall be marked
with approved markers (Sub-Section 6/8) of size and type shown on the
Drawings or as indicated by the Engineer. The location of markers shall be as
shown on the Drawings. No asphalt course with be laid unless the ends of the
ducts or protected services have been exposed and marked with markers.
6/1.8 No work concerning services will be started without having first informed and
obtained approval of the Concerned Authorities. Services works shall be
executed in accordance with the relevant clauses of the Specifications.
6/1.9 The protection of existing services shall be carried out before the earth work
starts in the vicinity of the services to be protected.
6/1.10 Where new cable/ducts are to be laid along side, over or under the existing, the
Contractor shall take care to interfere as little as possible with the existing
services and connections thereto and any damage shall be repaired by the
Contractor to the approval of the appropriate Authority or by appropriate Authority
at the cost of the Contractor.
6/1.11 If some services have already been protected by the various Departments no
protection will be carried out under this Contract, but such protection can be
extended and/or upgraded as instructed by the Engineer on Site after having
consulted with the Concerned Authority.
6/1.12 All concrete works shall conform to the requirements of Section 4 of the
Specification.
6/1.13 Road crossing ducts shall extend beyond the road line at each side of the road
as shown on the Drawings. When appropriate, the excavation for the road
crossing and laying of ducts, concreting etc., shall only be carried out on half the
width of the road at one time, the other half being left available for traffic. In this
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case the necessary traffic warning signs on self-supporting tripods/cones shall be

provided well ahead of the duct crossing work and all care and attention
exercised to avoid risk of traffic accidents during preparation and execution of the
work.
6/1.14 To prevent soil and/or sand blocking the ducts, the openings at both ends are to
be protected with appropriate blanking caps.
6/1.15 The Contractor shall be responsible for public safety during execution of work.
He will take all steps, including where necessary the provision of ropes, picket
fence, etc., on each side of the trenches and excavations with warning lights and
night watchman etc. to ensure the safety of the public. The Contractor will be
held responsible for any damage to property or injury to persons due to his
negligence. Any instruction from the Engineer concerning the safety aspects of
the work must be carried out immediately, but the Contractor shall remain
responsible for the adequacy of the safety measures.
6/1.16 The Contractor shall after completing each duct, make the necessary
arrangements with the Services Authorities for testing and acceptance of the
work.
6/1.17 The Contractor shall supply continuous warning tape for Services Authorities with
the following requirements.
a) The Contractor shall install approved warning tapes during backfilling work
over buried pipes, cables, conduits and ducts, as required. Warning tapes
shall be coloured and inscribed for identification according to the
requirements of the relevant Authority.
b) Warning tape shall be approved high quality, acid and alkali-resistant

polyethylene film 250 mm wide, and with a minimum thickness of 150
microns. Tape shall have minimum tensile strength of 125 Kg/sq.cm.

Longitudinally and 105 Kg/sq.cm. Laterally with an elongation factor of 350%.
c) Tape shall be printed with 50 mm high black lettering, alternatively in Arabic

and English. The complete wordings shall be repeated every 2 m along the
tape. The colours shall be vivid, glossy and permanent with a life expectancy
of 40 years.
d) Warning tapes shall be placed with the inscriptions facing upwards. The level
of the tape relating to the top of service shall be in accordance with the
requirements of the relevant Authority.
e) Warning tapes over non-metallic services shall be backed with Aluminium foil
to facilitate detection.
6/1.18 All trenches and other excavation shall be maintained in a dry condition and the
Contractor shall arrange a suitable dewatering system for any dewatering
involved, in agreement with the Engineer, to keep the working place clean and
dry. The Contractor shall be deemed to have included in his rates for all costs
associated with this work.
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6/2 EXCAVATION FOR EXISTING SERVICES
6/2.1 The Contractor’s attention is again drawn to Section 1 of the Specification,

regarding existing services and diversions, which must be strictly adhered to.
6/2.2 The position of existing services as shown on the drawings are for informational
purposes only and do not necessarily show exact locations, depths, spacing’s,
and smaller services such as house connections which are not normally indicated
on such drawings. The Contractor shall excavate by hand, take trial pits at
regular distance and also at all road intersections to locate existing services, their
number, depth and route direction. As these services are located the Contractor
shall prepare shop drawings indicating the aforementioned information.
6/2.3 After existing services, according to the Engineer’s instruction, have been
exposed and if according to the opinion of the Engineer and after approval of the
concerned authorities it is found necessary to proceed with the lowering or
diversion, thereof, the Contractor shall proceed with the relevant excavation in
co-ordination with the said authorities.
6/2.4 The Contractor shall maintain records of such excavation in a form acceptable to
the Engineer. Two copies of such records shall be submitted to the Engineer on
a weekly basis or as agreed with by the Engineer.
6/2.5 The Contractor shall include all tools, labour, equipment and accessories as
required to complete the hand excavation. The Contractor shall include all
materials, labour and equipment necessary to protect the existing utilities, as well
as any shoring and protection during hand excavation.
6/2.6 All materials removed shall be disposed of by the Contractor in accordance with
the specifications or as directed by the Engineer.
6/2.7 When directed by the Engineer, all such excavation shall be backfilled with
suitable material, placed and compacted, all in accordance with the requirements
of the Specifications. The Contractor shall place fill material and compact with
care to avoid damage to the existing services. The Contractor shall be
responsible for any and all damages caused by his construction operations.
6/2.8 The works relevant to the lowering of the existing service(s) will be started as
soon as, according to the Engineer, all the necessary precautions have been
taken to prevent any injury to person and/or property or services.
6/2.9 The excavation for lowering the existing service(s) shall be performed by hand
down to the elevation indicated by the Engineer and/or the concerned authority.
6/2.10 At all times the Contractor shall provide and maintain, at his expense, access to
the adjoining properties to the satisfaction of the Engineer.
6/2.11 Where hedges are damaged or destroyed the whole shall be restored and
reinstated with shrubs of the same kind as the hedge, planted in due season in
an approved manner and fenced on each side with post and rail stock proof
fences finished on top with one strand of galvanized barbed wire, or otherwise
protected as required by the owners or occupiers and the Engineer.
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6/2.12 Where fences or walls are damaged or destroyed the whole shall be restored and
reinstated with like materials to the satisfaction of the owners or occupiers and
the Engineers.
6/2.13 The Contractor shall ensure that no trees are damaged or permanently removed
in carrying out the Contract except where directed due to the presence of
permanent works.
6/3 SERVICES DUCTS
6/3.1 The Contractor shall supply (unless otherwise specified) and install all the
necessary service ducts required by the Contract. The duct material shall be as
specified on the Drawings. A sample of the proposed duct shall be submitted to
the Engineer for his approval prior to their use. (For ducts for works for
Etisalat/DU, refer to Sub-Section 6/28).
6/3.2 In general all ducts lying work is subject to the approval of the Engineer and any
particular requirements of the concerned Authority.
6/4 EXCAVATION FOR DUCTS
6/4.1 The trench shall be excavated with the width and to the depth shown on the
drawings or as indicated by the Engineer.
6/4.2 The sides of pits and trenches shall be vertical and adequately supported at all
times. Excavation may if considered necessary be battered with a safe slope, but
only with the Engineer’s written permission.
6/4.3 The bottom of the trench shall be accurately graded. Care shall be taken not to
excavate below the depths indicated. Where rock is encountered, the rock shall
be excavated to the required depth. Uneven surfaces of the bottom of trench
shall be excavated 150 mm deeper. Such depth in rock shall be backfilled with
approved fill material and compacted as specified and/or as directed by the
Engineer.
6/4.4 Where ducts are laid in the line of the road construction, the bottom of the
excavation shall be compacted to a density of 95% M.D.D., as determined by BS
1377 Part 4 (method 3.5, 3.6) or as otherwise approved by the Engineer. The
insitu density test shall be carried out in accordance with BS 1377 Part 9 Method
2.2.
6/4.5 Excavated material shall, if found unsuitable as defined in the Specification, be

disposed of to an approved tip and replaced with suitable material. All surplus
suitable excavated material shall be used in road construction or disposed of in
an approved manner.
6/4.6 Where split ducts are required for existing services crossing the works, hand
excavation shall be carefully undertaken until the position of apparatus to be
protected is fully exposed.
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6/5 BEDDING AND LAYING OF DUCTS
6/5.1 As soon as possible after trench excavation, ducts of the required diameter shall
be joined in accordance with the Drawings and manufacturer’s instructions.
6/5.2 Ducts shall be laid to the lines and levels indicated on the Drawings with the
required depth of cover. Where the specified minimum cover cannot be
achieved, or as otherwise directed by the Engineer, they shall be bedded and
surrounded with 150 mm of concrete Class 15/20.
6/5.3 Unless surrounded in concrete, ducts shall be bedded on a layer of sand 150 mm
thick and fully surrounded with sand to a depth of 300 mm above the duct barrel,
well packed and tamped. Filling with suitable material above this level shall be
free from large stones. For multiple ducts, the spaces between ducts are to be
filled with compacted sand and the ducts surrounded to a depth of 300 mm
above the uppermost layer. Trench backfill shall be compacted to the
requirements of the Specifications.
6/5.4 The line of ducts shall be maintained as straight as possible. Short length of
duct, but not less than 600 mm, long may be used to achieve any required
deviation in the duct runs.
6/5.5 Ducts shall be cut by the Contractor as necessary only at right angles to their
length using a saw in a simple cutting guide. The inside cut edges shall be
thoroughly rounded off or dressed before installation to prevent damage to cables
drawn through the ducts.
6/5.6 Existing services shall be protected where necessary, unless otherwise directed
by the Engineer, using spilt uPVC ducts laid as described above, fully surrounded
with 150mm of concrete Class 15/20. The Contractor shall consult the Engineer
prior to carrying out protection works to agree the exact method.
6/5.7The halves of the split ducts shall be wired together and wrapped twice with
polythene sheeting to prevent the ingress of concrete.
6/6 BACKFILLING OF TRENCHES
6/6.1 After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer being
well compacted by hand with iron rammers weighing not less than 5 kg, until the
trench has been filled to a height of 300 mm above the top of the cable/duct.
6/6.2 The reminder of the trench shall then be refilled in compacted layers not
exceeding 200 mm in thickness, each layer being well compacted, with power
rammers, vibrating plate compactors or other mechanical means of a type to be
approved until the ground is thoroughly consolidated up to the required level for
surface reinstatement. Each layer shall be compacted to not less than 95% of its
maximum dry density as determined by BS 1377 Part 4 (method 3.5, 3.6).
Should the quantity of the excavated material be not sufficient, due to
unsuitability or otherwise, for the process of backfill and fill, the Contractor shall
obtain the quantity required of such backfill and fill from approved borrow pits and
transport same to the site of the work at his own expense.
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6/6.3 Trenches shall not be backfilled until all required tests are performed and until the
Engineer has verified that the cables/ducts have been installed in accordance
with the Specification and Drawings.
6/6.4 Lumps and clods shall be broken up before use. Materials shall not be dropped
from a height and where directed, water shall be added to assist in adequate
consolidation.
6/6.5 Where cover to cables/ducts is less than 400 mm, or where ordered by the
Engineer, protection in the form of concrete encasing shall be provided according
to an approved drawing or as ordered by the Engineer.
6/7 TESTING DUCTS
6/7.1 On completion of all ducting, two mops of appropriate sizes connected to each
end of an iron mandrel shall be passed twice each way to clean the ducts and to
remove foreign matter. All proving tests shall be witnessed by the Engineer and
the service Authority. Should any obstruction or other defect be discovered it
shall be removed or rectified immediately to the Engineer’s satisfaction.
All testing is to be complete before commencement of asphalt works.
6/8 MARKING AND RECORDING OF DUCTS
6/8.1 Unless otherwise shown on the Drawings each cable duct of length greater than
3 m shall be provided with a drawcord of approved 15 mm diameter nylon rope.
The length of each 15 mm drawcord shall be such that at least 1 m extends from
each end of the duct. As soon as each duct or set of ducts have been provided
and the draw cords installed the ends shall be plugged with a wooden or other
approved bung and a single coat of bituminous paint shall be applied over the
end of the duct and the bung. The free end of drawcords shall be stored in an
approved manner. The Contractor shall ensure that all ducts are kept free from
dirt, rubble, water and other obstructions.
6/8.2 In kerbless stretches of new roadway the Contractor shall provide suitable cast
aluminium stud duct markers (Type 2) to be fixed into the road surface over the
line of the respective duct or ducts at each end of the duct run, shown on the
Drawings. The head of the stud shall be suitably inscribed in Arabic and English,
with the approved abbreviation of the concerned Authority, such as, D.E.C,
E.T.C, etc. Should the markers not be placed immediately on completion of duct
runs, the Contractor shall expose the end of the duct to satisfy the Engineer of its
position when placing the marker. The stud to be provided will be as per the
products manufactured by approved manufacturers based in U.A.E. In this
regard the Contractor must submit his proposals with samples for approval.
6/8.3 In kerbed areas of new roadway Type 1 and Type 2 duct markers shall be used.
Type 1 duct marker shall be of concrete construction, in situ or precast
depending on the location, as per the details shown in the Contract drawings,
complete with approved abbreviation cast thereon. The finished product shall be
solid in appearance, free of segregation, honey combing broken edges and other
defects. The cost of these particular markers will be subsidiary to the relevant
duct provision item.
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6/8.4 The Contractor shall prepare and maintain up to date drawings for each Service
Authority giving details of each duct laid including precise location, level, number
and type, and these drawings to be submitted to the Engineer.
DUBAI ELECTRICITY AND WATER AUTHORITY (DEWA) WORKS
6/9 ELECTRICITY WORKS - GENERAL
6/9.1 The works relate to the following:
a) The installation, jointing and commissioning of low, medium and high

voltage power cable and pilot/telephone cable.
b) The relocation and protection of existing cables and pilot/telephone
cables.
c) The provision of duct crossing for future development use, all in
accordance with the relevant sections of the Specification and to the
satisfaction and approval of the Engineer and DEWA representative.
6/9.2 Where existing cables require extension of existing protection ducts of concrete
encasement or where shown on the drawings, the Contractor shall provide such
protection by means of split PVC ducts with concrete surround all as per the
relevant clauses of the Specification. The longitudinal beam of the split duct shall
be sealed with waterproof tape to prevent the ingress of grout.
6/9.3 Elsewhere, following lowering as found necessary, additional duct(s) will be

furnished and installed alongside existing cables in accordance with the
requirements of the DEWA and relevant Contract Drawings.
6/9.4 If requested, and upon receipt of authorization by DEWA Engineer, the

Contractor shall excavate, remove de-energized cable(s), transport to store or
dispose of as directed by DEWA Engineer, and backfill the excavation. The cost
of the excavation shall be paid under the relevant items of the Bill of Quantities.
6/10 ELECTRICITY WORKS - SUPPLY OF CABLES AND ACCESSORIES
6/10.1 The cables, pilot cables and enclosures, straight through joints, splitter boxes,
jointing accessories, PVC tiles, marker tape and earthing strip required for
installation of cables shall be procured either from DEWA or from an approved
source of DEWA.
6/10.2 The 11/6.6 KV power cables shall be 3 or 1 core, Copper or Aluminum

Conductors XLPE/SWA/PVC according to IEC 60502-2 in drum lengths of
250/400 meters respectively. Sizes, types and specifications shall further be in
accordance to DEWA.
6/10.3 The 33 KV power cable shall be 3 Core or 1 core, copper stranded conductor
HSL-MIND type PILC/SWA/PVC according to latest edition of IEC 60055-2 or
XLPE/SWA/PVC according to IEC 60502-2 and is in drums of 400 metre lengths.
Sizes, types and specifications shall further be in accordance to DEWA.
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6/10.4 The 132 KV power cable shall be single Core, copper conductor, XLPE insulted,
copper screened, metallic sheathed and HDPE outer sheathed according to
latest relevant IEC, BS publications including amendments. For reference
standard IEC & BS publications are mentioned in attached Annexure. Sizes,
types and specifications shall further be in accordance to DEWA.
6/10.5 The composite, 33 KV pilot/telephone cable comprises of 6 pilot cores of 2.5

sq.mm. Each in two triple sleeves and 8 telephone pairs of 1/1.13 mm in four
quad formations wound on 1000 metre drum lengths however sizes, types and
specifications shall further be in accordance to DEWA.
6/10.6 132 KV pilot cables comprises of 14 pair 1/1.13 mm copper conductor,

polyethylene insulated, paired, polyethylene sheathed, galvanized single wire
armoured, PVC sheathed wound on 1000 metre drum length or fiber optic cable
as applicable to be used however sizes, types and specifications shall further be
in accordance to DEWA.
6/10.7 Cable tiles are made of high density PVC compound and are in 1 metre lengths
with provision of interlocking longitudinally 20 and 15 cms. Wide tiles shall be laid
centrally as a physical cover over 6.6 KV, 33 KV power and pilot/telephone
cables respectively.
6/10.8 Upon taking delivery, if the Contractor feels that material given is of inferior
quality, he should immediately bring to the notice of the DEWA and the Engineer.
6/11 ELECTRICITY WORKS - INSTALLATION OF CABLES

.
6/11.1 Trenching with mechanical aids shall be permitted at the discretion of the
Engineer where minimum of services exist, and where location of services is
already effected, otherwise only manual excavation shall be permitted.
6/11.2 The cables are to be laid in trenches to the dimensions shown on the Drawings.
All cables, screens and armoring will be solidly earthed at each end of the route
to the station earthing system. Separate cable tiles are required for the main
cables and for the pilot cables. The tiles for the 33 KV cables shall be 1000 mm
long and 200 mm wide. The tiles for the pilot and 6.6 KV cables shall be 1000
mm long and 150 mm wide. The tiles are to be placed centrally over each cable
and are to be laid with ends interlocked with adjacent tiles. Plastic warning tape
shall be installed at the specified level.
6/11.3 Pressure testing of the cables will be carried out for the whole of each route. Any
failure of the joint or cable due to its mishandling shall be rectified by the
Contractor at no extra charges. All additional material required for making good
the fault/damage shall be at the Contractor’s cost. All work is to be guaranteed
for one year by the Contractor.
6/11.4 The Contractor shall remove within a period of 15 days after completion of route,
all the empty cable drums from the works and transport to stores.
6/11.5 Contractor shall supply ‘As laid drawings” for the cable circuit to a scale of 1:1000
indicating the following:
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- Layout of cable work

- Length size, type and grade of cables
- Location of each joint with respect to permanent landmarks available at site.
- Name of the circuit, Contract number, date of completion, Name of Contractor
with signature, DEWA’s Senior Distribution Construction Engineer’s approval.
6/11.6 After the route/circuit is completed, the Contractor shall take full care to clear the
site completely and leave it neat and tidy. All the remains i.e. excess earth,
stones, tile pieces, rubbish or any unwanted solid waste should be removed to
tip.
6/11.7 Route markers as per the Drawings shall be provided along straight runs of cable
at locations approved by the Engineer and generally at intervals not exceeding
100 meters. Markers shall also be provided to identify the change of the cables
route and also for location of every underground joint.
6/11.8 Even though the circuit may be energized due to compelling reasons, the taking
over date for maintenance/guarantee period shall be the date on which all the
outstanding work pointed out to Contractor is completed satisfactorily and official
taking over certificate issued to the Contractor.
6/12 WATER WORKS - GENERAL
6/12.1 This section deals with the specification for works to be carried out in connection
with Water Service pipe work to be ultimately taken over by the Dubai Electricity
and Water Authority. Works shall comply with the current DEWA standard
specification and this will take precedence over the following.
6/12.2 The works include for the supply, installation, testing and commissioning of the
Water Service installation, the layout for which is shown on the Drawings. The
Contractor shall include for all labour, materials, tools and tackle, complete with
all trenching and backfill.
6/12.3 The Contractor shall include for the preparation for all necessary working
Drawings. The Contractor shall be responsible for the location of other services
and the correct setting out of the installation.
6/12.4 The work also involves the exposing of existing water pipe lines for the purpose
of transferring existing house connections if any to the new distribution system
and for the connection of the new system thereto, and the recovery and disposal
of all abandoned existing connection lines, all as indicated in the Drawings or
otherwise directed by the Engineer.
6/12.5 The Contractor shall allow in his program for the non continuous nature of the
work relating to the water services.
6/13 WATER WORKS - MATERIALS TO BE FURNISHED BY THE CONTRACTOR
6/13.1 All materials shall be provided by the Contractor, unless otherwise specified,
including but not limited to pipes, collars, rubber rings, valves, hydrants and
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fittings.
6/13.2 The materials provided by the Contractor shall include all materials for temporary
works, planking and strutting, excavations, shuttering and formwork, staging and
scaffolding, approved filling materials, approved road surfacing and paving
materials, all materials required for repairing the internal coating of valves, etc.,
such as primer, coal tar enamel etc., all concrete of each required class including
reinforcing steel and mesh, all surface boxes etc.
6/13.3 All materials supplied locally by the Contractor shall be of the best quality in their
class and of the respective kinds as described in the Contract and in accordance
with the Engineer’s instructions and to the satisfaction of DEWA. They shall be
inspected from time to time at the site during the progress of the work.
6/13.4 Any materials arriving on site found unsuitable shall be rejected. The Contractor
shall replace the rejected material at his own expense.
6/13.5 The Contractor shall, before supplying any local material, prepare and submit, at
his expense, to the Engineer for approval samples of materials which he
proposes to use. Such samples shall be retained by the Engineer. The materials
represented shall not be used in the works unless and until the samples have
been approved in writing by the Engineer.
6/14 WATER WORKS - STANDARDS
6/14.1 All calculations, drawings and submissions shall be in SI (System International)

units. Material items shall be to the latest BS (British Standard) or equivalent
comparable internationally re-cognized standard of construction and quality.
6/15 WATER WORKS - PIPES General

6/15.1 Asbestos Cement (AC) pressure pipe shall conform to the requirements of ISO
160. Pipe shall be manufactured in the U.A.E. All pipe and joints shall be
supplied by one manufacturer.
Class
6/15.2 AC pipe shall meet the requirements for Class 18 suitable for an operating
pressure of 9 bars.
Pipe wall thickness shall meet all design requirements of Class 18 pipe as
follows:
Nominal Diameter (mm) Outside diameter (mm) at the end
75 93
80 106
100 126
150 178
225 255
300 344
550 616
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600 668
700 780
900 1000
1200 1320
Cement
6/15.3 All cement used in the manufacture of asbestos cement pipe and joints shall be a
high sulphate resisting cement conforming to BS 4027: 1980. Copies of cement
mill certificates shall be submitted with each consignment delivered to site.
Joints
6/15.4 Asbestos cements pipe shall be provided with spigot ends to be joined with
‘Reka’ type couplings with two rubber rings. Rubber rings shall conform to the
requirements of BS 2494. Joints shall be capable of withstanding a test pressure
of 18 bars without any leaks even when deflected to the angle specified below:
Nominal diameter Max. Joint deflection angle

mm degrees
Up to 225 5
250 - 350 4
400 - 550 3
600 - 1000 2
1100 - 1500 1
Copies of test reports showing compliance to these requirements shall be

submitted to DEWA and the Engineer for approval. Joint lubricant shall be an
approved vegetable-based type and shall be supplied by the pipe manufacturer.
Length
6/15.5 Asbestos cement pipe shall be manufactured in 3 metre lengths for diameters
225 (9”) and smaller and in 5 meter nominal lengths for larger sizes.
6/15.6 Testing
Asbestos cement pipes shall be factory tested in accordance, with the ISO 160 -
1980 copies of test certificates shall be submitted for each consignment
manufactured, and delivered to site. Sampling and inspection shall be in
accordance with section 5 of ISO 160 - 1980. Witnessing of factory testing by
DEWA representative may be required before any consignment is delivered to
site. All compulsory and optional tests shall be carried out by the manufacturer.
DEWA shall have the right to return up to 1% of pipes and joints delivered to site
for factory testing by the DEWA representative. All pipes testing shall be
performed on immersed samples.
6/15.7 Markings:
Each pipe and all joints shall be legibly and indelibly marked with the following:-
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i. The manufacturing standard.

ii. The manufacturer’s name.
iii. Manufacturing date.
iv. Nominal diameter (ND) in mm.
v. Pressure rating in bars (class).
vi. Inspection mark.
6/16 WATER WORKS - GRP FITTINGS
6/16.1 All the fittings (bends, adapters, tees, etc.) shall be GRP (Glass Fibre Reinforced)
pressure fitting which comply with the following specifications:-
General
6/16.2 This section covers the design, manufacture and testing of glass fibre reinforced
(GRP) pressure fittings for use with Asbestos Cement pipelines in nominal sizes
80 mm and larger. GRP fittings shall be locally manufactured in the U.A.E.
Construction
6/16.3 GRP fittings shall have the following principal construction:-
➢ A corrosion resistant, resin rich liner having a minimum thickness of 0.5

mm. The liner surface shall be reinforced with “C” glass mat impregnated
with vinyl ester or Epoxy Resin.
➢ A structural wall consisting of continuous glass filament windings and/or

woven roving’s and chopped glass reinforcements and may include fillers,
all impregnated with Resin.
➢ A resin-rich exterior surface having a minimum thickness of 0.25 mm,

impregnated with resin.
6/16.4 No pigments shall be allowed in the GRP fittings.
Design Requirements
6/16.5 GRP fittings and flanges shall be designed for service at the following
conditions:-
Maximum Operating Pressure 10 Bars

Minimum Site Test Pressure 15 Bars
Maximum Allowable Vacuum - 1 Bar
Minimum Depth of Cover 1.0 Metre
Maximum Depth of Cover 4.0 Metre
Truck Loading (Wheel Load) 100 KN
Maximum Service Temperature 50 Deg.C.
6/16.6 Flanged fittings shall be designed for installation above ground (in Chambers)
with no thrust blocks.
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6/16.7 Flanged branches on Spigot Tees and puddle (Wall) flanges shall be designed to
resist End thrust from closed valves.
GRP Joints
6/16.8 Spigot Joints, where specified shall have the same outside diameter (O.D.) as
Asbestos Cement (AC) pipe class 18 used by SEWA. The joint dimensions and
tolerances shall be equal to AC pipe spigots such that the joint remains water
tight under all normal operating conditions. The spigot ends shall be clearly
marked with a Homeline indicating the proper insertion limit for the AC couplings.
6/16.9 Flanged Joints, where specified shall be GRP filament wound flanges
manufactured from Vinyl ester or Epoxy resin. Flanges shall be flat faced and
drilled to BS 5404 PN 10 drilling pattern. Full face rubber gaskets 3 mm
minimum thickness shall be provided by the fitting manufacturer.
6/16.10 Laminated or Adhesive Joints, used in the fabrication of fittings shall be

equal or superior in strength to the sections they join. The thickness of laminated
joints shall not be less than the wall thickness of the adjoining pipe section.
6/17 WATER WORKS - PHYSICAL AND CHEMICALREQUIREMENTS OF GRP FITTINGS

Chemical Requirements
6/17.1 GRP fittings shall not impart any taste, odour or colour to drinking water. All
resins used shall be suitable for use in drinking water systems.
Dimensions
6/17.2 GRP fittings shall be produced in Metric sizes and shall be classified by their
nominal inside diameter (N.D.). The actual fitting inside diameter shall not be
less than the following in the table below:-
NOMINAL DIAMETER MINIMUM INSIDE DIAMETER

ND (mm) mm
80 78
100 98
150 148
200 198
225 223
250 248
300 298
550 546
600 595
700 695
750 744
900 892
1200 1190
Elbows
6/17.3 Elbows of nominal diameter 300 mm and smaller shall be of the smooth radius
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type, having a turning radius of 1.5 times the elbow nominal diameter. Elbows
larger than 300 mm shall be of a mitred type of nominal radius of 1.5 times the
elbow nominal diameter so as to produce as smooth as flow possible. All internal
surfaces shall be finished smooth.
Flanges
6/17.4 The minimum GRP flange wall thickness shall not be less than that shown in the
table below:-
NOMINAL DIAMETER MINIMUM INSIDE FLANGE

ND (mm) THICKNESS (mm)
80 32
100 32
150 32
200 37
225 42
300 48
550 68
600 68
700 73
750 77
900 82
1200 106
Wall Thickness
6/17.5 The wall thickness of GRP fittings shall be determined by the manufacturer to
meet the design requirements of these specifications but shall in no case be less
than the values shown in the table below:-
NOMINAL DIAMETER MINIMUM WALL THICKNESS

ND (mm) Mm
80 3.2
100 3.2
150 3.2
200 3.2
225 3.4
300 3.6
550 4.4
600 5.7
700 6.3
750 7.3
900 9.5
100 12.5
(Excluding liner and Exterior layer).
Mechanical Properties
6/17.6 GRP fittings shall meet the following minimum strength requirements:-
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PROPERTY TEST METHOD MINIMUM VALUE

Hoop Tensile Stress ASTM D2290 180 Mpa
Axial Tensile Stress for ASTM D638 40 Mpa
spigot fittings
Axial Tensile Stress for ASTM D638 90 Mpa
flanged fittings
Stiffiness (E1/D) BS 5480 5000 Pa
Visual Requirements
6/17.7 GRP fittings shall be free from delamination, crazing, dry areas or cracks. Spigot
ends shall be free from end delamination, torn edges, gouges and shall be
finished smooth to ensure water tightness.
Testing GRP Fittings
6/17.8 The following tests shall be carried out by the fitting manufacturer at the intervals
specified. Test results and certificates shall be submitted to DEWA for each
consignment delivered. Witnessing of factory testing by the DEWA
representative may be required.
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Sl.No. TEST FREQUENCY
1. Visual Inspection Every Item
2. Dimensions Every Item
3. Hydraulic Once per 100 Flanged Items

Pressure
4. Stiffness Once per 100 Equal Items
5. Longitudinal Once per 100 Equal items

Tensile Stress
6. HoopTensile Once per 100 Equal Items

Stress
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All GRP pipes shall be tested at DCL or approved testing laboratory for the
following tests also.
1. Initial Longitudinal unit Tensile Strength by a Tensile Strip Test as per BS

4580 App. “A”.
2. Initial specific stiffness under ring deflection in accordance with BS 4580
App. ‘H’.
Submittal/Drawings
6/17.9 Prior to start of production, the fittings manufacturer shall submit to DEWA
dimensional drawings of each fitting required for approval.
6/17.10 For flanged fittings, the manufacturer shall submit before delivery, the
bolt-torquing sequence and maximum recommended torque for each flange size
supplied.
Markings
6/17.11 Each fitting shall be indelibly marked with the following:-
➢ Manufacturer’s name or Trademark

➢ Nominal Diameter (N.D) in mm
➢ Pressure rating in Bars
➢ Manufacturing Date
➢ Inspection Mark
6/18 WATER WORKS - VALVES
6/18.1 Sluice valves supplied shall be suitable for use IN UAE, the valves shall be
supplied complete with gaskets and galvanized nuts and bolts. The sluice valves
shall be in accordance with BS 5163, latest edition. Manufacturer’s test
certificates are required the nominal pressure shall be 10 bar.
6/18.2 Double spigot valves with beveled edges are required unless otherwise indicated.
The outside diameters of the machined ends shall fit with the specified pipes.
6/18.3 Valves greater than 300 mm dia shall be butterfly type valves.
6/18.4 The maximum tolerance shall be + 0.6 mm. It is preferred that the manufacturer
makes an allowance for the 300 microns epoxy coating during machining.
6/18.5 Valves shall be grey cast iron, metal seated as per BS 1452 with a wedge of grey
cast iron and gun metal rings, the stem shall be of high tensile brass with a grey
cast iron stem cap. Toraidal sealing rings are required for stem sealing for all
valves of 300 mm dia or less.
6/18.6 Valves up to and including 300 mm shall be clockwise closing without
handwheel.
6/18.7 Where flanges are required they shall be drilled to PN 10 in accordance with the
BS 4504 unless stated otherwise.
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6/18.8 Additional markings on the valves shall be the year of manufacture and an
individual number which relates directly to the manufacturer’s test certificate.
6/18.9 The valves shall be coated externally and internally to 300 microns with an epoxy
coating suitable for use with drinking water, the primer shall be zinc rich and the
preferred colour of the coating is blue.
6/18.10A certificate verifying the suitability of the epoxy paint for use with drinking water
is required from the manufacturer endorsed by the National Water Council, U.K.,
or similar body.
6/18.11The manufacturer shall supply the original test certificate for each valve supplied,
the certificate shall relate to the individual number cast on each valve, the
certificate shall give the date of test.
6/19 WATER WORK - MANHOLE COVERS AND FRAMES
6/19.1 The manhole covers and frames shall be in accordance with the BS 497 : 1976
grade A loading.
6/19.2 The frame shall be square with a circular clear opening of 600 mm diameter and
be single sealed.
6/19.3 The cover shall be badged “DEWA” in English and Arabic and also with the
DEWA logo. The pattern shall have the prior approval of the Dubai Electricity
and Water Authority.
6/19.4 The keys shall be provided for every 10 Nos. of covers supplied.
6/19.5 The cover and frame shall be coated with suitable heavy duty abrasion resistant
epoxy paint to a minimum DFT of 375 microns.
6/19.6 DEWA reserves the right to request a manufacturer’s certificate certifying

compliance with the specification.
6/20 WATER WORKS - HANDLING AND STORAGE OF PIPES
6/20.1 Prior to undertaking any work, the Contractor shall submit to the Engineer for
approval, his proposal for the handling and storage of pipes and all fittings
thereto. Such proposals shall ensure that all pipes are properly handled and
stored both by his staff and sub-contractors staff.
6/20.2 The storage surface should be as level as firm as possible and clear of rocks or
solid objects that might damage the pipes. Stockpiles should not exceed a
certain height. This height is limited for safety and practical reasons as per the
following table :-
Dia (mm) 80-400 450-600 700-1000 1000-1400 >1500
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Layers in 5 4 3 2 1
Stockpile
Height <2 m <2.9m <3.0m <2.8m <2.0m
6/20.3 Asbestos cement coupling rings shall be stored lying flat and particular care shall
be taken to prevent damage to the internal face of the ring or the turned ends of
the pipes which may affect the sealing of the coupling.
6/20.4 Rubber sealer rings and gaskets shall be stored in a cool, dry dark place away
from grease, oil and sunlight until required.
6/21 WATER WORKS - EXCAVATION LAYING AND JOINTING OF PIPES
6/21.1 The trench depth shall be according to the approved shop drawings but never
less than 1.0 m between the ground level and the pipe crown level.
6/21.2 The Contractor shall excavate trenches to a sufficient depth and width according
to the following table:-
Where: is the width of the trench at the crown pipe level
Dia. (mm) MIN. (mm) MAX. (mm)
80-200 600 700

250 700 800
300 800 900
350-2000 DN+600 DN+1000
6/21.3 The side of trenches shall be adequately supported at all times. Trench sides
must be vertical and no battering will be allowed without the express permission,
in writing, of the Engineer.
6/21.4 The Contractor shall thoroughly compact the bottom of the trench formation, the
trench shall be cleaned of all stones, soil and other debris that might have fallen
therein.
6/21.5 Immediately following a prepared trench, pipes shall be laid and jointed on
specified pipe bedding material. Bricks or hard material shall not be placed
under the pipes for temporary support.
6/21.6 Prior to laying, each pipe and fittings shall be carefully examined both inside and
outside for any damage, and all dust, dirt and foreign matter shall be removed.
6/21.7 For assembling, the Contractor shall adhere to the following conditions:-
Preparation of the Reka Coupling
6/21.8 In order to avoid its damage the sealing rubber ring must be fitted into reka
coupling just before laying starts. Ensure that the groove of the rubber ring is
carefully cleaned, the ring is then fitted according to the following:-
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a) Lay the coupling horizontally.

b) Fit the ring into the groove.
c) Check that the ring is uniformly and fully seated into the groove all the
way round.
d) For large diameter (600 mm and above) two men are necessary to insert
the ring.
Mounting The Coupling In The Pipe
6/21.9 Clean coupling and pipe with a soft brush and insert them fully. Lubricate the
pipe end and the coupling ring by means of a dry clean piece of cloth or a
sponge. For lubricant use Eternit supplied products soap. in dusty conditions
lubricate generously the coupling only.
6/21.10 For small diameter pipes (Dia. <300) the coupling can be mounted by hand.
Use a timber block to protect the coupling and force the coupling into the correct
position as indicated by a black line on the pipe.
6/21.11 For larger diameters and where this method does not work the pulling can be
achieved by means of suitable mechanical devices. The gap between the pipes
(15 mm) is achieved automatically because the coupling stop at the level of the
strap fixed to each end of the pipe. N.B. It is essential to push the coupling to the
home line and not beyond, otherwise the pipes in the coupling will touch each
other and consequently not allow any expansion.
6/21.12 Maximum deflection angles for curved pipelines shall be according to the
following schedule :-
Dia 0 (mm) R (m)

L=3m L=5m L=3m L=5m Where
80-250 5 290 963 38.18 57.33 R : radius
300-350 4 232 399 97.71 71.25 of
curvature
400-600 3 175 262 63.6 95.5 O :offset
700-1200 2 117 175 95.4 143.25 L : length
1300 1 59 88 190.8 286.50 of pip
Backfilling
6/21.13 The Contractor shall backfill the pipes as follows:
The backfilling material shall be brought up on both sides of the pipe first to the
level of the centre of the pipe line and then to height of 30 cm above the top of
the pipe barrel. This backfill material shall be placed in layers each not more
than 15 cm thickness and shall be carefully compacted for the full width of the
trench with hand tools to the satisfaction of the Engineer.
Under The Road, Parking Areas and Footpaths
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6/21.14 Backfill shall be in layers of thickness not exceeding 150 mm. Backfill shall have
a minimum soaked CBR (BS 1377 Part 4 Method 7) and compacted to not less
than 95% of the maximum dry density as determined by BS 1377 Part 4 (method
3.5 or 3.6). Backfill within 30 cm of road subgrade level shall meet the
requirements of improved subgrade described in Section 2 of the Specification.
The insitu test shall be carried out in accordance with BS 1377 Part 9 Method
2.2.
Outside the Road
6/21.15 Backfill shall be in layers of thickness not exceeding 250 mm compacted

carefully to a minimum of 90% maximum Dry Density to the finished ground level.
The insitu test shall be carried out in accordance with BS 1377 Part 9 Method
2.2.
6/21.16 In order to prevent stones and soil from entering the pipe, a suitable cap and or
plug shall be provided with which the last pipe laid shall be closed when
pipelaying is not actually in progress. The plug shall be of the screw up
expanding type or of tapered wood.
6/21.17 Where the cover to pipes is less than 1.0 m or where ordered by the Engineer,
protection in the form of concrete slabs above the pipe shall be provided
according to an approved drawing by DEWA.
6/22 WORKS - PIPE ANCHOR AND THRUST BLOCKS
6/22.1 Pipe anchor and thrust blocks, shall be constructed on pipelines at all bends,
slopes greater than 1/6 and shop ends, tees and as otherwise required by site
conditions.
6/22.2 The thrust blocks shall be designed by the Contractor in accordance with BS
8110. The Structural Use of Concrete. The Contractor shall show that soil
resistance is greater than or equal to 1.2 times the force exerted by the pipe
when tested to 9 bar pressure. The soil resistance shall be calculated as the
frictional resistance of the soil against the thrust block. In calculating the passive
resistance the co-efficient of passive pressure of the soil shall be factored by 0.5.
6/22.3 The design of thrust blocks shall not be less than the dimensions given on the
drawings. This design is always subject to DEWA approval.
6/22.4 Before any internal pressure is applied to a pipeline, all the permanent concrete
thrust blocks shall have been cast in contact with the undisturbed ground and
cured for a minimum of 7 days.
6/22.5 Concrete Class 30 with Sulphate Resisting Cement shall be used for the
construction of thrust blocks.
6/23 WATER WORKS - CLEANING OF PIPELINES
6/23.1 On completion of construction, and before any sterilisation, internal surfaces of

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pipelines shall be cleaned thoroughly by flushing in such a way as to remove all

oil, grit and other deleterious matter.
6/23.2 Flushing of the new pipeline may be carried out by temporary connections to the
existing water system if present in the working area. DEWA will charge for giving
the water to the Contractor as per normal rates. In the absence of mains water
supply tankers shall be used.
6/24 WATER WORKS - TESTING PIPELINES
6/24.1 The Contractor shall provide written notice to the Engineer of any tests two days
before the test is to be carried out. All tests must be witnessed by the Engineer.
The Contractor shall maintain written records of the tests and provide copies of
the records to DEWA prior to the completion of the project.
6/24.2 The Contractor shall provide all, water, fittings, pipe stoppers, test pump,
pressure gauges and the necessary equipment and tools for pipework testing.
Hydraulic pumps, gauges and apparatus shall be equipped with locking devices
to prevent tampering during the test period.
6/24.3 Prior to hydraulically testing the pipelines the Contractor shall provide adequate
temporary thrust blocks only at the ends of uncompleted sections. Pipes shall be
partially backfilled to about 500 mm above the crown of the pipe, in order to
anchor the pipes during testing. Joints and fittings, however, shall remain
uncovered for inspection until the pipeline has been tested satisfactorily.
6/24.4 The length of the section of pipeline to be tested may be determined by the
Engineer/Contractor but shall not exceed 500 metres. The levels of the length of
pipe under test shall be such that the minimum test pressure specified is
achieved at all points whilst the maximum test pressure specified is not exceeded
at any point.
6/24.5 Valves shall not be used to isolate sections forming the pipeline whilst testing
operation are in progress.
6/24.6 Before testing the line should be filled slowly and evenly with water through any
convenient top or valve from the lowest point. At every high point an automatic
air release valve must be installed. After expelling all the entrapped air out of the
test portion, all air release valves should be closed. If it is not possible to fill the
line from the lowest point an additional outlet should be added at the inlet point to
release air at that point and this line/section should be kept filled for 24 hours
before the pressure test.
6/24.7 The test pressure shall be 1.5 times the maximum working pressure or 9 bar
whichever is greater. The pressure shall be raised slowly to the specified test
pressure and maintained at that pressure for a period long enough for the
Engineer to examine the whole section under test. Thereafter, for a period of not
less than 4 hours, the leakage of water as measured by the amount drawn into
the pumps to maintain the pressure shall not exceed 0:1 litre per millimetre of
pipe diameter per kilometer of pipeline per 24 hours for each 30 meters head of
pressure applied at the lowest point. Expected losses due to absorption shall be
as specified by the pipe manufacturer.
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6/24.8 The pipework, joints and connections shall be examined. Should leaks be
detected the pipework shall be repaired to the satisfaction of the Engineer and
the test repeated.
6/25 WATER WORKS - FINAL CLEANING AND STERILISATION
6/25.1 Upon completion of hydraulic tests the Contractor shall flush out the pipework
with chlorinated fresh water and a cleaning swab will be passed through the
pipework, this process will continue until the flushing water runs clear.
6/25.2 The Contractor shall prepare a solution of chlorinated dosing solution using
calcium hydrochloride at a rate of 77g/cu.m. of system water volume, or with
chlorinated water containing between 30 and 50 mg per litre of free chlorine. The
solution shall be slowly pumped into pipeline and a chloride level of 50 p.p.m.
shall be maintained for a period of 8 hours. The pipework shall be flushed out,
until the chloride level drops below 0.2 p.p.m. per litre.
6/26 WATER WORKS - CONNECTIONS TO EXISTING PIPELINE
6/26.1 All final connections of new pipelines to existing pipelines will be carried out by
the Dubai Electricity & Water Authority. The Contractor is to provide one week of
notice to DEWA for this work and shall render all necessary assistance.
6/27 WORKS FOR ETISALAT - GENERAL
6/27.1 General
The works relate to the protection and diversion of existing telephone ductlines,
for major trunk communications services alterations, including demolition and
rebuilding where instructed, to existing telephone manholes and joint boxes and
the provision of duct crossing for future development purposes. The layout of the
works for Etisalat are shown in the Drawings.
6/27.2 Where applicable, all civil works essential to the relocation/replacement of the
existing major coaxial cable systems including duct installation, manhole and joint
box construction shall be carried out by the Contractor within the stipulated
Contract period for sectional completion.
6/27.3 Where applicable, the installation of new Etisalat cables shall be carried out by
Etisalat within the time stipulated in the Contract.
6/27.4 Civil works for Etisalat other than the above shall be carried out by the Contractor
according to his approved programme.
Ducts
6/27.5 The installation of ducts of the required diameter shall be in accordance with
Etisalat Specifications as per Sub-Section 6/29.
Manholes and Joint Boxes
6/27.6 The existing manholes to be demolished and rebuilt and the new manholes to be
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constructed, if shown on the Drawings, are for information purposes only and do
not necessarily show the exact locations thereof. Exact details and locations of
these manholes will be determined on site in accordance with the Etisalat
6/27.7 The construction of new manholes shall be performed in accordance with the
Drawings.
6/27.8 Manholes shall be as per types shown on the Drawings or as required by

Etisalat. The concrete mix shall be Class 30 according to the requirements of
Section 4 of this Specification.
6/28 MATERIAL SUPPLIED BY ETISALAT
6/28.1 PVC pipes, drawcord, manholes frame and covers, and all other fixtures and
fittings will be furnished by Etisalat. The Contractor shall make the necessary
arrangements for providing labour and all equipment for loading at the Etisalat
Stores, for transporting to site, unloading, storing and fixing in position the above
mentioned material. The Contractor’s responsibility for material furnished by
Etisalat shall begin upon the Contractor’s acceptance at the place of delivery. All
such materials can be examined and tested by the Contractor, and all defective
material shall be rejected by him at the time and place of delivery.
6/28.2 All material found to be defective or damaged at this time will be replaced by
Etisalat. Once accepted by the Contractor at the place of delivery, he has no
right for any claim. All defective or damaged material discovered prior to final
acceptance of the work shall be removed by the Contractor and replaced by new
approved material at his own expense.
65/28.3In that event, the Contractor shall be responsible for the safe storage of all
material furnished to or by him, accepted by him until it has been incorporated in
the Works and finally accepted by the Employer. Any material lost or stolen from
the site shall be replaced by the Contractor at his own expense.
6/29 INSTALLATION OF PVC DUCT

(DUCT NO. 54D) AS SUPPLIED BY ETISALAT.
2/29.1 General: Duct No. 54D is manufactured from PVC. It is supplied in 6.0 metre
effective lengths, has an internal diameter of 90 mm and a nominal wall thickness
of 3.25 mm. Each duct length has a tapered socket at one end which will accept
the barrel of the duct. Couplings, Ducts 54A, 300 mm in length are also available
for use with short lengths of duct which have no socket. Couplings Duct, 54A
shall not be used for duct leading into buildings.
2/29.2 Trench: The trench shall be excavated to the required width and depth; the
trench bottom shall be free from stones, level and well tamped. The duct shall be
laid at standard depths unless otherwise specified.
6/29.3 Formations: Duct No. 54D may be laid as a single duct or in multiway formation
as follows:
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a) Up to and including 9 ways in rectangular formation.

b) Over 9 ways rectangular formation with concrete surround.
c) The duct bank must be properly secured to the ground before concreting
to avoid displacement due to flotation
Laying and Jointing
a) For Singleway
6/29.4 The open starting end of the trench shall be blanked off with a board or boards,
to act as an anvil against which the duct can be driven home. The duct shall be
recessed into the wall of jointing chambers 10 mm from the inside surface. The
surface of the duct shall be roughened with glass paper or sand paper for its
length in the jointing chamber wall.
6/29.5 The duct shall be laid on the trench bottom with the socket towards the duct
layer; the spigot end and the inside of the socket of the duct to be jointed shall be
thoroughly cleaned with dry rag.
6/29.6 The spigot end of the duct shall be offered to the socket initially pushed in by
hand and then to achieve proper engagement a suitable wooden batten is placed
across the remove socket and tapped with a hammer. Full engagement should
be ensured. Occasionally, due to variations in size, this cannot be achieved, in
which case, excessive force must not be exerted after a tight joint has been
effected.
6/29.7 When jointing short lengths of duct together with a Coupling, Duct No. 54A, both
spigot ends and the inside of the Coupling shall be thoroughly cleaned with
methylated spirits applied with a clean rag. The spigot ends should be given a
liberal coating of PVC Cement and then fitted into the coupling. This operation
involves using toxic and inflammable materials.
b) For Multiway Upto and Including 9 Ways
6/29.8 The preparatory work and jointing shall be as for single way.
6/29.9 The first layer of ducts shall be laid on the prepared trench bottom so that their
outer surface touch each other and a minimum gap of 75 mm remains between
the outside ducts and the sides of the trench timbering where used. Wooden
stakes or an approved alternative shall be driven into the ground at 3 metre
intervals along the trench to keep the ducts in the correct position. Suitable
material shall be placed to fill the spaces between the ducts and the next layer of
duct when the latter is bedded down. The second and subsequent layers of duct
shall be laid between the wooden stakes so that they are vertically above and
then bedded down to touch the ducts in the layer below, the spaces between the
ducts being filled in the same way with suitable fill material. The joints shall be
staggered so that no joint touches any other joint.
6/29.10 At approximately 5 metres from the jointing chamber at each end of the track,
the duct formation shall open to provide a gap between each duct, both vertically
and horizontally, of 25 mm using, spacers. Over this 5 metres section all spaces
between the duct and the trench wall shall be filled with well compacted fill.
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c) For Multiway ducts over 9 ways
6/29.11 The preparatory work and jointing shall be as for single-way duct.
6/29.12 The first layer of duct shall be laid on the prepared trench bottom so that their
outer surfaces touch each other and a minimum gap of 75 mm remains between
the outside ducts and the sides of the trench, or trench timbering where used.
Mild steel bars, 12 mm diameter and of the required length shall be driven into
the ground at 1.5 metre intervals along the trench to keep the ducts in the correct
position. The second and subsequent layer of duct shall be laid between the mild
steel bars so that they are vertically above and touching the ducts in the layer
below. The joints shall be staggered so that no joint touches any other joint. On
completion of the assembly of the duct nest, 6 mm diameter mild steel bars shall
be placed horizontally across the uppermost layer of ducts and tied to the vertical
bars.
6/29.13 Where the total number of layers of duct in any one formation exceeds 8 and the
number of ducts in each layer exceeds 2 the following shall apply. Between the
two layers of duct midway, or approximately midway, from the top and bottom of
the duct nest an intermediate layer of reinforced concrete, 75 mm in depth and
with 12 mm mild steel reinforcing bars conforming to the layout of reinforcing in
the top cover detailed on the Drawings shall be placed across the duct nest. The
additional reinforcing required by this sub-paragraph shall not be required in the 5
metre sections detailed in sub-paragraph 14 below.
6/29.1 4At approximately 5 metres from the jointing chambers at each end of the track
the duct formation shall open out to provide a gap between each duct, both
vertically and horizontally of 25 mm. Banks of spacers shall be placed 325 mm
and 1325 mm from the jointing chamber wall to provide this spacing. Each
spacer bank shall enclose all the ducts except those in the bottom layer on which
the spacer bank shall rest. Where sub-paragraph 13 applies, the 75 mm
intermediate layer shall be reduced over 5 metre sections to provide the required
25 mm spacing at the jointing chambers.
6/29.15 Where the total number of layers of duct exceeds three, concreting of spaced
formations shall be in stages such that the number of layers of duct laid and
concreted at each stage shall not exceed three. The concrete shall be brought to
a level which shall not interfere with laying of subsequent layers of duct and
spacers.
6/29.16 Concrete class and workability as specified by Etisalat and approved by the
Engineer shall be used throughout.
The concrete shall be evenly placed around the duct to give a finished minimum
thickness of 75 mm on both sides and to a depth of 130 mm above the top layer
of ducts. Care must be taken to ensure that each batch, as it is placed, is
properly compacted without creating unbalanced side thrust against the ducts.
Each batch shall be vibrated using a vibrator having a maximum diameter of 51
mm, the vibrator shall be lowered into the concrete between the wall of the trench
and the outside of the duct nest and shall not touch the duct. In spaced
formation sections care must be taken to ensure that the gaps between the ducts
are properly filled with concrete, the final layer of concrete shall be thoroughly
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trowelled.
6/29.17 With formations of four or more ducts wide, mild steel reinforcing bars
conforming to the Drawings shall be placed and wired in position before placing
concrete over the uppermost ducts of the completed nest.
6/29.18 In the case of column entry manholes, the duct formation shall open out to enter
the manhole as shown on the appropriate manhole drawing and at right angles to
the entry wall. The distance over which the transformation is made shall be no
greater than is necessary to satisfy the 5 metres minimum bedding radius for duct
No. 54D. The ducts shall be secured in position during concreting with spacers,
built up to the required centres or by reinforcing rods which may be encased in
the concrete. The volume between the separated duct formations shall be
excavated and filled with concrete of the same quality as that surrounding the
duct formations.
Alternative Method of Jointing and Laying
6/29.19 Provided that space permits, duct No. 54D may be jointed above ground and fed
into the trench from one end. The leading end of each duct way being guided
into position using a suitable hooked tool made from 6 mm diameter mild steel
reinforcing bar.
6/29.20 Bends: Normally bends are not supplied since the duct is sufficiently flexible to
provide a minimum bending radius of 5 metres. Tighter bends should not be
attempted otherwise kinking of the duct may result.
6/29.21 Variations: Any variation of duct formation and/or depth shall only be carried out
with the prior agreement of the Engineer or Etisalat Civil Works Supervisor.
6/29.22 Backfill: (a) Backfilling of trenches where duct No. 54D has been laid without
concrete surround shall be carried out carefully in a manner that shall not disturb
the duct formation. Where duct No. 54D has been laid with concrete surround
the end shuttering and trench supporting timber, if used, shall be removed not
less than 12 hours after the concrete has been placed. Backfilling of the trench,
in accordance with the Specifications shall not be carried out until a further 48
hours have elapsed.
6/30 WORKS FOR DUBAI MUNICIPALITY DRAINAGE DEPT.
6/30.1 These works consist of the provision of the pipeline road crossings for the future
use of the Dubai Municipality Drainage Department and the diversion of existing
pipelines as shown on the Drawings. All materials shall be approved by them
and the Engineer prior to use in the works. Clauses 6/31 to 6/59 detail the
requirements for these works. Group A, B and C pipes shall be in accordance

with the details shown on the drawings.
6/30.2 For structural purposes pipes shall be classified into three groups:
Group A : Rigid pipes which do not depend on lateral support from the bedding
and trench sides for structural strength.
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Pipe materials include:
Concrete
Clayware
Asbestos Cement
Pitch Fibre
Grey Iron
Group B : Flexible pipes which depend on laterial support from the bedding and
trenches sides for structural strength and no prevent distortion.
Pipe materials include:
RP (Reinforced Thermosetting Plastic Pipes)

UPVC (Unplasticised Polyvinyl Chloride)
HDPE (High Density Polyethylene)
PP (Polypropylene)
Group C: Pipes which have some flexibility but which have sufficient strength to
support loadings without assistance from the ground.
Pipe materials include:-
Steel
Ductile Iron.
6/31 SETTING OUT
6/31.1 Before any excavation for drainage is commenced the Contractor shall define the
centre line or other agreed reference line of the Works and erect the necessary
profiles throughout their full length if so required by the Engineer.
6/32 EXCAVATION FOR DRAINAGE PIPELINE
6/32.1 Trenches for pipes shall be excavated to a sufficient depth and width to enable
the pipe and any specified or agreed joint, bedding, haunching and surrounding,
to be accommodated. Trenches shall be of width not exceeding that shown on
the Drawings. The width of trenches for flexible jointed pipes shall not be less
than the outside diameter of the pipe plus 600 mm unless otherwise detailed on
the drawings.
6/32.2 The sides of the trenches, manholes and other excavations shall be adequately
supported at all times. Trench sides must be vertical and no battering will be
allowed without the express permission, in writing, of the Engineer. Excavations
deeper than 1.5m alongside roads must be supported by trench sheeting.
6/32.3 The material excavated in forming pipe drains shall, if unsuitable, be removed
from site and shall be replaced with suitable material in accordance with the
Specification.
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6/32.4 All unsuitable excavated material shall be carted to tip.
6/32.5 No back throwing shall be allowed and all materials must be brought to the
surface and placed clear of the trench side.
6/32.6 The Contractor shall keep the trench excavation free from water at all times.
6/33 STORAGE AND HANDLING OF PIPES
6/33.1 Method Statements must be approved for the transportation, handling and
storage of pipes before any pipes are delivered to site.
6/33.2 All pipes shall be handled and stored in compliance with the manufacturer’s
recommendations subject to the approval of the Engineer and to the following
limitations:-
6/33.3 Care shall be taken to prevent damage and distortion to the pipes, pipe end,
fittings and couplings during lifting and transportation.
Fittings and specials of any type shall be stored in a single layer only.
Pipes and fittings shall at all times be adequately protected from damage during
transport, storage and handling. Cracked or chipped pipes shall not be used in
the permanent works.
Steel, ductile iron and large diameter plastic pipes shall be fitted in the factory
with end caps or reinforcement adequate to prevent distoration during transport,
storage and handling.
Pitch fibre and plastic pipes and fittings shall be protected from direct sunlight
and excessive heat. Deformed pipes and fittings shall not be used in the
permanent works.
All rubber gaskets, rings and jointing pieces for use with pipes shall be stored in a
cool, shaded store until use. No rubber gaskets, etc. shall be used if any
perishing or deterioration of the rubber due to being exposed to sunlight or any
other reasons is evident.
6/33.4 At every point of loading or unloading, all pipes or casting must be handled by
approved lifting tackle. Unloading by rolling down planks or any other form of
inclined ramp will not be allowed.
Pipes shall not be unloaded from a vehicle by tipping or dropping.
6/33.5 Pliable straps, slings of nylon or rope shall be used to lift pipes, and steel cables
or chains will not be used without written permission.
.
Pipes shall be lifted by flat braided wire slings or band slings except in the case
of externally coated pipes and plastic pipes for which band slings having a width
of at least 300 mm shall be used. Wire rope slings shall not be used for any
pipes. No pipe shall be lifted by means of hooks applied to the ends of the pipe
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or by means of appliances such as grabs and tongs.
6/33.6 Nesting of pipes for transportation will be permitted provided method statements
demonstrate that effective precautions will be taken to protect inner surfaces from
damage.
6/33.7 All coated pipes shall be thoroughly inspected on arrival at site for detection of
any damage to the coatings which shall be made good in an approved manner.
6/34 GRP (GLASS REINFORCED THERMOSETTING RESIN PIPES)
6.34.1 When pipes are transported or stacked they shall be supported on cradles
conforming to the shape of the pipe at not more than 5 meter centres. Pipes
must on no account be stacked directly on the ground but if individual pipes are
placed on the ground prior to laying care shall be taken to remove all rocks and
any potentially damaging debris.
6.34.2 Pipes shall not be stacked higher than 2 pipes high, fitting shall be stored single.
6.34.3 Rubber rings shall as far as possible not be exposed to sunlight, and shall be
protected from exposure to greases and oils which are petroleum derivatives and
from solvent and other deleterious substances. The manufacturer’s approved
jointing lubricants must be used at all times.
6.34.4 GRP pipe and fitting laminate for storm water pumping mains shall consist of an
inner chemical resistant layer and an outer structural layer.
No pigments or dyes may be incorporated into the laminate and no sand fillers
may be present in the inner chemically resistant layer. Pipes and fittings for
pressure mains shall not incorporate sand in the outer structural layer unless
permission to do so has been obtained from the Engineer.
The inner chemically resistant layer shall be composed of either a vinyl ester or a
bisphenol A fumerate resin, suitably reinforced. This inner layer shall have a
minimum thickness of 1 mm and the inner surface shall be reinforced with ‘C’
glass or synthetic tissue. The resin content by weight reducing from
approximately 90% at the inner surface to 65% - 75% at the outer surface of the
1 mm liner.
The outer structural layer shall be composed of an isophthalic resin or equivalent

reinforced with ‘E’ glass woven rovings as appropriate to give a final product of
sufficient strength to meet the tensile and flexural requirements of the pipe. The
exterior surface shall be relatively smooth with no exposed fibres or projections.
Where the Engineer’s approval has been obtained to use a manufacturing

process which precludes the possibility of liner pre-gelling an acid resistant grade
of ‘E’ glass reinforcement shall be used.
The results of the strain-corrosion tests carried out in accordance with ASTM
D3681 whilst the pipe is exposed to 10% sulphuric acid at a temperature of 500C
shall indicate that the pipe has a lifetime of 50 years under operating conditions.
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The following tests shall also be carried out by pipe manufacturers at their works.
The results of these tests shall be made available to the Engineer on request.
The Engineer shall also be allowed to witness some or all of the tests.
1. Works hydraulic tests
a) Pipes and fittings to be hydraulically tested to a rated pressure, if

specified, or to three times the maximum sustained operating pressure or
to 25 bars internal pressure whichever is the lesser.
The above tests to be in accordance with BS 5480 and for a minimum

duration of test to be 5 minutes.
b) Joints - 1 in every 100 pipes/fittings produced shall be tested in

accordance with ASTM D-3517-81.
2. Raw Materials - All raw materials shall be tested by sampling of

consistency to their Specification.
3. Wall thickness - This shall be measured for every pipe.
4. Stiffness - The test to be carried out to ASTM D2412 and at a frequency

of 1 pipe in 30.
5. Beam Strength - Tests to be in accordance with ASTM D3262 for gravity

pipe and ASTM D3517 for pressure pipe. A frequency of 1 pipe in 100
shall apply.
6. Reinforcement content - An analysis of glass reinforcement, resin and

filler content of a minimum of 1 pipe in 20 shall be made. The tests shall
include analysis of the inner 1 mm liner by separation from the structural
layers before ignition.
The following shall apply to pipe design etc.:
a) the maximum pressure attained in the pipeline inclusive of surge shall not
exceed the maximum sustained working pressure rating of the pipe
b) the surge pressure amplitude (i.e. the difference between the maximum
and minimum surge pressure) shall not exceed one half of the maximum
sustained working pressure of the pipe.
c) the pipe shall have a minimum stiffness of 5000 N/m2.
d) the maximum long term diametrical deflection shall not exceed 5%
e) wall strains shall be limited to values declared by the manufacturer on the

basis of long term performance test information. Typically, these shall be
a maximum of 0.5%. When calculating wall strains using the formula.
e = Df d t
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D D
(Where e = strain, d = diametrical deflection in mm, t = pipe wall thickness in mm,

D = pipe diameter in mm and Df is a factor primarily dependant on the ratio of
pipe stiffness to soil stiffness and on the bedding) the values of Df to be adopted
shall be as follows;
Pipe stiffness (N/mm2) Df
5,000 6
10,000 5
30,000 4
6/35 UPVC (THERMOPLASTIC PIPES)
6/35.1 Care shall be taken to prevent distortion or sagging of the pipes during
transportation, handling and storage. They shall be stored in the shade either on
bearing timbers on a level surface, staked to prevent movement, or in suitable
racks. Not more than two layers shall rest on the bottom layer, and for spigot and
socket pipes, sockets shall be at alternate ends so that no pressure comes on a
socket. Bearing timbers shall be spaced at not more than 1 metre and shall be
wide enough to prevent denting of the pipe wall. Sharp edges (e.g. of metal)
shall be avoided. Similar care shall be taken with pipes in transit.
6/35.2 All thermoplastic pipes shall be shaded from direct sunlight during handling,
storage and laying.
uPVC pipe material shall consist ultraviolet degredation and shall incorporate a
rodent inhibitor.
6/35.3 The Contractor shall ensure that pipes do not come into contact with bituminous
or other hydrocarbon based materials.
6/35.4 uPVC gravity pipes shall comply with BS 4660, 5481 or other approved standard.
Pipes shall not exceed 6 metres in length. uPVC pressure pipes shall be Class
‘E’ to BS 3506.
All jointing for sewers shall be approved spigot and socket flexible joint with
neoprene rubber. Solvent welding will not be allowed.
Any pipe or part with discoloration, scratching, abrasion, pit marks or otherwise
considered unsuitable by the Engineer shall be rejected.
uPVC for slotted land-drains/slotted carried drains shall be uPVC pipes to BS

4660/ BS 5481 complying with the minimum infiltration rates laid down in BS
1194. The pipes shall be perforated with holes or slots to a configuration subject
to approval by the Engineer. The minimum cross-sectional area of the
perforations, at the inside surface of the pipe barrel, shall be 2700 mm2 per metre
run of pipe. uPVC (Thermo Plastic) pipes shall be tested at DCL for Ring
Stiffness as per BS EN ISO 9969 : 1995.
6/35A ASBESTOS CEMENT PIPES AND FITTINGS
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6/35A.1 Asbestos cement pipes, joints and fittings shall be manufactured and tested to
ISO 160 or BS EN512 for all pipelines. Sulphate resisting cement with a medium
to low C3A content shall be used in the manufacture of asbestos cement pipes,
joints and fittings.
Asbestos cement pressure and gravity pipes and joints shall be Class 18 unless
otherwise specified.
For gravity pipes the crushing strength shall be carried out on one percent of the
total number of pipes and joints. For pressure pipes the bursting test shall be
carried out on one percent of the number of pipes and fittings.
A jointing ring shall be provided at each end of the pipe this being rubber or
neoprene or a compound of both. Internal test pressure and the prevention of
infiltration of groundwater are to be the major design criteria of the joints. The
Engineer shall be given details of vacuum-type tests on the joints.
All bends and fittings required along the route of the pressure pipelines other
than those bends obtained by deflection of the pipe joints shall be of GRP
material. Bends and fittings shall be obtained from the same supplier as the
asbestos cement pipes and shall be compatible with the pipes and jointing
system used.
Clearly visible, legible, indelible manufacturer's stamps including designated

class of pipe and production date shall be provided on the external face of all
pipes.
For identification purposes, all asbestos cement pipes and fittings laid for
drainage application shall be externally coated with a black bituminous paint.
Potable water pipelines in asbestos cement are uncoated.
All relevant tools recommended by the manufacturer shall be provided by the

Contractor and he shall ensure that he has sufficient numbers of each tool
available in order that the work is never held up for the need of any such tool.
6/35A.2 Asbestos cement pipe shall be provided with spigot ends to be jointed with ‘Reka’
type couplings with two rubber rings. Rubber rings shall conform to the
requirements of BS 2494.
Joint lubricant shall be an approved vegetable-based type and shall be supplied

by the pipe manufacturer.
6/35A.3 Asbestos cement pipe shall be manufactured in 3 metre lengths for diameters of
100 mm and smaller and in 5 metre nominal lengths for larger sizes.
6/35A.4 Asbestos cement pipes shall be factory tested in accordance with BS

EN512:1995. Copies of test certificates shall be submitted for each consignment
delivered to site. Sampling and inspection shall be in accordance with Section
6.4 of BS EN512:1995. Witnessing of factory testing by the Engineer may be
required before any consignment is delivered to site. All compulsory and optional
tests shall be carried out by the manufacturer.
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Each pipe and joint shall be legibly and indelible marked with the following:
i. The manufacturing standard.

ii. The manufacturer’s name
iii. Manufacturing name
iv. Nominal diameter (ND) in mm
v. Nominal Pressure rating in bars
vi. Inspection mark
vii. Date of manufacture
viii. ‘AT’ for products of type AT (Asbestos Technology)
ix. ‘NT’ for products for type NT (Non-Asbestos Technology)
6/36 TRENCH WIDTHS FOR PIPELINES
6/36.1 Nominal trench widths for single pipelines shall be defined as 1.50 times the
diameter plus 300 mm subject to a minimum trench width of 750 mm.
6/36.2 Nominal trench width for two or more pipes in the same trench (laid in parallel
with similar invert levels) shall be defined as the sum of the internal diameters
plus 450 mm between the pipes, plus 450 mm.
6/36.3 Any excavation from the bottom of the trench to 300 mm above the level of the
crown of the pipe which exceeds the nominal widths defined above shall be filled
with concrete or the specified bedding materials as directed on site.
6/36.4 Except where wide trenches are required to suit ground conditions as defined
below, method statements may propose trench widths narrower than the nominal
widths defined but they must be sufficiently wide for safe working and to allow the
pipes to be correctly laid and jointed and the bedding and surround compacted.
6/37 PIPELINES IN WIDE TRENCHES
6/37.1 Wide trenches shall be constructed to not less than the defined widths for those
categories of Group B flexible pipelines in granular surround defined below.
6/37.2 Prior to commencing trench excavation in an area an assessment of the Modulus

of Deformation (E’s) shall be made of the soils likely to be encountered at
springing level of the pipes. In non-cohesive soils, approved static cone
penetrometer tests shall be carried out. In cohesive soils other approved
methods shall be used to determine E’s. Tests shall be carried out at intervals to
be determined on site which in variable ground conditions may be to every pipe
length.
6/37.3 If the value of E’s determined from the results of such tests is greater than 2.5
MN/m2 then trench width is not critical. If less than 2.5 MN/m2 then trench
widths shall be constructed as directed by the Engineer unless alternative means
of increasing the passive resistance of the trench sides are detailed or are
proposed in method statements where economic or environmental restrictions
make wide trenches undesirable.
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6/38 PIPELAYING
6/38.1 Pipes shall be laid and jointed in accordance with all relevant recommendations
of the manufacturer. Any variations between the manufacturer’s
recommendations and this Specification shall be highlighted in the Contractor’s
Method Statements and a ruling will be given with the approval.
6/38.2 Pipes shall be checked for soundness and be thoroughly cleaned out
immediately prior to laying.
6/38.3 The setting of the pipeline to the required levels and alignments shall be carried
out by approved procedures such as boning between sight rails. Large diameter
pipes, 1000 mm diameter of greater, shall be individually set to level and line by
instrument.
All spigot and socket pipes shall be laid with the socket pointing up the gradient.
6/38.4 For pipelines laid in trenches, pipejacks, headings and tunnels the permissible
tolerances in line and level unless otherwise specified shall be +/- 3 mm in level
and +/- 12 mm from centre line between manholes or access points. Also where
a gravity pipeline or sewer is shown as a straight line between manholes it will
not be accepted as having passed the final test unless a light can be sighted
through the length concerned.
6/38.5 For pipeline jointing systems incorporating flexible jointing rings pipes shall be
laid with a gap between the end of the spigot and the base of the socket, or
between spigots. This gap shall be not less than 6 mm or greater than one third
of the straight draw test dimension specified for the pipe joint and it shall be
achieved by approved means, such as marking the outside of the pipe or using
removable metal or hardwood feelers.
When making flexible joints in large diameter pipelines, the weight of the pipe
being placed shall be supported by the lifting plant until the joint has been
completed. The jacking equipment shall provide a concentric thrust on the pipe.
6/38.6 Where flexibly jointed pipes are laid to curves the horizontal displacement at any
joint as laid shall not exceed three quarters of the maximum allowed by the
manufacturer.
6/38.7 Pressure pipelines shall be secured at all changes in direction by concrete

anchor blocks.
6/38.8 For pipelines laid in headings the individual pipes shall not exceed 1.50 m in
length and the heading shall be driven complete from shaft to shaft before
pipelaying is commenced.
6/38.9 After laying a length of pipeline but before preliminary testing is carried out, the
pipeline shall be checked for level and gradient on top of the pipes. If a pipe is
not at the correct level it shall be unjointed and removed, the bed shall be
adjusted and the pipe shall be re-laid and rechecked for line and level.
6/38.10After the joint has been made and the preliminary testing completed the annular
gap at a socket or collar outside the flexible jointing ring shall be closed with fine
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grained clayey soil or an approved joint sealant to prevent the entry of granular
material, backfill material or concrete.
6/38.11The cutting of pipes for making up lengths shall be carried out by a method which
leaves a clean square end.
Concrete pipes shall be cut with a concrete saw or by hand. If cut by hand the
end of the pipe shall be trimmed even and square and if reinforced, the steel
shall be cut flush with the face of the concrete. If instructed by the Engineer the
exposed ends of the steel shall be protected with bitumen or a cement grout.
Asbestos cement pipes shall be cut with the tool supplied by the manufacturer or
by a disc cutter. Cut ends of pipes to be used in pipe runs shall be accurately
reformed to the shape required for the joint with a tool made for the purpose.
6/39 PIPELINE BEDDED ON TRENCH BOTTOM
6/39.1 Where pipes are to be bedded directly on the trench bottom the formation shall
be trimmed to provide even bedding of the pipeline and to be free of extraneous
matter that may damage the pipe or its coating.
6/39.2 Joint holes at each pipe joint shall be scooped away in the trench bottom to
enable the joint to be made.
6/40 PIPELINES IN CONCRETE CRADLES AND SURROUNDS
6/40.1 Where pipes are to be laid with a concrete cradle or surround they shall be
supported initially above the trench bottom on concrete setting blocks. The
blocks shall either be laid accurately to level and covered with damp-proof
sheeting beneath the pipe barrel or shall be provided with two hardwood wedges
each to an approved pattern to enable the pipe level to be adjusted.
6/40.2 The blocks and wedges shall be of sufficient size and strength to prevent
settlement of the pipes during laying and at least two concrete blocks shall be
provided for each pipe.
6/40.3 The concrete shall be poured on one side of the pipe until it can be worked under
the pipe along its full length to ensure that no voids develop. The concrete shall
then be brought up equally on both sides of the pipe until the required level is
reached.
6/40.4 Approved measures appropriate to the pipe material shall be provided to prevent
flotation or other movement during placement or curing of the concrete.
6/40.5 Concrete cradles to pipes of al diameters and surrounds to pipes of one meter
diameter or less shall be poured in a single operation. Concrete surrounds to
pipes over one meter diameter shall normally be poured in two lifts, with a
horizontal joint not more than 100 mm below the crown of the pipe. Concrete
shall be prevented from entering pipe joints.
6/40.6 Concrete cradles and surrounds shall be interrupted over their full cross sectional
area at each pipe joint, by shaped expansion joint filler. The thickness of filler
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shall be 18 mm for pipe diameters less than 450,36 mm for pipe diameters 450 to
1200 and 54 mm for pipe diameters greater than 1200.
6/40.7 In spigot and socket pipelines the joints in the bed shall be at the face of each
socket, and in all flexible joints the concrete shall be prevented from entering the
pipe joint.
6/41 PIPELINES ON GRANULAR BEDS
6/41.1 Where granular bedding to pipelines are detailed the minimum thickness of
bedding material beneath the pipe shall be:-
6/41.2 150 mm (minimum 100 mm under sockets) for pipes not exceeding 300 mm
internal diameter except when bedded on rock.
The granular bedding material shall have a Compaction Fraction value not
exceeding 0.20 determined by the following test:
For testing pipe bedding material, a representative sample of about 40 Kg. shall
be heaped onto a clean surface and quartered to obtain approximately 10 Kg.
The moisture content of the sample should not differ materially from that of the
main body of material, at the time of use in the trench.
A 150 mm internal diameter open ended cylinder, 250 mm high, shall be placed
on a firm flat surface and loosely filled, without tamping, from the 10 Kg. sample.
Any surplus material shall be struck off level with the top of the cylinder. The
area around the filled cylinder shall be cleared of all surplus material and the
cylinder then lifted clear of its contents and placed alongside the material.
Approximately one quarter of the material shall then be replaced into the cylinder
and compacted by tamping vigorously with a 40 mm diameter metal rammer
weighing about 1 Kg. until no further compaction can be obtained. This operation
shall then be repeated for each of the remaining quarters; tamping the final
surface as level as possible.
The distance from the top of the cylinder to the surface of the final layer shall
then be measured and this value, divided by the height of the cylinder, shall be
taken as the Compaction Fraction.
6/41.10Stone for land drains shall be clean, hard and durable nominal single size 20 mm
and/or nominal single size 63 mm in accordance with the following table and
placed as shown on the drawings.
Test Sieve Percent by Weight Passing

mm Nominal size of single size stone
63 mm 20 mm
75 100 --
63 85-100 --
37.5 0-30 100
20 0-5 85-100
14 -- --
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10 -- 0-25
5 -- 0-5
2.36 -- --
6/41.3 200 mm (minimum 100 mm under sockets) for pipes exceeding 300 mm internal
diameter or for pipes for 300 mm internal diameter or less when bedded on rock.
6/41.4 The time interval between placing bedding material on the trench formation and
commencing pipelaying shall be as short as is practicable.
6/41.5 The bedding material shall be compacted in layers not exceeding 200 mm with
one pass of a plate vibrator for gravel and two passes for sand or other approved
equivalent mechanical method. Hand tamping or punning will only be permitted
where insufficient space is available to allow the use of mechanical plant.
6/41.6 Recesses shall be formed in the bedding to accommodate pipe joints while
ensuring continuous even support along the pipe length. Bedding material shall
be prevented from entering pipe joints. After the joint has been made bedding
material shall be carefully placed and hand compacted beneath the joint barrel to
close any void left by the recess.
6/41.7 Where the formation of the trench is of silt or soft clay and is below the natural
water table a 75 mm blinding layer of sand shall be substituted for the specified
bedding material directly above formation and carefully compacted if directed on
site.
6/41.8 Where the pipeline is located beneath the permanent ground water level the
granular bedding material shall be laid on and enclosed within a filter fabric
membrane.
6/41.9 The pipe bedding material should conform to manufacturers recommendations

unless otherwise specified. Granular bedding material for pipes shall consist of
free draining, hard, clean, chemically table, sand gravel or crushed stone. When
tested in accordance with BS 812 Part 103 and gravel or crushed stone shall
comply with the table below:
Bedding material shall be capable of producing a stable formation for pipe laying
shall not be subject too bulking or settlement due to changing weather or ground
water conditions after placing and consolidation.
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Pipe Bedding Material
Percentage of Mass Passing

Test Pipe dia. Pipe dia. Pipe Pipe dia
Less 300-525 dia. Exceeding
than 300 mm 600- 1350 mm
mm 1350
mm
63 mm -- -- -- 100
37.5 mm -- -- 100 85-100
20 mm -- 100 85-100 0-25
14 mm 100 85-100 -- --
10 mm 85-100 0-50 0-25 0-5
5 mm 0-25 0-10 0-5 --
2.36 mm 0.5 -- -- --
6/42 PLACING SURROUNDS TO PIPELINES Group A Pipe Materials

6/42.1 Except where concrete surrounds are detailed, either granular bedding material
or approved selected excavated granular material shall be introduced at both
sides of the pipe and compacted until it has been brought up to at least 150 mm
above the crown of the pipe.
6/42.2 The methods of selecting excavated materials may include sieving either in bulk
or above the trench.
6/42.3 Wherever practicable the placing and compaction of the surround material shall
be carried out in sequence with the removal of the trench supports. In particular
trench sheets or boards shall be raised clear of each layer prior to its compaction.
Group B and C Pipe Materials
6/42.4 Except where concrete surrounds are detailed Group B and C flexible pipelines
shall be laid with granular bedding and surround, as specified, to at least 300 mm
above the crown of the pipe (unless concrete protection slabs are detailed).
6/42.5 In narrow trenches and where the Contractor’s method of working involves the
use of trench sheets or other forms of trench support it is imperative that, unless
the Contractor is instructed to leave them in place and burn or cut off the tops,
the trench supports are carefully withdrawn to a point above the crown of the pipe
as the backfill material is placed to ensure that voids between surround and
trench side will be eliminated.
6/43 COMPACTION OF PIPE SURROUNDS
6/43.1 The granular material shall be carefully laid and compacted at the sides of pipes
according to one of the following methods for alternative types of compaction
plant as agreed with or directed by the Engineer.
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Max. Layer Alternative Methods

Surround Thickness (Number of Passes of Compaction Plant)
Material
(mm) Hand Rammer Vibrating Plate 100 Kg Power
Rammer
Gravel 200 2 1 2
Sand 150 3 2 4
6/44 PIPELINES BELOW PERMANENT GROUND WATER LEVEL
6/44.1 For Group A, B and C pipelines located beneath the permanent ground water
level by granular bedding material or approved selected excavated granular
material forming granular bedding and surround shall be laid on and enclosed
with a filter fabric membrane.
6/45 BACKFILLING TRENCHES
6/45.1 The backfilling of trenches shall be commenced as soon as practicable after the
pipeline works have been completed, tested and approved by the Engineer.
6/45.2 Trenches other than in roads and paved/tiled areas shall be backfilled with
selected excavated material unless otherwise specified in layers not exceeding
150 mm compacted thickness to not less than 90% of the maximum dry density
determined by BS 1377 Part 4 (Method 3.5 or 3.6). The insitu density shall be
determined by BS 1377 Part 9 (Method 2.1 or 2.2).
6/45.3 All filling materials which are in the opinion of the Engineer of a non-cohesive
nature shall be well watered to the approval of the Engineer in the layers
specified to obtain the specified compaction.
6/45.4 Any excavated material which is in the opinion of the Engineer unsuitable for
backfill shall be removed from the site by the Contractor and any deficiency of
backfill shall be made good with suitable material as ordered by the Engineer at
the Contractor’s expense.
6/45.5 Trenches in roads and paved/tiled areas shall be backfilled in layers not
exceeding 150 mm (compacted thickness) with suitable materials as defined in
Section 2 of the Specification. Backfill shall have a minimum soaked CBR of
15% and compacted to not less than 95% of the maximum dry density
determined by BS 1377 Part 4 (Method 3.5 or 3.6). Backfill within 300 mm of the
road subgrade level shall meet the requirements of improved subgrade described
in Section 2 of the Specification.
6/45.6 The backfill requirements for backfill around manholes and catchpits are as for
trenches except that the compaction by mechanical means shall commence from
the excavation formation level and to the specified densities.
6/45.7 Test to determine the compaction of the backfill shall be carried out for each layer
and at locations to be directed by the Engineer.
6/45.8 The use of power rammers will not be permitted over any pipe until the depth of
fill above the crown of the pipe is at least 300 mm.
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6/45.9 Regardless of the means of backfilling adopted it is the Contractor’s responsibility

to ensure that he satisfactorily backfills all excavations and causes no damage to
permanent works or adjacent structures and he shall at his own expense take all
steps necessary to comply with his obligations.
6/46 DEFLECTION MEASUREMENTS ON GROUP B AND GROUP C PIPELINES
6/46.1 All Group B and C pipelines will be subjected to in-situ deflection measurements.
Any section of pipe failing to meet the deflection criteria defined below shall have
its surround material recompacted, such procedure being repeated until the in-
situ deflection is found to be satisfactory. Pipes will be regarded as damaged
and shall be removed from the trench and condemned if their in-situ deflection at
any time exceeds the values stated.
Materia SDR Deflection Criteria At Least 2 Weeks Damaged and

l % After Completion After Completing Not To Be Re-
of Surround the Trench Max. Used
Permissible Range Measured Any
Vertical Diametered Plant
Only
uPVC 10 - 0 - 1.0 1.0 2.25
15
uPVC 15 - 0 - 1.5 2.0 3.75
25
RP 30 - 0 - 1.5 2.0 4.50
40
RP 40 - 0 - 2.0 2.5 5.25
50
uPVC 25+
RP 50+ 2.5 3.0 7.5
PP 15+
HDPE 10+
6/46.2 ‘SDR’ is the Standard Dimension Radio, which is the ratio of pipe diameter
divided by pipe wall thickness.
6/46.3 In the above paragraph deflection shall be considered as the maximum

difference between the measured in-situ diameter and the stated non-deflected
diameter on any axis divided by the non-deflected diameter.
6/46.4 For pipelines of 600 mm diameter and above, internal measurements of

deflection shall be made continuously in both the vertical and horizontal planes
and readings shall be recorded at each pipe joint, at the mid point of each pipe
length, at any point where the limiting deflections above are exceeded and at any
other point directed by the Engineer.
6/46.5 Where the length of pipeline between manholes or access points exceeds 100
metres the measurements shall be taken progressively on completion of
backfilling and shall be verified after temporary reinstatement of the trench within
reasonable limits of each access point.
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6/46.6 For pipelines smaller than 600 mm diameter deflections shall be checked by
pulling through an approved cylindrical plug dimensioned to suit the permissible
minimum deflected diameter of the pipe.
6/47 STANKS TO PIPELINES IN GRANULAR BEDDING
6/47.1 Where pipes are laid on a granular bed or with a granular backfill, a stank, i.e. an
impermeable barrier shall be provided across the full width of the trench and for
the complete depth of the bedding and fill at manholes and chambers. Where
the spacing between manholes and chambers exceeds 100 m then a stank shall
also be formed mid way between manholes or chambers except in the case of
GRP pipelines. No intermediate stank is required to GRP pipelines.
6/47.2 Stub pipelines from manholes or chambers laid for use as future connections
shall be constructed to such lengths as to clear existing and proposed road
carriageways and to clear the bedding and surround construction of the main
pipeline to avoid future disturbance of the main pipeline. Below the water table a
stank shall be constructed through the bedding of the future connection pipeline
outside the main pipeline construction to facilitate future dewatering operations.
6/47.3 The stank shall consist of:-
Either a 300 mm long plug of fine grained clayey soil or a 300 mm long plug of a
mixture of sand and bitumen consolidated in an approved manner.
or A mixture of sand and clay or the local material known as sabkha

compacted to form an impermeable barrier at least one meter in length.
or A layer of thick polyethylene cut to fit around the pipe across the full width
of the trench and laid on the granular bedding material at its natural repose
angle.
6/47.4 All methods must form an impermeable barrier. Bitumen shall not be used for
thermoplastics pipes.
6/48 THRUST AND ANCHOR BLOCKS TO PRESSURE PIPELINES
6/48.1 Underground pressure pipelines shall be provided with concrete blocks as

follows:-
6/48.2 Thrust/anchor blocks shall be provided at every installed bend, tee or angle
branch.
6/48.3 Anchor/thrust blocks shall be provided on pipelines laid to gradients steeper than
1:20; up to 1:15 every third pipe shall be anchored, up to 1:10 every second pipe
and at 1:5 every pipe shall be anchored.
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6/48.4 Concrete shall extend to undisturbed ground on thrust faces of thrust blocks and
on both faces of anchor blocks.
6/48.5 Where details are not shown on the Drawings the Contractor shall prepare
proposals for thrust and anchor blocks and submit them to the Engineer for
approval. Such approval shall not relieve the Contractor of his responsibility for
the adequacy of his proposals.
6/48.6 Special details shall be shown on the Drawings or instructed at site where
environmental or ground conditions dictate.
6/49 PIPES PROTRUDING FROM STRUCTURES, CONCRETE SURROUNDS AND ANCHOR

BLOCKS
6/49.1 Unless otherwise detailed a pipeline at or below ground level protruding from a
structure shall have two flexible joints adjacent to the structure located as
follows:-
Pipe Diameter Distance to First Distance between First

mm Joint mm and Second Joint mm
(Maximum) Min. Max.
Up to 300 150 450 2.5* dia.
300 to 1000 300 1.5* dia. 2.5* dia.
Above 1000 450 1.5* dia. 2.5* dia.
6/49.2 Method statements may propose that first joint be formed by building an
appropriate sleeve, collar or coupling into the wall of the structure and particular
attention must be given to maintaining circularity of the fitting. Where such a
detail is proposed the sleeve, collar or coupling must be capable of maintaining
an effective seal under the specified deflection and loading conditions specified
for flexible joints.
6/49.3 In the case of Group ‘B’ pipe materials, particular attention will be placed on
elliptical deflection conditions.
6/49.4 These joints will be required at surrounds and anchor blocks unless directed
otherwise on site.
Group A and C Pipe Materials
6/49.5 Between the structure and the first joint any disturbed ground below the pipe will
be removed and replaced with concrete Class 40/20 in the form of a cradle, all to
the direction of the Engineer. The cradle shall not extend beyond the first joint.
6/49.6 Beyond the first flexible joint within the excavated working space of the structure
the concrete fill shall be brought up to 300 mm below the pipe invert only.
Specified bedding materials will then be used.
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Group B Pipe Materials
6/49.7 Within the excavated working space for the structure disturbed ground below the
pipe will be removed and replaced with concrete Class 40/20 to within 300 mm of
the underside of the pipe. Specified bedding materials will then be used to
support the pipe.
6/49.8 The width of the concrete backfill shall be not less than the nominal widths.
6/49.9 Where a flexible pipe passes through a rigid concrete face to a structure or
surround the pipe shall be protected from stress concentration and possible
fracture of the pipe at the concrete face. A 10 mm thick neoprene or other
approved synthetic rubber strip shall be wrapped around and cemented to the
pipe unless special wall protection units are used.
6/49.10 The precise configuration is detailed on the drawings but the neoprene will
normally extend through the width of a wall to a dry chamber or structure but will
be limited to 150 mm or 100 mm in water retaining structures or manholes.
Where a neoprene edge is exposed to liquid (groundwater or liquid inside the
structure) a sealant groove shall be formed if detailed and filled with an
appropriate, approved, joint sealant.
6/49.11 Care shall be taken to ensure that the rubber strip is not displaced during
concreting.
6/49.12 Where a pipeline protrudes from a concrete surround, no protection from stress
concentration will be required if the surround ends at a flexible joint leaving the
next pipe free. If the surround ends on a pipe barrel the specified protection will
be provided and, for pressure pipes only, the protruding pipe will be wrapped
from the edge of the neoprene strip along to the next flexible joint at which the
concrete surround is interrupted with an approved compressible material such as
damproof sheeting or building felt of minimum thickness 2 mm.
6/50 PROTECTION OF PIPELINE COMPONENTS
6/50.1 All buried valves, couplings, flange adapters, and other metal components shall
be encased to guard against corrosion. Other pipe joints, valves and similar
items on both buried and exposed pipelines shall be cased where specified or
6/50.2 The encasing shall be by one of the following methods, as detailed.
1. Surrounding with concrete Class 40/20.

2. Enclosed by an approved hot-poured bitumen compound.
3. Wrapped with tape.
6/50.3 Method (2) shall not be used with plastic pipes. The item to be encased shall first
be cleaned and its original surface treatment made good. The surface shall be
dry before encasing is carried out, which shall not be done before the pipeline
has been tested.
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6/50.4 The bitumen compound shall be cast in purpose-built molds in accordance with
instructions issued by the supplier.
6/50.5 Before wrapping with tape the item to be encased shall be enclosed with an
approved mastic or inert putty-like filler which shall be molded by hand so as to
provide a smooth surface for the tape. The tape shall be tightly spiral wrapped
with 25 mm overlaps so as to enclose the whole of the item and a minimum of
150 mm of pipe length on each side. The enclosure shall be firmly pressed up to
prevent air being trapped under the wrapping.
6/51 INDICATOR POSTS TO PRESSURE MAINS
6/51.1 Where pressure mains pass through waste ground or across roads, the
Contractor shall erect indicator posts of approved precast reinforced concrete
design at locations described to him by the Engineer.
6/51.2 The depth, location and size of the pressure main shall be detailed in Arabic and
English, to an approved design, on an engraved plastic or non-corrodible plate
attached to the post.
6/51.3 In addition at non-ventilated air valve chambers, the Contractor shall erect
indictor signs on posts, to an approved design, at locations described to him by
the Engineer.
6/51.4 The words ‘WARNING GAS ON ENTRY’ together with an appropriate pictorial
representation shall be detailed in Arabic and English, to an approved design, on
an engraved plastic or non-corrodible plate attached to the post.
6/52 ENCLOSING GRANULAR OR STONE SURROUND WITH FILTER FABRIC
6/52.1 Where filter fabric is used to enclose granular bedding the fabric will be placed on
the proposed trench formation and carefully supported during pipe laying
operations. When the pipe has been laid complete with bedding to the correct
level the filter fabric shall be closed over the top of the bedding by forming a ‘lap’
of 300 mm minimum width onto the pipe barrel from each side. All membrane
joints shall be overlapped a minimum of 500 mm.
6/52.2 Where filter fabric is used to enclosed granular or stone pipe surrounds, the
fabric will be placed on the prepared trench formation and carefully supported
during pipe laying operations. When the pipe has been laid complete with
surround to the correct level the filter fabric shall be closed over the top of the
surround by forming a ‘lap’ of minimum width 500 mm. All membrane joints shall
be overlapped a minimum of 500 mm.
6/52.3 Care shall be taken not to puncture or damage the membrane in any way during
the operations or during backfilling of the trench.
6/52.4 Geotextile filter fabric shall be thermally bonded non-woven produced from
continuous filament synthetic fibre.
Where described in Contract or as directed by the Engineer the geotextile filter

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fabric shall have the following properties
Grade 1
Nominal Weight = 210-240 g/m2

Mean Water Flow (100 mm head) = 35 L/S / m2
Upper limits of 90 percentile of pore sizes = 60 microns
Minimum tear strength (ASTM 1117) = 550 N
Minimum CBR puncture resistance
(DIN 54307E) = 2400 N
Grade 2
Nominal Weight = 130-150 g/m2

Mean Water Flow (100 mm head) = 50 L/S/ m2
Upper limit of 90 percentile of pore sizes = 120 microns
Minimum Tear Strength (to ASTM 1117) = 270 N
Minimum CBR puncture resistance
(DIN 54307E) = 1200 N
The fabric shall be protected from the effects of ultraviolet rays until it is to be
used. The fabric shall be laid with 300 mm laps on the prepared sub-strate.
6/53 GROUTING OF PIPELINES
6/53.1 Grouting shall be carried out in accordance with approved method statements
which shall include jetting and cleaning operations to the satisfaction of the
Engineer prior to grouting abandoned pipelines or insertion of secondary pipes
into existing pipelines.
6/53.2 The gravity and pressure pipeline lengths to be abandoned and grouted shall be
agreed with the Engineer.
6/53.3 Where a secondary sleeve pipe has been inserted through an existing pipeline
the annulus between the pipes shall be grouted.
6/54 PIPEWORK WITHIN STRUCTURES
6/54.1 Pipework shall be supplied to the general arrangements and limits indicated on
the Contract Drawings and shall be supplied complete with all joint rings,
gaskets, washers to each side of a bolted joint, nuts, bolts, grease and any other
components necessary for the complete installation.
6/54.2 The layout and design of the pipework shall be such as to facilitate its erection
and the dismantling of any section for maintenance of associated plant by
inclusion of approved mechanical couplings or flange adapters.
6/54.3 Where a common delivery pipe is used, individual pump delivery branches unless
otherwise shown on the drawings shall be jointed to it in a horizontal plane and
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angled to prevent sharp changes of flow.
6/54.4 Adequate supporting and anchoring arrangements for all pipes shall be included
which may take the form of straps, stays, tie bars or concrete cradles.
6/54.5 All pipe hangers and supports inside pumping stations and valve chambers or
other structures shall be of good quality stainless steel. All fixing bolts shall be
stainless steel grade 316 S16.
6/54.6 Cast and ductile iron pipes shall be provided with puddle flanges where they pass
through the walls of underground or water retaining structures.
6/54.7 Small bore pipework for sump pumps, vents, etc. may be galvanised steel or
approved plastic materials.
6/54.8 All pipes connected to pressure vessels, pumps, etc. shall have flanged
connections.
6/54.9 All pipes shall be checked for alignment and mating of flanges and connections
before being secured. Pipes shall not be sprung into position.
6/55 MANHOLES, CATCHPITS AND CHAMBERS
6/55.1 Manholes and chambers shall be constructed in accordance with the drawings in
the positions indicated thereon or wherever else instructed by the Engineer and
such manholes, catchpits and chambers shall be watertight.
6/55.2 All manholes and collection chambers in contact with sewage shall be protected
internally with GRP lining which shall be of minimum thickness 7.0mm and which
shall extent from the benching up the walls, across the roof slab soffit and up the
access shaft to lap onto the manhole frame. It shall be designed to be capable of
protecting the concrete for the design life of the manhole.
6/55.3 Pipes entering and leaving manholes, catchpits and chambers shall be laid soffit
to soffit unless otherwise shown on the drawings.
6/55.4 The Contractor is reminded that all construction joints must be perfectly
watertight and is referred to the relevant clauses in other section of this
specification.
6/55.5 The Contractor shall submit full details of his manhole, catchpit and chambers
proposals to the Engineer for approval prior to commencing the works.
6/55.6 Reinforced Plastic Sealing Plates
Covers for sewerage shall be provided in with a reinforced plastic sealing plate in
accordance with Clause 4.5.3.2 (a). The design of cover, frame and sealing plate
shall be such that no load can be transferred from the cover to the sealing plate.
Reinforced plastic sealing plates to access covers shall be designed to provide a

push-fit, gas-tight seal with the cover frame. The sealing plate shall be in the
form of a plug with a flange to prevent the plate passing into the manhole. The
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seal shall be achieved by means of an approved integral synthetic rubber gasket

mechanically locked into the periphery of the plate. The gasket shall be suitable
for the service temperature range 00C to 600 C and possess good weathering and
ozone resistance. Any lubricant used on the seal shall be silicon based. The
underside of the plate shall have a resin-rich finish and there shall be no exposed
fibres. Cut and/or drilled faces shall be sealed with resin.
The plate shall have a minimum thickness of 5 mm and be capable of

withstanding a static load of 150 kg. applied centrally over a 150 cm. square
surface area with a deflection, measured at the centre of the plate, not exceeding
25 mm.
A minimum of two number reinforced plastic lifting handles shall be provided per
plate. They shall be of the same materials as the plate and securely laminated to
the plate or fixed by stainless steel blind rivets.
The complete seal plate shall be resistant to 10% sulphuric acid at 500C for 100
days.
6/55.7 Rubberised Bitumen Emulsion: Rubberised bitumen for application to buried

concrete surface as detailed on the Drawings shall consist of a water bound
emulsion containing not less than 65% of bitumen with fine particles of rubber
dispersed in the bitumen, the consistency being such that it can be applied to the
surface by brush at normal air temperature. The rubber content of the dried film
shall not be less than 10% when tested in accordance with DM500.
The Contractor shall submit to the Engineer for approval three samples in one
litre containers of the rubber bitumen emulsion. The Contractor shall also submit
to the Engineer certificates that the material complies with the requirements of
the specification.
6/55.8 Waterproofing for Structures: Waterproofing membranes for structures shall

consist of a self adhesive sheet membrane comprising a multilayer polyethylene
film coated on one side with an elastic rubber/bitumen compound and where
necessary be protected with approved protection board. The membrane shall
have a minimum overall thickness of 1.5mm and a tensile strength of 40 N/mm2
when tested in accordance with ASTM D638 and shall in all respects conform to
the requirements of British Code of Practice 102. Rubberised mastic and primer
for use with waterproofing membranes shall be special compounds provided by
the manufacturer of the membrane and formulated for its intended use. The
system shall be suitable for application in tropical climates.
The surface to be treated shall be cleaned and primed in accordance with the
manufacturer’s recommendations before the application of the system. The
materials shall not be applied in rain, fog or sea spray.
6/55.9 Waterstops
1. Alternatives from those indicated on the drawings will be accepted only if

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the Engineer is satisfied that their material and their performance are not
inferior.
2. Waterstops shall be manufactured either from rubber or from

polyvinylchloride (PVC), at the discretion of the Contractor subject to the
approval of the Engineer. PVC waterstops of the hollow centre bulb type
shall be manufactured from low-modulus PVC, where so described on the
Drawings.
3. No splices will be permitted in straight strips. Strips and special

connection pieces shall be well cured in a manner such that any cross
section shall be dense, homogeneous and free from all porosity. All
junctions in the special connection pieces shall be full moulded. During
the vulcanising period the joints shall be securely held by suitable clamps.
The materials at the splices shall be dense and homogenous throughout
the cross section.
4. If, after placing concrete, waterstops are materially out of position of

shape, the surrounding concrete shall be removed, the waterstop reset,
and the concrete replaced, all at the Contractor’s expense.
5. Field splices for rubber waterstops shall be performed by hot or cold

vulcanising in accordance with the manufacturer’s recommendation.
6. Field splices for polyvinyl-chloride waterstops shall be performed by heat

sealing the adjacent surfaces in accordance with the manufacturer’s
recommendations. A thermostatically controlled electric source of heat
shall be used to make all splices. The heat shall be sufficient to melt but
not to char the plastic. Field splices shall be carried out only by
individuals trained and approved by the supplier.
7. Waterstops when being installed shall be cut and spliced at changes in

directions as may be necessary to avoid buckling or distortion of the web
or flange. Field splices shall develop watertightness equal to that of the
unspliced material and have a tensile strength of not less than 50 per cent
of the unspliced material.
6/56 CATCHPIT/MANHOLE LININGS COVERS AND FRAMES
6/56.1 Manhole covers and frame shall be with the exception of those for sewerage
manholes cast ductile iron of non-rock construction. Manhole/catchpit covers
and frames shall be heavy duty Grade ‘A’ complying with BS 497 : Part 1 or
Class D to DIN 1229. Covers shall be circular with 600 mm dia clear opening.
All covers shall have a single seal and closed keyways. A heavy grease seal is
to be formed between the cover and frame to prevent the ingress of sand.
Double triangular covers must be loosely coupled by stainless steel bolts with
nuts provided with an approved method to render the nuts incapable of both
undue tightening or loosening.
Holes provided in non-ventilating covers for lifting keys shall not penetrate
through and there shall be no projections above cover level.
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6/56.2 Manhole and chamber covers shall have appropriate wording in English and
Arabic as per the Table in 6/56.6. Prior to manufacture of the covers the
Contractor shall submit full size stencils of the inscriptions to the Engineer for
approval.
6/56.3 All covers and frames shall be delivered to site with a transit protection coating.
Immediately prior to the issue of the Certificate of Completion the cast iron items
shall be power wire brushed and protected with 375 microns of bitumen epoxy
paint. Frames and covers shall be placed immediately after completion of the
manhole and chamber.
6/56.4 Approved list of suppliers for manhole/catchpit covers, gullies, frames.
1. Elkington
2. Passavant
3. Stanton
4. Selflock
5. Brikhouse Boards.
6/56.5 The Contractor shall guarantee that spare parts shall be available from the
supplier for at least 10 years after the completion of the works.
6/56.6 All covers and frames of a particular grade from a supplier shall be
interchangeable and shall be approved by the Engineer and Dubai Municipality
Drainage and Irrigation Department.
Manhole And Chamber Covers And Frames
Surface Water Sewerage Land Drainage

Drainage
Cover shape Circular Double Triangular Circular
Size of 600 mm diameter (manholes) 600 mm diameter
Opening Square inspection
(Chambers)
600mm x 600mm
Grade BS 497 Part 1 BS 497 Part 1 BS497 Part 1
Grade A Grade A Grade A
(Heavy Duty) (Heavy Duty) (Heavy Duty
Material Ductile iron Ductile iron with Ductile iron
316 SS bolts
Protective 375 microns 375 microns 375 microns
Coating abrasion resistant abrasion resistant abrasion resistant
heavy duty heavy duty heavy duty
bitumen epoxy bitumen epoxy bitumen epoxy
Key ways Closed Closed Closed
Seating Single seal non- Single seal non- Single seal non-
rock, filled with rock, filled with rock, filled with
grease to exclude grease to exclude grease to exclude
sand sand sand
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Internal GRP No Yes No

sealing plate
Locking No No No
Inscriptions Stormwater Sewerage Stormwater
(Arabic & English) (Arabic & English) (Arabic & English)
Covers for Pumping Stations and Associated Chambers shall be rectangular 600
mm x 750 mm or 600 mm x 900 mm or multiple of these sizes, as detailed on the
drawings with the concrete infill, and shall be heavy duty.
Where ventilated covers are detailed the total area of ventilation shall not be less
than 5% of the minimum clear opening area and the covers shall be provided with
suitable protective sand traps which shall seat in the access cover frame.
6/56.7 In general, the GRP linings and frames for manholes shall be similar in
manufacture to the GRP pipes.
The internal surface of the liner material shall be smooth and both the internal
and external surfaces of liners and formers shall be clean and free from defects
such as protruding fibre, voids, pits, bubbles, cracks, blisters or foreign matter
what would impair their performance in service.
Benching standing areas shall have an approved non-slip finish built into the
GRP.
The external surface of the liner and former shall have suitable GRP lugs
moulded on the surface at appropriate spacings to allow adequate bonding to the
concrete.
The liner and former material shall have adequate strength to withstand on and
off loading and site handling. It shall not excessively buckle or distort to effect
circularity, watertightness or continuity of laminate when a concrete surround is
being placed. (Internal bracing whilst pouring may be adopted at the Contractor’s
expense).
Joints where permitted shall be as detailed as shall be made using an external

purpose-made sleeve or plate laminated by an approved technique to the liner
and shall be equal or superior in performance to the lining both in the
circumferential and longitudinal directions. Overbonding shall extend for a
minimum of 150 mm either side of the joint.
Manhole Benching and Channels
a) Storm Water Drainage
6/56.8 Epoxy Mortar for Storm Water Drainage: All benching and channels in any
manhole or any other structure such as chambers, pump station wet-well etc.
shall be formed to have a minimum of 100 mm thickness of an approved epoxy-
resin mortar system.
The epoxy mortar system shall be a trowellable, two component epoxy resin
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system consisting of a prefilled base and unfilled reactor which when mixed shall
produce a high strength, impermeable and chemically resistant mortar.
The epoxy mortar system shall have excellent chemical resistance to sodium
chloride and sulphuric acid (shall pass the relevant chemical resistance test), and
shall have high impact resistance. Typical properties are given:
component epoxy mortar
Sag at 10 mm thickness None

Working Time ASTM C308 <90 min at 250C
Full Cure at 250C 3 to 7 days
Setting Time at 250 C 30 to 45 min.
Water Absorption ASTM C413 <0.07%
Compression Strength BS 6319 Part 2 >40 N/mm2 at 250C
7 days cure
Flexural Strength BS6319 Part 33 N/mm2 at 250C
7 days cure
Tensile Strength BS 6319 Part 7 8 N/mm2
Bond Strength BS 6319 Part 4 >30N/mm2
Density BS 6319 Part 1 1750 kg/m3
When placed on a concrete substrate the epoxy mortar system shall have an
adhesive strength of not less than the internal cohesive strength of concrete.
To achieve the necessary adhesion to the substrate an epoxy primer compatible

for use with the mortar and the substrate shall be applied.
The epoxy mortar, or the primer where required, shall be suitable for application
onto a substrate with a moisture content of 4% or less as measured by the ‘wet-
check’ Moisture Meter or other instruments approved by the Engineer.
The pot-life of the mixed mortar shall not be less than one hour at the
temperature at the place of application at the time of mixing. The Engineer may
restrict application to such time as the ambient temperature is sufficiently low for
the specified pot-life to be ensured.
There shall be strict control of surface cleanliness between primer and epoxy
mortar and between coats of the same. Vacuum removal of dust and sand shall
be employed and water soluble contamination shall be removed as specified
above. Where dirt or dust has become trapped in the primed surface it shall be
removed with suitable abrasive paper. The surface being primed shall be free of
visible moisture throughout these operations.
The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a
maximum tolerance of +4 hours. Where this is exceeded the surfaces to be re-
coated shall be suitably abraded to remove gloss and give key.
Mixing of the components shall be strictly in accordance with the manufacturer’s

recommendations and care shall be taken to avoid the entrainment of air in the
mixes.
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Wet thickness gauge shall be used by the mortar applicators continually to check
the sufficient mortar is being applied to achieve the required dry thickness.
Foul Water Drainage
All bending and channels in any manhole or any other structure such as
chambers, pumping station wet well etc. designed to handle sewage shall be
formed of a minimum 7 mm thickness of GRP.
The quantity of GRP used for benching and channels shall be the same as
specified for pipes except that the surface of the benching shall have a durable
non-slip surface.
6/57 GULLIES AND CONNECTIONS
6/57.1 Gullies shall comprise the gully cover and frame or gully grating and frame as
specified and the gully pot.
6/57.2 Road Gullies : Road gullies shall be polypropylene or GRP, conforming with BS
556, Part 2, 450 mm internal diameter by 900 m or 1050 mm deep, without trap,
and with 150 mm outlet. They shall be complete with GRP perforated grit bucket
and incorporate a 200 mm opening to the base.
The gully pot shall be surrounded by a minimum of 150 mm of concrete as shown

on the drawings.
6/57.3 Gully grating and frames shall be to DM Standard as indicated on the Drawing
shall be of the raised kerb type complete with sand seal, road retaining bar and
an internal removable GRP debris grating. The weir depth shall be a minimum of
165 mm and the frame and cover are to be protected with 375 micron bitumen
epoxy coating system at the place of manufacture. The clear opening size shall
permit removal of the GRP grit sand bucket.
6/57.4 The gully pot shall be surrounded by a minimum of 150 mm of concrete as shown
on the drawings.
6/57.5 The connection into the carrier drain shall be 160 dia. uPVC pipe and if not made
at a manhole or catchpit shall be by means of an oblique junction which may be
of either UPVC, GRP or C1 and the assembly shall be surrounded in concrete as
detailed on the drawings and all shall be approved by the Engineer.
6/58 HOUSE CONNECTION LATERALS
6/58.1 A house connection lateral comprise the pipe work from the existing drainage of
an individual property or properties to a sewer and normally connects to the
sewer at a manhole or as may be directed by the Engineer and may include
inspection chambers etc. along its length.
6/58.2 The position and other details of individual house connection laterals are not
generally shown on the drawings but will be determined by the Engineer as the
work proceeds.
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6/58.3 In general the house connection laterals and details of individual connection will
be similar to the typical and standard details shown on the drawing and as
6/58.4 The Contractor shall in consultation with the Engineer prepare a detailed
programme of work for any connections within the boundary of private lands in
order that any necessary notices may be given by the employer to the owners or
tenants before the Contractor’s entry onto such private lands.
6/59 TESTING AND CLEANING OF GRAVITY DRAINS
6/59.1 All gravity drains and connections with water tight joints of 750 mm diameter or
less, shall be tested prior to covering with an air test or at the Engineer’s
discretion with a water test in accordance with Clause 6/59.2 and 6/59.3 in the
presence and to the satisfaction of the Engineer. Unless otherwise instructed
non-pressure pipelines shall be tested in sections between manholes. In addition
pipelines shown as straight lines on the drawings shall be subjected to a light test
as detailed in the pipe laying specifications.
6/59.2 Air Test: The length of pipes under test shall be plugged and air pumped in until a
pressure of 100 mm of water is held in the manometer tube. After allowing a
suitable time for stabilisation of the air temperature the pressure shall without
further pumping hold to not less than 75 mm over a period of five minutes.
Release of the air pressure shall be carried out by removal of the stopper at the
end of the pipeline away from the manometer which will remain connected.
Failure to carry out the air pressure release in this manner will render the test
invalid.
6/59.3 Water Test: The lower end of the length of pipe under test, and any junctions or
connections shall be plugged and the pipe shall be filled with water, to give an
internal pressure of 1.20 m head of water at the crown of the pipe at the high
end, but not more than 6 m at the low end. After allowing a suitable period of
time for absorption of water by the pipe the loss of water over a period of 30
minutes shall be measured by addition water from a measuring vessel at regular
intervals of 10 minutes and noting the quantity required to maintain the original
water level. The total quantity added should not exceed 7.5 litre per hour per 30
metre of pipe per metre of nominal internal diameter.
6/59.4 Gravity pipelines and manholes shall be tested for infiltration after backfilling. All
inlets to the system shall be effectively closed and any residual flow shall be
deemed to the infiltration.
The pipeline, including manholes, shall be accepted as satisfactory if the

infiltration including infiltration into manholes, does not exceed 1.0 litre per hour
per metre of pipeline per metre of nominal internal diameter.
Notwithstanding the satisfactory completion of the infiltration test, if there is any

discernible flow of water entering the pipeline at a point which can be located
either by visual or closed circuit television inspection, the Contractor shall take
such measures as are necessary to stop such infiltration.
6/59.5 The Engineer may require any length of pipe suspected of being damaged to be
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retested by the water test at any time during the Contract.
6/59.6 The bore, linearity and jointing of all drains, less than 300 mm diameter shall be
checked by drawing through each completed length of pipe a mandrel 750 mm
long and 12 mm less in diameter than the nominal bore of the pipe, unless an
alternative method of checking is agreed by the Engineer.
6/59.7 During the Contract the Contractor shall keep the interior surfaces of all pipelines
and manholes etc. free from any cement, bricks, soil or other superfluous matter,
6/59.8 On completion of the works, or earlier if the Engineer agrees or directs, all manholes,
drains and connections, which are complete shall be flushed from end to end with
clean water and left clean and free from obstructions.
6/60 IRRIGATION WORKS - ASBESTOS CEMENT PRESSURE PIPE
6/60.1 General: Asbestos Cement (AC) pressure pipe shall conform to the requirements of
BS EN 512. All pipes and joints shall be manufactured by an approved by the Dubai
Municipality AC pipe manufacturer having successful similar experience in the
manufacture and supply of high pressure AC pipe. Evidence of such experience
shall be included in the tender submission. The manufacturer shall be certified to
ISO 9002 OR BS 5720 Part 2.
6/60.2 References: The latest issue of the following standards are applicable where
referenced in the following specifications:
BS 5750 1987
BS EN 512 1995
BS 2494 1986
BS 4027 1980
ISO 2785 1974

ISO 9002 1987
Full range of AC pipe diameters used for the entire project (150 to 1200 mm dia.)
must be U.A.E manufactured and delivered by the same manufacturer.
6/60.3 Class: AC pipes shall meet the requirements for Class 18, suitable for an
operating of 9 bars up to and including 1000 mm and 10 bars above 1000 mm
dia. Pipe wall thickness shall meet all the design requirements for class 18 pipe
as follows.
Nominal Diameter Outside Diameter at
The pipe end
Mm mm
80 106
100 126
150 178
200 234
225 255
250 288
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300 344
350 402
400 456
450 508
500 560
550 616
600 668
700 780
800 888
900 1000
1000 1110
1200 1320
All pipes shall withstand full vacuum (-1 bar).
6/60.4 Cement: The cement in the manufacture of asbestos cement pipes and joints
shall be of high sulphate resisting cement conforming to BS 4027:1980. Copies
of cement mill certificate shall be submitted with each consignment of pipe
delivered to the site.
6/60.5 Joints: Asbestos cement pipes shall be provided with spigot ends to be joined
with ‘Reka’ type couplings using two rubber rings. Rubber rings shall conform to
the requirements of BS 2494. The Joints shall be capable of withstanding a test
pressure of 18 bars without any leaks when deflected to the angle specified
below:
Nominal Diameter Max. Joint Deflection Angle

mm Degrees
up to 225 5
250 – 350 4
400 – 550 3
600 – 1000 2
1200 1
AC pipes joints to be designed to provide sealing in negative pressure

surge: -1 bar (full vacuum) against internal and external pressures.
6/60.6 Length: Asbestos Cement pipes shall be manufactured in 5 metre nominal length
for all range of diameters.
6/60.7 Width of AC Reka Joints
Nominal Dia. Width of AC Joint

mm mm
75 104
80 104
100 120
150 120
200 150
225 150
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300 150
350-500 200
550 240
600 240
700 240
800 – 1100 270
1200 300
6/60.8 Design Calculations: Structural pipe design calculation as per ISO 2795-1974
shall be submitted to the Engineer, if requested, for review and approval.
6/60.9 Testing: Asbestos Cement pipes shall be factory tested in accordance with BS
EN 512. Copies of test certificates shall be submitted for each consignment
manufactured and delivered to site, and all compulsory and optional tests shall
be carried out by the manufacture. The Engineer may instruct the return of up to
2 percent of pipes and joints delivered to site for factory testing. The cost of
returning the pipes and joints to the factory, and for testing shall be borne by the
Contractor.
The pipes which are damaged in testing shall be replaced with new pipes at no
additional cost by the Contractor.
6/60.10 Markings: Each pipe and joint shall be legibly and inlegibly marked with
the following:
i. Manufacturing standard
ii. Manufacturer’s name or trade mark
iii. Manufacturing date (pipe only)
iv. Home line positions at pipe ends (pipe only)
v. Nominal Diameter (ND) in mm (inside and outside)
vi. Pressure rating in bars (Class) (inside and outside)
vii. Inspection mark
viii. Coupling ‘homeline” position on spigot ends.
6/60.11 External Coating: The bitumen coating shall comply with the requirement
of BS 3416, 1975 Type 1 and II for back shinning coating.
The painting shall be applied as per manufacturers recommendation and shall be

applied on clean dry surface by using hand wire brush.
Pipe and joints shall be coated for differentiation with uncoated AC water
pipeline.
6/60.12 AC Pipe Joint Lubricant: Soft soap as recommended by the pipe

manufacturer shall be supplied and applied for pipe joint lubricant. The soap
shall be odourless and paste like consistency. The soap should be washable
with water. It shall be vegetable-based and shall be free from fish, whale, or
other animal oils and fats, free from resins and any poisonous material. It shall
be supplied in packings of 20-25 kgs. Net. Soft soap shall be supplied by the
pipe supplier.
6/61 IRRIGATION WORKS - GLASS REINFORCED PLASTIC (GRP) FITTINGS
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All fittings (including bends, tees, reducers and flanges) used with AC pipelines
shall be GRP (Glassfibre reinforced plastic) fittings and shall comply with the
following specification:
AWWA C-950-88 AWWA Standard for ‘Fibreglass”

(Glass Fibre Reinforced Resin) Pressure Pipe
BS 5480 : 1990 Glass Fibre Reinforced Plastics (GRP) Pipes and Fittings
for use for Water Supply or Sewerage; Parts 1&2.
6/61.1 General: This specification covers the design, manufacture and testing of glassfibre
reinforced plastic (GRP) pressure fittings for use with Asbestos Cement pressure
pipe in nominal sizes 80 mm and larger. GRP fittings and pipe shall be designed and
manufactured in accordance with AWWA C950-88 and the requirements herein. All
components shall be produced by one manufacturer.
The manufacturer shall be approved by Dubai Municipality and must demonstrate the
experience and capability to produce fittings of the same diameter and pressure
range as those required. The manufacturer shall be certified to ISO 9002 or BS 5750
Part:2. Full range of fittings diameters used for the project must be manufactured
and delivered by the same manufacturer.
6/61.2 Construction: GRP fittings shall have the following principal construction:
i. A corrosion resistant, resin rich having a minimum thickness of 0.5 mm.

the liner surface in contact with water shall be reinforced with ‘C’ glass
veil or mat impregnated with Vinylester or Epoxy Resin. The liner shall be
continuous along the circumference of the pipe and shall be of uniform
thickness and composition.
ii. A structural wall consisting of continuous glass filament findings and/or

woven roving and chopped glass reinforcement, and may include fine
fillers, all impregnated with Isophthalic, Vinylester or Epoxy resin as
required.
iii. A resin-rich exterior surface having a minimum thickness of 0.25 mm.
iv. No dark pigments shall be allowed in the GRP fittings.
6/61.3 GRP fittings and flanges shall be designed in accordance with AWWA C950 for
service at the following conditions:
Maximum operating pressure 16 Bar

Maximum allowable vacuum -1 Bar
Minimum depth of water 1.0 meter
Maximum depth of cover 3.0 meter
Truck loading (wheel load) 90 KN
Service temperature (Maximum) 40 deg.C
Flange x flange fittings shall be designed for installation above ground (in
chambers) without thrust blocks. Flanged branches on spigot tees shall be
designed to resist end thrust from closed valves.
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The pressure rating for GRP pipe or fittings shall be based on the long term
hydrostatic design pressure established as per Section 2.12.3.08-2 (a) of this
Specification with a design factor of 2.0.
Spigot joints, where specified shall have the same outside diameter (OD) as
approved by Dubai Municipality for Asbestos Cement (AC) pipe to which it is to
be joined. The joint dimensions and tolerances shall be equal to AC pipe spigots
such that joint remains watertight under all normal operating and surge
conditions. The spigot ends shall be clearly marked with a ‘homeline’ indicating
the proper insertion limit for the AC couplings. The spigot width shall not be less
than half the AC coupling joint width.
Flanged joints, where specified shall be GRP filament wound flanges

manufactured from Epoxy or Vinylester resin and glass reinforcements. Flanges
shall be flat faced and drilled to BS 4504 PN 16 drilling pattern. GRP flange
gasket (full face) design and thickness shall be as recommended by the GRP
fitting manufacturer. Hand lay-up flanges shall not be acceptable.
Laminated or Adhesive joints used in the fabrication of fittings shall be equal or

superior in strength to the sections they join. The thickness of laminated joints
shall not be less than the wall thickness of the adjoining pipe section. All hand
laminations or windings shall utilize only one type of resin throughout.
6/61.4 Chemical Requirements: GRP fittings shall be not impart any taste, odour or colour
to drinking water. GRP pipe/fittings shall be certified and listed for potable water use
by the water research center (WRC)m UK, in accordance with BS 6920 or by the
National Sanitation Foundation (NSF)–USA in accordance with NSF Standard 14.
6/61.5 Dimensions – GRP fittings shall be produced in Metric sizes and shall be classified
by their nominal inside diameter (ND). The actual fittings inside diameter shall not be
less than that shown in the table below:
Nominal Diameter (ND) Minimum Inside Diameter

(mm) (mm)
80 78
100 98
150 148
200 198
225 223
250 245
300 298
350 348
400 397
450 447
500 497
550 547
600 597
700 696
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800 795
900 895
1000 995
1200 1195
All standard fittings up to and including diameter 300 mm used in the distribution
system shall be filament wound on precision steel moulds. Standard 90 and 45
degree bends of nominal diameter 300 mm and smaller shall be of the smooth
radius type, having a turning radius of 1.5 times the bend nominal diameter.
Fittings diameter 350 mm and larger may be of the moulded or miltered
(manufactured from GRP pipe sections) construction and internal surfaces shall
be finished smooth.
The thickness of GRP flanges shall not be less than shown in the table below:
Nominal Diameter (ND) Minimum GRP Flange Thickness

(mm) (mm)
80 – 100 38
150 – 200 44
225 46
250 – 350 54
400 58
450 64
500 – 600 68
700 72
800 78
900 85
1000 88
1200 108
The wall thickness of GRP fittings shall be determined by the manufacturer to

meet the design requirements of this specifications but shall in no case be less
than the minimum thickness shown in the table below:
Nominal Diameter ND Minimum Pipe Thickness

(mm) (mm)
80 – 400 6.0
450 6.7
500 7.5
550 8.2
600 9.0
700 10.0
800 11.5
900 13.0
1000 14.5
1200 17.5
Flange drilling shall be as per BS 4504 PN 16.
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6/61.6 Mechanical Properties: GRP fittings shall meet the following minimum strength
requirements:
Property Test Method Minimum

Value per
Table
1. Hoop Tensile ASTM D2290 Portable 10

Strength of AWWA C950
For class 250 psi
2. Axial Tensile ASTM D638 Per table 11

Stress BS 5480 of AWWA C950
For class 250 psi
3. Axial Tensile ASTM D638 70 Mpa

Stress for BS 5480
Flg.x f.g.fittings
4. Stiffness ASTM D2412

(E1/D3) BS 5480
Dia < = 300 10,000 Pa
Dia > 300 5,000 Pa
6/61.7 Visual Requirements: GRP fittings shall be free from delamination, crazing, dry areas
or cracks. Spigot ends shall be free from end delamination, torn edges and guages
and shall be finished smooth to ensure watertightness. All laminates shall be fully
cured with a minimum Barcol hardness of 33 when tested in accordance with ASTM
D2583.
6/61.8 Testing :
(1) Routine Tests: The following test shall be carried out by the GRP
pipe/fitting manufacturer at the frequency specified. test results and
certificates shall be submitted to the Engineer for each consignment
delivered. Witnessing of factory testing by the Engineer may be required.
The Dubai Municipality and the Engineer shall have the right to return up
to 2% of the material delivered back to the factory for inspection and/or
testing by its Representative at no additional cost. Test methods shall be
in accordance with AWWA C950 5480.
Test Frequency
i) Visual Inspection Every item

ii) Dimensions Every time
iii) Hydraulic Pressure Once per
at 24 bars for 30 seconds 10 Flg. X Flg. items
iv) Stiffness Once per 100 items
v) Barcol hardness Every item
(resin cure)
vi) Axial & Hoop Tensile Once per 100 items
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Stress
vii) All GRP pipes used for fittings fabrication shall be factory pressure
tested at 24 bars for 60 seconds. All GRP pipes shall be tested at
DCL for the following tests also.
3. Initial Longitudinal unit Tensile Strength by a Tensile Strip Test
as per BS 4580 App. “A”.
4. Initial specific stiffness under ring deflection in accordance with
BS 4580 App. ‘H’.
(2) Qualifications (type) Tests: The following tests shall be carried out on
actual pipe/fittings produced by the manufacturer to establish and accept
the design basis for the products. These tests are not routine quality
control tests.
a) Long term hydrostatic design pressure of the GRP pipe or fitting

shall be established in accordance with AWWA C950 Section
2.4.2
b) Short term hoop tensile strength shall be within the ultimate

strength of the pipe fittings. Laminated joints and flanged joints
shall withstand a hydrostatic test pressure of 3.5 times the rated
working pressure with no signs of leakage or weep. For flanged
joints, the flanges shall be blinded and the ends unrestrained
during the test.
6/61.9 Submittals/Drawings: Prior to start of production, the fittings manufacturer shall

submit to the Engineer detailed drawings of each fitting required for approval.
Design calculations, samples and sample testing may also be required by the
Engineer for approval at no extra cost to the Client.
For flanged fittings, the manufacturer shall submit before delivery, the
recommended gasket details, the bolt torquing sequence and maximum
recommended torque for each flange size supplied.
6/61.10 Markings: Each fitting shall be indelibly marked with the following:
- Manufacturer’s name or trade mark

- Nominal diameter (ND) in mm (inside and outside)
- Pressure rating in bars
- Manufacturing date, month & year
- Inspection mark
- Coupling “homeline”, ‘position’ position on spigot ends
6/61.11 Tangential Flanged Tee: This shall be used as washout tee which shall have a
bottom tangential flanged outlet. Tee shall be spigot x spigot x branch flange. The
size and the configuration of the Tee shall be as detailed on the drawings. The detail
of product and engineering data shall be submitted. Spigot ends of tee shall be
compatible with AC joint used for this project/contract.
6/62 IRRIGATION WORKS - VALVES
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6/62.1 All valves and flanges shall have minimum pressure rating of 16 bars manufactured
to British Standards. The flange to flange length of the valve shall conform to ISO
5752 Series 3, 14 or 15 as specified below with various valve types. All construction
bolts shall be of SS Grade 316. Valves shall be non-rising stem types and the stem
shall be SS Grade 316 TI/1.4571 or cast aluminium bronze with gun metal or Bronze
stem nut. All valves to be suitable for sewage final effluent.
6/62.2 Gate Valves shall comply with BS 5163. Gate Valves which are hand-wheel
operated shall have anti-clockwise opening. Maximum force required at the
circumference of the hand-wheel to open the valve against unbalance pressure
should not exceed 500N. All valves shall include a double ‘O’ Ring releasing system
which complies with Clause 9 of BS 5163./1986. Hand-wheel shall have marked
words ‘open’ and ‘close’ in English with rotation direction arrows. Hand-wheel shall
be protected with epoxy coating.
Stem of the valve to be of stainless steel. Seats on body and wedge to be made
from stainless steel for sizes above DN 400. Upto size DN 400 Resilient seated
gate valves are preferred with ductile iron wedge fully covered with rubber on all
sides and with replaceable stem nut.
Valve body to have epoxy resin coating of 300 microns (dft) inside and outside.
Valve stem seals shall be of the stuffing box and gland form for valves above DN
400 and of the double ‘O’ ring system enclosed in stainless steel PN material for
size upto DN 400.
Flanges shall be of faced and drilled to PN 16 unless to suit already existing

pipework and approved by the Engineer.
6/62.3 Butterfly valves shall comply in all respects with BS 5155 : 1984. Body with all
flanges faced and drilled for PN 16 and the disk shall be made of Ductile cast iron
corresponding to BS 2789-73 Grade 500/7. Disk shall be mounted on stainless steel
shafts located in PTFE lined self lubricating bearings with synthetic nitrile rubber
shaft seal.
The valve disc shall be the double offset eccentric type – single offset for DN 1000
and larger – fitted with a non-ageing sealing element of NBR (nitrile Rubber Profile
Seal) or similar approved material held in place by an adjustable one-piece clamping
ring secured with Stainless Steel adjusting set screws mechanically locked in place
(not resin bonded). The profile seal shall provide a bi-directional tight shut off,
against a solid rolled in body seat ring of Stainless Steel.
The valve disk shall be as streamlined as possible to ensure low head losses and
secure movement without disk flutter.
The disk stub shafts shall be manufactured from Stainless Steel, and positively
keyed to the valve disk and incorporate a key securing device (valve disks pinned to
stub shafts are not acceptable).
The stub shaft bearings shall be of maintenance-free self-lubricating PTFE lined

bushes, and shaft seals of NBR or equivalent.
The epoxy coated valve gearbox shall be fitted with a sealed for life maintenance-
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free travelling fork and nut gearbox, suitable for buried service duty and capable of
easy operation at full pressure differential equal to nominal pressure, enclosed in
cast iron casing, grease packed, with ball thrust bearings coupled with handwheel
and position indicator.
Travelling fork and nut gearboxes shall be used for small and medium sizes, slider-
rank gearbox for bigger ones, according to the pressure rating.
6/62.4 Non-return valves shall be of the single door swing check type including hydraulic
damper lever arm and balancing weights. The disk shall be resilient seated. Valves
shall be provided with removable covers on top of the body to enable hinges and disk
to be inspected and removed. Spindle should be made of stainless steel.
Valves shall be provided with air release lock on the removable cover. Face to face
length of non-return valves shall be either two times nominal dia plus 100 mm or to
ISO 5752 series 10. All construction bolts and valve spindle shall be stainless steel
grade ASTM 316 L. If application allows short body type check valves to ISO 5752
series 14 with hydraulic damping device will also be acceptable.
This short body tilting disk check valves must meet following requirements.
The check valves shall be the double flanged type of short body (face-to-face
dimension to ISO 5752 Series 14) drilled to BS 4504 PN 16. The body shall be of
ductile cast iron to BS 2789-73, grade 500/7 or better.
The valve disk shall be of the same material as the body and be as streamlined as
possible to ensure low head losses.
Shafts of high-tensile ferric chrome-nickel steel.
Disk seat ring of stainless chrome-nickel steel.
Precise seal of the valve disk inserted in ring of stainless steel. This seal provides
tight sealing of the valve at pressure below 2 bars.
Bearing bushes shall be self-lubricating/PTFE lined and maintenance free.
The check valves shall be equipped with lever and counter weight and if necessary
according to application with Hydraulic damping device for setting the closing time.
The hydraulic damping device shall be used to damp closing and opening shocks of
the valve and shall act in both limit positioning (damped opening range 10 degrees
and damped closing range 15 degrees).
6/62.5 Surge anticipator relief valves shall be fluid actuated and have a single moving
assembly. A flexible, non-wicking, FDA approved, nylon fabric reinforced synthetic
elastomer diaphragm shall be integral with this assembly to form a sealed chamber,
operating free of drag or wear. The diaphragm shall not be used as a seating
surface. This assembly shall have a stem which is fully guided by separate upper
and lower bearings to preclude binding or deflection. When the valve is in the closed
position sealing at the seat shall be accomplished by the contact and a smooth seat
surface. The seat design shall be removable and not have edges that will induce
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seal cutting, or wear at low flows. Progressive throttling of flow shall be

accomplished by a characterized profile quad ring retainer washer. The valve body
and cover shall be of cast iron. An FDA approved fused epoxy coating shall be
applied to the internal and external exposed surfaces of these components after
cleaning and degassing. This coating shall be standard on all basic valves 2-16. All
internal valve components shall be removable and repairable while the valve body
remains in the line. Packing glands and/or stuffing boxes are not permitted and there
shall be no pistons operating the valve or controls. Valve sizes 2-3” shall be
standard equipped with a flow-clean strainer mounted in the inlet supply port of the
main valve. Valve sizes 4” and larger shall be standard with an externally mounted
y-strainer for protection of the control circuit and WATTS ball valves to isolate the
pilot system from the main valve.
The valves shall open on a low or high pressure wave. The high pressure relief pilot
shall be set to open at any pressure above the normal operating pressure of the
system. The high pressure control shall be adjustable, spring loaded, normally
closed, direct acting, diaphragm valve designed to permit flow when controlled
pressure exceeds the spring setting. The low pressure pilot shall be set to open the
main valve at any pressure below normal system operating pressure.
6/62.6 It shall be an adjustable spring loaded, direct acting, normally open, diaphragm
actuated valve. The low pressure control shall control the filling of a hydraulic
accumulator which opens the main valve and prevents the main valve from
remaining open an excess amount of time. the control system shall have adjustable
opening and closing speed needle valves. The specification shall note when valve 6”
and larger are to be installed with the system in a horizontal position.
6/62.7 All valves shall have a drain plug at the bottom of the body.
6/63 IRRIGATION WORKS - DISMANTLING JOINT AND FLANGE ADAPTOR
6/63.1 Dismantling Joint
This shall be used on GRP, AC, cast and ductile iron and steel pipes and joints
between each of the materials as shown on the drawings. This shall provide
flexibility at installation stage of flanged pipework systems.
The dismantling joint to comprise a flange adaptor, flange spigot piece and tie bars,
in a complete package and to allow a greater adjustment length allowance at the
installation stage. Adjustability to be provided by the combination of a flange adaptor
and flanged spigot. Up to 50 mm of longitudinal adjustment (dependent upon
diameter) to be available due to telescopic action of the spigot within the flange
adaptor. Once the final installation position is achieved bolt up procedures for the
flange adaptor and tie bars to be applied.
The dismantling joint shall be fitted in accordance with the manufacturer’s

recommendation. Flanges shall be NP 16 rating.
Steel for spigot and flange adaptor body in accordance with BS EN 10025:1990
Grade Fe 430 A.
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Rubber gasket to BS 2494:1990 or to suit service. Steel

for studs to BS 970:Part 1:1983 Grade 070 M20. Steel for
tie bolts to BS 1506:1990:Table 1: Type 630-860
6/63.2 Flange Adaptor

This shall be used on GRP, AC, cast and ductile iron and steel pipes to enable plain-
ended pipe to be connected either to flanged pipe or flanged valves or other fittings.
Flange adaptor to be provided with flat mating faces, suitable for bolting to rised
faces.
Flange adaptors to suit pressure rating of the flange PN16.
The overall pressure rating of the assembled adaptor to be equal to that of the lower
rated component, either pipe or flange.
Form of adaptor (straight sleeve, expanded sleeve or tapped flange) to be chosen as

per site requirements.
Material:
➢ For < 150 mm dia.body – ductile iron, end flange – malleable cast iron.
➢ For > 150 mm dia.body – ductile iron
➢ For < 300 mm dia.end flange – rolled steel.
➢ For > 300 mm dia.body – fabricated rolled steel, end flange – rolled steel.
Material Specification
➢ Rolled steel section, mild steel plate – BS 4360: 1986 Grade 43A
➢ Blackheart malleable cast iron – BS 6681:1986 Grade B32-10
➢ Whiteheart malleable cast iron – BS 6681:1986 Grade W34-04
➢ Ductile iron – BS 2789:1985 Grade 420/12
➢ Studs and nuts to be SS Grade 316 to BS 970: Part 1:1983 Grade 070
IG20.
6/64 IRRIGATION WORKS - DUCTILE IRON FITTINGS
6/64.1 Ductile Iron Fittings shall comply with ISO 2531 PN10 and made of ductile iron
according to ISO 1083 a grade 500 having min. tensile strength of 500 N/sq.mm.
Fittings to have surface prepared by sand blasting to Swedish Standard 515 059900
– 1967 and have fusion bonded epoxy coating of minimum 300 microns dry film
thickness inside and outside.
6/64.2 Bolts, nuts and washers to be in stainless steel type 316. Flanges for all pipes and
fittings to be faced and drilled for 10 m bars pressure.
6/64.3 Flange gaskets to be 3 mm thickness made of rubber (GU G7-306).
6/65 IRRIGATION WORKS - HYDRAULIC TEST
6/65.1 The types and grades of valves etc. shall be subject to hydraulic tests at
manufacturer’s works in accordance with the requirements of the respective British
Standards. Valves and fittings unless specified otherwise shall be suitable for
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working pressure of 16 bars minimum.
6/65.2 Body tests shall be applied with the fitting in the open position and each side opened
to atmosphere alternatively where appropriate.
6/66 IRRIGATION WORKS - DIELECTRIC COUPLINGS
6/66.1 Where pipes of dissimilar metals are joined, provide dielectric (insulating) couplings,
fittings, unions or flanges.
6/67 IRRIGATION WORKS - BOLTS, PIPE HANGERS AND SUPPORTS
6/67.1 All bolts for couplings, covers, flanged joints, etc. to be of SS 316 stainless steel.
6/67.2 Piping hangers, supports and anchor points shall be fabricated to British or approved
equal standards. The hangers, rods, supports and other supporting devices and
accessories shall be capable of supporting at least twice the line load of the products
being supported. Pipe hangers and supports and all bolts, nuts, washers, etc. shall
be of good quality stainless steel.
6/67.3 Brackets for guide rails/ropes shall be of stainless steel.
6/67.4 Fixing to concrete to be done using chemical anchor of approved by the Engineer
manufacturer.
6/68 IRRIGATION WORKS - NON-DISRUPTIVE ROAD CROSSING
6/68.1 Thrust Boring activities or any other non distruptive/trench less works (ND/TL) as
referred in Article 8 of DM Administrative Order No. 16 or relevant standard as
approved by the Engineer shall be carried out under the following standard
conditions of NOC’s for thrust bore or ND/TL across any road. Additional specific
condition may be laid down for a particular road when the NOC is granted,
depending on useage.
a) Excavation for access/reception pit shall be carried within caisson/sheet

piles driven to a toe depth of 0.25 H or lesser depth as supported by
calculations. Caissons/sheetpile shall be placed at a minimum offset of 5
m from the edge of any asphalt pavemenyt or as specified in the NOC.
b) The excavations must be well guarded by crash barriers, barricades,

cones, tapes, flashing lights as directed by Road Department and Dubai
Traffic Police from time to time.
c) Break tank must be provided in discharge line to monitor silt migration

during any dewatering. If silt is observed, the dewatering operation must
be stopped immediately.
d) The road levels must be recorded at thrust bore or ND/TL locations at 2m

intervals upto 20 m on either side along each lane divider line, and this
record of initial levels be submitted to Roads Depeartment as initial
reference in an approved format and prior to any dewatering work. All
levels to be recorded during 2300 hours to 0600 hours and no lane
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closure will be permitted during the day time. The traffic diversion for
levels must be approved by Roads & Transport Authority Roads
Department and Police before any work is carried out. The points hwere
initial and subsequent levels are to be taken should be fixed with Hilti type
nails for repeatability. Surface paint, chalk or other marks are not
acceptable.
Any subsidence of soil or road structure shall be immediately brought to

the notice of Roads Department and all operations must be immediately
stopped until such time as full extent of damage is determined.
The levels on predetermined points must be jointly observed every

alternative ay to determine subsidence (if any) upto the end of
dewatering. The final levels shall be taken jointly with consultant and
Dubai Municipality Roads Department representative at three months
from the date of removal of dewatering lines or as directed by Roads &
Transport Authority Roads Department. A report on final levels shall be
submitted through Consultant to Roads & Transport Authority Roads
Department not later than 2 weeks from the date of final level.
e) The pipe jacking method shall be such that the steel sleeve must at all the
times have a 1 m plug of soil in the pipe and no occasion unsupported
advance bore excavation to be carried out.
f) The access and reception pit areas must be fully lit during night time, and
noise and dust pollution be kept to minimum to avoid disturbance to local
residence.
g) In the event of damage to roads, service or adjacent structures that may

occur due to the thrust bore or ND/TL operations, the entire repairs and
compensation will be to Contractor’s account. The reinstatement shall be
carrie dout as per method statement to be agreed with an executed to the
approval of Roads & Transport Authority Roads Department.
h) NOC approval is subject to approval by Traffic Engineering Department of

Dubai Police as well as Roads & Transport Authority Roads Department.
Annexure-2
LIST OF STANDARDS FOR 132 KV XLPE CABLES
IEC 60060 HV test techniques
IEC 60229 Tests on Cable Over sheaths, which have a special protective function
and are applied by extrusion
IEC 60230 Impulse tests on cables and their accessories
IEC 60183 Guide to the selection of high voltage cables
IEC 60228 Conductors for insulated cables
IEC 60233 Tests for hollow insulators for use in electrical equipment
IEC 60270 Partial discharge measurements
IEC 60287 Calculation of current rating of cables

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IEC 60331 Fire Resisting Characteristics of electric cables
IEC 60332 Tests on electric cables under fire conditions
IEC 60811 Common test methods for insulating and sheathing materials of electric
cables
IEC 60840 Tests for power cables with extruded insulation for rated voltages above
30kV up to 150kV
IEC 60859 Cable connections for gas insulated metal-enclosed switchgear for rated
voltages of 72.5kV and above
IEC60885 Electrical test methods for electric cables
IEC 60949 Calculation of thermally permissible short-circuit currents, taking into

account of non-adiabatic heating effect
IEC 61443 Short-circuit temperature limits of electric cables with rated voltages
above 30kV (Um=36kV)
IEEE575 IEEE Guide for the application of Sheath-Bonding Methods for Single
Conductor Cables and the Calculation and the Calculation of Induced
Voltages and Current in Cables Sheaths
BS EN 12548 Composition of lead and lead alloy sheaths of electric cables
BS EN 50307 Lead and Lead alloys. Lead and lead alloy sheaths and sleeves of
electric cables
BS 1442 Specification for galvanized mild steel wire for armoring cable
BS 2484 Specification for straight concrete and clayware cable covers
BS 6121 Mechanical cable glands
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SECTION 7 – STREET LIGHTING
7/1 GENERAL
7/1.1 General Conditions: All Control cabinets, cables, lighting masts including holding
down bolts with nuts and washers, brackets, luminaries, flood lights, lamps,
service cut-outs and appurtenances will be supplied, delivered, installed tested
and commissioned by the contractor, or as itemised in the Bill of Quantities.
The Contractor shall supply and install all cabling and warning tapes required for
the roadway lighting starting from the DEWA substation to the end of the lighting
circuit.
The DEWA shall install any new sub-stations required for the system.
The Contractor shall be responsible for the civil works of the roadway lighting
system (except as otherwise specified) the layout for which is shown on the
drawings. This work may include road sign illumination and under-bridge lighting.
The works include also the provision and installation of duct crossings for service
cables. The installation of ducts to the required diameter shall be according to
Section 6 of these Specifications.
The position, type of ducts and constructional details are shown on the Drawings
but final location will be determined on the basis of the approved shop drawings
by the Engineer.
The Contractor shall liaise with the Roads & Transport Authority Street Lighting
Section Engineer and co-ordinate his activities where appropriate, with the Dubai
Electricity and Water Authority.
The base/foundation connection to be adequately grouted. No site welding will

be permitted. Galvanised steel holding down bolts shall be conforming to BS
4360 Grade 50C. The Contractor shall supply a precision made steel template to
ensure correct horizontal and vertical holding down bolt alignment with 2 nuts
below and on top of mast base-plate.
All stainless steel components shall be of Grade AISI 316.
Materials and equipment shall be suitable for use under the prevailing conditions
of a harsh marine environment.
In calculating the rating of electrical cables, switch-gear and all items of

equipment, the necessary derating factors shall be determined and applied to
ensure that the equipment will operate satisfactorily and meet its design criteria.
The electrical supply system shall be 380/220 volts, 3-phase, 4 wire, 50 Hz and
supplies shall be made available at appropriate locations by DEWA.
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Layouts of conduits are to be detailed by the consultant. The Contractor shall

confirm the detail and submit to the Engineer for approval before commencing
construction of any structure.
Reference Standards
The installation shall comply with:
Regulation for electrical installation (Sixteenth Edition) the Institution of Electrical

Engineers, London.
Relevant British Standards and Codes of Practice, or equivalent as approved by

the Engineer.
Standards and Recommendations issued by the International Electro-Technical

Committee.
United Arab Emirates Electricity and Water Regulations and Guide and the
general requirements of the local supply authority.
Chartered Institution of Building Services Guide Book (IES) for external lighting.
CEI
VDE
International Commission of Illumination (CIE) recommendations on lighting.
All Standards and Codes referred to shall be the latest issue at the time of
invitation to the Tender.
Main Power Supply
The Contractor shall contact the supply authority at an early stage of the Contract
to make all the necessary arrangements for the power supply.
The supply for the lighting masts will be from new and/or from existing feeder
pillars located as shown on the Drawings. Power supply to new feeder pillars
shall be from new, or existing DEWA sub stations as shown on the drawings.
The supply will be 3 phase and neutral 380/220V, 50 Hz.
Check of Equipment Supplied by Others
The Contractor shall ensure that all equipment supplied by others forming part of
his installation shall be new and in accordance with the standards required. Any
defect must be reported in writing within seven days of receipt of the equipment
in order to allow changes to be made or replacements instructed by the Engineer.
The following are the general conditions under which the cable shall operate:-
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Electrical energy is generated as three phase alternating current at a frequency

of 50 +/- 5%.
The working voltage on any of the systems does not normally exceed fluctuations
+/- 10% above the nominal voltage.
The material covered by this specification shall be suitable for operation during
the varying atmospheric and climatic out door conditions in Dubai.
7/2 CABLES
7/2.1 Distribution Cables
All cables accessories and materials shall be of the best quality and most suitable for
local climatic conditions and shall be such that the cable shall withstand without damage,
any conditions arising from short circuits, switching operations and sudden variations of
load and voltage as may be met under normal working conditions. The cable shall be
suitable to be buried directly in saline soil. The Contractor shall submit for approval a
sample cut-piece of each type of cable and one metre length of any cable size with the
required embossment or with non erasable print. The materials are to be accompanied
by manufacturers installation instructions. The specification provides for manufacturing,
testing of four core power stranded copper conductor XLPE/SWA/MDPE cable, rated
service voltage 600/1000 volts.
7/2.1.1 Construction
Conductors: The conductors shall be stranded plain annealed copper in accordance

with IEC Publication 228: Conductors of Insulated Cables or BS 6360 : 1981.
The conductors shall comply with the test requirements mentioned at Clause 9 of BS
6360 : 1981 and test certificates from independent authorities / labs. shall be submitted.
Insulation: The insulation shall be XLPE (GP8) complying with table 16 of BS 5467
1989 and BS 6899 in addition to IEC Publication : 502:1983 Table III.
Test Certificates from independent approved bodies / authorities to be submitted prior to

delivery to site.
The insulation thickness shall comply with BS 5467 : 1989 Clause 6, Table 16.
Core insulation colors shall be Red-Yellow-Blue-Black.
The insulation shall meet the Test Requirements mentioned in the following standards:-
Section three of IEC Publication 502 : 1983.
Clause 20 of BS 5467 : 1989 relating to compatibility.
Clause 5 of BS 6746 : 1984.
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BS 6469 : 1984.
BS 6234 : 1987.
Clause 5, Table 5 of BS 5467 : 1989 relating to insulation.
Bedding: The inner sheath shall be black extruded PVC bedding complying with the
requirements of BS 5467 : 1989 and BS 6746:1984 for Type 9 compound or IEC
Publication : 502:1983.
Fillers and Binders: Non hygroscopic synthetic fillers to be applied integrally with the
bedding in accordance with BS 5467 : 1989 Clause 8 and IEC Publication : 502:1983 to
form a compact and circular cable.
The fillers and binders shall comply with the compatibility test given in Clause 20.1 of BS
5467:1989.
Wire Armour : The armour shall consist of a single layer galvanised steel round wires of
appropriate size mentioned in Table 16 of BS 5467 : 1989, and IEC Publication
502:1983. The armour wires must cover the entire periphery of the inner sheath as per
BS 5467 : 1989.
Armour Tests: Samples of galvanised steel armour wires shall be tested for mechanical
strength and electrical resistance in accordance with BS 5467 : 1989, and BS 1442 :
1969, respectively.
Testing requirements for zinc coatings on steel wire and for quality requirements shall
comply with BS 443 : 1982. Test Certificates from independent approved
authorities/laboratories shall be submitted prior to delivery to site.
Oversheath: The oversheath shall be MDPE (Medium Density Polyethylene) type TS2
complying with BS 6234 : 1987.
Thickness of oversheath should comply with BS 5467 : 1989, table 16 or IEC Publication
502 : 1983.
7/2.1.2 Testing of Cables
Tests on the complete cable shall be carried out according to the schedules
given in Table 5 under Clause 15 of BS 5467 : 1989. Test Certificates from
independent approved authorities / laboratories shall be submitted prior to
delivery to site.
7/2.2 Earth Cable
This specification provides for manufacturing and testing of single core stranded
copper conductor PVC cable (non-armoured). The cable, in general, shall
comply with BS 6004 : 1984.
7/2.2.1 Construction
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Conductor: The conductors shall be stranded plain annealed copper in

accordance with IEC Publication 228: Conductors of Insulation Cables or BS
6360 : 1981.
The conductor shall comply with the test requirements mentioned at Clause 9 of
BS 6360 : 1981 and test certificates from independent authorities / laboratories
shall be submitted.
Insulation: PVC insulation complying with the requirements of BS 6746 : 1984 for
Type 9 compound Radial thickness of insulation and outer diameter according to
Table 1 of BS 6004 : 1990.
Compliance to the requirements shall be checked with the appropriate tests listed
in Table 8 of BS 6004: 1990. Test Certificates from independent approved
bodies/laboratories shall be submitted prior to delivery to site.
Insulation Colour : Yellow-green.
Cable Identification: The oversheath may be engraved or embossed along two

lines with the following legend, complying with BS 5467 : 1989 or where PVC
oversheath is used, embossing process must be applied.
First Line: “ROADS & TRANSPORT AUTHORITY STREET LIGHTING 600/1000

V”
The letters and figures shall be upright block characters. The maximum size of
the characters shall be 13 mm and the minimum size 15% of the approximate
overall diameter of the cable or 5 mm whichever is greater. The gap between the
end of one legend and the beginning of the next shall not be greater than 150
mm.
Second Line: “ XXXX 19XX UAE 4 xXX MM CU 3955 M”
This shall be equally spaced with the first line along the circumference. An
identification of the manufacturer, year, country, number of cores x conductor
cross section, type and metering length shall be marked at regular intervals on
the sheath. This shall not effect the spacing between repetitions of the legend for
the voltage designation.
Sealing And Drumming Of Cables: Before dispatch, the manufacturer shall cap
the ends of all cables so as to form a seal to prevent the ingress of water during
transportation and installation.
All cables shall be delivered to site with the manufacturer’s seals, labels or other
proof of origin intact. The labels and seals shall be retained for inspection by the
Engineer.
Each drum length of cable shall be allotted a distinctive and separate reference
number. This number shall appear on the Test Sheets covering the respective
length of cable and shall also be clearly marked on the cable drum. All cables
shall be capped on the drum to prevent the ingress of water.
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7/2.3 Cable Installation
7/2.3.1 General
The arrangements of cables and all methods of installation shall be subject to

approval by the Engineer.
Cables shall be installed in one length from terminal point to terminal point. The
radius of each bend or change in direction of the route of any cable shall not be
less than the minimum stated in paragraph 59 of the current issue of UAE
Electricity Regulations and Guide, the IEE Regulations, the relevant BS
specifications, or the cable manufacturer’s recommendations, whichever is the
greater.
Multi-core cables carrying alternating current for three phase working shall be laid
strictly in accordance with the IEE Regulations.
The Contractor shall lay in the trench along with the power cable a single core
copper earthing cable of not less than 16 sq.mm diameter for 4 x 16, 4 x 25 and 4
x 35 sq.mm dia, 25 sq.mm for 4 x 50 sq.mm dia. and 35 sq.mm for 4 x 70 sq.mm
dia power cables respectively. The earthing cable shall run all the way from the
feeder pillar to the last column on each circuit. Looping of the earthing cable
shall be made inside each column.
7/2.3.2 Cables Laid Directly In The Ground
The Contractor shall excavate trenches along approved cable routes to the
minimum depths shown on the detailed drawings.
All loose rock, stones and other sharp materials shall be removed from the
trench.
The Contractor shall supply washed sieved sand and cable warning tapes. He
shall supply and lay these materials along the trench route as specified in the
drawings.
The Contractor shall lay, level and compact clean sand in the bottom of the
trench to a depth of 75 mm before laying the cables. After laying the cables he
shall then cover them with a further 75 mm of clean sand, level and compact.
The backfilling of the trench, including the laying of PVC warning tape, shall then
be completed in accordance with Clauses 6/45.2 and 6/45.5
The Contractor shall leave for future use in cable trench loops of one meter cable
at the entry and exit duct of each foundation.
7/2.3.2 Cables Laid In Ducts
Where cables cross under roads and paved areas they shall be drawn into ducts
provided complete with temporary tapering wooden plugs of suitable diameter to
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prevent the ingress of soil into the ducts.
7/2.3.3 Cables In Concrete Trenches shall be installed in a support system comprising

moulded reinforced nylon hooks and clamps attached into a heavy gauge
galvanised steel channel fixed to the walls by stainless steel Grade AISI 316
cast-in ragbolts or by stainless steel AISI 316 threaded studs grouted into
percussion-drilled holes with polyester resin anchor grout.
7/2.3.4 Cables Fixed To Steel Work Or Concrete Walls
XLPE insulated cables installed on steel work shall be held in moulded reinforced
nylon hooks and clamps which shall be spaced so as to avoid sagging of cables.
In no instance shall the spacing of the cleats exceed 750 mm.
All cleats and runs of cables shall be arranged in the nearest and least obtrusive
manner.
Al steel work required for supporting cable cleats, shall be galvanised and
painted as specified for Miscellaneous Metal work.
7/2.3.5 Cables In Saddles
Where MICC/PVC cables are required to be fixed in saddles, PVC sheathed

copper fixing saddles shall be used. Saddles shall be fixed with stainless steel
grade AISI 316 the PVC saddle sheath which would allow galvanic action
between the saddle and its fixing.
Runs shall be neat and free from kinks, care being taken in the routing to avoid
risk of damage to or interference with other equipment.
7/2.3.6 Cable Support Spacing
Spacing of cable supports shall be as laid down for the relevant size and type of
the cable in the UAE Electricity Regulations and Guide. the IEE Regulations and
the relevant BS Specification.
7/2.4 Termination of Cables
All jointing materials shall conform to the relevant requirements of the British
Standard/IEC Standard and the Contractor shall state the types of compounds he
proposes to use.
All cables shall be colour-coded in accordance with the IEE Regulations. In the
final sub-circuits, cores shall be identified by the colours red, yellow or blue as
appropriate. Tapes and sleeves will not be permitted.
The Contractor shall allow for at least 300 mm of the cable to be cut off
immediately before the termination is made. This requirement shall apply to all
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cable ends.
All cable ends are to be sealed against the ingress of water, deleterious matter,
etc.
7/3 EARTHING
7/3.1 Earthing System
Contractor shall install an earthing system to the last column/mast of every circuit
including all feeder pillars as shown on the Drawings. The earth installation shall in
general be in accordance with British Code of Practice CP 1013, and in accordance
with the requirement of Dubai Electricity & Water Authority and the UAE Electricity
and Water Regulations.
Where the requirements of the UAE Electricity and Water Regulations and Guide
differ from those of the IEE Regulations, the former shall prevail.
Electrodes shall consist of 16 mm minimum diameter hard drawn copper rod driven
vertically to a minimum depth of 3.0 m. Rods shall be complete with hardened steel
tip and driving cap. Rods shall be capable of being extended in lengths, as
necessary, by the provision of permanent screw mechanisms.
A PVC coated earth continuity conductor of 75 mm2 cross-section copper cable shall
be inserted between the earthing stud in the pillar or lighting column and the earth
electrode. The connection of the copper tape cable to the earth electrode shall be
made by means of a suitable conductor clamp. After final acceptance tests, the
connection shall be wrapped in petrolatum impregnated tape.
The earthing conductors shall have a minimum current carrying capacity in

accordance with CP 1013.
Each electrode shall be driven to a depth such that it penetrates the summer water
table by minimum of 2 metres.
Earth electrode distance should not exceed 5 metres out of centre of foundation of
last column, and at an agreed location adjacent to the feeder pillar.
7/3.2 Earth Electrode Terminations
Every connection of an earthing leads to an earth electrode shall be made in a pit

measuring approximately 300 mm x 300 mm x 300 mm. The connection shall be
soundly made by use of hard soldered joints, or clamps. All earth electrodes and
earthing leads shall be of copper.
The contractor shall ensure that throughout the installation all metallic parts of all
equipment, other than current-carrying conductors, are bonded to form a continuous
path by way of connecting the armouring (or earth conductors) of the local authority’s
cables at feeder pillars, sub stations, etc.
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After installation, the pit shall be filled with sand and a removable cover placed on pit.
7/4 TESTING AFTER INSTALLATION

After cable laying and installation of earthing systems the Contractor will perform the
following tests:-
7/4.1 Continuity of Conductors
A test shall be made to verify the continuity of each conductor, including the earth
continuity conductor of each circuit.
7/4.2 Insulation Resistance Test
This test will be applied to each section of cables and will comprise of:
Phase to phase insulation resistance.

Phase to neutral insulation resistance.
Phase to earth insulation resistance.
Neutral to earth insulation resistance.
The resultant insulation resistance for any of the above measurements shall not be
less than 8 to 10 mega ohm per metre cable length and measured with 1000 volt.
For these tests, a voltage not less than 2.5 times the normal voltage of the supply
shall be applied for the measurement of insulation resistance.
7/4.3 Earth Resistance Test
To be performed with specific calibrated earth resistance metre. The resistance of

any point in the earth continuity system of the installation to the main earth electrode
shall not exceed 1 ohm, and the resistance to earth at this termination shall not
exceed 0.5 ohm.
Inspection certificates, completed by the Contractor shall be generally in accordance

with IEE regulations.
Brand type and calibration report of test equipment used for testing the electrical
installation by the Contractor shall be subject to the approval of the Engineer.
These calibration reports are to be submitted to the Roads & Transport Authority
Street Lighting Section along with the test results prior to the commencement of the
maintenance period.
Owing to the highly corrosive nature of the sub-soil at certain locations the Dubai
Electricity and Water Authority shall be consulted regarding the metal to be used for
the earth termination.
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7/5 CONCRETE FOUNDATIONS FOR MASTS
Concrete for the foundations shall be Class 30 in accordance with Section 4 of these
Specifications.
The cement content shall be increased by 10% if any part of the foundation is below
the water table.
The Contractor shall provide the Engineer with shop drawings with supporting design
calculations for approval prior to construction of the foundations.
A sample foundation is to be approved by the Engineer and Roads & Transport

Authority Roads Lighting Section before commencement of the work and the same
standard is to be maintained throughout the contract.
Denso tape shall be placed on the exposed section of the threaded part of the
holding down bolts before casting the foundations. After concreting the bolts shall be
thoroughly cleaned, greased and checked with a template to ensure accurate
placement.
7/6 EXISTING STREET LIGHTING FACILITY
Street lighting services which fall within the site of the works which are damaged by
the Contractor shall be repaired/rectified by the Contractor within 24 hours. The
Contractor shall be responsible for obtaining road closure permission where
applicable and to provide necessary material and manpower.
7/7 SPECIFICATIONS FOR CONVENTIONAL (up to 16 Meters) ROAD LIGHTING POLES

(COLUMNS) & BRACKETS.
7/7.1 General:
The road lighting poles are intended to hold more lanterns, and consist of one or
more parts: a post, possibly an extension piece and, if required a bracket. The road
lighting poles, in general, shall comply with the requirements of BS 5649: Part 1 to
8.
7/7.2 Specific
Pole upto a height of 14 meters shall be of one solid piece other than the bracket.
Poles of 16 meters height shall be made of not more than two sections.
The light poles shall be suitable for supporting a lantern array as shown on the
drawing.
The pole shaft shall have an octagonal cross section, continuity tapered and
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longitudinally welded. The welding of the steel lighting pole shall be metal-arc
welding complying with BS 5135. No circumferential weld shall be accepted.
All pole shafts shall be provided with substantial rigid flange plate, thickness as per
drawing, with an opening for cable entry.
The plate shall be welded with the shaft with 2 Butt welds from inside and outside.
The weld shall be metal-arc welding complying with BS 5135.
The pole shaft shall be fabricated from a high strength structural steel complying with
the requirements of BS 1840.
The steel used for the fabrication of the shaft shall be of material conforming to BS
4360, ‘weldable structural steels’, Grade 50C, aging resistant and suitable for hot dip
galvanising. Alternatively, steel conforming to or better than Euronorm 25-72 grade
FC 360B shall be used in accordance with BS 5649: Part 3: 1978.
The flange plate shall be fabricated from mild steel conforming to BS 4360, Grade
43C.
The brackets shall be fabricated from steel conforming to BS 4360, Grade 43C.
The anchor bolts, shall be fabricated from steel conforming to BS 4360, Grade 50C
or Euronorm 25-72 grade FC 360B as per BS 5649: Part 3: 1978. Each anchor bolt
to be provided with 2 Nos. nuts and 2 nos. washers.
Poles, Flange plates/base plates, doors, brackets, anchor bolts, nuts and washers
shall be protected against corrosion from inside and outside in compliance with the
requirements of BS 729: 1971 (The minimum average zinc coating weight on one
side should not be less than 714 g/sq. meter) and clause 4.2, 4.3, and 4.4
respectively of BS 5649: Part 4:1978 or EN 40: Part 4.
Poles with bracket(s) and lantern(s) shall be able to withstand a wind-speed of 160
km/hr. including gust factor. The maximum stress for a wind-speed of 160 km/hr.
shall not exceed 50% of the minimum strength of the material. The design loads
shall meet the requirement of BS 5649: Part 6: 1982.
The maximum horizontal and vertical deflection at the top of a pole, shall not exceed
the value given in Clause 6.5 of BS 5649: Part 7: 1985.
The maximum allowable tolerances for the pole, bracket(s), base plate/flange plate
and anchor bolts shall comply with BS 5649: Part 2: 1978 and EN40: Part 2.
The relevant thickness and dimensions of poles, brackets, doors, base plate/flange
plate and anchor bolts shall be as shown on the drawings.
The poles and vertical parts of the arm bracket(s) shall be constructed, so that the
exterior surfaces of the poles shall be free from protuberances, dents, cracks or other
imperfections. Appropriate wrapping and packing is to be done before shipping to
maintain this quality and to preserve the finish during shipping and storing. Anchor
bolts shall be packed in wooden boxes.
The lighting pole to be adequately reinforced and strengthened at the location of the
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inspection compartment opening to compensate for loss in section of the post at this
point.
The poles shall have a base compartment with a vandal resistant, dust and
waterproof door for housing the service cut-out. The door opening shall be of
adequate dimension as shown on the drawing for easy access and maintenance.
A galvanised corrosion resistant steel clamp for fixing a wooden board for mounting
the service cut-out shall be welded inside the base compartment. The wooden board
must be provided in the compartment. It shall be easily removed and refixed to steel
clamp provided. The wooden board shall be not less than 20 mm thickness
seasoned Marine Ply and be of the same size as the compartment door and shall be
non-hygroscopic and rot resistant.
The base compartments and cable ways shall comply with the requirements of BS:
5649: Part 5: 1982.
A 30 mm long threaded stud of corrosion resistant steel carrying 2 nuts and 2

washers to be provided for earth connection. The stud to be located in an easy
accessible place near the inspection cover inside the lighting column (stud diameter
to be of M8 size) in compliance with Clause 5 of BS 5649: Part 5: 1982 or ENO: Part
5.
The door shall be flush and secured by a positive action lock which forces the door
out when opening. All loose parts of the locking device shall be so arranged that
they are held captive on the door when it is in the open position. All the moving parts
of the locking device shall be stainless steel of Class 316 - material. An approved
neoprene sealing gasket shall be affixed to the door opening to ensure a water-proof
and dust proof enclosure to IP 53. There shall be a stainless steel chain (6 mm),
class 316 material strength, between the pole and the door to ensure the door cannot
be lost if incorrectly secured.
The structural design of the poles (columns) shall be tested in accordance with BS
5649: Part 8: 1982. Test certificates from independent approved
authorities/laboratories shall be submitted along with the tender.
Bolts, nuts and washers shall be tested at DCL for coating thickness as per BS EN
ISO 1461 : 1999.
7/7.3 Miscellaneous Requirements:
Offered material shall be supplied exactly as indicated on specifications and

drawings.
Shipment will be allowed only after the approval of the free sample given by the
Contractor.
Erected poles shall be clean, free from dust, debris and damages.
A test certificate from an independent laboratory shall be submitted confirming the

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galvanisation coating weight and component composition, as specified elsewhere.
7/7.4 Design Information
The Contractor shall submit for approval the following design calculations and data
prior to the fabrication of any part of the light poles or brackets.
Shop drawings showing general dimensions of all components of the pole including
mounting bracket(s) for single and multiple luminaries array.
Detailed scaled shop drawings of both pole and luminaries mounting brackets.
Shop drawings giving the details of the fixing and locking system between the pole
and the luminaries mounting bracket.
The total maximum load moments for each section under maximum stresses.
Computation of stresses in the base plate and anchor bolts, under maximum
windload with maximum number of luminaries in place. Consider the weight and the
windage area of each luminaire to be 12.5 kg and 0.15 sq. metre respectively.
Maximum deflection at the top of the pole, under conditions and wind velocities
mentioned earlier.
Contractor may submit any new treatment method for extra protection against
corrosion of the base plate area and up to the height of 300 mm.
Detail calculations of the necessary strength for anchor bolts to be used should be
submitted for different height of pole.
Means of assembling two section poles (e.g. 16 m poles) shall be indicated in detail.
Impact resistance calculations at a height of one metre above the base plate of the
column.
Maximum tolerable impact calculations to shear the plate from the pole from an
impact point one metre above the flange plate.
Materials specification for each parts of the column.
Contractor shall provide along with the samples, table showing all data and all test
results mentioned under this Clause and indicate deviations from contract
specifications, if any.
7/8 STREET LIGHTING LUMINARIES AND FLOOD LIGHTS
7.8.1 General
The luminaries and flood lights shall be designed to receive one high pressure
sodium and/or mercury lamp, with internal control gear necessary for the operation of
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the lamp. Luminaries shall operate on 220 Volts AC, +/- 10% at 50 Hz +/- 5%.
The street lighting luminaries and flood lights shall follow the provisions of the latest
versions of the following standards.
1. BS 4533
2. BS 4533 : Part 102 Section 102.3 : 1990
3. BS 1615
4. BS 1470
5. BS EN 60922 : 1991
6. BS EN 60923 : 1991
7. BS 6500 : 1990
8. IEC 568 Part 1 and 2
9. BS 4533 : Part 103 : Section 103.1 : 1988
10. BS 5489 Part 1, 2 & 3 : 1992
11. BS 5225 : Part 1
12. BS 5101 (Part 1) and (Part 2)
13. BS 6193 : 1990
14. BS 3772 : 1990
15. BS 2011 (Part 1.1: 1989 and Part 2.1 all).
7/8.2 Construction
The luminaries and flood lights shall accommodate lamps with cap base E40 size, as
complete with the following assembly.
Injected moulded silicon aluminium alloy casting body in two compartments as per
Clause A2, Section 1.4 of BS 4533 Part 1.
Super purity one piece aluminium reflector of grade S1 of BS 1470 with an anodic
coating of not less than grade AA10 of BS 1615.
Strong very high thermally resistant and mechanically transparent protector. The
protective bowl or diffuser shall be made of toughened glass.
Neoprene gaskets/or high quality felt gaskets silicon.
Stainless steel hinges, mounting clips and fastening bolts, Grade AISI 316.
Movable porcelain lamp holder with position markings and anti-vibration fixation
device.
Complete control gear (as per BS 4782: 1971) mounted on easy removable
equipment mounting board.
Two adjustable cable entries.
A terminal block for the connection of incoming supply cables shall be provided in
luminaries incorporating auxiliaries and shall be situated as close as possible to the
point of entry of the supply cable and shall be readily accessible.
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All means of clamping the electrical supply cables shall be provided in the lantern
where necessary to relieve the termination of strain. The cable clamp arrangement
shall not damage the insulation of the cable.
Protective sheath for power supply cable, and expandable nylon cable grip for wiring,
conforming to BS 6500: 1990.
Brass earth terminal set-in housing.

Cover for the control gear compartment shall be same as that indicated in para 2 of
this Clause.
The lamp caps and the lamp holders shall meet the requirements of BS 5101 (Part 1)
and BS 5101 (Part 2) respectively.
7/8.3 Mechanical Requirements
Luminary shall be with separate compartments for the optical system and for the
control gear.
The tightness of the optical compartment shall be IP65, according to the I.E.C. 598-1
standard (International Electrotechnical Commission). This tightness degree shall be
achieved by the use of neoprene gaskets or silicon gasket. The design of the
luminary shall be such that the sealing gasket will never be exposed to sunlight or to
the luminous flux emitted by the lamp.
The tightness of the control gear compartment shall be IP54 or better, according to
the IEC 598-1 standard
The opening of the control gear compartment shall allow a complete and easy visual
check of all electrical parts and shall be suitable for easy access and easy
maintenance.
The mechanical strength of the body its accessories and the protector of the luminary
shall be sufficient to withstand without any damage the drop test as per BS 2011 Part
1.1: 1989 & Part 2.1 Ea.
The luminary shall be able to withstand without any damage a wind speed of 160
Km/h including gust factor.
Special precautions shall be given to the choice of materials which shall be able to
resist without any damage or aging or alteration in its structural or physical
properties, the severe Gulf climatic conditions, as indicated under Clause 7/19, in
addition, to the heat emitted by the lamp.
Fixing shall be of an effective locking means using stainless steel bolts.
The weight of the luminary including protector cover and control gear shall not
exceed 15 kg.
The luminary in general shall comply with the requirements mentioned at BS 2011.
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All fixings which carry the weight of the lantern and internal accessories shall be
provided with suitable locking devices to prevent the dislodgement of any part of the
lantern by vibration either in service or in maintenance. Compliance shall be
checked as per BS 2011 Part 1.1: 1989, and Part 2.1 Ea to Ef.
7/8.4 Electrical Requirements
Provision for one lamp for each lantern shall be made. The electrical accessories
such as ballasts, ignitors and capacitors shall be prewired and preassembled on
metallic supports that are fixed into the control gear compartment.
Special care shall be taken to allow easy maintenance and quick replacement of the
accessories. They shall be bolted (and not riveted) on the removable supports. The
supports shall be laid down in the compartment and in no case shall be suspended
by bolts, for security reasons and maintenance facilities.
All electrical accessories shall be able to withstand, in continuous operation and

without any damage, the temperature existing inside the control compartment, in an
ambient temperature of 50 degree C. Cable connections to the lamp holder within
the lantern shall be of the heat resistant type with silicon or glass fibre or other
approved insulation. The arrangement shall comply with BS 4533.
The cable feed terminals and the earth screw shall be fixed inside the control gear
compartment. A cable holder shall be mounted near the terminals. An isolating
conduit shall be fitted to protect the incoming feeder cable. The arrangement in
general shall comply with BS 4533.
A separate set of control gear shall be provided for the lam p comprising one choke
associated with one capacitor, one ignitor and starter (instant type) if any. The
control gear should be encapsulated in an approved enclosure conforming to IP 54
tightness. Terminals of all ballasts, capacitors, ignitors (if any) and starters shall be
shrouded. The ballast shall be designed to operate the lamp and control it
continuously in ambient temperatures ranging from 0 degree C to 80 degree C.
The ignitors shall be solid state fully electronic, non-timed, multi-pulse,

superimposed, pulse type which shall not require the use of tapped ballasts nor be
dependent on external capacitors. The ignitor shall not produce a high voltage pulse
across the ballast windings, and shall have screwed terminals. The ignitor shall be
fully encapsulated impervious to the ingress of moisture, and shall have a
temperature rating not less than 90 degree C.
The choke shall be of reactor, non-tapped and tropicalised of Class H Insulation and
Vacuum impregnated with an unsaturated polyester resin of not less than
thermalclass H (180 degree C. in accordance with IEC 85:1984). The capacity of the
choke should be such as to keep the illumination of the lamp within the design limit.
The capacitor shall be of the diphyenyl impregnated type and shall be in a leak proof
metal container fitted with an internal discharge resistor. The permitted operating
temperature of the capacitor shall be marked on its case and shall be 85 deg. C.
The capacitors shall have value sufficient to raise the power factor of the complete
system to 0.85 or better. Each lamp shall operate using only one choke and one
capacitor. Any combination of two or more capacitors to have the equivalent value of
capacitance will not be accepted. Choke and capacitors shall comply with the latest
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BS EN 60922: 1991 & BS EN 60923: 1991.

The control gear shall be supplied by the lantern manufacturer and shall be
incorporated in a separate compartment in a way that heat emitted by lamp is not
conducted or transferred to the gear components. It shall also be distinctly marked
with the month and year of manufacture, in addition, to the standard marking.
The lantern shall have a screw type lamp holder. The lead at the higher potential
above earth shall be connected to the centre contact.
The operating temperature and thermal endurance characteristics shall conform to

Clause 17, Section 2.7, Part 2 of BS 4533.
7/8.5 Photometrical Requirements:
The lamp fitting shall be adjustable to allow the luminous flux distribution to be
adapted to the geometrical installation conditions.
The adjusting devices of the lamp shall be sufficiently sturdy, and designed in a way
it cannot be disturbed, during its normal life time (vibrations) or during maintenance
operations (lamp replacement).
This device shall have permanent marking so that the lamp position recommended
by the manufacturer can be easily realised.
The photometrical classification of the luminaries, according CIE Nr. 34 publication

shall incorporate the following characteristics, depending on the lamp position
adjustment:
- Longitudinal flux control: Throw - intermediate or long

- Transverse flux control : Spread - Narrow or average
- Glare control : SLI - Greater than 3.
7/8.6 Photometrical Performance Requirement
Computer calculation relating to illuminance and luminance results detailed

hereinafter shall be submitted. The overall luminance uniformity ratio (UO) &
longitudinal luminance uniformity ratio (UI) which will be achieved on roadway,
values of glare control (G), threshold increment (TI) and specific Lantern Index (SLI)
wherever applicable.
For the luminance calculation, the road surface to be considered is the R4 type with
QQ = 0.08 according to CIE Standards.
The calculations shall be performed in accordance with CIE Nr. 30 publication and
shall be based on the data given in the drawings. These computer calculations shall
achieve the results mentioned in the drawings.
These results are to be achieved taking into consideration a total maintenance factor
of 0.8 (dust depreciation factor x lamp lumen depreciation factor).
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If possible to have more spacing the computer calculations shall determine the
maximum spacing of poles to be adopted to achieve the above results.
7/8.7 Documents to be submitted with the offer
The manufacturer shall supply following technical documentation and information for
each type of luminaries for the approval of the Engineer. The approval of the
Engineer does not absolve the Contractor of the contractual obligations regarding the
performance and compliance to the specification requirements.
Catalogue sheet of the luminary
Detailed construction drawing of the luminary Polar diagram of luminous intensity in

road way vertical plane and transverse vertical plane.
Utilisation factor curve for actual inclination of luminary.
Isolux diagram for actual inclination of luminary.
Intensity table, in the C-gamma co-ordinates recommended by CIE Nr. 27

Publication.
Computer calculation printout showing the illumination and luminance levels.

Longitudinal Uniformity Ratio (UI), overall Uniformity Ratio (UO), specific lantern
index (SLI), glare control mark (G) and threshold increment (TI).
Tightness test certificate conforming to IP65 protection degree for the optical
compartment of the luminaries and the IP54 protection degree for the control gear
compartment. This test certificate shall be issued by an independent official
laboratory.
Shock test certificate confirming the resistance of the body to an impact energy as
per Clause 4.4 Section 1.4 of BS 4533, Part 1. This test certificate shall be issued by
an independent official laboratory.
Wind resistance certificate confirming that no damage will occur to the luminary at
winds up to 160 km/hr. for a short period. This certificate shall be issued by an
independent official laboratory.
Total weight of the luminary (with lamp and control gear)
Power factor of one complete luminary (under normal working conditions)
Total electric consumption of the luminary, including control gear losses.
Rated lumen output of the lamp under nominal conditions.
Depreciation curve of the luminous flux with burning hours.
Luminous flux variation with the main voltage
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Make and type of ballast and capacitors separately with their electrical
characteristics, e.g. Impedance, power factor, Temperature rise ( t), max.
temperature (tw) and power losses.
The Contractor shall submit with his tender full details of areas using the same type
of luminaries in the Middle East and Gulf Area.
A computer program according to CIE standard on 5 1/4” size floppy disc fully IBM
compatible should be supplied in the matrix program for the offered luminary.
The Contractor shall submit for the Engineer’s approval dimensional drawings of the
control gear arrangements showing the exact position of chokes and capacitors
within the lantern.
7/8.8 Materials to be submitted with the offer
The Contractor shall submit along with the offer 5 sets of luminaries of each type to
equip 5 mast for examination and photometrical test on site.
The materials to be accompanied by manufacturer’s assembling and erection

instruction.
The contractor shall carry out site testing after installation work is completed for
photometric performance in accordance with the contract specification requirements.
All the test shall be carried out in the presence of the Engineer. The luminance
measuring device shall be provided by the Engineer.
The final acceptance of any submitted offer shall be strictly depending on the
photometric and electrical performance test on site.
7/9 SPECIFICATIONS:
LOW VOLTAGE FLEXIBLE POWER CABLES FOR CONVENTIONAL LIGHTING COLUMNS &
LUMINARIES
7/9.1 General:
The following specifications are for manufacturing and testing of circular, flexible,
copper conductor, confirming to harmonised code H05 VV-F, 300/500 Volts grade,
PVC insulated, sheathed cable rated for 70 deg. C. as per BS 6500 Table 16, which
is to be used inside the lighting columns between luminaries and service Cut-out.
7/9.2 Conductors:
The conductors shall be stranded plain/tinned annealed copper in accordance with

BS 6360: 1981 Class 5 flexible conductor.
The conductor shall comply with the test requirements mentioned in BS 6500 : 1990
and test certificates from independent authorities/labs. shall be submitted.
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7/9.3 Insulation
The insulation shall be PVC insulation Type T12 complying with BS 6500: 1990
suitable for 70 deg. C.
Test Certificates from independent approved bodies/authorities to be submitted with
the offer as evidence.
The insulation thickness shall comply with BS 6500 : 1990 Table 16.
Core insulation colours of each core shall be as per Table 16 of BS 6500: 1990.
The insulation shall meet the Test Requirements mentioned in BS 6500.
7/9.4 Sheath
Type: The sheath shall be PVC type TM2 complying with the latest edition of BS
6500.
Thickness: Thickness of sheath should comply with Table 16 of BS 6500: 1990.
Testing: Tests on the complete cable shall be carried out according to BS 6500:
1990. Test Certificates from independent approved authorities/laboratories shall be
submitted with the offer as evidence.
Cable Identification: Cable identification shall be according to BS 6500: 1990.
7/10 SPECIFICATION FOR MID-HINGED HIGH MAST
7/10.1 Mid-Hinged Mast
All masts and brackets shall be designed to meet the wind loading requirements of
British Standard CP3 Chapter V, Part 2: 1972, and ILE Technical Report No. 7. The
design must consider wind velocities of 160 kph. including a gust factor of 1.3.
The steel used for the construction of the mast and bracket shall have a tensile
strength of no less than 4450 kg/sq.cm. to BS 4360 and all welding shall be in
accordance with BS 5135.
All manufacturer’s certificates shall be supplied with respect to the steel used in the
mast.
The mast shaft shall have an octagonal cross-section continuously tapered and
longitudinally welded. No circumferential weld shall be acceptable, except at the
mid-hinged point.
The high mast shall be designed to accommodate a set of four luminaries and
associated brackets for achieving the luminance level requirement as specified
elsewhere.
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A door opening shall be provided in the base of the mast of adequate dimensions to
permit clear access to equipment namely Control Gear, and Cutouts complete with a
close fitting weather-proof door having a heavy duty lock. The door seam tightness
shall conform to IP 54 standard. The opening shall be adequately reinforced to
maintain the strength of the mast.
The base flange shall be free of laminations and the welded connection to the mast
shall fully develop the strength of the section. The base plate shall be manufactured
as per the loading requirement or as specified elsewhere.
Inside each mast there shall be a galvanised steel earthing bolt with a diameter of
M8.
The entire mast and bracket shall be hot-dip galvanised internally and externally
according with BS 729: 1971.
All component parts or fasteners shall also receive the same hot-dip ganvanised
treatment, threaded components centrifugally spun to remove local excess of zinc.
Galvanising shall be performed in such a manner as will provide a minimum coating

weight of 714 gr/sq. m of surface (minimum 100 microns DFT).
Coating weight shall be determined by a suitable magnetic or electronic measuring

device. However, in case of dispute, the Engineer may direct that a stripping test in
accordance with BS 729 be carried out.
The mast shall be of a suitable dimension to accommodate the control gear and
cutout in the bottom compartment.
The spindle of mid-hinged mast shall be stainless steel grade AISI 316.
All bolts, nuts, locking screws and door chain shall be stainless steel Grade AISI 316.
Copper braid for electrical conductivity to be provided between fixed and movable
sections.
The mast shall have a special arrangement in order to impose no stress or pulling
force upon the mast internal cabling.
At mid-hinged point there shall be arrangements to prevent ingress of water,

moisture and dust (Minimum IP54).
Stainless steel rod of grade AISI 316 shall be provided for slip joint adjustment.
The cables support plate at mid-hinged point shall be provided to secure the lantern
wire to eliminate any stress on power cables.
Provision of securing the movable part with the fixed part in lowered position shall be
made by using hooks and rope.
All calculations showing the maximum forces encountered in the mast while lowering
or raising the mast to be submitted.
All calculations showing the maximum forces on the foundation and the mast holding
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down bolts while lowering or raising the mast to be submitted.
All calculations showing the forces encountered by the wind loading to be submitted.
All calculations showing the max top flexation under given wind load and the forces
occurring on the holding down bolts to be submitted.
All calculations showing the maximum forces and pressure encountered by the mast
raising and lowering equipment during operation to be submitted.
Details of the power supply cable tension release facility in the top of the mast to be
submitted.
The Contractor shall depute a Technician at site to demonstrate the assembly

procedures.
The mast shall be hinged approximately midway above the base so that it may be
raised/lowered by means of externally operated rope and counter weight. The rope
shall be portable and to be easily detachable for use with other high masts.
The Contractor shall afford every facility for the inspection of the mast and shall carry
out tests on materials and welds as may be instructed by the Engineer and the
Employer. Materials or workmanship which are not in accordance with the
Specification shall be replaced by the Contractor at his own cost and risk.
7/10.2 Luminaries Specification
The luminaries of the mid-hinged high mast shall be as per Clause 7/8 or as
specified elsewhere.
7/11 LOW VOLTAGE FLEXIBLE POWER CABLE FOR MID-HINGED HIGH MASTS
7/11.1 General
Low Voltage cable shall be used inside the high mast between the luminaries and
service cut-out. The following specifications are for manufacturing and testing of 3
core x 4 sq.mm flexible, copper conductor, 450/750 Volts grade, rubber insulated,
sheathed cable rated for 85 deg. C as per the below mentioned standards:
IEC 245 Part 4

VDE 082 BS 6007: 1983.
The maximum and the minimum overall diameter of the cable shall be 16 mm and 13
mm respectively.
7/11.2 Conductors
The conductors shall be stranded plain/tinned annealed copper in accordance with

IEC publication 228: Conductors of Insulation Cables or BS 6460: 1981 or VDE 0295
Clause 5.
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The Conductor shall comply with the test requirements mentioned in BS 6007: 1983
and test certificates from independent authorities/labs. shall be submitted.
7/11.3 Insulation
The insulation shall be rubber insulation complying with BS 6007: 1983 suitable for
85 deg. C.
Test Certificate from independent approved bodies/authorities to be submitted with

the offer as evidence.
The insulation thickness shall comply with BS 6007: 1983 Clause 11.3, table 12 and
the applications mentioned in the same standard or as per VDE 0281/4.85 and IEC
245.
Core insulation colours of each core shall be as per Clause 6 of BS 6007: 1983 or to
VDE 0293.
The insulation shall meet the Test Requirements in the following standards.
a) BS 6007: 1983
b) IEC 245 Part 4
C) VDE: 0282
7/11.4 Fillers & Binders
Non hygroscopic synthetic fillers to be applied integrally with the bedding in

accordance with BS 6007: 1983 Clause 7 to form a compact and circular cable.
7/11.5 Oversheath
Type: The oversheath shall be rubber type EM2 complying with the latest edition
of BS 6007 : 1983.
Thickness: Thickness of oversheath should comply with Clause 9.3 of BS 6007 :

1983.
7/11.6 Testing:
Tests on the complete cable shall be carried out according to the schedules
given under Clause 12, 13 and 14 of BS 6007: 1983. Test Certificates from
independent approved authorities/laboratories shall be submitted with the offer
as evidence.
7/11.7 Cable Identification:

Cable identification shall be according to BS 6007: 1983.
7/12 CROWN HIGH MAST
7/12.1 Lighting Requirements
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The general lighting requirements shall be as set out on the drawings.
The numbers, locations, types and aiming angles of luminaries and high masts
shown on the drawings are indicative only. The final design shall be determined
by the Contractor from the manufacturer’s photemetric data. The calculations
shall be submitted to the Engineer in the form of drawings of the roadway system,
overprinted with pole/mast positions, showing illuminance levels, and overall

illuminance uniformity.
For the luminance calculation, the road surface to be considered is the R4 type
with Q0 = 0.08 according to CIE standards.
The calculations shall be performed in accordance with CIE Publication No. 30

regarding the grid of calculated points and of observer positions. Computer
calculations shall demonstrate the achievement of the following minimum lighting
criteria.
Average illuminance level :greater than 50 lux
Overall uniformity ratio

Uo = L min/L av: not less than 0.5
These results shall be achieved taking into consideration a total maintenance

factor (dust depreciation factor x lamp lumen depreciation factor) of 0.80.
7/12.2 Flood Lighting Masts
7/12.2.1 General: Lighting mast height shall be as shown on the drawings or specified
elsewhere. Masts shall be equipped with a mobile crown arrangement.
7/12.2.2 Structure and Construction:
The mast shall not be more than 3 and 3 sections, other than the luminaires
carriage for 30 and 40 meters high masts respectively.
The mast shall be suitable for supporting the array of lanterns.
The column shaft shall have a polygonal cross-section, continuously tapered and
longitudinally welded. The welding of the steel column shall be metal-arc welding
complying to the provision of BS 5135. No circumferential weld shall be
accepted.
The shaft shall be manufactured and fabricated from a high strength structural
mild steel plate, single thickness without laminations complying with the
requirements of BS 1840, cut and folded to form a polygonal section.
The shaft shall be delivered in separate sections to be assembled on site by slip-

on joint system.
The steel used for the fabrication of the shaft shall be of material complying to BS
4360, weldable structural steel, grade 50C, aging resistant and suitable for hot
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dip galvanising.
All mast shafts shall be provided with substantial rigid flange plate, with an
opening for cable entry.
The plate shall be welded to the shaft with 2 Butt welds-to one from inside and
the other from outside. The weld shall be metal-arc welding complying with the
The luminaries carriageway and the anchor bolts shall be fabricated from steel
confirming to BS 4360, grade 50C. Anchor bolt to be provided with 3 Nos. nuts &
2 Nos. washers.
Mast with luminaire carriage and mobile ring and lantern shall be able to
withstand a wind-speed of 160 km/hr. including gust factor. The design loads
shall meet the requirement of BS 5649: Part 6: 1982.
The Mast and vertical parts of the arm brackets shall be constructed straight.
The exterior surfaces of the mast shall be free from protuberances, dents, cracks
or other imperfections.
The lighting mast to be adequately reinforced and strengthened at the location of

the inspection compartment opening to compensate for loss in section of the
mast at this point.
The masts shall have a base compartment with a vandal resistant, dust and
water proof door.
The door opening shall be provided in the base of the mast and it shall be of
adequate dimension to allow clear and easy access to the equipment mounted
therein. The door shall be fitted with a heavy duty lock. All the moving parts of
the locking device shall be stainless steel Grade AISI 316. An approved
reference sealing gasket shall be affixed to the door opening to ensure a water
proof and dust proof enclosure to IP 53. The base plate shall be free from
laminations and shall be fully welded to the mast base.
The structural design of the masts shall be tested in accordance with BS 5649:
Part 8: 1982. Test certificates from independent approved bodies shall be
submitted for approval by the Engineer.
Assembly of masts shall be in accordance with the manufacturer’s instructions.
7/12.2.3 Hot Dip Ganvanising:
The poles, flange plates, base plate, doors, luminaire carriage, anchor bolts, nuts
and washers shall be protected against corrosion from inside and outside.
The operation shall consist of dipping the steel parts into a zinc bath at a
temperature of 450 deg. C. after completion of the treated comprising of
degreasing, pickling, rinsing, fluxing and drying separately. The galvanising shall
be made in accordance with the requirements of BS 729 : 1971 (The minimum
average zinc coating weight on one side shall not be less than 715 g/m2).
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Masts shall be finished and painted as specified elsewhere.
7/12.3 Lowering and Raising Devices
The lowering raising device with latching mechanism allows for load to be
removed from hoisting unit when luminaries ring is latched in.
The lowering and raising system shall consist of, but not limited to:
- Driving Head
- Mobile Ring
- Hoisting Unit
7/12.3.1 Driving Head
The driving head shall be made of hot dip galvanised steel (refer to 7/12.2.3
above) and shall be fixed to the top of the plate by a flange secured to the most
top by at least 6 bolts.
The driving head shall be pre-assembled and tested in the factory prior to
shipment and supplied complete with 3 stainless steel ropes (Grade AISI 316)
and associated double-pulley assemblies and electrical power cable. Each steel
rope and power cable shall have their own separate arm, housing the pulleys
made of stainless steel, grade AISI 316 mounted on self lubricating ball bearings
and seamless axles.
The housing cable, 3 units, shall be made of stainless steel grade AISI 316.
Each cable shall have a safety factor of not less than 5 times the safe working
load of winch. The hoisting cables shall be of three connectors allowing
regulations from ground.
Three latching sleeves assuming correct positioning, entering and locking of the
mobile part of the crown when raised and locked in final position shall be
provided.
The locking system shall take up vibration free all horizontal and vertical loads of
the mobile part of the crown even when exposed under the most severe climatic
conditions.
The top of the driving head shall be covered with a canopy made of 3 mm
thickness aluminium sheet.
The latching and unlatching operations shall be regulated by two limit switches
located at the base of the mast, easily reachable through the inspection door.
The mobile part is fastened in raised position to the fixed part of the head gear by
means of 3 positive latching system protected against corrosion, and the
suspension cables shall be tension free. Both latching system and the
suspension cables to be approved by the Engineer.
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All bolts, nuts and washers of the pole shall be made of stainless steel grade AISI
316.
The electrical power cable shall be round, extra flexible, 500/750 Volt grade, with
EPR insulation and HOFR outer sheath rated for 85 deg. C.
They shall be capable of withstanding the mechanical stresses produced by the

anchoring and pulley system and shall be suitably rated to carry the maximum
electrical loading. Outer sheath shall be suitable for exposure to strong sun-light
and a marine environment, and shall be coloured black.
Arrangements shall be provided to ensure that the power cables and stainless
steel wire ropes are separated before passing over their respective pulleys, and
close-fittings guides shall protect the pulleys to prevent ropes and cables leaving
the pulley grooves.
7/12.3.2 Mobile Ring:
The mobile ring shall be fabricated and coated against corrosion according to the
pole specification. It shall be complete with lanterns and brackets to suit lighting
design requirements consisting of flood lights and control gear boxes.
During lowering and raising operations the mobile ring shall smoothly and without
any sideward movement/rotation slide along the shaft with 3 groups of plastic
rollers at 120 degrees.
All bolts, nuts and washers of mobile ring shall be made of stainless steel grade
AISI 316.
7/12.3.3 Hoisting Unit:
Suitable numbers of drum winches, with base flanges for mounting on holding
down bolts shall be fitted in the bottom of mast for operation by hand and power-
tool, for raising and lowering the mobile ring. The winch shall be fitted with a
friction winch clutch, ratchet and pawl, and the handle. Spindle-plate shall have a
safety pin-locking device. Winches shall be totally enclosed to exclude dust and
blown sand from gears and oil baths.
The mobile ring shall be raised and lowered by means of remote control push
button panel box 10M away. The control box shall conform to IP 55 heavy duty
anticorrosion, protected against U.V. of sunlight, and shall have proper locking
arrangements.
Winch power tools shall be portable multi-speed, reversible units incorporating a

torque limiting device. They shall be supplied with a flexible supply cable and a
remote control switch to allow winches to be operated from a distance of 10
meters. A supporting system shall be provided to securely locate power tools
during operation. Power tools shall be rated to raise the crown from ground to
mast top in not more than 15 minutes.
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One spare winch power tool set shall be handed over to the Engineer on
completion of the contract.
7/12.4 Electrical Equipment
The driving head shall be designed to accommodate a round power cable. Plugs
and sockets shall comply with IEC304-1, and IEC 309-2.
Internal control panels within mast bases shall incorporate a main circuit breaker
for isolation of main power, and outgoing MCBs for the rising multi-core cables.
They shall have the facility for terminating incoming power cables and shall be
fitted with weatherproof plug and socket arrangement to allow connection of the
rising multi-core cables. Control panels shall be complete with a 16A, 220V
weatherproof socket and ELCB of appropriate rating to supply the winch power
tool. Control panels shall receive protective treatment as specified and shall be
sealed to IP 54 of BS 5490.
On the mobile ring a weather proof (IP 65 grade of protection) distribution box
made of 3 mm. thick aluminium sheet, housing the terminal clamps and a
powered socket with cable for flood lights, ground test shall be provided. The
protective treatment of the distribution box shall be as specified elsewhere for
other panels.
All cable glands shall be made of brass conforming to BS 6121.
The contractor shall supply and install 2.5 mm2, 3 core butyl rubber insulated and
sheathed flexible cords to be pulled through flexible conduits for the connections
between terminal boxes, control-gear boxes and individual flood light fittings.
An earthing terminal shall be provided within the mast base, located so that easy
access for connection/disconnection of the copper earthing tape can be
achieved.
7/12.5 Warning Labels
To avoid wrong operations the supplier shall put inside the inspection door cover
warning labels in Arabic and English language.
7/12.6 Miscellaneous Requirements
Offered material shall be supplied exactly as indicated on specifications and

drawings.
Shipment will be allowed only after the approval of the Engineer.
On completion of installation, exposed nuts and bolts heads of holding down

bolts shall be capped with grease filled UPVC caps.
7/12.7 Design Information
The Contractor shall submit for approval the following, design parameters,
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calculations and data prior to the fabrication of any part of the masts or brackets.
General dimensions of all components of the mast include mounting mobile ring
and multiple luminaries array.
Detailed scale drawings of both mast and luminaries mounting brackets.
Details of the fixing and locking system between the mast and the luminaries
mounting bracket.
The total maximum load moments for each section under maximum stresses.
Computation of stresses in the base plate and anchor bolts under maximum
windload with maximum number of luminaries in place.
Maximum deflection at the top of the mast, under conditions and wind velocity
mentioned earlier.
Supplier may submit any new treatment method for extra protection against
corrosion of the base plate area and up to the height of 300 mm.
Detail calculations of the necessary strength for anchor bolts to be used.
Means of assembling of mast’s sections shall be indicated in details.
Impact resistance calculations at a height of one meter above the base plate of
the column.
Maximum tolerable impact calculations to shear the plate from the mast and from
an impact point one meter above the flange plate.
Materials specification for each parts of the column.
7/12.8 Test Certificate
The Contractor to provide with each mast a detailed test certificate:
- for mast shaft materials and accessories;

- for the electrical power supply system;
- for the hoist system;
- for galvanisation coating weight and component composition; and
- for anchor bolts, nuts and washers for both material and galvanisation.
7/12.9 Important Note
The Contractor shall provide the Engineer with a written guarantee that the
hoisting and latching systems used in the mast shall work maintenance free for a
period of at least 20 years from date of commissioning.
The Engineer reserves the right to reclaim from Contractor any cost involved for
repair or replacement of any item related to the hoisting and latching system
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used during the twenty years period.
7/12.10 Flood Light Luminaries Specification
The flood lights shall be of 1 x 1000 Watt high pressure sodium lamp, with control
gear housed in a separately mounted 3 mm aluminium powder coated whether-
proof box on the frame, necessary for the operation of the lamp. Luminaries shall
operate on 220 Volts. AC, +/- 10% at 50 Hz +/- 5%. The flood lights shall be as
per the requirements of specification of Clause 7/8.
Complete control gear (as per BS 4782: 1971) mounted on easy removable
equipment mounting board housed in a separately mounted weather-proof box
on the frame. Each set of control gear shall be separately fused at the mast
head with 20 amp MCB. The control gear boxes shall be made of 3 mm thick
aluminium sheet and shall receive epoxy powder coating on both inside and
outside surfaces. The box door shall have polymide type hinges and two Alen
key type locking devices made of stainless steel grade AISI 316.
An approved locking device shall be provided with luminaries to allow this to be

locked in its set position.
7/13 AVIATION LIGHT
Aviation lights to be provided and installed to the top of high mast of higher than
30 meters. The aviation light is to be in accordance with the Civil Aviation
requirements and shall be permanently powered.
The lights are to be fixed to the mobile ring and positioned so luminaries can be
easily replaced.
7/14 LIGHTING BENEATH OVER-BRIDGES
General: Area flood lighting shall be provided under the flyovers. Flood lights
shall be positioned as designed by the Contractor to the requirements of
Specification Clause 7.17, and to the Engineer’s approval.
Floor Light Luminaries: Flood lighting luminaries shall be of the high pressure
sodium type as per the flood lighting specification mentioned elsewhere and with
internally housed control-gear with appropriate lens and reflector. Each luminaire
shall house appropriate Lamp wattage associated control gear and power factor
correction capacitor to achieve the luminance level required beneath flyovers.
Control of under-bridge flood lights shall be from the nearest road lighting control
panel. Cabling to luminaries shall be concealed in ducts and conduits cast into
structures, with suitable junction boxes at changes of direction.
7/15 GANTRY SIGNS ILLUMINATION
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7/15.1 Luminaries and Conduits
Lighting luminaries for the illumination of gantry signs shall be high pressure
mercury and comply with the requirements of the relevant Clauses of BS 4533;
Section 102.3 and 103.1. Other requirements will comply with the specification
for Flood Lighting described elsewhere, and internally housed control-gear. Each
luminaire shall house a 1 x 400 watt high pressure mercury lamp.
Wiring to lighting luminaries shall be by means of PVC cables in a GI pipe. GI

pipe shall be securely fixed to structural steel work by distance saddles and a
flexible conduit from GI pipe to luminaire.
Final connections to lighting luminaries shall be carried out by short lengths of

EPR insulated, butyl-sheathed flexible cable. The interface between the PVC
cable system and the flexible cable shall be a weather-proof 3-pin socket outlet
and plug.
7/15.2 Control of Gantry Sign Luminaries
Gantry sign luminaries shall be controlled by road lighting control panel. The
control box for each gantry shall be mounted on the steel structure and shall be
complete with all electrical accessories required. Main power supply shall be
taken from the nearest feeder pillar by XLPE/SWA/MDPE cabling as specified
elsewhere.
7/15.3 Gantry Sign Lighting Requirements
The gantry sign lighting shall be as per CIE No. 35 (TC-4.6) 1978, and shall have
a maintained average luminance of 180 candelas per square meter (for white
letters) and the ratio of the maximum luminance of one colour in a specified area
to the minimum luminance in the same area shall not exceed.
- 2.5 for the inner zone of each area with a definite colour;
- 5 for the outer zone of each area with a definite colour; and
- 8 over the total area of the sign face.
Whereas the inner area shall be that area bounded by a similar rectangle of
length and height equal to 70% of the overall length and height of the rectangular
area located symmetrically within the sign.
The maintained average luminance value are to be based upon the total of
lantern dirt depreciation factor and a lamp lumen depreciation factor of 0.65.
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7/16 LAMPS
The lamps required shall comply with the following
Table 7.16.1 - Street Lighting Lamps
Type Power into Total Luminous Lamp Life Time hr.

Lamp (Watt) Flux (1m) Base (Min.Values)
High 125 6,400 E27 16,000
Pressure 250 15,500 E40 16,000
Mercury 400 23,000 E40 16,000
Vapour
High 70 7,000 E27 24,000
Pressure 150 16,000 E40 24,000
Sodium 250 2700 E40 24,000
1000 48,000 E40 24,000
13,000 E40 24,000
Rapid
Start 58 5,200 G13 12,000
HG TLD
Tube
Light
Remarks:
1. The high pressure mercury vapour lamps shall be milky white colour.
2. The high pressure sodium lamps shall be clean tubular type and golden
white colour.
3. The tube light specified above shall be white/33 colour, 5 feet long and 26
mm diameter.
4. Lamp thread: Tin copper or chrome plated copper.
5. Operating Voltage : 220 Volts +/- 10% at 50 Hz +/- 5%
6. At half life, the maintained luminous flux shall not be less than 75% of the
initial luminous flux.
7. The high pressure mercury vapour lamp shall conform to BS 3677: 1982.
8. The high pressure sodium vapour lamp shall conform to BS 6193: 1988.
9. Failure rate shall not exceed 3% in the first 100 burning hours.
10. Test Certificate from approved independent laboratories shall be
submitted along with the tender documents.
7/17 SPECIFICATION FOR STREET LIGHTING SERVICE CUTOUT
7/17.1 Application
The street lighting service cutout are required to be installed at the base of
columns (poles) for protecting the luminaries fixed at the top of the columns
against short circuits.
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7/17.2 Rating
The service cutout shall be rated at 380V/220V, 50 Hz. operation, at 50 deg. C
amb. temp. and 95% relative humidity.
7/17.3 Standard
The street lighting service cutout shall conform to the provisions of BS 5486 (Part
1) - 1977 or IEC 439.
7/17.4 Construction
The typical arrangement of a street lighting services cutout along-with

dimensions and materials of construction are shown in the drawings.
7/17.4.1 The street lighting service cutout shall consist of:
- Housing with cover

- Fuse carriers of required numbers
- 4 Terminal Blocks, R, Y, B, N
- 2 Brass cable glands with shrouds, for sizes mentioned in the BOQ
- 1 Knock-out for Brass cable glands, 3 c x 10 sq.mm - 4 Nylon cable
glands with shrouds of best quality, 3c x 4 sq.mm
- 1 N-terminal, 6-way 10 sq.mm
- 1 E-terminal, 6-way 10 sq.mm
Fuse Holder shall be DIN rail mounted fully insulated and capable to accept
cylindrical H.R.C. fuses of suitable rating with fuse dimensions of 10 x 38 mm.
7/17.4.2 Terminal Assembly:
4 cable terminals (3 phase and 1 neutral) shall be fixed to a high quality phenolic
fibre board, or glass fibre reinforced insulator. The dielectric strength of the
insulator shall not be less than 2 Kv/mm.
The flexural strength of the insulator shall be not less than 1000 kg/cm2 the
insulator material to be in accordance to DIN 7735 type 2081 or similar approved.
Each cable terminal assembly shall be capable of accepting 2 Nos. sector

shaped copper cables of not less than 35 mm2 each.
Each incoming and outgoing terminal shall be bolted to an electrolytically tinned

H.C.H.D. copper bar of 40 x 5 mm cross section.
Each cable terminal shall have the provision to connect and to tap off a lugged 4
mm2 phase coloured wire of not less than 10 cm. long.
The tap of wire shall be bolted on to the main terminal by using a M5 x 15 mm slit
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head screw with spring washer.
1 No. lugged tap of wire in phase colour to be provided and fitted on each
terminal.
All terminal parts to be made from materials which are not subject to develop
corrosion when used in combination with each other.
A high quality flexible phase insulating barrier shall be provided between all
terminals as well as on both sides of the end terminals. The phase barrier shall
protrude sufficiently on all sides of the terminal to ensure electrically safety.
Brass cable glands shall conform to BS 6346/1969 and shall be type BW,
complete with lock nut. They shall be mounted together with a 1 mm thick tinned
copper plate, linking them together. The copper plate shall be bonded to an
external earth stud and to the earth bar.
Neutral and earth bars shall be of nickel plated brass, accepting 10 mm2 cable
sizes. The earth bar shall be solidly bounded to the metal housing.
7/17.4.3 Housing:
The housing consists of a base plate, holding all components and glands, and a
removable cover. The material shall be electrogalvanised sheet steel, polyester
powder coated to a film thickness of min. 100 microns, against corrosion under
Dubai climatic conditions. The plate shall be 3 mm thick and the cover 1.25 mm
thick. Protection class shall be IP 44. The base plate shall have 2 Nos. rear
fixing holes of 7 mm diameter.
The cover fixing screws shall be captive. The overall dimensions are shown in
the drawing.
7/17.4.4 Testing:
The cutout shall be tested as per the provisions of BS 5486 Part 1 : 1986 and
IEC 439-1 : 1985 Clause 8, and routine test certificates shall be submitted for
Engineer’s approval.
7/17.4.5 Materials to be submitted with the offer:
Each contractor shall submit with his offer three numbers of each type of cutout
required for, and fully assembled. The materials to be accompanied by
manufacturers operating instructions.
7/18 FEEDER PILLAR SPECIFICATION
7/18.1 General
This section contains a description and the specifications for the lighting control
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panels as indicated on the drawings, described in the Bill of Quantity and as

specified herein:
The panel shall consist of a single compartment cabinet with one door opening.
All panels shall be constructed fully suitable for permanent out door installation
for the control of road way lighting. (Each control panel shall have two single
phase 40 amp MCB complying with BS 3871 : Part 1 : 1984 and connected to the
outgoing side of KWH meter suitable to supply power to a traffic control panel.)
The cabinets (Feeder Pillars) shall be constructed in a way to ensure easy

installation of a direct 3-phase KWH direct reading meter. All cabling for
connecting the meters shall be installed by the Contractor (KWH meters will be
supplied by Dubai Electricity and Water Authority and installed by the contractor)
The cabinets (Feeder Pillars) with a capacity of 210 amp and above shall be
delivered with a 3-phase, CT operated KWH meter, the meter shall be fused and
installed in the cabinet ready for operation.
The meter and CT must be approved and calibrated by the Dubai Electricity &
Water Authority prior to installation. All calibration cost to be borne by the
Contractor. A signed DEWA test report for each meter to be submitted to the
Engineer. Each complete feeder pillar must be accompanied by a copy of the
DEWA KWH meter test certificate. The copy to be placed inside the cabinet in
the drawing pocket. Each feeder pillar must be furnished with a single line “As-
Built” wiring diagram.
7/18.2 Equipment Housing
Housing shall be to standards equivalent to BS EN 60529:1991.
The enclosure shall be fabricated from high grade aluminium sheet with
thickness not less than 3 mm. The sheet aluminium enclosure shall be coated
with a thermosetting powder of an epoxy resin base modified by polyester resins.
The enclosure shall be provided with a smooth finish and excellent protection
against corrosion for 10 years maintenance free outdoor use. It should also have
excellent chemical protection properties against acid, salt, water and solvents.
All other sheet metal should be hot dip galvanised in accordance with BS 729:
1986.
The panel enclosure shall be made suitable to withstand the dynamic stresses in
the event of a short-circuit. The doors shall be Neoprene gasketed to provide
protection against the ingress of moisture and dust to degree IP55 of IEC 529.
The gasket shall be adequate to maintain this protection at 60 degree C.
ambient.
The enclosure shall have 4 louvers (ears) for diagonal ventilation. Prevention of
the ingress of dust through louvers shall be provided to maintain the degree of
protection of IP 55 of IEC 529. The colour of the enclosure must be beige (RAL
7032).
A pre-fabricated sloped canopy of suitable dimensions to protect the cabinet from

water and direct vertical sunlight shall be provided. The material shall comply
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with the requirements mentioned at Para 19/20.2.1 above
An air gap not less than 1.5 cm shall be present between the canopy and the
cabinet.
The compartment doors shall have robust weather-proof hinges of polymid type
with suitable and substantial lockable latching device. A metal pocket for the
schematic diagram and the “As-Built” diagram shall be provided in the enclosure
door. The diagram shall not be stuck to the enclosure. The enclosure door shall
have two locks of flush non-rusting type with separate keys (two numbers) to
each panel. All keys shall have the same profile and design to match all doors.
Non-rusting materials shall mean stainless steel Grade AISI 316 or gun metal.
An ultra violet resistant reinforced window with a suitable dimension

(approximately 10 cm x 10 cm) is to be supplied on the panel door opposite to the
proposed location of the KWH meter.
7/18.3 The door shall be designed in a manner that opening of 180 degree can be
attained. An anodised aluminium label, preferably dual colour, bearing “Roads &
Transport Authority” in both Arabic and English, 50 cm size in first row, and
“Street Lighting Panel” in 25 mm size for the second row shall be attached to the
door in a proper location and firmly attached with rivets. All hinges are to be gun
metal or stainless steel.
The enclosure shall be provided with a door switch-operated internal illumination

lamp circuit complete with self-contained control gear fluorescent tube suitably
protected from accidental damage and located in the top side of the panel.
The panel shall have full size neutral and earth bar completely bonded to the
main shell and connected to the door by a braided copper wire. Provision shall
be made in the enclosure to terminate the earth busbar with the earth electrode
outside the panel. The earth bar is to be tin plated copper.
Four numbers of openings in the bottom plate anchoring the feeder pillar to the
concrete foundation shall be provided. Dimension, location and size of anchor
bolts to be used is to be specified. A 3mm bakelite plate has to be included,
separating the aluminium bottom from the concrete base. The controller housing
panel shall allow building up equipment complying with IEC 439 and BS 5486
Part 1 : 1990.
The equipment mounting panel shall be hot dip galvanised steel sheet not less
than 3 mm thick epoxy coated, or 5 mm Pertinax and shall be easily installed and
removed from the front of the cabinet in assembled form. All devices and
equipment shall be accessible from the front of the panel. All hinges and locks
are to be easily removable/replaceable.
The panel shall be provided with a removable gland plate of maximum 1 mm

thickness near the bottom to fix compression type brass glands along with earth
tag. All incoming and outgoing cables shall enter and leave the cabinet at the
bottom.
Cable gland entry holes are to be factory punched and are to be the knockout
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type or sealed with appropriate rubber cover. The number of cable entry holes
shall not be less than six and shall be according to the cable size and the unused
relative dimension are to be specified by the Engineer.
The feeder pillar dimensions shall be within the range specified herein:
Height : 1000 mm (without canopy) : Dimensions +/- 10mm

Width : 750 mm “
Depth : 250 mm “
and consist of the following:
7/18.4 Contactor/AC.3
All contactor shall be provided to control simultaneously all outgoing circuits.
The remote control contactor shall be of the single coil actuated, electrically
operated, suitable to carry not less than the rated current of the main circuit
breaker at 60 degree C. ambient and shall be obtained without the use of latches
or semi-permanent magnets.
The contactor shall comply with BS 5424: Part 1: 1977 and shall be for AC3 class
duty. Rated insulation voltage for 660 V AC. The contactor shall have minimum
making and breaking capacity in accordance with utilisation category AC 3 of IEC
158-1 and shall be suitable for minimum class II intermittent duty. Ambient
operation temperature shall be in the range of -10 degree C to 90 degree C.
The contactor components must be suitable for continuous duty and for repetitive
load switching. The contactor selected shall be such that all current carrying and
live parts shall be properly shielded and it shall not be possible to come into
accidental contact with them. All contact assemblies shall be dust protected, and
an arrangement for easy removal of the coil shall be provided (Preferably slide in
type). The coils of all contactors shall be suitable for operation at a voltage of
220 +/- 10 to 15% and frequency of 50 Hz. operation. The pick up of the coil
shall be from 0.75 to 1.1 of the voltage. The operation of the contactor shall be
by means of a photocell.
7/18.5 Circuit Breaker (Incoming MCCB)
There shall be one moulded case circuit breaker for the incoming feeder to each
control panel. It must be rated for three phases, 380V A.C. 50 Hz to IEC 157-1
and BS EN 60947-2: 1992 specifications as indicated on the drawings.
Moulded case circuit breakers shall be suitable to accommodate auxiliaries and

under-voltage release. They shall be of the thermal magnetic type with a short
circuit capacity withstand of not less than 50 KA at 380V, and shall be suitable for
60 degree C. ambient temperature operation with the prevailing enclosure
condition. Pad locking facility for the MCCB shall be provided. The exposed
incoming terminals shall be provided with a suitable insulated cover up to the
equipment mounting plate in order to allow no access to the live incoming
terminals. There shall be minimum clearance of 300 mm between the incoming
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glanded cable and input terminals of the MCCB.
Bus bars shall be provided throughout the main power circuit. All bus bars are to
be tin plated copper and colour sleeved according to phase.
The capacity of the Terminal sockets for MCCB shall be 185 sq.mm stranded
Cu/A1 cables through suitable terminal tin plated copper bars.
7/18.6 Wiring and Cabling
All secondary internal wiring within the control cabinet shall be with heat resisting,
1000V hard grade PVC/XLPE Insulated copper cables, colour coded or sleeved
for easy phase identification suitable for the circuit rating, arranged neatly and
firmly attached. All the wiring leads shall be so arranged to allow current reading
with a clip-on ammeter on each phase of main incoming and all outgoing circuits.
All wiring shall be housed in wiring trunking conforming an integral part of the
enclosure whenever possible.
Bus bars shall be of the same amperage ratings at 60 degree C. ambient at

enclosure condition as the main circuit breaker and shall be made of tinned
copper flats and round bars complying with BS 159. They shall be colour
sleeved for easy phase identification and adequately supported to withstand
dynamic stresses in the event of short circuit. Exposed bus bars shall be
insulated and screened to prevent accidental contact in live conditions. An earth
or ground bar not less than 40 mm x 4 mm shall be solidly bolted with stainless
steel bolts of grade AISI 316 to the main body of the control cabinet.
Sufficient vacant area (25 cms x 30 cms minimum) shall be left for future
installation of a KWH meter. Wooden back board shall be provided for the
installation of a KWH Meter.
All wire terminals into connectors shall have wire ends or straight lugs. All the
wires selected should have the amperage rating at 60 degree ambient and
sufficient allowance for enclosure derating.
The suppliers’ attention is drawn to that fact that:
all incoming cable feeders to the panel shall be armoured, solid aluminium
conductors, 4 core, XLPE insulated and PVC over-sheathed;
all outgoing cable feeders from the panel shall be armoured, stranded copper
conductors, 4 Core, XLPE insulated and PVC over-sheathed. The outgoing
terminals shall be suitable for 2 cables of 70 mm2, 50 mm2, 35 mm2 and 25
mm2; therefore, all the connectors must be suitable to receive these types of
cable.
All output cables shall be connected through rugged terminals. All terminals shall
be designed for sector shaped stranded copper conductors. All incoming and
outgoing cables are to enter from the bottom of the enclosure and hence all the
connections must be done at the bottom and not at the sides.
All cables and wires must be colour coded as per the following detail.
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Blue, Red and Yellow for phases

Black for neutral
Green/Yellow for the earth wherever required.
7/18.7 Fuse and Fuse Base
There shall be a LV HRC system consisting of fuse boxes, fuse cartridge and
accessories complying with BS 88.
The fuse base shall be suitable for cylindrical type fuses of size 22 x 58 mm and
the base shall be of modular construction suitable for Din Rail mounting. The
bases are to be made of thermo setting, self extinguishing material rated for
100A. Metal parts, contacts and springs are to be zinc plated and passivated for
protection against corrosion. All modular fuse carriers with shielded terminals
shall be similar to Legrand 21471 single pole or equivalent.
Cylindrical cartridge type fuse links suitable for the bases are to be used. They
shall conform to IEC 269-2 and BS 1361 (1986) or DIN 43620 and shall withstand
a repture capacity of 100 KA. Fuses shall be of a low internal loss and low
internal temperature rise. All fuse are to be protected by insulating shield or
similar.
Each feeder pillar must have one number 4 Amps single phase HRC fuse with
base for the cabinet internal lamp circuit.
Each feeder pillar shall have one number single phase 20 Amps ELCB and
appropriate corrosion resistant switched socket outlet (3 pin square British type
with box pattress) as per BS 1363 (1984) appropriately located and neatly and
tightly fitted inside the enclosure.
7/18.8 Cable Glands
All cable glands shall be brass compression type cable glands complying to BS
6121 with earth tags and lock buds for XLPE/SWE/PVC/MDPE cables 4 core. All
cable glands to be supplied with matching cable sleeves.
Cable lands shall be weatherproof, with inner and outer seals suitable for steel
wire armoured cables. The contractor shall drill for the installation of the glands
where necessary.
Glands shall be fitted with PVC shrouds filled with waterproof plastic compound
and made fast to the cable with PVC tape.
Glands shall be fitted with earthing rings to allow connection of protective

conductors. The contractor shall carry out all work involved in terminating the
cables, supplying weatherproof plastic compound, PVC shrouds, tape, etc., all
7/18.9 Control System
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The switching of the lighting luminaries shall be through an automatic control

arrangement comprising of a photocell and selector switch.
Photo-Electric Switch:
The cabinet shall be equipped with a photo-electric switch of the following

specification:
The photo-electric control switch or cell for the control cabinet shall operate from
a supply voltage of 220 Volts and be rated for a load of 100 Watts. They shall be
adjustable for turning on and turning off within a range of 5-2000 lux. It shall be
suitable for operation within 0 degree to +60 degree C. temperature range. It

shall have a fail-safe feature so that the lighting remains energised in the event of
component failure. The photo-electric control switch shall be housed and
mounted inside the control cabinet. An on-off auto switch of 5 amp rating shall
be provided and properly labelled for controlling and by-passing the photo-
electric cell. A resistor type surge protection shall be provided in parallel to the
photocell switch. Photocell to be fitted inside the cabinet behind a factory made
transparent ultra violet resistant window of size 10 cm x 10 cm. The photo-
electric cell shall be fully electronically operated type.
Selector Switch
A selector switch for performing the following functions shall be provided in the
cabinet
- Auto ON/OFF
- ON
- OFF
7/18.10 Power Supply Distribution Panels-Documents and Information to be submitted
The Contractor shall submit the relevant design calculations, drawings and data
for approval prior to the fabrication of any panels, which is to include but shall not
be limited to the following:-
General dimensions of the panel anchor bolts, opening locations and gland plate
openings.
Detailed scale drawing for the fixed components in the panel including important
maintenance and operating instructions of the manufacturer.
General description of the material, manufacturing, fabrication, coating and

treatment of feeder pillar panel.
Door hinges, locks and flaps drawings (including materials).
Internal cabinet ventilation (circulation and air flow design).
Detailed general arrangement drawing.
Single line diagram.

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Chart showing yearly on/off times according to the latitude of Dubai indicated
above.
7/18.11 Testing
The cabinets and internal main circuitry shall be manufactured and tested in
accordance to the testing specifications of BS 5486 Part 1: 1990 and IEC 439-1:
1985 Clause 8.
The Contractor shall submit ASTA or KEMA tests certificates for routine and type
test from independent approved laboratories/bodies to show the compliance of
his product.
7/18.12 General
The Contractor shall submit three samples of each type of feeder pillar panel
complete with all auxiliaries and ready for installation for Engineer’s approval.
However, the approval of Engineer does not absolve the Contractor of the
contractual obligations as to the performance compliance to the specification
requirements.
All components, catalogues, manufacturers ratings, cables glands calculations

and detailed drawings are to be attached with the sample submittals.
The Contractor shall submit to Roads & Transport Authority ASTA and/or KEMA
test certificates for Feeder Pillars along with the samples.
7/18.13 Specifications for Loop Detectors
Reference to the Roads Department Circular No. 12/97 the following NEVER
FAIL LOOP SYSTEM (Performed Detectors) shall be implemented for all stop
line detectors.
The following specification and installation instructions have to be followed

carefully.
The Contractor to supply, install and test the above mentioned loops according to
the satisfaction of the Roads Lighting Section.
7/18.13.1 Loop Detectors for Temporary Works:
Specifications
* Heads and tails (lead-ins) shall be constructed of 3/8” (9.5mm) O.D.

hydraulic flex hose.
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* Heads and tails shall be completely filled with hot rubberized asphalt.
* Tees at junction of head/tail shall be schedule 80 CPVC.
* Lead-ins shall be twisted 3 times per foot minimum.
* Wire shall be 20-gauge, stranded, teflon-coated, single conductor
(Military-MIL-W-16878/4 Type E, 200 degree centigrade 600V.
* Wires shall be continuous through head and tail - no splices.
* All loops shall be tested three ways prior to shipment resistance to ground
(measured in megaohms), resistance (measured in ohms), inductance
(measured in microhenries). All test results (readings) to be sent to Dubai
identified per loop.
Installation instruction
* Mark on the ground location in Loops in accordance to STOP LINE.

* Make sure that the pavement is clean from dust and moisture.
* Open loop on the ground.
* Cut 30 cm piece tape and fold in two, then placed under TEE.
* Secure corners with strips of tape
* Cover loop with asphalt tape.
* Press tape in order to adhere with asphalt.
7/18.13.2 Loop Detectors for Permanent Works
Specification
* Loops shall be constructed from polypropylene conduit with 3/8” I.D. (9.5
mm) 5/8” O.D. (16mm).
* Conduit shall be filled with hot rubberized asphalt which allows the loop to
remain flexible once cooled, prevent incursion of moisture and set the
turns of wire firmly in place.
* Loops shall have 5” expansion/contraction joints at intervals along the
loop to allow for movement of the pavement and to prevent breakage on
the wire and/or conduit due to this movement. Each
expansion/contraction joint shall have a 9” long schedule 80
polypropylene cover slide to be placed over the joint.
* The encapsulated copper loop wire shall be 20 gauge, stranded, teflon-
coated, single conductor. (Military-MIL-W-16878/4 Type E 200 degree
centigrade, 600V Loop shall have 4 turns.
* Loop shall have one continuous wire through the loop head-in to prevent
loop malfunctions due to spicing.
* Lead-in wires shall be encased in a non-conductive 2250 psi flex hose
constructed with a seamless extruded polyester fiber braid reinforcement
and a non-conductive, seamless extruded urethans non-perforated jacket.
Fill lead-in hose completely with hot rubberized asphalt. Twist wires in all
lead-ins a minimum of three turns per foot for the entire length of the lead-
in. Attach lead-ins to loop heads with a schedule 80 CPVC tee.
* All loops shall be tested three ways prior to shipment resistance to ground
(measured in megaohms), resistance (measured in ohms), inductance
(measured in microhenries). All test results (readings) to be sent to Dubai
identified per loop.
Installation Instruction
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Loops are installed in a grove on the surface of WET-MIX or AGGREGATE

ROAD BASE (according to Road Design). Refer to the enclosed sketch.
* Remove loop from container and unfold 24 hours before installation.

Verify dimensions and test.
* Mark on the ground location of loops in accordance to design STOP LINE.
* Open loop on the ground and mark the place.
* Excavate trench 30 x 30 mm by hand tools.
* Slide sleeve over the expansion/contraction joint and tape ends of sleeve
directly to conduit.
* Place loop in the trench.
* Cover loop with Fine Asphalt mix (remove big size stones).
* Compact asphalt with hand compactors.

* Lead cable from kerbstone to manhole protect in a 1” PVC conduit.
* Protect exposed lead wires during construction.
7/18.13.3 General
For both types of installation mentioned above, the following procedures the
Contractor has to follow.
* Contractor to call the DM representative and check the received loops

before laying. The pass approval shall allow the Contractor to start
installation.
* Contractor to follow the mentioned installation instructions.
* DM to check finally that the loops have not been damaged after laying of
asphalt and completion of the works.
* The end of the lead cable to be kept safely in the nearest bypass
chamber constructed especially for the loop detectors.
* The Contractor has to take great care from day of receiving the loops to
the handing-over date to avoid any damage that may occur to the
insulation of the supplied loops.
7/19 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI
The average prevailing local conditions at Dubai City shall be assumed as

follows:
Max. Ambient Temperature 55 deg.C

Min. Ambient Temperature 1 deg.C
Design Ambient Temperature 50 deg.C
Max, incident light intensity (energy) 780 m/W/cm2
Light intensity (measured under the sun
approximately 50,000 Lux
Max. metal temperature under sun 85 Deg. C
Min. Barometric Pressure 998 mb
Max. Barometric Pressure 1030 mb
Max. Ambient Humidity 100%
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Min. Ambient Humidity 20%

Design Ambient Humidity 80%
Max. Design Wind Velocity 1 60 Km/hr.
Average Yearly Rainfall 80 to 150mm
The climate of Dubai is relatively mild from November to April, and hot from May
to October with high relative humidity.
Under certain combinations of the above climatic conditions considerable

condensation may take place.
Particular attention should be paid to the prevailing corrosion conditions. A

considerable amount of salt is contained in the atmosphere which together with
the extremely high ambient humidity, can produce severe corrosion problems.
Distribution of rainfall is irregular, and the precipitation amounts are normally of

no significance, but attention should be paid to the fact that sudden heavy
rainfalls in a very short period of time can occur.
The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr. and sandstorms and
duststorms occur in the summer months.
7/20 LIGHTING REQUIREMENT
Table 7/20.1
Luminaries Type 1000 400W 250W 250W 150W 125W

W HPSV HPSV HPMV HPSV HPMV
HPSV
No. of luminaries 4 2 1 1 1 1
per pole
Installation height 25 14 10 8 10 6
(m)
Spacing of poles 110 50 45 30 45 25
(m)
Width of the road 15 11 7.3 7.3 7.3 7.3
(m)
Number of lanes 4 3 2 2 2 2
Set back from - - 3.45 3.45 3.45 1.0
kerbline (m)
Centre median 10 6 - - - -
width (m)
Table 7/20.2
1000W 400W 250W 250W 150W

HPSV HPSV HPSV HPMV HPSV
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Average luminance level 3.0 2.5 1.5 0.8 1.0

Lav
Overall uniformity ratio Uo, 0.4 0.4 0.4 0.4 0.4
higher than
Longitudinal uniformity ratio 0.7 0.7 0.7 0.7 0.7
UI higher than
Glare control mark : G 6 6 6 6 6
Threshold increment TI 10% 10% 10% 10% 10%
7/21 Tunnel / Under Bridge Lighting System
Not included
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SECTION 8 - CONCRETE PILE FOUNDATIONS
8/1 DESCRIPTION
8/1.1 All pile foundations shall be bored cast-in-place concrete piles and shall
be constructed as indicated on the Drawings and in compliance with
these specifications.
8/2 MATERIALS
8/2.1 The materials for the manufacture of the reinforced concrete shall be in
accordance with Section 4 - "Concrete Works".
8/2.2 The temporary steel casings and the permanent casings or liners shall
be cylindrical, of the diameter indicated on the Drawings and shall be of
sufficient strength to maintain shape and location during boring and
placement of concrete. The casings shall be sufficiently watertight to
exclude ground water during placing of concrete.
8/2.3 In case drilling mud is used, bentonite, as supplied to the site and prior
to mixing shall be in accordance with Specification DFCP 4 of the Oil
Companies Materials Association.
8/3 GROUND CONDITIONS
8/3.1 Factual information and reports on site investigation for the Works will
be provided to tenderers. However, in the event that a full report is
given, including interpretations, opinions or conclusions, no
responsibility is accepted by the Employer.
8/3.2 The Contractor shall report immediately to the Engineer any

circumstances which indicates that in the Contractor's opinion the
ground conditions differ from those reported in or which could have been
inferred from the site investigation reports or trial pile results.
8/4 TOLERANCES
8/4.1 SETTING OUT
Setting out of the main grid line shall be carried out by the Contractor. The
installation of marker pins at pile positions as required by the Engineer shall be
accurate to 75 mm in any direction. An additional tolerance for a pile head cut off
below ground level will be permitted in accordance with Sub-Section 8/13.8
and/or 8/16.
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8/4.2 VERTICALITY
At the commencement of installation, the equipment governing the alignment of
the bored pile, shall be made vertical to a tolerance of within 1 to 100. The
maximum permitted deviation of the finished pile from the vertical is 1 in 75.
8/4.3 RAKE
The equipment governing the direction and angle of rake shall be set to give the
correct alignment of the pile within a tolerance of 1 in 50. The piling rig shall be
set and maintained to attain the required rake. The maximum permitted deviation
of the finished pile from the specified rake is 1 in 25 for piles raking up to 1:6 and
1 in 15 for piles raking more than 1:6 .
8/4.4 FORCIBLE CORRECTIONS TO PILES
Forcible corrections to concrete piles to overcome errors of position or alignment

shall not be made. Forcible corrections may be made to other piles only if
approved and where the pile shaft is not fully embedded in the soil.
8/5 PILING METHOD AND PROGRAMME
8/5.1 The Contractor shall supply for approval all relevant details of the
method of piling and the plant he proposes to use. Any alternative
method to that specified shall be subject to approval.
8/5.2 The Contractor shall inform the Engineer each day of the intended
programme of piling for the following day and shall give adequate notice
of his intention to work outside normal hours and Public Holidays.
8/5.3 The Contractor shall submit to the Engineer his proposed sequence and
timing for boring piles, having regard to the avoidance of damage to
adjacent piles.
8/5.4 Any proposals by the Contractor for ground treatment of any nature or
for temporary lowering of the water table by well pointing or any other
method shall be subject to the approval of the Engineer. The Contractor
shall however remain fully responsible for any effects of such ground
treatment or control of the level of water tables upon the existing roads,
building and structures in the vicinity of works.
8/5.5 Any proposals by the Contractor for underpinning, needling and shoring
of existing structures in the vicinity of the works shall be carefully
designed by the Contractor and be subject to approval of the Engineer.
8/6 PILING RECORDS
8/6.1 The Contractor shall keep records as follows for the installation of each
pile and shall submit two signed copies of these records to the Engineer
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not later than noon of the next working day after the pile was installed.
The signed records will form a record of the work.
Any unexpected boring conditions shall be noted in the records.
DATA TO BE RECORDED
a. Contract
b. Pile reference number (location)
c. Pile type
d. Nominal cross-sectional dimensions or diameter.
e. Nominal diameter of underream/base.
f. Standing groundwater level from direct observation or given site
investigation data.
g. Date and time of boring.
h. Date of concreting
i. Ground level at pile position at commencement of installation of pile
(commencing surface).
j. Working level on which piling base machine stands
k. Depth from ground level at pile position to pile to
l. Toe level.
m. Pile head level as constructed.
n. Pile Cut-off level.
o. Length of temporary casing
p. Length of permanent casing.
q. Soil samples taken and in situ tests carried out during pile formation or
adjacent to pile position.
r. Length and details of reinforcement.
s. Concrete mix.
t. Volume of concrete supplied to pile where this can be measured in
practice.
u. All information regarding obstruction delays and other interruptions to the
sequence of work.
8/7 DAMAGE TO ADJACENT SERVICES AND STRUCTURES
8/7.1 If damage will be, or is likely to be, caused to mains, services or

adjacent structures, the Contractor shall submit to the Engineer his
proposals for making surveys, monitoring movements or vibrations, and
minimising or avoiding such damage.
8/7.2 The Contractor shall carry out the work in such a manner and at such
times so as to minimize noise and disturbance.
8/8 CONCRETE FOR PILES
8/8.1 Concrete for piles shall be Class 30 or as shown on the drawings and
shall be in accordance with Section 4 of the Specification and the
following requirements:
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8/8.2 When a designed mix is specified the Contractor shall be responsible for
selecting the mix proportions to achieve the required strength and
workability, but the Engineer will be responsible for specifying the
minimum cement content and any other properties required to ensure

durability.
8/8.3 The Concrete shall have sufficient workability to enable it to be placed

and compacted by the methods used in forming the piles.
8/8.4 For piles exposed to potentially aggressive ground or groundwater,

approved measures shall be taken to ensure durability. Reference
should be made to Building Research Establishment Design 363
published in the U.K. relating to sulphate attack.
8/8.5 The cement content in any mix shall not be less than 360 kg/CU.m.
Where concrete is to be placed under water or drilling mud by tremie the
cement content shall be not less than 380 kg/CU.m., or where the pile
will be exposed to sea water 400 kg/CU.m.
8/8.6 All concrete aggregates, cement and water shall be sampled and tested
as frequently as deemed necessary by the Engineer as detailed under
the relevant clauses in section 4 concrete work. All test samples shall be
supplied by the Contractor at his own expense.
8/8.7 Trial mixes shall be prepared for concrete in accordance with BS 5328,
showing that the proposed mix proportions and manufacture will
produce a concrete of the strength and quality required, having
adequate workability for compaction by the method to be used in
placing.
8/8.8 The Contractor shall keep a detailed record of the results of all tests on
concrete and concrete materials. Each test shall be clearly identified
with the piles to which it relates
8/9 REINFORCEMENT FOR PILES
8/9.1 The reinforcement for the piles shall conform to the requirement of
SECTION 4 of the specification.
8/9.2 Reinforcement in the form of a cage shall be assembled with additional

support, such as spreader forks and lacings, necessary to form a cage
which can be lifted and placed without permanent disortion. Intersecting
bars shall be fixed together by approved means. Hoops, links or helical
reinforcement shall fit closely around the main longitudinal bars and be
bound to them by approved wire, the ends of which shall be turned into
the interior of the pile. Reinforcement shall be placed and maintained in
position to provide the specified projection of reinforcement above the
final cut-off level.
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8/9.3 The cover to all reinforcement in cast-in-place piles shall be not less
than 75mm unless otherwise approved by the Engineer. Spacers shall
be designed and manufactured using durable materials which will not
lead to corrosion of the reinforcement or spalling of the concrete cover.
8/9.4 The number of laps in longitudinal steel bars shall be kept to a minimum.
Joints in reinforcement shall be such that the full strength of each bar is
effective across the joint and shall be made so that there is no
detrimental displacement of the reinforcement during the construction of
the pile.
8/10 BORING FOR PILES
8/10.1 Prior to boring the Contractor shall check the casing position for each
pile during and immediately after placing the casing, and agree it with
the Engineer.
8/10.2 Where the open bore is unstable, temporary casing or bentonite

suspension may be used to support the wall of the bore prior to
concreting.
8/10.3 Piles shall not be bored so close to other piles which have recently been
cast and which contain workable or unset concrete that a flow of
concrete could be induced from or damage caused to any of the piles.
8/10.4 The Contractor shall carry out the work in such a manner and at such
times as to minimise noise and disturbance.
8/10.5 Any proposals by the Contractor for ground treatment of any nature or
for temporary lowering of the water table by well pointing or any other
method shall be subject to the approval of the Engineer. The Contractor
shall however remain fully responsible for any effects of such ground
treatment or control of the level of water tables upon the existing roads,
buildings and structures in the vicinity of the Works.
8/10.6 Any proposals by the Contractor for underpinning, needling, and shoring
structures in the vicinity of the works shall be carefully designed by the
Contractor and be subject to the approval of the Engineer.
8/10.7 Temporary casings shall be free from significant disortion. They shall be
of uniform cross-section throughout each continuous length. During
concreting they shall be free from internal projections and encrusted
concrete which might adversely affect the proper formation of piles.
8/10.8 Where piles are bored under water or bentonite suspension in an

unlined state, the insertion of a full-length loosely fitting casing to the
bottom of the bore prior to placing concrete will not be permitted.
8/10.9 Where boring takes place through unstable water bearing strata, the
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process of excavation and the depth of temporary casing employed shall

be such that soil from outside the area of the pile is not drawn into the
pile section and cavities are not created outside the temporary casing as
it is advanced.
8/10.10 Where the use of drilling fluid is specified or approved for maintaining the
stability of a bore, an adequate temporary casing shall be used in
conjunction with the method so as to ensure stability of the strata near

ground level until concrete has been placed. During construction the
level of drilling fluid in the pile excavation shall be maintained within the
cased or stable bore so that it is not less than 1.0 m above the level of
external standing groundwater at all times.
In the event of rapid loss of drilling fluid from a pile excavation, the bore shall be
backfilled without delay and the instruction of the Engineer shall be obtained
before boring at that location is resumed.
8/10.11 All reasonable steps shall be taken to prevent the spillage of bentonite
suspension on the Site in areas outside the immediate vicinity of boring.
Discarded bentonite shall be removed from the Site without undue
delay. Any disposal of the bentonite shall comply with the regulations of
the Dubai Municipality.
8/10.12 Pumping from pile bores shall not be permitted unless the bore has been
sealed against further water entry by casing or unless the soil is stable
and will allow pumping to take place without ground disturbance below
or around the pile.
8/10.13 For a pile constructed in a stable cohesive soil without the use of
temporary casing or other form of support, the pile shall be bored and
concrete shall be placed without such delay as would lead to significant
impairment of the soil strength.
8/10.14 Each pile bore which does not contain standing water or drilling fluid shall
be inspected directly or indirectly prior to concrete being placed in it.
This inspection shall be carried out from the ground surface in the case
of piles of less than 750mm diameter. Torches or other approved means
of lighting, measuring tapes, and a means of measuring verticality shall
be provided. For piles of 750mm diameter or larger, equipment shall be
provided by the Contractor to enable his representative and the
Engineer to descend into the bore for the purpose of inspection. Any
method of descent and the equipment used shall comply with the
8/10.15 On completion of boring and where inspection of a dry pile bore indicates
the necessity, loose disturbed or softened soil shall be removed from the
bore. Where pile bores contain water or drilling fluid, a cleaning process
shall be employed before concrete is placed. Large debris/or
accumulated sediment shall be removed using appropriate approved
methods, which shall be designed to clean while at the same time
minimising ground disturbance below the pile bases. Water or drilling
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fluid shall be maintained at such levels throughout and following the

cleaning operation that stability of the bore is preserved.
8/11 DRILLING FLUID
8/11.1 Bentonite, as supplied to the Site and prior to mixing, shall be in

accordance with Specification DFCP 4 of the Oil Companies Materials
Association.
8/11.2 A certificate shall be obtained by the Contractor from the manufacture of

the bentonite powder, showing the properties of each consignment
delivered to the Site. This certificate shall be made available to the
Engineer on request.
The properties to be given by the manufacturer are the apparent viscosity range
(in centipoises) and the gel strength range (in newtons per square metre) for
solids in water.
8/11.3 Bentonite shall be mixed thoroughly with clean fresh water to make a
suspension which will maintain the stability of the pile bore for the period
necessary to place concrete and complete construction. The
temperature of the water used in mixing the bentonite suspension, and
of the suspension when supplied to the borehole, shall be not lower than
5 deg. C.
8/11.4 Where saline or chemically contaminated groundwater occurs, special

precautions shall be taken to modify the bentonite suspension or
prehydrate the bentonite in fresh water so as to render it suitable in all
respects for the construction of piles.
8/11.5 The frequency of testing drilling fluid and the method and procedure of
sampling shall be proposed by the Contractor for approval prior to the
commencement of the work. The frequency may subsequently be varied
as required, depending on the consistency of the results obtained,
subject to approval.
Control tests shall be carried out on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be measured
daily as a check on the quality of suspension being formed. The measuring
device shall be calibrated to read to within 5g/L. Tests to determine density,
viscosity, shear strength and pH value shall be applied to bentonite supplied to
the pile bore. For average soil conditions the results shall generally be within the
ranges in Table 1.
The tests shall be carried out until consistent working pattern has been
established, account being taken of the mixing process, any blending of freshly
mixed bentonite suspension and previously used bentonite suspension. When
the results show consistent behaviour, the tests for shear strength and pH value
may be discontinued, and tests to determine density and viscosity shall be
carried out as agreed with the Engineer. In the event of a change in the
established working pattern, tests for shear strength and pH value shall be
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reintroduced for a period if required.
TABLE 1
Property to be Range of results Test Method

measured at 20 deg. C
Density Less than 1.10g/ml Mud density balance

Viscosity 30-90s Marsh cone method
or
less than 20 cP Fann Viscometer
Shear strength 1.4-10N/Sq.m. Fann Viscometer
or
4-40N/Sq.m. Fann Viscometer
pH 9.5 - 12 pH indicator paper strips
or electrical pH meter
The testing methods pertaining to the above table should confirm to API-RP13B
(standard procedure for testing drilling fuilds)
* Where the Fann Viscometer is specified, the fluid sample should be screened by a
number 52 sieve (300 u) prior to testing.
8/12 PLACING CONCRETE
8/12.1 The method of placing and workability of the concrete shall be such that
a continuous monolithic concrete shaft of the full cross-section is
formed.
8/12.2 The concrete shall be placed without such interruption as would allow
the previously placed batch to have hardened. The method of placing
shall be approved.
8/12.3 The Contractor shall take all precautions in the design of the mix and
placing of concrete to avoid arching of the concrete in temporary casing.
No soil, liquid or other foreign matter which would adversely affect the
performance of the piles shall be permitted to contaminate the concrete.
8/12.4 Slump measured at the time of discharge into the pile bore shall be in
accordance with the standards shown in table 2.
The concrete shall be of the workability approved when in its final position and
shall remain sufficiently workable for all pile construction procedures to be safely
completed.
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TABLE 2
Piling Mix Slump

Workability Minimum Range Typical conditions of Use
mm mm
A 75.00 75-150 Placed into water free permanently

lined bore of 600mm dia. or over, or
where casing level lies below temporary
casing; reinforcement widely spaced,
leaving ample room for free movement
of concrete between bars.
B 100.00 100-200 Where reinforcement is not spaced
widely; where cut-off level of concrete
is within temporary casing; where pile
bore is water-free and the diameter is
less than 600mm.
C 150.00 150 or Where concrete is to be placed by
more tremie under water or drilling mud or by
pumping.
8/12.5 Internal Vibrators shall not be used to compact concrete.
8/12.6 Approved measures shall be taken to ensure that the structural strength
of concrete placed in all piles is not impaired through grout loss,
segregation or bleeding. Concrete shall be directed vertically into the
centre of each vertical pile so that grout is not lost from the initial
discharge.
8/12.7 Before placing concrete, measures shall be taken to ensure that there is
no accumulation of silt or other material at the base of the boring, and
the Contractor shall ensure that heavily contaminated bentonite
suspension, which could impair the free flow of concrete from the tremie
pipe, has not accumulated in the bottom of the hole.
8/12.8 Concrete to be placed under water or drilling fluid shall be placed by

tremie and shall not be discharged freely into the water or drilling fluid.
Pumping of concrete may be approved where appropriate.
8/12.9 A sample of the bentonite suspension shall be taken from the base of
the boring using an approved sampling device. If the specific gravity of
the suspension exceeds 1.20 the placing of concrete shall not proceed.
In this event the Contractor shall modify or replace the bentonite as
approved to meet the Specification.
8/12.10The concrete shall be a rich coherent mix of high workability and cement
in accordance with Subsection 8/8.5 and mix C, Table 2. The concrete
shall be placed in such a manner that segregation does not occur.
8/12.11The hopper and pipe of the tremie shall be clean and watertight
throughout. The pipe shall extend to the base of the bore and a sliding
plug or barrier shall be placed in the pipe to prevent direct contact
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between the first charge of concrete in the tremie and the water or
drilling fluid. The pipe shall at all times penetrate the concrete which has
previously been placed and shall not be withdrawn from the concrete
until completion of concreting. A sufficient quantity of concrete shall be
maintained within the pipe to ensure that the pressure from it exceeds
that from the water drilling fluid. The internal diameter of the pipe of the
tremie shall be not less than 150 mm for concrete made with 20mm
aggregate. It shall be so designed that external projections are
minimised, allowing the tremie to pass within reinforcing cages without
causing damage. The internal face of the pipe of the tremie shall be free
from projections.
8/12.9 A sample of the bentonite suspension shall be taken from the base of
the boring using an approved sampling device. If the specific gravity of
the suspension exceeds 1.20 the placing of concrete shall not proceed.
In this event the Contractor shall modify or replace the bentonite as
approved to meet the Specification.
8/12.10 The concrete shall be a rich coherent mix of high workability and cement
in accordance with Subsection 8/8.5 and mix C, Table 2. The concrete
shall be placed in such a manner that segregation does not occur.
8/12.11 The hopper and pipe of the tremie shall be clean and watertight
throughout. The pipe shall extend to the base of the bore and a sliding
plug or barrier shall be placed in the pipe to prevent direct contact
between the first charge of concrete in the tremie and the water or
drilling fluid. The pipe shall at all times penetrate the concrete which has
previously been placed and shall not be withdrawn from the concrete
until completion of concreting. A sufficient quantity of concrete shall be
maintained within the pipe to ensure that the pressure from it exceeds
that from the water drilling fluid. The internal diameter of the pipe of the
tremie shall be not less than 150 mm for concrete made with 20mm
aggregate. It shall be so designed that external projections are
minimised, allowing the tremie to pass within reinforcing cages without
causing damage. The internal face of the pipe of the tremie shall be free
from projections.
8/12.12 No concrete shall be placed until all driving within a radius of 4.5 meters
has been completed, nor until all the shells for any one cluster have
been completely driven. If this cannot be done, all driving within above
limits shall be discontinued until the concrete in the last pile cast, has
been set for at least seven days.
8/12.13 Unless designated as basement piles all piles shall be placed with their
tops at least 1 metre above pile cut-off level in their respective pile caps.
All boreholes, except for basement piles or unless otherwise specified,
shall be filled with concrete to the top of the hole so that the Engineer
can be assured that all the bentonite has been displaced by the
concrete.
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8/13 EXTRACTION OF CASING
8/13.1 Temporary casings shall be extracted while the concrete within them
remains sufficiently workable to ensure that the concrete is not lifted.
During extraction the motion of the casing shall be maintained in an axial
direction relative to the pile.
8/13.2 When the casing is being extracted, a sufficient quantity of concrete

shall be maintained within it to ensure that pressure from external water,
drilling fluid or soil is exceeded and that the pile is neither reduced in
section nor contaminated.
8/13.3 The concrete level within a temporary casing shall be topped up where
necessary during the course of casing extraction in such a way that the
base of the casing is always below the concrete surface until the casting
of the pile has been completed.
8/13.4 Adequate precautions shall be taken in all cases where excess heads of
water or drilling fluid could occur as the casing is withdrawn because of
the displacement of water or fluid by the concrete as it flows into its final
position against the walls of the pile bore. Where two or more
discontinuous lengths of casing (double casing) are used in the
construction the proposed method of working shall be approved by the
Engineer.
8/13.5 For piles cast in dry bores using temporary casing and without the use of
a permanent lining, pile heads shall be cast to a level above the
specified cut-off so that, after trimming, a sound concrete connection
with the pile can be made. The casing level shall be within the tolerance
above the cut-off level shown in Table 3 but shall not be above the
commencing surface level. No pile shall be cast with its head below
standing water level unless approved measures are taken to prevent
inflow of water causing segregation of the concrete as temporary casing
is extracted; and where applicable, the standing water level for each pile
shall be agreed with the Engineer, and this level is to be treated as the
cut-off level for the purpose of calculating tolerance.
8/13.6 For piles cast in dry bores within the permanent lining tubes or
permanent casings, or where their cut-off levels are in stable ground
below the base of any casing used, pile heads shall be cast to a level
above the specified cut-off so that, after trimming, a sound concrete
connection with the pile can be made. The casting level shall be within
the tolerance above the cut-off level shown in Table 4, but shall not be
above the commencing surface level.
8/13.7 For piles cast under water or drilling fluid, the pile heads shall be cast to
a level above the specified cut-off so that, after trimming to remove all
debris and contaminated concrete, a sound concrete connection with the
pile can be made. The casing level shall be within the tolerance above
the cut-off level shown in Table 5, but shall not be above the
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commencing surface level. Cut-off levels may be specified below the

standing groundwater level, and where this condition applies the
borehole fluid level shall not be reduced below the standing groundwater
level until the concrete has set.
8/13.8 Where the cut-off level of piles lies at depths greater than 10m below the
commencing surface, than the tolerances given in Tables 3 - 5 will be
varied after discussion with the Contractor and before commencement
of the piling to take account of the special conditions which apply.
8/13.9 During extraction of temporary casings, where circumstances are such

that newly placed unset concrete is brought into contact with external
groundwater, precautions shall be taken to ensure that the internal
concrete pressure at all levels within the pile exceeds the external
groundwater pressure.
TABLE 3 Casting tolerance above cut-off level for piles cast in dry bores sing
temporary casing and without the use of a permanent lining.
Cut-off distance below Casting tolerance above

commencing surface H,m Cut-off Level m
0.3+H/12+C/8
0.15 - 10.00 Where C=length of
temporary casing below
the commencing surface *
* If H is greater than C this tolerance is no longer applicable and the tolerances in

Table 4 will apply.
TABLE 4 Casting tolerance above cut-off level for piles cast in dry bores
within permanent lining tubes or permanent casings, or where
their cut-off levels are in stable ground below the base of any
casing used.

0.15 - 10.00 0.3+H/10
TABLE 5 Casting tolerance above Cut-off level for piles cast under water or drilling fluid*.

0.15 - 10.00 1.0+H/12+C/8
Where C=length of
temporary casing below
the commencing surface
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In cases where a pile is cast so that the cut-off is within a permanent lining tube,
the appropriate tolerance is given by deletion of the casing term C/8 in the table.
8/14 TEMPORARY BACKFILLING
8/14.1 After each pile has been cast, any empty bore remaining shall be
protected and shall be carefully backfilled as soon as possible with the
approved materials.
8/15 DISPOSAL OF EXCAVATED MATERIAL
8/15.1 Disposal of excavated material shall be carried out by the Contractor as

necessary to facilitate the works and to the satisfaction of the Engineer.
8/16 CUTTING OFF PILE HEADS
8/16.1 When cutting off and trimming piles to the specified cut-off level, the
Contractor shall take care to avoid shattering or otherwise damaging the
rest of the pile. Any cracked or defective concrete shall be cut away and
the pile repaired in an approved manner to provide a full and sound
section at the cut-off level.
8/17 INTEGRITY TESTING OF PILES
All testing shall be carried out as per Laboratory Testing Clause.
8/17.1 Where integrity-testing is called for but the method is not specified, the
method to be adopted shall be approved by the Engineer and shall be
one of the following:
a. Sonic Method - ASTM – D 5882: 1996

b. Vibration Method - ASTM – D 4945: 1996
c. Sonic Logging - ICE – Section9 : 1996
8/17.2 Other methods may be adopted to the approval of the Engineer and
subject to satisfactory evidence of performance.
8/17.3 In the cast-in-place concrete piles, integrity tests shall not be carried out
until 7 days or more have elapsed since pile-casting unless otherwise
approved.
8/17.4 Where the method of testing requires the positioning of sensing

equipment on the pile head, the head shall be clean, free from water,
laitence, loose concrete, overspilled concrete and blinding concrete, and
readily accessible for the purpose of testing.
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8/17.5 The testing shall be carried out by an approved specialist firm in

accordance with the DM Administrative Decision No.(160) for year 2000.
8/17.6 The interpretation of tests shall be carried out by competent persons and
the full test results and findings shall normally be given to the engineer
within 10 days of the completion of each phase of testing. Full details of
the ground conditions and construction method shall be made available
to the specialist firm when required in order to facilitate interpretation of
the tests.
8/18 LOADING TESTS
8/18.1 Each test pile and working pile to be tested shall be loaded axially to 2.0
times and 1.5 times the working load respectively as specified on the
Drawings. The tests shall not be commenced until the concrete has
reached 90% of its design strength and shall be maintained on the pile
as aforementioned or for such further period as the Engineer may direct.
8/18.2 Loading tests shall be carried out at the date ordered on individual piles
selected by the Engineer.
8/18.3 Piles selected by the Engineer shall be tested as follows:
(a) The test load shall be applied by a method approved by the Engineer and
shall be measured within an accuracy of 2 percent. Settlements shall be
measured within an accuracy of 0.25mm.
(b) The test load and unloading shall be applied in suitable increments and
as smoothly and expeditiously as possible.
(c) The load after each increment shall be kept constant until the rate of
settlement does not exceed 0.25 mm per hour.
(d) The amount of settlement shall be recorded before the next load
increment.
(e) The full test load shall be maintained for 48 hours and the total settlement
recorded.
(f) The load after each reduction shall be kept constant until the rate of
recovery does not exceed 0.25 mm per hour.
(g) The amount of recovery shall be recorded before the next load reduction.
(h) The Contractor shall, within 24 hours of the completion of the test, submit
to the engineer for each pile tested graphs showing :
- Load and settlement plotted above and below a common base line
of time
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- Settlement and recovery plotted vertically against a base line of

time.
(i) The settlement of the pile under the test load and the recovery of the pile
after its subsequent removal shall be within the limits agreed with the
Engineer.
8/18.4 The temporary caps will be cut away and the debris removed by the
Contractor.
8/18.5 The Contractor shall keep detailed records in collaboration with the
Engineer of the settlement and recovery of the pile as the increment of
load are applied and removed respectively.
8/18.6 The Contractor shall provide the Engineer with two copies of his records
of each test.
8/18.7 If the tests indicate that, in the opinion of the Engineer, the piles are
unsatisfactory for the working load, the Contractor shall at his own
expense replace the tested pile in a suitable position and if necessary
support to be given to the structure to be carried.
8/18.8 The Contractor shall bear the cost of any additional work made
necessary as a result of the unsatisfactory pile or piles. The Contractor
shall also satisfy the Engineer that any piles constructed prior and
subsequent to the results of the tests being known are capable of
carrying the specified working load. Further tests shall be carried out, if
required by the engineer, and any piles deemed to be unsatisfactory by
the Engineer shall be replaced or augmented by further piles. No extra
cost will be accepted or extension of time granted in connection with the
foregoing work.
8/18.9 The Contractor shall state in his proposals the measures he intends to
take if the ultimate load of any pile fails to reach the required value
under the loading test, with regard to lengthening, redriving and retesting
of the test pile, and also to the provision of additional piling to augment
or replace the tested pile. No extra cost will be accepted or extension of
time granted in connection with the foregoing work.
8/18.9 The Contractor shall state in his proposals the measures he intends to
take if the ultimate load of any pile fails to reach the required value
under the loading test, with regard to lengthening, redriving and retesting
of the test pile, and also to the provision of additional piling to augment
or replace the tested pile. No extra cost will be accepted or extension of
time granted in connection with the foregoing work.
8/19 FAILURE OF PILE
8/19.1 A pile shall be considered to have failed when any of the following
conditions apply:
- On completion of a load test, the residual settlement after rebound
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exceeds 6 mm.
- The test load as specified in the contract shall not have been achieved.
- The maximum settlement exceeds 10 % of the least lateral dimension of

the pile under ultimate load.
8/20 RECTIFICATION OF FAILURE
8/20.1 In the event of a pile failing a load test, notwithstanding any contrary
proposals by the Contractor, the Engineer may insist on the following
methods of rectification (as a minimum) :
- When a trial pile - an additional trial pile shall be driven as directed by the
Engineer and tested. If this second trial pile fails, the Engineer shall order
such changes in the design of the pile as he considers necessary.
- When part of the main piling operation - a further pile in the same group
shall be tested. If this second test pile fails, the Engineer shall order such
changes in the design of the pile/pile group as he considers necessary.
8/20.2 In the case of the first pile of the main piling operation failing a test load,
but subsequent piles passing the load test, a new pile shall be driven to
replace the defective pile in a position agreed by the Engineer at the
expense of the Contractor.
8.20.3 In the event of additional works being carried out as a result of new piles
being required under this Clause, the cost of this additional work will be
at the expense of the Contractor.
8/21 PROTECTION OF PILING FROM CHEMICAL ATTACK
8/21.1 All Piles shall have protective sleeve for a minimum depth of 3 m below
the cut-off level of the pile. This sleeve shall be plastic or metal bedded
in mastic to form a fully water-proofed seal to the concrete.
8/22 CLEARANCE OF WORKS
8/22.1 Upon the completion of the works the Contractor shall clear away and
remove from the Site all constructional plant, equipment, surplus
materials, rubbish, etc. and leave the whole of the Site and Works clean
and in perfect condition to the satisfaction of the Engineer.
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APPENDIX “A”
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APPENDIX “A1”
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CONTINUATION OF APPENDIX “A1”
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APPENDIX “A2”
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APPENDIX B
LABORATORY TESTS WHICH MAY BE CARRIED OUT BY

INDEPENDENT LABORATORIES
Laboratory Tests which may be carried out by independent laboratories accredited in

accordance with DM - Dubai Central Laboratory accreditation requirements.
SR Name of Test Test Method

No.
(1)* Determination of insitu Density Test by Sand Replacement BS 1377 : 1990
Method Suitable for Fine and Medium Grained Soils. (Small Part 9 Clause 2.1
Pouring Cylinder Method).
(2)* Determination of insitu Density Test by Sand Replacement BS 1377 : 1990
Method Suitable for Fine, Medium and Coarse Grained Part 9 Clause 2.2
Soils. (Large Pouring Cylinder Method)
(3)* Determination of Dry Density-Moisture Content BS 1377 : 1990 Part
Relationship Using 4.5 kg Rammer for Soils with Particles 4 Test 3.5
up to Medium - Gravel Size
(4)* Determination of Dry Density - Moisture Content BS 1377 : 1990 Part
Relationship Using 4.5 kg Rammer for Soils with some 4 Test 3.6
Coarse Gravel - Size Particles
(5) Method for determination of Compressive Strength of BS 1881 : 1983 Part
Concrete Cubes 116
(6) Determination of the Compressive Strength of Pre-Cast BS 6073 : 1981

Concrete Masonry Units. Parts 1 & 2
(7) Determination of the Compressive Strength of pre-cast BS 6717 : 1986 Part
concrete paving blocks 1
(8) Determination of Block Density BS 6073 : 1981 Part
2
(9) Measurement of Dimension of Precast Concrete Masonry BS 6073 : 1981 Part
Units 1
(10) Measurement of Dimension of Precast Concrete Paving BS 6717 : 1986 Part
Blocks 1
(11) Determination of Chloride Content in Concrete Blocks BS 1881 : 1988 Part
124
(12) Any other testing which is required under for certification of blocks as per Dubai
Municipality regulations
(13) Any other testing which is required under the contract and cannot be carried out by
the Dubai Municipality’s Dubai Central Laboratory.
* For road works, the above test (1), (2), (3) and (4) may be carried out at an independent
accredited laboratory only for earthworks and filling outside the road corridor.
Note : The most recent edition of any test method standard shall always be adopted by the
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laboratory unless otherwise required by Dubai Municipality.
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APPENDIX C
EQUIPMENT FOR THE ENGINEER’S OFFICE

The Contractor shall provide and maintain for the Engineer’s exclusive use surveying equipment
and consumables which shall include the following:
SL. No. DESCRIPTION QUANTITY REQUIRED

Theodolite with direct reading to 1 sec of arc. Complete
1. 1 No.
with tripod
Wild TC-1610 VIP total sttion with module reader REC
2.
build with 3 prisms and accessories or similar 1 No
Reflectors (Prism) for above distance measuring device
4. with 2 No. x three prism holder and 2 No. x single prism
6 Nos.
holder
5. Battery and charger for total station equipment 2 Nos.
6. External Car battery cable 1 No.
Automatic level – Wild NAK 2 or similar complete with
7. 1 No.
tripod7
8. 4 metre Sectional staff 2 Nos.
9. Parallel plate micrometer for above NAK 2 2 Nos.
10. Plumbing pole 2 Nos.
11. Tribrach with optical plumnet and tripod 5 Nos.
12. Target (with carrier) 4 Nos.
13. Double prism optical square 1 No.
14. Prismatic Compass 1 No.
15. Ranging road (2.5 m long) with stands 6 Nos.
Sheradised plastic coated graduated steel measuring
16. 1 No
band 100 m long
17. 50 mm long steel measuring band similar to above 1 No.
18. 30 m long fibreglass measuring tape 1 No.
19. 5 m long measuring tape 1 No.
20. 3 m long measuring tapes - As required
21. Tape repair kit 1 No.
22. 1 mtr long precise spirit level 1 No
23. 1 Kg Plumb bob 1 No.
24. Survey umbrella 1 No.
25. 3 Kg. Hammers 1 No.
26. Chaining arrows 5 Nos.
27. Level plate 2 Nos.
28. Not Used
29. Red and White Survey Flags 5 Nos.
30. Casela wet and dry thermometer 1 No.
31. Manhole lifting keys for:
Heavy duty covers 1 No.
Medium duty covers 1 No
Light duty covers 1 No.
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32. Weatherproof rubber coated torches 1 No.

33. Safety Equipment: Helmets, Harnesses etc. - as required
34. Consumables Wooden survey pegs, Steel survey pins, nails various sizes,
marking chalk, paint and paint brushes, surveyors field books, other
stationery items such as pens, pencils, writing pads, books etc
MISCELLANEOUS TESTING EQUIPMENT TO BE PROVIDED FOR THE USE OF THE ENGINEER
In addition to the furnishings and equipment scheduled before the following equipment for recording
and testing materials shall also be provided: -
Sl.No. Test Equipment Required to

Test in Accordance With:
1. Determination of Surface 3 m straight edge with calibrated wedge
2. Cover to Reinforcement Concrete Cover Meter
3. Record of Temperature Maximum – Minimum Thermometer
Asphalt Thermometer (2 No.)
Concrete Thermometer (4 Nos.)
4. Picks, Shovels, Spades, Trowels, Chisels, 1
Kg. Hammers (2 each)
5. Screwdriver, Pillars, adjustable spanner (2
each)
6. Sieve Brush, Wire brush, Soft brustle brush
(2 No. each)
7. Preparation and curing of 150 Cube moulds to Part 108 and curing Tanks
mm concrete test cubes to Part 111 of BS 1881. Sufficient capacity
shall be provided to hold the cubes from 1
months concrete production at peak
production rates. (The curing tanks shall be
maintained in a secure location under the
sole control of the Engineer or shall have
lockable covers).
8. Concrete Slump Test 3 sets of equipment to BS 1881 Part 102.
9. Determination of surface UK Transport and Road Research
regularity of road pavement Laboratory (TRRL) Rolling Straight Edge.
(Not required for Arterial Roads,
Expressways and Freeways).
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ROADS AND UTILITIES

VOLUME 2 – PART II
PARTICULAR SPECIFICATIONS

20010410
JUNE, 2022
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications

Volume 2 – Part VI Particular Specifications for Fire Fighting

Works

Architectural
Volume 2 – Part VIII Building General Specifications – MEPF
Volume 5 Soil Investigation Report and Project

Environmental and Health & Safety Requirement
AE7 PROJECT NO. 20010410 i REV 1 – ISSUED FOR CONSTRUCTION

VOLUME 2 – PART II DATE OF ISSUE: 16 JUNE, 2022
DUBAI – UAE
Project: 20010410
District One – Phase 3B – 3B Extension and 3C
Roads and Utilities
Volume 2 – Part II
CONTENTS
SECTION 1 – GENERAL ......................................................................................................... 2

1/1 TO 1/30 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS ....... 2
1/31 PC-COMPATIBLE CONSTRUCTION SCHEDULING SYSTEM ......................................... 4
1/32 PROJECT MILESTONES ...................................................................................................... 15
1/33 SITE AVAILABILITY ............................................................................................................... 15
1/34 ALTERNATIVE ........................................................................................................................ 16
1/35 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS.............. 16
1/35.1 CONTRACTOR SUPPLIED MATERIAL...................................................................... 17
1/36.5 WELDING ......................................................................................................................... 17
1/36.6 COATING ......................................................................................................................... 18
1/36.7 DESIGN PERIMETERS ................................................................................................. 18
SECTION 2 - SITE CLEARANCE AND EARTHWORKS ........................................................ 19
2/1 TO 2/26 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS........ 19
2/25 NOT USED ............................................................................................................................... 20
2/26 PREVIOUS STRUCTURE BACKFILL ................................................................................. 20
SECTION 3 – PAVEMENT CONSTRUCTION ......................................................................... 24
3/1 TO 3/47 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS .. 24

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3/33 PLACING OF THE MIX .......................................................................................................... 24

3/33.4 SPREADING AND FINISHING ..................................................................................... 24
3/33.6 JOINTS ............................................................................................................................. 25
3/37.8 ADDITIONAL TEXT FOLLOWING THE WORD “PERMITTED” .............................. 25
3/43.4 ADDITIONAL TEXT FOLLOWING SECTION 4/43.3 OF THE GENERAL
SPECIFICATION. ................................................................................................................................... 25
3/47.3 REPLACE THE FOLLOWING TEXT: .......................................................................... 25
SECTION 4 - CONCRETE WORKS ........................................................................................ 26
4/2 TO 4/36 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS .. 26
4/2 AGGREGATES GENERAL REQUIREMENTS .................................................................. 26
4/9 BAR SCHEDULES AND SHOP DRAWINGS ..................................................................... 26
4/11 PLACING AND FIXING REINFORCEMENT ...................................................................... 27
4/13 SPACER BLOCKS .................................................................................................................. 27
4/14 ADMIXTURES ......................................................................................................................... 28
4/15 CONCRETE MIX SPECIFICATIONS................................................................................... 28
4/16 CONCRETE MIX DESIGN..................................................................................................... 28
4/17 QUALITY CONTROL .............................................................................................................. 29
4/18 RESPONSIBILITY AND CRITERIA...................................................................................... 30
4/19 CONSISTENCY OF CONCRETE......................................................................................... 30
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS ................................................ 31
4/23 READY MIXED CONCRETE................................................................................................. 31
4/24 MASS CONCRETE................................................................................................................. 31
4/25 COMPACTION OF CONCRETE .......................................................................................... 32
4/26 CONSTRUCTION JOINTS .................................................................................................... 32
4/27 CURING CONCRETE ............................................................................................................ 34
4/30 CONCRETE IN HOT WEATHER ......................................................................................... 34
4/31 MINIMUM TEST REQUIREMENT FOR CONCRETE ....................................................... 37
4/33 CLASSES OF FINISHES ....................................................................................................... 38
4/36 POST-TENSIONED CONCRETE WORKS ........................................................................ 39
4/36.1 GENERAL DESCRIPTION ............................................................................................ 39
4/36.2 CONCRETE AND MATERIALS .................................................................................... 44

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4/36.3 CONSTRUCTION ........................................................................................................... 60

4/38 TRIAL POUR FOR BRIDGE DECK ..................................................................................... 68
4/39 PLACING CONCRETE FOR BRIDGE DECKS ................................................................. 68
4/41 PRECAST CONCRETE ......................................................................................................... 73
SECTION 5 - ANCILLARY WORKS ........................................................................................ 74
5/47 CONCRETE BARRIER WALL .............................................................................................. 74
5/47.1 DESCRIPTION ................................................................................................................ 74
5/47.2 MATERIALS ..................................................................................................................... 74
5/47.3 CONCRETE FINISH ....................................................................................................... 74
5/47.4 CURING............................................................................................................................ 75
5/47.5 JOINTS ............................................................................................................................. 76
5/49 PROTECTION OF SHOULDERS AND SLOPES .............................................................. 76
5/49.1 CEMENT STABILIZED AGGREGATE CAPPING LAYER ........................................ 76
5/49.2 TESTING .......................................................................................................................... 77
5/49.3 METHOD .......................................................................................................................... 77
5/50 METAL WORKS ...................................................................................................................... 78
5/50.1 STRUCTURAL STEEL .............................................................................................................. 78
5/50.2 STAINLESS STEEL ................................................................................................................... 78
5/50.3 GALVANIZING ............................................................................................................................ 79
5/53 CRANE AND HOIST FOR UTILITY CULVERTS ............................................................... 79
5/55 ALTERNATIVES ..................................................................................................................... 79
SECTION 6 - WORKS IN CONNECTION WITH SERVICE AUTHORITIES ............................. 80
GENERAL REQUIREMENTS ............................................................................................................... 80
DEWA - ELECTRICITY DIVISION........................................................................................................ 80
6/9 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS .............. 80
SECTION 7 - ROADWAY LIGHTING....................................................................................... 81
7/1 MODIFICATIONS AS NECESSARY TO SUIT PROJECT REQUIREMENTS .............. 81
7/4 TESTING AFTER INSTALLATION ...................................................................................... 81
SECTION 8 – CONCRETE PILE FOUNDATIONS – NOT APPLICABLE ................................ 82
SECTION 9 – JOGGING TRACK ............................................................................................ 84
9/1 DESCRIPTION ........................................................................................................................ 84

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9/2 MATERIAL ............................................................................................................................... 84

9/2.1 CONIPUR 70 ................................................................................................................... 84
9/2.2 CONIPUR 326 ................................................................................................................. 86
9/2.3 CONIPUR EPDM 0.5-1.5MM ........................................................................................ 89
9/2.4 CONIPUR 210 ................................................................................................................. 90
9/2.5 CONIPUR 2200 ............................................................................................................... 94
9/3 METHOD STATEMENT – CONIPUR 2S MODIFIED SYSTEM ...................................... 96
9/3.1 SCOPE ............................................................................................................................. 96
9/3.2 PRODUCT INVOLVE ..................................................................................................... 97
9/3.3 MANUFACTURER / SUPPLIER ................................................................................... 97
9/3.4 GENERAL ........................................................................................................................ 97
9/3.5 PREPARATION ............................................................................................................... 97
9/3.6 PRIMING .......................................................................................................................... 98
9/3.7 BASE LAYER................................................................................................................... 98
9/3.8 EPDM MAT ...................................................................................................................... 98
9/3.9 PORE SEALER ............................................................................................................... 98
9/3.10 COATING .................................................................................................................................... 99
9/3.11 SEALING LACQUER ................................................................................................................. 99
SECTION 10 – BICYCLE TRACK ......................................................................................... 100
10/1 GENERAL ..................................................................................................................................... 100
10/2 QUALITY ASSURANCE ............................................................................................................. 101
10/3 PRODUCTS .................................................................................................................................. 101
10/4 WARRANTY.................................................................................................................................. 103
10/5 EXECUTION ................................................................................................................................. 103

DUBAI – UAE
Volume 2 – Part II PARTICULAR

SPECIFICATIONS
PREFACE
The following Particular Specifications shall be read in conjunction with all other
applicable sections of the Roads and Transport Authority General Specifications.
Other Roads and Transport Authority General Specifications clauses shall be fully
applicable to all the work described in this section if not specifically addressed
otherwise herein. In case of conflict between these Particular Specifications and other
Roads and Transport Authority General Specifications that may form part of the
construction contract documentation, the more restrictive of the applicable
requirements shall control.
The following amendments/additions shall be considered applicable to the construction

requirements of MOHAMMED BIN RASHID AL MAKTOUM CITY, DISTRICT ONE – PHASE 3B
– 3B EXTENSION AND 3C
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SECTION 1 – GENERAL
1/1 to 1/30 Modifications as necessary to suit project requirements
1/7.12 The Contractor shall provide all referenced ASTM, BS Standards or any other
standard indicated or referred to within the testing requirements of the
Contract Specifications.
1/12.19 Additional text after the first paragraph.

As soon as possible after the Contract has been awarded, the Contractor shall
submit to the Engineer a list of the suppliers from whom he proposes to
purchase the materials necessary for the execution of the Works. Each
supplier must be willing to permit the Engineer, or his representative, access
to their premises during ordinary working hours for the purpose of obtaining
samples of the materials in question and witness the testing, if required.
Alternatively, if required by the Engineer, the Contractor shall deliver the
samples of the materials to the Engineer’s office. Samples shall be taken in
accordance with the relevant Standard where applicable. Materials
subsequently supplied shall conform within any specified tolerances to the
quality of samples which have been approved by the Engineer.
The information regarding the names of the suppliers may be submitted at

different times, as may be convenient, but sources of supply shall not be
changed without the Engineer’s prior approval.
When any material or article is required to comply with a Standard, such

material or article or its container shall bear the stamp of the registered
certification trademark of the appropriate Institution. Alternatively, the
contractor shall submit to the Engineer test certificates furnished by the
supplier or manufacturer of the material or article indicating compliance with
the relevant Standard.
1/13.5 Contractor shall make himself familiar with all Authorities latest Circulars,
mandates, Revisions, alterations and changes that in conflict with any of
specifications details and all requirements that included in the Contract
Documents.
Contractor shall adopt and proceed to follow these latest regulations in

executing the Contract without any objection nor it should be a reason or a
basis for claims for additional cost.
1/14.20 While working in the vicinity of existing GRP pipelines the latest requirements
of the pipe manufacturer and relevant service authority shall be followed. The
most recent guidelines published by the pipe manufacturer shall be obtained
prior to the start of work. In addition to complying with these requirements the
following conditions are stipulated:
1. Within 2 meters of the GRP pipeline edge only non-tamping and vibrating
rollers of not more than 8,000 kg are to be used.
2. No vibrating rollers to be used within 5 meters of the GRP pipeline edge
for any construction works.
3. All haul roads are to be clearly defined and at least 10 meters from the
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pipeline edge. At permitted crossing points approved protection

measures are to be temporarily installed.
4. Mechanical excavators can be used with caution down to a depth of

cover of 600 mm above the existing GRP pipe crown. Below that depth,
all excavations must be done manually.
5. When using heavy road equipment if the depth relative to the equipment
weight is less than the values shown in the table, a reinforced concrete
protection slab to be designed by the Contractor to meet the pipe
manufacturer’s requirements shall be placed at least 300 mm above the
crown of the existing pipe. The slab should have a width of 2 x Nominal
Diameter with the existing pipe being centered below the protection slab.
Minimum Safe Pipe Cover (mm)

Equipment Weight Kind of Equipment
Kilograms Tamped Vibrated
Less Than 100 250 mm 150 mm

100 To 200 350 mm 200 mm
200 To 500 450 mm 300 mm
500 To 1000 700 mm 450 mm
1000 To 2000 900 mm 600 mm
2000 To 4000 1200 m 800 mm
4000 To 8000 1500 m 1000 mm
8000 To 12000 1800 mm 1200 mm
12000 To 18000 2200 mm 1500 mm
The thickness, and reinforcement design of the protection slab is to be

proposed by the Contractor and approved by the Engineer.
6. Marker posts are to be installed indicating the alignment and depth of the
existing GRP pipeline. This is to warn heavy equipment operators of the
location of the buried GRP pipe so that they avoid driving over it in areas
where cover is below that permitted for the particular heavy equipment
being operated.
1/17.7 Additional text after the first paragraph.
Where temporary road markings are to be provided on finished final

carriageway surfaces, (generally wearing course) either pressure sensitive
tapes or removable raised pavement markers should be utilized subject to the
Engineer’s approval.
1/17.10 No Contractor’s plant except for trucks shall be allowed to use the temporary
diversion. All other plant and equipment must use designated haul roads,
unless otherwise directed by the Engineer.
1/21.2 Additional text
Working Drawings shall reflect any change, addition or deletion to the original
scope of works, as detailed on the original Contract drawings, and shall,
subject to approval by the Engineer, represent work constructed in place.
These drawings shall be prepared and issued, as per the requirements of
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Clauses 1/21.4 and 1/21.5.
1/21.8 While preparing the shop drawings or working drawings in connection with
utilities or authority related networks, the Contractor shall ensure that no
utilities or networks clashes or conflicts with the other proposed or existing
networks or utilities. The Contractor shall coordinate the design drawings or
information provided under the Contract and then shall prepare the shop or
working drawings accordingly free of clashes or similar inconsistency. The
Engineer’s review and approval shall not relieve the Contractor for any of his
liability under Contract. Any works if constructed wrongly as a result of shop
drawings or working drawings prepared incorrectly or inconsistently will be
solely Contractor’s responsibility, and have to be rectified without any cost to
the Employer. The Contractor shall prepare all the drawings in line with
authority requirements – and wherever approval is required from authorities
shall obtain such approvals. The Engineer review and approval shall not be
construed as approval for execution of the works, if authority approval is
required.
1/22.1 Additional text.
The Contractor shall submit to the Engineer for his checking and verification
digital record and hard copy of all executed works to be incorporated in the as-
built record drawings.
Such coordination or cooperation should be carried out throughout the

Construction period, whereby the Contractor should expect any out of
sequence works due to interfacing with other Contractors. The Contractor
therefore shall, as directed by the Engineer, allow appropriate opportunities for
carrying out work by other contractors.
1/31 PC-Compatible Construction Scheduling System
1/31.1 The Contractor shall prepare and submit to the “Engineer/Employer” for his
consent, with a copy to the Employer, a Construction Scheduling System as
described in this clause. In preparing this system, the scheduling of the work
is the responsibility of the Contractor. To the extent practicable, the
Construction Scheduling System shall be prepared and maintained at the work
site.
1/31.1.1 The requirement for the system is included to assure adequate planning and
execution of the work by the Contractor, to provide the Contractor and the
“Engineer/Employer” forward visibility of the effect of current job progress, or
lack of progress, or delays, or change orders on specified contract completion
date and designated milestones, to allow the Contractor to make adjustments
in planning, scheduling, crew size, equipment, procurements, etc., in sufficient
time to maintain or regain the specified contract completion and designated
milestones, to assist the “Engineer/Employer” in appraising the
reasonableness of the schedule, to provide the “Engineer/Employer” a basis
for making decisions relative to time extensions, and to provide a basis for
progress payments.

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1/31.1.2 The Contractor shall enter the actual progress to the Construction Scheduling
System using the method described in this clause and submit reports to the
“Engineer/Employer” at the intervals herein required. If the report shows that
the Contractor will not meet specified contract completion dates or designated
milestones, the Contractor shall take steps necessary to regain the specified
contract completion dates and designated milestones, including those steps
that may be required by the “Engineer/Employer”, without additional cost to
the “Engineer/Employer”. In this circumstance, the “Engineer/Employer” may,
in addition to other remedies provided under this clause, require the
Contractor to increase the number of shifts, overtime operations, days of work,
and/or the amount of construction plant, and to submit for approval any
supplementary schedule or schedules in Construction Scheduling System
form as the “Engineer/Employer” deems necessary to assure that the
specified contract completion date and designated milestones will be
regained.
1/31.1.3 If in the opinion of the “Engineer/Employer” the Contractor fails to follow, or

performs work out of sequence to, the approved Network, the
“Engineer/Employer” may require the Contractor, without additional cost to the
“Engineer/Employer”, to revise the approved Network to conform to his
operations, revise its operations to conform to the approved Network, or any
combination thereof as in the opinion of the “Engineer/Employer” is necessary
to assure that forward visibility of the Contractor's progress towards specified
contract completion times or designated milestones is adequately provided.
1/31.1.4 If the Contractor fails within the time limits set forth in this clause to submit an
acceptable Construction Scheduling System, or fails to submit acceptable
Construction Scheduling System revisions for modifications issued under the
terms of this contract, or fails to submit acceptable Construction Scheduling
System revisions otherwise required, or to adequately status the Construction
Scheduling System, or perform an acceptable mathematical analysis, to
provide acceptable progress reports as required by this clause, the
“Engineer/Employer” may, in addition to other remedies provided under this
clause, withhold approval of all or any portion of the progress payments until
an acceptable Construction Scheduling System network, revision, status,
mathematical analysis, or progress report is submitted and approved, or
provided under Section 1/31.2.4. hereinafter.
1/31.1.5 Failure of the Contractor to comply with the requirements of the

“Engineer/Employer” under this clause shall be grounds for a determination by
the “Engineer/Employer” that the Contractor is not prosecuting the work with
sufficient diligence to ensure completion within the time specified in the
contract. Upon making this determination, the “Engineer/Employer” may
terminate the Contractor's right to proceed with the work, or any separable
part of it, in accordance with the default terms of this contract.
1/31.1.6 The Contractor shall have on site to the extent deemed necessary by the
“Engineer/Employer”, a Scheduling Engineer to set-up, developed and
maintain the Construction Scheduling System as described herein. The
Scheduling Engineer shall be fully familiar and experienced in project
scheduling and scheduling maintenance using scheduling system similar to
those described herein.

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1/31.2 Submittal of the Construction Scheduling System
1/31.2.1 A preliminary schedule indicating activities and sequence of operations for the
first 4 month of the construction contract shall be submitted by the Contractor
within 10 calendar days after the date of Letter of Acceptance. The
preliminary schedule shall consist of not more than 100 activities and shall be
either a Construction Scheduling System diagram or bar chart. The activities
of the preliminary schedule shall interface with the activities in the complete
network required hereinafter, and shall include description, activity
identification (if Construction Scheduling System), durations, and costs. This is
mostly required to address the mobilization efforts and the necessary initial
critical material submittals and procurement.
1/31.2.2 The complete Construction Scheduling System shall be submitted for approval
within 28 calendar days after the date of Letter of Acceptance. This contract
initially assumes that the line items of the Construction Scheduling System are
those of the work items contained in the contract bill of quantities unless the
contractor foresees, and subject to the approval of the “Engineer/Employer”
that the changes are necessary to better identify the progress of the project,
however, in all cases, the total value of items should be the same as the totals
in the contract line items.
1/31.2.3 Revisions to the Construction Scheduling System, shall be submitted for

approval within 10 calendar days of a request to revise or disapproval of a
prior submission. Approved revisions to the Construction Scheduling System,
shall be incorporated in the Construction Scheduling System, and copies
forwarded as set forth in this clause within 5 days of receipt of approval.
1/31.2.4 In the event revisions to the Construction Scheduling System are required,
whether on the network, diagram, statusing, mathematical analysis, or
progress report, and the Contractor fails to submit acceptable revisions, the
“Engineer/Employer” may elect to furnish the Construction Scheduling
System revisions, which the Contractor shall incorporate into his Construction
Scheduling System and use. In such an event, the “Engineer/Employer” may
deduct the cost of preparing the Construction Scheduling System revisions
from the contract amount.
1/31.2.5 The Construction Scheduling System shall be statused monthly and a

progress report shall be submitted by the 10th of the month with a data cut-off
day (data date) as of the end of the prior month.
1/31.2.5.1 Additional progress reporting required by the

“Engineer/Employer” shall be submitted when the mathematical
analysis reveals negative float. In such case, the Contractor
shall status the Construction Scheduling System, execute a
mathematical analysis, and submit a progress report at more
frequent intervals, as directed by the “Engineer/Employer”, and
take other measures as may be directed in accordance with the
provisions of this clause.
1/31.3 Revisions to the approved Construction Scheduling System shall be

accomplished in the following manner.

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1/31.3.1 No revision shall be incorporated into the Construction Scheduling System

until approved by the “Engineer/Employer”, except activity durations adjusted
in accordance with Section 1/31.7.2.4. hereinafter.
1/31.3.2 Previously completed activities shall not be changed or modified except to

correct errors in fact. Specific written permission is required from the
“Engineer/Employer” prior to such correction, and a memorandum not of
correction shall be appended to the Construction Scheduling System.
1/31.3.3 The Contractor shall propose a revision to the Construction Scheduling

System and submit it for approval upon receipt of a request for proposals for a
change order, receipt of a Notice to Proceed prior to contract modification for a
change order, and upon any modification of the contract that effects the
Construction Scheduling System.
1/31.3.4 Approved revisions for change orders shall not be incorporated until a contract
modification has been issued, or a Notice to Proceed is issued prior to a
contract modification.
1/31.3.5 The Contractor may at any time propose revising any activity in progress or
not started, add activities, revise logic or activities in progress or not started,
change crew or equipment levels, durations, monetary amounts, delete
activities not started, or any other change which in the opinion of the
“Engineer/Employer” is consistent with sound planning and job management,
and does not jeopardize specific contract completion date or cloud forward
visibility of job progress.
1/31.4 Network Analysis
The Construction Scheduling System shall consist of network, diagrams,

network statusing, a mathematical analysis, and progress reports as set forth
in this clause.
1/31.5 The Network shall include in addition to construction activities the submittal
and approval of Contractor furnished design documents, the submittal and
approval of material samples and shop drawings requiring
“Engineer/Employer” approval, the procurement of all critical or major
materials and equipment, initial quality control inspections, fabrication of major
or critical materials and equipment and their installation and testing and all
activities of the “Engineer/Employer” that affects progress.
1/31.5.1 Diagrams shall depict the Network and display the order and
interdependence of activities and the sequence in which the
work is to be accomplished. Diagrams shall be drafted to show
a continuous flow from left to right with no arrows from right to
left. The following information shall be shown on the diagrams:
each activity, activity identification, activity description,
monetary value of activity, activity duration, payment item
applicable to the activity monetary value, specified contract
completion dates, designated milestones, and all activity
dependencies with any applicable lags and leads. Facilities with
discrete completion dates shall be identified by separate sub-
networks interconnected with the basic diagram or specially
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noted.
1/31.5.2 The activity identification numbering system shall be assigned

so that preceding activity event numbers are smaller
numerically than the following activity event numbers. Skip
numbering should be used on the original network to allow
addition of subsequent activities for change order and logic
changes.
1/31.5.3 Activity durations may be expressed in either work days,

calendar days, or both. In either case, a conversion calendar
shall be provided and maintained that displays the following for
the contract duration:
1. Work days (if used) after award

2. Calendar day after award
3. Day of week
4. Date (day, month, and year)
5. Holidays
1/31.5.3.1 Activity durations shall be established in accordance with

Section hereinafter.
1/31.5.4 The sum of the monetary values of all the activities shall total
the contract amount. The sum of the monetary values of all
activities associated with a payment item shall total to the
payment item amount.
1/31.5.5 Contract milestones shall be award date, Notice to Proceed

(Authorization to start construction), each individual phase's
start and complete dates, specified contract completion dates,
any other milestone specified as such in the contract, and any
activity start or finish date with negative float that the
“Engineer/Employer” designates as a milestone.
1/31.5.6 The Contractor shall plan and schedule the work to be

completed within the contract time. The Contractor shall adjust
resources and propose appropriate adjustments and revisions
in Network logic and activity durations when current contract
completion dates and designated milestones are in jeopardy, in
accordance with the provisions of this clause.
1/31.6 Statusing the Construction Scheduling System
1/31.6.1 Approved revisions shall be incorporated prior to statusing.
1/31.6.2 Statusing the Construction Scheduling System shall be as of the data cut-off
day (date) defined in Section 1/31.2.5, and accomplished as set forth herein.
1/31.6.2.1 Statusing of activities completed in the current report period

shall consist of changing the completed activities Early-
Finish date to the actual completion date and annotating it
as such, and fixing the activity Late-Start date at its current
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value and annotating it as fixed. Actual dates shall be

posted in calendar days after award, or by calendar date.
1/31.6.2.2 Statusing of activities started in the current report period

shall consist of changing the started activities Early-Start
date to the actual start date and annotating it as such, and
fixing the activity Late-Start date at its current value and
annotating it as fixed. Actual dates shall be posted in
calendar days after award or by calendar date.
1/31.6.2.3 Statusing of activities in progress shall consist of calculating

each activity's percent physically complete and the activities
remaining duration from the data cut-off day. The Contractor
shall calculate the percent physically complete based on the
ratio of material and labor incorporated in the activity to total
materials and labor required to be incorporated in this
activity. The Contractor shall calculate the remaining
duration in accordance with Section 1/31.7.2.3, utilizing the
unincorporated quantity of material and labors and in
accordance with Section 1/31.7.2.4 if applicable.
1/31.7 The mathematical analysis shall consist of a time analysis and a resource
analysis. Except for the initial Construction Scheduling System submittal, the
Construction Scheduling System shall be statused prior to performing the
mathematical analysis.
1/31.7.1 The time analysis shall consist of forward pass and a backward pass, yield
early and late starts and finishes, calculation of total float for each activity, and
identification of critical paths and paths of negative float, and calculation of
float cushion for milestones.
1/31.7.1.1 The forward pass shall define Early-Start and Early-Finish

for each activity, and commence initially at the first activity
whose early start date shall be fixed as calendar day one.
Contract award shall be calendar and work day zero. After
actual starts and actual finishes have been experienced and
statused, subsequent forward passes shall commence at
the last actual date posted on each path, or the data cut-off
day for activities in progress. Early-Start and Early-Finish
shall be posted in calendar days after award or by calendar
date. A new forward pass shall be accomplished for each
Construction Scheduling System statusing, and for all
revisions to the Construction Scheduling System that would
affect the results of the forward pass. Such revisions
include but are not limited to changes in the Construction
Scheduling System status, activity durations, conversion
calendar, or network logic. The early dates resulting from
the forward pass represent the Contractor's projected
schedule for accomplishing the work.
1/31.7.1.2 The backward pass shall define Late-Finish and Late-Start

for each activity, and shall always commence with the
specified contract completion dates. The activity

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representing contract completion shall have its Late-Finish

date fixed at the specified contract completion date, and
shall not be altered unless the contract completion date is
officially extended by modification of the contract.
Subsequent backward passes will terminate along each
path at the first occurrence of a late date fixed in
accordance with Section 1/31.6.2, or the data cut-off day for
activities in-progress. Late-Finish and Late-Start shall be
posted in calendar days after award or by calendar date. A
new backward pass shall be accomplished only when
approved revisions to the Construction Scheduling System,
or changes in activity durations made in accordance with
Section 1/31.7.2.4 occur that would affect the results of the
backward pass. Such revisions include but are not limited
to changes in network logic, activity durations, or conversion
calendar. The late dates resulting from the backward pass
represent the schedule required to meet specified contract
completion dates and milestone.
1/31.7.1.3 Total float or slack is defined as the Late-Start date minus

the Early-Start date, or the Late-Finish date minus the
Early-Finish date, of each of the activities in the
Construction Scheduling System schedule. Start float is the
total float calculated by start dates, and finish float is the
total float calculated by finish dates. Total float or slack is
not time for the exclusive use or benefit of either the
“Engineer/Employer” or the Contractor unless approved by
the “Engineer/Employer” on a case by case bases for each
individual activity. Total float shall be calculated in calendar
days. Total float is the measure of Contractor days ahead
or behind schedule.
1/31.7.1.4 The critical path is defined as a path whose total float is

zero. The Least-Float-Path is defined as the least positive
(or most negative) path of total float. When the
Least-Float-Path is positive, the Contractor is ahead of
schedule. When paths of negative total float occur, the
Contractor is behind schedule. Contract completion dates
and designated milestones that occur in paths of negative
total float are in jeopardy.
1/31.7.1.5 Float cushion is defined as the number of Contractor

scheduled non-work days (weekends and holidays)
imbedded between the current statusing date (data cut-off
date) and the late accomplishment date of a milestone.
1/31.7.1.5.1 When a progress report reveals a milestone date with

negative float, the Contractor may elect to offset the
negative float by scheduling to work those float cushion
days on those activities that will advance the early
accomplishment date of the milestone the amount of the
offset.

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1/31.7.1.5.2 If the current progress report reveals a milestone with

negative float, and the Contractor does not elect to offset
the negative float by working the float cushion, and fails to
present an acceptable plan to regain the schedule, the
“Engineer/Employer” may, in addition to other remedies
provided in the special clauses, require that the Contractor
work such days in the float cushion as the
“Engineer/Employer” may designate until the Contractor
demonstrates to the satisfaction of the “Engineer/Employer”
that the schedule is regained.
1/31.7.1.5.3 If the Contractor elects, or the “Engineer/ Employer”

requires the Contractor to regain schedule by working days
in the float cushion, the “Engineer/Employer” may require
that the Contractor revise the affected portion of the
conversion calendar, recalculate the time analysis and
resubmit the affected portions of the Construction
Scheduling System for approval.
1/31.7.1.6 Extensions of Time
In the event of any conflict under this Clause with any

Clause in the Tendering & Contract Conditions, then
Condition of Contract shall take priority:-
1/31.7.1.6.1 Extensions of time to specified contract completion dates or

designated milestone dates for changes ordered will be
granted only to the extent that the equitable time
adjustments for the activity paths affected exceed their
positive total float at the time the Notice to Proceed for the
change is issued. In arriving at an equitable time
adjustment, the “Engineer/Employer”, may consider whether
the changes ordered can reasonably be accomplished by
increasing or utilizing idle labor, equipment or other
resources such that the specified contract completion dates
can be met without granting a time extension.
1/31.7.1.6.2 Extensions of time to specified contract completion dates, or

designated milestone dates, for causes covered under
contract clauses other than the changes clause, will be
granted only to the extent that the equitable time due
exceed the positive total float along the activity paths
affected at the time the cause for the time extension
occurred.
1/31.7.2 The resource analysis shall establish and document

resources (building material and equipment) to be
incorporated into the work defined by the activity, the
resource (labor and equipment) used to incorporate such
building material and equipment into the work defined by
the activity, and the time (activity duration) required to
complete the activity.

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1/31.7.2.1 Each construction activity shall have its total quantity

requirements set in accordance with the contract bill of
quantities, should the contractor determines that such
quantity is in error to an extent that may delay the contract,
the contractor will notify the “Engineer/Employer”
immediately of such contradiction supported by accurate
take-off. Each construction activity shall have it’s material
requirement and the total work effort in man-days
established with labor skills and construction equipment
identified.
1/31.7.2.2 The rate at which building material and equipment is to be

incorporated into the work shall be proportional to the
number of laborers for each labor skill required, the working
capacity of construction equipment, the efficiency of the
labor and equipment in the physical environment, and
applicable labor regulations.
1/31.7.2.3 The time (activity duration) shall be proportional to the total

quantity of material to be incorporated as determined in
Section 1/31.7.2.1, and inversely proportioned to the rate at
which the material can be incorporated as determined in
Section 1/31.7.2.2, plus any time for normal environmental
factors including normal weather delays, normal ambient
temperature effects, other normal seasonal factors that
affect construction, and normal holidays (if activity durations
is expressed in calendar days).
1/31.7.2.4 Activity durations shall be adjusted to account for activities

concurrently utilizing common resources with limited
availability. In such cases, the time analysis shall be
adjusted for those activities and all activities subsequent in
time to the concurrent-using activities.
1/31.7.2.5 In the event that the actual durations experienced on

completed and in-progress activities are, in the opinion of
the “Engineer/Employer”, habitually and significantly greater
than the planned durations, the “Engineer/Employer” may,
in addition to other remedies set forth in this clause, require
the Contractor to revise the remaining durations on
in-progress activities and durations on future activities to
durations which, in the opinion of the “Engineer/Employer”,
are more realistic. Should such revised durations result in
the occurrence of negative float paths jeopardizing specified
contract completion dates, the “Engineer/Employer” may
avail himself of any and all remedies set forth in this clause
to regain the specified completion dates.
1/31.8 Reports
1/31.8.1 The progress report shall include the incorporation of approved revisions to
the Network, statusing all activities in progress, completed, or started since the

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last approved report submission, a mathematical analysis based on the

revised and updated Construction Scheduling System, and reports as set forth
below.
1/31.8.2 Based on the statused Construction Scheduling System and mathematical

analysis, the Contractor shall provide activity reports organized as follows:
1. For each activity specified below, the following shall be included: activity
identification, activity description, percent physically complete, monetary
amount, earnings (the percent physically complete times the monetary
amount) and pay item number. Monetary amounts shall be divided into
material and labor for all construction activities or activities requiring
material or installation of equipment.
2. Activities shall be included in the groups and order as follow:
a) Activities completed with subtotal on earnings, and sub-sorted by

pay item.
b) Activities in progress, with subtotal on earnings, and sub-sorted by
pay item.
c) Total on earnings of all activities completed and in progress.
d) Overall contract percent complete.
1/31.8.3 The Contractor shall maintain a tabular and graphic history by month of
cumulative earnings, and a projection by month of anticipated earnings. The
anticipated earnings shall be based on the early finish dates of the activities in
progress and activities not yet started. The graphic history shall be plotted on
a graph that also included the late start earning projections. The late start
earning projection shall not be revised except to incorporate contract
modifications, or revisions in accordance with 3.1, with such changes
annotated on the graph, or when a backward pass is performed in accordance
with Section 1/31.7.1.2.
1/31.8.4 The Contractor shall report overall contract percent completion based on the
total of earnings to date divided by the total contract amount times 100.
1/31.8.5 The Contractor shall provide a milestone report that shall include for each
milestone the following: milestone description, early accomplishment date,
late accomplishment date, total float, and float cushion. The report shall
include a narrative text on the cause and proposed cure of each occurrence of
negative total float. Actual dates shall be posted by changing the early
accomplishment date and affixing an (A) after the date. Late accomplishment
dates shall not be altered except to incorporate contract modifications or in
accordance with Section 1/31.3.1, or 1/31.7.1.2.
1/31.8.6 Report Medium
1/31.8.6.1 For projects which, in the opinion of the

“Engineer/Employer”, require more than 150 activities to
adequately manage, the Contractor shall submit all of the
Construction Scheduling System input data and/or
Construction Scheduling System output data and reports
required by this clause in appropriate files on 3-1/2-inch

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floppy disks. Such files shall be fully usable and compatible

with the “Engineer/Employer” Construction Scheduling
System computer system described herein:
Hardware: IBM Compatible PC with Intel Pentium

Processor with a minimum of 32 MB ram and
a fast graphic display card.
Software: Primavera Project Planner under Window

(Version 2).
1/31.8.6.2 The Contractor's Construction Scheduling System must be

compatible with the “Engineer/Employer” computer system
specified.
1/31.8.6.3 In addition to the requirements of Section

1/31.8.6.1 herein before the “Engineer/ Employer” may
require printed copies of the Construction Scheduling
System diagram, and printed tabular sorts of the required
analysis data. If required, such tabular sorts shall contain
for each activity: the activity identification, description,
duration (remaining duration on activities in progress),
Early-Start and Early-Finish (annotated to indicate actual
dates when appropriate), Late-Start and Late-Finish
(annotated to indicate if fixed, when appropriate), total float
(start and finish floats, if applicable), monetary value of the
activity, percentage physically complete, earnings to date
and payment item number. Sorts to be provided shall
include activity listing, total float, Early-Start, Late-Start,
Early-Finish, Late-Finish, and any other sort as may be
required by the “Engineer/Employer”. Either the late-start or
late-finish sort shall list preceding and succeeding activities
for each activity of the Construction Scheduling System.
Each sort shall be sub-sorted by ascending activity
identification number (in arrow diagram by i-th node, and
each i-th node by j-th node). Total float will be sorted in
order of least positive float first and sub-sorted as above. If
Customer-furnished property (CFP) is to be furnished to the
Contractor to incorporate into the work, separate sorts of
CFP by early and late starts shall be provided and sub-
sorted as above. Any footprints need-dates for CFP,
required by the Contractor from the “Engineer/Employer”,
shall be included in the CFP sort. Printed copies of the
Construction Scheduling System diagram shall be on 60mm
by 85mm (A1 size) paper, unless otherwise authorized by
the “Engineer/ Employer”.
1/31.8.7 Summary Networks and Bar Charts
1/31.8.7.1 For large networks (over 150 activities) and for a completely
automated Construction Scheduling System, the Contractor
shall provide a summary network diagram and a bar chart.
1/31.8.7.2 The Summary Network diagram shall be tied to and driven

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by the complete network. The Summary Network shall combine all

the subnets, and, as a minimum, contain all the specified and
designated milestones, and any other feature of the work contained
in the complete network that in the Contracting Officer's opinion
requires summary visibility.
1/31.8.7.3 The Bar Chart shall be extracted from the Summary

Network. The Bar Chart shall be time scaled, and display each
activity separately, and contain all specified and designated
milestones, and any other feature of the work contained in the
complete network that in the opinion of the “Engineer/Employer”
requires Bar Chart visibility.
1/31.8.7.4 The Summary Network and the Bar Chart may be combined into one
time-scaled diagram, if in the opinion of the “Engineer/Employer”, the
relevant information is clearly presented and the pertinent
dependencies and paths are visible.
1/32 Project Milestones
1/33 Site Availability
The site with the constructions limits as define by the Contract Documents
will be available to the Contractor starting on the project commencement
date except as noted below:
1/33.1 It is likely that the areas will be available to execute the Infrastructure
works in different sequences then what is depicted in the Program of
Works or given in the Tender Documents. In which case, the Infrastructure
Contractor shall relocate their resources to areas which are available for
possession or to change the sequence of works for the next stage where
they are already working/in progress.
1/33.2 Additionally, The Employer and The Consultant – may – at his discretion
and/or as per the project Phased Handover Strategy – direct the
Infrastructure Contractor to give priority to certain works or order the
Infrastructure Contractor to do certain works first or to complete
certain works first. Infrastructure Contractor shall duly comply with such
directions and to have allowed herein any additionally expenses in compliance
thereof. Any subsequent claim for additional cost and time will not be
entertained.
1/33.3 The above shall be closely coordinated with other Consultant and Contractors on
a day to day basis. The infrastructure Contractor shall coordinate and
cooperate with other Consultant / Contractor in reaching amicable solutions.
1/33.4 The Contractor shall be responsible for his construction activities on the site,
and shall coordinate his own activities or program with other contractors for the
purpose of completion of Works within the Time for Completion as specified
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under the Contract. This may also requires out of sequence execution of
works. The Contractor, in order to complete the works within Time for
Completion, shall mitigate any delay, if occurs, particularly in obtaining NOCs
and or possession of the site / working areas or as a result of any obstruction or
hindrance by other contractors.
The Contractor shall also ensure to provide full co-operation and coordination to
the other contractors and shall not hinder or obstruct the other contractors’
activities on the site.
Contractor shall facilitate within his area of possession access to other

Contractors when required to facilitate their works.
1/33.5 Client’s decision on award regarding any of the infrastructure works

components may be phased or deferred or cancelled. As such, Client, shall
have the right/authority to cancel or delay certain or any part of the works, in
full or in part, separately or collectively, without objection by the
successfulinfrastructure tenderer and same would not be a reason or a basis
for claim for additional costs.
1/33.6 Commencement shall be as per the “Notification of Commencement” to be

issued by Client after Contract Award.
1/33.7 The Time for Completion shall be as per stated in the agreement starting from
the Commencement date.
1/33.8 It is expected that Infrastructure Tenderers/Bidders shall visit the site

and familiarize/satisfy themselves with the existing conditions at site, and,
consider requirements within submissions.
1/33.10 Infrastructure Tenderers/Bidders shall have a flexible logistic plan to

account for changing in terms of access, location of cranes associated with
the construction of villas, etc. This may lead of foreign material being mixed
with the existing soil and slight change in the topography of the surveyed
area.
1/34 Alternative
Should the Contractor elect to submit any alternative system to that

detailed in the plans, the contractor shall employ an accredited consultant
approved by Roads & Transport Authority to undertake a complete design
and produce detailed drawings to be submitted to the Engineer. Such
alternatives shall be submitted two-month minimum prior to the date
required for approval of the subject design or commencement of any
related works items. The contractor shall allow in his alternative bid for the
compensation of the Engineer for his review and checking of such
alternative.
1/35 Modifications as necessary to suit project requirements

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1/35.1 Contractor Supplied Material
i) Pipeline Wall Thickness shall be minimum of 6.35 mm (Sch. 20) per

ASME / ANSI B 36.10 or 6.4 mm per API 5L.
ii) The pipe supplied shall meet the requirements of following codes
and standards :
– ASME/ANSI B31.4 Liquid Petroleum Transportation Pipeline
– API SPEC. 5L Specification for Line Pipe (forty-first edition, April 1,

1995)
– API RP 5L1 Recommended Practice for Railroad Transportation of

Line Pipe
– API STD 1104 Standard for Welding Pipelines & Related Facilities
– API RP 5L5 Recommended Practice for Marine transportation of

line pipe
– API RP 5LW Recommended Practice for Transportation of Line Pipe
on Barges & Marine Vessels
iii) Contractor shall submit to Owner /Operator the Mill Certificate report on:
- Heat Analysis
- Product Analysis
- Chemical Analysis
- Mechanical Properties and test
iv) Pipe shall be seamless, in double random length with beveled ends.
v) Suitable steel bevel end protection (full cover caps) shall be fitted to the
ends of all length of pipe and bends.
vi) Mill welded jointers shall not be acceptable
vii) Wrinkle bends or mitre bends shall not be allowed

viii) Wall thickness after bending shall not be less than 93% of the nominal
wall thickness of the pipe.
ix) Gasket material specified in the spec. is “Compressed Asbestos Fiber”
which is hazardous. It should be replaced with non-asbestos gasket
material suitable for Jet fuel service. As pipeline is rated for class 300#,
gasket should be made of 304SS central ring with non-asbestos
material as per API601.
1/36.5 Welding
i) All welding of pipeline including procedures and qualifications shall be

carried out in accordance with the requirements of following codes and
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standards.
- API 1104
- ASME/ANSI B 31.4
- ASME Section IX
- DEP 31.60.10 (for hot tapping, if required)
1/36.6 Coating
i) Polyethylene external coating shall be factory applied by approved

applicator. All Factory coated pipes shall be lifted with equipment of a
suitable capacity using owner/operator approved cotton belted slings
and spreader bars.
ii) Use of chain or wire for handling pipes shall not be allowed.
iii) Internal coating refers to MIL spec amine epoxy coated, it should be
Shell spec. and MIL spec certified. The internal lining soak test must be
performed before the pipe is used for construction. This would be one of
the quality tests before accepting the pipe for use.
1/36.7 Design Perimeters
i) The design life of pipeline external coating shall be minimum of 30 years.
ii) External pipeline (PE Coating) and heat shrinkable sleeves should be
suitable for temperature ranging from 60 - 80 deg. C.
iii) The heat shrinkable sleeves on the weld joint shall be wide enough so
as to overlap onto the mainline coating by a minimum of 50 mm on
each side of weld joint.

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SECTION 2 - SITE CLEARANCE AND EARTHWORKS
2/3.7 Where shown on the drawings or otherwise directed by the Engineer all
fences, walls or boundary structures to be erected or reinstated shall be
done in the same kind and form as the one it is intended to replace. The
wall, fence or boundary structure shall be made to match the remaining
existing portions. All materials and workmanship shall be in accordance
with the relevant standards and specifications contained herein.
2/13.2 The following requirements for soaked CBR shall replace the requirement
given in Clause 2/13.2 of the General Specifications. Soaked CBR value at
95% minimum dry density (not less than 8% when tested according to BS
1377: Part 4 (Method 7).
The following text shall be added:
Dune sand if used, shall be free from organic matter and may contain up to
20% of rock, stone fragments or cobbles exceeding 20mm but not more
than 63mm in size. Layers of dune sand between layers of granular
materials shall not be allowed.
2/17.1 The following text shall be added:

Dune sand may be used if approved by the Engineer. In such case the
Contractor shall allow in his program an adequate period for performing
compaction trials, before commencing earthworks, to the satisfaction of the
Engineer.
If suitable, dune sand is to be used as fill and compacted in dry condition
(moisture content maximum 5%) in layers of 30cms to a level of 1.5 meter
below top of sub-grade.
The field relative compaction shall be 95% minimum of the Maximum Dry
Density (MDD) (as determined by BS 1377 Part 4”method 3.5 or 3.6”) at
Optimum Moisture Content (OMC) at any depth.
2/19.2 Dune Sand – Compaction Test (Field Density)
The Field Density and actual moisture content shall be determined using a
modified form of BS 1377: Part 9 (Method 2.1 or 2.2).
The Engineer will decide the most appropriate methodology after trials
undertaken by the Contractor at his own cost.
2/20.8 Plate bearing tests shall be carried out in accordance with ASTM
D1194/D1196. Frequency and unit shall be as directed by the Engineer.

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2/21.6 Alternative methods of soft area treatment which may be directed by the
Engineer are:
1) Non-friable boulders of sizes between 150-300mm shall be end dumped
over the soft area and rolled until the area is stabilized to the satisfaction
of the Engineer. Further stones of 10-70 mm size shall be rolled into the
area until all the areas are leveled and well blinded.
2) Crushed rock material free from dirt, organic matter, shale and any other
deleterious material. The acceptance criteria shall be as follows:
Grading (BS 812:part 103, Section

103.1:1985)
Sieve (mm) % Passing
150 mm 100
100 mm 80 - 100
37.5 mm -
25 mm 20 - 50
19 mm -
9.5 mm 0 -15
Physical Requirements
All aggregate materials shall comply with the requirements of sections
2/20.8 and 2/21 of the General Specifications in addition to the following:
Loss of Magnesium Sulfate Soundness 10% Max
(ASTM C 88, 5 cycles)
Loss of Abrasion Test 35% Max
(ASTM C131 or C 535)
2/25 Not Used
2/26 Previous Structure Backfill
2/26.1 Description - Pervious structure backfill shall include the furnishing, placing
and compaction of pervious material adjacent to structures.
2/26.2 Materials - Pervious structure backfill shall conform to the requirements of
Section PS 2/26.4.
2/26.3 Construction Methods - Pervious structure backfill shall be placed adjacent
to abutments except as indicated in clause PS 2/27, retaining walls, box
culverts, and elsewhere as called for. It shall be placed above a plane
extending on a 2 to 1 slope from the upper edge of the footing to the top of
the embankment, or as shown on the plans. Where the face of undisturbed
material is above or beneath this slope plane, the amount of pervious
structure backfill shall be decreased or increased accordingly, if ordered by
the Engineer.
In filling behind abutments, retaining walls, box culverts, or other structures,
the fill is placed against undisturbed material, or against compacted

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embankments having a length in a direction at right angles to the abutment

wall or culvert not less than twice the height of the structure against which the
fill is placed.
The slope of the embankment on which the pervious structure backfill is to be
placed shall be plowed deeply or cut into steps before and during the placing
of pervious structure backfill so both types of material will be thoroughly
bonded and compacted.
Each layer of pervious structure backfill shall be spread to a thickness not
exceeding 150mm in depth after compaction and shall be thoroughly
compacted as directed by the Engineer by the use of power rollers or other
motorized vehicular equipment, by tamping with mechanical rammers or
vibrators, or by pneumatic tampers. Any equipment not principally
manufactured for compaction purposes and equipment which is not in proper
working order in all respects shall not be used within the area described
above.
Special attention shall be given to compaction in places close to walls where
motorized vehicular equipment cannot reach. Within 1m of the back face of
walls and within a greater distance at angle points of walls, each layer of
pervious structure backfill shall be compacted by mechanical rammers,
vibrators, or pneumatic tampers.
The dry density of each layer of pervious structure backfill formed from
broken or crushed stone, broken or crushed gravel or reclaimed
miscellaneous aggregate free of bituminous concrete shall have a dry density
after compaction that is no less than 100 percent of maximum dry density for
that material when tested in accordance with BS 1377 part 9, method 2.2.
Each layer of the pervious structure backfill shall be compacted at optimum
moisture content. No subsequent layer shall be placed until the specified
compaction is obtained for the previous layer.
Where weep holes are installed, bagged stone shall be placed around the
inlet end of each weep hole, to prevent movement of the pervious material
into the weep hole.
2/26.4 Pervious Structure Backfill - Pervious structure backfill shall consist of

broken or crushed stone, broken or crushed gravel.Materials for this work
shall conform to the following requirements:
1. Broken or crushed stone - shall consist of sound, tough, durable

stone, reasonably free from soft, thin, elongated, friable, laminated,
micaceous or disintegrated pieces, mud, dirt or other deleterious
material and shall be sized to meet the requirements of Grading “B”. It
shall meet the requirements of loss on abrasion not more than thirty five
percent using ASTM C131/C535.
2. Bank or crushed gravel - shall consist of sound, tough, durable

particles of crushed or uncrushed gravel free from soft, thin, elongated

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or laminated pieces and vegetable or other deleterious substances. It shall

be subject to testing for soundness in accordance with Clause PS 2/26.5
when directed by the Engineer. It shall meet Grading “B” and the
requirements for plasticity and resistance to abrasion indicated in Article PS
2/26.6.
2/26.5 Gradation, Plasticity, Resistance to Abrasion and Soundness Requirements:
1. Gradation
Grading
Sieve Sizes (mm) A B C
Percent Passing by Mass
125 mm 100
90 mm 100 90 - 100
37.5 mm 55 - 100 55 - 95 100
19 mm 45 - 80
6.3 mm 25 - 60 25 - 60 25 - 60
2.0 mm 15 - 45 15 - 45 15 - 45
425 m 5 - 25 5 - 25 5 - 25
150 m 0 - 10 0 - 10 0 - 10
75 m 0-5 0-5 0-5
The grading percentages specified in the above table shall apply to the
material after it has been delivered to the construction site as well as when
tested at the pit or other source of supply.
When the fraction of the dry sample passing the 150 m mesh sieve is greater
than eight percent by mass, the sample will be washed as indicated. The
amount obtained from washing shall be added to that obtained by dry sieving;
and the total amount passing each sieve shall meet the above gradation.
2. Plasticity
Plasticity index when tested as per BS1377 = P2 = Test 5: 1990: Test
shall not exceed 6.
3. Test for Resistance to Abrasion - Gravel materials shall show a loss

on abrasion of not more than 30% using ASTM C131 or C535.
4. Soundness - When tested with magnesium sulfate solution for soundness
using ASTM C88 – “5 cycles”, coarse aggregate shall not have a loss of
more than 12 percent at the end of five cycles.
Type of Test Standard Method
1. Gradation BS 1377 Part 2 Test 9.2
2. Plasticity BS 1377 Part 2 Test 5.4

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3. Resistance to Abrasion ASTM C131 or ASTM 535
4. Soundness ASTM C88
2/26.7 Free-Draining Materials - Free draining material shall consist of sand,

gravel, rock fragments, quarry run stone, broken stone, reclaimed
miscellaneous aggregate containing no more than 15 percent by mass of
bituminous concrete or mixtures thereof. This material, or the material from
any one source of a mixture, shall not have more than 70 percent, by mass,
passing the 425 m mesh sieve and not more than 10 percent, by mass,
passing the 75 m mesh sieve.

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SECTION 3 – PAVEMENT CONSTRUCTION
3/33 Placing of the Mix
3/33.4 Spreading and Finishing
The mixture shall be laid upon an approved surface, spread and struck off to
the required grade elevation. When paving widths of one or two traffic
lanes, the entire width shall be placed by one paver in one pass; longitudinal
joints will not be permitted. When paving widths of more than two traffic
lanes, two pavers shall operate in echelon so that the entire width of the
roadway is covered in one pass. The second paver shall follow as closely
as possible behind the first paver so that the temperature of the mixture in
the advance lane will not fall below 80oC. Each paver shall be fully manned
at all times that paving operations are in progress.
Plant production, the number of trucks, and the speed of the asphalt
paver(s) shall be such as to insure delivery of the mixture to the project in
sufficient quantities and at such intervals as to permit the paving operation.
Failure to maintain such delivery shall be cause for the Engineer to suspend
the work.
When delivery of material is delayed so that a paver remains idle for more
than 30 minutes or when the temperature of the mix falls below the minimum
specified in Section 3/33.1 of the general specification, the paver shall be
moved away from the end of the lane and the material in place fully
compacted. When adequate material is at hand to insure against further
delay, the material at the end of the partially completed lane shall be cut
back and a transverse joint constructed.
If a void should appear on the asphalt mat after it has been screeded, the
contractor shall place asphalt mixture by hand in the void and rake out all
large aggregate. Broadcasting will not be permitted. The Contractor must
minimize stepping over the fresh mat of asphalt during laying.
Spillage of mix in front of the paver is not permitted.
The truck bed shall be raised slowly. When the mix is dumped too rapidly,
segregation occurs as course aggregates will roll down the side of the loads.
The hydraulic system of the truck-bed hoist should be frequently inspected to

guard against hydraulic fluid leakage. Such a leakage on the roadway surface
will prevent good bonding between the roadway and the new mat.
Bumping the Paver - When an end dump truck is used to deliver mix to the

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paver, the driver must back the truck up to the lay down machine but stop just
short of the push rollers on the front of the paver. Once the truck has come to
a halt and the driver has released the brakes on the vehicle, the paver
operator should start the machine moving forward picking up the stopped
truck.
3/33.6 Joints
Longitudinal and transverse joints in succeeding courses shall be offset from
the joint in the underlying course be not less than fifteen (15) centimeters
stepping progressively as shown on the Plans or as directed by the Engineer.
The longitudinal joint in the surface course shall be coincident with the last
lines.
Transverse joints shall be carefully constructed an thoroughly compacted to

provide a smooth riding surface. Joints shall be straight edged to check
smoothness. If the line of joint is formed with a bulkhead, it shall form a
straight line and vertical face. If a bulkhead is not used to form the joint, the
joint shall be made by sawing the compacted mixture a sufficient back of the
end of the placement to assure full thickness of the pavement at the joints; the
material ahead of the sawed joint shall be removed. In either case, the joint
shall be painted with a thin coat of tack coat before the fresh material is
placed against it. Cross rolling, unless prohibited by field conditions is
required to obtain through compaction of these joints.
Where longitudinal joints are constructed, and due to the required
Where longitudinal joints are constructed, and due to the required
maintenance of traffic or to unforseeable conditions, the temperature of the
mixture at the longitudinal edge of the strip first laid becomes less than 80oC,
the edge shall, prior to paving the adjacent strip, be painted with a thin coat of
tack coat. If the edge of the joint is not vertical, it shall be saw cut to a vertical
face.
3/37.8 Additional text following the word “permitted”
Up to Three (3) individual results from any consecutive twenty (20) may be
permitted to fall below the requirement value providing no individual result falls
below ninety-sic (96) percent for base course and ninety-seven (97) for
wearing course.
3/43.4 Additional text following Section 4/43.3 of the General Specification.
The rideability tests to be carried out on all major highways and the test on
any other roads to be decided by the Engineer in Consultation with the Client.
The rideability test will be carried out free of charge by RTA.
3/47.3 Replace the following text:
tested for bitumen content by ASTM D-2172: by ”tested for bitumen content in
accordance with ASTM Draft Method No. 7 or the latest edition of the ignition
method”.
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4/2 Aggregates General Requirements
The following paragraphs are additional to the requirements of Section 4/2 of

the General Specifications:
1. Aggregates shall contain no harmful material that will adversely affect

the strength and durability of the concrete or attack steel reinforcement.
Aggregates shall not be composed of or contain any materials likely to
cause staining or otherwise to disfigure finished concrete surfaces.
2. The Contractor shall provide evidence that aggregate sources do not

contain material that is potentially reactive to alkalis. The Contractor
shall also arrange for the potential analysis of aggregates in accordance
with ASTM C294 and C295 to identify the mineral constituents. Only
aggregates not susceptible to alkali aggregate reaction, all of which are
certified by an expert competent in concrete chemistry as unlikely to be
reactive, shall be used.
3. Fine aggregates shall be natural sand, manufactured crushed rock sand,

or a combination of both. The Contractor shall note that the term
“manufactured crushed rock sand” does not include crushed rock fines
which are by-products of course aggregate production. A combination of
natural sand and manufactured crushed rock sand will only be permitted
where the two materials are separately batched and where each
separate material, with the exception of grading, complies with the
requirements of this specification. In addition, the evidence of full scale
comparative site trials shall be carried out to clearly demonstrate that a
combined fine aggregate provides improved concrete relation to the use
of either material as a sole fine aggregate.
4/9 Bar Schedules and Shop Drawings
4/9.1 Additional text:
The Contractor shall submit to the Engineer for approval along with bar
schedules, working drawings in enough details. Before ordering reinforcing
steel, the Contractor shall obtain the approval of the Engineer for the working
drawings and bar bending schedules.
4/9.2 Delete the text of this clause and replace with:
Prior to the execution of the works, the Contractor shall provide and submit to
the Engineer for approval any working drawings additional to the Contract
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Drawings, which may be found necessary for the completion of the work.
4/11 Placing and Fixing Reinforcement

Verify the requirement for cover using covermeter’s measurements at a

frequency of one reading per one square meter of the concrete surface with a
minimum of 10 readings for each element. Such readings shall be submitted
to the Engineer for approval before surface protection is applied.
2. In addition to other requirements, each concrete element shall satisfy

both of the following conditions:
a) Eighty percent (80%) or more of the cover readings shall exceed

the nominal cover.
b) All the cover reading shall exceed the minimum cover specified on
the drawings.
In case of either or both of the above conditions are not met, the element
in question shall be considered defective and shall be removed
immediately from the Site and replaced at the Contractor’s cost, or
subject to the Engineer’s approval, additional surface protection
measures shall be specified by the Engineer and supplied and applied
by the Contractor at no extra cost to the contract value. All delays
resulting from such defective work shall be borne by the Contractor.
4/13 Spacer Blocks
Add the following text
Spacer Blocks (Buried Concrete Surfaces)

Concrete cover blocks required for ensuring that the reinforcement is correctly
positioned, shall be as small as possible consistent with their purpose, of a
shape acceptable to the Engineer, and designed so that they will not overturn
when the concrete is placed. They shall be made of concrete with 10mm
maximum aggregate size to produce the same strength as the adjacent
concrete. Tying wire complying with the requirements of the specification shall
be cast in the block for the purpose of tying it to the reinforcement.
Spacer Blocks (Exposed Concrete Surfaces)

Concrete cover blocks required for ensuring that the reinforcement is correctly
positioned, shall be as small as possible consistent with their purpose, of a
shape acceptable to the Engineer, and designed so that they will not overturn
when the concrete is placed. They shall be made of asbestos cement, factory
produced and of the same strength as the adjacent concrete. Tying wire
complying with the requirements of the specification can be cast in the block
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for the purpose of tying it to the reinforcement.
4/14 Admixtures

The use of an admixture containing chlorides, inorganic sulfates or other

corrosive agents will not be permitted.
Plasticisers and superplasticisers shall not contain substance, which adversely

affect the durability and performance of the concrete.
If two or more admixtures are used simultaneously in the same concrete mix,
data including manufacturer certificate shall be provided to assess their
interaction and ensure their compatibility.
4/15 Concrete Mix Specifications
Add the following to Table 4.5 – Table of Mixes
Concrete Max Min Qty of Max free Characteristic cube

Class Size Cement water/ cement strength CCS
Agg. ration
Mm Kg. per m³ 7 day 28 day
N/mm² N/mm²
50/20 20 420 0.40 36 50
4/16 Concrete Mix Design

Failure to comply with the permeability requirements of PS 4/17/4 paragraphs

1 and 2 will render the mix design and/or the curing procedure unacceptable.
The Contractor shall carry out as many trial mixes as necessary to
demonstrate that the mix design and curing procedure adopted will produce
concrete of the specified strength and permeability.
4/16.7 When the mix has been approved, no variations shall be made in the
proportions, the source of the cement and aggregates, or in the type, size and
grading zone of the latter without the consent of the Engineer who prior to
giving such consent may require further tests to be made.
The Engineer may also require practical tests to be made on the site by filling
trial molds to confirm the suitability of the mix for the Works. In these tests,
the type of plant used for mixing, the method of compaction used, and the

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formwork face to the mold shall be similar in all aspects to those intended for
use in the Works.
4/17 Quality Control
4/17.4 Durability Tests
4/17.4.1 The following paragraphs are additional to Clause 4/17.4 of the General
Specifications:
1. Initial Surface Absorption Test (ISAT) shall be carried out on prototype

samples of different components of the structure before the mix design
or manufacturing method are approved. The prototype samples shall be
short sections of not less than 1.0m x 1.0m x full thickness. The
samples shall be fully reinforced and cast in similar environment as the
actual structure. The ISAT tests shall be carried out in accordance with
BS 1881 between 28-40 days after casting the samples and the
maximum value shall not exceed the following limits at 10 minutes after
starting the test:
In-situ construction: Less than 0.20 ml/m2/s.
2. In addition to ISAT, the chloride permeability of the concrete shall be

determined using cores taken from the prototype samples cast for ISAT,
in accordance with ASTM C1202 “Electrical Indication of Concrete’s
Ability to Resist Chloride Ion Penetration”. The following limits shall not
be exceeded.
In-situ construction coulombs.
3. The concrete will be deemed to comply with the permeability

requirements of this specification if all test results comply with the
following:
a) ISAT results for unprotected surfaces:

Limit given in paragraph 1 above.
b) ISAT results for protected surfaces:
One fifth of the limits for the unprotected surfaces.
c) Rapid Chloride Permeability test results for unprotected surfaces:
Limit given in paragraph 2 above.
d) Rapid Chloride Permeability test results for protected surfaces:
Charge passed should be less than 500 coulombs.
4. If any of the ISAT and the rapid chloride permeability test result of
unprotected or protected surfaces of a sample failed to meet the above
requirements, then all the concrete work represented by such sample
shall be deemed not to comply with the permeability requirements.
5. If, in the opinion of the Engineer, the concrete which has failed to meet
the permeability requirements of this specification is likely to cause
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durability problems, three cores shall be cut from the area represented
by failed samples for additional ISAT and rapid chloride permeability
testing. The actual location shall be decided by the Engineer.
6. The cost of cutting and testing cores and any resultant delay shall be
borne by the Contractor regardless of whether the permeability of the
deposited concrete proves to be satisfactory or not.
7. Where the permeability test results found by testing the three cores
taken from the structure is confirmed as not complying with the
permeability requirements, then the Engineer may instruct that further
cores to be cut and tested in order to determine the full extent of the
defective concrete and further investigations to be carried out.
8. Defective concrete shall be cut out and replaced or alternative remedial

action shall be taken, as the Engineer directs, and the cost of such work
and any resultant delay shall be borne by the Contractor.
4/17/6 Non structural/reinforced Concrete
Non structural, non-reinforced concrete, examples — bedding, backing to

kerbs, concrete surrounds, haunches etc. as directed by the Engineer shall be
sampled and tested, cured, stored and transported in accordance with BS
1881 parts 108, 111 and 116. A set of six (6) cubes shall be taken for each 50
m3 or part thereof daily. 3 tested at 7 days, 3 tested at 28 days. The results
shall exceed the class of concrete strength by 1.64 times the standard
deviation on an average calculated from a minimum of 20 results. No
individual average of 3 cubes shall fall below 85% of the class/grade of
concrete
4/18 Responsibility and Criteria
The Contractor shall design and be responsible for the performance of all
concrete mixes used in structures. The mix proportions selected shall
produce concrete that is sufficiently workable and finishable for all uses
intended and shall conform to the requirements of the drawings and all other
requirements of this Section.
4/19 Consistency of Concrete
Delete the text of Section 4/19.1 of the General Specifications and replace
with:
4/19.1 The consistency of concrete at point of placing shall be specified by the

Contractor in his mix design subject to the approval of the Engineer.
The specified slump shall assure sufficient workability for the concrete
consistent with the method of concrete placement intended. The design
mix shall maintain a low water-cement ratio while providing the required
workability particularly for pumped concrete. The Contractor shall
clearly indicate the specified slump while concrete is affected by
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admixture. The consistency of concrete at the time of delivery shall not

vary by more than 25mm from the designated consistency or as directed
by the Engineer.
4/20 Tolerances in Proportioning the Materials
4/20.4 The following paragraph is addition to Section 4/20 of the General

Specifications:
Admixtures - Admixtures shall be measured by volume if in liquid form and by

weight if solid. The measurement shall be accurate to within 3.0 percent
throughout the range of use.
4/23 Ready Mixed Concrete
The following paragraphs are additional and overriding requirements to those

of Section 4/23 of the General Specifications:
4/23.7 The requirements of this specification in respect of materials, testing, storage,

patching and mixing, shall apply equally to the central batching plant of the
ready mix producer. In particular, works test cubes and permeability samples
shall be taken on site as specified irrespective of any cubes which may have
been taken by the supplier.
4/23.8 The addition of water at site shall not be permitted. Concrete delivery vehicles
shall not be fitted with means of direct delivery of water into the drum.
4/24 Mass Concrete
Mass Concrete placement shall be defined as any pour in which the concrete
being cast has dimension of 1.50 meter or greater in three different directions.
For all mass concrete pours, the mix temperature shall not exceed 25 degrees
centigrade as measured prior to placement of the concrete into the forms.
Further, the Contractor shall be required to maintain a temperature differential
of 20 degree’s or less between the interior and exterior of all mass pour
elements during curing.
Mass concrete Construction shall confirm to the requirement and

recommendation specified in ACI Publication 207.1R ‘’Mass concrete’’
and ACI 207.2R’’ Effect of restraint, Volume change, and reinforcement of
Cracking of Mass Concrete’’.
The Contractor shall provide temperature monitoring devices to record

temperature development between the interior and exterior of the element at
point approved by the Engineer and shall monitor the mass pours to measure
temperature differential. Temperature monitoring shall continue until the
interior temperature is within 20 degrees Centigrade of the lowest ambient
temperature or a maximum of two weeks.
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The “Resident Engineer shall be provided with a copy of each set of readings
as they are taken a temperature chart for each mass pur element showing
temperature readings vs. time. Prior to [placing any mass concrete on this
project, the Contractor shall submit for approval.
• An analysis of the anticipated thermal development within mass pour

placements using the proposed materials and casting methods.
• A plan outlining specific measures to be taken to control the temperature

differential within the limits noted above.
• Their proposed monitoring system.
If the Contractor is proposing a special concrete mix design as part of the

temperature control plan, this mix design should also be submitted for review.
If monitoring indicates that the proposed measures are not controlling the
concrete temperature differential within the 20 degrees specified, the
Contractor shall make the necessary revisions to the plan and submit the
revised plan for approval.
The contractor shall assume all risks connected with the placing of mass pour
concrete and approval of the Contractor’s plan will in no way relieve the
Contractor of the responsibility for satisfactory results. Should any mass
concrete placed under this specification prove unsatisfactory, the Contractor
will be required to make the necessary repairs or remove and replace the
material at the Contractor’s expense.
All costs associated with special temperature controls for mass concrete
placement shall be included in the unit const of the concrete cast, and will be
without addition specific compensation. The control of temperatures in mass
concrete pours shall be in addition to any other requirements found in the
plans, the General Specifications, and the Particular Specification which may
apply to the work in question.
4/25 Compaction of Concrete
Additional text.
4/25.5 Accumulation of water on the surface due to any cause during concreting is to
be prevented as far as possible and any such water is to be removed before
further concrete is placed.
4/26 Construction Joints
4/26.10 The location of all construction joints shall be shown on the shop drawings for
the approval of the Engineer. The face edges of all joints that are exposed to
view shall be carefully finished true to line and elevation. Shear keys, formed
into or out from the surface of the previously placed concrete or steel dowels
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shall be used where required. Shear keys formed into the concrete shall be
formed by the insertion and subsequent removal of beveled wood strips which
shall be thoroughly saturated with water prior to insertion. Additional steel
dowels may at the direction of the Engineer, be used in lieu of keys. The size
and spacing of the keys and dowels shall be as approved by the Engineer.
4/26.11 Care shall be exercised not to injure the concrete or break the concrete-steel
bond at any time. In constructing bridge floors where longitudinal joints are
specified, a platform shall be constructed outside the longitudinal joints and
supported on the lower slab form and workmen shall not be permitted to stand
or walk on the projecting reinforcement bars until the concrete has hardened.
Bonded Construction Joints - Except where otherwise specified,

bonded construction joints where required shall be made using either of
the following procedures:
Plant Joint - After the concrete has hardened so that the header board
or form can be removed without damage to the concrete, it shall be
removed and the cement paste removed from the surface by washing
with water under pressure or by sandblasting to expose clean, well-
bonded aggregate.
To facilitate the removal of the cement paste, the surface of the header
board or form that shall be in contact with the first pour may be
thoroughly covered with a retarder.
The retarder shall be a ready-to-use liquid compound that delays the set
of the surface concrete to facilitate the exposure of the aggregate and
shall be approved by the Engineer in advance of the beginning of the
work. It shall produce results satisfactory to the Engineer and shall be
evaluated on the basis of the manufacturer’s data and
recommendations. When the retarder is used, washing with water under
pressure shall be used to expose clean, well-bonded aggregate.
After the surface has been prepared, the concrete shall be kept
saturated with water until the new concrete is placed, or it shall be
saturated for a period of 4 hours before placing of new concrete, the
forms shall be drawn tight against the concrete already in place.
Epoxy Resin Joint - After the header board or form is removed and the
concrete has cured for the normal period, the second pour will be
bonded to the first pour by the application of a two-component liquid
polysulphide polymer epoxy resin concrete adhesive to the concrete joint
surface. The epoxy concrete adhesive shall conform to the
requirements of United States Government Federal Specification MMM-
B-350A or ASTM CB81.
The surface on which the adhesive is to be applied shall be free of oil,

dirt and loose concrete. All unsound concrete shall be removed until a
base of strong, undamaged concrete is exposed on which to apply the
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adhesive. Heavy deposits of dirt or oil products shall be removed by

wire brushing or sandblasting. The surface shall be free of moisture and
dry before application of the adhesive. The adhesive shall not be
applied to newly placed concrete before the normal curing period has
elapsed.
Immediately before application, the two adhesive components shall be

combined in the proportions specified by the adhesive manufacturer.
The components shall be intimately blended by hand or with a slow
speed motor drive mixing device. The mixture of adhesive shall next be
thinned by adding and blending the solvent into the adhesive. The
amount of adhesive mixed at one time shall be limited to that quantity
which can be conveniently applied within the pot life of the adhesive.
The two components and solvent shall not be mixed more than 30
minutes prior to use. The resulting adhesive shall be brushed onto the
concrete in a layer 1mm to 2mm thick. After the adhesive has been
applied, concrete shall not be placed against it until the solvent has
evaporated. The adhesive must be tacky and not dry at the time of
concrete application. Areas that have been allowed to become dry shall
be recoated before concrete is placed.
Because of toxicity of the materials, including the solvents, some safety

and health hazards exist in the handling and use of the materials, and
may cause serious rashes in persons sensitive to the materials. Further,
in the use of solvents as cleaning aids there exists a fire and flash
hazard.
The Contractor shall obtain from the formulator of the materials complete
instruction as to the safety, health and handling precautions that must be
exercised with respect to the materials to be used, and as to the
procedure that shall be followed in the event that workmen come in
contact with the material. Before they are permitted to proceed with the
work, the workmen shall be instructed as to the hazards to which they
will be exposed, the necessary safety precautions and the procedure to
be followed in the event of accidental contact with the materials.
4/27 Curing Concrete
Water used for curing shall be in accordance with Specification

Clause 4/6.
4/30 Concrete in Hot Weather
1. No Concreting shall be carried out without the Engineer’s approval. The

Contractor shall submit for the Engineer’s approval full details of his
proposal for ensuring compliance with the recommendations of “The CIRIA

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guide to Concrete Construction in the Gulf Region”, ACI 305

“Recommended Practices for Hot Weather Concreting” and ACI 308
“Recommended Practice for Curing Concrete” and the following:
a. The temperature of the concrete at the time of placing shall not exceed
32°C for in-situ concrete and 30°C for precast concrete. The Contractor
shall ensure that accurate concrete thermometers and air temperature
thermometers are available at all times during concreting.
b. The Contractor shall take special measures to control the temperature of

the concrete below the above limits. Such measures shall be approved
by the Engineer and shall include but not limited to the following:
• Aggregate stockpiles shall be protected from the direct rays of the sun by
shades. The stockpiles shall not be watered.
• Water for mixing concrete shall be cooled by means of mechanical

equipment or the addition of ice, Storage tanks shall be painted white or sited
under shade and distribution pipes shall be insulated or painted white, and
maintained white.
• Cement shall be stored in the shade. Bulk storage containers shall be painted
white, and maintained white
• The mixing plant and delivery equipment shall be painted white and sited
under shade wherever possible. The interval between mixing and placing
shall be kept to a minimum.
• Reinforcement shall be kept in the shade for minimum period of four hours
before concreting.
• Immediately before the concrete is placed formwork, construction joints, etc.,

shall be sprinkled with cool water complying with Section 4/6 of the General
Specification.
• During the curing period exposed concrete surfaces shall always be

protected from the direct rays of the sun, and the formwork, as far as
possible, shall be protected.
• In a prevailing arid wind, temporary windbreaks shall be provided.
2. The Contractor shall provide and use an ample and clear water supply,
hose and fog nozzles. Only water complying with Section 416 of the
General Specification will be allowed for washing forms, curing concrete or
compaction of structural fill material adjacent to concrete.
3. The Contractor shall provide and use an ample and clear water supply,
hose and fog nozzles. Only water complying with Section 4/6 of the
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General Specification will be allowed for washing forms, curing concrete or

compaction of structural fill material adjacent to concrete.
4. The Contractor shall schedule his operation to place and finish the
concrete during the period in which the air temperature in the shade is
below 35CC or as approved by the Engineer in accordance with the
General specifications requirements.
Control of Temperature
The temperature of the concrete when placed shall not exceed 32°C nor shall
concrete be mixed or placed when the shade air temperature is 35°C or above,
or is expected to reach such a level during concreting and 3 hours after
placing, without special permission from the Engineer.
For all concrete sections the Contractor shall take precautions to limit the
effects of heat of hydration.
For concrete sections greater than 1200 mm thick, the Contractor shall submit
to the Engineer for approval detailed proposals of the measures to be taken.
These measures shall include but are not limited to: control of concrete mix
constituents; curing water; formwork type; surface insulation; and, cooling by
embedded pipes. All submissions shall be based on measured values of heat
of hydration generated by the proposed mix to meet the criteria set out below:
Maximum temperature difference between the core and the surface of any
pour. Design target 15°C. Field maximum 20°C.
Maximum temperature difference between a new pour and a previous pour.

Design target 12°C. Field maximum 15°C.
Absolute maximum temperature anywhere in a pour. Design target 60°C. Field

maximum 70°C.
Instrumentation shall be installed in the Works to verify compliance with the

above criteria. Temperature measurements shall be made b means of
thermocouples positioned in a line perpendicular to the concrete faces. The
thermocouples shall be fixed: at the concrete faces; at the centre of the
section; and, at equal intervals of approximately 300mm.
Temperatures shall be measured and logged continuously from the start

of the pour until instructed to stop by the Engineer. The Contractor shall
submit to the Engineer for approval details of the proposed methods and
equipment for the measuring and logging of temperatures.
If temperature measurements exceed any of the criteria above then action shall
be taken in accordance with the sub-section on defective concrete.

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4/31 Minimum Test Requirement for Concrete
Unless the Engineer otherwise directs, the testing program conforming to the
applicable procedures set out in the relevant ASTM and BS specifications
shall include at least the tests specified in the following paragraphs:
1. Test for clay, silt and dust, moisture content and a sieve analysis shall
be carried out on every 500m3 of fine aggregate and 1000m3 of coarse
aggregate delivered to site or as directed by the Engineer.
2. Chemical analyses of the aggregate shall be carried out on every

1000m3 or as directed by the Engineer of each type of aggregate
delivered to site. Petrographic analyses of the aggregate shall be
carried out on all new sources of aggregate or when directed by the
Engineer.
3. All tests to determine the physical and mechanical properties of the

aggregate including the magnesium sulfate soundness, soaked and
unsoaked 10% fines and immersed rotations tests, shall be carried our
on every 1000m3 of each type of aggregate delivered to site or as
4. Slump tests shall be carried out at the rate of one test per load concrete
delivered to or transported on site, or one test per 10m3 of concrete
whichever is the lesser. Any variation from these slumps necessitated
by the use of superplasticisers and the like shall be approved by the
Engineer.
5. Samples for compressive strength tests shall be taken as specified in the

General Specifications Clause 4/31 Table 4.6 with a minimum of one
sample taken every day that the mix is used. A sample consists of 6
cubes, 3 to be tested at 7 days and 3 at 28 days. Additional cubes may
be taken as directed by the Engineer.
6. For each component of the structure (such as pier, abutment, etc.)

permeability samples shall be tested in accordance with Section PS
4/17.4 of this specification for permeability compliance. For each
sample, a minimum of 5 tests, each for Initial Surface Absorption and
chloride permeability, shall be carried out.
Portion of the surface of each permeability sample shall be protected in

accordance with Section PS 4/17.4 and a minimum of 5 tests, each for
Initial Surface Absorption and chloride permeability, shall be carried out
on the protected portion of the sample.
Permeability samples shall be cast concurrently with and cured similar to

the work they represent at the following rates:
• One sample for each bridge substructure.

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• One sample for each bridge superstructure.

• When directed by the Engineer.
4/33 Classes of Finishes
4/33.4 Class of Finish
All exposed surfaces of the structure shall be of a quality that satisfies the
Engineer and the Client. The Contractor shall prepare samples for all
Classes of finish for all exposed surfaces. The length of the sample shall be
6m (mm). The width of the sample shall represent the final structure and
shall be to the approval of the Engineer. The samples shall clearly
demonstrate the finish that will be achieved at locations where multiple
joints occur in the formwork.
The sample will demonstrate the final finished appearance of the concrete
Oil removal of fom9work. The Contractor shall at his own expense surface
make as samples as required by the Engineer until a sample panel has
been accepted by the Engineer as satisfactory.
The final approved sample, when accepted will form the standard against
which the corresponding surfaces in the works will be judged. No concrete
shall be cast in these areas until the trials have been completed to the
Engineer’s satisfaction.
Samples shall not be made until the complete methodology (including all
materials to be used, pouring, curing, vibration of concrete etc.,), size and
location of the sample is approved by the Engineer.
Class F3a
All exposed surfaces on the underside of the deck and sides including the
circular edge piping are to be Class F3a. The requirements for Class F3a
are as for Class F3 except that finish should be a seamless struck finish to
the approval of the Engineer.
The Contractor may propose to use GRC formwork to form the circular
edge piping. A fine butt joint will be accepted. Samples sections shall be
presented to the Engineer for approval. These samples shall include the
balustrade fixing details.
Class F3b
Exposed surfaces of the abutment and New Jersey Barrier are to be Class
F3b. The requirements for Class F3b are as for Class F3 except that finish
should be a patterned struck finish to the approval of the Engineer. Details
of the patterns shall be provided by the Engineer.

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Class F3b surface texture treatment shall be obtained by the use of form
liners. Before ordering form liners, the Contractor shall submit of each form
liner panel for selection and approval by the Engineer.
Form liner panels shall remain stable and free from distortion in the climatic
conditions relevant to the Site.
The form liners shall be set in the forms and used in accordance with the
manufacturer’s instructions. Care shall be taken when setting formwork to
ensure that the depth of texture treatment is outside of the neat wall line
providing the concrete cover to reinforcing steel specified in the Contract
Documents.
Irregularities of pattern and holes in the final textured surfaced shall be

patched with cement mortar and all stains shall be removed to the
satisfaction of the Engineer either by wire brushing or by sandblasting.
4/36 Post-Tensioned Concrete Works
4/36.1 General Description
Post-tensioned concrete work shall be as indicated on the Drawings, as

specified herein and/or included in the Bills of Quantities. This work includes,
but not by way of limitation, supplying and fixing formwork, falsework and
temporary works; supplying, testing and placing prestressing steel with all
accessories, metal ducts and anchors; supplying concrete of the class as
indicated on the Drawings or specified herein and transporting and placing it
in prepared forms; tamping, vibrating, finishing and curing the concrete;
pointing and jointing with cement mortar; post-tensioning prestressing steel;
pressure grouting ducts; all in accordance with the specifications and Contract
Documents.
Before a pretensioning or post-tensioning subcontract is awarded, the

Contractor shall submit to the Engineer for approval, the name and address of
the organisation proposed for the performance of the tensioning operations
under these Specifications.
The named proposed organisation shall submit evidence that it has, for the
preceding five years, performed work comparable to the tensioning work
under these Specifications, and shall verify this experience by citing
references for substantial quantities of work comparable to those contained in
this Contract which have been successfully accomplished. The reference shall
include the following information:
• Project Name and Country
• Client Authority
• Contractor

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• Engineer
• Description of the post-tensioning works including ambient

temperature at time of grouting, length and diameter of ducts stressed
and grouted, precautions to overcome the effects of high temperatures
etc.
4/36.1.1 Standards And Codes
Standards and codes shall be as specified in Section 4, Concrete Works of

the General Specifications.
4/36.1.2 Submittals
The submittals listed herein shall be provided to the Engineer well in advance
of the commencement of any pre-stressing works to allow the Engineer
sufficient time to review and give approval.
The Submittal requirements must not be taken as exhaustive, and the

Contractor shall supply any additional information necessary to enable the
Engineer to fully evaluate the Contractor’s pre-stressing proposals. All
submissions must be thoroughly checked by the Contractor for numerical and
conceptual errors before submitting to the Engineer for approval.
Any delays in the Engineer granting his approval consequent to incomplete,

late, inadequate or unchecked submissions shall be entirely the Contractor’s
responsibility.
1. Shop Drawings - Shop drawings shall be submitted to the Engineer for

approval in accordance with Section 4/9 of General Specifications and
as specified herein.
All submissions must be thoroughly checked by the Contractor for

numerical and conceptual errors before submitting to the Engineer for
approval.
The working drawings and computations shall be checked by the

Contractor before submittal to the Engineer. All working drawings,
computations and related data shall be accompanied by design data
indicating that the forces indicated on the Drawings are obtainable and
that all prestressing hardware is adequate to transit these forces.
All drawings and computations shall be approved by the Engineer

before commencing any fabrication or delivery of material. No deviation
from the approved working drawings shall be made by the Contractor
without written permission from the Engineer. Any member not
fabricated in accordance with approved working drawings shall be
rejected by the Engineer.

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Supplementing the requirements for shop drawings specified in Section

4/9, the Contractor shall include with the shop drawings a description of
the equipment to be used and the procedure for constructing post-
tensioned concrete work.
The type and size of ducts and method of holding the ducts in position,
tendon sizes, jack clearances and procedures, stressing sequences,
grout connections and vents, anchorage details and bonding and
grouting procedures shall also be indicated.
Any delays in the Engineer granting his approval consequent to

incomplete, late, inadequate or unchecked submissions shall be entirely
the Contractor’s responsibility.
Certificates - Certificates from the manufacturers shall be furnished to

the Engineer certifying that the materials and equipment to be provided
comply with the requirements of these specifications.
2. Test Reports - The Contractor shall furnish to the Engineer six (6)
copies of test reports and certificates as specified herein, unless
Submittals shall include but not be limited to the following:
Materials and Equipment
1. The materials specifications indicating tensile strength and

relaxation characteristics, etc. of the proposed strand together with
a copy of the relevant specification.
2. Details of cast in anchorages, ducting, vent pipes, etc.
3. Stressing equipment including jacks, load cells, pressure gauges
etc, supported by calibration and other test certificates.
4. Grouting equipment and gauges supported by calibration and other
test certificates.
5. Specification of materials of anchorage protection.
Method Statements
1. Description of method and stressing equipment to be used.

2. Method and timing of placing strand (before or after concreting).
3. Method and equipment for concreting and protecting end
anchorages.
4. Example of stressing record sheets including intervals of
load/elongation readings.
5. Number of cubes intended for establishing the required strength for
stressing etc.
6. Sequence of stressing.
7. Grouting procedures and grout pressures to be adopted.
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8. Flushing procedures in the event of rejected grout or other

complication.
Calculations and Drawings
1. Arrangement of ducts including horizontal and vertical alignment

together with the duct support method and frequency of support.
2. Location of vents/drains.
3. Anchorage cast in items and reinforcement details.
4. Design data including friction coefficient; wedge pull in; other losses
including an allowance for anchorage friction and lack losses.
Indication of maximum jacking force showing that stresses in
concrete are no worse than those which would occur under the
original post-tensioning arrangement.
5. Predictions for load/elongation behaviour.
4/36.1.3 Quality Assurance
1. In the event the Contractor proposes to perform the post-tensioned

concrete work with his own forces, the Contractor shall submit all details
of his qualifications as specified herein and as required by the Engineer
for approval by the Engineer of the Contractor to perform the work.
2. In the event the Contractor is unable to provide acceptable and

adequate information of his qualifications to perform this work and is
rejected by the Engineer for the post-tensioned concrete work, the
Contractor will be required by the Engineer/Employer to subcontract
such works.
3. The Contractor will be required to submit to the Engineer for review and
approval, the following information regarding his qualifications or those
of the proposed subcontractor:
a) The Contractor shall submit the name and address of the proposed
organization or subcontractor, along with a complete and detailed
description of their qualifications and experience in the
performance of post-tensioned concrete work.
b) The named proposed organization or subcontractor shall submit

evidence acceptable to the Engineer that the organization or
subcontractor is experienced in the field of prestressing systems.
Further, the Contractor or proposed subcontractor shall submit
data acceptable to the Engineer that they have, within the last five
years, performed such construction or work comparable to the
post-tensioned concrete works as specified in these Particular
Specifications and indicated on the Drawings. The Contractor shall
confirm this experience by citing a minimum of two projects
comparable to the current project which have been successfully
accomplished.

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c) Approval by the Engineer of the Contractor’s organization or the

subcontractor for the performance of the post-tensioned concrete
works shall not relieve the Contractor of overall responsibility for
such work.
d) In the event the Contractor or an approved subcontractor

demonstrates an inability to perform the work as specified in this
Section for Post-Tensioned Concrete Works subsequent to the
approval by the Engineer, the Engineer reserves the right to rescind
such approval and require that the Contractor submit the name of
another subcontractor to perform the work. All re-submittals shall
comply with the requirements specified herein and all Contract
Documents.
4/36.1.4 Sampling and Testing
1. Concrete - Concrete sampling, testing and frequency of testing shall be

in accordance with Section 4, Concrete Works, and as amended in
Section PS 4/17.
2. Prestressing Steel - All reels of prestressing steel shall be

accompanied by an inspection and test certificate furnished by the
supplier indicating the number of reels in the shipment represented by
the certificate, modulus of elasticity, stress/strain curves, tensile
strength, relaxation test results and strand chemical composition.
For each certificate furnished, a sample, as described herein, shall be

furnished to the Engineer for testing purposes.
The Contractor shall make arrangements with the vendor to furnish the
Engineer, samples as selected at random from the lot of reels
represented by each certificate. samples shall be not less than 1.20m in
length.
All samples submitted shall be accompanied by a certification from the

vendor certifying that the samples were taken from and are
representative of, the lot of reels to be furnished.
All of the above the anticipated date of use. The Contractor shall make
no claim for additional compensation if his work is delayed awaiting
approval of the materials testing.
The Contractor shall have no claim for additional compensation if his

work is delayed while awaiting approval of the materials furnished for
testing.
4/36.1.5 Scheduling of Post-Tensioned Concrete Works
The scheduling of all post-tensioned concrete work shall be such that

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construction of each individual superstructure unit can be completed within a

90-day period commencing with the first concrete pour through completion of
the post-tensioning and duct grouting operations unless otherwise indicated
on the Drawings, or directed by the Engineer.
The Contractor shall have sufficient materials on hand prior to commencing

work on any given superstructure unit to ensure completion of the unit within
the specified 90-day period.
4/36.1.6 Materials, Delivery, Storage and Handling
Prestressing steel shall be protected from physical damage and corrosion at

all times from manufacture to grouting or encasing in concrete. Physically
damaged post-tensioning steel will be rejected by the Engineer. The
development of visible rust or other results of corrosion will be cause for
rejection by the Engineer.
Prestressing steel shall be packaged in containers or shipping forms for the

protection of the steel from physical damage and corrosion during shipping
and storage. The manufacturer shall place a corrosion inhibitor, which
prevents rust or other results of corrosion directly to the steel, and in the
package or form, or shall use a corrosion inhibitor carrier type packaging
material. Corrosion inhibitor shall have no deleterious effect on steel or
concrete or bond strength of steel to concrete.
Shipping packages shall be clearly marked with a statement that the

packages contain high-strength post-tensioning steel, and that care is to be
used in handling; and that shows the type, kind and amount of corrosion
inhibitor contained, including the date packaged and safety instructions for
use.
Reel identification tags showing all the relevant details for the reel shall be
securely placed both on the inside and outside of the packaging.
4/36.2 Concrete and Materials
4/36.2.1 Post-Tensioning Systems
1. Post-tensioning systems for concrete box girders shall be of internationally

recognized types acceptable to the Engineer, as indicated on the
Drawings, and as specified in these Particular Specifications.
a) All the anchorage devices must be certified and have been tested
according to the acceptance test requirements for highly aggressive
environments to the approval and the satisfaction of the Engineer.
b) Strands shall be of the type as defined on the drawings.
c) Wire shall not be tempered and shall be of the type specified in the
drawings.
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d.) Anchorage assemblies, jacks, gauges, grout fittings, and other

related equipment and accessories shall be standard with the
system manufacturer and approved by the Engineer. Anchorage,
couplers and splices for bonded prestressing shall develop at least
95% of the minimum specified ultimate strength of the prestressing
steel tested in an unbonded state without exceeding the
anticipated set.
e.) Bituminous protective coating: complying with United States

Government Federal Specification SS-A-701.
f.) Epoxy bonding agent complying with United States Government

Federal Specification MMM-G-650A.
g.) Ducts for bonded post-tensioning strand shall be flexible,

galvanized, interlocked, mortar and grout tight and fabricated of not
lighter than 28 gauge steel. Ducts shall be at least 6 mm larger
than the nominal diameter of the strand or wire bundles and the
cross sectional area shall be at least twice that of the net steel
area. The ducts shall have grout openings at each end, and shall
be vented at high points of the ducts at piers. Ducts shall ensure
adequate bond between the grouted strand and the concrete
structure and shall comply with the recommendation give in FIP
Guide to Good Practice. Grouting of Tendons in prestressed
Concrete” published by Thomas Telford Ltd. Except where the
specifications give other requirements.
2. Post-tensioning systems of other manufacturers which are comparable

and equal in all respects to the specified systems may be used, provided
the proposed alternative post-tensioning systems have the prior approval
of the Engineer. The Engineer will be the sole judge as to whether or not
any proposed alternative system of post-tensioning is comparable and
equal to the specified systems.
4/36.2.2 Concrete
Concrete for post-tensioned concrete work shall be Class 45/20 (unless

otherwise indicated on the Drawings) specified in Section 4, Concrete Works,
of these General Specifications.
4/36.2.3 Reinforcement Steel
Reinforcement steel shall comply with the requirements of Section 4,

Concrete Works, of these Standard Specifications and where specifically
indicated on the Drawings or directed in the Particular Specifications.
Additional reinforcement may be required to support the ducts. Such

reinforcement will be at the Engineer’s discretion.

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4/36.2.4 Duct Grout Materials
1. Grout admixture shall be a balanced blend of expanding, fluidifying, and

water-reducing agents containing no calcium chloride, nitrates or other
chemicals causing steel corrosion.
2. Portland cement shall be as specified in Section 4 of General

Specifications.
3. Water shall comply with the requirements of Section 4, Concrete Works,

of these General Specifications.
Properties of Grout
Duct grout shall comply with the requirements given in the relevant
sections of the Specifications with regard to the following:
• fluidity and bleeding in the plastic condition

• volume change when hardening
• strength when hardened
The tests are specified in Section PS 4/36.2.5.
Fluidity - The fluidity of grout during the injection period shall be

sufficiently high for it to be pumped effectively and adequately to fill the
duct without excessive segregation, but sufficiently low to expel the air
and any water in the duct. When tested by the methods given in Section
PS 4/36.2.5 the grout shall have the values given in Table 1.
Table 1: Fluidity Test Requirements
FLUIDITY(S)
30 min. after mixing or at
Test Method Immediately end of injection period (see At duct Outlet
After Mixing Note 1)
Immersion > 30 < 80 > 30

Tube
Cone < 25 < 25 > 10
Notes:
1. Mixing time shall be measured from the point when all the materials are in the mixer.
Bleeding - The bleeding of the grout shall be sufficiently low to prevent

excessive segregation and settlement of the grout materials, when
tested by one of the methods given in Section

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PS 4/36.2.5.
The grout shall not be subject to bleeding in excess of 2% after 3 hours

or 4% maximum when measured at 18C in a covered cylinder
approximately 100mm diameter with a height of grout of approximately
100mm, and the water shall be reabsorbed by the grout during the 24
hours after mixing.
Volume Change - The volume change assessed may be either

increased or decreased. When tested in accordance with the methods
given in Section PS 4/36.2.5 the volume change of the grout shall be
within the range 0% and +3%. For grouts with expanding agents there
shall be no decrease in volume.
Strength - The compressive strength of grout may be assessed using

either of the specimen shapes and sizes given in Table 2 and using the
corresponding procedure given in the Table. In either case the
compressive strength shall be not less than the compressive strength of
the surrounding concrete at 7 and 28 days.
Table 2 : Compressive Strength Specimens
Specimen Specimen Dimensions Test Procedure

Shape (mm)
Prism 40 x 40 x 160 PS 4/36.2.5
Cylinder 100 dia x 80 height PS 4/36.2.5
Batching and Mixing of Grout - The proportions of materials used in the

mix may be selected on the basis of prior documented experience with
similar materials and equipment, and under comparable field conditions
(weather, temperature, etc.) and shall be verified by tests made on the
grout before grouting begins.
The water content shall be the minimum necessary to obtain the

required workability for proper placement and under no circumstances
shall the water/cement ratio exceed 0.44. The water content of any
admixtures shall be taken into account when calculating the
water/cement ratio. The materials shall be batched by weight with an
accuracy of +2% for cement and admixtures and +1% for water.
All materials shall be batched by mass except in the case of water which
may be batched by mass or volume.
Mixing shall be carried out mechanically to obtain a homogeneous and

stable grout with the plastic properties given in the Specification.

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Depending upon environmental or material influences (eg. Temperature,

configuration of the tendon and the properties of the cement use), the
w/c ratio shall be kept as low as possible having regards to the required
plastic properties of the grout.
A sufficient amount of material shall be batched to ensure complete

grouting of a duct making due allowance for overflow. The grout shall be
mixed in a machine capable of producing a homogenous grout and after
mixing, keeping the grout in slow continuous agitation, until it is ready to
be pumped into the duct, Water shall be added to the mixer first,
followed by the cement and if agreed by the Engineer, admixtures. The
batch quantities of cement and admixtures may be added as a whole or
in part in sequence until the total quantities are added.
Temperature at Grouting - Records shall be kept of the maximum and

minimum air temperatures and the temperature of the members to be
grouted.
Ambient temperature during grouting shall not be above 35Co.
Grout temperature at duct inlet and outlet shall not be above 32oC during
mixing or pumping. If necessary cold water shall be used for grout
mixing to maintain recommended temperature.
4/36.2.5 The Testing of Grout
The following tests, listed below, comply with the requirements of the F.I.P.
(Federation Internationale de la Precontrainte) Guide to Good Practice.
1. General Conditions - The grouts shall be tested by competent personnel

experienced in the subject, and in laboratory conditions of temperature
and humidity as follows:
Temperature (20 ± 2) oC
Humidity > 65% R.H.
The grout for the tests shall be made from the materials specified in and
mixed in accordance with the requirements of these Specifications. The
temperature of the freshly mixed grout is to be given in all test reports.
2. Fluidity Test - Immersion Method
Principle - The tests consists of measuring the time a plunger needs to

drop through a defined amount of grout in a tube.
Apparatus
a) Calibrated immersion equipment according to figure 1.

b) Wooden measuring rod according to figure 1.

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The water content shall be the minimum necessary to obtain the

required workability for prdpér placement and under no circumstances
shall the Water / cement ratio exceed 0.44. The water content of any
admixtures shall be taken into account when calculating the water /
cement ratio. The materials shall be batched by weight with an accuracy
of ±2% for cement and admixtures and ±1 % for water.
Calibration Procedures - The immersion equipment shall be calibrated

with glycerol (analytical grade) having a density of 1.23 T/M3 at 20oC.
The temperature of the room, immersion equipment and glycerol shall
be (20 + 1) oC during the calibration.
The cylinder shall be filled with about 1.9 litres of glycerol up to
approximately 250mm below the rim. After filling the immersion
equipment the glycerol shall be allowed to rest for about 1 hour. The
plunger then shall be immersed to expel any air bubbles from the
glycerol, which may have been introduced during the filling of the
cylinder.
After one hour the plunger shall be positioned so that its stop on the tail
rod lies on the spacer placed at the top of the tube. The spacer shall
then be pulled away to allow the plunger to sink to the top of the tube.
The immersion time (the time taken for the plunger to sink) shall be
recorded in seconds to the nearest second. The calibration shall be
repeated at least 3 times.
The mean value of all measured immersion times shall be (34 + 1)s. If
the mean value deviates for this figure, the weight of the plunger shall be
increased where t > 35s or reduced where t < 33s. This is done by
varying the quantity of the lead pellets in the plunger. Repeated
calibration procedures shall be delayed for at least 30 minutes to ensure
expulsion of any air bubbles that may be have been introduced during a
preceding calibration procedure.
Test Procedure
Preparation - The immersion equipment shall be calibrated before it is

used. Calibration of the immersion equipment shall be performed
subsequently once a year and/or after any damage.
Directly before the test, the inside of the tube and the plunger shall be
slightly wetted.
Procedure - The cylinder shall be filled with approximately 1.9 liter of

grout up to approximately 260mm below the rim, so that on introduction
the plunger is fully immersed when its stop on the tail rod lies on the
spacer placed at the top of the tube. The spacer should be pulled away
to allow the plunger to sink to the stop on the tube. Thereafter the
plunger should be raised back to its initial position, the spacer inserted
and again pulled away. The immersion time shall be measured, i.e. the
time it takes for the plunger to sink to the point where its tail stop touches
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on top of the tube. The immersion times of the grout shall be measured
immediately after the mixing process and after a further 30 minutes. For
the latter test, unused grout from the same mix as that used for the
former immersion test shall be used. The grout is to be kept in motion
while carrying out all tests. Each test shall be carried out three times in
succession with the same filling.
Reporting the Results - The result shall be reported as the average of

the immersion times to the nearest second of the second and third
immersion, i.e ignoring the first immersion time.
3. Fluidity Test - Cone Method
Principle - The fluidity of grout, expressed in seconds, is measured by

the time necessary for a stated quantity of grout to pass through the
orifice of the cone, under stated conditions.
2
Apparatus - The following apparatus is required for the test:
a) Cone - A cone of dimensions shown in figure 2. The cone shall be

robust and manufactured from materials not reactive with any duct
grout materials specified in these Specifications. The volume of
the cone (excluding the cylindrical portions at top and bottom) shall
be 1.7 liters + 10%.
b) Sieving Medium - The sieving medium aperture shall be 1.5mm
and the medium shall be fitted as shown in figure 2.
c) Stopwatch
d) Container of 1 litre capacity.
Test Procedure
Preparation - The cone shall be mounted with its axis vertical and its
largest diameter uppermost. The sieving medium shall be fixed at the
position indicated in figure 2. During the test the cone shall be prevented
from vibrating. The container under the cone outlet. All surfaces of the
cone shall be clean and slightly moistened. Close the lower cone orifice.
Procedure - Pour 1.5 liters of the grout through the sieving medium into
the cone sufficiently slowly to prevent the build-up of air in the grout in
the cone. Open the lower cone orifice and at the same time, start the
stopwatch. Measure the time taken to the nearest 0.5s to fill the
container. The presence of lumps on the sieving medium shall be
reported. Two tests shall be carried out, the first immediately after the
grout is mixed and the second 30 minutes thereafter or alternatively at
the end of the grouting period.
Reporting of Results - Report the time taken to the nearest 0.5s. Report
also the presence of lumps.
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4. Bleeding Tests
Principle - The test consists in measuring the quantity of water remaining
on the surface of the grout which has been allowed to stand protected
from evaporation.
Apparatus - A transparent I00 ml cylinder 25mm in diameter and 250mm
in height graduated in ml. Alternatively a transparent cylinder 50mm in
diameter and 200mm in height graduated in mm.
Procedure
Preparation - Place the cylinder on a surface free from shocks or

vibration. The grout used may be from the same batch as that used for
the fluidity test.
Procedure for 25mm diameter cylinder

Pour 95ml to l00mI of grout into the cylinder. Note the precise level of
the grout (v) ignoring the meniscus. After 3 hours, measure the quantity
of water on top of the grout (vl). taking appropriate measures to prevent
evaporation. The test is carried out on one sample of grout.
Procedure for 50mm diameter cylinder
Pour grout into the cylinder to a height of approximately 150mm. Note

the height to the top of the grout (h) ignoring the meniscus.
After 3 hours, measure the height of water on top of the grout (hl) taking
appropriate measures to prevent evaporation. The test is carried out on
one sample of grout.
Reporting of Results - Bleeding at the end of 3 hours is given by:
vl x I00% for 25mm diameter cylinder

v
and
hl x 100% for 50mm diameter cylinder
h
where
vl is the volume of water on the surface of the grout after 3 hours
in ml)
v is the initial volume of grout (in ml)
hl is the height of water on the surface of the grout after 3 hours
(in mm)
h is the initial height of grout (in mm)
The report shall state the temperature at the time of test.

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5. Volume Change Test
Principle - Testing shall be in accordance with the FIP (Federation

International de La Precontrainte) Guide for Good Practice Procedures.
The volume change is measured as a percentage of the volume of grout
between the start and the end of the test. The test measures mainly the
volume change caused by segregation or expansion.
The grout used in this test may have been used for the bleeding test
(see Test 4).
Cylinder Method
Apparatus - A transparent cylinder 50mm in diameter and 200mm in

height as required for test 4.
Procedure - Place the cylinder on a surface free from shocks and

vibration. Fill it with the grout to a height (h). Twenty four hours after
filling the cylinder measure the height (h2) to determine the change in
volume.
Reporting of Results - The volume change at the end of 24 hours is

given by:
h2 - h
h x 100%
where
h is the initial height of grout (in mm)

h2 is the height of grout after 24 hours (in mm)
Can Method
Apparatus
a) Three cans, 120mm high and approximately 100mm in diameter,

with lids capable of preventing the loss of moisture.
b) Measuring rod or sliding calipers
c) Plates
• Stop plate for placing on the can with a diameter of 120mm
(see figure 3)
• Stop plate for placing on the grout with a diameter of 96mm
(see figure 4)
d) Filling gauge 100mm high
Procedure - Place the cans on a surface free of vibration and heat

radiation and store for 24 hours. Immediately after mixing pour the grout
into each can using the filling gauge, to a depth of 100mm. The
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measurement of the distance from the top edge of the can to the top of
the grout is to be taken:
• immediately after the containers are filled and

• 24 hours after the containers are filled by one of the following
methods:
a) Measurement with the Stop Plate on the Can - immediately after

the cans have been filled with grout, measure the distance
between the surface of the grout and the stop plate on the can in at
least six places with the depth gauge (first measurement). The
marking must coincide with the top edge of the can (reference
point). Then the cans are sealed by covering with the lid weighted
with approximately 300g until the second measurement is carried
out 24 hours after the filling of the cans.
b) Measurement with the Stop Plate on the Grout - Immediately

after filling the cans, put the stop plate (figure 4) on the fresh grout
and measure with the depth gauge the distance between this plate
and the top edge of the can in at least six places (first
measurement). Then the cans are sealed. The second
measurement shall be carried out 24 hours after the filling of the
cans. In the second measurement the distance between the stop
plate and the top edge of the can is measured at the same places
as for the first measurement. After the second measurement the
cans are sealed as before, and used as necessary for the
compression strength tests (6).
Reporting of Results - The difference of the average values between

first and second measurement(s) in mm corresponds at I00mm grout
level to the volume change in percent and is reported as the percentage
change in volume. Report the percentage change in volume as the
average of the three containers to the nearest 0.1 %. Report increase of
volume as (+) and decrease
as (-).
6. Compression Strength Test
a) Compression Strength Test - Prism
Principle of the test - The compression strength of grout in this test

(which is an adaptation to grouts of the mechanical tests described
in BS EN 196-1) is determined on the broken halves of prisms.
Apparatus
i) Mixer for grout in accordance with the requirements of these

Specifications for hatching and mixing of grout.
ii) Air conditioned cabinet at (20 + 1) oC and (95 ± 5) % relative
humidity.
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iii) Test machine and the device in accordance with 4.7 and 4.8
of B.S. EN 196-1.
iv) Metal molds in accordance with 4.5 of BS EN 196-1.
v) Metal straight edge in accordance with figure 3 of BS EN 196-
1.
Procedure
Moulding of the Test Specimens - File moulds and accessories

shall be prepared and the specimens made in accordance with BS
EN 196- 1 , with the exception noted below.
Each mould (fitted with a hopper) shall be filled with the prepared
grout. As an exception to the procedure in B.S. EN 196-1 and in
view of the liquidity of the grout the test specimens shall not be
subjected to any vibration or shock so as to prevent rapid
deterioration of the grout (loss of grout, drying out, bleeding or
sedimentation).
Remove the hopper gently. Immediately strike off the excess grout
with the metal straight edge held almost vertically and moved
slowly, with a transverse sawing motion once in each direction.
Smooth the surface of the specimens using the same straight edge
held almost flat.
Label or mark moulds to identify the specimens.
Curing of Test Specimens - The curing of test specimens shall be
carried out in accordance with BS EN 196- 1, until they are tested.
Compression Test - The compression tests shall be carried out in

accordance with BS EN 196- 1. The compression strength shall be
measured on six test specimens from three prisms broken in
flexure.
Reporting of Results - The report shall provide all the results of the
compression tests, in MPa. The value obtained for each test shall
be the mean of the individual results.
b) Compression Strength Test - Cylinders
Principle - The compressive strength of grout in this test is

determined on the three cylinders used in the volume change test
given in Test 5.
Apparatus
i) The cans as described in Test 5.

ii) An air conditioning cabinet as described in Test 6.
iii) A compression test machine as described in BS
EN 196-1
iv) Implements for sawing and grinding test specimens.
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Procedure
After measuring the volume change (see 5.) the three cylinders
shall be stored in the air conditioning cabinet at (20 + 1) oC until
they are to be prepared for test. Immediately prior to test the
specimens shall be carefully demolded.
Each specimens is prepared for test by sawing through the cylinder

near the upper surface and then grinding both circular surfaces of
the cylinder until the disc to be loaded in the test has a thickness of
80mm.
Each specimen shall then be placed in the compression test

machine and loaded, at a uniform rate of 0.5 MPa/s, on its ends
until the maximum load (Fc) is reached.
Reporting of Results - The compressive strength Rc is calculated in

MPa from
Rc = Fc/A
Where Fc is the failure load

A is the cross sectional area
And shall be measured on three specimens, the mean value of
which shall be reported as the compressive strength

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7. Frequency of Testing - The testing of the grout made from certified or

otherwise quality assured materials shall be carried out prior to the start
of grouting operations and at the following minimum of testing in the
course of grouting.
Bleeding: 2 tests per day. One sample is to be taken at the

mixer and one sample at the duct outlet when the
grout there has a satisfactory fluidity value.
Volume Change: 1 test per day.
Strength: 1 test per 7 days or a minimum of two tests per

grouting operation whichever is greater.
Fluidity: To be tested at outlet and inlet for each duct during

grouting operation.
4/36.2.6 Built-In Materials
The Contractor shall furnish and install all built-in materials and items as
indicated on the Drawings, as specified herein and as directed by the
Engineer.
Built-in materials shall include, but not by way of limitations, all inserts,
hardware or similar items as indicated on the Drawings or specified in the
Particular Specifications.
4/36.3 Construction
The construction of all Post-Tensioned Concrete Works shall be as specified

herein.
4/36.3.1 Post-Tensioned Method Statement
The Contractor shall submit, to the Engineer for review, complete details of
the method, materials and equipment he proposes to use in the prestressing
operations, including any additions or rearrangement of reinforcement steel
from that indicated on the Drawings. Such details shall outline the method
and sequence of stressing and shall include complete specifications and
details of the prestressing steel and anchoring devices, working stresses,
anchoring stresses, type of ducts, and all other data pertaining to the
prestressing operation, including the proposed arrangement of the
prestressing steel in the members, pressure grouting materials and
equipment. The Contractor shall not cast any member to be prestressed
before the detailed shop drawings are complete and approved by the
Engineer.

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4/36.3.2 Formwork and Falsework
1. Formwork, shoring, and removal of forms shall be as specified in Section

4, Concrete Works, of the General Specifications and as further
specified herein.
2. Formwork shall be marine plywood for all superstructure concrete work.

Treated commercial plywood may be used for internal vertical and
inclined web surface. Treatment of plywood shall be by way of 3 coats
of polyurethane varnish or similar approved materials
3. The deck slab forms and all related formwork for concrete box girder
construction, including all supporting falsework, shall be designed and
constructed in order to facilitate removal of all formwork materials from
within the cells of the concrete box girders. The deck forms shall be
suspended from the girder stems which shall be stripped of all forms
prior to placing the deck forms. The deck slab forms shall in no way
interfere with the required concrete bond between the deck slab and the
girder stems.
Stay-in-place deck forms will be permitted for the deck slab of concrete
box girder construction, provided they are galvanized steel or other non-
combustible material acceptable to the Engineer which will not
deteriorate in any way. Further, such stay-in-place deck forms shall not
increase the volume of concrete, the depth of the deck slab or reduce
the dimension of concrete coverage over the reinforcement steel. The
Contractor shall submit samples of the proposed form material and all
details and design for the use of stay-in-place deck forms. The decision
of the Engineer shall be final for acceptance or rejection of stay-in-place
forms.
A 3cm slip joint shall be placed transversely in the deck forming between
each diaphragm to eliminate resistance of the deck forms to deck
shortening during prestressing.
The Contractor shall submit shop drawings and design calculations for
the forms, and falsework to the Engineer for approval prior to
commencing work.
Prior to erecting falsework for the deck superstructure the Contractor

shall confirm by way of testing the bearing capacity and expected
amount of settlement of the supporting ground.
4. Falsework and forms shall be set to provide the structural camber

indicated in the Drawings for long-term deflection, falsework settlement,
and shall comply with the required lines and grades.

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4/36.3.3 Placing Post-Tensioning Systems
1. Anchorage devices, ducts, tendons and other appurtenant post-tensioning

equipment and accessories shall be accurately positioned in the forms and
secured in place as indicated on the drawings and approved shop
drawings. Installation of the post-tensioning system shall be coordinated
with the placement of reinforcing steel and embedded items as specified
elsewhere in these Standard Specifications. Care shall be exercised to
keep ducts and tendons free of form coating compounds and other
substances which might break or reduce the concrete bond.
2. Joints in ducts shall be securely taped to prevent penetration of the duct

by concrete or laitance, and ends of ducts shall be sealed and protected
after the stressing operations. Joints in adjacent ducts shall be spaced at
least 300mm apart.
3. Field measurements of vertical locations of centers of gravity of the

tendons shall not vary by more than 6mm from the dimensions indicated
on the Drawings.
4/36.3.4 Pouring Sequence
- The sequence for placing concrete for the cast- in-place, multi- cell,
concrete box girder bridge shall be as follows:
A concrete pour sequence plan shall be prepared by the Contractor for each
superstructure and submitted to the Engineer for approval prior to
commencing any bridge superstructure work. The pour sequence plan shall
show the locations of all construction joints which shall b bonded joint as
specified herein. Concrete pours within each element shall be alternated to
eliminate shrinkage to the greatest extent possible.
The placing of concrete .in each pour shall start at the low point and shall
proceed upgrade, unless otherwise permitted by the Engineer.
4/36.3.5 Mixing and Placing Concrete
1. Concrete work for box girder superstructure construction shall comply

with the applicable provisions of Section 4, Concrete Works, of these
General Specifications and the Particular Specifications, herewith.
2. Prior to placing concrete, tendon profiles shall be rechecked to ensure

that proper location and concrete cover will be maintained. Any ducts
found to be damaged shall be repaired or replaced as directed by the
Engineer.
3. Prior to placing forms for box girder deck slabs, the Contractor shall
demonstrate, to the satisfaction of the Engineer, that either the
prestressing steel is free and unbonded in the duct or, in the event
prestressing steel has not yet been placed, that all ducts are
unobstructed.
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4. The Contractor shall exercise care during concrete placement to prevent

concrete from entering anchorage hardware. Concrete shall be placed
in such a manner that tendon alignment and reinforcement positions are
maintained, and concrete shall be vibrated with particular attention at
tendon anchorage locations to ensure optimum compaction and
penetration at these points.
5. Curing of concrete shall be in accordance with Section 4, Concrete

Works, of these General Specifications.
6. The Contractor shall keep a record showing the date and time of
placement of cast-in-place, post-tensioned concrete in each portion of
the structure. This record shall be available for examination at all times
by the Engineer. Upon completion of construction of each structure, two
copies of such records shall be submitted to the Engineer.
4/36.3.6 Stressing Operations
1. Tensioning shall be carried out only in the presence of the Engineer or

his representative, unless permission in writing has been obtained to the
contrary.
2. Post-tensioning of cast-in-place concrete shall be performed as soon as

the last placed concrete has attained a cube compressive strength of 36
Newtons per square millimeter, or as specified on the Drawings, or more
based on the results of two cube tests.
3. The Contractor shall provide, at no additional cost to the Client, a Team

of one Engineer and two Technicians who are skilled in the post-
tensioning method to give such aid and instruction in the use of the
prestressing equipment and installation of the prestressing steel as may
be necessary to obtain the specified results.
4. Prestressing tendons in continuous span post-tensioned structures shall

be tensioned by jacking at each end of the tendon or at one end of
tendons as indicated on the Drawings.
5. All post-tensioning shall be by means of hydraulic jacks equipped with

accurate reading calibrated hydraulic pressure gauges to permit the
stress in the prestressing steel to be computed at any time. A certified
calibration curve shall be furnished with each jacking system and
independently calibrated master gauge shall be provided on site. In the
event inconsistencies occur between the measured elongation and the
jack gauge reading, the jack gauge shall immediately be recalibrated. In
the event still further discrepancies occur, the cause shall be determined
and reported to the Engineer. An agreement within five 5% percent shall
be satisfactory.

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6. The Drawings indicate jacking locations of the tendons. Proper

allowance shall be made for friction losses and one tendon from each
bridge or each of tendons with similar configuration shall be checked for
friction loss at the very start of the post-tensioning.
7. In case the friction losses in tests exceed the computed losses, all wires
shall be relieved and lubricated with water-soluble oil and retensioned.
8. Each tendon shall be stressed until either the required elongation or the
maximum force is reached. Elongation is the preferred method of stress
determination wherever possible. The tendons shall be tensioned by
jacking to the total forces indicated on the Drawings.
9. The post-tensioned prestressing steel shall be anchored at an “initial

stress” that will result in the ultimate retention of working forces or
stresses of not less than those indicated on the drawings, but in no case
shall the prestressing steel be tensioned above 80 percent of the
ultimate tensile strength of the wire or strands.
10. Prior to post-tensioning any member, the Contractor shall demonstrate

to the satisfaction of the Engineer that the prestressing steel is free and
unbonded in the duct.
11. The Contractor shall keep records of the elongation and tension applied
to each tendon, and this record shall be submitted to the Engineer
promptly upon the completion of stressing of each member. At the time
of stressing the first member, the stresses in the individual tendons shall
be checked to establish a procedure for ensuring uniform results. At
any later time, a recheck may be ordered by the Engineer if it appears
that the design stresses are not being obtained. The Contractor shall
have written permission from the Engineer before capping any
prestressing anchorage.
12. The Contractor shall obtain written permission from the Engineer before
capping
any prestressing anchorage.
4/36.3.7 Grouting of Tendons
1. General - After the tensioning of all tendons has been completed and the
total retained stress is equal to or exceeds that indicated on the
Drawings, for each member, and the steel strands or wires have been
anchored, the annular space between the conduit and the tendons shall
be grouted.
2. Grouting - Tendons shall be grouted within 7 days after tensioning but

not before 8 to 12 hours after tensioning. The tendons shall be
protected against corrosion by a plug at each end to prevent the
passage of air, and such plugs shall be left in place until the tendon is
grouted.
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3. Grout Mixture - The grouting mixer and pump shall be in top mechanical
condition and of such size and capacity to ensure continuous grouting of
the largest tendon until it is completed and shall be capable of grouting
to a pressure of at least 1.07N per sq. mm. The Contractor shall submit
his mix design as per the requirements of PS 4/16 and the
recommendation of the admixture manufacturer for the approval of the
Engineer.
4. Equipment - The grouting equipment shall include a mixer

capable of continuous mechanical colloidal mixing which will produce a
grout free of lumps and undispersed cement. The equipment shall be
able to pump the mixed grout in a manner which will comply with all
provisions of these Standard Specifications. Accessory equipment
which will provide for accurate solid and liquid measures shall be
provided to batch all materials such as flow meter or similar approved
method. The pump shall be a positive displacement type and be able to
produce an outlet pressure of at least 10.5kg per sq. cm. The pump
shall have seals adequate to prevent introduction of oil, air or other
foreign substance into the grout, and to prevent loss of grout or water.
A pressure gauge having full scale reading of no greater than 2.15N per
sq. mm shall be placed at some point in the grout line between the pump
outlet and the duct inlet.
The grouting equipment shall contain a screen having clear openings of

3.2 mm maximum size to screen the grout prior to its introduction into
the grout pump. If a grout with a thixotropic additive is used, a screen
opening of 4.8 mm is satisfactory. This screen shall be easily accessible
for inspection and cleaning.
The grouting equipment shall utilize gravity feed to the pump inlet from a
hopper attached to and directly over it. The hopper shall be kept at least
partially full of grout at all times during the pumping operation to prevent
air from being drawn into the post-tensioning duct.
The Contractor shall furnish and maintain back-up equipment and such
additional equipment to ensure continuous, uninterrupted grouting of all
tendons. Such back-up equipment shall be equal to the main grouting
equipment and shall be prepared and ready to operate at the start of any
grouting operations. The Contractor shall submit a description of all
grouting equipment including back-up equipment for approval by the
Engineer prior to commencing work specified in this Section of these
5. Mixing of Grout - Water shall be added to the mixer first, followed by

Portland cement and admixture, unless otherwise required by the
admixture manufacturer.
Mixing shall be of such duration as to obtain a uniform thoroughly

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blended grout, without excessive temperature increase or loss of

expansive properties of the admixture. The grout shall be continuously
agitated until it is pumped.
Water shall not be added to increase grout flowability which has been
decreased by delayed use of the grout.
Proportions of materials shall be based on tests made on the grout

before grouting is begun, or may be selected based on prior
documented experience with similar materials and equipment and under
comparable field conditions (weather, temperature, and similar factors).
The water content shall be the minimum necessary for proper
placement.
6. Grouting - Flushing of metal ducts shall be optional. Water used for

flushing ducts may contain slaked lime (calcium hydroxide) or quick-lime
(calcium oxide) in the amount of 12gm per liter.
7. Injection of Grout - All grout and high point vent openings shall be open
when grouting starts. Grout shall be allowed to flow from the first vent
after the inlet pipe until any residual flushing water or entrapped air has
been removed, at which time the vent shall be capped or otherwise
closed. Remaining vents shall be closed in sequence in the same
manner.
a) The pumping pressure at the tendon inlet shall not exceed 1.8N
per sq. mm.
b) If the actual grouting pressure exceeds the maximum

recommended pumping pressure, grout may be injected at any
vent which has been or is ready to be capped, as long as a one-
way flow of grout is maintained. If this procedure is used, then the
vent which is to be used for injection shall be fitted with a positive
shutoff.
c) When one-way flow of grout cannot be maintained as outlined in

the above paragraph, the grout shall be immediately flushed out of
the duct with water.
d) Grout temperature shall be pumped through the duct and

continuously wasted at the outlet pipe until no visible slugs of water
or air are ejected and the efflux time of the ejected grout shall not
be less than the injected grout. To ensure that the tendon remains
filled with grout, the outlet and/or inlet shall be closed. Plugs, caps
or valves thus required shall not be removed or opened until the
grout has set.
e) Grout temperature at duct inlet and outlet shall not be above 32°C
during mixing or pumping. If necessary, the mixing water shall be
cooled. Grouting shall not proceed when shade temperature
exceeds 35Co.
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f) Grouted tendons or girders shall not be disturbed for 24 hours after

grouting.
4/36.3.8 Protection of End Anchorages
1. As soon as possible after tensioning and grouting is completed, clean

exposed end anchorages, wires and other metal accessories of rust,
displaced mortar, grout and other such materials, then apply to all such
dry metal surfaces a heavy, unbroken coating of epoxy bonding agent.
2. Install tight-fitting forms and hold in place securely against the previously
placed concrete.
3. After applying epoxy bonding agent, apply a patching mortar prepared

by mixing one part type V, Portland cement to three parts of clean sand
(ASTM C33) measured by volume, and sufficient water to provide a stiff
but workable consistency. Apply the patching mortar, and manipulate,
finish and cure as specified in Section 4, Concrete Works. After mortar
patches have cured, apply two heavy brush coats of bituminous
protective coating material, applied as recommended by the
manufacturer, including the recommended thickness.
4/36.3.10 Access Doors
`Access shall be provided in post-tensioned box girders as located and as

detailed on the Drawings.
All access doors shall be fabricated of steel shapes, plates and accessories
complying with Dubai Municipality requirements and the Client.
All steel shall be galvanized. Access or cover shall be made of GRP to be

mounted to steel frame.
The furnishing and installing of access doors as indicated on the Drawings

and specified herein will not be measured or paid for separately but shall be
considered a subsidiary obligation to and included in the various concrete
Items of work included in the Bills of Quantities.
4/36.3.11 Vent Pipes
The Contractor shall include the unplasticized polyvinylchloride (PVC) vent

pipes in the cells of the concrete box girders as indicated on the Drawings.
The vent pipes shall be of the size as indicated on the approved shop
Drawings and shall be PVC extruded from one hundred percent virgin
materials. The pipe material shall be new and homogeneous throughout and
free from visible cracks, holes, foreign materials, blisters, wrinkles and dents.
All vent pipes shall be anchored in an approved manner so as to prevent

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displacement or movement during the placement of concrete. No separate

payment for vent pipes will be made by the Client.
4/36.3.12 Opening Bridges to Traffic
No equipment or vehicular traffic will be allowed on any bridge superstructure

until the post-tensioning and grouting operation is completed, falsework has
been removed, and all concrete has been cured for the time required in these
Particular Specifications, or as further directed by the Engineer.
4/38 Trial Pour for Bridge Deck
The Contractor shall perform a complete trial using a mock-up section of the
actual structure to be designated by the Engineer. The mock-up section shall
include longitudinal and transverse construction joints between the deck and
the kerbs and parapets.
The Contractor shall be required to demonstrate using his proposed

construction method, concrete mix, form work (including void forrners), post-
tensioning, grouting, staffing, etc., for the construction of the bridge structure,
his ability to produce the prestressed concrete of the required quality,
dimensions and surface finish.
The sample section shall be fully representative of the actual structure in

dimensions and all details be at least ten meters tong.
The trial section shall be tested for integrity (i.e. concrete quality and strength,
post- tensioning works, grouting etc.) by slicing sections at locations directed
by the Engineer and by taking samples for testing at an approved laboratory.
The Contractor will not be permitted to commence with concrete pouring until
the trial run is completed and accepted by the Engineer.
The Engineer may require the Contractor to repeat the mock-up if the results
are unsatisfactory.
The Contractor shall not receive any separate compensation for the trial run.
All costs associated with the trial run shall be included in other pay items for
the bridge structure.
4/39 Placing Concrete for Bridge Decks
4/39.1 General
On bridge decks, a smooth surface, true to the required grade and cross
section, shall be obtained. The Contractor shall use either an approved
finishing machine complying with the requirements specified herein for
finishing bridge roadway deck concrete and approach slabs or any other
approved method. All concrete at bridge roadway deck and approach slabs
shall be placed and compacted as approved by the Engineer.
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4/39.2 The use of hand finishing tools or equipment shall be limited to small areas
where the specified finishing machine cannot be used and where specifically
authorized by the Engineer in writing. The type of tools and equipment to be
used for hand finishing shall be subject to approval by the Engineer.
4/39.3 The concrete finishing machine shall include but not by way of limitation, the
following:
a. The finishing machine shall be of a type approved by the Engineer,

power driven and equipped with at least 2 screeds, and shall be fully and
accurately adjustable to produce a crowned or flat surface required. The
finishing machine shall be designed and operated to strike off, screed
and consolidate. The finishing machine shall have a minimum of one
reciprocating, non vibratory screed. The machine shall have ample
strength and sufficient power and be so geared as to operate
consistently, regularly and smoothly.
b. The concrete finisher float shall be attached to the finishing machine. It

shall be equipped with independent wheels which ride on the rails and it
shall be of sufficient weight as to not flex under the pressure of the
concrete. The float shall be easily adjustable from crown to flat. The
float shall be a minimum of 76cm in length with a minimum 60cm in
contact with the concrete. The float pan shall be suspended from the
frame, float freely on the concrete and shall be capable of being adjusted
in both height and width. The float pan, once adjusted, shall be
equipped hydraulically or by other suitable means so that it may be
raised from the operator's platform and when powered shall
automatically return to its preset position.
c. The machine shall be so constructed that the travel of the floating

mechanism can be adjusted to conform to the concrete cross section
indicated on the Drawings or formed by the finishing machine.
d. Concrete bridge roadway decks and approach shall be struck off and
screeded with a finishing machine; the use of a vibratory screed will not
be permitted.
e. The method of consolidating the concrete shall be as approved by the

Engineer. The use of vibrating equipment shall be subject to approval of
the Engineer.
Finishing of concrete placed in bridge decks shall consist of striking off the
surface of the concrete as placed, floating the surface so struck off and
finishing as specified herein.
The placing of concrete in bridge roadway decks will not be permitted until the
Engineer is satisfied that the rate of producing and placing concrete will be
sufficient to complete the proposed placing and finishing operations within the
scheduled time, that experienced finishing machine operators are employed to

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finish the deck, the fogging equipment and all necessary finishing tools and
equipment are on hand at the site of the work and in satisfactory condition for
use. Finishing machines shall be set up sufficiently in advance of use to
permit inspection by the Engineer during the daylight hours before each pour.
4/39.4 Rails for the support and operation of finishing machines shall be completely
in place and firmly secured for the scheduled length for concrete placement
before placing of concrete will be permitted. Rails for finishing machines shall
extend beyond both ends of the scheduled length for concrete placement a
sufficient distance that shall permit the float of the finishing machine to fully
clear the concrete to be placed unless otherwise approved by the Engineer.
Rails shall be adjustable for elevation and shall be set to elevations, with
allowance for anticipated settlement, camber, and deflection of falsework as
required to obtain a bridge roadway deck true to the required grade and cross
section. Rails shall be of a type and shall be so installed that no springing or
deflection shall occur under the weight of the finishing equipment and shall be
so located that finishing equipment may operate without interruption over the
entire bridge roadway deck or approach slabs being finished. Rails shall be
adjusted as necessary to correct for unanticipated settlement or deflection
which may occur during finishing operations.
4/39.5 The Contractor shall form and place all concrete on bridge decks and
approach slabs to comply with all. lines, levels, profiles as indicated on the
drawings and shall include all depressions or notches to receive expansion
joints as indicated and as specified in PS5/41, Bridge deck expansion joints.
4/39.6 Immediately prior to placing bridge deck concrete or approach slabs, the
Contractor shall check all forms, falsework and wedges and shall make all
necessary adjustments. Care shall be exercised to ensure that settlement
and deflection due to the added weight of the bridge deck concrete shall be a
minimum. Suitable means such as telltales shall be provided by the
Contractor to readily permit measurement by the Engineer of settlement and
deflection as it occurs.
4/39.7 In the event settlement or other unanticipated events occur, which in the
opinion of the Engineer would prevent obtaining bridge deck or approach
slabs complying with the requirements of these Particular Specifications,
placing of deck concrete shall be discontinued until corrective measures
satisfactory to the Engineer are provided. If the Contractor fails to provide
satisfactory measures prior to initial set of the concrete in the affected area,
the placing of concrete shall be discontinued and a bulkhead installed at a
location determined by the Engineer. All concrete in place beyond the
bulkhead shall be removed.
4/39.8 Concrete for bridge decks shall be placed in a uniform heading approximately
normal to the structure centreline or, in the case of screeds supported on
transverse headers, parallel to the centreline as directed by the Engineer.
The rate of placing concrete shall be limited to that which can be finished
before the beginning of initial set.

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4/39.9 Immediately after the concrete has been placed and consolidated, the surface
shall be struck off with the finishing machine until the required surface is
obtained.
The strike off method and equipment shall be subject to approval by the
Engineer. Approval shall be withdrawn if performance is not satisfactory. The
equipment shall be capable of finishing roadway decks within the surface
tolerances set forth in these Particular Specifications. Improper adjustment
and operation which results in unsatisfactory consolidation and smoothness
shall be corrected immediately. Unsatisfactory performance may be cause for
rejection of the equipment and removal of the in-place concrete.
4/39.10 In areas inaccessible to a finishing machine and where permitted by the

Engineer, following the completion of the strike off by hand methods, the
bridge roadway slab or approach slab surface shall be floated to a smooth
uniform surface by means of floats 3 meters or more in length. When a
finishing machine is used, the finished surface shall be floated in a similar
manner unless otherwise directed by the Engineer. Adequate floats shall be
used to remove roughness and minor irregularities left by the strike board or
finishing machine and to seal the concrete surface. Excessive working of the
concrete surface will not be permitted by the Engineer. All floats shall be used
in such a manner that each transverse pass overlaps the previous pass by a
distance of at least one-half the length of the float.
When hand-operated float boards are used, they shall be from 3.5 meters to
4.5 meters long, ribbed and trussed as necessary to provide a rigid float and
shall be equipped with adjustable handles at each end. The float shall be
wood, not less than 25mm thick and a minimum of 20cm wide. Adjusting
screws spaced at no more than 60cm on centres shall be provided between
the float and the rib. The float board shall be maintained free of twist and true
at all times.
Precast concrete work shall be as indicated on the Drawings, as specified

herein and as directed by the Engineer. All precast concrete work shall
comply with the following:
GENERAL REQUIREMENTS:
Precast concrete shall have the same compressive strength as specified in

the drawing.. All Clauses referring to cast-in-situ concrete shall apply to
precast concrete. In addition, the Contractor shall satisfy the Engineer that the
precast concrete units are not moved or loaded until they have attained the
required strength. The precast forms shall account for all profile, vertical curve
correction, camber correction and proper matching with other segments of the
bridge either precast or cast in situ. The precast forms shall allow for
continuity reinforcement to project through the forms to facilitate the
subsequent construction stages. The interface surface between precast
segment and cast in situ shall be treated in the same manner as specified for
construction joints.

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Curing of precast elements shall be as per the requirements of the

specification.
TRANSPORT, STORAGE AND ERECTION:
The number of units that can be stacked on top of one another is to be limited
to 5.Unfts shall be stored, transported and fixed so that they shall not be
overstressed at any time or suffer any damage. The contractor shall submit
calculations showing the lifting points and the resulting stresses for the
Engineer’s approval. No tension shall be allowed in the concrete during any of
these operations. Precast units shall be adequately braced and supported
during erection to ensure proper alignment and safety.
FINISH:
On removal from the forms, the precast concrete units shall be examined and
all surfaces that will be permanently visible shall have a smooth and dense
finish of uniform texture free from holes, fins and shutter staining. Any precast
concrete unit, which is found to be defective in any respect, will be rejected.
PRECAST PRODUCTS:
The Contractor shall manufacture all precast units of diverse sizes with
materials as specified in this Section and shall transport same to the Site of
Work by his own means of transport. The Contractor shall examine these
materials before shipping and make sure that they are of good quality and
comply with these Standard Specifications. The Contractor shall be responsible
for any damage sustained by this material in the course of transportation or on
Site, and shall allow in his prices for all costs of labour, haulage, transportation,
offloading onSite, waste and everything necessary for this work
METHOD STATEMENT:
The Contractor shall submit a complete method statement detailing his

precasting operations, curing, shipping and handling and erection. For the
erection operation the method statement shall include all details and calculation
for the temporary supports, lifting devices and crainage operations as well as
the preparations preceeding the closure pours of the bridge structure.
4/39.11 All finishing bridges shall be of rigid construction and shall be free of wobble
and spring when used by the operators of longitudinal floats and shall be
easily moved.
After the floating has been completed but while the concrete is still plastic, the
slab surface shall be tested with a 3 meter straightedge, which shall be held in
contact with the surface in successive positions parallel to the bridge roadway
deck or approach slab centreline and then at right angles to it. The whole
area shall be tested from one side of the deck or slab to the other. Testing
along and across the deck or slab shall be in successive stages of not more
than one-half the length of the straightedge. An depressions found shall be
filled at once with freshly mixed concrete, struck off, consolidated and
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refinished. High areas shall be cut down and refinished. The testing and
refinishing shall continue until the entire surface is found to be free from
deviations of more than 6mm under the 3 meter straightedge. Allowance shall
be made for crown, camber and vertical curvature. Any straight-edging and
corrective work performed on the plastic concrete shall not relieve the
Contractor of testing the smoothness requirements on the hardened concrete
as outlined hereinafter.
4/39.12 The final surface of bridge roadway deck or approach slabs shall be textured
with either a light broom finish or a burlap drag. Such equipment required to
produce the final surface texture shall be secured to the finishing machine.
The texturing operation shall be so executed that the surface is uniform in
appearance and free from rough and porous spots, irregularities, and
depressions.
Fogging equipment to be furnished shall be capable of applying water to the

concrete in the form of a fine mist in sufficient quantity to curb the effects of
rapid evaporation of mixing water from the concrete on the deck resulting from
the concrete on the deck resulting from wind, high temperature or low
humidity, or a combination of these factors. The fog mist shall be applied at
the times and in the manner directed by the Engineer.
4/39.13 Concrete barriers and parapets shall not be placed until the centering or
falsework for the structure span has been released. Special care shall be
exercised to obtain smooth and tight-fitting forms which can be held rigidly to
line and grade and can be removed without injury to the concrete. All
moldings, panel work, and bevel strips shall be constructed according to the
drawings, with neatly mitered joints. All corners in the finished work shall be
true, sharp, and clean-cut and shall be free from cracks, spalls, or other
defects.
4/39.14 Concrete for sidewalk and median slabs shall be well-compacted, then struck-
off with a strike board and floated with a wooden float. An edging tool shall be
used on all edges and at expansion joints. The surface shall not vary more
than 3mm under the 3 meter straightedge. The surface shaft be lightly
broomed to a granular texture which will not be slick when wet.
4/41 Precast Concrete
ALTERNATIVES
Should the Contractor elect to submit any alternative system to that detailed in
the plans, the Contractor shall employ an accredited consultant approved by
the Dubai Municipality to undertake a complete design and produce detailed
drawings to be submitted to the Engineer. Such alternative shall be submitted
two months minimum prior to the date required for approval of the subject
design or commencement of any related work items. The Contractor shall
allow in his alternative bid for the compensation of the Engineer for his review
and checking of such alternative.

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SECTION 5 - ANCILLARY WORKS
5/47 Concrete Barrier Wall
5/47.1 Description
The work specified in this Section consists of constructing concrete barrier

wall in accordance with these specifications in conformity with the lines,
grades, dimensions and notes shown in the plans. Concrete barrier wall shall
be plain or reinforced in accordance with the details shown on the plans. The
wall shall be constructed by use of stationary removable forms or sliding forms
in accordance with these specifications.
Stationary removable forms may be used provided they render a completed

barrier wall with acceptable alignment and finish. Forms shall be constructed
of metal or timber with a form liner. Forms which are damaged or are not in
alignment shall not be used.
When the slip form method is elected in lieu of the stationary forming method,
the concrete shall be placed with a slip form machine approved by the
Engineer designed to form and consolidate the concrete in one pass in such a
manner that a minimum of hand finishing is necessary to provide a dense,
suitably finished barrier rail in conformance with the plans and specifications.
The sliding forms shall be rigidly held together laterally so that the forms will
not spread. The slip form machine shall be operated with a continuous
forward movement, as nearly as possible, to minimize stops and starts of the
machine. The concrete consolidation elements of the machine shall be
arranged to start and stop simultaneously with the starting movement and
stopping movement of the slip form machine. The consolidation elements
shall consist of internal vibrators and form vibrators. the slip form machine
shall be a self-contained, self-powered unit.
Deshuttering oil shall not have any adverse affect on the specified finishes.
5/47.2 Materials
The materials used in the concrete barrier wall shall conform with the
requirements of various Sections of the general specifications.
5/47.3 Concrete Finish
1. Stationary Form Construction - Concrete barrier wall constructed

using stationary forms, either precast or cast-in-place, shall be given
finish as specified in the plans. The stationary form shall be aligned and
erected so that all plane surfaces of the finished wall will have no
deviation greater than 10 mm measured as an ordinate between the
concrete and a 3 m straightedge. All deviations greater that 10 mm shall

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be corrected in a manner approved by the Engineer at the Contractor’s

expense. Sections of wall showing evidence of unconsolidated
concrete, deviations in alignment and profile or other defects which
cannot be satisfactorily repaired shall be removed and replaced by the
Contractor at his expense. Straight edging shall be accomplished by
half lapping the straightedge for the full length of all plane surfaces.
2. Slip Form Construction - The method of providing finished texture to

the slip formed barrier walls shall consist of hand trowelling, brushing or
both to eliminate pockmarks, blemishes and any other discontinuities in
surface texture. The final finish shall have a fine texture and be free of
pinholes, pockmarks and blemishes.
Sections of slip formed barrier walls having areas of unconsolidated

concrete, having blemishes or having pockmarks greater than 13 mm in
diameter after hand trowelling and brushing shall be removed and recast
or repaired in an approved manner by the Contractor at his expense.
Areas of unsatisfactory surface finish shall be repaid by hand methods
using mortar screened from the concrete used to construct the barrier
wall. The mortar screened from the barrier wall concrete shall be used
only to fill holes and surface blemishes below the slip formed surface of
the concrete. Mortar shall not be used as a surface overlay coating on
the barrier wall concrete.
During the finishing operation, while the concrete remains plastic, all
plane surfaces of the slip formed barrier wall shall be straight edged with
a 3m straightedge. The straight edging shall be accomplished by half
lapping the straightedge for the full length of the plane surfaces. Any
deviation found during straightedging, greater than 10 mm, measured as
an ordinate between the concrete surface and the straightedge, shall be
corrected by the Contractor in an approved manner at his expense.
Surface overlay coatings of mortar screened from the concrete or
surface overlay coatings of concrete shall not be used to correct
alignment deviations.
Sections of slip formed barrier wall having unconsolidated concrete,

surface blemishes, deviations in alignment of profile, or other defects
which cannot be satisfactory repaired shall be removed and replaced by
the Contractor at his expense.
5/47.4 Curing
Cast-in-place and precast barrier walls shall be cured for 12 hours by leaving
the form in place. After removal of the form, the barrier wall shall be cured the
remaining portion of the required 72 hours curing by one of the methods
specified in the general specification.
Curing for barrier walls which have been slip formed shall be accomplished in
accordance with the General Specifications.

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5/47.5 Joints
5/47.5.1 General
Expansion and contraction joints in concrete barrier wall mounted on or

adjoining rigid structures shall be placed in a manner similar to the type and
method of jointing used in the supporting or adjoining structure. Expansion
and contraction joints in concrete barrier wall that is supported by soil or
flexible foundation materials shall be placed in the manner detailed in the
plans.
5/47.5.2 Contraction Joints in Walls Supported by or Adjoining

Rigid Structures
Contraction joints may be formed or sawed. When contraction joints are

sawed, they shall be sawed as soon as the concrete has hardened sufficiently
to permit sawing without raveling and before uncontrolled cracking occurs but
in no case later than 12 hours after casting. Contraction joints shall match
adjacent contraction joints in the structure and they shall be spaced at 4.5 to
9.0 m intervals.
5/47.5.3 Expansion Joints in Walls Supported by or

Adjoining Rigid Structures
Expansion joints shall be constructed at right angles to the face and shall
extend through the entire cross-section of the barrier wall. Expansion joints
shall be constructed at the same location and width as the expansion joints in
the structure on which they rest or at 30 meter maximum.
Expansion joints for precast or cast-in-place stationary form construction shall

be formed or an expansion filler material may be pre-set and attached to the
forms as required. When slip forming is used, the joint shall be sawed
through the plastic concrete the full depth and width of the barrier section.
Where the “plastic sawing” method is used, close fitting shields shall be
placed over the concrete on each side of the joint for protection during sawing
and hand finishing the concrete at the joint.
5/49 Protection of Shoulders and Slopes
5/49.1 CEMENT STABILIZED AGGREGATE CAPPING LAYER
1. Materials Materials shall conform to Section 3/6 “Granular

Subbase Materials or the Specifications except that CBR shall
not be required to be determined.
2. The Sulfate Resisting Cement shall conform to Section 411.1 of the
Specifications
3. Water to conform to Section 416.2 of the Specifications.
4. The mix shall have the following properties/proportions:

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i) Cement 4% by weight of the aggregates.

ii) Water to conform to the Optimum Moisture Content
Corresponding to the Maximum Dry Density determined
according to ES 1377 part 4.
iii) Capping Layer shall be compacted to 95% of the MOD.
When tested in accordance with the British Department of Transportation

Specification for Highway Works, Part 3, the minimum compressive strength
at 7 days for an individual cube compacted at OMO should be not less than 4.
5N,mm2; and not less than 7.13 N’mrn2for an average of 5 cubes.
5/49.2 TESTING
The testing frequencies shall conform to the following:
a) One sample each for grading, P.I., Sand Equivalent and Loss due to
Abrasion per 2000 cu.m. of mixed aggregate before the addition of
cement.
b) MOD determination every 2000 cu.m compacted volume of

complete mix including cement.
c) One sample every 2000 cu.m of compacted volume for cement

content determination according to BS 1924 Part 2 Method 5 1.
d) One lnsitu Density determination for every 500 sq.m. of laid capping
layer.
5/49.3 METHOD
1. The approved material is stockpiled next to blending plant.
2. The required quantity of cement and water shall be added before

the aggregate material passed through the mixer. After mixing the
material is loaded on tricks ready for site use.
3. The verge and side slopes shall be prepared to the specified levels
and slopes ready to receive the capping layer material, 50 cm
rounding to both verge and slope and shall also be done.
4. The material is dumped by trucks and is spread by grader to cover

the verge and side slope upto the existing ground, the 50 cm
rounding is also formed.
5. The material shall be compacted to 95% of M.D.D.:
a) -First by steel roller, starting from the toe and moving up;
b) -then tyre roller, starting from the toe and moving up;

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c) -and a final pass with steel roller,
6. The levels and compaction of the capping layer shall be checked.
7. Curing for three consecutive days shall be done by spraying sweet

water on the finalized surface to keep it continuously wet.
5/50 Metal Works
5/50.1 Structural Steel
All structural steel shall be new and shall comply with the following
specifications and requirements:
1. Structural carbon steel shall comply with the specification for steel for bridges
and buildings of ASM A36 and/or AS88, unless otherwise specified herein,
indicated on the Drawings, or in the particular specifications.
2. High Strength steel bolts and washers shall comply with ASTM A325. All high
strengths nuts shall be of such capacity develop the bolt strength.
3. Steel anchor bolts, nuts and washers and assembly bolts, nuts and washers
for round tube post bases shall be ASTM A307.
4. Steel bolts, nuts and hardened washers shall be galvanized in accordance

with ASTM A153 unless otherwise indicated on the Drawings or in the
5/50.2 Stainless Steel
All stainless steel shall be new and shall comply with the following specifications
and requirements:
1. All members or parts called for on the Drawings to be stainless steel shall be
AISI Type 302, 303, 304 or 316 and complying with ASTM A276. Unless
otherwise indicated on the Drawings or in the Particular Specifications,
stainless steel shall be Type 316 with a mill finish.
2. Unless otherwise indicated on the Drawings or in the Particular Specifications,

all bolts shall be of the same type of stainless steel as the adjoining parts.
3. Stainless steel pipe rails and posts shall be as indicated on the Drawings and
shall be of AISI Type 304 stainless steel tubing (except Type 312 can be used
for curved corners) complying with ASTM A-54. The completed handrail shall
have a surface finish complying with ASTM Designation A480 No. 2B finish.
Unless otherwise indicated on the Drawings, all posts and railings shall be 38
mm nominal (48 mm outside diameter) stainless steel with 16 gauge wall
thickness. Where possible, the minimum shop fabricated length of handrail
shall be 6 meters.

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5/50.3 Galvanizing
Shall be by the hot dip process in accordance with ASTM A123 and A385. The
galvanizing coating shall be uniform and bright when the galvanized surfaces are not
to be painted.
All fabrication shall be completed and ready for assembly before galvanizing. No
punching, drilling or cutting shall be permitted after galvanizing.
Precautions shall be taken against embitterment, warpage and distortion in

accordance with ASTM A143 and in accordance with ASTM A384.
5/53 Crane and Hoist for Utility Culverts
The Contractor shall propose a complete crane, rail and hoist system to be installed in
the utility culverts. The assembly shall be capable of carrying a maximum load of 5
tones. All components shall be galvanized or treated to prevent corrosion of metal
parts. All metal components shall meet the requirements of section PS 5/50 of these
particular Specifications. The size and spacing of concrete inserts for the anchoring of
the crane rail shall be in accordance with the crane manufacturer recommended
installation details. The Contractor shall submit all details including shop drawings or
the crane, hoist and rail assemble for the approval of the Engineer.
5/55 Alternatives
Should the Contractor elect to submit any alternative system to that detailed in the
plans, the Contractor shall employ and accredited consultant approved by Dubai
Municipality to undertake a complete design and produce detailed drawings to be
submitted to the Engineer. Such alternative shall be submitted two months minimum
prior to the date required for approval of the subject design or commencement of any
related work items. The Contractor shall allow in his alternative bid for the
compensation of the Engineer for his review and checking of such alternative.

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SECTION 6 - WORKS IN CONNECTION WITH SERVICE AUTHORITIES
GENERAL REQUIREMENTS
6/1.19 Wherever the approval of any drawings, material submittals, NOCs and or similar is
required from authorities during the construction period, the Contractor shall diligently
follow-up the submission either made by the Contractor directly or through the
Consultant / the Engineer. The Contractor shall made all arrangements for such
follow-ups and shall adhere to authority requirements. Failure to do so in a timely
manner, the sole responsibility of any consequence shall be on Contractor.
Authorities may require the submissions to be made through the Consultant or the
Engineer whereby the Consultant or the Engineer shall do so, the Contractor,
however shall prepare all the submittals in accordance with authority requirements or
as advised by the consultant or the Engineer diligently, and shall also follow-up with
the Authority in getting approval of those submittals / NOCs. The responsibility of
getting approvals from authorities will remain with the Contractor regardless of
submission made through Consultant or the Engineer.
6/1.20 Final tie-in connection details / location for utilities, if shown on the drawings, are
indicative only and may not represent the actual required scope and are subject to
change as a result of authority directions. The Contractor shall confirm such details
with the relevant authority prior to commence any tie-in works.
Contrary to as shown in the drawings or specified in the Contract or Tender

Documents, authority may direct to connect utility networks to any other nearby (or
even away from the project limits) existing pipelines, pump stations or substation
(feeding source or discharge point) etc. as per their requirements. The Contractor
shall comply with the authority requirements and shall allow for any additional efforts,
coordination etc. in their scope. Extra works if required to be carried out shall be
reimbursed at Contract rates, the scope however deemed to be inclusive of all such
coordination, engineering, procurement, execution, testing and commissioning of the
tie-in works as per authority requirements.
DEWA - ELECTRICITY DIVISION
6/9 Additional text under Section General
Before starting any work in the vicinity and under overhead power lines, the
Contractor shall submit Method of Statement including shop drawings if
required for the approval of the Engineer and the relevant service authority.
No work shall be carried out until the approval is obtained.

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SECTION 7 - ROADWAY LIGHTING
7/1 Insert the following in Section 7/1 General:
The following procedures shall be strictly followed by the Contractors while

working on street lighting services within the project boundaries.
1. The Contractor shall strictly comply with all requirements of Dubai

Electricity and Water Authority’s Safety Manual.
2. The Contract shall be fully responsible for repairing underground

services within 24 hours within the project boundary. Failure to repair
any underground fault within 24 hours shall result in applying fines in
accordance with the Local Order No. 84/93.
3. Maintenance of above ground services shall remain the responsibility of

Roads Lighting Section who shall notify the contractor prior to
commencing any work within the project boundary.
4. The following safety measures shall be taken while working on street

lighting services:
* To keep the main power supply breaker (MCCB) in OFF position.
* To install identification tag inside the street lighting panel to prevent

energizing of the main supply by others.
7/2.3 Cable Installation
Insert New Clause:
B.6 All ducts and cables laid in the trenches shall be in inspected by the
Roads Lighting Section’s representative, prior to their back-filling and
compaction.
B.7 Trenches back-filled, and compacted without our inspection, shall not
accepted. And the contractor shall expose the ducts for our inspection
at his own costs and risks.
7/4 Testing after Installation
Change to first sentence to read:
After cable laying and installation of earthing systems but prior to erection of
the lighting columns the contractor will perform the tests as stipulated in
Clause 7/4 of the General Specifications.
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ECTION 8 – CONCRETE PILE FOUNDATIONS – Not Applicable

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SECTION 9 – JOGGING TRACK
9/1 Description
The work specified in this Section consists of constructing the jogging track in
accordance to these Specifications or an alternative specifications that is subject to
the Engineer approval.
9/2 Material
9/2.1 CONIPUR 70
Moisture Curing Single Component PUR Primer
1. Product Description - CONIPUR 70 and CONIPUR 74 is a moisture curing,

solvent containing, single component PUR primer with low viscosity.
2. Field of Application – CONIFUR 70 is used as a primer on Bituminous

substrates for sports surfaces while CONIPUR 74 is used for concrete substrates.
3. Properties - CONIPUR 70 and CONIPUR 74 shows good adhesion to non-

porous substrates. It is of very low viscosity and therefore exhibits a high capillary
activity.
CONIPUR 70 and CONIPUR 74 is easy to apply. The material reacts

withhumidity and eliminates carbon dioxide to produce a resistant, tough elastic
film.
Fully cured, CONIPUR 70 exhibits excellent mechanical properties
4. Technical Data
Figures are guide values and should not be used as a base for specifications
at 23 ° C for CONIPUR 70 0.97 for CONIPUR 70
Density g/cm3
at 20 °C for CONIPUR 74 1.0 for CONIPUR 74
Solid Density % 43
Viscocity 4mm DIN cup, 23 °C s 13
NCO Content % 5.0

Substrate and °
min. C 8
application °
max C 40
temperature
Recommended min. % 40
relative humidity max % 90
5. Consumption – Approx 0.15 kg/m2 for CONIPUR 70 and 0.20 kg/m2 for

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CONIPUR 74
6. Application Method - CONIPUR 70 is a single component material. Pour the

amount required from the pack into an application pack and apply it immediately.
The average material temperature should be 15-25 °C.
CONIPUR 70 is applied to the pre-treated surface by spraying, using low

pressure airless equipment.
For small areas also a paint roller or brush can be used.
When exceeding the maximum coverage quantity, the material can foam and
cure very slowly. We therefore recommend applying a thin and uniform layer.
Avoid puddles.
The working life and curing time of CONIPUR 70 is influenced by the ambient,
material and substrate temperature. At low temperatures, the chemical reactions
are generally slowed down; this lengthens the pot life, re-coating interval and
open time. At the same time, the viscosity increases which leads to a higher
consumption. High temperature and humidity accelerate chemical reactions so
the contrary is true. Direct sunshine on the coating shortens the time frame
considerably.
The next layer can be applied when the primer becomes sticky.
Apply only as much as can be re-coated during the following 24 hours.
If this interval is exceeded, a new coat of bonding agent has to be applied to

avoid poor adherence.
After application, the material should be protected from direct contact with water.
Within this period, adhesion of the next coat could be impaired.
7. Cleaning Agent - Re-usable tools should be cleaned carefully with CLEANER

40 or other suitable solvents (e.g. butyl acetate). Never use water or
alcoholic solvents as cleaners.
8. Substrate Condition – Substrate to be coated have to be firm, dry and load

bearing, free of loose and brittle particles and substances which impair adhesion
such as oil, grease, rubber skid marks, paint or other contaminants.
The temperature of the substrate must be at least 3°C above the current dew
point temperature.
9. Pack Size – CONIPUR 70 is supplied in 180 kg drums or 18 kg pails.
10. Colour – Straw coloured.

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11. Storage – Store in original closed packing under dry conditions at a temperature
range of 5 – 25 °C.
Do not expose the drums to direct sunlight.
Before use, please see “best before” date on the pail / drum.
12. Safety Precautions – CONIFUR 70 is non-hazardous in its cured condition.
For protective measures, transport regulations and waste management please

refer to the Material Safety Data Sheet of the Product.
CONIFUR 70 meets the requirements of the EC directive 2004/42/EC.
9/2.2 CONIPUR 326
Moisture Curing Single Component PUR Binder
1. Product Description - CONIPUR 326 is a moisture curing, solvent free,

un-pigmented PUR binder of medium viscosity.
It is based on MDI and TDI. The content of monomeric TDI (tolylene di-
isocyanate) is very low.
2. Fields of Application - CONIPUR 326 is used as a moisture curing binder for

recycled granules for in situ base mats.
Depending on the type of surface, these mats are coated with a CONIPUR top
sealer, a structural spray coating or a self leveling coating in order to obtain
weather resistant and permanently elastic synthetic coatings.
3. Properties - Due to the medium viscosity, CONIPUR 326 is easily mixed with the
rubber granules and there is hardly any run- off from the granules.
The long curing time of CONIUR 326 allows day construction joints to be easily
and correctly made.
The yellowing which occurs when CONIPUR 326 is exposed to UV light does not
affect its mechanical properties.

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4. Technical Data
Density DIN 53217, at 23°C g/cm3 1.06
Viscocity at 23°C mPas 4000
NCO Content DIN 53185 % 10.2
TDI monomer percentage DIN 55956 % < 0.5

at 23°C / 50 % rel.
Ready for foot traffic h 48
hum.
Substrate and application minimum °C 8
temperature maximum °C 40
minimum % 40
Permissible relative humidity
maximum % 90
5. Application Method – During application the temperature of CONIFUR 326

should be between 15 and 25 °C.
For the installation of a base layer, mix 1-4 mm recycled rubber granules
(normally SBR) and CONIPUR 326 in a ratio of 100:21 (by weight) using a forced
mixer rotating at approximately 300 rev/min, for 3-5 minutes. Ensure that the
mixer reaches the sides and bottom areas of the mixing vessel.
The material is applied using a specially designed paving machine. In order to

achieve good surface strength, the rubber granule mat must be compacted
thoroughly. If necessary roll the surface additionally.
Particular attention should be paid to the construction joints, which, if possible,

should be made before the material has significantly cured. If this cannot be
accomplished cured joints should be primed with CONIPUR 72 and well
trowelled.
The mechanical characteristics decrease if above mentioned quantity of

CONIPUR 326 is lowered, and the requirements of DIN V 18035-6 or IAAF
specifications might not be met.
The rubber granules must be dry as moisture will accelerate the curing
of the binder making installation more difficult or even impossible and may result
in the binder foaming, leading to an uneven surface and a weak mat.
The working life and curing time of CONIPUR 326 are influenced by the ambient,
material and substrate temperature, as well as by humidity. At low temperatures
and humidity, the speed of reaction is reduced resulting in a longer pot life, re-
coating interval and open time. At the same time, the viscosity increases requiring

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increased mixing time and a higher consumption. At high temperatures and

humidity, the speed of reaction is accelerated and the contrary is true.
When the humidity is below 40 % it may be necessary to carefully mist spray the
mat with water to avoid unacceptable cure times, which might impair the quality of
the elastic layer.
At low temperatures, curing can be slightly accelerated by use of catalyst. The

quantity of catalyst needed depends on the ambient conditions and has to be
defined at the job site and may vary daily. As a guide, 0.2 %w/w of
ACCELERATOR 10 or 12, as a percentage of the binder, may be used.
For the installation of the granule mats, we recommend the use of recycled
rubber that have been tested and shown to be suitable for use with CONIPUR
326.
In order to meet the required standards (DIN V 18035-6 or IAAF), the size of the
granules should be between ø 1-4 mm.
6. Cleaning Agent - Re-usable tools should be cleaned carefully with

CLEANER 40 or other suitable solvents (e.g. butyl acetate) before curing has
taken place. Never use water or alcoholic solvents as cleaners on uncured
materials!
7. Substrate Condition - Substrates to be coated have to be dry, load bearing, free

of loose particles and substances which impair adhesion such as oil, grease,
paint or other contaminants.
The requirements mentioned in DIN V 18035-6 or the governing body

specifications, regarding evenness, declivity and water permeability should be
met.
On concrete, it is necessary to apply CONIPUR 74 (see product data sheet)

before installing in situ rubber granule mats. The bond strength of the substrate
must be at least 1.0 N/mm2 (check with an approved pull off tester e.g. Herion,
load rate 100 N/s).
The moisture level must not exceed 4 % (check with CM equipment), which
corresponds to maximum 75 % relative humidity according to ASTM F 2170. If
using the calcium chloride test, the maximum allowable vapour emissions is 4.0
lbs. as per ASTM F 1869.
On asphalt, primer CONIPUR 70 must be used. Never use CONIPUR 74 on

asphalt.
The temperature of the substrate must be at least 3 °C above the current dew
point temperature.
8. Pack size – CONIPUR 326 is supplied in 210 kg drums.

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9. Colour – Straw coloured.
10. Storage – Store in un opened drums under dry conditions at a temperature range
of 5 - 25°C.
Before use, please see "best before" date on the pail / drum.
11. Safety Precautions – CONIPUR 326 is non-hazardous in its cured condition.
For protective measures, transport regulations and waste management please

refer to the Material Safety Data Sheet of the product.
CONIPUR 326 meets the requirements of the EC directive 2004/42/EC.
9/2.3 CONIPUR EPDM 0.5-1.5mm
Granules for the In-Situ Construction of Running Tracks and Multi-Purpose

Playgrounds.
1. Product Description - CONIPUR EPDM 0.5 - 1.5mm granules are used for
spray coat application.
2. Field of Application – CONIPUR EPDM 0.5-1.5mm is used – together with a

CONIPUR coating – for the in-situ construction of running tracks or multi-purpose
playgrounds.
3. Properties – CONIPUR EPDM 0.5-1.5mm granules are available in different

colours.
The granules are durable, flexible, of high quality and easy to apply.
4. Technical Data
Figures are guide values and should not be used as a base for
specifications
Specific weight, grain size 0.5-1.5mm kg/dm3 1.6 +/- 0.03
Bulk density, grain size 0.5-1.5mm g/l 550 +/- 10
Polymer content % ≥ 22
Tensile Strenght N/mm2 > 0.5

Elongation % > 500

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4. Pack Size – CONIPUR EPDM 0.5-1.5mm is delivered in bags at 25kg.
5. Colour – Red, further colours on request.
6. Storage – CONIPUR EPDM 0.5-1.5mm to be stored under dry conditions and

sheltered from weather.
7. Safety Precautions – CONIPUR EPDM 0.5-1.5mm is after application non-

hazardous.
9/2.4 CONIPUR 210
Two Component, Self Levelling PUR Coating for Sports Surfacing Systems with
Granular Finish.
1. Product Description - CONIPUR 210 is solvent free, elastic, self leveling, two
component polyurethane coating.
2. Fields of Application – CONIPUR 210 is used as a self leveling coating for the
installation of sports surfacing systems, for example, full pour or sandwich
systems, for athletic tracks, runways, multipurpose sports facilities, school
playgrounds and ball game courts.
CONIPUR 210 can also be used for the re-topping of old PUR surfaces.
3. Properties – CONIPUR 210 exhibits a long pot life, excellent curing properties
and a very good moisture resistance during the curing process.
The material shows an outstanding durability, wear resistance, strength and

elasticity once fully cured.
The material is easy to apply in most of the world’s climate zones.
4. Technical Data
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Mixing ratio in parts by weight 100 : 65
component A, at 23°C g/cm3 1.42

Density component B, at 23°C g/cm3 1.08
mix at 23°C g/cm3 1.26
component A, at 23°C mPas 5000

Viscosity component B, at 23°C mPas 3500
mix at 23°C mPas 3500
at 12°C min 41
Pot Life at 23°C min 33
at 30°C min 28
Ready for foot traffic

at 23°C and 50% rel. humidity h > 16
(broadcast surface)
Ready for removing excess

at 23°C and 50% rel. humidity h < 20
granules
Recoating interval (only for
at 30°C and 75% rel. humidity h, max 36
surfaces not broadcast with
at 23°C and 75% rel. humidity h, max 48
EPDM)
Substrate and application minimum °C 10

temperature maximum °C 40
Permissible relative
maximum % 90
humidity
after 24h, at 23°C and 50% 35
Shore a hardness relative humidity
after 28 days 50-55
Tensile Strength DIN 53504 N/mm2 2.0
Elongation at break DIN 53504 % 150
Tear strength DIN 53515 N/mm 3.7
5. Application Method - The A component of CONIPUR 210 has to be

homogenised before application. This can be achieved by rolling the drums or by
thoroughly stirring in tote using a forced stirrer.
Components A and B of CONIPUR 210 are weighed out in separate drums in the

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ratio of 100:65 by weight respectively.
Part A and part B are poured into a mixing container and thoroughly mixed using
a slowly rotating mixer at about 300 rev/min ensuring that the mixer reaches the
sides and bottom of the mixing vessel.
The mixing process takes at least 2 minutes and should be performed until the
blend is homogeneous and streak free.
The mixed material is then tipped into 2nd clean drum and mixed for a further
minute. For any mixer we recommend you follow the manufacturer’s instructions
but it is essential to obtain a homogenous mix.
The average component temperature should be 15-25 °C.
After the mixing, CONIPUR 210 is applied to the pre-treated substrate using a
squeegee, scraper, or a notched trowel. The tooth size should be selected
according to the thickness of the layer required.
Within 5-10 minutes, the fresh surface has to be covered with excess EPDM or
recycled granules (appropriate grain size usually ø1-3 mm to ø1-4 mm).
In order to avoid possible bald spots, it might be necessary to broadcast

additional granules after some minutes. Excess and loose granules are removed
after curing and can be re-used.
Working and curing time of CONIPUR 210 are influenced by the ambient and
substrate temperature. At low temperatures, the chemical reactions are slowed
down; this lengthens the pot life, re-coating interval and open time. High
temperature and humidity accelerate chemical reactions so the contrary is true.
Direct sunlight shortens the time frames considerably.
CONIPUR 210 exhibits excellent water resistance during curing. Nevertheless, as

with all systems based on isocyanate, water might cause foaming on the surface
of the coating, therefore, after application, the material should be protected from
contact with water for a few hours.
In case of (expected) rain, CONIPUR 210 should not be applied.
6. Cleaning agent - Re-usable tools should be cleaned carefully with CLEANER 40

or other suitable solvents (e.g. butyl acetate). Never use water or alcoholic
solvents as cleaners.
7. Substrate condition - Substrates to be coated have to be firm, dry, load bearing

and free of loose and brittle particles and substances which impair adhesion such
as oil, grease, rubber skid marks, paint or other contaminants.
Under these conditions CONIPUR 210 can be applied directly on asphalt without
any primer.
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On concrete, it is necessary to apply primer CONIPUR 74 (see product data

sheet). The bond strength of the substrate must be at least 1.0 N/mm2.
The moisture level must not exceed 4 % (check with CM equipment), which
corresponds to maximum 75 % relative humidity according to ASTM F 2170. If
using the calcium chloride test, the maximum allowable vapour emissions is 4.0
lbs. as per ASTM F 1869.
point temperature.
Fresh surfaces consisting of smooth or broadcast CONIPUR 210, CONIPUR

2340 or fresh pore-sealed surfaces with CONIPUR 203 or CONIPUR 222 can be
recoated without the use of a primer if substrate is dry and clean.
In case of coatings or pore sealers older than 24-48 hours (please refer to the
technical data sheets of the corresponding product), the application of primer
CONIPUR 72 with a maximum coverage rate of 0.08 kg/m², before
recoating, is mandatory. If necessary the surface should be ground.
When coating an old PUR surface, adhesion tests should be carried out first. It
may be necessary to grind the surface and remove the dust.
In all cases the surface must be thoroughly cleaned by high-pressure water and
then left to thoroughly dry.
Always apply CONIPUR 72 (max. coverage is 0.08 kg/m²) as a primer before the
application of CONIPUR 210.
8. Pack size - CONIPUR 210 is supplied in 260 kg drums or 1.354 kg tote

(containers) for component A and 210 kg drums or 880 kg tote (containers) for
component B.
9. Colour – Standard colours: oxide red and oxide green. Other colours on request.
10. Storage – Store in original closed packing under dry conditions at a temperature
range of 5-25°C.
Before use, please see "best before" date on the pail /drum.
11. Safety Precautions – CONIPUR 210 is non-hazardous in its cured condition.
For protective measures, transport regulation s and waste management please

refer to the Material Safety Data Sheet of the product.

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9/2.5 CONIPUR 2200
Two Component PUR Sealing Lacquer
1. Product Description - CONIPUR 2200 is a pigmented solvent containing, low

viscous, highly elastic, two component PUR satin finish sealing lacquer.
2. Fields of application - CONIPUR 2200 is indoor and outdoor as a weathering

resistant, highly elastic sealing lacquer for elastic CONIPUR coatings.
CONIPUR 2200 is especially used on outdoor sports surfaces to improve UV

resistance and colour stability of structural spray coatings (in most cases blue and
grey) or EPDM rubber granule mats.
It can also be applied to improve the wear resistance of EPDM broadcast

surfaces (e.g. CONIPUR MX+ or CONIPUR SW).
3. Properties - CONIPUR 2200 exhibits good adhesion to non-porous substrates

e.g. most elastic CONIPUR surfaces or EPDM granules.
CONIPUR 2200 is easy to apply and is used to improve the UV resistance as well
as the aesthetic appeal of elastic CONIPUR systems.
Fully cured, CONIPUR 2200 exhibits excellent mechanical properties and is

resistant to water, sea and waste water, a variety of alkaline substances, diluted
acids, brine, mineral oils, lubricants and fuels.
4. Technical Data
Figures are guide values and should not be used as a base for
specifications
Mixing ratio in parts by weight 100:19
Solid Content % 64
component A, at 23°C g/cm3 1.24

Density component B, at 23°C g/cm3 1.15
mix at 23°C g/cm3 1.27
Viscosity mix, 4 mm DIN cup, at 23 °C s 90
Application time at 23°C min 60
Minimum, at 23°C h 24
Re-coating interval
Maximum, at 23°C d 3
Dust dry after at 23°C h 1
Fast to handling at 23°C h 5

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Ready for foot traffic at 23°C h 24
Fully cured, ready for

at 23°C d 5
exposure to traffic
Substrate and minimum °C 10

application temperature maximum °C 30
Permissible relative
maximum % 80
humidity
5. Application Method – CONIPUR 2200 is supplied in the correct proportions of

component A (resin) and component B (hardener).
Pour component B into component A and ensure that the pain containing
component B is emptied completely.
To achieve a homogenous mix, thoroughly mix with a slow rotating mixing device
at about 300 rev/min. Ensure that the mixing device reaches the side and bottom
areas of the mixing vessel.
The mixing process takes at least 2 minutes and should be performed until the
blend is homogenous and streak free.
Pour the mix into another clean pail and mix it again for one additional minute.
The temperature of both components should be between 15-25°C.
CONIPUR 2200 is applied to the pre-treated substrate by spraying.
For indoor sports surfaces the material can be applied with a paint roller as well.
CONIPUR 2200 is normally sprayed by using a low pressure airless spraying

machine.
To obtain a uniform sealing lacquer on structured coatings (e.g. CONIPUR MX+,

CONIPUR SW and CONIPUR SP), CONIPUR 2200 must be sprayed in 2 coats
from opposite directions.
The pot life and curing time of CONIPUR 2200 are influenced by the ambient,
material and substrate temperature. At low temperatures, chemical reactions are
generally slowed down; this lengthens the pot life, re-coating interval and open
time. At the same time, the viscosity increases which leads to a higher
consumption. High temperature and humidity accelerate chemical reactions so
the contrary is true. Direct sunlight shortens the time frames considerably.
After application, the material should be protected from direct contact with water
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for approx. 10 hours (at 15 °C). Within this period, water could cause foaming of
the sealing lacquer.
If necessary, the viscosity of CONIPUR 2200 can be reduced by adding up to 10

% SOLVENT 32.
6. Cleaning agent - Re-usable tools should be cleaned carefully with CLEANER 40

or other suitable solvents (e.g. butyl acetate). Never use water or alcoholic
solvents as cleaners.
7. Substrate condition – CONIPUR 2200 is applied to highly elastic CONIPUR

coatings of EPDM surfaces.
Substrates to be coated have to be firm, dry, load bearing and free of loose and
brittle particles and substances which impair adhesion such as oil, grease, rubber
skid marks, paint or other contaminants.
Pre-treatment of the substrate by e.g. grinding or sanding (smooth floors only) is

only necessary if the coating is very dirty, when applied onto old coatings or if the
re-coating interval has been exceeded.
point temperature.
8. Pack size - CONIPUR 2200 is supplied in 9.9 kg and 29.8 kg working packs.
Component A and B are supplied separately in the correct proportions.
9. Colour - oxide red, oxide green, RAL 5015.
10. Storage - Store in original closed packing under dry conditions at a temperature
range of 15 - 25 °C.
Do not expose to direct sunlight.
Before use, please see "best before" date on the pail / drum.
11. Safety precautions - CONIPUR 2200 is non-hazardous in its cured condition.
For protective measures, transport regulations and waste management, please

refer to the material Safety Data Sheet of the product.
9/3 Method Statement – CONIPUR 2S Modified System
9/3.1 Scope
Supply and installation of CONIPUR 2S Modified (approx. 18mm thick), a rubberized

flooring for a jogging track over an asphalt (substrate supplied by others).

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• Preparation
• Priming
• Installation of Base Layer
• Installation of EPDM layer
• Pore Sealer Application
• Coating Application
• Sealing Lacquer Application
9/3.2 Product Involve
Primer : CONIPUR 70 (for asphalt)
Base Layer (11 mm thick) : SBR granules (1-4mm) + CONIPUR 326 (binder)
0.5-1.5mm-red EPDM granules (Red) + CONIPUR
EPDM Layer (6 mm thick) :
326 (Binder )
CONIPUR 210 Modified (CONIPUR 210 + Silica
Pore Sealer :
Flour)
Coating : CONIPUR 210 + Silica Sand + EPDM dust
Sealing Lacquer : CONIPUR 2200 (Red)
9/3.3 Manufacturer / Supplier

Conica AG Switzerland
9/3.4 General
1. The area where the rubber flooring will be laid shall be inspected, marked on the
drawings and the structure and agreed & signed off upon in terms of area as well
as quality prior to acceptance for the flooring to go on.
2. The main contractor to provide the floor / substrate in a blemish free and in a flat
condition as acceptable to the client / consultant.
9/3.5 Preparation
1. The surfaces agreed for the rubber flooring installation to go on shall be accepted
by Conica free from oil, grease, rubber skid marks, paint, friable matter, curing
compounds, coatings, markings, surface cracks, structural defects or any
other matter that shall hamper the installation of the safety flooring in any way.
2. Vacuum the area to remove the dust and loose debris.

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3. The kerbstones have to be finished 18mm above the substrate such that the
rubber surfacing is flush with the kerbstone top.
9/3.6 Priming
4. Apply the primer CONIPUR 70 for asphalt on to the substrate.
5. Allow for this application to cure sufficiently.
6. Protect the material from direct contact with water till the next coat is applied.
9/3.7 Base Layer
Mixing of SBR Granules and CONIPUR 326
7. Mix the batched CONIPUR 326 and SBR Granules (1‐4mm) using a specially
designed mixer to the specified mixing ratios.
Application of the Mix
8. Install the Base layer at a thickness of 11 mm (approx.) to the primed surface to

form the resilient base layer while the primed surface is still tacky.
9. Allow sufficient curing prior to installation of the EPDM mat.
9/3.8 EPDM Mat
Mixing of EPDM Granules and CONIPUR 326
10. Mix the batched CONIPUR 326 and EPDM Granules (0.5‐1.5mm) using a
specially designed mixer to the specified mixing ratios.
11. Install the EPDM mat at a thickness of 6mm (approx.) to the installed SBR to
form the top resilient EPDM layer using an automated paving machine.
12. Allow for sufficient curing before proceeding to the next application.
9/3.9 Pore Sealer
Mixing of CONIPUR 210 (red) and Silica Flour
13. Mix the CONIPUR 210 and Silica Flour using a paddle mixer to the specified
mixing ratios.
14. Install the pore filler, CONIPUR 210 modified, onto the EPDM surface to fill the
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voids between the EPDM granules.
15. Allow for sufficient curing.
9/3.10 Coating
Mixing of CONIPUR 210 (red), EPDM dust (0-0.5mm) and Silica Sand
16. Mix the batched CONIPUR 210, EPDM dust (0-0.5mm) and Silica sand using a
paddle mixer to the specified mixing ratios.
17. Install the coating on the surface by trowelling and then back rolling.
18. Allow for this application to cure sufficiently.
9/3.11 Sealing Lacquer
Mixing of Sealing Lacquer
19. Stir the components A and B individually in their containers to ensure that if there
are any settled particles, they are back to suspension in the solution.
20. Pour the components into another container and mix it with a slow rotating mixing
device at about 300rev/min till the mix is free of striations and a homogeneous
mix is obtained.
Application of Sealing Lacquer
21. Spray-apply pigmented CONIPUR 2200 (red) to seal the surface.
22. Allow the application to cure sufficiently.

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SECTION 10 – BICYCLE TRACK

10/1 GENERAL
SECTION INCLUDES
A. Furnishing and installing a synthetic all-weather jogging track surface.

1. Polyurethane/EPDM surface finish for running/jogging track.
a. Black traditional Asphalt Course as a substrate for Polyurethane/EPDM surfacing.
2. Blue pigmented Asphalt Course (Wearing Course) for bicycle track finish.
SUBMITTALS UNDER THIS SECTION
A. General: Contractor shall prepare and submit to the approval of Engineer the submittals listed here
after in this Article in accordance with requirements of Conditions of the Contract and Submittal
Procedures.
B. Action Submittals:
1. Qualification Data: For manufacturer of surfacing system, third party testing agency, Asphalt
Course (AC) Sub-Contractor and material supplier of bas course and asphalt pigment.
2. Data Sheets:
a. Base Course: Data sheet and third-party grading test reports for base material.
b. Asphalt Course: Data sheet for each material used in asphalt wearing course, including
but not limited to, the blue pigment.
c. Track Surfacing System: Manufacturer’s Product Literature and Specification Data for
track surfacing system. Include the following:
1) Data sheet for each material used in submitted surface finish system.
2) Third party test report for ASTM C 1028 Skid Resistance Test, based on testing
specimens of submitted flooring during the last 12 months.
3. Samples:
a. Samples of base material:
b. Color samples for customer verification for track surfacing system and for pigmented
AC.
4. Mix Design: Comprehensive asphaltic wearing course design mix prepared according to the
requirements of referenced standards and Authority Having Jurisdiction by the approved third
party testing agency. Include reports of material grading, tests, asphalt properties testing
reports and any mix ingredient.
5. Test Reports:
a. Track Surfacing System: Test results from a Weather-meter exposure test from an
independent lab shall be submitted by the installer to the requiring agency prior to
installation of the surface. The surfacing system (granules and primer) shall be tested for
a minimum of 10,000 hours and show no less than 15% tensile strength (PSI)
degradation.
b. Asphalt Wearing Course: Field quality control test reports as specified in this Section
and the earthworks
6. Special Warranty: Drafts sample of the manufacturer’s written warranty for the track
surfacing system at time of Substantial Completion.
7. Insurance Certificate: Product liability insurance certificate with Employer’s name as
certificate holder.
C. Informational Submittals:
1. Manufacturer’s Certificate: Written statement on Manufacturer’s letterhead certifying that
the top surface will not discolor via fading for a period of five (5) years from date of installation.

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2. Cleaning and Maintenance Data: Submit manufacturer’s written instructions for

recommended maintenance practices.
10/2 QUALITY ASSURANCE
A. Compliance Codes and Standards:

1. Regularity Requirements: Comply with requirements of Dubai Municipality and Roads and
Transportation Authority in Dubai.
2. General Specifications Track Construction: Refer to the American Sports Builders
Association (United States Tennis Court and Track Builders Association).
3. Materials Compliance Standards: As referenced in this Section and related Sections
referenced throughout this Section.
4. Asphalt Mix Design Standard: According to Asphalt Institute Handbook.
B. Manufacturers Qualifications: Not less than 10 years of successful experience in producing and
supplying submitted.
C. Pavement Subcontractor:
1. Not less than 20 years of successful experience in hot-asphalt paved roads.
2. Accredited in RTA.
3. Previous sufficient experience in constructing athletic tracks and colored pigment.
D. Testing Laboratory Qualifications:

1. Are to meet qualifying requirements in ASTM, AASHTO, or Asphalt Institute Standards.
2. Are to be accredited from RTA.
10/3 PRODUCTS
10/3.1 MANUFACTURERS
A. Proposed Manufacturers: Subject to compliance with specifications and other Contract

requirements, the following manufacturers are proposed for consideration of Contractor as offering
products that may be incorporated into the Work:
1. Polyurethane/EPDM Surfacing:
a. Conipur.
b. Mondo.
c. Copeland Coating Company Inc.
d. Conica.
e. EPI Sports.
f. Polytan.
g. Equal and approved unnamed
2. Blue Pigment:
a. Shanghai Roadphalt Asphalt Technology Co., Ltd.
b. South, China.
c. Go Green.
d. Omos PMB.
Equal and approved unnamed

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10/3.2 MATERIALS TRACK EMBANKMENT AND SURFACING SUBSTRATES
A. Polyurethane/Track Embankment: Fill material for forming track embankment shall be as specified
in Earthworks
B. Base Course: Fill material for forming track embankment shall be as specified in Earthworks.
Asphalt Wearing Course: Are to comply with requirements and recommendation of RTA for
subject application.
10/3.3 TRACK SURFACING SYSTEM MATERIALS
A. General: Synthetic track shall be 13-mm-thick, permeable track surfacing system, with a paved-in-
place rubber granules and polyurethane binder base layer. The Urethane track surface will be
designed for use as a durable, resilient surface which may be placed over asphalt and concrete
running tracks and all field events. It may also be used to resurface existing all weather tracks,
including rubberized asphalt providing the existing surface has good structural integrity and planarity.
B. Polyurethane/EPDM Surfacing Material:

1. Urethane Primer: Manufacturer’s Standard polyurethane-based primer manufactured for use
on the substrate used in the Project (asphalt paving substrate), provide special primer for
asphalt pavement.
2. Urethane Binder: All Polyurethane binder shall be polyurethane-based approved for running
track applications on asphalt pavements. Binder shall be a single component polyurethane,
moisture curing, and medium viscosity polyurethane binding argent based on Methylene
Diphenyl diIsocyanate MDI.
3. Premium Black EPDM Rubber (For bottom Layer of the Base): All rubber granules shall be
of a high quality industrial grade. The rubber granules shall be control gradation (1- 3.5 mm)
containing minimum dust, less than 4% by weight. Use only premium EPDM.
4. EPDM Colored Rubber (For Top Layer of the Base): All EPDM colored virgin rubber
granules shall be processed and graded to 0.05 -1.5 mm in size unless otherwise specified.
The rubber shall contain a minimum of 20 % EPDM and be approved by the resin
manufacturer. The specific density shall be 1.60 +/- 0.08 and shore a hardness of 60.
a. Finish Color of Track: Match existing parts of the Track.
5. Clear Polurethane Protective Coating: Whenever the used polyurethane is aromatic
polyurethane, provide aliphatic polyurethane top coating on all track area.
C. Pigmented Course Surfacing:

1. General: Are to comply with requirements and recommendation of RTA for suject application
and requirements in this Section.
2. Blue Pigment: Provide a high performance pigment for hot asphalt pavement. Pigment shall
be Synethtic pigment recommended for use in asphat mix to produce Blue asphalt wearing
surface. Color of pigment is to be Marline Blue - Light. Intensity of color is to be as necessary
to match existing parts of the track. Maximum percentage of pigment in mix shall be between
6%, unless otherwise recommended by pavement subcontractor or pigment manufacturer.
3. Coarse Aggregate: Coarse crushed dolomite rock, at grading recommended in referenced
mix design method.
4. Fine Aggregate (Sand): fine crushed dolomite rock, at grading recommended in referenced
mix design method.
5. Fillers: As recommended in refernced design method of asphalt mix.

DUBAI – UAE
10/3.4 MARSHALL MIX DESIGN
A. Marshall Mix Design Procedure: The Marshall mix design method consists of 6 basic steps, as
follows:
1. Aggregate selection.
2. Asphalt binder selection.
3. Sample preparation (including compaction).
4. Stability determination using the Hveem Stabilometer.
5. Density and voids calculations.
6. Optimum asphalt binder content selection.
B. Marshall Mix Design Procedure:

1. The mix design for AC used as substrate for Polyurethane/EPDM track surfacing material or
used as colored pigmented surfacing material shall be designed for Heavy Traffic as per Table
1 for Marshall Design Criteria, from Aspalt Insitute in USA, latest Update but not less than the
following criteria:
a. Mix Criteria: Heavy Traffic, > 106 Esals.
b. Compaction (number of blows on each end of the sample): 75 Blow.
c. Stability (minimum): 6672 N.
d. Flow (0.25 mm): 8-16.
e. Percent Air Voids: 3-5.
C. Mixing of Pigmented Asphalt: The pigmented asphalt mixture shall be throughly mixed to obtain
uniform color throughout the 50-mm thickness shown on Drawings.
10/4 WARRANTY
A. Special Manufacturer's Warranty: A warranty form acceptable to Engineer, signed by

Polyurethane/EPDM track surfacing system manufacturer and Installer agreeing to repair or replace
waterproofing that does not comply with requirements specified. Warranty include but shall not be
limited to, integrity of the system, resilience and color stability.
1. Warranty Period: Ten (10) years from date of Substantial Completion.
10/5 EXECUTION
10/5.1 BASE SUBSTRATE REQUIREMENTS
A. Synthetic running track surfacing shall be applied on top of wearing asphalt course paved on top
base course applied and compacted on top compacted leveled natural grounde-grade.
B. The layout, structural integrity, drainage and planarity are to be checked by the quality control
department of Contractor prior to the commencement of the surfacing work. Before application of the
surface course, the asphalt base shall be tested for planarity using a 3-meter straight edge. There
shall be no deviation from the specified grade in either the stone or the asphalt in excess of 3-mm in
any direction. The lateral slope from outside to inside shall be 1%, and a maximum slope of 0.1% in
any running direction. Asphalt base shall be allowed to cure a minimum of 14-21 days prior to
commencement of surfacing.

DUBAI – UAE
10/5.2 SURFACE PREPARATION
A. Scheduling: Asphalt wearing course of the track shall be installed after the base course has been
properly prepped and cured. The temperature should be 40 degrees and rising during installation of
surface.
B. Base Course:
1. Material and Workmanship: Shall be specified in Earthworks.
2. Thickness: Shall be as indicated on Drawings.
C. Asphalt Course:
1. Asphalt paving shall be cured for a minimum of 14-21 days prior to synthetic surfacing being
applied.
2. Contractor shall provide documentation that the asphalt paving meets those requirements set
forth for asphalt paving.
3. Asphalt compaction tests are to be provided showing a compaction of 95% or greater. The
asphalt shall be checked with a 3-meter straight edge in all directions. Defected areas not in
conformance with requirements recommended by surfacing system shall be repaired and/or
replaced. Flooding the asphalt surface to located irregularities is highly recommended.
D. Cleaning: The entire subsurface shall be clean, dry and free from any foreign and loose material
such as dirt, oil, grease, and the like.
10/5.3 INSTALLATION OF POLYURETHANE/EPDM SURFACING
A. Primer: After the asphalt base has cured for a minimum of 21 days, a prime coat consisting of
Polyurethane Binder mixed with the proper solvent (1:1 w/w) shall be applied with an airless sprayer
or paint roller. Only the area to be covered within the working day shall be primed to ensure a good
bond to the base.
B. Base Layer: After priming, the 13-mm-thick black resilient rubber base layer shall be applied. Black
EPDM rubber shall be mixed with Polyurethane binder using an approved mixer. After rubber is
suitably mixed with binder, the rubber shall be poured, placed, and leveled by using an approved
paver to provide a resilient base layer.
C. Protection: Contractor shall be responsible for the protection of the track surface during the curing
period, and upon completion of the installation.
10/5.4 FIELD QUALITY CONTROL
A. General: Engage an approved independent testing and inspecting agency to sample and test pile
surface preparation materials.
B. Testing:
1. Subgrade: As specified in Earthworks.
2. Base Course: As specified in Earthworks.
3. Asphalt Course:
a. Asphalt Mix and Compaction: As per RTA Standards or Standards referenced in this
Section.
b. Calfornia Bearing Ratio at the intervals and evaluation criteria in Standards referenced
in this Section


ROADS AND UTILITIES

VOLUME 2 – PART III
DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE
SPECIFICATIONS

20010410
JUNE, 2022
DUBAI – UAE
Project:20010400
Roads and Utilities
GENERAL INDEX
Volume 1 Construction& Contract Conditions

Specifications

Volume 2 – Part VI Particular Specifications for Fire Fighting

Works

Architectural

E7 PROJECT NO. 20010410 iii REV 1 – ISSUED FOR CONSTRUCTION
VOLUME 2 – PART III DATE OF ISSUE: 16 JUNE, 2022
DUBAI MUNICIPALITY SEWERAGE
AND DRAINAGE SPECIFICATIONS
DUBAI – UAE
Volume 2 – Part III

DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE
SPECIFICATIONS
PREFACE
All drainage and sewerage to be performed under this contract shall follow the specifications
given in Volume 2 – Part III and IV – Dubai Sewerage and Drainage Master Plan standard
specification. For all other works the contractor shall refer to the applicable specifications as
given in Volume 2 Part I and II.
Clause 1.2 of Dubai Sewerage and Drainage Master Plan Specifications shall not be applicable
to this Contract. The Contractor is referred to the requirements given in the General
Specifications with regard to the Site Office for the Engineer.
E7 PROJECT NO. 20010410 iv REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
MEYDAN GROUP LLC
Project: 20010410
Roads and Utilities
Volume 2 – Part III
DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE SPECIFICATIONS
CONTENTS
SECTION 1 - GENERAL ........................................................................................................................... 1

1.1 GENERAL INFORMATION............................................................................................................. 1
1.1.1 PREAMBLE ........................................................................................................................ 1
1.1.2 ABBREVIATIONS .............................................................................................................. 1
1.1.3 DATUM ............................................................................................................................... 2
1.1.4 RIGHT OF WAY ................................................................................................................. 2
1.1.5 GEOTECHNICAL INFORMATION ................................................................................... 3
1.1.6 INTERPRETATION OF DRAWINGS ................................................................................ 3
1.1.7 RESPONSIBILITY OF CONTRACTOR ............................................................................ 3
1.1.8 GOVERNING STANDARDS ............................................................................................. 3
1.1.9 GROUNDWATER LEVELS IN DUBAI .............................................................................. 3
1.1.10 POLLUTION OF KHOR DUBAI OR ARABIAN GULF ...................................................... 3
1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE (REFER VOL 1, APPENDIX C) ........... 4
1.3 GENERAL REQUIREMENTS......................................................................................................... 4
1.3.1 MATERIALS ....................................................................................................................... 4
1.3.2 SETTING-OUT THE WORK .............................................................................................. 4
1.3.3 NOTICE OF OPERATIONS .............................................................................................. 5
1.3.4 TRAFFIC SAFETY AND CONTROL ................................................................................. 5
1.3.5 ACCESS TO PRIVATE LAND........................................................................................... 6
1.3.6 ROADS AND SITE TO BE KEPT CLEAN ........................................................................ 6
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DUBAI – UAE
1.3.7 COMPENSATION FOR DAMAGE TO PROPERTY ........................................................ 6

1.3.8 EXISTING SERVICES ....................................................................................................... 6
1.3.9 CONTINUOUS WORKING ................................................................................................ 7
1.3.10 TEMPORARY STAGING FOR STRUCTURES ............................................................... 7
1.3.11 WATER SUPPLY ............................................................................................................... 8
1.3.12 FILLING IN HOLES AND TRENCHES ............................................................................. 8
1.3.13 PROTECTION OF WORKS FROM WEATHER ............................................................... 8
1.3.14 KEEPING THE WORKS FREE FROM WATER .............................................................. 8
1.3.15 SIGN BOARDS .................................................................................................................. 8
1.3.16 TEMPLATES ...................................................................................................................... 9
1.3.17 ASSISTANCE TO THE ENGINEER ................................................................................. 9
1.3.18 SURVEYING EQUIPMENT ............................................................................................. 10
1.3.19 LABORATORY (SEE APPENDIX, PART 3 OF 3) ......................................................... 11
1.3.20 MINIMUM TEST REQUIREMENTS................................................................................ 11
1.3.21 SOURCES OF MATERIALS ........................................................................................... 17
1.3.22 PROGRAMMING THE PROGRESS OF THE WORKS ................................................. 17
1.3.23 PROGRESS REPORTS .................................................................................................. 18
1.3.24 PROGRESS PHOTOGRAPHS ....................................................................................... 18
1.3.25 FLOWS IN PIPELINES AND AT PUMPING STATIONS ............................................... 19
1.3.26 SUPPRESSION OF NOISE ............................................................................................ 19
1.3.27 CLOSING OF ROADS ..................................................................................................... 19
1.3.28 NOC FROM RELEVANT AUTHORITIES ........................................................................... 20
SECTION 2 - EARTHWORKS ................................................................................................................ 21
2.1 CLEARING & GRUBBING ...................................................................................................... 21
2.2 REMOVAL OF STRUCTURES AND OBSTRUCTIONS ....................................................... 21
2.2.1 GENERAL ........................................................................................................................ 21
2.2.2 REMOVAL OF PIPES...................................................................................................... 22
2.3 STRUCTURAL EXCAVATION................................................................................................ 22
2.3.1 GENERAL ........................................................................................................................ 22
2.3.2 PRE-CONSTRUCTION AND LAND DRAINAGE RECORDS ....................................... 23
2.3.3 SETTING OUT ................................................................................................................. 24
2.3.4 TOPSOIL AND SURFACING MATERIALS .................................................................... 24
2.3.5 LAND DRAINS ................................................................................................................. 24
2.3.6 HAND EXCAVATION ...................................................................................................... 24
2.3.7 SUPPORT TO EXCAVATIONS ...................................................................................... 24
E7 PROJECT NO. 20010410 vi REV 1 – ISSUED FOR CONSTRUCTION
DUBAI – UAE
2.3.8 DEWATERING ................................................................................................................. 25

2.3.9 FORMATION.................................................................................................................... 27
2.3.10 EXCAVATION AT OR NEAR ROADS ................................................................................ 27
2.3.11 EXCAVATION FOR STRUCTURES................................................................................... 29
2.3.12 EXCAVATION FOR PIPELINES ......................................................................................... 30
2.3.13 EXCAVATION FOR CABLES/DUCTS ............................................................................... 30
2.3.14 EXCAVATED MATERIAL .................................................................................................... 30
2.3.15 REPLACEMENT OF UNSUITABLE MATERIAL ................................................................ 31
2.3.16 DISPOSAL OF MATERIAL ................................................................................................. 31
2.3.17 COFFERDAMS .................................................................................................................... 31
2.4 BACKFILLING EXCAVATIONS.................................................................................................... 32
2.4.1 GENERAL ........................................................................................................................ 32
2.4.2 SELECTED BACKFILL .................................................................................................... 32
2.4.3 SPECIAL BACKFILL........................................................................................................ 34
2.4.4 FILTER MATERIAL ......................................................................................................... 34
2.4.5 STRUCTURAL AND NON-STRUCTURAL FILLING ...................................................... 34
2.4.6 BACKFILLING OF TRENCHES FOR CABLES/DUCTS ................................................ 35
2.5 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT ................................... 35
2.5.1 GENERAL ........................................................................................................................ 35
2.5.2 REINSTATEMENT OF UNPAVED LAND ...................................................................... 36
2.5.3 REINSTATEMENT WITHIN ROAD CORRIDORS ......................................................... 36
2.5.4 REINSTATEMENT OF OTHER SURFACE AREAS ...................................................... 37
2.5.5 EXCAVATION AND REINSTATEMENT IN DEVELOPED RESERVATIONS .............. 37
SECTION 3 - CONCRETE WORKS ...................................................................................................... 38
3.1 GENERAL ................................................................................................................................ 38
3.2 MATERIALS ............................................................................................................................. 38
3.2.1 CEMENT .......................................................................................................................... 38
3.2.2 AGGREGATES GENERAL REQUIREMENTS .............................................................. 39
3.2.6 ADMIXTURES ................................................................................................................. 46
3.2.7 CONCRETE MIX SPECIFICATION ................................................................................ 47
3.2.8 CEMENT MORTAR AND GROUT .................................................................................. 48
3.3 CONCRETE MIX DESIGN ...................................................................................................... 48
3.3.3 WATER/CEMENT RATIO ............................................................................................... 50
3.3.4 MEASUREMENT OF INGREDIENTS ............................................................................ 50
3.3.5 MIXING CONCRETE ....................................................................................................... 50
E7 PROJECT NO. 20010410 vii REV 1 – ISSUED FOR CONSTRUCTION
DUBAI – UAE
3.3.6 RE-MIXING CONCRETE ................................................................................................ 51

3.3.7 CONCRETE TESTING .................................................................................................... 51
3.3.7.1 GENERAL .................................................................................................................... 51
3.3.7.2 PRELIMINARY TESTING ............................................................................................ 51
3.3.7.3 WORKS TESTING ............................................................................................................... 51
3.3.7.4 WORKABILITY TESTING ................................................................................................... 52
3.3.8 FREQUENCY OF TESTING AGGREGATE AND CONCRETE .................................... 52
3.4 TRANSPORTING AND PLACING CONCRETE .................................................................... 53
3.4.1 GENERAL REQUIREMENTS ......................................................................................... 53
3.4.2 PLACING CONCRETE IN HOT WEATHER .................................................................. 54
3.4.3 PLACING CONCRETE IN WATER (TREMIE CONCRETE) ......................................... 54
3.4.4 BLINDING CONCRETE .................................................................................................. 55
3.5 COMPACTING CONCRETE................................................................................................... 55
3.5.1 TAMPING ......................................................................................................................... 55
3.5.2 VIBRATING ...................................................................................................................... 55
3.6 CURING OF CONCRETE ....................................................................................................... 55
3.7 JOINTS IN CONCRETE .......................................................................................................... 56
3.7.1 INTERVALS DURING CONCRETING............................................................................ 56
3.7.2 CONSTRUCTION JOINTS .............................................................................................. 56
3.7.3 JOINTING FRESH TO SET CONCRETE....................................................................... 57
3.7.4 EXPANSION JOINTS ...................................................................................................... 57
3.7.5 EXPANSION JOINT FILLER ........................................................................................... 57
3.7.6 EXPANSION JOINT ........................................................................................................ 57
3.7.7 WATERSTOP ACROSS JOINTS IN CONCRETE STRUCTURES .............................. 58
3.8 INSPECTION OF CONCRETE ............................................................................................... 59
3.9 FAULTY CONCRETE WORK ................................................................................................. 59
3.10 REPAIRS TO CONCRETE ................................................................................................. 59
3.11 SUPERVISION OF CONCRETE WORK ........................................................................... 59
3.12 FINISHING OF CONCRETE ............................................................................................... 59
3.13 DESIGN AND CONSTRUCTION OF FORMWORK.......................................................... 60
3.13.1 GENERAL ............................................................................................................................ 60
3.13.2 SPACING BLOCKS AND TEMPORARY CONSTRUCTION TIES ................................... 60
3.13.3 SLAB FORMS ...................................................................................................................... 60
3.13.4 TYPE OF FORMWORK ...................................................................................................... 61
3.13.5 PREPARATION OF FORMWORK FOR CONCRETING ................................................... 61
E7 PROJECT NO. 20010410 viii REV 1 – ISSUED FOR CONSTRUCTION
DUBAI – UAE
3.13.6 APPROVAL OF FORMWORK BEFORE CONCRETING .................................................. 61

3.13.7 REMOVAL OF FORMWORK .............................................................................................. 62
3.13.8 CONCRETE BELOW GROUND ......................................................................................... 62
3.14 READY MIXED CONCRETE .............................................................................................. 62
3.14.1 COMPLIANCE WITH SPECIFICATION ............................................................................. 62
3.14.2 DOCUMENTATION ............................................................................................................. 63
3.15 REINFORCEMENT STEEL ................................................................................................ 63
3.15.1 GENERAL ............................................................................................................................ 63
3.15.2 MATERIAL SPECIFICATIONS .......................................................................................... 64
3.15.3 CONSTRUCTION OF REINFORCEMENT ........................................................................ 64
3.16 PRECAST CONCRETE KERBS, EDGINGS & QUADRANTS ......................................... 66
3.17 IN-SITU CONCRETE EDGING ........................................................................................... 67
SECTION 4 - PIPES, PIPEWORK, MANHOLES AND CHAMBERS .................................................. 68
4.1 PIPE MATERIALS ................................................................................................................... 68
4.1.1 PIPE CLASSIFICATIONS AND PRESSURE RATINGS ............................................... 68
4.1.2 JOINT REQUIREMENTS AND LIMITATIONS .................................................................... 68
4.1.3 ASBESTOS CEMENT PIPES AND FITTINGS .................................................................... 70
4.1.4 UNPLASTICISED POLYVINYL CHLORIDE PIPES AND FITTINGS (UPVC) ................... 71
4.1.5 UPVC PIPES FOR LAND DRAINS ...................................................................................... 71
4.1.6 GLASS REINFORCED PLASTIC PIPES AND FITTINGS (GRP) ....................................... 72
4.1.7 POLYETHYLENE PIPES (HDPE OR HPPE) ................................................................. 76
4.2 STORAGE AND HANDLING OF PIPES ................................................................................ 77
4.2.1 GENERAL ............................................................................................................................... 77
4.2.2 GLASS REINFORCED PLASTIC PIPES (GRP)................................................................... 78
4.2.3 THERMOPLASTIC PIPES ..................................................................................................... 78
4.3.2 COMPACTION FRACTION TEST .................................................................................. 80
4.4 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION..................................... 81
4.4.1 GENERAL ........................................................................................................................ 81
4.4.2 NOMINAL TRENCH WIDTHS ......................................................................................... 81
4.4.3 PIPELAYING AND JOINTING ........................................................................................ 82
4.4.4 PIPELINES IN CONCRETE CRADLES AND SURROUNDS........................................ 83
4.4.5 PIPELINES ON GRANULAR BEDS ............................................................................... 84
4.4.6 PLACING SURROUNDS TO PIPELINES ...................................................................... 85
4.4.7 BACKFILLING OF TRENCHES - PIPELINES/STRUCTURES ..................................... 86
4.4.8 DEFLECTION MEASUREMENTS ON GROUP B PIPELINES ..................................... 86
E7 PROJECT NO. 20010410 ix REV 1 – ISSUED FOR CONSTRUCTION
DUBAI – UAE
4.4.9 STANKS TO PIPELINES IN GRANULAR BEDDING .................................................... 88

4.4.10 THRUST AND ANCHOR BLOCKS TO PRESSURE PIPELINES ................................. 88
4.4.11 PIPES PROTRUDING FROM STRUCTURES, CONCRETE SURROUNDS AND
ANCHOR BLOCKS .......................................................................................................................... 89
4.4.12 PROTECTION OF PIPELINES AND PIPELINE COMPONENT ................................... 90
4.4.13 INDICATOR POSTS TO PRESSURE MAINS................................................... 91
4.4.14 ENCLOSING GRANULAR OR STONE SURROUND WITH GEOTEXTILE
FILTER FABRIC .............................................................................................................................. 91
4.4.15 UNDERGROUND SERVICES WARNING TAPES ..................................................... 92
4.5 PIPEWORK WITHIN STRUCTURES ..................................................................................... 93
4.6 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES ................................................ 94
4.6.1 GENERAL ........................................................................................................................ 94
4.6.2 CONSTRUCTION OF MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES .... 94
4.6.3 ACCESS COVERS, FRAMES, AND GRATES .............................................................. 95
4.7 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS ..................................... 98
4.7.1 APPROVED LIST OF SUPPLIERS .............................................................................. 100
SECTION 5 - BRICKWORK AND BLOCKWORK .............................................................................. 101
5.1 MATERIALS ........................................................................................................................... 101
5.1.1 CONCRETE BRICKS AND BLOCKS ........................................................................... 101
5.1.2 BRICKS .......................................................................................................................... 101
5.1.3 SAND FOR MORTAR.................................................................................................... 101
5.1.4 LIME FOR MORTAR ..................................................................................................... 101
5.2 CONSTRUCTION .................................................................................................................. 102
5.2.1 GENERAL ...................................................................................................................... 102
5.2.2 ENGINEERING BRICKWORK ...................................................................................... 102
5.2.3 BLOCKWORK................................................................................................................ 102
5.2.4 CEMENT MORTAR ....................................................................................................... 103
5.2.5 CEMENT LIME MORTAR ............................................................................................. 103
5.2.6 CEMENT MORTAR RENDERING ................................................................................ 103
SECTION 6 - INSPECTION AND TESTING OF PIPELINES AND STRUCTURES ......................... 104
6.1 CLEANING AND INSPECTION OF PIPELINES ................................................................. 104
6.2 TESTING OF PIPELINES ..................................................................................................... 104
6.2.1 GENERAL ...................................................................................................................... 104
6.2.2 TESTING OF NON-PRESSURE PIPELINES .............................................................. 105
6.2.3 TESTING OF PRESSURE PIPELINES ........................................................................ 107
6.3 TESTING OF VALVES .......................................................................................................... 109
E7 PROJECT NO. 20010410 x REV 1 – ISSUED FOR CONSTRUCTION
DUBAI – UAE
6.4 TESTING OF RENOVATED AND REPLACED PIPELINES ............................................... 109

6.5 TESTING OF WATER RETAINING STRUCTURES ........................................................... 109
SECTION 7 – NOT USED ..................................................................................................................... 110
SECTION 8 – NOT USED ..................................................................................................................... 111
SECTION 9 - CORROSION PROTECTION AND ODOR CONTROL ............................................... 112
9.1 MATERIALS ........................................................................................................................... 112
9.1.1 CORROSIVE ENVIRONMENTS................................................................................... 112
9.1.2................................................................................................................................................ 112
PAINT ............................................................................................................................................. 112
9.1.3 IMPERVIOUS TANKING MEMBRANE ........................................................................ 112
9.1.4 PVC SHEET LINING MATERIALS ............................................................................... 113
9.1.5 REINFORCED PLASTIC LINERS ................................................................................ 113
9.1.6 IN-SITU LAMINATIONS ................................................................................................ 114
9.1.7 EPOXY MORTAR .......................................................................................................... 115
9.1.8 BITUMINOUS EMULSION ............................................................................................ 116
9.1.9 WATERPROOF PAPER ................................................................................................ 116
9.1.10 PROTECTIVE MATERIALS FOR WRAPPING PIPELINE COMPONENTS .................. 116
9.1.11 APPROVED PAINT SUPPLIERS ..................................................................................... 116
9.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE .............. 117
9.2.1 GENERAL ...................................................................................................................... 117
9.2.2 PROTECTIVE COATINGS/PVC LINERS..................................................................... 117
9.2.3 REINFORCED PLASTIC LINERS ................................................................................ 119
9.2.4 CUTTING AND SEALING OF REINFORCED LINERS ............................................... 120
9.3 ODOR CONTROL FACILITIES ............................................................................................ 120
9.3.1 GENERAL ...................................................................................................................... 120
9.3.2 SOIL MOISTURE AND PH PROBES ........................................................................... 120
9.3.3 ACTIVATED CARBON ODOR CONTROL FILTER ..................................................... 120
9.3.4 NATURAL SOIL ODOR CONTROL FILTER ................................................................ 120
SECTION 10 - BUILDING SPECIFICATIONS PIPELINE RENOVATION, REPLACEMENT AND
ABANDOMENT ..................................................................................................................................... 123
10.1 GENERAL .................................................................................................................................. 123
10.1.1 RENOVATION, REPLACEMENT AND ABANDONMENT WORKS ........................... 123
10.1.2 USE OF APPROVED SPECIALIST FIRMS / SUB-CONTRACTORS ........................ 124
10.1.3 HEALTH AND SAFETY ................................................................................................. 124
10.1.4 MATERIALS ....................................................................................................................... 124
E7 PROJECT NO. 20010410 xi REV 1 – ISSUED FOR CONSTRUCTION

DUBAI – UAE
10.1.5 DIVERSION OF SEWAGE FLOWS.............................................................................. 128

10.1.6 FLOW CONTROL .......................................................................................................... 128
10.1.7 MAINTAINING CLEAN CONDITIONS .......................................................................... 129
10.1.8 SEWER PRE-RENOVATION SURVEYS ......................................................................... 129
10.1.9 CLEANING OF SEWERS ................................................................................................. 129
10.1.10 TRAFFIC CONTROL AND DIVERSION ................................................................... 130
10.1.11 MANHOLE CONNECTIONS ..................................................................................... 130
10.1.12 HOUSE CONNECTIONS .......................................................................................... 130
10.2 PIPELINE RENOVATION - SLIPLINING.......................................................................... 130
10.2.1 GENERAL .......................................................................................................................... 130
10.2.2 SLIP-LINING EXECUTION ........................................................................................... 131
10.3 PIPELINE RENOVATION - DEFORMED PIPE LINING .................................................. 133
10.3.1 GENERAL ...................................................................................................................... 133
10.3.2 MATERIALS - HDPE OR HPPE PIPE .......................................................................... 133
10.3.3 FURTHER SITE WORK PREPARATION..................................................................... 133
10.3.4 PIPELINE OBSTRUCTIONS......................................................................................... 134
10.3.5 SEWER LINING EXECUTION ...................................................................................... 134
10.3.6 GUARANTEE......................................................................................................... 136
10.3.7 FINISHING TO MANHOLES ................................................................................. 136
10.4 PIPELINE RENOVATION - INVERSION OF SOFT LINING ........................................... 137
10.4.1 GENERAL ...................................................................................................................... 137
10.4.2 MATERIALS ................................................................................................................... 137
10.4.3 INVERSION TYPE RESIN SYSTEM ............................................................................ 138
10.4.4 TESTS ............................................................................................................................ 138
10.4.5 SOFT LINING DESIGN ................................................................................................. 139
10.4.6 SEWER LINING EXECUTION ...................................................................................... 140
10.4.7 GUARANTEE ................................................................................................................. 142
10.4.8 FINISHING TO MANHOLES ......................................................................................... 142
10.5 PIPELINE REPLACEMENT - PIPE BURSTING .............................................................. 143
10.5.1 GENERAL ...................................................................................................................... 143
10.5.2 PIPE BURSTING - EXECUTION .................................................................................. 144
10.5.3 FINISHING TO MANHOLES ......................................................................................... 144
10.5.4 OBSTRUCTIONS .......................................................................................................... 145
10.5.1.2 PIPELINE ABANDONMENT ..................................................................................... 145
10.5.1.3 GENERAL .................................................................................................................. 145
E7 PROJECT NO. 20010410 xii REV 1 – ISSUED FOR CONSTRUCTION
DUBAI – UAE
10.6.2 GROUT AND GROUTING FOR ABANDONED PIPELINE ......................................... 145

10.6 SEWER CLEANING AND CCTV SURVEY ..................................................................... 146
10.6.1 GENERAL .......................................................................................................................... 146
10.7.2 SEWER CLEANING ...................................................................................................... 146
10.7.3 SURVEY AND OPERATIONAL EQUIPMENT ............................................................. 148
10.7.4 PERFORMANCE OF SURVEY ........................................................................................ 148
10.7.5 SURVEY DATA REPORTING ...................................................................................... 150
10.7.6 DRAWINGS ................................................................................................................... 150
10.7.7 METRIC MEASUREMENT............................................................................................ 151
10.7.8 PHOTOGRAPHS ........................................................................................................... 151
10.7.9 EQUIPMENT STANDARDS ............................................................................................. 151
10.7.9.1 PICTURE QUALITY................................................................................................... 151
10.7.9.2 VIDEO PLAYBACK .................................................................................................... 152
10.7.9.3 FOCUS, IRIS AND ILLUMINATION ADJUSTMENT ................................................ 152
10.7.9.4 EQUIPMENT TESTING ............................................................................................. 152
10.7.10 QUALITY CONTROL ................................................................................................. 153
SECTION 11 – NOT USED ................................................................................................................... 155
SECTION 12 - SAFETY PROCEDURES............................................................................................. 156
12.1 GENERAL ...................................................................................................................... 156
12.2 FAMILIARISATION WITH SAFETY PROBLEMS ........................................................ 156
12.3 SAFETY OFFICER ........................................................................................................ 156
12.4 SAFE WORKING CONDITIONS AT THE SITE ........................................................... 156
12.5 SAFETY EQUIPMENT .................................................................................................. 157
12.6 SAFETY PROCEDURES .................................................................................................. 158
12.6.1 GENERAL .......................................................................................................................... 158
12.6.2 ATMOSPHERE MONITORING......................................................................................... 159
12.6.3 ATMOSPHERE VENTILATION ........................................................................................ 159
12.6.4 SAFETY HARNESS .......................................................................................................... 159
12.6.5 EMERGENCY BREATHING APPARATUS ...................................................................... 159
12.6.6 ACTIVE CONFINED SPACE ENTRY ............................................................................... 160
12.6.7 WASHING FACILITIES ..................................................................................................... 160
12.6.8 COMMUNICATION............................................................................................................ 160
12.6.9 LIGHTING .......................................................................................................................... 160
12.7 TRAFFIC CONTROL ......................................................................................................... 160
SECTION 13 – NOT USED ................................................................................................................... 161
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SECTION 14 – NOT USED ................................................................................................................... 162

SECTION 15 – NOT USED ................................................................................................................... 163
SECTION 16 - MICRO-TUNNELLING AND PIPE JACKING ............................................................ 164
16.1 GENERAL .......................................................................................................................... 164
16.1.1 LIST OF APPROVED SPECIALIST FIRMS/SUB-CONTRACTORS .............................. 166
16.2 SURVEY CONTROL ......................................................................................................... 166
16.2.1 GENERAL .......................................................................................................................... 166
16.2.2 SURVEY REFERENCES .................................................................................................. 166
16.2.3 STRUCTURAL SURVEY................................................................................................... 166
16.2.4 SITE INVESTIGATIONS ................................................................................................... 167
16.3 GEOTECHNICAL INSTRUMENTATION.......................................................................... 167
6.3.1 SETTLEMENT POINTS ................................................................................................ 168
16.3.2 SETTLEMENT ANCHORS ................................................................................................ 169
16.3.3 INCLINOMETERS (IF REQUIRED) .................................................................................. 169
16.3.4 GROUNDWATER OBSERVATION WELLS .................................................................... 169
16.3.5 OPTICAL SURVEYS ......................................................................................................... 169
16.4 DEWATERING ................................................................................................................... 169
16.4.1 SUBMITTALS .................................................................................................................... 170
16.5 SITE INVESTIGATION ...................................................................................................... 170
16.6 QUALITY CONTROL ......................................................................................................... 170
16.7 EQUIPMENT ...................................................................................................................... 171
16.8 EXECUTION ...................................................................................................................... 171
16.9 TESTING ............................................................................................................................ 172
16.10 SAFETY ................................................................................................................................. 172
SECTION 17 - GENERAL, ELECTRICAL AND MECHANICAL SPECIFICATION ......................... 173
17.1 ELECTRICAL AND MECHANICAL PLANT TO BE SUPPLIED ..................................... 173
17.2 DRAWINGS AND INFORMATION REQUIRED FOR ELECTRICAL AND MECHANICAL
PLANT 173
17.2.1 AT THE START OF THE CONTRACT ............................................................................. 173
17.2.2 AS BUILT RECORD DRAWING ....................................................................................... 174
17.2.3 PRIOR TO DELIVERY OF THE PLANT ........................................................................... 174
17.2.4 PRIOR TO THE ISSUE OF THE TAKING-OVER CERTIFICATE .................................. 175
17.2.5 DURING THE MAINTENANCE PERIOD ......................................................................... 176
17.3 WORKMANSHIP AND DESIGN OF PLANT.................................................................... 176
17.4 LUBRICATION OF PLANT................................................................................................ 177
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17.5 INITIAL CHARGES OF OILS AND OTHER CONSUMABLES ....................................... 178

17.6 SPARES ............................................................................................................................. 178
17.7 TOOLS AND LUBRICANTS.............................................................................................. 178
17.8 DELIVERY OF SPARES, TOOLS AND LUBRICANTS .................................................. 179
17.9 PROTECTION AND PACKING FOR SHIPMENT/STORAGE ........................................ 179
17.10 AUTOMATIC CONTROL OF PLANT ................................................................................... 179
17.11 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF ........................................... 180
17.12 MAINTENANCE OF PLANT ................................................................................................. 180
17.13 RETURN TO SITE................................................................................................................. 181
17.14 OPERATING AND MAINTENANCE MANUALS ................................................................. 181
17.14.1 INTRODUCTION ....................................................................................................... 181
17.14.2 GENERAL REQUIREMENTS AND CONTENTS ..................................................... 182
17.15 WORKS TESTING AND INSPECTION OF MANUFACTURED ITEMS ............................ 185
17.16 TESTING AND CERTIFICATION OF MOTORS ................................................................. 186
17.17 SITE TESTING AND COMMISSIONING OF ELECTRICAL AND MECHANICAL PLANT187
17.18 PLANT SUPPLIERS FOR THIS CONTRACT ..................................................................... 190
17.19 CLIMATE ............................................................................................................................... 191
17.20 ELECTRICITY SUPPLY........................................................................................................ 192
17.21 DERATING DUE TO THE CLIMATIC CONDITIONS ......................................................... 192
17.22 TROPICALISATION .............................................................................................................. 192
17.22.1 GENERAL......................................................................................................................... 192
17.22.2 METALS ........................................................................................................................... 192
17.22.3 SCREWS, NUTS, SPRINGS, PIVOTS ETC. .................................................................. 193
17.22.4 WOOD .............................................................................................................................. 193
17.22.5 ELECTRICAL INSULATING MATERIALS ...................................................................... 193
17.23 WORK IN DANGEROUS AREAS ........................................................................................ 193
17.24 CLASSIFICATION OF HAZARDOUS AREAS .................................................................... 193
17.25 HEALTH AND SAFETY AT WORK, ETC. ACT 1974 ......................................................... 193
17.26 PROGRESS REPORTS ....................................................................................................... 194
17.27 QUALITY ASSURANCE AND STANDARDS ...................................................................... 194
17.28 ADAPTATION OF EQUIPMENT .......................................................................................... 194
17.29 GUARANTEE ........................................................................................................................ 195
17.30 CO-ORDINATION ................................................................................................................. 195
17.31 TESTING AND COMMISSIONING PROCEDURES AND DOCUMENTS ......................... 195
17.32 SITE RELIABILITY TRIALS .................................................................................................. 196
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SECTION 18 - ELECTRICAL SPECIFICATON .................................................................................. 199

18.1 HV AND LV FACTORY BUILT ASSEMBLIES (F.B.A.'S) ................................................ 199
18.1.1 CONSTRUCTION .......................................................................................................... 199
18.1.2 EARTHING BAR ............................................................................................................ 200
18.1.3 TERMINALS................................................................................................................... 200
18.1.4 BUSBARS ...................................................................................................................... 200
18.1.5 ANTI-CONDENSATION HEATERS .............................................................................. 200
18.1.6 INDICATING LAMPS ......................................................................................................... 201
18.1.7 INDICATING INSTRUMENTS .......................................................................................... 201
18.1.8 MOTOR STARTER ISOLATION ....................................................................................... 201
18.1.9 CONTROL CIRCUIT PROTECTION ................................................................................ 201
18.1.10 ROTOR RESISTANCES .................................................................................................. 201
18.1.11 SOCKET OUTLETS ......................................................................................................... 201
18.1.12 METERING ....................................................................................................................... 202
18.1.13 LABELING ........................................................................................................................ 202
18.1.14 SPARES ........................................................................................................................... 202
18.1.15 FUTURE EQUIPMENT .................................................................................................... 202
18.1.16 STANDBY GENERATOR CONNECTION ...................................................................... 202
18.1.17 WEATHERPROOF SWITCHBOARDS ........................................................................... 203
18.1.18 PANEL WIRING ............................................................................................................... 203
18.1.19 THERMAL OVERLOAD RELAYS ................................................................................... 204
18.2 CIRCUIT BREAKERS ....................................................................................................... 204
18.2.1 H.V. CIRCUIT BREAKERS ................................................................................................ 204
18.2.2 AIR BREAK CIRCUIT BREAKERS ................................................................................... 204
18.2.3 GENERAL ........................................................................................................................... 204
18.3 EARTH LEAKAGE CIRCUIT BREAKERS AND SWITCH DISCONNECTORS ............ 205
18.4 FUSE-SWITCHES AND FUSE-SWITCH DISCONNECTORS ....................................... 206
18.5 FUSES ............................................................................................................................... 206
18.6 CURRENT TRANSFORMERS ......................................................................................... 206
18.7 INSTRUMENT VOLTAGE TRANSFORMERS ................................................................ 206
18.8 ISOLATING TRANSFORMERS ........................................................................................ 206
18.9 SELECTOR SWITCHES ................................................................................................... 207
18.10 EARTHING ............................................................................................................................ 207
18.11 AC MOTORS ......................................................................................................................... 207
18.12 MOTOR STARTERS ............................................................................................................. 208
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18.12.1 GENERAL......................................................................................................................... 208

18.12.2 L.V. STARTERS ............................................................................................................... 209
18.12.3 H.V. STARTERS .............................................................................................................. 211
18.12.4 SLIP RING ROTOR RESISTANCE MOTOR STARTERS ............................................. 211
18.13 MOULDED CASE CIRCUIT BREAKERS (M.C.C.B'S) ....................................................... 213
18.14 PUMP CONTROLS ............................................................................................................... 213
18.15 TELEMETRY SYSTEM ......................................................................................................... 214
18.16 BATTERY UNITS .................................................................................................................. 214
18.17 TRANSFORMERS ................................................................................................................ 215
18.17.1 STANDARDS ................................................................................................................... 215
18.17.2 WINDINGS ....................................................................................................................... 215
18.17.3 CONSTRUCTION ............................................................................................................ 216
18.17.4 FITTINGS ......................................................................................................................... 217
18.18 INSTRUMENTS, INDICATORS AND TRANSMITTERS .................................................... 217
18.18.1 GENERAL......................................................................................................................... 217
18.18.2 INSTRUMENT RANGES ................................................................................................. 218
18.18.3 FIELD MOUNTED INSTRUMENTS ................................................................................ 218
18.18.4 PANEL MOUNTED INSTRUMENTS .............................................................................. 219
18.18.5 INDICATORS ................................................................................................................... 219
18.18.6 DIGITAL INDICATORS .................................................................................................... 219
18.18.7 INTEGRATORS ............................................................................................................... 219
18.18.8 CHART RECORDERS ..................................................................................................... 219
18.18.9 TRANSMITTERS ............................................................................................................. 220
18.19 FLOW MEASURING EQUIPMENT ...................................................................................... 221
18.19.1 ELECTRO MAGNETIC FLOW METERS ........................................................................ 221
18.19.2 ULTRASONIC IN-LINE FLOW METER .......................................................................... 222
18.19.3 ULTRASONIC OPEN CHANNEL FLOW MEASURING EQUIPMENT .......................... 223
18.19.4 INSTALLATION OF ULTRASONIC SENSORS .............................................................. 223
18.20 LEVEL MEASURING & CONTROL EQUIPMENT .............................................................. 223
18.20.1 ULTRASONIC LEVEL MEASURING EQUIPMENT ....................................................... 223
18.20.2 PRESSURE LEVEL MEASURING EQUIPMENT ........................................................... 224
18.20.3 FLOAT LEVEL CONTROL EQUIPMENT........................................................................ 224
18.21 GENERAL DESCRIPTION OF LIGHTING AND SMALL POWER INSTALLATIONS....... 224
18.21.1 SMALL POWER INSTALLATIONS........................................................................... 224
18.21.2 LIGHTING INSTALLATIONS ........................................................................................... 225
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18.21.3 EMERGENCY LIGHTS .................................................................................................... 227

18.22 PORTABLE PLANT............................................................................................................... 227
18.23 WIRING & CABLING ACCESSORIES ................................................................................. 227
18.23.1 WIRING ............................................................................................................................ 227
18.23.2 DISTRIBUTION BOARDS ............................................................................................... 228
18.23.3 SOCKET OUTLETS ......................................................................................................... 228
18.23.4 SWITCHES ....................................................................................................................... 229
18.23.5 LIGHTING FITTINGS ....................................................................................................... 229
18.24 CABLES ................................................................................................................................. 230
18.24.1 GENERAL......................................................................................................................... 230
18.24.2 PLYSW & PVC OVERSHEATH CABLES ....................................................................... 231
18.24.3 PVC SWA PVC CABLES ................................................................................................. 231
18.24.4 XLPE PVC SWA PVC CABLES ...................................................................................... 232
18.24.5 PVC INSULATED CABLES ............................................................................................. 232
18.24.6 PVC INSULATED MICC CABLES .................................................................................. 232
18.25 CABLING METHODS ........................................................................................................... 232
18.25.1 GENERAL......................................................................................................................... 232
18.25.2 CONDUIT SYSTEM AND ASSOCIATED CABLES ....................................................... 235
18.25.3 FLEXIBLE CONDUIT ....................................................................................................... 237
18.25.4 CABLE TRUNKING AND ASSOCIATED CABLES ........................................................ 237
18.25.5 CABLE TRAY ................................................................................................................... 237
18.26 EARTHING ............................................................................................................................ 238
18.27 ELECTRIC ACTUATORS ..................................................................................................... 239
18.28 PLC’S AND MICROPROCESSOR EQUIPMENT ............................................................... 241
SECTION 19 - MECHANICAL SPECIFICATION ................................................................................ 244
19.1 FINISH ................................................................................................................................ 244
19.2 MATERIALS ....................................................................................................................... 244
19.3 VALVES ............................................................................................................................. 244
19.3.1 GENERAL .......................................................................................................................... 244
19.3.2 NON-RETURN VALVES ................................................................................................... 245
19.3.3 GATE VALVES FOR SEWAGE AND RELATED FLUIDS ............................................... 246
19.3.4 AIR VALVES ...................................................................................................................... 246
19.3.5 FLUSH VALVES ................................................................................................................ 247
19.3.6 FLAP VALVES ................................................................................................................... 247
19.4 PUMPS ............................................................................................................................... 248
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19.4.1 GENERAL REQUIREMENTS ........................................................................................... 248

19.4.2 SUBMERSIBLE PUMPS ................................................................................................... 249
19.5 PRESSURE AND COMPOUND GAUGE FOR SEWAGE AND SLUDGE ..................... 251
19.6 CENTRIFUGAL FANS (AIR BLOWERS) ......................................................................... 251
19.7 SUPPORTS AND FIXINGS .............................................................................................. 252
19.8 SETTING OF MACHINERY .............................................................................................. 252
19.9 SUPPORT OF PIPEWORK AND VALVES ...................................................................... 253
19.10 PENSTOCKS......................................................................................................................... 253
19.10.1 GENERAL......................................................................................................................... 253
19.10.2 AUSTENITIC NI RESIST IRON PENSTOCKS .............................................................. 254
19.10.3 STAINLESS STEEL PENSTOCKS ................................................................................. 254
19.10.4 PLASTIC PENSTOCKS ................................................................................................... 255
19.10.5 ACTUATORS ................................................................................................................... 255
19.11 LIFTING EQUIPMENT .......................................................................................................... 255
19.11.1 ELECTRICALLY OPERATED TRAVERSING CRANES ................................................ 255
19.11.2 MANUALLY OPERATED LIFTING EQUIPMENT .......................................................... 257
19.11.3 LIFTING FRAMES ............................................................................................................ 257
19.11.4 LIFTING DAVITS .............................................................................................................. 257
SECTION 20 - MISCELLANEOUS ELECTRICAL AND MECHANICAL ............................................ 259
20.1 METAL AND PLASTIC MATERIALS................................................................................ 259
20.1.1 ALUMINIUM ALLOY .......................................................................................................... 259
20.1.2 STEEL ................................................................................................................................. 259
20.1.3 STAINLESS STEEL ........................................................................................................... 259
20.1.4 REINFORCED THERMOSETTING PLASTICS ................................................................ 260
20.2 METAL AND PLASTIC PREFABRICATED ITEMS ......................................................... 264
20.2.1 LADDERS AND SAFETY HOOPS .................................................................................... 264
20.2.2 UNDERGROUND HYDRANTS AND COVERS ................................................................ 264
20.2.3 OPEN MESH AND CHEQUER PLATE FLOORING ........................................................ 264
20.2.4 GALVANISED STEEL GUARDRAILING .......................................................................... 265
20.3 ODOUR CONTROL EQUIPMENT ................................................................................... 265
20.3.1 DESIGN PARAMETERS ................................................................................................... 265
20.3.2 DESCRIPTION AND ARRANGEMENT OF PLANT ........................................................ 266
20.4 VENTILATION ................................................................................................................... 268
20.4.1 GENERAL ........................................................................................................................... 268
20.4.2 EXTRACT FANS ................................................................................................................ 269
E7 PROJECT NO. 20010410 xix REV 1 – ISSUED FOR CONSTRUCTION
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20.4.3 WET WELL VENTILATION................................................................................................ 269

20.4.4 DRY WELL VENTILATION ................................................................................................ 269
20.4.5 MOTOR ROOM VENTILATION......................................................................................... 269
20.4.6 FANS .................................................................................................................................. 269
20.4.7 FAN MOTORS ................................................................................................................... 270
20.4.8 DUCTING ........................................................................................................................... 270
20.5 AIR CONDITIONING ......................................................................................................... 270
20.5.1 WALL MOUNTED AIR CONDITIONING UNITS............................................................... 270
20.5.2 CENTRALISED AIR CONDITIONING SYSTEMS ............................................................ 271
20.5.3 SPLIT UNIT AIR CONDITIONERS.................................................................................... 272
20.6 STANDBY DIESEL GENERATING PLANT ..................................................................... 272
20.6.1 APPLICATION .................................................................................................................... 272
20.6.2 GENERAL DESCRIPTION OF THE PLANT..................................................................... 273
20.6.3 ENGINE - GENERAL ......................................................................................................... 273
20.6.4 ENGINE - LUBRICATION .................................................................................................. 274
20.6.5 ENGINE - FUEL SYSTEM ................................................................................................. 274
20.6.6 ENGINE - COOLING .......................................................................................................... 274
20.6.7 ENGINE - EXHAUST SYSTEM ......................................................................................... 275
20.6.8 ENGINE - SPEED CONTROL ........................................................................................... 275
20.6.9 ENGINE - STARTING ........................................................................................................ 276
20.6.10 ENGINE PANEL ............................................................................................................... 277
20.6.11 ENGINE - SAFETY DEVICES ......................................................................................... 277
20.6.12 ENGINE WIRING ............................................................................................................. 277
20.6.13 ALTERNATOR OUTPUT ................................................................................................. 278
20.6.14 ALTERNATOR CONSTRUCTION .................................................................................. 278
20.6.15 ALTERNATOR - TERMINALS ......................................................................................... 278
20.6.16 ALTERNATOR - INSULATION ........................................................................................ 278
20.6.17 ALTERNATOR - HEATERS............................................................................................. 278
20.6.18 ALTERNATOR - WAVEFORM, REGULATION AND RADIO FREQUENCY
INTERFERENCE ........................................................................................................................... 278
20.6.19 CONTROL PANEL CONSTRUCTION ............................................................................ 279
20.6.20 CONTROL PANEL - FRONT PANEL .............................................................................. 279
20.6.21 CONTROL PANEL - ALARM ANNUNCIATOR............................................................... 280
20.6.22 CONTROL PANELS - GENERAL ................................................................................... 280
20.6.23 BULK FUEL TANKS ......................................................................................................... 281
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20.6.24 FUEL TRANSFER PUMPS.............................................................................................. 281

20.6.25 FUEL SYSTEM................................................................................................................. 282
20.6.26 ENCLOSURE ................................................................................................................... 282
20.7 FIRE ALARM AND EXTINGUISHING SYSTEMS ........................................................... 282
20.7.1 GENERAL ........................................................................................................................... 282
20.7.2 MANUAL FIRE ALARM CALL POINT ............................................................................... 283
20.7.3 OPTICAL SMOKE DETECTOR......................................................................................... 283
20.7.4 DETECTOR BASE ............................................................................................................. 283
20.7.5 FIRE ALARM PANEL ......................................................................................................... 283
20.7.6 FIRE EXTINGUISHING EQUIPMENT .............................................................................. 285
20.8 ACCESSORIES ................................................................................................................. 285
20.9 GAS DETECTORS ............................................................................................................ 286
20.9.1 PORTABLE GAS DETECTORS: GENERAL ................................................................... 286
20.9.2 PORTABLE GAS DETECTOR .......................................................................................... 287
20.10 SURGE .................................................................................................................................. 287
E7 PROJECT NO. 20010410 xxi REV 1 – ISSUED FOR CONSTRUCTION

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SECTION 1 - GENERAL
1.1 GENERAL INFORMATION
1.1.1 Preamble
These Specifications shall be read in conjunction with the other documents of the
Tender and Contract Documents and Drawings. The Contractor shall comply with
all the provisions contained within these Documents. The Contractor shall take
note of the Appendices contained in Part 3 of 3 of these Specifications. Where
items in Part 1 of 3 of the Specifications are also covered in the Appendices the
requirements of the Appendices shall take precedence.
Any clause in these Specifications which relates to work or materials not required
by the Contract shall be deemed not to apply.
In order to avoid needless repetition of such phrases as "to the Engineer" and "by
the Engineer" or "the Engineer's Representative" throughout these Specifications
it shall be understood that when an order, instruction, decision, exercise of
judgment or other similar act is indicated, such order, instruction, decision,
exercise of judgment or other similar action will be issued, given, made or
referred to the Engineer or the Engineer's Representative.
1.1.2 Abbreviations
In this Contract the following abbreviations have the meanings hereby assigned
to them:
"AASHTO" means the specification issued by the American Association of State

Highway and Transportation Officials.
"ACI" means the specification issued by the American Concrete Institute.
"ASA" means the specification issued by the American Standard Association.
"ASTM" means the specification by the American Society for Testing and
Materials.
"ANSI" means American National Standards Institute.
"BS" means the specification issued by the British Standards Institution.
"BS. EN" means European Standards adopted as a British Standard.
"CP" means the Code of Practice issued by the BS.
"ISO" means International Standards Organisation.
"mm" means millimetre.
"cm" means centimetre.

DUBAI – UAE
"sq. cm, or cm2" means square centimetre.
"lin. m" means linear metre.
"sq. m, or m2" means square metre.
"cu. m, or m3" means cubic metre.
"km" means kilometre.
"kg" means kilogrammes.
"t" means tonne.
"gal" means U.S. gallon.
"ml" means millilitre.
"l" means litre.
"U S G" means U.S. gauge.
"No." means Number.
Where no units are quoted for a figure the relevant "System International" (SI) unit
should be assumed.
1.1.3 Datum
The levels shown on the Drawings are referred to a series of bench-marks,

located throughout the area of the project, and whose positions and values are
shown on the Drawings. In the event of any such bench-mark having become
obliterated, the Contractor shall make his own arrangements to ensure that the
Works are constructed to the levels shown on the Drawings or as amended by
the Engineer, and if it is found necessary to cover or destroy any of such
indicated bench-marks the Contractor shall transfer the level of such
bench-marks to other approved fixed points, which shall then be surveyed and
marked on the Drawings. The survey station details obtained by the Contractor
from the Dubai Municipality Survey Section shall be at Contractor’s cost.
1.1.4 Right of Way
The Contractor shall make all the necessary arrangements for any land required
for working areas outside the right of way, including payment when necessary,
and the Employer does not accept any liability in connection with such land. This
includes land for compounds, temporary roads, detours, diversions and stock
piling materials.

DUBAI – UAE
1.1.5 Geotechnical Information
Any soils and materials test results and information provided for the Contractor
with the Contract Documents at Tender stage are for his information only. The
Contractor shall be deemed to have studied this information during the
preparation of his Tender and to have carried out any further tests as he may
consider necessary. No claims for additional payment will be considered from the
Contractor on the grounds that the information is insufficient, incorrect, or
misleading.
1.1.6 Interpretation of Drawings
The Employer and the Engineer accept no responsibility for any omissions from
or for correctness of the representation of existing features on the Drawings.
1.1.7 Responsibility of Contractor
Where the approval of the Engineer is required under these Specifications such
approval shall not relieve the Contractor of his duties, responsibilities or liabilities
under the Contract.
1.1.8 Governing Standards
For all materials where no governing standard is quoted in the Specification then
a suitable national standard approved by the Engineer (BS, BS EN, AASHTO or
ANSI/ASTM) shall be used.
The most recent edition of any standard shall always be adopted unless
otherwise stated in the Specification or directed by the Engineer.
The equivalence between AASHTO and ANSI/ASTM will only be accepted when
directed by the Engineer. The Engineer may consider other national standards
(BS, BS EN, AASHTO, ANSI/ASTM) in place of those stated in the
Specifications.
1.1.9 Groundwater Levels in Dubai
The Contractor will be deemed to have carried out his own investigations at the
time of Tender to ascertain for himself the nature of the soil conditions and in
particular the groundwater levels that will be encountered.
Method statements for dealing with groundwater shall be submitted within three
weeks of the signing of the Contract.
1.1.10 Pollution of Khor Dubai or Arabian Gulf
The Contractor shall ensure that no extraneous matter, rubbish or polluting liquid
is deposited or discharged to the Khor Dubai (Creek) or to the foreshore or sea of
the Arabian Gulf.

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1.2 SITE OFFICE FOR ENGINEER'S REPRESENTATIVE (REFER VOL 1, APPENDIX C)
1.3 GENERAL REQUIREMENTS
1.3.1 Materials
Materials delivered to the Site for the purpose of the Works, shall be
accompanied by a "Certificate of Guarantee" signed by the authorised
representative of the manufacturer, which will legally bind the manufacturer to the
product delivered.
Such Certification shall state that the materials specifications and test results are
in compliance with the specified requirement of the pertinent designations of the
most recent edition of ASTM, BS or any other approved equivalent National
Standard unless otherwise directed.
Falsification of such Certificates, Materials, Specifications or Test Results shall

be just cause for the rejection of the materials.
1.3.2 Setting-Out the Work
The Contractor shall stake-out the work as to lines and grade in accordance with
the Drawings and secure the approval of the Engineer's Representative before
constructing the work. The Engineer's Representative will, if he deems it
necessary revise the lines or grades and will require the Contractor to adjust and
to stake-out accordingly. The Contractor shall give the Engineer's Representative
not less than 24 hours notice of his intention to set out or give levels for any parts
of the Works, in order that arrangements may be made for checking. The
Contractor shall be responsible for obtaining any setting-out data he may require
from Dubai Municipality Survey Section. The Contractor shall also be
responsible for obtaining Dubai Municipality Survey Section’s approval on right-
of-way. Any costs incurred in this shall be borne by the Contractor.
The Contractor shall, as a requirement of the Contract and without extra charge,
provide all necessary instruments, appliances, surveyor personnel and labour,
and any other material or staging, which the Engineer's Representative may
require for checking the setting out or for any relevant work to be done. Any
marks made by the Engineer's Representative or Contractor shall be carefully
preserved and, if destroyed, shall be replaced by the Contractor at his own
expense and to the approval of the Engineer. Work shall be suspended for the
time necessary for checking the lines and levels on any part of the work, and
shall proceed only after approval of measurements.
In the case of any variation from the approved works, the Contractor shall give
the Engineer three copies of cross-sections and profiles of the graphical record or
notes and computations of his stake-out as required by the Engineer. At his
option he may submit cross-mark on one copy with his approval of the proposed
lines of the work or his revisions thereof and return it to the Contractor. The
Contractor shall resubmit for approval any cross-sections the Engineer may
amend.

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1.3.3 Notice of Operations
The Contractor shall, when required, supply in writing full information regarding
the localities in which the materials are being obtained and in which the work is
being prepared.
No permanent work shall be carried out without the consent in writing of the
Engineer's Representative. Full and complete notice, in writing, shall be given 24
hours in advance of the time of the operation in order to make such
arrangements as deemed necessary for inspection.
1.3.4 Traffic Safety and Control
1. The Contractor shall provide, erect and maintain such traffic signs, lamps
barriers and traffic control signals as may be necessitated by the
construction of the Works in accordance with Dubai Municipality and Dubai
Traffic Police requirements. The Contractor shall submit proposals for
dealing with such situations to the Engineer Dubai Municipality and Dubai
Traffic Police for consent. Compliance with this Clause shall not relieve the
Contractor of any of his other obligations and liabilities under the Contract.
2. The Contractor shall, after consultation with any statutory or other authority
concerned, submit to the Engineer for his approval a programme based on
such consultation showing the scheme of traffic management he proposes
for carrying out the Works before commencing any work which affects the
use of the public highway rights of way or parking areas and thereafter
furnish such further details and information as necessitated by the Works or
as the Engineer may require.
3. The Contractor shall not commence any work which affects the public
highway until all traffic safety measures necessitated by the work are fully
operational.
4. The traffic diversion and signs, lamps, barriers and traffic control signals
shall be in accordance with the requirements of Dubai Municipality (also
refer to Clause 11.5).
5. Traffic signs shall comply with the requirements of Dubai Municipality. The
flashing rate for flashing lamps shall be within the range 120-150 flashes per
minute. The minimum luminous intensity of the lamps shall be 0.5 candela
for steady lamps, 1.0 candela for ripple lamps at their peak, and 1.5 candela
for flashing lamps at their peak.
6. The Contractor shall keep clean and legible at all times all traffic signs,
lamps, barriers and traffic control signals and he shall position, re-position,
cover or remove them as necessitated by the progress of the Works.
7. Where road diversions roads are approved these must be maintained at

frequencies to suit the traffic volume using them. A good running surface
must be maintained and must at all times be free from ruts and potholes.

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1.3.5 Access to Private Land
The Contractor shall give three weeks notice to the owner/occupier before
entering private lands and the Contractor shall not enter on to those lands until
given permission by the Engineer.
1.3.6 Roads and Site to be Kept Clean
The Contractor shall take great care and all reasonable precautions to ensure
that roads and thoroughfares used by him either for the construction of the Works
or for the transport of plant, labour and materials are kept clean during of such
construction or transport and in the event of their requiring cleaning in the opinion
of the Engineer the Contractor shall take all necessary and immediate steps to
clean them.
On completion of dewatering the Contractor shall immediately dismantle and

remove from the Site disused discharge pipes and dewatering points.
Each individual site of work must be clean during the work and must be
thoroughly cleaned up on completion.
1.3.7 Compensation for Damage to Property
The Contractor shall reinstate all properties whether public or private affected by
the Works, Temporary Works, constructional plant, labour materials or transport
to a condition at least equal to that existing before his first entry on to them.
If in the opinion of the Engineer the Contractor shall have failed to take
reasonable and prompt action to discharge his obligations in the matter of site
clearance or reinstatements the Engineer will inform the Contractor in writing of
his opinion in which circumstances the Employer reserves the right to carry out
the reinstatement himself or to arrange for it to be carried out by others or to
make payments to the owners and occupiers in respect of such matters for which
the Contractor is responsible. All such costs incurred and payments made will be
deducted from any monies due or which shall become due from the Employer to
the Contractor.
1.3.8 Existing Services

Drains, pipes, cables and similar existing services encountered in the course of
the Works shall be guarded from injury or damage by the Contractor at his own
cost so that they may continue to function uninterruptedly to the satisfaction of
the owners thereof and the Contractor shall not store materials or otherwise
occupy any part of the site in any manner likely to hinder the operations of such
owners.
1. The Contractor shall protect and support, during the progress of the Works, all
pipe mains, cable wires and other apparatus which might be endangered by
his operations. The approximate positions and alignments of known services
are indicated on the Drawings, but no guarantee of exact location can be
given, and the Contractor must communicate with the authorities and/or
proprietors concerned to locate them exactly, and he shall then prepare shop
drawings 1/500 scale for each Utility as directed by the Engineer. When
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approaching each indicated position, the Contractor shall search, by safe

methods which will not endanger the service, to determine its precise position.
2. The Contractor shall make his own arrangement with the owners of the
services and with other persons interested, for any diversions, temporary
stoppages and reinstatements, and he shall allow in his programme for all
such arrangements.
3. If any underground service is encountered unexpectedly, excavation shall

cease, and the Engineer's Representative shall be notified immediately.
Emergency work, as necessary, should be put in hand without delay and
without prejudice to the indemnity of the Employer.
4. The Contractor shall give notice, in writing, to the Engineer and to the
appropriate service company of all damages to existing services caused by
him or by any Sub-Contractor in the course of the Works. He shall be held
responsible for any such damage and shall immediately have such damage
made good at his own expense and shall relieve the Employer of all claims in
respect of any loss or interruption involved.
5. If in the opinion of the Engineer, it is necessary or expedient that any pipe,

drain, ditch, cable or overhead wire (including supports) should be broken out,
stopped up, diverted, taken down, or altered, the cost of doing so shall be the
responsibility of the Contractor. Such work shall be executed only on the
written instruction of the Engineer.
6. All existing sewers, culverts, water courses and drains of every kind and
condition that have been altered, extended or otherwise interfered with either
directly or indirectly by the work, or that may by leakage, silting, stopping of
free flow or otherwise interfere with or delay the execution of the work, shall be
made good, cleaned, placed in working order, supported, maintained, and
protected and the Contractor shall provide everything necessary for efficiently
dealing with, protecting, pumping or removing, as the case may be, all water,
sewage, or spoil there from.
1.3.9 Continuous Working
If in the opinion of the Engineer it is necessary for the safety of the Works or for
any other reason, the Contractor shall, when so ordered, carry out the Works, or
any portion thereof continuously by day and night. The Contractor will be
reimbursed the agreed extra costs, provided the necessity for the order is not a
result of the Contractor's negligence.
1.3.10 Temporary Staging for Structures
Temporary staging shall be provided by the Contractor to enable the construction

operations to be performed in the required sequence. The staging shall be
properly designed and constructed for the loads which it will be required to
support, and complete details of the arrangements proposed shall be submitted
to the Engineer for approval.
Such approval, however, will not relieve the Contractor of his responsibility for the
adequacy of the staging. The cost of such staging is to be included in the

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tendered rates and prices entered in the Bills of Quantities.
1.3.11 Water Supply
The Contractor shall carry out an investigation prior to submitting his Tender as to
the availability of water for the purpose of the Works and shall consult and
arrange with the appropriate authorities and consider all legal aspects. The
Contractor shall be entirely responsible for the supply of sufficient water of the
specified quality at all times throughout the Contract, and the costs shall be
deemed to be covered in the Contract rates and prices.
1.3.12 Filling in Holes and Trenches
The Contractor, immediately on completion of any part of the work, shall, at his
own expense, fill up all holes and trenches which have been made or dug by him
and are not part of the Works. Holes, cavities, trenches or depressions shall be
backfilled with suitable materials and compacted to the grade required or as
directed by the Engineer. The Contractor shall clear away all rubbish and
materials that is no longer required for the execution of the work, whether his own
or any other party to the satisfaction of the Engineer.
1.3.13 Protection of Works from Weather
The Contractor, at his own expense, shall protect all works and materials from
injury by weather. All damage caused by adverse weather conditions, whether by
flooding or intense heat or any other weather conditions, shall be rectified by the
Contractor at his own expense. Abnormal weather conditions shall not be
considered any reason for a claim by the Contractor for compensation for
damage.
1.3.14 Keeping the Works Free from Water
The Contractor shall at his own expense keep the works at all times well drained
and excavations whether above or below the normal water level of the water
table free from storm or percolating water which may accumulate on the Site and
which may interfere with progress of construction or has or is likely to have
deleterious effect on the work in progress or the use thereof, by provision of
temporary open drains and sub-soil drains, diversion of ditches and other surface
water channel or by pumping or other means as required.
1.3.15 Sign Boards
The Contractor shall provide and erect signboards as detailed in the BOQ, at the
Site and at the Offices of the Engineer and the Contractor. Normally signboards
will be required on all major road approaches to the Site.
The layout and lettering size and location of all signboards and their siting shall
be subject to the approval of Dubai Municipality.
The signboards shall give, in English and Arabic, the name of the Project and the
names, Post Office Box numbers and contact telephone numbers of the

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Employer, the Engineer and the Contractor. The boards shall be of dimentions
as shown on the drawings and shall be of durable construction capable of
withstanding the effects of the climate for at least the period of the construction
and the Defects Liability Period. The boards shall be mounted on substantial
frames.
The signboards shall be periodically cleaned, remain legible and be maintained in

a structurally safe condition throughout the period of construction and Defects
Liability Period. Upon issue of the Defects Liability Certificate they shall be
removed from the Site within two weeks.
1.3.16 Templates
When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of certain
work. The templates will be in accordance with the Specifications and Drawings
where such are provided.
All templates must be approved and shall be maintained in good order to provide
the section required for the entire works. Templates may be checked from time to
time and any deficiencies noted shall be rectified immediately.
The Contractor shall also supply straight edges and lines when required to
control the work.
1.3.17 Assistance to the Engineer
1. The Contractor shall provide and maintain for the use of the Engineer such
surveying and engineering instruments as the Engineer may require for his
duties as detailed in (Clause 1.3.18). The Contractor shall provide the
Engineer with all necessary assistance in checking the setting out of the
Works and interpreting any information used by the Contractor for this
purpose including the sole use of a minimum of three (3) chainmen.
2. The Contractor shall provide the Engineer with all assistance, equipment and
material required to document and record progress of the Works.
3. The Contractor shall provide all assistance, equipment and material

required by the Engineer for all the measurement of the Works for monthly
valuation and for the final certificate payment.
4. The Contractor shall be responsible for all follow up and co-ordination with
all the service departments. (Electricity, Water, Drainage, Street Lighting,
Telephone, Horticultural, etc.).
5. The Contractor shall provide all unskilled labour and necessary tools as
6. If at any time before the commencement or during the progress of the work it
appears to the Contractor that for the proper execution of a specified part of
the Works, shop drawings are necessary, these drawings shall be
established by the Contractor and submitted to the Engineers'
Representative for approval. The Engineer's Representative shall have
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authority to order at any time and the Contractor shall agree to provide any
number of shop drawings which, in the opinion of the Engineer's
Representative are necessary for the proper execution of a specified work.
The Contractor shall not proceed with the above mentioned work until these
shop drawings are approved by the Engineer's Representative. The
Contractor shall not be entitled to any extra compensation or extension of
time for the preparation of the above mentioned drawings.
These details shall be dimensioned in the metric system and shall describe
accurately the method of fabrication, applied finish and sizes of all members
and fixings and shall indicate methods of marking of components for site
erection.
7. The Engineer shall furnish the Contractor transparencies and AutoCad

ver.12 diskettes of the original drawings to be corrected as the Works
proceed. The Contractor shall correct where required, prepare and supply
the Engineer's Representative the updated transparencies and diskettes for
his approval. The diskette copies shall be in Microstation DGN format of a
standard and detail acceptable to the Dubai Municipality Drainage and
Irrigation Department.
Such record Drawings produced by the Contractor shall include but not be
limited to the following information:
- Offsets from permanent references such as road edge, road centreline,

kerbline, building line, etc., at suitable intervals as directed by the
Engineer, for all services encountered during the Works and during trial
trenches including description of offsets..
- Level profiles for all sewerage, drainage, rising mains.
- House connection layout and details to be completed as separate

drawings and included on main sewer layout drawings.
8. The Contractor shall not be entitled to any extra payment or extension of

time for the preparation of the above mentioned record drawings.
The Contractor shall at the commencement of works, provide the Engineer's

Representative for his full and exclusive use sufficient number of water, soil,
concrete, asphalt, and room thermometers as required by the Engineer.
1.3.18 Surveying Equipment
The equipment required on Site under this Contract shall be to the Engineer's
approval.
1.3.18.1 Expendable Materials
The Contractor shall provide adequate supplies of expendable materials such as

stationary, pencils, inks, drawing paper, pens, pegs, brushes, paint and other
similar items required for the satisfactory completion of survey and as required by
the Engineer's Representative.
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1.3.19 Laboratory (see Appendix, Part 3 of 3)
1.3.19.1 General
All testing shall be in accordance with DM Administrative Decision No. 160 for
2000.
1.3.20 Minimum Test Requirements
The following is the schedule of minimum requirements governing tests of

materials which shall be carried out during the execution of the Works. Should
the Engineer's Representative deem it necessary to increase or reduce the
number of the following mentioned tests, he shall issue his written instructions to
the Contractor as and when required, following due consultation with the
Employer.
All materials shall be tested as per the relevant BS and ASTM Standards referred
to in the DM DCL test schedules.
Table 1-4. Minimum Test Requirements of Materials
Materials Frequency Relevant Standard
Water for concrete One test for each source BS 3148

and as directed by the
Engineer thereafter.
Portland Cement One bag of cement for

quality BS 12 - O.P.C
testing shall be taken BS 4027 - S.R.C
from each 1700 bags or BS 4550
fraction thereof for each
source or manufacturer.
The Engineer may in lieu
of this accept a testing
certificate.
Coarse Aggregate One sample for quality BS 812

for Concrete testing shall be taken
from each designated
source. After approval
one sample shall be
taken for quality test-
ing from each 1000 m3
when the material is
in use. On each sample
2 sets of the required
tests should be carried
out except sieve analysis
which shall be 3 in number.

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Table 1-4. Minimum Test Requirements of Materials (Cont’d)
Materials Frequency
Fine Aggregate As for Coarse Aggregate

for concrete
Bituminous One sample of each type

Materials of material shall be
taken for each source or
delivery from the manuf-
acturers. Subsequent tes-
ting shall be as directed
by the Engineer but not
less than one sample for
each 500 drums (55gal)
or equivalent.
Aggregates for One sample for quality
tes-
Bituminous ting shall be taken from
Mixtures each designated source.
After approval one sample
shall be taken for quality
testing from each 1000 m3
when the material is in use.
Mineral Filler One sample for quality

for Bituminous testing from each 50
Mixtures tonnes or fraction thereof.
Bituminous i. One sample of each days

Mixtures production or each 200
tonnes laid or part there-
of whichever is greater,
shall be taken for quality
testing. The sample should
be taken from the paving
machine after approximately
half of any one load has
been laid or from the plant.
ii. One core sample for speci-

fic gravity testing shall
be taken for each 300
lin. m of traffic lane or
2000 m2 or parts thereof
for each completed layer
of pavement.

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Materials Frequency
Subgrade and/or A quality testing procedure

Embankment (laboratory) for each sub-
grade material or embankment
material shall be carried
out for each 1500 m3 of
material as follows:-
i. Granular Gradation.
ii. Atterberg Limits Liquid

and Plastic Limits,
Linear Shrinkage.
iii. Compaction Test Dry Density /

Moisture content relationship
Proctor with compaction
curve to optimum moisture
content and max. dry density.
iv. C.B.R. at 95% of MDD.
After laying and

compaction a quality
testing procedure
on each 1000 m2 or
part thereof should
be carried out as follows:-
v. Field density – 3 No. unit as in Volume

Testing Frequency shall be as specified in Volume 2: Prt1.
vi. Moisture content

if directed by the Engin-
eer the following tests
may also be carried out
on the material as laid
on site.
vii. Field C.B.R. with a speedy

estimate for moisture
content and dry unit weight.

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Materials Frequency
Sub-bases and A quality testing procedure

Aggregate Road- (laboratory) for each
sub-base
bases. or granular road base
out for each source but not
exceeding 1000 m3 of
material as follows:
i. For every completed layer,

one field density shall be
determined on each 500 m2.
ii. Liquid Limit.
iii. Plastic Limit.
iv. Linear Shrinkage.
v. Sand Equivalent.
vi. Compaction Test by

Modified Proctor method
with compaction curve.
vii. CBR at 100% of the Modi-

fied Proctor density.
After laying and compact-

ion the following testing
procedure shall be followed
for every 1000 m2 of each
layer:-
viii. Field density (3 no.) or as directed by the Engineer.

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Materials Frequency
Wetmix Macaday A quality testing procedure
Road Bases (laboratory) for each sub-base

or granular road base
out for each source but not
exceeding 1000 m3 of
material as follows:
i. For every completed layer,

three field density shall be
determined on each 750 m2.
ii. Liquid Limit.
iii. Plastic Limit.
iv. Linear Shrinkage.
v. Sand Equivalent.
vi. Compaction Test by

Modified Proctor method
with compaction curve.
vii. CBR at 100% of the Modi-

fied Proctor density.
After laying and compact-

ion the following testing
procedure shall be followed
for every 1000 m2 of each
layer:-
viii. Field density (4 nos.)

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Materials Frequency
Reinforcing Reinforcement steel shall

Steel be supplied to site with a
manufacturer's test
certificate for each load.
Where directed testing on
any sample of reinforcement
for the following types
may be required:-
i. Steel fabric reinforcement.
ii. Mild steel and high yield

(hot rolled) bars.
iii. Cold worked steel bars.
Chemical Analysis of Steel

for carbon content as dire- .
cted by the Engineer.
Concrete One set of at least 6 cubes (or

4 cylinders) shall be obtained
from each 75 m3 or fraction
thereof placed
in each day or class of concrete.
Slump tests and compaction

factor tests shall be carried-
out at the site of the actual
placing of concrete as
Preparation of concrete
specimens & curing of
specimens
Minimum cement content

of hardened concrete as

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Materials Frequency
Precast Concrete Flexural/transverse stren-

gth and water absorption
for each supplier of
precast kerbs and slabs
(2 no. samples). Subsequent-
ly, on approval of a source
or supplier 2 sample will be
tested every 2000 lin. m for
kerbs and every 2000 m2 for
slab tiles.
1.3.21 Sources of Materials
The Contractor shall be responsible for obtaining the Approval of the local
Authorities for the sources of materials and he shall have no right to claim for any
compensation if he is to pay for the material at its source.
1.3.22 Programming the Progress of the Works
A detailed computer-based programme using critical path methods shall be

produced by the Contractor as set out in the Conditions of Contract. This shall
include full details of resources and rates of progress. The Engineer may require
the Contractor to modify the programme on occasions during the course of the
Contract. The Contractor shall work to the latest approved programme at all
times.
In planning his programme the Contractor shall allow reasonable time for the
Engineer to confirm setting out details as the Works proceed in accordance with
the programme.
The Contractor shall indicate on his programme whether the work is to be carried
out during normal site hours or whether overtime or a shift system is necessary to
execute the Works.
The Contractor shall present a weekly summary to the Engineer detailing

personnel, plant materials and equipment orders and shipping movements of
same.
Before the close of Site on each working day the Contractor shall submit a brief
programme for the following working day stating in which area of the site work will
be carried out and the location of plant and labour. The format of the programme
shall be agreed with the Engineer. The Contractor shall also submit for the
Engineer’s approval a daily record of manpower and plant resources.

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1.3.23 Progress Reports
The Contractor shall be required to submit to the Engineer weekly and monthly
progress reports on the first day of the week following and the first day of the
month following respectively.
Weekly Report
The report shall include: the meteorological data; Contractor's plant and labour
returns; a brief summary of work completed.
Monthly Report
The report shall include: a description of the month's work; details of any problems
relating to the Works; quantities; records of test results; charts illustrating progress
in terms of work done against programmed work and the financial status of the
Contract including value of works completed, certified and monies received;
progress photographs.
Monthly progress Report as well as the Final Materials Report both containing the
prescribed Summary of Testing ferquancy Forms shall be submitted to DCL for
review in accordance with Circular No. 8/2004 (Ref. # 812/02/02//1/4063/678
dated 22/2/2004 issued by the Director of Roads Department and the fax message
No. 812/02/02/1/630 dated 09/06/2004 issued be the Director of DCLD.
1.3.24 Progress Photographs
The Contractor shall arrange to take monthly record photographs of the Works in
progress. These photographs shall cover such extent of the Works as the Engineer
shall direct. The days upon which the photographs are to be taken shall be decided
by the Engineer.
The Contractor shall provide the Engineer on the last day of each month one set of
progress photographs, with dates imprinted on it, which shall comprise the
following:
- One colour negative of each photograph for an anticipated maximum of fifty

exposures per month.
- Ten colour prints (294 x 210 mm) of each of a maximum of twenty of the
negatives as selected by the Engineer.
The prints are to be processed by an approved professional and shall be in

colour on heavy weight paper with matt finish. The photographs shall have
computer produced descriptions incorporated thereon. Each photograph shall be
provided with an approved clear plastic cover for binding.
The copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of exposure.

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1.3.25 Flows in Pipelines and at Pumping Stations
During the execution of the Works the Contractor shall maintain flows in pipelines
and at pumping stations or alternatively provide adequate means of diverting the
flows or overpumping of the flows to the satisfaction of the Engineer.
The Contractor should note that the Employer may decide to carry out
overpumping utilising his own plant and resources and the Contractor shall make
due allowance for the necessary coordination with the Employer with respect to
the Contract programme. Such arrangements will not relieve the Contractor of
his obligations for the maintenance of flows and the safety of the Works,
personnel and the general public.
No claim for delay or additional work arising from this requirement will be
considered by the Employer.
1.3.26 Suppression of Noise
The Contractor shall make every reasonable endeavour both by means of

temporary works and by the use of appropriate plant or silencing devices to
ensure that the level of noise resulting from the execution of the Works does not
constitute a nuisance.
1.3.27 Closing of Roads
The Contractor shall give four weeks notice in writing to the Engineer of his
intention to commence work on any public road (which shall include un-made
rights-of-way).
The closure of public roads will not be permitted without the written permission of
the Dubai Municipality Roads Department, the Dubai Traffic Police and the
Engineer. The Contractor shall submit five (5) copies of his proposals for diverting
traffic indicating positions of all signs, cones, lights and anything else which may
be necessary. The Contractor shall comply with any Specification for traffic
diversion, including surfacing requirements, safety and control laid down by the
Authorities in Dubai and shall be responsible for continuous maintenance.
A period of up to 30 days may be required by the Dubai Municipality to process

permits authorising the cutting of existing carriageways.
In the event of such permission being refused the Contractor shall have no claim
for any additional payment.
No work will be permitted on a public road verge, central reservation or garden

without the SIGNED approval of the respective Authorities copies of which must
be submitted to the Engineer before work commences.
The Contractor’s work shall be so arranged that use of the roads affected by the
work shall be restored to the public with the minimum of delay. Laying of the

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pipelines, backfilling, testing of the pipeline, temporary reinstatement and

clearance of the Site shall follow closely behind excavation and the Engineer may
limit the length of excavation when necessary.
1.3.28 NOC from Relevant Authorities
Not withstanding the requirements of clause 48 of "Conditions of Contract for

Works of Civil Engineering Construction, (Part 1 - General Conditions)" it shall be
the Contractor's responsibility to obtain all required No Objection Certificates
(NOC) from the relevant Authorities and submit them to the Engineer prior to the
Engineer issuing a Taking Over Certificate.

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SECTION 2 - EARTHWORKS
2.1 CLEARING & GRUBBING
Unless otherwise specified, the areas designated for clearing and grubbing shall be
cleared of all trees, stumps, bushes, roots, rubbish, debris, and other objectionable
matters.
Before removal of any trees or shrubs the Contractor shall obtain written consent from
Dubai Municipality Horticultural Section at least two weeks in advance of the planned
removal. The Engineer's approval of any removal of trees and undergrowth must be
obtained before commence-ment of work.
Trees and plants designated for preservation shall be protected from injury or
damage which could result from the Contractor's operations including dewatering.
The form of protection for vegetation within the site shall be of a type and standard
approved by the Dubai Municipality Horticultural Section.
The Contractor shall avoid, as far as practicable, injury to shrubbery, vines, plants,
grasses and other vegetation growing outside of the clearing limits. The dragging,
piling and burning of debris, the piling of materials of various kinds and the performing
of other work which may be injurious to vegetation shall, in so far as practicable, be
confined to areas which have no vegetation or which will be disturbed by excavation.
For the full width to be cleared, all objectionable materials and any other obstructions
shall be grubbed from areas to be excavated, to the satisfaction of the Engineer.
The topsoil should be scarified to a depth of at least 15 centimetres and investigated

if any unsuitable materials exists. The unsuitable materials, if any, shall be removed
to the depth required by the Engineer's Representative and replaced by approved
suitable material.
Cavities left below subgrade elevation by the removal of stumps or roots shall be
carefully backfilled and the backfill material compacted to the Engineer's satisfaction.
All tree trunks, stumps, bush, limbs, roots, vegetation, and other debris removed in
clearing and grubbing shall be either burned or removed to approved location outside
the right-of-way or otherwise disposed of so as to leave the roadway and adjacent
areas free from unsightly debris. Burning shall be done at such time and in such
manner as to prevent any damage to areas adjoining the right-of-way.
2.2 REMOVAL OF STRUCTURES AND OBSTRUCTIONS
2.2.1 General
Removal of structures and obstructions shall consist of the removal, wholly or in part,
and satisfactory disposal of all structures and obstructions within the right-of-way
which have not been designated to remain. Salvaging designated materials shall be
included.

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Prior to starting the removal of structures and obstructions, the Contractor shall carry
out a thorough survey of structures, fences, trees, etc., that are to be removed. The
Engineer shall be fully informed of the results of this survey and the amount and
extent of the planned removal and the plan shall then be agreed by the Engineer.
Indications on the Drawings that existing structures, pavements sidewalks, curbs,

gutters and other existing improvements are to become an integral part of the
planned improvements shall be considered to mean that such designated
improvements are to remain even though not specifically noted to remain.
Existing highways, improvements, facilities, adjacent property and services

designated for preservation shall be protected from injury or damage which could
result from the Contractor's operations.
The Contractor shall raze, remove and dispose of all structures and obstructions as
required including, but not limited to, the following: buildings, sheds, walls, slabs,
foundations, inlets, catch basins, culverts, headwalls, trash racks, irrigation structures,
standpipes, manholes, valves, ditch lining, pipelines, tanks, pool lining, posts, poles,
columns, signs, fences, gates, planters, curbs, gutters, sidewalks, driveways, trees,
stumps, shrubs and plants.
Holes, cavities, trenches or depressions left by the removal of structures or

obstructions shall be backfilled with suitable materials and compacted to the grade
required or as directed by the Engineer.
2.2.2 Removal of Pipes
Where required, the Contractor shall be responsible, prior to removal of pipes, for the
disconnection of all services and clearance from the Dubai Municipality and all
Service Authorities.
All pipes to be removed and either salvaged or relaid shall be carefully removed and
every precaution taken to avoid breaking or damaging the pipe. The pipes shall be
stored when necessary so that there will be no loss or damage before relaying. The
Contractor will be required to replace sections lost from storage or damage by
negligence or by the use of improper methods in their removal.
2.3 STRUCTURAL EXCAVATION
2.3.1 General
Structural excavation shall consist of the excavation and removal of all materials
necessary for the construction of structures, pipelines and cables/ducts, including
foundations and substructures, in accordance with the details shown on the Drawings
and these Specifications and/or as directed.
The Contractor shall notify the Engineer a sufficient time in advance of the beginning
of excavation to allow pre-construction measurements and records to be made of the
undisturbed ground (refer to Clause 2.3.2). The required excavation shall then be
performed in reasonably close conformity to the lines, grades and cross sections
established or shown on the Drawings.
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The sides of excavation may be sloped as required by soil conditions to stabilize the
sides for safe working conditions. Such excavation shall be limited to the amount
considered necessary for safety.
The Contractor shall take all necessary steps by means of shoring, timbering, or
otherwise (also refer to Clause 2.3.7) to avoid slips and falls of the sides of the
excavation but if any should occur the Contractor shall remove at his own expense all
such fallen or disturbed material from the excavation and shall replace with backfilling
as described elsewhere.
The Engineer may direct the Contractor to protect his excavation with timbering
where, in his opinion, such timbering is necessary to ensure the safety of the
workmen, adjoining structures and work generally. Any action taken by the Engineer
in this regard will in no way relieve the Contractor of any responsibility or liability
under the Contract.
Where a firm bearing material is not encountered at the elevation established for
bearing, due to soft, spongy or otherwise unstable soil, all such unsuitable material
shall be removed to the extent directed (see Clause 2.3.15).
No back throwing shall be allowed and all materials must be brought to the surface
and placed clear of the trench side.
The Contractor shall keep the trench excavation free from water at all times.
The Engineer reserves the right to direct the Contractor as to the lengths of trench or
portions of bulk excavations which shall remain open at any one time.
The use of explosives for any purpose whatsoever during the Contract is prohibited.
2.3.2 Pre-Construction and Land Drainage Records
Before an excavation is started:-
(1) Ground levels shall be agreed at suitable intervals with the Engineer's
Representative.
(2) Surface materials and conditions will be recorded in collaboration with the
Engineer's Representative and where appropriate the owners or occupiers of the
land.
(3) The Contractor shall take photographs to illustrate existing damage or conditions
which may prove contentious at the time of reinstatement.
This information shall be neatly presented in bound volumes and submitted to the
Engineer. To this shall be added details of any existing natural or piped subsoil
drainage or other underground features as work proceeds.
Trial excavations may be ordered by hand or other methods to reveal sub-surface

conditions of any kind. The Contractor shall submit a written report or sketch drawings
of data so obtained and the excavations shall not be backfilled without approval.

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2.3.3 Setting Out
Before any structural excavation is commenced the Contractor shall define the centre
line or other agreed reference line of the Works and erect the necessary profiles
throughout their full length if so required by the Engineer. The Contractor shall be
responsible for obtaining all verifications from the Dubai Municipality Survey Section
and the Contractor shall bear all associated costs.
2.3.4 Topsoil and Surfacing Materials
Before commencing excavations or filling to an area, topsoil and other surfacing

materials shall be stripped and stored separately from the subsoil (refer to Clause
2.1). Subsequent spreading of topsoil shall be as directed on site.
2.3.5 Land Drains
Where pipelines are to be laid in agricultural land the surface and subsoil drainage
shall be maintained whether natural or artificial. Before commencing work the
Contractor shall ascertain from the owner or occupier of the land the location of any
existing land drains or mole drains.
2.3.6 Hand Excavation
Where instructed or necessary for reasons of limited access or any other reason,
excavation shall be carried out by hand at no additional cost.
2.3.7 Support to Excavations
The sides and/or the bottom of excavations in excess of 1.2 metres shall be
adequately supported.
The Contractor shall provide the necessary support for excavations and shall submit
to the Engineer his proposals for the supporting of excavations by trench sheeting or
other approved means at least seven days prior to the commencement of any
excavation works. His proposals shall take into account the nature of the ground to
be excavated, the level of the water table at the site and the proximity of buildings and
roads.
If in the opinion of the Engineer the support proposed for the excavations by the
Contractor is insufficient then the Engineer will order the provision of stronger support
than that provided by the Contractor and in this event the Contractor shall adopt the
methods so ordered by the Engineer and shall have no claim against the Employer
for any costs incurred in adopting the additional measures.
Trench supports shall be so arranged to permit withdrawal during the placing of the
pipe bedding and backfilling so as to prevent voids.

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The Contractor shall not remove temporary works supporting the excavations until in
the opinion of the Engineer the permanent work is sufficiently advanced to permit
such removal which shall be executed under the personal supervision of a competent
foreman.
All temporary works supporting the excavation shall be removed during backfilling
unless previous approval has been obtained from the Engineer. Where temporary
supports have been used in the excavation any such supports left in because it is
impracticable to remove them shall be left in at the expense of the Contractor.
Should temporary supports need to be left in any excavation carried out in open cut
owing to the Engineer deciding that their permanent installation is necessary for the
stability of an adjacent structure or service the Contractor shall be reimbursed in
accordance with the provisions of the Contract.
Any advice, permission, approval or instruction given by the Engineer relative to such
support or the removal thereof shall not relieve the Contractor from his responsibilities
or liabilities under the Contract.
Timbering steel sheeting strutting and sheet piling for the support of excavations
where provided shall be fixed in accordance with BS 6031.
Battered sides to trenches or other excavations will only be permitted if they can be
constructed within the limits of the site, without damage or interference to existing
services, properties or structures, without undue interference with pedestrians and
traffic and to slopes which are sufficiently flat to ensure stability of the ground.
2.3.8 Dewatering
A high water table is expected and the Contractor must do all necessary measures to
ensure proper dry conditions are maintained at all times during construction. The
Contractor shall provide and maintain ample means and devices (including spare
units kept ready for immediate use in case of breakdowns) with which to intercept
and/or remove promptly and dispose properly of all water entering trenches and other
excavations. Such excavations shall be kept dry until the structures, pipes, and
appurtenances to be built therein have been completed. In addition precautions shall
be taken to prevent floatation of partially built structures, completed structures to be
filled on commissioning of the Works and pipelines awaiting backfilling.
Dewatering methods proposed in the Contractor’s method statements may include

temporary drains, intercepting ditches, cut-off drains, sub-drains, sumps, wells,
pumps, well-points or other dewatering equipment and shall include all other things
necessary to keep water out of the excavations or to lower groundwater around
structures liable to floatation.
All necessary precautions shall be taken to prevent any adjacent ground from being
adversely affected by loss of fines through any dewatering process.
Method statements shall include proposals for disposal of the water arising from
dewatering systems.
All water pumped or drained from the work shall be disposed of in a suitable manner
without undue interference with other work, damage to pavements, other surfaces, or
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property. Suitable temporary pipes, flumes, or channels shall be provided for water
that may flow along or across the site of the work. No such water is to be disposed of
into the existing sewer systems of the town or otherwise without prior written approval
of the Dubai Municipality Drainage and Irrigation Department.
If permission is given to use new or existing pipes or culverts which are not part of the
live sewerage system, they shall be thoroughly cleaned of all silt and any resulting
damage made good after use.
When the Contractor proposes to make use of existing dewatering pipelines, ducts,
etc., he shall satisfy himself as to their condition prior to his use of them. If any of
these items is found to be in an unsatisfactory condition then, before use, the
Contractor shall notify the Engineer who may give instructions for the item to be
replaced or repaired. Time taken to carry out such work will not be considered as
delay to the Contractor's operations.
During use the Contractor shall be responsible for the condition of the pipeline, duct,
etc., and any defect or failure shall be made good at the Contractor's expense. Any
delay to the Contractor's works caused by such defect or failure shall be deemed as
the Contractor's responsibility.
After use by the Contractor such pipeline, duct, etc., shall be handed back to the
Municipality in a condition not less than that at the commencement of use. Any
repairs or replacement required shall be at the Contractor's expense.
It cannot be guaranteed that permission will be given to use existing ducts and
pipelines.
All temporary works for control of water shall be sited clear of the Works, except
where temporary sub-drains under the Works are approved in which case the pipes
shall be laid with a 75 mm surround of gravel, and the top surface of the surround
shall be covered with tarred felt cloth or other approved material.
Unless otherwise directed all temporary drains and sub-drains shall be finally sealed
with concrete at approved intervals and all temporary ditches, sumps, wells, etc., shall
be refilled and reinstated as specified elsewhere.
In the exceptional event that lagoons for the storage of groundwater are permitted,
they must be suitably protected with fencing and attended by day and night to prevent
access by the general public and will not be sited adjacent to buildings. Approved
means of preventing the formation of mosquito larvae on the surface of the lagoons
will be employed.
All necessary precautions shall be taken to prevent any groundwater from entering
mains to be used for the conveyance of potable water.
A. Temporary Underdrains
Temporary underdrains, if used, shall be laid in trenches, beneath the grade of

the structure. Trenches shall be of suitable dimensions to provide room for the
chosen size of underdrain and its surrounding gravel.

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Underdrains, if used, shall be laid at an approved distance below the bottom of

the normal excavation and with open joints wrapped in geotextile, and entirely
surrounded by graded gravel, or crushed stone to prevent the admission of sand
or other soil into the underdrains. The distance between the bottom of the pipe or
structure and the top of the bell of the underdrain pipe shall be at least 8 cm.
unless otherwise permitted. The space between the underdrain and the pipe or
structure shall be filled with screened gravel or crushed stone which shall be
rammed if necessary and left with a surface suitable for laying the pipe or building
the structure.
B. Wellpoint Drainage System
Where the nature of the Works necessitates, the Contractor shall dewater the
excavations by means of an efficient wellpoint drainage system which will drain
the soil and prevent saturated soil from flowing into the excavation. The
wellpoints shall be designed especially for this type of service. The pumping unit
shall be designed for use with the wellpoints, and shall be capable of maintaining
a high vacuum and of handling large volumes of air and water at the same time.
If required by the nature of the Works, the installation of the wellpoints, pumps,
surge tanks, settlement tanks, geotextile and other such requirements shall be
done under the supervision of the competent representative of the manufacturer.
The Contractor shall do all special work such as surrounding the wellpoints with
sand or gravel or other work which is necessary for the wellpoint system to
operate for the successful dewatering of the excavations.
Material to be used in the wellpoint system is to be corrosion resistant where

possible.
2.3.9 Formation
Damage to the formation shall be prevented by bottoming-up with hand excavation

immediately before placing concrete or pipelaying. Any damaged formation shall be
excavated and refilled with concrete or selected material as instructed.
The formation of excavations for pipelines shall be dry, even and free of stones and
other protrusions.
No permanent works of any kind shall be constructed on an excavated surface until

the formation has been approved by the Engineer’s Representative.
2.3.10 Excavation at or Near Roads
A. Safety
When excavating at or near roads, to protect persons from injury and to avoid
interference with traffic, adequate barricades, construction signs, torches,
guards, flashing lights, etc., as required by the Engineer shall be provided and
maintained during the progress of the construction work (refer to Appendix 1 for
Road Diversions and Road Signs). All materials, stockpiles and equipment shall

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be placed in such a way that no obstruction or interference to traffic is made

and that these are enclosed by fences or barricades and protected by lights.
All excavations shall be protected on all sides by an approved temporary yellow

plastic safety fencing, barricades and lights. The yellow plastic safety fencing
shall be manufactured of durable HDP polymer with Ultra Violet stabilizers. The
safety fencing shall be a minimum of 1.0 metre high.
B. Description
The Contractor shall make excavations in such a manner and to such minimum
widths as will give adequate room for building the structures or laying and
jointing the piping; shall furnish and place all sheeting, bracing, and supports;
shall carry out all cofferdamming, pumping, and draining, and shall render the
bottom of the excavations firm and dry and acceptable in all respects.
In no case, except with the approval of the Engineer, shall the earth be plowed,
scraped, or dug by machinery so near to the finished subgrade as to result in
the disturbance of material below said subgrade, the last of the material to be
excavated shall be removed by hand immediately before the placing of the pipe,
masonry, or other structure.
C. Extent of Open Excavation
The extent of open excavation at any one time will be controlled by the
conditions, but shall always be confined to the limits prescribed by the Engineer.
D. Separation of Surface Materials
The Contractor shall remove only as much of any existing pavement as is

necessary for the work. The Engineer may require that the pavement be cut
with pneumatic tools, cold planer, milling machine or the like without extra
compensation to the Contractor, when in the opinion of the Engineer it is
necessary to prevent damage to the remaining road surface. Where pavement
is removed in large pieces, it shall be disposed of before proceeding with the
excavation.
From areas within which excavations are to be made, loam and topsoil shall be
carefully removed and separately stored to be used again as directed, or if the
Contractor prefers not to separate surface materials, he shall furnish, as
directed, loam and topsoil at least equal in quantity and quality to that
excavated at no cost to the Works.
E. Sheeting and Bracing
In addition to the general requirements of Clause 2.3.7 the Contractor shall

furnish, put in place, and maintain such sheeting, bracing, etc., as may be
necessary to support the sides of the excavation and to prevent any movement
of earth from beneath the adjacent road surface which could in any way
diminish the width of the excavation to less than that necessary for proper
construction, or could otherwise injure or delay the work, or endanger adjacent
road and structures. If the Engineer is of the opinion that at any point sufficient

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proper supports have not been provided, he may order additional supports
placed at the Contractor's expense.
For any excavations in or adjacent to roads all trenches must be supported by

an approved method to ensure no settlement of roads either during
construction, when withdrawing supports or thereafter.
F. Bridging Trenches
The Contractor shall, at his own expense, provide suitable and safe bridges and
other crossings where required for the accommodation of travel, and to provide
access to private property during construction, and shall remove said structures
thereafter.
G. Road Signs
All existing road signs, street name plates and the like affected by the Works
are to be carefully taken down and stored. Signs to be re-erected shall be
cleaned, provided with new fixings where necessary and the posts re-painted as
required. Redundant signs shall be transported to the stores or depots of
relevant Authorities. Any sign, street name plate or the like damaged by the
Contractor during his operation shall be repaired or replaced at the Contractor's
cost.
2.3.11 Excavation for Structures
Where concrete is to be placed on an excavated surface other than rock, special care
shall be taken not to disturb the bottom of the excavation. When the nature or
condition of the bearing material upon which concrete is to be placed is determined to
be such that the use of heavy excavating equipment will reduce the stability of the
soil, the final half meter of excavation to grade shall be performed either by means of
light equipment or by hand labour methods.
Should the Contractor excavate to a depth greater than that required for the
construction of the foundations or pile caps, such excavation shall be filled with Class
C concrete at his own expense. Should the material forming the bottom of any
excavation, while acceptable at the time of excavation, become puddled soft or loose
during the progress of the Works, the Contractor shall at his own expense, remove all
such softened or loosened material and replace with Class C concrete as directed by
Where rock, in either ledge or boulder formation or other unyielding material, is

encountered in one portion of structural excavation for a box culvert and yielding
material (with bearing capacity less than 1000 kN/m² determined by appropriate tests)
is encountered in an adjacent area of the structural excavation for the same box
culvert, such unyielding material shall be removed for a minimum depth of half meter
below grade and replaced with special backfill.
Where such unyielding material is encountered in excavation other than for box
culverts or where an entire excavation for a box culvert bears on such materials, the
rock or other unyielding material shall be cleared of all loose fragments and cut to a
firm surface as directed.
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The placing of concrete shall follow as closely as practicable the structural

excavation.
2.3.12 Excavation for Pipelines
Trenches for pipes shall be excavated to a sufficient depth and width to enable the
pipe and any specified or agreed joint, bedding, hauncing and surrounding to be
accommodated. Trenches shall be of width as specified and as shown on the
drawing.
Where rock, in either ledge or boulder formation or other unyielding material is

encountered, such unyielding material shall be removed for a minimum depth of half
meter below grade and replaced with special backfill (see Clause 2.4.3).
2.3.13 Excavation for Cables/Ducts
The Contractor in carrying out excavation for cables/ducts shall, where required, erect
and maintain an approved type of temporary yellow plastic safety fencing (refer to
Clause 2.3.10) around any work and shall provide fenced access ways across the
trenches.
The bottom of the trench shall be accurately graded. Care shall be taken not to
excavate below the depths indicated. Where rock is encountered, the rock shall be
excavated to the required depth. Uneven surfaces of the bottom of trench shall be
excavated 150 mm deeper. Such depth in rock shall be backfilled with approved fill
material and compacted as specified and/or as directed by the Engineer.
Whenever unsuitable soil is encountered, which in the opinion of the Engineer is to be

removed, it shall be removed to the depth required and the trench backfilled to the
proper grade with approved fill material and compacted.
The width and depth of the trenches for electrical and telephone cables/ducts shall be
as specified in the relative drawings or as ordered by the Engineer. Banks may be
sloped or widened to facilitate placement of cables, but not the extent that will cause
interference with other utilities and structures. No battering of trenches shall be
allowed under existing carriageways, unless otherwise agreed by the Engineer.
2.3.14 Excavated Material
All excavated material will remain the property of the Employer unless designated as
surplus to the Contract requirements in which case it will be removed from site
immediately. The Contractor shall dispose of such surplus material as per Clause
2.3.16.
All excavated material shall be deposited so that it will cause as little damage and
inconvenience as possible.
Excavated material for use as backfill shall be as approved. Different classes of

material shall be handled and deposited separately.
The excavated material, if found unsuitable as backfill, shall be removed from site and
shall be replaced with suitable imported backfill to the approval of the Engineer.
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Unsuitable material shall include the following:
- Peat, organic soil and other similar materials.

- Materials from swamps, marshes and bogs.
- Materials susceptible to spontaneous combustion.
- Stumps, roots and perishable material.
- Excessively wet materials.
- All materials producing bearing capacity lower than the assumed design value.
- Clays of liquid limit exceeding 40% and/or plasticity index exceeding 6%.
All surplus and unsuitable excavated material and rubble shall be transported to the
approved tip.
Where (natural) subsoil drainage depends on the relative positions of pervious or

impervious strata, special care shall be taken to separate those materials and replace
them in their natural positions.
2.3.15 Replacement of Unsuitable Material
Since the services works are also within the limits of Road corridor for all Earthworks
please follow Volume -2 part-1 specifications of this same project as follows:
Clause 2/13.2 for suitable Matrial
Clause 2/13.3 for unsutable matrials .
2.3.16 Disposal of Material
The Contractor shall seek approval for all the proposed disposal sites from the Dubai
Municipality before work commences and disposal at such sites shall be at no extra
cost to the Employer.
No excavated material shall be wasted without written permission from the Engineer,
and when such material is to be wasted, it shall be hauled to the approved tip or as
otherwise directed by the Engineer. Excavated materials wasted by the Contractor
without written permission of the Engineer shall be replaced by the Contractor at his
own expense.
The Contractor shall adhere rigidly to the requirements of Dubai Municipality Circulars
on the temporary storage and disposal of excavation material. These include but are
not limited to :-
- All material shall be stockpiled at an approved location and surrounded with

approved barricades. The Contractor shall also display his name and contact
telephone number.
- Certain separate areas will be designated for the disposal of hard debris such as
building rubble, broken concrete, kerbing, road pavement and the like. The
Contractor shall use only these designated areas and shall keep these disposal
areas neat and tidy at all times.
2.3.17 Cofferdams

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Suitable and practically watertight cofferdams shall be used wherever waterbearing

strata are encountered above the elevation of the bottom of the excavation.
The Contractor shall, on request, submit detailed drawings for approval showing his
proposed method of cofferdam construction and other pertinent features not shown in
detail on the Drawings. No construction shall be started until such Drawings are
approved, however, such approval shall not relieve the Contractor of any
responsibility for the successful completion of the construction.
No timber or bracing which will extend into the concrete shall be left in cofferdams or
cribs.
Any pumping from the interior of any foundation enclosure shall be done in such a
manner as to preclude the possibility of any portion of the concrete material being
carried away. No pumping will be permitted during the placing of concrete or for a
period of at least 12 hours thereafter, unless it is done from a suitable sump
separated from the concrete work by a watertight wall. Pumping to remove water from
a sealed cofferdam shall not begin until the seal has set sufficiently to withstand the
hydrostatic pressure.
Cofferdams or cribs, including all sheeting and bracing, shall be removed by the
Contractor after the completion of the substructure. This removal work shall be carried
out in such a manner as not to disturb or mar the concrete.
2.4 BACKFILLING EXCAVATIONS
2.4.1 General
Backfilling around structures and in pipe trenches shall be carried out as detailed
below except where otherwise designated/directed.
The Contractor shall backfill all excavations in an expeditious manner to minimize

disruption to the general public.
Backfilling of trenches other than in roads and paved/ tiled areas shall normally be
carried out using selected excavated materials similar to the in-situ materials in which
the trench or structure is being constructed.
Special backfill shall be used for backfilling trenches in roads, paved/tiled areas, and
where designated or directed.
Where the excavation is near an existing structure liable to subsidence, where part of
the Works may later be constructed over or near it or in emergencies the Contractor
may be instructed to backfill with concrete.
2.4.2 Selected Backfill
Material for backfilling may be selected from any part of the site and methods of
selection may include sieving to remove large particles or methods of hand or
machine sorting together with soil classification and soil property testing.
Backfilling with selected material shall be carried out as defined below.

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Cohesive Soils
Cohesive soils shall be placed in layers not greater than 150 mm thick (compacted
thickness) and compacted such that throughout each layer placed the dry density is
not less than 95% of the MDD of the soil or the air voids content (volume of air
divided by total volume of soil) is not greater than 10% which ever gives the higher
state of compaction.
If site trials show that the specified compaction can be achieved with layers greater
than 150 mm compacted thickness approval may be given to backfill in layers of
greater thickness, but not exceeding 250 mm, providing the plant utilised is that used
for the trials.
The placement moisture of the soil shall be within the range 2% above to 2% below
the O.M.C content of the soil before excavation.
Granular Soils
Granular soils shall be placed in layers not greater than 150 mm thick (compacted
thickness) and compacted such that throughout each layer placed the dry density is
not less than 95% of the maximum dry density as determined by BS 1377 on the
same soil at the same moisture content.
If site trials show that the specified compaction can be achieved with layers greater
than 150 mm compacted thickness approval may be given to backfill in layers of
greater thickness, but not exceeding 400 mm, providing the plant utilised is that used
for the trials.
Unless otherwise directed the moisture content shall be maintained and if necessary
adjusted by approved means to fall within the range 1.5% above to 1.5% below the
optimum moisture content.
For free draining granular soils that have no clearly defined optimum moisture
content, compaction shall be carried out to achieve a relative density of not less than
95%. During compaction the soil shall be made as wet as practicable.
Testing of Backfill
Tests to determine the optimum dry density of the backfill material shall be carried out
as directed, the frequency depending on consistency of material and test results.
Unless directed otherwise on site testing for density and moisture content of in-situ
soils shall be at the minimum rate of :-
(1) One test per backfill layer for each structure.
(2) One test per backfill layer for every 30 linear metres of pipeline trench backfill laid
in one operation.
Backfill for a Replacement Land Drain

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Where a land drain passes through an excavation the backfill shall first be taken up to
form a bed for replacement pipes. The severed drains shall then be exposed at each
side of the trench to allow for connection and laying of a new drain across the
excavation. This new drain shall be of similar pipes of the same diameter as those in
the existing drain. Before any further backfilling is done the Contractor shall notify the
owner or occupier to enable him to inspect the reinstated land drain. The replacement
drain shall be surrounded with pipe bedding to a minimum thickness 150 mm before
further backfilling.
2.4.3 Special Backfill
The material used for special backfill shall be obtained from designated and approved
sources.
Special backfill complying with the properties of Aggregate Roadbase Material

specified in Clause 3/8 of Appendix 4, Part 3 of 3 of the Specifications shall be placed
as fill or backfill in the areas required and in reasonably close conformity to the lines,
grades and dimensions shown on the Drawings. Special care shall be taken to keep
rocks away from structures.
The materials shall be placed in layers of not more than 20 centimetres in depth
before compaction, and each layer shall be compacted by means of mechanical or
pneumatic tamping devices or other suitable equipment to density of at least 95
percent of the maximum dry density as determined in accordance with the latest BS
1377: Part 4 and the correction shall be made according to BS 1377.
Water shall be added to the material, by prewetting or by applying uniformly to each

layer, when required for compaction, but only of sufficient quantity to ensure proper
compaction.
The layers of material placed around structures shall be placed on opposite sides to
approximately the same elevation at the same time.
Special care shall be taken in placing and compacting material under haunches of all
pipe to prevent moving or raising the pipe from its bedding.
Material shall not be placed against any concrete abutment, wing wall, retaining wall,
box culvert or similar structure until the concrete has been in place at least 14 days,
unless otherwise authorised.
2.4.4 Filter Material
When required, filter material shall be placed in backfilling structures in accordance

with the details shown on the Drawings. Filter material shall conform to the specified
requirements for Fine Aggregate.
2.4.5 Structural and Non-Structural Filling
Structural filling is required within road corridors and/or wherever a structure is to be

supported on the fill and where settlement is required to be minimal. Non-Structural
filling will normally be carried out to embankments and other fill areas. Embankments
shall normally be overfilled and subsequently trimmed to the required profiles.
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Structural Filling
Structural filling shall be carried out using approved well graded natural sands and
gravel or special backfill in accordance with Clause 2.4.3.
Non-Structural Filling
The material and the procedure for Non-Structural filling shall be same as outlined in
Clause 2.4.2.
2.4.6 Backfilling of Trenches for Cables/Ducts
After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer being well
compacted by hand with iron rammers weighing not less than 5 kg, until the trench
has been filled to a height of 300 mm above the top of the cable/duct.
The remainder of the trench shall then be refilled in compacted layers not exceeding
200 mm in thickness, each layer being well compacted with power rammers, vibrating
plate compactors or other mechanical means of a type to be approved until the
ground is thoroughly consolidated up to the required level for surface reinstatement.
Each layer shall be compacted to not less than 95% of its maximum dry density.
Should the quantity of the excavated materials be not sufficient, due to unsuitability or
otherwise, for the process of backfill and fill, the Contractor shall obtain the quantity
required of such backfill and fill from approved borrow pits and transport same to the
site of work at his own expense.
Trenches shall not be backfilled until all required tests are performed and until the
Engineer has verified that the cables, etc., have been installed in accordance with the
Specifications and Drawings.
Lumps and clods shall be broken up before use. Materials shall not be dropped from
a height and where directed water shall be added to assist in adequate consolidation.
Where cover to cables/ducts is less than 400 mm, or where ordered by the Engineer,
protection in the form of concrete encasing shall be provided according to an
approved drawing or as ordered by the Engineer.
2.5 PROTECTION OF EXISTING SERVICES AND REINSTATEMENT
2.5.1 General
Where new pipes, mains, cables/ducts, etc., are to be laid alongside, over or under
the existing, the Contractor shall take care to interfere as little as possible with the
existing services and connections thereto and any damage shall be repaired by the
Contractor to the approval of the appropriate Authority or by appropriate Authority at
the cost of the Contractor.
The Contractor shall make all arrangements for protecting existing services and for
temporarily diverting them to maintain the services without interruption.
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Existing services, pipes, mains, ducts, etc., exposed in trenches for new work shall be
protected in accordance with the requirements of the relevant Authority before
trenches are refilled.
The Contractor shall lay cables, fittings, specials, etc., under hedges, fences, walls,
etc., as necessary.
Where hedges are damaged or destroyed the whole shall be restored and reinstated
with shrubs of the same kind as the hedge, planted in due season in an approved
manner and fenced on each side with post and rail stock proof fences finished on top
with one strand of galvanised barbed wire, or otherwise protected as required by the
owners or occupiers and the Engineer.
Where fences or walls are damaged or destroyed the whole shall be restored and
reinstated with like materials to the satisfaction of the owners or occupiers and the
Engineer.
The Contractor shall ensure that no trees are damaged or permanently removed in
carrying out the Contract except where directed due to the presence of permanent
works.
2.5.2 Reinstatement of Unpaved Land

In general the reinstatement of stripped areas of unpaved land shall restore the
ground to a condition not inferior to that which existed before the site was occupied.
The compacted backfill shall be taken up to a level which allows for settlement. In
arable, grassed and similar areas the surface to be topsoiled shall then be loosened
to a depth of 200 mm and topsoil replaced on it to the specified depth without
compaction using approved topsoil of comparable quality to make up any deficiency.
Areas where grass is to be sown shall be worked to a fine tilth, levelled, graded and
rolled with a light roller. The seed shall be sown evenly at the specified rate of
application in the proper season and in suitable weather conditions, and the areas
again rolled. Restoration and re-seeding of any areas where the new grass is
inadequate shall be carried out as instructed.
As an alternative to seeding the 'dibbing in' at 200 mm centres of 'Bugunda' or similar

tropical grass tufts may be required.
The grass shall be well watered four times a day and the Contractor will be required
to keep the grass cut short until the Defects Liability Certificate has been issued.
2.5.3 Reinstatement within Road Corridors
Trenches and other excavations within road corridors may be opened in four types of
ground:-
(1) in paved carriageways
(2) in footpaths and other paved areas (other than carriageways)
(3) in grassed verges and planted areas

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(4) in unmade ground which does not fall into any of the above three categories.
In addition there are four classes of carriageway construction as follow:-
(1) Estate roads: single carriageway
(2) Main access: single/dual carriageway
(3) Primary distributors
(4) Main arterials/highways, etc.
All reinstatement works falling into the above categories/classes shall be carried out
either in compliance with the current Local Order and any subsequent revision thereof
issued by Dubai Municipality or in compliance with the details shown on the Contract
Drawings, whichever is the greater in either construction depth or asphalt thickness.
2.5.4 Reinstatement of Other Surface Areas
Surfaced areas not in road corridors shall be reinstated using materials similar to and
not inferior to those existing prior to commencement of the Works.
2.5.5 Excavation and Reinstatement in Developed Reservations
The Dubai Municipality Horticulture Section will remove any trees, bushes and plants
from developed reservations that they wish to preserve prior to the commencement of
work by the Contractor. The Contractor must allow in his rates for the removal and
disposal of any remaining trees, bushes and plants necessary for the execution of the
Works and to keep sweet soil separate in accordance with the current Local Order.
The reinstatement of the developed reservation shall be in accordance with Clause

2.5.3.

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3.1 GENERAL
The prevailing standard for all concrete work shall be BS 8110 and such
amendments as shall be approved by the Engineer in accordance with the CIRIA
Guide to Concrete Construction in the Gulf Region.
Concrete work shall consist of furnishing all materials and constructing structures of
the forms, shapes and dimensions shown on the Drawings or as directed, using
Portland Cement concrete, in accordance with the details shown on the Drawings
and these Specifications.
Portland Cement concrete shall consist of a mixture of Portland Cement, fine

aggregate, coarse aggregate, water and additives when required. The mixture shall
be proportioned, mixed, placed and cured in accordance with the requirements of
BS 8110: Part 1. Where an additional clause conflicts or is inconsistent with the
requirements of BS 8110 the additional clause shall always prevail. The concrete
mixes shall be designed mixes for special or ordinary concrete as defined in BS
8110, the design requirements of which are laid down in this Specification.
3.2 MATERIALS
3.2.1 CEMENT
Sulphate Resisting Cement
Sulphate Resisting Cement shall comply with BS 4027 or ASTM C150 Type 5. In
addition the cement shall comply with the following:-
- The acid soluble alkali level measured as (Na20+0.658 K20) shall not
exceed 0.6% by weight determined in accordance with BS EN-196 Part
2:1995.
- The maximum limit for Tricalcium Aluminates content is 3.5% when tested
according to BS EN 196 : Part 2 : 1995.
- The specific surface shall be not greater than 375 m2/kg and not less
than 280 m2/kg when tested in accordance with BS EN 196-Part 6.
Ordinary Portland Cement
Ordinary Portland Cement shall conform to the requirements of BS 12 or ASTM

C150 Type 1 with the following amendments:-
- The acid soluble alkali level measured as Na2 0+0.658 K20 shall not
EN 196 Part 21.
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- The specific surface (fineness) shall be not greater than 375 m2/kg and
not less than 280 m2/kg when tested as described in BS EN 196 :Part 6.
- Ordinary Portland Cement shall contain not less than 4% and not more
than 13% of Tricalcium Aluminates by weight.
Moderate Sulphate Resisting Portland Cement
Moderate sulphate resisting Portland Cement shall comply with ASTM C150
Type 2 but containing not less than 4% and not more than 8% proportion by
weight of tricalcium aluminates with the following amendments. In either case
the cement shall not contain more than 2.5% proportion by weight of sulphur
trioxide.
- The acid soluble alkali level measured as Na20+0.658 K20 shall not
EN196-21.
- The specific surface (fineness) shall not be greater than 375 sq.m/Kg and
not less than 280 sq.m/Kg when tested as described in BS EN 196 : Part
6.
Each cement batch shall bear manufacturer’s name and batch number. Type of
cement shall be the same as mentioned in the approved analysis report. Each
separate consignment of cement shall be tested by the manufacturer before
delivery and certified copies of such tests shall be supplied to the Engineer
before any part of the consignment is used in the works. The Engineer reserves
the right to order a re-test of cement at any time. Approval of cement does not
relieve the Contractor of the responsibility to produce concrete of the specified
strength.
Cement shall be delivered to site in bulk, or with the Engineer’s approval, may be
supplied in sealed bags, which shall bear the manufacturer’s name and the date
of manufacture. Each consignment shall be accompanied by a copy of the
manufacturer’s batch test certificate and certificate of guarantee.
Each consignment of cement shall be kept separate, identified and used in order
of delivery.
Any consignment not used within 2 months from the date of manufacture will not
One brand only of cement as approved by the Engineer shall be used throughout
the works unless otherwise authorized by the Engineer in writing.
3.2.2 AGGREGATES GENERAL REQUIREMENTS
Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS 882 “Concrete aggregates
from natural sources” and the fine aggregate shall also comply with Dubai
Municipality Administrative Order No. 143/91.

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The aggregates used in the permanent works shall be naturally occurring or

crushed materials obtained only from approved sources.
Before any material from a particular source is used, the Contractor shall obtain
representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.
The results of these tests, etc. shall be submitted to the Engineer and his
approval shall be obtained before any of the material is used in the works. Part
of each sample will be required for concrete trial mixes and part shall be retained
for comparison with subsequent deliveries.
Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812 Part 102.
The maximum size of the aggregate shall not be larger than 1/5 of the narrowest
dimension between sides of the number for which the concrete is to be used and
not larger than 3/4 of the maximum clear distance between reinforcing bars.
Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
Coarse aggregate shall be crushed aggregate obtained from a quarry approved
by the Engineer.
Unless otherwise authorized by the Engineer coarse aggregate shall be delivered

to site in separate sizes according to the maximum specified aggregate size for
each grade of concrete.
Each and every stockpile of aggregate shall meet the requirements of Table 4.1.
The frequency of testing of aggregates shall be in accordance with Table 4.2.


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Table- Limits for Physical, Chemical and Mechanical Properties of Aggregates for
Concrete
SR. KIND OF REQUIREMENT TEST PERMISSIBLE LIMITS

METHODS
No. BS 812 : FINES COARSE
ASTM:
1. Grading BS EN 933- Standard Standard

1-1997
2. Material finer than 0.075 mm BS EN 933- max. 3% Max. 1%

Natural, uncrushed/crushed 1-1997 or max. 7% Max. 1%
Crushed rock ASTM
C117:2004
3. Clay lumps and friable C142 max. 1% max. 1%

particles
4. Light weight pieces C123 max. max. 0.5%

0.5%
5. Organic impurities for fine C40 The colour of the

aggregate supernatant liquid is
lighter than standard
colour solution
6. Water absorption C128/C127 max. max. 2.0%

2.3%
7. Specific Gravity (apparent) C128/C127 min. min. 2.60

2.60
8. Shell content in aggregates Part 106

Coarser than 10 mm max. 5%
Between 5mm & 10mm max. 15%
9. Particle shape
Flakiness index Part 105.1 max. 25*
Elongation index Part 105.2 max. 25*
Partially crushed faces of DMS 8

Aggregate (100% with at
least one crushed face)
* The index shall be 25% for combined aggregates and should not exceed more than
30% for individual sizes.

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Table - Limits for Physical, Chemical and Mechanical Properties of Aggregates for
Concrete (Con't)
SR. KIND OF REQUIREMENT TEST PERMISSIBLE LIMITS

No. METHOD
S
BS 812 : FINES COARSE
ASTM:
10. Acid soluble Chlorides, CL. Part 117,

Appendix
For reinforced concrete made C
with SRPC cements max. max.0.01%
OPC & MSRPC cements 0.03% max 0.02%
max.
For mass concrete 0.03%
made with
SRPC cements max 0.02%
OPC & MSRPC cements max.0.04%
max.0.03%
For prestressed concrete & max.0.03% max 0.01%
steam structural concrete
max.
0.03%
11. Acid soluble sulphate, S03 BS EN max. 0.3% max. 0.3%

1744-
1:1998
12. Soundness, MgS04 (5 cycles) C88 max. 12% max. 12%
13. Mechanical Strength

10% fines value Part 111 min. 100KN
or Impact value Part 112 max. 30%
Los Angeles Abrasion C131/C53 max. 30%

5
14. Drying Shrinkage Part 120 max. 0.05%

15. Potential Reactivity
Note 2 C289 Innocuous Innocuous
Of Aggregates,
Chemical Method
Of Cement-Aggregate C227 6 month expansion 0.10%
Combination max.
Note 1: There is no requirement of shell content in sands passing 5mm sieve size.
Note 2: Aggregates may initially be assessed for its reactivity in accordance with ASTM
C289 and if potential reactivity is indicated, then mortar bar tests in accordance
with ASTM C227 shall be carried out.
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Table- Frequency of Routine Tests on Aggregates

METHOD
1. Grading – BS EN 933-1-97 Each 2 weeks or per 500 m3

whichever is more frequent.
2. Material finer than 0.075 mm - do -

- BS EN 933-1-97 or ASTM C 117
3. Clay lumps and Friable Particles - do -

-ASTM C142
4. Organic impurities ASTM C40 - do -
5. Water absorption - ASTM - do -

C128/C127
6. Specific Gravity - ASTM C128/C127 - do -
7. Shell content – BS EN 933-7:1998 - do -
8. Particle shape BS812 : Part 105 - do -

Section 105.1 ; BS812: Part 105
Section 105.2
9. Acid soluble chlorides, CL - do -

Qualitative - BS812 : Part 117-
Appendix-C
Appendices A/B & C
10. Acid soluble sulphates, - do -

S03 – BS EN 1744-1:1998
11. Soundness, Mg S04 (5 cycles) - do -

ASTM C88
12 Mechanical Strength
10% Fines or impact value - do -

-BS812 : Parts 111, 112
Los Angeles abrasion - - do -

ASTM C131/C535
13. Moisture variation in sand - by Twice daily
Moisture Meters
14. Drying Shrinkage At the start of the project and
BS812 : Part 120 whenever there is a change
in the source of supply

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Table- Frequency of Routine Tests on Aggregates (Cont'd)

METHOD
15. Potential Reactivity: At the start of the project and

wherever there is a change in
of aggregates (ASTM C295, C289) the source of supply
of Carbonate (ASTM C586)
of Cement aggregate combination

(ASTM P214 and C227)
Frequency of testing may be amended by the Engineer based on previous test

results
Note : Drying Shrinkage and potential reactivity of aggregates shall be

determined initially at the start of the project or whenever there is a
change in the source of supply.
FINE AGGREGATES
The gradation of fine aggregate shall be in accordance with BS 882 latest edition.
Each batch of aggregate delivered to site shall be kept separate from previous
batches and shall be stored for at least 3 (three) working days before use to
allow inspection and tests to be carried out.
Fine Aggregate shall be clean sharp natural and/or crushed sand and shall
comply with BS 882.
The Contractor shall mechanically wash aggregate to remove salts and other
COARSE AGGREGATE FOR CONCRETE
Coarse aggregate shall be prepared as single sized aggregate and blended to

produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS882.
Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall not be used.
The Contractor shall mechanically wash aggregate to remove salts and other
COMBINED AGGREGATE

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Approved coarse aggregate and fine aggregate in each batch shall be combined
in proportions as specified in BS 882 and as approved by the Engineer.
However, in no case shall materials passing the 0.075mm, sieve exceed three
(3) percent by weight of the combined aggregate.
The combined aggregate gradation used in the work shall be as specified, except
when otherwise approved or directed by the Engineer. Changes from gradation
to another shall not be made during progress of the work unless approved by the
Engineer.
WATER FOR CONCRETE
The Contractor shall make his own arrangement and obtain approval for the
supply of water.
The mixing water should be clear, apparently clean and free from matter harmful
to concrete in its fresh or hardened state. Potable water can be used. Water of
questionable quality should comply with the physical tests of Table 4.3 and
chemical limitation listed in Table 4.4. Water shall also meet the requirement of
BS 3148.
The temperature of water for concrete should not be less than 5 degree celsius
nor more 25 degree celsius. Water may be cooled to not less than 5 degree
celsius by the gradual addition of chilled water or ice but on mixing, no ice
particles should be present in the mix. Alternatively, flaked ice may be used.
The ice to be used should be crushed and should be the product of frozen water,
which complies, with acceptance criteria of Tables 4.3 and 4.4.
Water for curing concrete shall not contain impurities in sufficient amounts to
cause discoloration of the concrete. Sources of Water shall be maintained at
such depth and the water shall be withdrawn in such a manner as to exclude silt,
mud, grass and other foreign matter.
Table - Acceptance Criteria and Physical Tests for Mixing Water
Limits ASTM
Test
Compressive strength, 90 C109

min.%
control at 7 days
Setting time, deviation from from 1:00 C191

control, h:min. early to 1:30
later

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Table - Chemical Limitations for Mixing Water
SL.No Max. Concentration Limit, ppm Test Method

.
1. Chloride as Cl 250 ASTM D512
2. Sulphates as SO4 350 ASTM D516
3. Alkali carbonates and 500 ASTM D513
bicarbonates
4. Total dissolved solids, 2000 BS1377 :
including 1, 2 & 3 above Part 3 : Test
8
5. PH min.7/max.9 ASTM
D1293
3.2.5.2Specific Requirements
Water for washing aggregate and for mixing or curing of concrete shall be tested in
accordance with BS and ASTM standards and shall meet the following
requirements:
Table 3-5. Chemical Limitations for Mixing Water

Parameter Maximum Test Method
Concentration
Limit
1. Chlorides as C1 250 mg/l ASTM D512
2. Sulphates as SO3 350 mg/l ASTM D516
3. Alkali carbonates and
bicarbonates 500 mg/l ASTM D513
4. Total dissolved solids,
including 1, 2 & 3 above 2,000 mg/l BS 1377: Part 3
5. pH Min. 7/max. 9 ASTM D1293
The temperature of water for concrete should not be less than 5 C nor more than
25C. Water may be cooled to not less than 5C by the gradual addition of chilled
water or ice but on mixing, no ice particles should be present in the mix.
Alternatively, flaked ice may be used. The ice to be used should be crushed and
should be the product of frozen water which complies with the above requirements.
3.2.6 Admixtures
Unless agreed by the Engineer neither admixtures nor cements containing

additives shall be used.
Where the use of admixture had been agreed by the Engineer, they shall conform
to the requirements of Type A, Type D, Type F or Type G as specified in ASTM
C494 and shall be used in strict accordance with the manufacturer’s instructions.
The Contractor shall be entirely responsible for the use of any approved
admixtures. Samples of proposed admixtures shall, if required, be submitted to an
approved testing authority by the Contractor in order to ascertain its suitability for
use in the Works.

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Approved methods and equipment shall be used for dispensing and incorporating
the admixture into the concrete. The dispensing unit shall be designed so that the
discharge of the admixture is visible.
The cost of such admixtures shall be included in the cost of concrete and no extra
payment shall be made if they are used. The proportions of cement, fine aggregate
and water shall be determined by the Contractor before concreting commences
and submitted together with such test results as may be required to the Engineer
for approval and the Contractor shall not commence concreting before such
approval is given nor shall he alter or vary in any way the proportion of mix unless
he submits fresh test results and mix proportions to the Engineer for approval.
The approval by the Engineer of such mix designs does not in any way absolve the
Contractor of any of the requirements of the Specifications.
3.2.7 Concrete Mix Specification
The classes of concrete and their respective minimum cement content,

consistencies and the minimum required compressive strengths shall be as shown:
Table 3-6. Concrete Classification and Mixes

Comp. Strength Slump Min.Cemen Max. Free
(N/mm )2 (mm) t Content Water/Ceme
Class of (kg/m3) nt Ratio
Concrete
7 28
days days
A (30/20/SRC) 20 30 40 - 75 310 0.55
B (25/20/SRC) 16 25 50 – 275 0.60
100
C 10 15 50 - 250 0.65
(15/20/SRC) 120
The chloride and sulphate levels in the concrete mix shall comply with the
requirements of Table 3-7.
Table 3-7. Maximum Limits of Chloride & Sulphate in Concrete Mix
Chlorides as Sulphate as
Type of Concrete C1* (According SO3*
to BS 1881:Part (According to
124) BS 1881:Part
124)
a. For reinforced concrete
if made with OPC/MSRC 0.30% 3.70%
if made with SRC 0.06% 3.70%
b. For mass concrete
if made with OPC/MSRC 0.60% 3.70%
if made with SRC 0.12% 3.70%
c. For prestressed concrete and 0.10% 3.70%
heat-cured reinforced
concrete
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*Maximum limits of chloride and sulphate content as a percentage by weight of

cement in the mix.
The OPC and MSRC cements can also contain chlorides, the relevant standard BS
12 allows upto 0.1% C1. Therefore any chloride content present in the cement has
to be taken into account while computing total C1 in the mix. In case the cement
contains the maximum limit of 0.1% Cl, then the aggregates, water and admixtures
used for prestressed concrete or heat-cured reinforced concrete should be
absolutely free of chlorides.
3.2.8 Cement Mortar and Grout
Unless otherwise specified, mortars and grouts shall be composed of Ordinary

Portland Cement (satisfying Clause 3.2.1) and sand (satisfying Clause 3.2.2) in the
following proportions:-
NOMINAL PROPORTIONS
Quality Portland Cement Sand
G1 1 1
G2 1 2
G3 1 3
The amount of water (satisfying Clause 3.2.5) added shall just be sufficient to
make the mortar or grout workable consistent with its purpose.
3.3 CONCRETE MIX DESIGN
Concrete Mix Design and Trial Mixes shall be verified by DM-DCL.
Preliminary laboratory tests shall be carried out to determine the mixes to satisfy
the specification with the approved materials.
Trial mixes shall be tested to determine the following properties of mixes

proposed for initial field tests:
a) Bleeding in accordance with ASTM C232 (non-vibrating) shall not exceed

0.5%.
b) Drying shrinkage in accordance with BS 1881 Part 5.
c) Air content if applicable BS EN 12350 Part 7.
d) Free water/cement ratio
e) Workability BS 1881 Part 102.
f) Fresh and hardened concrete densities BS 1881 Parts 107 and 114
respectively.
g) Compressive strength BS 1881 Part 116.
h) Water depth of penetration BS EN 12390 Part 8.
i) Chloride permeability to ASTM C1202 (maximum 2000 coulomb at 28
days).

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j) Initial Surface Absorption Test (ISAT) of concrete shall be as per BS 1881

Part 208.
k) Water absorption of hardened concrete – BS 1881:P-122:1983
If the values obtained are unacceptable, the mixes shall be re-designed.
At least 35 days before commencement of concreting trial mixes shall be

prepared under full-scale site conditions and tested in accordance with BS 1881.
Samples of concrete incorporating the reinforcing details to be used shall be cast

and examined, before hardening using hand tools, and after hardening by coring
to assess the mixes. Cores shall be taken in accordance with BS 1881 Part 120.
Trial mixes shall be made on each of three days; the workability shall equate to
the designed target value. Six cubes from each mix shall be taken, three for test
at 28 days.
Further trial mixes shall be made if the range (the maximum minus the minimum
of the three cube results in any batch) exceeds 15% of the average of that batch,
or if the range of the three batch averages exceeds 20% of the overall average of
the batches.
The mixes shall be tested to determine the following properties:

a) Bleeding in accordance with ASTM C232.
b) Air content if applicable BS EN 12350 Part 7.
c) Free water/cement ratio.
d) Tensile strength in accordance with BS EN 12390 – 5 and ASTM C 496.
The average 28-day CCS of the three trial mixes shall not be less than the
designed mean strength, and the results of the above tests shall be acceptable
before the mix is approved. Otherwise the mix shall be re-designed.
The Engineer will review the Contractor’s trial-mixes and crush the test cubes at
seven (7) and twenty-eight (28) days. The Engineer will then determine which of
the trial mixes shall be used. If none of the trial mixes for a class of concrete
meets the Specifications, the Engineer will direct the Contractor to prepare
additional trial-mixes. No class of concrete shall be prepared or placed until its
job-mix proportions have been approved by the Engineer.
The approval of the job-mix proportions by the Engineer or his assistance to the
Contractor in establishing those proportions, in no way relieves the Contractor of
the responsibility of producing concrete which meets the requirements of these
Specifications.
The Engineer may also require practical tests to be made on the Site by filling
trial moulds to confirm the suitability of the mix for the works, the type of plant
used for mixing, the method of compaction used and the formwork face intended
for use in the works.
All costs connected with the preparations of trial-mixes and the design of the job-
mixes shall be borne by the Contractor.
In the event, any Concrete mix that is currently being used in another running
DM project, is proposed by the contractor for used in this contract, then prior to
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according approval, the Engineer will ensure that,
contractor comply with Specification requirements as stated in this
contract and
2) The mix proposed complies with clause 4/16 of this contract by verifying it at
DCL.
Note: Any mix that is obsolete and currently not in use shall be
accepted at all for re-approval.
3.3.3 Water/Cement Ratio
The quantity of water to be added to the cement and aggregates during mixing
shall be just sufficient to produce a workable mix to enable it to be well compacted
and worked into corners of formwork and around reinforcement. All mixes shall be
designed in respect of the proportioning of water so that the Slump Test as carried
out according to BS 1881: Part 102 shall be in accordance with the requirements
laid out in Clause 3.2.7. Measurement of water on the Site shall take into account
the moisture present in the aggregates, and Slump Tests shall be taken frequently
to ensure that variations in the moisture content of the aggregate are fully taken
into account in determining the amount of water to be added.
3.3.4 Measurement of Ingredients
The aggregates for the concrete shall be measured by weight but measurement by
volume may be allowed in special circumstances with the approval of the
Engineer.
When the aggregates are to be measured by weight the weight batching machines
shall be of a type approved by the Engineer's Representative. They shall be kept
clean and in good condition and adjustment. At intervals as the Engineer's
Representative may require, the Contractor shall check the accuracy of each
weight-batching machine.
When the aggregates are to be measured by volume, the proportions of fine and
coarse aggregates shall be measured in well constructed gauge boxes, of
dimensions approved by the Engineer's Representative to guarantee that whole
multiples of such gauge boxes will ensure the use of one more whole bags or
containers of cement and the capacity of the concrete mixer shall be such as to
ensure that no splitting of cement bags or containers is required. Gauge boxes
shall be properly filled and struck off level, addition of fine aggregates to allow for
bulking due to moisture content being made as required.
An efficient water measuring device shall be fitted to each concrete mixer.
Any cement container shall be such as to contain an accurately weighed amount of

cement.
3.3.5 Mixing Concrete

The concrete shall be mixed in a power driven machine of the batch type, no hand
mixing being allowed. The mixer shall be large enough to admit the use of 1
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cement bag or container or whole multiples of bags or containers at a time. The

mixing shall continue until there is a thorough distribution of the materials and the
mass is uniform in consistency and colour. The period of mixing, judged from the
time that all the ingredients including water are in the mixing drum shall be as
ordered by the Engineer's Representative but shall not be less than 2 minutes or
20 revolutions of the drum whichever is the longer. Should there be for any reason
a stoppage of greater than 30 minutes, the drum or other containers of the mixer
shall be thoroughly washed and cleaned before mixing is resumed. On completion
of the mixing the concrete shall be discharged onto clean boards or into clean
barrows. The method of discharge from the mixer shall be such as to cause no
segregation whether partial or otherwise of the concrete materials.
3.3.6 Re-Mixing Concrete

Concrete which has commenced to set shall not be remixed either with or without
additional water and in no case shall such concrete be used in the Works.
3.3.7 Concrete Testing
3.3.7.1 General
The compression tests shall be performed on cubes 150 x 150 x 150 mm as

described in BS1881: Part 116. Sampling, making test cubes and curing of cubes
shall be in accordance with BS 1881: Parts 101, 108 and 111 respectively.
The following methods of testing shall apply to standard concrete cubes.
3.3.7.2 Preliminary Testing
After the materials have been approved and at least 10 days before any concrete
is poured, the Contractor shall make preliminary sets of test cubes. Each set of
test cubes shall comprise of six cubes made from a single sample of concrete
taken from the point of final discharge of the wet concrete. Each cube shall be
made under the Engineer's Representative supervision. Cubes shall be tested as
follows: three cubes shall be tested 7 days after the date of manufacture and one
cube 28 days after the date of manufacture. Two cubes will only be tested if the
Engineer's Representative wishes to check the results of the tests on either of the
other two cubes and shall otherwise be preserved by the Contractor until the end
of the Period of Maintenance. Preliminary test cubes shall be made and tested for
all grades of concrete and for all proposed variations of quality, quantity or origin of
the aggregates and cement.
Should either the test cube crushed at 7 days or that crushed at 28 days fall below
the specified requirements and the failure is confirmed by the testing of the third
cube, the Contractor shall, on the Engineer's Representative's instructions alter the
mix design and/or the source of aggregates, cement or water and/or the method of
mixing including alteration of the type of mixer. The compressive strength of the
concrete cube at 7 days shall be equal to or more than two thirds the required
compressive strength at 28 days.
3.3.7.3 Works Testing

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During the course of the construction of the Works, the Contractor shall make test
cubes as required by the Engineer's Representative. One set of six cubes will
normally be taken from each individual concrete member, e.g. culvert invert, Irish
crossings, but additional cubes shall be taken as directed by the Engineer's
Representative. Three cubes will be tested at 7 days and three cubes at 28 days
as the Engineer's Representative directs. Where the strength of the concrete is
shown to be below that specified, the Contractor shall remove and replace at his
own expense all concrete from the concerned pour. The Engineer may require the
Contractor to cut out defective concrete from the Works at his own expense even
though test cubes made from that concrete have not failed.
3.3.7.4 Workability Testing
The Contractor shall carry out slump test in accordance with BS 1881: Part 102
and/or compacting factor test in accordance with BS 1881: Part 103 at such
frequency as the Engineer's Representative considers necessary to ensure that
the workability and consistency of the concrete is maintained in accordance with
the specified mix or accepted mix design and the trial mix. But in any case
workability tests shall be carried out at least once every two hours during which
concrete is being mixed.
3.3.8 Frequency of Testing Aggregate and Concrete
During the mixing and casting of concrete the frequency of testing for control
purposes shall be as indicated in Table 3-8 or as directed by the Engineer's
Representative. No direct payment is made for testing. The price of this work is to
be included in the bid prices of concrete.
Table 3-8. Required Frequency of Testing Aggregates & Concrete
Type of Test Frequency
Once for each source prior to

Grading of Fine and Coarse approval and once prior to casting
Aggregate; Flakiness and of each lift for any major concrete
Elongation Index; Aggregate structure or as directed by the
Crushing Value Engineer
Concrete Cube One set (Min. 6 Cubes) from each

mixer for each individual pour or
every 2 hours for large pours or as
Compacting Factor Test As directed by the Engineer.
Flexural Loading (1) (as As directed by the Engineer.
per BS 7263 : Part 1)
Absorption Requirement(2) As directed by the Engineer.

(as per BS 1881: Part 122)
Slump Test Once every hour from each mixer


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Cement As per BS EN 196

Steel
1.Deformed Steel Bar (Tensile & Bend – Rebend) as per
BS 4449:1997
2.Strand as per BS 5896:1990 if needed

Hardened Concrete
1. Air Content as per BS EN 12350- 7:2000
2. Flexural Prism as per BS EN 12390-5
3. Depth of Water (BS EN 12390 P-8:2000)
Penetration as per BS1881-p-208
4. ISAT as per ASTM C232
5. Bleeding as per BS-1881-P122
6. Water Absorption of
Hardened Concrete
Thickness of Coating as per BS EN ISO 1461:1999
Splitting Tensile Strength as per ASTM C-496:1996

of Concrete Cylinder
Notes: (1) Minimum requirement is 22.24 KN at 28 days

(2) Maximum 2% after 30 minutes
3.4 TRANSPORTING AND PLACING CONCRETE
3.4.1 General Requirements
Concrete shall be taken from the place of mixing to the place of depositing by approved
methods which will prevent the segregation or loss of the ingredients and which are
sufficiently rapid to ensure that the concrete does not commence to set before it is
compacted in position. The concrete shall be deposited as near as possible to its final
position in the Works and shall not be allowed to flow into position. Deposition of the
concrete through chutes shall not be permitted and neither shall the concrete be dropped
freely from a height exceeding 2.0 m. Pumping concrete through delivery pipes may be
permitted but only with the prior approval of the Engineer's Representative.
No concrete shall be placed in a foundation until the extent of excavation and the
character of bearing material have been approved and no concrete shall be placed in
any structure until the placement of reinforcing steel and the adequacy of the forms and
flasework have been approved.
The concrete shall be placed in its final positions as soon as possible after it has been
mixed, and in any case before the initial set has taken place. The Contractor shall
ensure that concrete which has already been placed in position and commenced to set is
not disturbed by the placing or compaction of further concrete nearby. All concrete shall
be carefully worked around and between reinforcement and all other embedded fittings
without such reinforcement or fittings being disturbed. Concrete is to be worked well up
against whatever surface it joints.
No concrete shall be mixed or placed when the light is insufficient, unless an adequate
and approved artificial lighting system is operated and such night work is approved by
the Engineer.
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3.4.2 Placing Concrete in Hot Weather

Concrete shall only be placed where the general requirements in regard to ambient
and mix temperatures laid down in the CIRIA Guide to Concrete Construction in
the Gulf Region are met. The parameters laid down therein shall only be exceeded
with the prior written consent of the Engineer.
Concrete shall not be placed when the shade air temperature exceeds 40 C or
during periods of windblown dust or rain.
The temperature of batched concrete at time of placing shall not exceed 32C
unless otherwise specified.
Measures shall be taken to provide cool concrete and cool concreting conditions in
order to reduce workability loss, premature drying of concrete and the
development of high temperatures and temperature gradients in placed concrete.
Proposed measures must be described in method statements and may include:-
(a) Painting white or silver all storage vessels, hoppers, pipes, walls or roofs
which contain or convey aggregates, cement or mixing water.
(b) Dampening the forms.
(c) Reducing the concrete temperature to the lowest practical level by procedures
such as :-
- Shading the aggregate.

- Cooling the mixing water before use.
- Screening the mixing plant and transporting vehicles from wind, rain and
sun.
(d) Erecting wind breaks and sunshades at the concrete placing location.
(e) Reducing the time between the placing of the concrete and the start of curing
to the minimum possible.
(f) Minimizing evaporation (particularly during the first few hours subsequent to
placing the concrete) by suitable means such as applying moisture by fog
spraying.
These measures are in addition to those specified for the curing of concrete.
In contracts which small structures spread over a large site, such as sewerage
contracts, where transportation times could be large, dry mixing of concrete with
addition of water immediately prior to placing may be proposed. Method
statements for such a proposal must describe methods for accurate batching of
water.
3.4.3 Placing Concrete in Water (Tremie Concrete)
Tremie concrete shall be deposited in water only if specified on the Drawings

and/or directed by the Engineer and under the Engineer's supervision. Concrete to
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be deposited in water shall have the cement content increased by 25% at the
Contractor's expense. Concrete shall be carefully placed in a compact mass in the
space in which it is to remain by means of a tremie bottom dump bucket or other
approved method that does not permit the concrete to fall through the water
without adequate protection. The concrete shall not be disturbed after being
deposited. No concrete shall be placed in flowing water and forms which are not
reasonably watertight shall not be used for holding concrete deposited under
water.
3.4.4 Blinding Concrete
Prior to placing any concrete on natural surfaces a blinding layer of Class C concrete
shall be laid to a minimum of 75 mm thickness. This blinding shall be suitably curved
prior to subsequent concrete placement. The blinding shall be clean and free from any
dust or impurities prior to subsequent concrete placement.
3.5 COMPACTING CONCRETE
3.5.1 Tamping
All concrete shall be thoroughly compacted to the maximum with approved rammers
without any segregation in its final position before it commences to set. Care shall be
taken to ensure that the use of spade type rammers does not cause segregation of the
aggregates and water. Initial compaction of slabs shall be with approved rammers and
compaction by a screed board shall be limited to that required for the final shape and
finish. During the placing and compaction of reinforced concrete, a competent steel
mixer shall be in attendance to adjust and correct if necessary the position of the
reinforcement.
3.5.2 Vibrating
Concrete shall be compacted by vibrating with an approved vibrator. The vibrators shall
not be attached to any reinforcement or embedded fitting and where vibrators of the
immersion type are used, care shall be taken to ensure that they do not come into
contact with the reinforcement or embedded fittings. Freshly placed concrete shall not be
vibrated in a manner likely to cause damage to concrete in other parts of the Works
which has already taken its initial set. Concrete shall not be vibrated in such a manner
and to such an extent as to cause segregation of the constituent materials. If shutter
type vibrators are used they shall be augumented by immersion type vibrators if the
thickness of the concrete member is more than 15 centimetres.
3.6 CURING OF CONCRETE
All concrete shall be protected from the harmful effects of sunshine, drying winds,
rain, flowing water, or other adverse effect. For at least 7 days after placing, the
concrete shall be prevented from drying out by being sprayed with fresh clean
water and covered with hessian, clean sand or other approved material which shall
be kept wet.
Whenever approved by the Engineer, membrane curing of concrete with an

approved liquid may be used as an alternative to curing with water except that
membrane curing liquid shall not be applied to surfaces of concrete from which the
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shuttering has been struck, until the concrete has been inspected and approved by
The concrete curing compound shall comply with the following requirements:
1) Only products which have been proved to be effective through extensive use
shall be proposed and manufacturers’ literature shall include recent test
certificates illustrating effective quality control and high curing efficiencies.
2) All materials shall be supplied in the containers marked by the manufacturer

with his name, date of manufacture, shelf life, pot life and instructions for
handling and application.
3) The liquid shall contain a white or silver colour pigment in sufficient quantity to
give a uniform colour when applied to the concrete surface.
4) The liquid shall be of such chemical composition and consistency that it can
be applied by an approved mechanical sprayer in fine spray to produce an
even, uniform, impervious, continuous film within one hour of application which
will not crack, peel or disintegrate within three weeks of application.
The compound shall not be poisonous, odorous or explosive and shall not
react chemically with cement.
5) Curing compounds shall not be applied to surfaces to which further concrete

or a surface finish is subsequently to be bonded unless the approval of the
Engineer is obtained to the use of a water soluble type.
The Contractor shall ensure that all concrete is adequately protected against
inclement weather until properly set and shall if necessary provide additional
protection to that specified above.
3.7 JOINTS IN CONCRETE
3.7.1 Intervals During Concreting
The timetable for the depositing of concrete between construction joints should be
so arranged that no face of concrete shall be left for more than 20 minutes before
fresh concrete is deposited against it. Pauses for meals, servicing of machines,
changes of shift, etc., and the distribution of concrete among the positions where
work may be proceeding simultaneously must be carefully organized to ensure that
the above mentioned interval shall not be exceeded.
3.7.2 Construction Joints
Construction joints shall be as shown on the Drawings or as directed by the

Engineer's Representative. If the Contractor wishes to make additional
construction joints he shall obtain the prior approval of the Engineer's
Representative. Such approval may include the provision and placing of additional
reinforcement at the Contractor's expense.
Construction joints shall be formed by inserting temporary vertical stopping-off
boards to form tongue and groove joint with the concrete placed subsequently
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except if separately detailed on the Drawings. Unless otherwise shown on the

Drawings construction joints shall be located as near as possible to the position of
minimum shear and tensile stress in the concrete.
3.7.3 Jointing Fresh to Set Concrete
At a construction joint, the face of the previously placed concrete shall be cleaned
of any skin or latance or loose material by brushing with a wire brush or other
approved method and washing with clean water. Insecurely held aggregate shall
be removed. Excess water shall be removed and the surface while still wet shall be
covered with 1:2 cement mortar which must be vigorously stippled into the surface
by means of a suitable stiff brush, the depositing of the fresh concrete following
closely.
3.7.4 Expansion Joints
Expansion joints shall be constructed at positions shown on the Drawings or as

directed by the Engineer and shall be formed according to the instruction and
dimensions shown on the Drawings.
Filled expansion joints shall be provided at every 6 m or as shown in the drawings

and/or directed by the Engineer for the kerb and concrete backing. Any excavated
surface for the concrete bedding should be watered and compacted to a minimum
95% of optimum density.
3.7.5 Expansion Joint Filler
Expansion joint filler shall be composed of approved durable non-extruding fibrous

material suitably impregnated to prevent deterioration. Sheet bitumen fillers will not
be accepted. Preformed strips of expansion joint filler shall be of such a nature as
not to be permanently deformed or broken by twisting, bending or other normal
handling on site. Samples shall be submitted for approval before ordering. The
vertical expansion joints in kerbs and parapets shall be formed with approved
vertical seal. Such vertical seal shall adhere to the vertical face sealed and shall
not flow under maximum local sun temperature nor shall it be sticky to the touch.
1) Expansion joints for precast upstand kerbs shall be at 6 m.
2) For flush kerbs cast in-situ, at 2 m max.
3) For precast slabs, every 4 m min.
3.7.6 Expansion Joint
Sealing Compound
The sealing compound shall be of an approved polysulphide compound, non-

pouring grade for vertical application and pouring grade for horizontal application,
as specified in Clause 9.2.1.2 (1) or it may be a rubber-bitumen compound.
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The rubber-bitumen compound shall be a flexible weather resistant seal, slump

resistant unaffected by permanent immersion in water, or by alkalis or sulphates.
The material shall have a minimum storage life of 12 months in original containers
stored in cool dry conditions and a density of 1.30 kg/litre.
The sealing compound shall adhere firmly to the concrete in all weather conditions.
The sealing compound shall not flow either along or down the joint during hot
weather. The sealing compound shall be durable and shall not weather beyond the
forming of a thin surface skin.
Samples shall be submitted for approval before ordering. Vertical sealer shall be
used with an approved priming compound. Application of the sealing compound
shall be strictly in accordance with the Manufacturer's instructions.
3.7.7 Waterstop Across Joints in Concrete Structures
Seepage of water through any joints in a water retaining or water excluding

concrete structure shall be prevented by the use of PVC Waterstop or other
material as directed and approved by the Engineer. They shall be placed centrally
as a water barrier across the designated joint in in-situ concrete structures and
cast centrally into the edges of adjacent concrete components.
Waterstop shall be used at all Expansion and Contraction Joints in concrete

structures below water table. For a Construction Joint, requirement of a waterstop
shall be indicated in the drawing. The Engineer may also require the Contractor to
provide waterstop at any additional Construction Joint approved at his request.
Waterstop shall be extruded from high grade grey PVC Compound. Flat Dumbell
plain web waterstop shall be used for a Construction Joint while for an Expansion
Joint or a Contraction Joint, a centre bulb waterstop shall be used. The width of the
waterstop shall depend upon the concrete thickness, the aggregate size and the
position of reinforcement. In general, the following shall be taken as a guide to
select the width, w, of a waterstop:-
w < t, but w > (6a+j)
where, t = concrete thickness

a = largest aggregate size
j = width of Expansion Joint
The following Technical Data shall apply :
Hardness : 42 - 52 BS Softness degrees at 25 C.
Tensile strength : 13.8 N/mm2 minimum at 25 C.
Elongation at break : 285 % minimum at 25 C.

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3.8 INSPECTION OF CONCRETE
The Contractor shall not proceed with the surface finish or making good of
concrete surfaces until he has received the Engineer's Representative's
permission to do so and he shall not apply cement slurry or mortar or any other
coating to the concrete surfaces from which the shuttering has been struck until
the concrete has been inspected and approved by the Engineer's Representative.
3.9 FAULTY CONCRETE WORK
The Contractor shall on the written instruction of the Engineer's Representative

remove and reconstruct any such portion of the work which in the opinion of the
Engineer's Representative is unsatisfactory as regards quality of concrete,
incorrect dimension of the cast portion, badly placed or insufficient reinforcement,
honeycombing or other such cause as shall render the construction not up to the
standard required and which in the opinion of the Engineer may affect the strength
or durability of the construction.
3.10 REPAIRS TO CONCRETE
The method of repairing and replacing defective concrete which the Contractor
proposes to adopt shall be submitted to the Engineer's Representative for prior
approval and the repair shall be carried out in such manner as the Engineer may
direct or approve.
3.11 SUPERVISION OF CONCRETE WORK
Throughout the progress of the concrete work the Contractor shall employ and
provide such supervision as is necessary to ensure
(a) the day to day control of the quality of the concrete and
(b) the mixing, transporting, placing, compacting, curing and protection of the
concrete, and
(c) the carrying out of all testing as specified herein and any further testing
which the Engineer's Representative may require, and
(d) the conducting of investigations as the Engineer's Representative may

require, and
(e) the preparation of reports and the keeping of such records as the Engineer's
Representative may require.
3.12 FINISHING OF CONCRETE
All concrete surfaces (except top faces of culvert decks) not requiring shuttering
shall be trowelled to a smooth dense surface with the minimum of cement and fine
particles being brought to the surface and shall be free from irregularities. Top
faces of culvert decks shall be carefully screeded and tamped to the required
shape and to a dense surface with the minimum amount of cement and fine
particles being brought to the surface and should be free from irregularities greater
than 3 mm in height or depth.
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Shuttered surfaces of concrete which will always be in contact with the ground may
be cast against sawn timber. All other exposed shuttered surfaces including
precast concrete shall be cast against steel, plywood or planed timber formwork
and shall be carefully rubbed down with carborundum to remove all imperfections
and irregularities. Surfaces which are honeycombed, porous or irregular and which
in the opinion of the Engineer's Representative do not comply with the
Specification shall be cut out and replaced with sound concrete as directed by the
Engineer's Representative. The cost of all normal surface finishes and making
good shall be deemed to be included in the tendered rate for the concrete.
3.13 DESIGN AND CONSTRUCTION OF FORMWORK
3.13.1 General
Formwork shall in every respect be adapted to the structure and the required
surface finish of the concrete. It shall include all temporary moulds for forming the
concrete to the required shape and finish and for the support of such moulds. It
shall be fixed in perfect alignment and securely ledged and braced so as to be able
to withstand, without displacement deflection or movement of any kind, the weight
of the construction and the movement of persons materials and plant. Joints shall
be close enough to prevent the leakage of liquid and fine materials from the
concrete.
The Engineer's Representative may at any time require the prior submission for
approval of the Contractor's proposals for design and construction of formwork
including supports. The formwork shall be constructed so as to permit its removal
without damage to the concrete.
3.13.2 Spacing Blocks and Temporary Construction Ties
Internal spacing blocks and construction ties shall be avoided as far as, in the
Engineer's Representative opinion, possible and practicable. Where it is intended
that the spacing blocks or construction ties shall be removed whether before or
after the concrete has set, the making good of the concrete shall be subject to the
Engineer's Representative's approval. The removal of the blocks or ties must not
jeopardise the stability of the construction. If, with the approval of the Engineer's
Representative, the spacing blocks and construction ties are allowed to remain in
the concrete then they shall be of such material and of such quality that they do
not prejudice the strength of the work. Concrete spacing blocks shall be made of
concrete at least equal in quality to the main concrete. Metal ties shall be
positioned such that they do not come into contact with any of the reinforcement or
fittings and no part of the tie shall be permanently embedded in the concrete
nearer than 5 cm to the exterior surface of the concrete.
All holes shall be filled with 1:2 cement mortar.
3.13.3 Slab Forms
Where timber is used for the soffits of slabs, the boards shall be placed and laid
perfectly true with close joints to prevent the percolation of liquid or fines from the
concrete. Tongue and groove planks shall be used if specified. All requisite bearer
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and struts shall be adjusted in position and placed where necessary on bearers as
specified in the case of beam forms.
3.13.4 Type of Formwork
3.13.4.1 Exposed Concrete Faces for Bridges
All concrete faces shall be left as struck with a fair face, true to line finish.
In order to have the finish as it will be formed, approved by the Engineer, test
pieces of 1 sq.m vertical panel 25 cm thick shall be cast. After approval they shall
be retained in position until the concrete works have been completed then they
shall be demolished and removed from the Works.
After careful inspection, all superfluous fines and similar projections shall be
carefully removed. No render or other applied finish shall be used to obtain a fair
face to the concrete. All concrete faces to be exposed in the finished works shall
be adequately protected against damage and surface staining during the execution
of the Works.
3.13.4.2 Sawn Formwork
Shall be used for all culverts.
3.13.5 Preparation of Formwork for Concreting
Immediately before the concrete is deposited, the formwork shall be thoroughly

cleaned out and freed from sawdust, shavings, wire cuttings, dust, sand, clay and
all other deleterious and extraneous materials. Temporary openings shall be
provided in the formwork to facilitate this work. The inside surfaces of the formwork
shall, immediately prior to final erection, be coated with mould oil. The mould oil
shall be of approved type and shall be applied uniformly and the quantities used
shall be the minimum consistent with its purposes. The Contractor shall ensure
that all steel reinforcement and adjoining concrete surfaces are kept free of mould
oil.
All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.
3.13.6 Approval of Formwork Before Concreting
The Contractor shall in all cases request the approval of the formwork by the
Engineer's Representative in sufficient time to allow an inspection to be made and
between the Contractor's request for approval and his intention to commence
concreting shall be not less than one clear normal working day and the Engineer's
Representative may require a longer period if, in his opinion, the formwork is of
such complexity as to require it.

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Contract.
3.13.7 Removal of Formwork
All formworks shall be struck without jarring the concrete or subjecting the same to
sudden shock.
Before striking any formwork, the Contractor shall satisfy himself that the concrete
is sufficiently hardened to bear its own load and any other loads that may be
placed on it.
No formwork is to be removed, if in the opinion of the Engineer's Representative,

the concrete has not set sufficiently. approval of the Engineer's Representative
shall not absolve the Contractor of his responsibilities under the Contract.
Subject to the above and the concrete test cube results, the minimum periods for
the removal of formwork generally are as follows:
Sides of beams, walls and columns - 2 days

Soffits of beams and slabs (props left in) - 7 days
Removal of props (beams and slabs) - 14 days
Soffits of precast beams - 7 days
(These times may be reduced only with the written approval of the Engineer)
In the case of the special types of formwork, striking times are to be approved by
the Engineer.
If a beam slab is required to support a construction load in excess of its design

load, the beam or slab is to be propped until the supported construction has
reached the age when the propping may be removed.
No supports for the shuttering may be left in the finished concrete without the
written permission of the Engineer.
3.13.8 Concrete Below Ground
All concrete placed below ground level shall have a minimum protection to its
outside faces with a bituminous membrane as per Clause 9.2.1.2 of this
Specification.
3.14 READY MIXED CONCRETE
3.14.1 Compliance with Specification
The use of concrete delivered to the Site in a plastic condition and ready for
placing in its final position shall be permitted subject to the following conditions:-
(a) The constituent materials and the concrete mix shall comply with the
requirements of this Specification.

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(b) The concrete shall be produced in accordance with the standards laid down
in the current edition of the "Authorisation Scheme for Ready Mixed
Concrete", published by the British Ready Mixed Concrete Association
(B.R.M.C.A.), except that
(i) Para. 11.1 (i) of the above publication shall be replaced by item (d) below.
(ii) Water shall be added to the mix under the control of the central batching
plant.
(iii) Dry batching with water added on site will not be permitted.
(c) The concrete shall be supplied by a depot approved by the Engineer and
Dubai Municipality.
(d) The concrete shall be placed in its final position and left undisturbed within 1-
1/2 hours maximum of the time when the cement first comes into contact
with wetted aggregates, ie. the time when hydration of the cement
commences. If the temperature is less than 4C or if the temperature is
above 21C, this period shall be reduced to one hour.
3.14.2 Documentation
The Engineer shall receive copies of the delivery tickets for each batch of
concrete, and have access to a site record book maintained by the Contractor in
which the following information is recorded for each batch of concrete delivered:-
(i) Delivery ticket number.
(ii) Slump of the concrete, testing on site immediately prior to placing.
(iii) Time when concrete is placed in position and left undisturbed.
(iv) Location that the concrete is placed.
(v) Works test cube reference.
3.15 REINFORCEMENT STEEL
3.15.1 General
This work shall consist of furnishing, fabricating and placing steel reinforcement
bars of the grade, type, quality, size, shape and quantity designated, all in
accordance with these Specifications and the details shown on the Drawings.
The Contractor shall be responsible for furnishing reinforcing steel in sufficient

quantity and of the proper sizes, lengths and shapes shown on the Drawings for
any given structure.

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3.15.2 Material Specifications
All reinforcement bars shall be of a deformed type in accordance with BS 4449,

except that plain bars may be used where specifically indicated on the Drawings.
Plain bars shall be in accordance with BS 4449.
All steel reinforcement shall conform to the requirements of the Specifications for
Deformed High Yield Steel Bars, Grade 460 Type 2, unless otherwise shown on
the Drawings or specified by the Engineer and shall be tested as per BS 4449 :
1997.
Mild steel where specified or called for shall be either deformed or plain bars
complying with ASTM A615 structural grade or BS 4449 or any equivalent National
Standard as directed and approved by the Engineer.
Tying wire shall be No.16 gauge soft annealed iron wire or No. 18 gauge stainless
steel wire or the equivalent AASHTO specification for tying wire.
Welded wire fabric shall be used as reinforcement for concrete where shown on
the Drawings and as directed. Welded wire fabric shall conform to the
requirements of AASHTO M55 or to BS 4483.
All reinforcement shall be protected against corrosion with a fusion-bonded epoxy

coating in accordance with the requirements of ASTM A775/A775M and BS 7295.
The Contractor shall be responsible for obtaining the Engineer’s approval to the
steel bars prior to coating commencing. Such approval will in no way relieve the
Contractor of his responsibilities under the Contract.
The Contractor shall furnish to the Engineer a certificate of compliance for each
shipment of coated steel 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 of the Specifications.
3.15.3 Construction of Reinforcement
Steel reinforcing shall be stored on timber packing clear of the ground. The steel
bars shall be free from sharp deformations, rolled-in silvers, deep recesses or
surface faults/blemishes which could result in inefficient or inadequate coating.
When fixed in the work and immediately prior to concreting, steel reinforcing shall
be entirely free from loose mill scale, loose rust, oil, grease, paint, mould oil, and
all other deleterious and extraneous material. All hooks, bends, etc., unless
otherwise shown on the Drawings shall be to BS 4466.
Before ordering reinforcing steel, the Contractor shall prepare bar bending
schedules at his own cost and submit them to the Engineer for his approval. Bar
schedules shall show the weight of each bar, the total weight of each bar size and
the total weight of bars, and bending diagrams for bars in accordance with BS
4466. The length of each bar shall be calculated in accordance with BS 4466
except that the minimum internal bending radius shall be four times the bar
diameter.

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The Contractor shall also provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of bar bending schedules or for the completion of the
Works.
The Engineer’s approval of the Contractor’s working drawings and bar bending
schedules shall in no way relieve the Contractor of responsibility for the
correctness of such drawings or schedules.
Steel reinforcement shall be bent accurately to the shapes and dimensions shown
on the approved bar bending lists or drawings. Bars shall be bent round mandrels
of the requisite diameter.
Steel reinforcement shall be cut and bent in accordance with BS 4466. Cutting or
bending by the application of heat is not permitted. Welding of reinforcement shall
only be permitted when approved in writing by the Engineer. If such approval is
given then the workmanship shall be in accordance with BS 5135. The Contractor
shall submit full technical details of his proposed procedures prior to seeking
approval.
Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than four
times the nominal size of the bar.
Links, hoops, stirrups are generally to be bent round pins of the same diameter as
the bars they are to embrace. Where however, such bars are less in diameter than
twice the diameter of the link, the radius of the bend shall be equal to the diameter
of the link.
3.15.3.1 Placing Reinforcement
The number, size, form and position of all reinforcement shall, unless otherwise
directed or authorized by the Engineer, be strictly in accordance with the Drawings.
Nothing shall be allowed to interfere with the disposition of the reinforcing bars.
Bars generally must be of the required lengths. Welding of the bars will not be
permitted. Lapping of the bars other than the lap splices shown on the Drawings
should be avoided. The Engineer may approve certain lappings under special
conditions. All lappings should comply strictly with the AASHTO specifications,
namely Article 1.5.6. Clause "c".
The steel reinforcement shall be firmly held in position by wire ties and concrete
blocks or other approved spacers designed to maintain the correct clear cover of
concrete over steel reinforcement. They shall be as small as possible consistent
with their purpose, and of a shape acceptable to the Engineer. Minimum cover to
reinforcement shall be 50 mm unless otherwise detailed. The position of spacers
and their method of use shall be approved by the Engineer. The steel
reinforcement shall be so connected as to form a rigid cage.
All intersecting bars shall be bound together with No.16 gauge soft iron wire with
the ends of the wire turned into the main body of the concrete.

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3.15.3.2 Maintaining Reinforcement in Position
Concrete distance blocks shall, unless otherwise directed, be used between the
reinforcement and the bottom and sides of the forms to ensure correct placing and
cover of the bars. The strength of such concrete distance blocks shall be not less
than that of the main concrete. The greatest care shall be taken to prevent any
displacement or bending of the members of the reinforcement adjusted and
temporarily fixed in position before commencement of the concreting.
Reinforcement temporarily left projecting from the concrete at construction of other
joints shall be adequately protected against displacement both during concreting
and afterwards and shall not be bent out of position unless agreed by the
Engineer's Representative. During the concreting competent steel fixer shall be in
attendance to re-set any reinforcement inadvertantly displaced.
3.15.3.3 Approval of Reinforcement Before Concreting
The Contractor shall in all cases request the approval of the Steelwork by the
Engineer's Representative in sufficient time to allow an inspection to be made and
between the Contractor's request for approval and his intention to commence
concreting shall not be less than one clear normal working day and the Engineer's
Representative may require a longer period if, in his opinion, the reinforcement is
of such complexity as to require it.
Contract.
3.16 PRECAST CONCRETE KERBS, EDGINGS & QUADRANTS
Precast concrete kerbs and edgings shall be hydraulically pressed and they and
precast concrete quadrants shall comply with the requirements of BS 7263: Part 1
and to the dimensions and shapes shown on the Drawings and/or as directed by
the Engineer. They shall be Class B concrete with sulphate resisting cement as
indicated in Clause 3.2.7 of this Specification. They shall be uniform in colour free
from cracks, flaws or other defects with well defined arises.
The kerbstones shall be 900 mm long or as directed by the Engineer's

Representative. Samples of kerbstones proposed to be used shall be submitted to
the Engineer for his approval prior to order or manufacture. Kerbstones shall not
be used before they have been inspected and approved by the Engineer. They
shall be fully cured when delivered to site (28 days min.).
Kerbstones shall be laid on concrete Class C bedded on 1:3 sand cement mortar
as specified and/or as directed by the Engineer. All kerbstones shall be well
bedded and settled in place true to line and level with a suitable wooden mould.
Before kerbstones shall be approved it should be ensured that their top surfaces
are in a uniform plane and their front faces are in correct alignment. Any
kerbstones not satisfying these requirements or having cracked or broken arises or
faces shall be removed and replaced or reset as instructed by the Engineer.
Joints between kerbstones shall be not less than 3 mm nor greater than 5 mm in
width and shall be uniform from top to bottom. Joints shall be left open.
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Where precast kerbs of straight section are laid to form radii, joints should be filled
with non-shrinkage mortar, and expansion joints (using flexel or similar joint filler)
shall be provided at 3 m centres. For radii of 10 m or less quadrants shall be used.
Kerbs of a reduced size shall only be used for this condition where approved by
the Engineer.
Tolerance in top level of kerbstones and horizontal alignment shall be  3 mm.
All kerbstones shall be painted alternately black and white. The paint shall be an
approved concrete paint giving a nominal thickness 100 microns in two applied
coats.
Tranverse strength and Water Absorption shall be in accordance with BS 7263 :

Part 1.
3.17 IN-SITU CONCRETE EDGING
In-Situ concrete edge strips shall be to the cross section shown on the drawings
and the class of concrete made with sulphate resisting cement indicated thereon in
accordance with Clause 3.2 of this Specification.
The edge strip shall be formed in as long lengths as possible and the form work
shall be set on the top surface of the sub-base, set to produce the line and level in
accordance with the requirements of this Specification. Care must be taken to
ensure that the top surface is carefully finished to achieve these requirements and
to provide the control of the wearing course. Expansion joints will be provided with
an approved joint filler at maximum 3 m centres as shown on the drawing and/or
as directed by the Engineer. The kerb shall be protected against covering or
splashing by bitumen or cement.

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SECTION 4 - PIPES, PIPEWORK, MANHOLES AND CHAMBERS
4.1 PIPE MATERIALS
4.1.1 Pipe Classifications and Pressure Ratings
For structural purposes pipes shall be classified into two groups:-
Group A : Rigid pipes which do not depend on lateral support from the
bedding and trench sides for structural strength.
Concrete
Clayware
Asbestos Cement
Pitch Fibre
Grey Iron
Group B : Flexible pipes which depend on lateral support from the bedding
and trench sides for structural strength and to prevent distortion.
Pipe materials include :-
GRP (Glass Reinforced Plastic)

uPVC (unplasticised Polyvinyl Chloride)
PP (Polypropylene)
Pressure pipes shall be supplied to the following rated pressure

classifications:-
Asbestos Cement 18 bar

GRP 12 bar
uPVC 12 bar (12 bar rated uPVC
pipes used to allow for temperature
derating).
4.1.2 Joint Requirements and Limitations
Unless pipes are detailed with rigid joints or are specified differently all pipelines
shall be jointed with approved mechanical, flexible joints with elastomeric joint
rings. The whole joint assembly shall be compatible with the pipe construction and
with the specified performance of the completed pipeline.
4.1.2.1 Flexible Joints
Flexible joints shall be as a separate sleeve coupling and double spigot assembly
with two sealing rings.

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Elastomeric joint sealing rings shall be manufactured to EN-681-1 from ethylene

propylene rubber (EPDM) and shall have a hardness measured in International
Rubber Hardness Degrees (IRHD) compatible with the pipe material.
Deflection: The completed joint shall be capable of accepting the following

ranges of deformation when subjected to internal pressure without
losing its seal at the specified test pressure, without direct contact
between spigot and socket/coupling and without inducing stresses
or strains in the pipe material beyond the safe working limits.
Table 4-1. Minimum Allowable Angular Deflection for Flexible Joints
Pipe Material Pipe Diameter (mm) Angular Deflection

(Degrees)
All materials up to 200 3

(except concrete Over 200 to 500 1.75
and clay pipes) Over 500 to 1350 1
Over 1350 0.5
Straight draw: Not less than 10 mm or the following proportions of the length of
the longest pipe/unit at any joint:
1% for polyethylene pipes
0.5% for polypropylene, polybutylene or ABS pipes.
0.3% for GRP and uPVC pipes
0.1% for asbestos cement pipes.
Shear: Pipe materials which are listed in structural Group A shall be

loaded to 10 times DN (mm) in newtons in accordance with BS
EN-512. Pipe materials which are listed in structural Group B shall
be subjected to a load of 17.5 N/mm of pipe diameter in
accordance with ASTM D-4161.
If the approved standard for a pipe material does not include a

shear test for the jointing system, this test shall be carried out in
accordance with test procedure of another appropriate pipe
material standard.
4.1.2.2 Flanged Joints
Flanged pipes shall incorporate an annular gasket at the Joints and these gaskets
shall be manufactured to BS 4865 from ethylene propylene rubber (EPDM) 3.0
mm thick and shall be dimensioned to full face of the pipe flange and to suit the
flange drillings. The hardness of the rubber (IRHD) shall be to the manufacturer's
recommendations to suit the pipe material but for pipe materials in Group A shall
be in the range 66 to 75.

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4.1.2.3 Flange Adaptors
The adaptors shall be manufactured from rolled steel or approved material with an
approved coating and be capable of withstanding the pressure tests of the pipeline
in which they are incorporated. The adaptors shall accommodate a deflection at
least 3o between adjacent pipes in any direction and they shall be capable of
accommodating a movement of 10 mm between the ends of pipes they connect.
The adaptors shall be protected as stated in Clause 4.4.12.2. The adaptors shall
be jointed as instructed by the manufacturer.
4.1.2.4 Bolted Couplings
Bolted couplings shall be flexible couplings and shall be capable of withstanding

the pressure tests of the pipeline in which they are installed. They shall also be
capable of accommodating the deflections and movements specified for flange
adaptors.
4.1.2.5 Nuts and Bolts
All bolts, nuts and washers shall be of stainless steel grade 320S17 to BS 970:
Part 1 or DIN 17440:1.4571 and shall remain unpainted. PTFE washers shall be
fitted beneath stainless steel washers for both bolthead and nut.
4.1.2.6 Shipping and Handling
All elastomeric joint sealing rings and gaskets for flanged pipes shall be supplied
and transported in light proof packaging so as to prevent damage due to ultra
violet radiation. The Contractor shall provide suitable storage facilities to prevent
ultra violet exposure until use.
4.1.3 Asbestos Cement Pipes and Fittings
Asbestos cement pipes, joints and fittings shall be manufactured and tested to ISO
160 or BS EN512 for all pipelines. Sulphate resisting cement with a medium to low
C3A content shall be used in the manufacture of asbestos cement pipes, joints
and fittings.
Asbestos cement pressure and gravity pipes and joints shall be Class 18 unless
For gravity pipes the crushing strength shall be carried out on one percent of the
total number of pipes and joints. For pressure pipes the bursting test shall be
carried out on one percent of the number of pipes and fittings.
A jointing ring shall be provided at each end of the pipe this being rubber or
neoprene or a compound of both. Internal test pressure and the prevention of
infiltration of groundwater are to be the major design criteria of the joints. The
Engineer shall be given details of vacuum-type tests on the joints.
All bends and fittings required along the route of the pressure pipelines other than
those bends obtained by deflection of the pipe joints shall be of GRP material.
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Bends and fittings shall be obtained from the same supplier as the asbestos
cement pipes and shall be compatible with the pipes and jointing system used.
Clearly visible, legible, indelible manufacturer's stamps including designated class

of pipe and production date shall be provided on the external face of all pipes.
For identification purposes, all asbestos cement pipes and fittings laid for drainage
application shall be externally coated with a black bituminous paint. Potable water
pipelines in asbestos cement are uncoated.
All relevant tools recommended by the manufacturer shall be provided by the

Contractor and he shall ensure that he has sufficient numbers of each tool
available in order that the work is never held up for the need of any such tool.
4.1.4 Unplasticised Polyvinyl Chloride Pipes and Fittings (uPVC)
uPVC non-pressure pipes and fittings shall be manufactured and tested to BS

4660 for pipes upto and including 160 mm diameter and BS 5481 for pipes greater
than 160 mm diameter; and to BS 3505 for pressure pipes.
uPVC pipes and fittings shall be installed in accordance with the manufacturer's
guidelines. Pipes shall be BS kite marked.
uPVC pipes shall be capable of withstanding ultraviolet degradation. A rodent

inhibitor shall be incorporated in the material of the pipe. Pipes shall be
manufactured with integral flexible rubber ring joints.
uPVC pipes for gravity pipelines shall have a standard dimension ratio, D:t
(diameter to thickness), of between 35 and 45.
The Contractor shall advise the manufacturer of the climatic and transporting
conditions at the site of the works and shall seek his advice on the storage of
uPVC materials on site. Subject to the Engineer's approval this advice shall be
followed at all times.
Any pipes exhibiting cracks, notches or deep scratches or other damage will be
condemned and shall not be incorporated into the permanent work under any
circumstances.
4.1.5 uPVC Pipes for Land Drains
Pipes for slotted land drains/slotted carrier drains shall be uPVC pipes. Prior to
perforation, the basic pipe shall be manufactured to BS 4660 and BS 5481, kite
marked, and shall comply with the requirements of Clause 4.1.4 of this
specification relating to uPVC pipes for non-pressure application. The slots shall
be designed to give at least the minimum infiltration rates laid down in BS 5911:
Part 114. The final configuration of the slots shall be subject to approval by the
Engineer.
The slots shall be cleanly machine cut and be not less than 3 mm or greater than 4
mm in width. The slots shall be in one 180 segment of the barrel in one or more
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longitudinal rows, the slots in each row being spaced equidistantly. Where more
than one row of perforations are provided the slots shall be staggered. No slots
shall be nearer to the ends of the barrel than the spacing between two adjacent
slots. The spacing between slots in any row may vary up to  20 mm.
The minimum cross-sectional area of the perforations, at the inside surface of the
pipe barrel, shall be 2700 mm2 per metre run of pipe but shall not affect the
structural integrity of the pipe. Care must be exercised to prevent impact damage
when placing stone surround and during backfilling operations over the pipes.
4.1.6 Glass Reinforced Plastic Pipes and Fittings (GRP)
4.1.6.1 General
Pipe manufacturers must be members of, or affiliated with, a quality control or

certification authority relevant to the pipes or fittings proposed for incorporation in
the Works. ISO 9001 certification is required for pipe manufacturers.
GRP pipe and fittings shall be manufactured in accordance with BS 5480. Resins
shall comply with BS 3532 or ASTM D1763. GRP pipe and fittings shall be at least
adequate to achieve a minimum working life of 50 years under all applicable
loading, environmental and installation conditions. The pipes and fittings shall be
designed to withstand up to 5% long term deflection in their installed conditions.
GRP pipe and fittings shall be supplied with a rated pressure of 6 bar for gravity
pipes and shall be suitable for service temperatures up to 50oC.
GRP pipe and fittings shall be composite laminate consisting of a corrosion

resistant inner liner, a structural layer and an exterior layer as follows:
1. The resin-rich inner liner shall have a minimum thickness of 1.5 mm,
consisting of ‘C’ glass veil backed with chopped strand ‘ECR/ADVANTEX’
glass all impregnated with vinylester resin.
2. The structural layer shall be reinforced with ‘ECR/ADVANTEX’ glass

impregnated with isophthalic resin but a vinylester resin may be used
throughout. Silica sand may be included as a stiffener agent.
3. The exterior resin-rich layer shall have a minimum thickness of 1.0 mm

consisting of ‘C’ glass veil impregnated with isophthalic or vinylester resin.
Silica sand aggregates as defined in BS 5480 shall contain no impurities. Fillers

as defined in BS 5480 shall not be used. The silica sand content of the pipe
material shall not exceed 50% in accordance with the test type submitted for
approval.
The resin shall be cured to reach a hardness not less than 90% of the resin
manufacturer's recommended hardness using a prescribed test.
A manufacturer's tolerance of ± 1.00% shall be allowed on the nominal diameter of

the pipe. The pipes shall be supplied in standard lengths of 3, 6 or 12 metres with
a tolerance of ± 25.00 mm. The deviation from straightness of the bore of the pipe
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shall not exceed 0.30% of the effective length or 15.00 mm whichever is smaller
and shall apply when measured on site. Up to 10% of the pipes will be allowed in
random lengths.
The ellipticity of any pipe when measured resting freely on the ground shall not be
more than 2% of the mean diameter at any point. No pipe known to have
undergone a deflection greater than 7% shall be incorporated into the Works.
Stiffness shall be minimum 5000 N/m2 for all pipes but for pipes to be used in
pumping stations and valve chambers the stiffness shall be minimum 10,000 N/m2
and pipes for use in microtunnelling or similar jacking operations the stiffness shall
be minimum 50,000 N/m2 unless enclosed in concrete.
The hoop flexural modulus shall be demonstrated by application of the following

equation:
Stiffness of the pipe = EI/D3
Where : E = bending modulus of pipe wall

circumferentially (in N/m2).
I = moment of inertia of pipe wall per

unit length (in m4/m)
D = nominal pipe diameter in metres
Calculations shall be provided to show that the proposed form of pipe manufacture
will give the specified physical properties identified in this specification.
Pipes shall have a resistance to longitudinal tensile force per unit of circumference
as under:-
Nominal Diameter (mm) Initial Ultimate Resistance (N/mm)
up to 700 100
700 to 1,000 120
1,000 to 1,600 160
1,600 to 2,400 250
2,400 to 4,000 300
When subjected to a parallel plate loading test no evidence of crazing or cracking

shall be evident with a deflection of 10% and no structural failure with a deflection
of 20%.
Evidence from the manufacturer shall be provided of the satisfactory completion of

the "strain corrosion test" on a sample of pipe representative of those to be
supplied together with an assurance that such tests are continuing. Testing shall
be in accordance with BS 5480 or ASTM D-3681. The appearance of blisters,
delamination, wicking or any other structural degradation of the test sample will
constitute failure of the test notwithstanding the wording of the standard test
procedure.

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The jointing system shall be an approved coupling system. Where the system
involves separate reinforced plastic couplings of sockets formed by a lay-up
process subsequent to pipe production, the resins used shall be clear and non-
pigmented to permit visual examination within the laminate.
Where GRP laminate is cut, exposed ends shall be sealed with a suitable resin
and approved prior to incorporation into the Works. Where such cutting and
sealing takes place at site the resins used and the methods of storage, mixing,
application and curing shall be strictly to the manufacturer's recommendation.
Before any such work takes place the manufacturer's representative shall visit the
site to demonstrate and give clear procedural advice to the Contractor in the
presence of the Engineer.
GRP pipe and fittings shall be as uniform as commercially practicable in colour,

opacity, density, and other physical properties.
GRP pipe and fittings shall be smooth and both the internal and external surfaces
shall be clean and free from delaminations, cracks, bubbles, pinholes, pits, blisters,
foreign inclusions and resin-starved areas that due to their nature, degree or extent
detrimentally affect the strength and serviceability of the pipe.
Unless authorized by the Engineer, repair will not be permitted on any pipes with
defects as listed below and such pipes shall not be incorporated into the works:-
(1) A scratch of greater depth than 0.30 mm.
(2) Cracks of any type on the inside of the pipe.
(3) Cracks on the outside, longer than 200 mm circumferentially or 6 mm

longitudinally.
(4) Delaminations.
(5) Damaged ends including bubbles, cracks, voids, exposed reinforcement

or extraneous matter.
(6) Internal protruding fibres.
(7) More than 25% of the external area with protrusions of any sort.
(8) Air voids and blisters exceeding 5 mm diameter or 1 mm in depth, greater

in area than 0.50% of internal or 1.00% of external surfaces.
(9) Pitting to more than 5% of the internal or 10% of the external surface area
and individual pits more than 1 mm diameter or 0.5 mm in depth.
(10) Wrinkles over than 3% of the surface area and individual wrinkles more
than 2 mm deep.
4.1.6.2 GRP Pipes and Fittings for Pumping Stations and Valve Chambers

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The design of GRP pipe and fittings for pumping stations and valve chambers shall
incorporate all the requirements of these specifications except for the following
over-riding or supplemental stipulations.
GRP pipe and fittings inside pumping stations and chambers shall be designed for
use above ground with no thrust blocks and shall have sufficient axial strength to
resist end thrust, temperature and bending stresses.
GRP pipe and fittings shall have a minimum pipe stiffness of 10,000 N/m2 and a
minimum wall thickness of 10 mm.
The design working pressure for pipes and fittings shall be 10 bar and the service
temperature shall be 50°C. A minimum surge allowance of 40% above the working
pressure shall be included in the design of pipes and fittings. Copies of the design
calculations shall be submitted to the Engineer for approval. The basis of design
shall be checked by conducting 'type' tests on representative sample(s) of
manufactured materials, in accordance with the requirements of BS 5480 or ASTM
D-2992.
The wall of the pipes and fittings shall be made up of:
1. A resin-rich inner liner of 1.5 mm minimum thickness, consisting of ‘C’ glass

veil, and 'ECR/ADVANTEX' glass and impregnated with vinylester or epoxy
resin.
2. The structural layer consisting of ‘ECR/ADVANTEX’ glass reinforcements

impregnated with vinylester or epoxy resin. Silica sand shall not be used.
3. An exterior resin-rich layer of 1.0 mm minimum thickness, reinforced with a ‘C’

glass veil and impregnated with vinylester or epoxy resin.
No dark pigments, sand or aggregate fillers shall be used for pipes and fittings.
Ultra Violet stabilizers shall be incorporated in the pipe and fitting construction.
GRP pipe and fittings for pumping station and valve chamber pipework shall have
a suitably designed restrained joint capable of withstanding the design operating
pressure with no leaks and without the use of thrust blocks.
The acceptable jointing system shall be GRP flanges. GRP flanges shall be
machine filament wound using 'E' or 'ECR/ADVANTEX' glass fibre reinforcements
and vinylester or epoxy resin. Hand layed up flanges shall not be permitted.
Flanges shall be drilled to BS 4504 (metric units) type PN 10.
4.1.6.3 Factory Testing
The following tests shall be carried out on manufactured GRP pipe and fittings at
the intervals specified. Test methods shall be in accordance with BS 5480 or
ASTM equivalent. Witnessing of factory testing by the Engineer's Representative
will be required prior to delivery of the material. Copies of the Manufacturer's test
reports shall be submitted to the Engineer after each consignment of pipe or fittings
delivered to the site.

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All GRP standard pipe and pipe used for fitting fabrication shall be factory pressure
tested to 20 bar for pressure pipes and 12 bar for non-pressure pipes.
The following tests shall be conducted on all GRP pipe and fittings:
- Dimension measurements (Wall thickness, Diameter, Length)
- Visual inspection
- Barcol Hardness (Resin Cure)
Mechanical property testing shall be conducted on 1% of GRP pipe and fittings

produced.
Other tests for quality assurance shall be carried out on representative sample(s)
as required by BS 5480 or ASTM equivalent.
4.1.6.4 Installation
GRP pipe and fittings shall be installed in accordance with the manufacturer's
written instruction. A field representative of the manufacturer shall be made
available as and when required during the installation of the GRP pipe and fittings.
All flanges shall be tightened in accordance with the Manufacturer's written
instructions using a torque wrench.
4.1.7 Polyethylene Pipes (HDPE or HPPE)
4.1.7.1 General
Polyethylene (PE) pipe, either high density polyethylene (HDPE) or high

performance polyethylene (HPPE) pipe shall be manufactured to conform to the
requirements of CP 312 Part 1 and 3, and BS 6437 or DIN 8075. Where pipes are
used for renovation work, pipes shall be of short lengths or short length conforming
to the requirements of the method selected and the available working space in the
manholes or drive shafts. Longer lengths may be used for new installation where
conventional open trench methods of construction are employed.
The base polymer shall be polyethylene with a derived density greater than 930
kg/m3 when determined in accordance with the method required by BS 3412. The
base polymer shall be blended with additives that are necessary for the
manufacture, storage and use of PE pipes for sewer lines, including antioxidants,
carbon black and UV stabilizers.
The material in pipe form shall have a thermal stability of at least 15 minutes when
tested in accordance with the isothermal method for differential thermal analysis.
The ovality of pipes up to and including nominal size 250 mm shall not exceed 0.02
the nominal size (mm). The ovality of pipes greater than nominal size 250 mm shall
not exceed 0.035 the nominal size (mm).
The ends of the pipe shall be cut, cleanly and squarely, to within the following
tolerances
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Nominal Size (mm) Maximum Out of squareness
180 - 225 4 mm
250 - 315 5 mm
The calculated 24 hour and 50 year creep module shall be not less than the values
given below when tested in accordance with either the pipe ring in tension or the
three point bend method.
Property Minimum Mean Requirement
Short term flexural creep

modulus (24 hour) Es 350 MPa
Long term flexural creep

modulus (50 year) El 130 MPa
The jointing system for polyethylene pipes and fittings shall be in accordance with
the pipe manufacturer’s recommendations subject to approval by the Engineer.
4.1.7.2 Wall Thickness
The polyethylene (HDPE or HPPE) pipe shall be Type 50 i.e. shall be designed to
sustain a maximum working stress of 50 bar at 20°C. The wall thickness shall be
based on a nominal pressure rating (PN) of 10 bar.
When manufactured in conformity with BS 6437, the wall thickness of HDPE pipe
shall be as follows:-
Table 4-2. Required Wall Thicknesses of HDPE Pipes
Nominal Mean outside Wall thickness (mm)

Size diameter (mm) Individual values Av.values
(mm)
min. max. min. max. max.
180 180.0 181.2 16.4 18.9 18.3
225 225.0 226.4 20.5 23.6 22.8
250 250.0 251.5 22.8 26.3 25.3
280 280.0 281.6 25.5 29.4 28.3
315 315.0 316.8 28.7 33.0 31.8
4.2 STORAGE AND HANDLING OF PIPES
4.2.1 General
Method Statements must be approved for the transportation, handling and storage
of pipes before any pipes are delivered to site.
All pipes shall be handled and stored in compliance with the manufacturer's
recommendations subject to the following limitations:-
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Pipes shall be transported, handled and stored with such packing and in such a
manner that damage does not occur and that contact is avoided with sharp edges
which may cause damage. During transit, pipes and fittings shall be well secured
and adequately supported along their length.
At every point of loading or unloading, all pipes or castings must be handled by

approved lifting tackle unless specified elsewhere. Unloading by rolling down
planks or any other form of inclined ramp will not be allowed. Pipes shall not be
tipped or dropped.
Pliable straps, slings or rope shall be used to lift pipes, and steel cables or chains
will not be used without written permission.
Nesting of pipes for transportation will be permitted provided method statements

demonstrate that effective precautions will be taken to protect inner surfaces from
damage.
All pipes and fittings shall be thoroughly inspected on arrival at site after off-
loading and prior to installation for detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For

other damages, proposals for repairs shall be submitted in writing for the
Engineer's approval. If in the Engineer's opinion the nature of any damage is such
that the condition of a pipe has been impaired and cannot be repaired, the pipe
concerned shall not be incorporated in the Works.
Suitably smooth and level storage areas shall be provided at or near the site and
made secure to prevent unauthorised access.
Pipes of different sizes and thickness shall be stocked separately.
4.2.2 Glass Reinforced Plastic Pipes (GRP)
When pipes are transported or stacked they shall be supported on cradles at least
100 mm wide, conforming to the shape of the pipe placed at not more than 3
metres centres. Pipes must on no account be stacked directly on the ground but if
individual pipes are placed on the ground prior to laying care shall be taken to
remove all rocks and any potentially damaging debris.
The number of layers in a stack shall not exceed the following:
Internal Diameter Maximum Number

of Pipe (mm) of Layers
Up to 500 5
500 to 700 3
The end pipes in each row shall be strapped to the battens. Pipes shall not rest
on their sockets.
4.2.3 Thermoplastic Pipes

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Pipes and fittings of plastic materials smaller than 300 mm diameter may be
handled manually and those equal or larger than 300 mm diameter shall be lifted
using a single fabric or large diameter rope sling. There shall be enough slack in
the sling to keep the hook at least 600 mm over the pipe. Use of wire rope chains
and fork lifts shall not be permitted.
Care shall be taken to prevent distortion of the pipes during transportation,

handling and storage. They shall be stacked either on bearing timbers on a level
surface staked to prevent movement, or in suitable racks. Not more than two
layers shall rest on the bottom layer, and for spigot and socket pipes, sockets
shall be at alternate ends so that no pressure comes on a socket. Bearing
timbers shall be spaced at not more than 1 metre and shall be wide enough to
prevent denting of the pipe wall. Sharp edges (e.g. of metal) shall be avoided.
Similar care shall be taken with pipes in transit.
Where shaped battens are used, they shall be at least 100 mm wide and not
more than 1.5 meters apart. The end pipes in each row shall be strapped to the
battens. The pipe shall not be stacked any higher than five (5) layers.
All thermoplastic pipes shall be shaded/protected from direct sunlight during

handling, transportation, storage and laying.
The Contractor shall ensure that thermoplastic pipes do not come into contact
with bituminous or other hydrocarbon based materials.
4.3 GRANULAR MATERIAL FOR PIPE BEDDING
Granular material for pipe bedding shall be free-draining, hard, clean, chemically
stable gravel or crushed stone to BS 882 and shall be graded in
accordance with BS 882 : Part 2 as shown in the following table:-
Table 4-3. Grading of Granular Material for Pipe Bedding
Test Sieve Percentage by Weight Passing Sieve

( mm) For Pipe For Pipe Diameters
Diameters upto 600 mm 400 mm and above
63 - -
37.5 - -
20 - 100
14 100 85 - 100
10 85 - 100 0 - 50
5 0 - 25 0 - 10
2.36 0- 5 -
Notes:
1) For pipes 400 mm to 600 mm diameter, either grading is acceptable.
2) Total acid soluble content of the material when tested in accordance with
BS1377 shall not exceed 0.3 percent by weight of sulphate expressed as
SO3 (sulphur trioxide).
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3) The material shall have a Compaction Fraction value not exceeding 0.15.
4) For uPVC pipes only rounded aggregates will be permitted but for all other
pipe materials crushed aggregates may also be used.
4.3.1 Stone for Land Drains
Stone for land drains shall be nominal single size 20 mm in accordance with the
following table or the manufacturer’s recommendations if different, and placed as
shown on the drawings. The stone shall also comply with the general
requirements of Clause 4.3.
Table 4-4. Grading of Stone for Land Drains

(mm)
75 -
63 -
37.5 100
20 85-100
14 -
10 0 - 25
5 0- 5
2.36 -
4.3.2 Compaction Fraction Test
For testing pipe bedding material, a representative sample of about 40 kg shall be

heaped onto a clean surface and quartered to obtain approximately 10 kg. The
moisture content of the sample should not differ materially from that of the main
body of material, at the time of use in the trench.
A 150 mm internal diameter open ended cylinder 250 mm high, shall be placed on a
firm flat surface and loosely filled, without tamping, from the 10 kg sample. Any
surplus material shall be struck off level with the top of the cylinder. The area around
the filled cylinder shall be cleared of all surplus material and the cylinder then lifted
clear of its contents and placed alongside the material.
Approximately one quarter of the material shall then be replaced into the cylinder
and compacted by tamping vigorously with a 40 mm diameter metal rammer
weighing about 1 kg until no further compaction can be obtained. This operation
shall then be repeated for each of the remaining quarters, tamping the final surface
as level as possible.
The distance from the top of the cylinder to the surface of final layer shall then be
measured and this value, divided by the height of the cylinder, shall be taken as the
Compaction Fraction.

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4.4 CONVENTIONAL (OPEN TRENCH) PIPELINE CONSTRUCTION
4.4.1 General
This section applies to conventional open-trench pipe works. Non-conventional

pipeworks have been detailed in Sections 14 and 16.
4.4.2 Nominal Trench Widths
Nominal trench widths for single pipelines shall be defined as 1.50 times the
diameter plus 500 mm, subject to a minimum trench width of 750 mm.
Nominal trench widths for two or more pipes in the same trench (laid in parallel
with similar invert levels) shall be defined as the sum of the internal diameters plus
450 mm between the pipes, plus 750 mm.
Any excavation from the bottom of the trench to 300 mm above the level of the
crown of the pipe which exceeds the nominal widths defined above shall be filled
with concrete or the specified bedding materials as directed on site.
A detailed method statement shall be submitted by the Contractor for agreement

by the Engineer to demonstrate an understanding of the correct method of laying
GRP and other pipes.
4.4.2.2 Pipelines in Wide Trenches
No wide unsupported trenches shall be permitted, in general, within the area of the
Works and therefore all trenches should conform to the minimum trench widths
stated above and shall be supported with the use of approved trench sheeting or
sheet piles. However in exceptional circumstances wide trenches may be
approved by the Engineer in which cases the following shall apply :-
- Wide trenches shall be constructed to not less than the defined widths for
those categories of Group B flexible pipelines in granular bedding defined
below.
- Prior to commencing trench excavation in an area an assessment of the

Modulus of Deformation (E's) shall be made of the soils likely to be
encountered at springing level of the pipes. In non-cohesive soils, approved
static cone penetrometer tests shall be carried out prior to excavation. In
cohesive soils other approved methods shall be used to determine E's.
Alternatively, standard penetration tests may be required by the Engineer prior
to excavation to suite pipe manufacturer’s standard method of deflection and
trench widths. Tests shall be carried out at intervals to be determined on site
which in variable ground conditions may be to every pipe length.
- If the value of E’s determined from the results of such tests is greater than 2.5
MN/m2 then trench width is not critical. If less than 2.5 MN/m2 then trench
widths shall be constructed to the widths defined in the following table unless
alternative means of increasing the passive resistance of the trench sides are
detailed or are proposed in method statements where economic or
environmental restrictions make wide trenches undesirable.
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Table 4-5. Wide Trench Widths for Non-Cohesive Soils
Static Cone Modulus of Wide TrenchWidths

Penetrometer Test Deformation (mm)
2 2
(Kg/cm ) E's (MN/m )
8.5 - 7.7 2.50 - 2.25 2.5 * dia.
7.7 - 6.1 2.25 - 1.80 3.0 * dia.
6.1 - 3.1 1.80 - 0.90 4.0 * dia.
3.1 0.90 5.0 * dia.
Alternative solutions to wide trench conditions may be adopted including

increasing stiffness of the pipes used or encasing with concrete as agreed by the
Engineer.
4.4.3 Pipelaying and Jointing
Pipes and fittings shall be laid and jointed in accordance with all relevant
recommendations of the manufacturer. Any variations between the manufacturer’s
recommendations and this specification shall be highlighted in the Contractor’s
Method Statements and a ruling will be given with the Engineer’s agreement.
Pipes and fittings shall be checked for soundness and be thoroughly cleaned out
immediately prior to laying and jointing.
The setting of the pipeline to the required levels and alignment shall be carried out
by approved procedure such as boning between sight rails or the use of laser
systems. Sight rails, if used, shall be at a suitable height vertically above 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 pipelines under construction to any
one gradient. Large diameter pipes, 1000 mm diameter or greater, shall be
individually set to level and line by instrument.
For pipelines laid in trenches and headings the permissible tolerances in line and
level unless otherwise specified shall be ± 3 mm in level and ± 12 mm from
centreline between manholes or access points. Also where a gravity pipeline or
sewer is shown as a straight line between manholes it will not be accepted as
having passed the final test unless a full circular light can be sighted through the
bore of the pipe for the length concerned.
For pipeline jointing systems incorporating flexible jointing rings pipes shall be laid
with a gap between the end of the spigot and the base of the socket, or between
spigots. This gap shall be not less than 6 mm or greater than one third of the
straight draw test dimension specified for the pipe joint or as recommended by the
pipe manufacturer, and it shall be achieved by approved means, such as marking
the outside of the pipe or using removable metal or hardwood feelers.
The annular space between the pipe and the socket at a flexible joint shall be
sealed with an approved joint sealant to prevent the ingress of loose material or
concrete. Sealing shall be done on completion of a satisfactory preliminary testing
prior to concreting or backfilling, but not prior to the test.

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For uPVC pipes solvent welded joints with parallel sockets shall not be permitted
unless made in the manufacturer's workshop.
Where flexible jointed pipes are laid to curves the angular displacement at any joint
as laid shall not exceed three quarters of the maximum recommended by the
manufacturer.
Flanged pipes shall incorporate an annular gasket at the joints. The gaskets shall
cover the full face of the flange and shall have holes cut in them corresponding to
the bolt holes in the flanges. However, in pipes fixed vertically a plain ring covering
the flange between the bolt circle and the bore of the pipe may be used. Gaskets
shall be manufactured as specified in Clause 4.1.2.2.
When flanged joints are to be made the Contractor shall follow manufacturer’s
guidelines for the tightening of nuts and bolts.
The Contractor shall make sure that all joints are made strictly in accordance with
the manufacturer's instructions.
Pressure pipelines shall be secured at all changes in direction by concrete anchor

blocks or other means of restraint approved in advance by the Engineer.
After laying a length of pipeline but before preliminary testing (specified in Section
6) is carried out, the pipeline shall be checked for level and gradient on top of the
pipes. If a pipe is not at the correct level, it shall be unjointed and removed, the bed
shall be adjusted and the pipe shall be relaid and rechecked for line and level. After
the joint has been made and the preliminary testing completed the annular gap at a
socket or collar outside the flexible jointing ring shall be closed with fine grained
clayey soil or cotton waste to prevent the entry of granular material.
Pipelines shall be temporarily capped when pipe laying ceases to prevent the
ingress of foreign matter. The Contractor shall ensure that the pipes remain clean
and free from obstructions, and if required by the Engineer, the pipelines shall be
cleaned out using approved methods and equipment which do not damage the
internal lining of the pipes and manholes.
4.4.4 Pipelines in Concrete Cradles and Surrounds
Where pipes are to be laid with a concrete cradle or surround they shall be
supported initially above the trench bottom on concrete setting blocks. The blocks
shall either be laid accurately to level and covered with damp-proof sheeting
beneath the pipe barrel or shall be provided with two hardwood wedges each to an
approved pattern to enable the pipe level to be adjusted.
The blocks and wedges shall be of sufficient size and strength to prevent settlement
of the pipes during laying and at least two concrete blocks shall be provided for
each pipe.
Concrete cradles and surrounds shall be of Class A. The concrete shall be poured
on one side of the pipe until it can be worked under the pipe along its full length to
ensure that no voids develop. The concrete shall then be brought up equally on
both sides of the pipe until the required level is reached.
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The length of pipeline laid in any one operation before concreting the pipeline shall
be that which in the opinion of the Engineer permits accurate laying of the pipeline
and concreting in an efficient and proper manner.
Approved measures appropriate to the pipe material shall be provided to prevent

flotation or other movement during placement or curing of the concrete.
Concrete cradles to pipes of all diameters and surrounds to pipes of one metre
diameter or less shall be poured in a single lift. Concrete surrounds to pipes over
one metre diameter shall normally be poured in two lifts, with a horizontal joint not
more than 100 mm below the crown of the pipe.
Concrete cradles and surrounds shall be interrupted over their full cross sectional
area at each pipe joint, by shaped expansion joint filler. The thickness of filler shall
be 18 mm for pipe diameter less than 450, 36 mm for pipe diameter 450 to 1200
and 54 mm for pipe diameters greater than 1200.
In spigot and socket pipelines the joints in the bed shall be at the face of each
socket.
In all flexible joints the annulus of the pipe socket shall be sealed with an approved
sealant to prevent the concrete from entering the pipe joint.
When support to excavations is provided, building paper or an approved material

shall be placed against that support before concreting to facilititate withdrawal of the
support.
4.4.5 Pipelines on Granular Beds
Where granular beddings to pipelines are detailed the minimum thickness of

bedding material beneath the pipe shall be :-
150 mm (minimum 100 mm under sockets) for pipes not exceeding 300 mm internal
diameter.
200 mm (minimum 100 mm under sockets) for pipes exceeding 300 mm internal
diameter.
The time interval between placing bedding material on the trench formation and
commencing pipelaying shall be as short as is practicable.
The bedding material shall extend to the full width of the trench and shall be
compacted in layers not exceeding 200 mm. The bedding material shall be
carefully compacted using a plate vibrator or other approved equivalent mechanical
method. Sufficient passes of a plate vibrator or other approved mechanical method
are required to achieve positive deflection of flexible pipes to ensure that final
deflections are within the specified limits. Hand tamping or punning will only be
permitted where insufficient space is available to allow the use of mechanical plant.
Recesses shall be formed in the bedding to accommodate pipe joints while

ensuring continuous even support along the pipe length. Bedding material shall be
prevented form entering pipe joints. After the joint has been made bedding material
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shall be carefully placed and hand compacted beneath the joint barrel to close any
void left by the recess.
Where the formation of the trench is of silt or soft clay and is below the natural
bedding material directly above formation and carefully compacted if directed on
site.
4.4.6 Placing Surrounds to Pipelines
In narrow trenches and where the Contractor's method of working involves the use
of trench sheets or other forms of trench support it is imperative that the trench
supports are carefully withdrawn to a point above the crown of the pipe as the
backfill material is placed to ensure that voids between surround and trench side
will be eliminated. Where the Contractor is instructed to leave trench supports in
place, the tops shall be burned or cut off.
4.4.6.1 Group A Pipe Materials
Except where concrete surrounds are specified or shown on the drawings, either
granular bedding material or approved selected excavated granular material shall
be introduced at both sides of the pipe and compacted until it has been brought up
to at least 150 mm above the crown of the pipe.
The methods of selecting excavated materials may include sieving either in bulk or
above the trench.
Wherever practicable the placing and compaction of the surround material shall be
carried out in sequence with the removal of the trench supports. In particular trench
sheets or boards shall be raised clear of each layer prior to its compaction.
4.4.6.2 Group B Pipe Materials
Except where concrete surrounds are detailed Group B flexible pipelines shall be
laid with granular bedding and surround, as specified, to at least 300 mm above the
crown of the pipe.
4.4.6.3 Compaction of Pipe Surrounds

The granular material shall be carefully laid and compacted at the sides of pipes
according to one of the following methods for alternative types of compaction plant
as agreed with or directed by the Engineer.
Table 4-6. Alternative Methods for Compaction of Pipe Surrounds
Surround Max.Layer Alternative Methods (Minimum Number

Material of Passes of Compaction Plant)
Thickne
ss
(mm)
Hand Vibrating 100 kg Power
Rammer Plate Rammer
Gravel 200 2 2 2
Sand 150 3 4 4
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The Contractor must demonstrate that alternative methods of compaction will

provide positive deflection of flexible pipes during installation.
4.4.6.4 Pipelines Below Permanent Groundwater Level
For Group A and B pipelines located beneath the permanent groundwater level and
for all slotted pipes any granular bedding material or approved selected excavated
granular material forming granular bedding and surround shall be laid on and
enclosed within a geotextile filter fabric membrane.
4.4.7 Backfilling of Trenches - Pipelines/Structures
After completion of placement and compaction of the surrounds to the pipelines

backfilling of trenches for pipelines shall proceed using selected excavated
materials in accordance with the specifications for earthworks.
The use of power rammers will not be permitted over any pipe until the depth of fill
above the crown of the pipe is at least 300 mm.
Services warning tapes shall be placed over the pipelines as specified in Clause
4.4.15.
The backfill requirements for trenches around structures shall be the same as that
for pipeline except that compaction by mechanical means shall commence from the
formation level (to the specified densities).
4.4.8 Deflection Measurements on Group B Pipelines
4.4.8.1 General
All Group B pipelines will be subjected to in-situ deflection measurements. Any

section of pipe failing to meet the deflection criteria shall have its surround material
recompacted, such procedure being repeated until the in-situ deflection is found
to be satisfactory.
In the above paragraph deflection shall be considered as the maximum difference

between the measured in-situ diameter and the stated non-deflected diameter on
any axis divided by the non-deflected diameter.
For all pipes the horizontal and vertical deflections shall be measured at each end
at points 100 mm and 1.5 m away from the joint and at 3.0 m intervals thereafter, or
as directed by the Engineer. For pipe lengths of less than 3.0 m these deflections
shall be measured at each end at a point 100 mm away from the joint and at the
mid-point.
For pipelines smaller than 600 mm diameter deflections shall be checked by pulling
through an approved cylindrical plug dimensioned to suit the permissible minimum
deflected diameter of the pipe.
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Alternately, a deflectometer of a form that can be drawn through the pipeline and be
capable of measuring diametric dimensions both vertically and horizontally may be
used for deflection measurement of pipes of diameter less than 600 mm. The
deflectometer shall be calibrated for each diameter regularly in the presence of the
Engineer to maintain the accuracy of the instrument. The device shall also provide
a means of identifying where each deflection measurement was taken along the
length of a pipeline. This shall be in the form of either a continuos printout or a
visual display on a remote monitor.
For pipes of 600 mm diameter and greater the device shall be in the form of a
telescopic spring loaded rod graduated for each diameter to show percentage
deflections.
The Contractor shall tabulate the results of the measurements and copies shall be
submitted to the Engineer immediately after each set of measurements has been
taken.
4.4.8.2 Deflection Measurements - GRP Pipes
The measurement shall be taken on at least three separate occasions:
1. After the pipe surround material has been placed and compacted to 300 mm
above the pipe crown.
2. On completion of all backfill material up to final ground level but before the
dewatering is removed. This measurement shall be taken within one day of
completion of backfilling.
3. Immediately prior to the issue of a Certificate of Completion.
Pipes exhibiting any negative deflection in the vertical in (1) above and/or pipes
exhibiting a deflection in excess of 2% in (2) above or 4% in (3) above shall be
exposed and the surround replaced and recompacted. Should any deflection
exceed 7% that pipe shall be replaced. Any pipe removed for this reason shall be
taken from site and not incorporated in the permanent works.
All pipes exposed for recompaction and pipes replaced for any reason shall
subsequently be subject to the three deflection checks listed above. Deflection
checks shall also be carried out on adjacent pipes for 50 m either side of the
recompacted or removed pipes.
4.4.8.3 Deflection Measurements - uPVC and other Plastic Pipes
The measurement shall be taken on at least two separate occasions:
1. As soon as a pipeline has been installed, tested and the trench backfilled, but
before the dewatering is removed.
If any of these tests indicate that the deflection may exceed the permitted values
the pipe or pipes shall be replaced. Any pipe removed for this reason shall be
taken from site and not incorporated in the permanent works.
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All pipes replaced for any reason shall subsequently be subject to deflection checks
as described above. Deflection checks shall also be carried out on adjacent pipes
for 20 m either side of the removed pipes.
The permissible positive or negative deflections on the pipelines shall be as follows

(a reduction in the diameter is considered to be a negative deflection):-
After Initial Installation 3%

Long Term 5%
4.4.9 Stanks to Pipelines in Granular Bedding
Where pipes are laid on a granular bed or with a granular backfill, a stank, i.e. an
impermeable barrier, shall be provided across the full width of the trench and for the
complete depth of the bedding at intervals not exceeding 50 m, and generally mid-
way between manholes or chambers.
The stank shall consist of:-
Either a 300 mm long plug of fine grained clayey soil or a 300 mm long plug of a
mixture of sand and bitumen consolidated in an approved manner.
Or a mixture of sand and clay or the local material known as sabkha compacted to
form an impermeable barrier at least one metre in length.
Or a layer of thick polyethylene cut to fit around the pipe across the full width of the
trench and laid on the granular bedding material at its natural repose angle.
All methods must form an impermeable barrier. Bitumen shall not be used for
thermoplastic pipes.
4.4.10 Thrust and Anchor Blocks to Pressure Pipelines
Underground pressure pipelines shall be provided with concrete blocks as follows:-
Thrust/anchor blocks shall be provided at every installed bend, tee or angle branch.
Anchor/thrust blocks shall be provided on pipelines laid to gradients steeper than

1:20, up to 1:15 every third pipe shall be anchored, up to 1:10 every second pipe
and at 1:5 every pipe shall be anchored.
Concrete shall extend to undisturbed ground on thrust faces of thrust blocks and on
both faces of anchor blocks.
Where details are not shown on the drawings the Contractor shall prepare
proposals for thrust and anchor blocks including calculations and submit them to
the Engineer's Representative for approval. Such approval shall not relieve the
Contractor of his responsibility for the adequacy of his proposals. Special details
shall be shown on the drawings or instructed at site where environmental or ground
conditions dictate.
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4.4.11 Pipes Protruding from Structures, Concrete Surrounds and Anchor Blocks
Unless otherwise detailed a pipeline at or below ground level protruding from a

structure shall have two flexible joints adjacent to the structure. A band of an
approved concrete encasement rubber shall wrap around the pipe prior to
placement of any concrete such that the rubber protrudes 25 mm from the concrete.
The pipe shall be layed so the distance to first exposed flexible joint and the
distance between first and second joint are as follows:-
Table 4-7. Requirements for Flexible Joints for Protruding Pipes
Pipe Diameter Maximum distance Distance between

(mm) to first joint (mm) first and second joint(mm)
Min. Max.
Up to 300 150 450 2.5 * dia.
300 to 1000 300 1.5 * dia. 2.5 * dia.
above 1000 450 1.5 * dia. 2.5 * dia.
In the case of Group B pipe materials, particular attention will be placed on elliptical
deflection conditions.
These joints will be required at surrounds and anchor blocks unless directed
otherwise on site.
4.4.11.1 Group A Pipe Materials
Between the structure and the first joint any disturbed ground below the pipe will be
removed and replaced with Class B concrete in the form of a cradle, all to the
direction of the Engineer. The cradle shall not extend beyond the first joint.
Beyond the first flexible joint within the excavated working space of the structure the
concrete fill shall be brought up 300 mm below the pipe invert only. Specified
bedding materials will then be used.
4.4.11.2 Group B Pipe Materials
Within the excavated working space for the structure disturbed ground below the
pipe will be removed and replaced with Class B concrete to within 300 mm of the
underside of the pipe. Specified bedding materials will then be used to support the
pipe.
The width of the concrete backfill shall not be less than the nominal trench widths
except for any permanent shuttering against temporary trench supports to facilitate
removal of such trench supports after concreting.
Where a flexible pipe passes through a rigid concrete face to a structure or

surround the pipe shall be protected from stress concentration and possible fracture
of the pipe at the concrete face. A 10 mm thick neoprene or other approved
synthetic rubber strip shall be wrapped around and cemented to the pipe unless
special wall protection units are used.

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The neoprene will normally extend through the width of a wall to a dry chamber or
structure but will be limited to 150 mm or 100 mm is exposed to liquid (groundwater
or liquid inside the structure) a sealant groove shall be formed if detailed and filled
with an appropriate, approved, joint sealant.
Care shall be taken to ensure that the rubber strip is not displaced during
concreting.
Where a pipeline protrudes from a concrete surround, no protection from stress

concentration will be required if the surround ends at a flexible joint leaving the next
pipe free. If the surround ends on a pipe barrel the specified protection will be
provided and, for pressure pipes only, the protruding pipe will be wrapped from the
edge of the neoprene strip along to the next flexible joint at which the concrete
surround is interrupted with an approved compressible material such as damp-proof
sheeting or building felt of minimum thickness 2 mm.
4.4.12 Protection of Pipelines and Pipeline Component
4.4.12.1 Pipelines
Protection of pipelines shall be in accordance with the manufacturer’s

recommendations which shall be included with submission details for agreement by
the Engineer. The minimum requirements are shown below:
Class A concrete protection slabs as detailed on the drawing shall be provided over
the uPVC pipelines under roads when cover to pipe is equal or less than 1.2 m
for a gravity line; and for pressure line at any depth. In case of GRP pipe concrete
surround shall be provided as per drawing if the depth of cover is less than 1.5 m
and the pipeline lies within a strip of 20 m each side of the centreline of the Road
Corridor.
4.4.12.2 Pipeline Components
All buried valves, couplings, flange adaptors, and other metal components shall be
encased to guard against corrosion. Other pipe joints, valves and similar items on
both buried and exposed pipelines shall be encased where specified or shown on
the drawings.
The encasing shall be by one of the following methods, as detailed.
(1) Surrounding with Class B concrete.
(2) Enclosed by an approved hot-poured bitumen compound.
(3) Wrapped with tape.
Method (2) shall not be used with plastic pipes.
The item to be encased shall first be cleaned and its original surface treatment
made good. The surface shall be dry before encasing is carried out, which shall not
be done before the pipeline has been tested.

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The bitumen compound shall be cast in purpose-built moulds in accordance with

instructions issued by the supplier.
The protective wrapping tape shall be open-weave cotton or synthetic fibre or

woven glass fibre coated on both sides with an even coat of petrolatum (petroleum
jelly) containing a filler. The tape and paste shall be suitable for use in the
prevailing climatic soils pumped liquid and ground water conditions.
Before wrapping with tape the item to be encased shall be enclosed with an
approved mastic or inert putty-like filler which shall be moulded by hand so as to
provide a smooth surface for the tape. The tape shall be tightly spirally wrapped
with 25 mm overlaps so as to enclose the whole of the item and a minimum of 150
mm of pipe length on each side. The enclosure shall be firmly pressed out to
prevent air being trapped under the wrapping.
4.4.13 Indicator Posts to Pressure Mains

Where pressure mains pass through open ground, not adjacent to roads, or where
the danger of accidental breakage by excavation is evident, the Engineer may
instruct the erection of indicator posts of an approved design. Details of the
indicator post construction and spacing shall be shown on the drawings or be
The depth, location and size of the pressure main shall be detailed in Arabic and
English, to an approved design, on an engraved plastic or non-corrodible plate
attached to the post.
In addition at all air valve chambers, the Contractor shall erect indicator signs on
posts, to an approved design, at locations described to him by the Engineer.
4.4.14 Enclosing Granular or Stone Surround with Geotextile Filter Fabric
All slotted pipes and pipes laid beneath the permanent groundwater level the
granular bedding material shall be laid on and enclosed within a geotextile filter
fabric.
Filter fabric used for subsurface drainage works shall consist of long-chain synthetic
polymer fibers composed of at least 85 percent by mass polyoiefins, polyesters, or
polyamids. They shall be formed into a network such that the filaments or yarns
retain dimensional stability relative to each other, including selvedges.
The fabric shall be stabilised against ultra-violet light, inert to commonly uncounted
chemicals and chemical properties of the in-situ soil and water, and it shall conform
to the following minimum requirements:
Table 4-8. Requirements for Geotextile Fabric for Subsurface Drainage
Property Test Method Min. Requirements

Grab Strength (N) ASTM D 4632 800
Puncture Strength (N) ASTM D 4833 355
Burst Strength (kPa) ASTM D 3786 2000
Trapezoid Tear (N) ASTM D 4533 220
Permeability (m/s) ASTM D 4491 10-4
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Apparent Opening Size ASTM D 4751 0.6

(mm)
Ultraviolet Degradation ASTM D 4355 70 @ 150 h
(Percent Retained Strength)
Where filter fabric is used to enclose granular or stone pipe surrounds, the fabric
will be placed on the prepared trench formation and carefully supported during pipe
laying operations. When the pipe has been laid complete with surround to the
correct level the filter fabric shall be closed over the top of the surround by forming
a 'lap' of minimum width 500 mm. All membrane joints shall be overlapped a
minimum of 500 mm.
Care shall be taken not to puncture or damage the membrane in any way during
installation or during backfilling of the trench. Fabric damaged or displaced before or
during installation or during placement of overlaying aggregate material shall be
replaced or repaired to the satisfaction of the Engineer at the Contractor's expense.
During periods of shipment and storage, the fabric shall be maintained wrapped in a
heavy-duty protective covering and protected from direct sunlight, ultra-violet rays
and temperatures greater than 60oC.
4.4.15 Underground Services Warning Tapes
Service protection tapes shall be installed above all sewage, drainage and irrigation
pipelines and pressure mains constructed or exposed under this contract excluding
individual service connections.
For pipelines with the top of the pipe barrel more than 900 mm below finished
surface level the tape shall be placed over the centreline of the pipeline at 600 mm
below finished surface level during backfilling and compaction operations. For
pipelines with less than 900 mm cover to the top of the pipe barrel the tape shall be
placed over the centreline of the pipe at 300 mm above the top of the pipe barrel
during backfilling, compaction and reinstatement operations.
The tape shall be continuous over pipelines and at joints between tapes from
separate rolls the joint shall be lapped a minimum of one metre.
Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and colour-fast in all soil conditions
at pH values of 2.5 to 11.0 inclusive.
The tapes shall be flexible with a minimum width of 150 mm and thickness of 150
microns and shall be subject to the Engineer's approval.
Site tests to confirm detectability of the warning tapes after installation and backfill
shall be performed when ordered by the Engineer.
Text in Arabic and English indicating the protected services lying below the tape
shall be permanent ink bonded to resist prolonged chemical attack by corrosive
acids and alkalis with the message repeated at a maximum interval of two metres.
Tapes shall be colour coded as follows, with black text as indicated. The sign and
styles of the text shall be approved by the Engineer.
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Sewers : Yellow
CAUTION : Sewer below
Sewage pressure mains : Yellow
CAUTION : Sewage pressure main below
Drains : Yellow
CAUTION : Drain below
Drainage pressure main : Yellow
CAUTION : Drainage pressure main below
Irrigation pressure mains : Orange
CAUTION : Irrigation pressure main below
4.5 PIPEWORK WITHIN STRUCTURES
(1) Pipework shall be supplied to the general arrangements and limits indicated on
the Contract drawings and shall be supplied complete with all joint rings,
gaskets, washers to each side of a bolted joint, nuts, bolts, grease and any
other components necessary for the complete installation.
(2) The layout and design of the pipework shall be such as to facilitate its erection
and the dismantling of any section for maintenance of associated plant by
inclusion of approved mechanical coupling or flange adaptors.
(3) Where a common delivery pipe is used, individual pump delivery branches
unless otherwise shown on the drawings shall be jointed to it in a horizontal
plane and angled to prevent sharp changes of flow direction.
(4) Adequate supporting and anchoring arrangements for all pipes shall be
included which may take the form of straps, stays, tie bars or concrete cradles.
All pipe hangers and supports inside pumping stations and valve chambers or
other structures shall be of 320S17 stainless steel. All fixing bolts shall be
stainless steel grade 320S17.
(5) GRP pipes shall be provided with puddle flanges where they pass through the
walls of underground or water retaining structures.
(6) Small bore pipework for sump pumps, vents, etc., may be an approved plastic
material.
(7) All pipes connected to pressure vessels, pumps, etc., shall have flanged
connections.

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(8) All pipes shall be checked for alignment and mating of flanges and connections
before secured. Pipes shall not be sprung into position.
4.6 MANHOLES, CHAMBERS, AND SPECIAL STRUCTURES
4.6.1 General
The Contractor shall construct all manholes, chambers, and special structures
including transition chambers and outfall structures as indicated on the drawings and
herein specified.
Manholes, chambers, and special structures shall conform in shape, size,

dimensions, materials, and other respects to the details indicated on the drawings or
as ordered by the Engineer.
4.6.2 Construction of Manholes, Chambers, and Special Structures
All manholes, chambers, and special structures shall have reinforced-concrete bases
as detailed on the drawings. Manhole bases for storm-sewers less than 600 mm and
bases for chambers may be precast or cast in place at the Contractor's option and as
approved by the Engineer. For precast reinforced-concrete manhole bases, openings
for pipes shall be cast in the base at the required location during its manufacture.
Field cut openings will not be permitted. All other manhole and special structure
bases shall be cast in place as indicated on the drawings.
Manhole and chamber cover slabs shall be cast in place reinforced-concrete as

marked on the drawings. The ductile iron frames and covers for manholes and
chambers shall be brought to grade by the number of courses of concrete blocks
shown on the drawings or as instructed by the Engineer and a reinforced concrete
frame into which the ductile iron frame is embedded.
Class B concrete shall be cast to a minimum thickness of 150 mm around the

concrete blocks for rigidity or as detailed on the drawings.
The inverts shall conform accurately to the size of the adjoining pipes. Side inverts
shall be curved and main inverts (where direction changes) shall be laid out in
smooth curves of the longest possible radius which is tangential, within the manhole,
to the centerlines of adjoining pipelines all as indicated on the drawings and
instructed by the Engineer.
The ductile iron frames, grates and covers shall be to the Dubai Municipality standard
frame, grate and cover as indicated on the drawings and hereinafter specified in
Clause 4.7.
All benching and channel shall be formed with Class A concrete unless shown
otherwise in the drawing. 7 mm minimum GRP laminate shall be applied to benching
and channel.
Manhole walls shall be plain Class A concrete formed to the shape and thickness
shown on the drawings by the use of sound formwork material to give a fair faced
finish.
Internal surfaces of manholes and structures shall be protected with a reinforced

plastic liner in accordance with Clause 9.2.1.3 or with an approved coating in
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accordance with Clause 9.2.1.2(2)(a) as and where shown on the drawing and the
external (buried) surfaces shall be protected in accordance with Clause 9.2.1.2 (1)
either with water-proof membrane with protection board or with a brush-applied
bituminous emulsion as indicated in the drawing.
Pipes entering and leaving manholes, chambers and special structures shall be laid
soffit to soffit unless otherwise shown on the drawings. Details of pipelines entering
and leaving manholes, chambers, etc., shall be as specified for pipes protruding from
structures in accordance with Clause 4.4.11.
All construction joints to manholes, chambers and special structures shall be

perfectly watertight. Waterstop across joints in structures as specified in Clause
3.16.3 shall be provided where detailed in the drawings or as directed. Joints shall
be fully scabbled.
Manholes and chambers shall be completely constructed as the Works progress and
as each one is reached by the pipework. Frames and covers shall be placed
immediately after the completion of the manhole and chamber.
4.6.2.1 Road Gullies
Gullies shall comprise the gully grating and frame and the polypropylene gully pot, all
as shown on the drawing.
The gully pots shall be supplied with a fibre glass sand bucket with lifting handle, as
detailed in the drawing. The sand bucket shall have perforations in its upper part and
small holes 3 mm in diameter in its bottom part. The total
area of perforations shall not be less than 20,000 sq. mm and the minimum diameter
of each hole shall be 50 mm. The depth of the bucket shall not be less than 750 mm.
The gully pot shall be surrounded by a minimum of 150 mm of concrete as shown on

the drawing.
The connecting pipe between the gully pot and the drain/manhole shall be 160 mm
dia. uPVC.
The connection into the drain pipe shall be made by means of an oblique junction
which may be of uPVC.
4.6.3 Access Covers, Frames, and Grates
4.6.3.1 General
The Contractor shall furnish all ductile iron frames, grates, and covers conforming to
the details shown on the drawings, and as specified in Clause 4.7 to Dubai
Municipality Standards.
The Contractor shall submit for approval detailed shop and working drawings of all
castings before fabrication. Such drawings shall be obtained from the supplier(s) he
chooses to select from the approved list of Dubai Municipality (see Clause 4.7.1).

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The castings shall be of good quality, strong, tough, even-grained ductile iron,
smooth, free from scale, lumps, blisters, sandholes, and defects of every nature
which would render them unfit for the service for which they are intended. Covers
and frames contact surfaces shall be machined and the compatible frames and cover
carefully marked to ensure correct covers and frames are matched on site.
If required by the Engineer, the Contractor shall obtain from the supplier/
manufacturer a guarantee that replacement component parts will be available for a
minimum period of 10 years from the issue date of the Completion Certificate.
All covers, frames and grates shall be delivered to Dubai with a transit protective
packaging or wrapping. Any damage occuring to the approved coating system shall
be made good prior to installation.
One set of prising and lifting keys of approved design shall be supplied by the
Contractor with each twenty manhole covers and frames supplied.
4.6.3.2 Access Covers and Frames
All access covers and frames shall be of heavy duty construction complying with BS
EN124 and the requirements of the Dubai Municipality Standards (Clause 4.7). With
the exception of those for sewerage manholes, access covers and frames shall be
sand tight with seatings designed to be non-rocking unless detailed otherwise.
Double triangular covers must be loosely coupled by stainless steel bolts with nuts
provided with an approved method to render the nuts incapable of both undue
tightening or loosening.
Holes provided in non-ventilating covers for lifting keys shall be appropriately shaped
pockets which shall not penetrate through and there may be no projections above
cover level.
Both sides of covers and frames shall be protected with an approved epoxy coating
system appropriate to the Dubai environment (refer to Clause 19.4). The coating
system may be applied at the place of manufacture or in Dubai under controlled
application conditions approved by the Engineer.
Covers for sewerage manholes and chambers shall also be provided with a
reinforced plastic sealing plate. The design of cover, frame and sealing plate shall be
such that no load can be transferred from the cover to the sealing plate.
Access covers shall be as follows :-
(1) Sewerage
(a) Manhole covers shall be 600 mm x 600 mm square clear opening double
triangular heavy duty, embossed with the word 'Sewerage' in Arabic and
English.
(b) Inspection chamber covers shall be single seal 600 mm x 600 mm square
clear opening heavy or medium duty, embossed with the word 'Sewerage' in
Arabic and English. Alternately, 600 mm x 600 mm square clear opening
double triangular covers may be used subject to approval by the Engineer.

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(2) Storm/Land drainage
Manhole covers shall be non-ventilated, 600 mm diameter clear opening

double semi-circular heavy duty with sealing plate, embossed with the word
'Storm' in Arabic and English.
(3) Pumping Stations, Associated Chambers and Where Specified
They shall be rectangular 600 mm x 750 mm or 600 mm x 900 mm or multiples

of these sizes, as detailed on the drawings with concrete infill, and shall be
heavy duty.
Where ventilated covers are detailed the total area of ventilation shall not be less
than 5 % of the minimum clear opening area and the covers shall be provided with
suitable protective sand traps which shall seat in the access cover frame.
4.6.3.3 Reinforced Plastic Sealing Plates to Access Covers
Reinforced plastic sealing plates to access covers shall be designed to provide a

push-fit, gas-tight seal with the cover frame. The sealing plate shall be in the form
of a plug with a flange to prevent the plate passing into the manhole. The seal shall
be achieved by means of an approved integral synthetic rubber gasket
mechanically locked into the periphery of the plate. The gasket shall be suitable for
the service temperature range 0oC to 60oC and possess good weathering and H2S
resistance. Any lubricant used on the seal shall be silicon based. The underside of
the plate shall have a resin-rich finish and there shall be no exposed fibres. Cut
and/or drilled faces shall be sealed with resin.
The plate shall have a minimum thickness of 5 mm and be capable of withstanding

a static load of 150 kg applied centrally over a 150 cm square surface area with a
deflection, measured at the centre of the plate, not exceeding 25 mm.
A minimum of two number reinforced plastic lifting handles shall be provided per
plate. They shall be of the same materials as the plate and securely laminated to
the plate or fixed by stainless steel blind rivets.
The complete sealing plate including gasket shall be resistant to 10% sulphuric
acid at 50oC for 100 days.
4.6.3.4 Road Gully Gratings and Frames
Road gully gratings and frames shall be of ductile iron construction to BS EN124
badged to Dubai Municipality Standard (Clause 4.7), and having a minimum
waterway of 900 sq. cm. The grating and frame shall be of a non-rocking
construction and shall be dimensioned as detailed in the drawing.
Gully gratings shall be of the raised kerb type complete with sand seal, road
retaining bar and a removable GRP debris bucket. The weir depth shall be a
minimum of 165 mm and the frame and cover are to be protected with an approved
epoxy coating system appropriate at the place of manufacture or
in Dubai under controlled application conditions approved by the Engineer. The
clear opening size shall permit removal of the GRP grit sand bucket.

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4.7 DUBAI MUNICIPALITY STANDARDS FOR COVERS AND GRATINGS
Table 4-9. Standards for Covers and Gratings for Storm/Land Drainage
MANHOLE GULLY GRATINGS

PUMPING
STN.
REQUIREMEN IN OUT FLUSHE UPSTAN ACCESS
T ROAD OF D D COVER
ROAD KERB KERB
Double Double
Shape Semi- Semi- Square -
Circula Circular Rectangula
r r
Size of clear 600 600 width weir dpt 600 x 750

opening dia. dia. Nom.450 165 600 x 900
Standard BS EN BS EN BS EN BS EN BS EN124
124 124 124 124
Strength D400 C250 D400 150 KN D400

(A (B 150) (A 350) (B 150)
350)
Material Ductile Ductile Ductile Ductile Ductile

Iron Iron Iron Iron Iron
Protective Epoxy Epoxy Epoxy Epoxy Epoxy

Coating
Ventilation No No - - No
Construction Solid Solid - - Concrete
Infill
Sealing Plate Yes Yes - - -
Inscriptions Storm Storm Storm Storm
Storm
Tightness Yes Yes - - -
Rocking No No No - No
Locking No No No - No
Interchangeabili Yes Yes Yes Yes Yes
ty
Other - - - GRP Special
GRID Keys
Suppliers 1-5 1-5 1-5 1-5 1, 2

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Table 4-10. Standards for Covers and Gratings for Sewerage
HOUSE PUMPING
REQUIREMEN MANHOLE CONNECTIO STN.
T N ACCESS
CHAMBER COVER
IN ROAD OUT OF
ROAD
Shape Double Double Square Rectangula

Triangular Triangular r
Size of clear 600 x 600 600 x 600 600 x 600 600 x

opening 750
600 x
900
Standard BS BS EN124 BS EN124 BS

EN124 EN124
Strength D 400 C 250 C 250 D 400

(A (B 150) (B 150)
350)
Material Ductile Ductile Ductile Ductile

Iron Iron Iron Iron
Protective Epoxy Epoxy Epoxy Epoxy

Coating
Ventilation No No No No
Construction Solid Solid Solid Concrete
Infill
Sealing Plate Yes Yes Yes -
Inscriptions Sewerage Sewerage -
Sewerage
Tightness Yes Yes Yes -
Rocking No No No No
Locking No No No -
Interchangeabili Yes Yes Yes Yes
ty
Other - - - Special
Keys
Suppliers 1-5 1-5 1-5 1, 2

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4.7.1 Approved List of Suppliers
1. ELKINGTON
2. PASSAVANT
3. STANTON
4. SELFOCK
5. GLYNWED BRICKHOUSE

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SECTION 5 - BRICKWORK AND BLOCKWORK

5.1 MATERIALS
5.1.1 Concrete Bricks and Blocks
Concrete bricks and blocks shall be constructed from Class B (sulphate resisting
Portland Cement) concrete but the coarse aggregate shall be 10 mm to 5 mm. The
blocks shall be cast in clean oiled moulds.
They shall be free from cracks, uniform in size, true to shape, free from deleterious
matter, clean, hard, impervious with smooth faces in appearance similar to normal
Class B concrete and with well defined arises. Paving blocks shall comply with
DM Local Order 44/90.
Bricks and blocks shall not be incorporated into the Works until they have matured
under suitable conditions for 28 days.
5.1.2 Bricks
Engineering bricks and special purpose bricks such as radial bricks, weir bricks,
copings and bull nosed bricks shall have an average compressive strength of at
least 69 N/mm2 and an average absorption not exceeding 4.5 percent by weight
measured by a standard boiling or vacuum method.
Faces of engineering bricks to be exposed to the weather or liquids shall not be

wire cut.
Bricks for arches and circular work of 1.5 metres and less in diameter shall be
purpose made radial bricks.
5.1.3 Sand for Mortar
Sand for mortar shall comply with the following table:-
Table 5-1. Sand for Mortar

Percentage by mass passing sieve
Sieve Size Rendering Brickwork/General Purposes
5.00 mm 100 100
2.36 mm 90 - 100 90 - 100
1.18 mm 70 - 100 70 - 100
600 microns 40 - 80 40 - 100
300 microns 5 - 40 5 - 70
150 microns 0 - 10 0 - 15
5.1.4 Lime for Mortar
Lime for cement-lime and lime-sand mortar shall be the hydrated type to the
approved standard.
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5.2 CONSTRUCTION
5.2.1 General
Bricks and blocks shall be properly stacked on level hardstanding. Broken blocks
shall be removed from the site.
Bricks shall be adequately protected from inclement weather.

During hot and dry weather bricks and blocks shall be wetted as necessary and
the tops of walls shall be wetted before a course is laid
All faces of brickwork or blockwork will be kept clean and no rubbing down of
exposed faces will be permitted.
Vertical faces of all bricks shall be well buttered before being laid and the whole
well grouted at each course.
Brickwork and blockwork should be built in a uniform manner. Corners and other
advanced work should be raked back and not raised above the general level more
than 1.0 m at one lift.
All blocks shall be laid on even full beds of mortar; vertical faces of all blocks shall
be well buttered before being laid and the whole well grouted at each course.
The overall dimensions of four blocks laid in mortar shall not exceed by more than
25 mm the overall dimensions of the same blocks laid dry.
5.2.2 Engineering Brickwork
Unless otherwise specified or ordered all engineering brickwork shall be built in

English bond.
In all engineering brickwork the overall dimensions of four bricks laid in mortar
shall not exceed by more than 25 mm the overall dimensions of the same bricks
laid dry.
When concrete is to be faced with brickwork, header bricks shall be built into every
fourth course and at intervals of 2 bricks horizontally so as to project 1/2 brick into
the concrete. Headers in successive courses shall be staggered.
5.2.3 Blockwork
All blockwork shall be built level, plumb and true to line with all perpends in line
vertically. Blockwork shall be built in stretcher bond and alternate courses shall be
bonded in at all junctions. All blockwork shall be set in gauged mortar as
described to the lengths, heights and thicknesses shown on the drawings. Fair
and fair-faced work shall be kept perfectly clean and no rubbing down of blockwork
will be allowed. Blockwork to be plastered shall have joints struck off flush and left
rough.

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5.2.4 Cement Mortar
Mortar for precast concrete units, brickwork and blockwork shall be gauged in the
proportions of one part of cement to three parts of sand. Lime shall only be added
if specifically ordered.
Cement mortar shall be mixed on a clean surface in small quantities sufficient only
for 30 minutes work and shall not be remixed or worked up again after setting or
hardening; any mortar that has become set or hard shall be rejected and removed
from the site.
Ingredients shall be measured in proper boxes and shall be turned over and
thoroughly mixed on a wooden platform.
5.2.5 Cement Lime Mortar
Cement lime (gauged) mortar shall consist of one part Portland Cement, one part
of lime and six parts of sand by volume (1:1:6). All materials shall be accurately
gauged using gauge boxes and shall be thoroughly mechanically mixed. Mortar
that has begun to set shall not be revived or re-used.
5.2.6 Cement Mortar Rendering
Cement mortar rendering shall consist of two or more coats; the undercoat shall be
13 mm thickness and scored to form a key for the final coat which shall be not less
than 6 mm in thickness. The finished coat shall be worked with proper metal floats,
and the face left with an even and polished surface. The mortar for the undercoat
of the rendering shall be gauged in the proportion of one part of cement to three
parts of sand, and the finished coat shall be in the proportion of one part of cement
to two parts of sand.
For at least 24 hours before rendering is applied the concrete or brickwork face or
previous coat of rendering shall be thoroughly soaked with water, and the finished
rendering shall be watered at least four times a day and kept damp for a period of
a least fourteen days after completion. Not more than three days shall elapse
between the application of one coat and its being covered up with a second or
finishing coat. All arises shall be sharp and linear.
When rendering is to be applied to brickwork, the joints shall be raked and cleaned
out to a depth of 13 mm.

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SECTION 6 - INSPECTION AND TESTING OF PIPELINES AND STRUCTURES
6.1 CLEANING AND INSPECTION OF PIPELINES
The Contractor shall ensure during and after construction that the pipes remain clean
and free of all silt, mortar, debris and other obstructions, and if required by the Engineer,
the pipelines shall be cleaned out using approved methods and equipment which do not
damage the internal lining of the pipes and manholes. When work is not in progress the
open ends of the pipeline shall be securely plugged with an approved watertight plug or
stopper to prevent the ingress of deleterious matter into pipelines.
After backfilling pipe trenches and completing chambers, hatch boxes, etc., and before
the trench surfaces are reinstated, the interior of pipelines shall be cleaned of silt and
debris by approved methods for inspection by the Engineer's Representative as follows:-
All newly constructed pipelines of 600 mm (nom.) internal diameter and smaller shall
have a loose plug passed through them to show that they are clear of obstruction and
free from deflection. The loose plug shall be dimensioned to suit the permissible
minimum deflected diameter of the pipe. Alternately, a deflectometer capable of
measuring diametric dimensions both vertically and horizontally may be used as
specified in Clause 4.4.8.
All newly constructed pipelines greater than 600 mm (nom.) internal diameter will after
cleaning be inspected from the inside and the Contractor shall provide a suitable trolley
for this purpose.
All renovated or replaced pipeline shall after cleaning, be inspected from the inside using
CCTV inspection as specified in Section 13.
In addition gravity pipelines or sewers shown as straight lines between manholes on the
drawings shall be subjected to a light sighting test as detailed in the pipelaying
specification Clause 4.4.3.
Pipelines, manholes, chambers/structures will be inspected again before being put in

service or taking over (whichever is sooner) and if required by the Engineer's
Representative shall be cleaned again in whole or in part by suitable means which may
include, if directed, flushing with clean water.
6.2 TESTING OF PIPELINES
6.2.1 General
The Contractor shall make his own arrangements for the supply of water used for testing
and cleaning of pipelines which shall be obtained from a source approved by the
Engineer. All water required for testing and cleaning shall be provided by the Contractor
at his cost.
Prior to commencement of flushing or testing, approval shall be obtained to the methods

and programme for testing and to the method of disposal of all fluids used for flushing or
testing purposes. Under no circumstances will permission be given for the discharge of
such fluids into the existing sewerage system.
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If permission is given to use new or existing pipelines or culverts which are not part of a
live system, they shall be thoroughly cleaned of all silt and any resulting damage made
good after use.
If lagoons for the storage of such fluids are permitted, they must be suitably protected
with fencing and attended by day and night to prevent access by the general public and
will not be sited adjacent to buildings. Approved means of preventing the formation of
mosquito larvae on the surface of the lagoons will be employed.
Testing of pipelines shall in all cases be applied in the presence of the Engineer's
Representative. The Contractor shall notify the Engineer at least 48 hours before hand of
his intention to test a section of pipeline. The Contractor, at his own expense, shall
provide complete plant and all struts, thrust blocks, etc., as may be necessary for
effectively testing the pipelines to the specified pressures.
Pipelines shall be properly completed and supported before being put under test. No
testing will be permitted until seven days after thrust blocks and other holding down
works have been completed.
For both gravity and pressure pipelines only testing of new, renovated, or replaced
sections of pipelines and fittings will be required under the Contract, in accordance with
this Specification, unless detailed otherwise. Such testing will be carried out before
making final connections to the existing network. However where tees or other fittings
are inserted into existing pipelines and where lengths of pipeline are replaced no
backfilling will be allowed at the tees or fittings or at the joints between new and existing
pipework until the pipeline has been returned to service and a visual inspection of all
such fittings and joints made at the network pressure.
Should any inspection be unsatisfactory or any test fail the Contractor shall replace
defective pipes, leaking joints or otherwise re-execute defective work as instructed
following which cleaning and testing will be repeated until the Engineer's Representative
certifies the pipeline to be satisfactory.
6.2.2 Testing of Non-Pressure Pipelines
All non-pressure pipelines of 600 mm nominal diameter or smaller shall be given a

preliminary air test when the pipeline is bedded and jointed before backfilling and a final
water test after backfilling in the presence and to the satisfaction of the Engineer.
Unless otherwise instructed non-pressure pipelines shall be tested in sections between

manholes.
Preliminary and final air and water tests will not normally be applied to pipelines greater
than 600 mm (nom.) internal diameter and acceptance of these pipelines will be
dependent on satisfactory visual inspection of the pipes and joints.
Air Test (Preliminary Test)
After a length of pipeline is bedded and jointed, and before backfilling, it shall be given a
preliminary test as detailed below:

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1. The Contractor shall plug all pipe outlets with suitable plugs, and brace each plug
securely where needed.
2. Air shall be pumped in slowly to the pipe until a pressure of 100 mm head of water
is indicated on a manometer connected to the system.
3. After the internal pressure of 100 mm is obtained, two minutes shall be allowed for
the air temperature to stabilize within the pipe.
4. Air may be added to restore the pressure to 100 mm.
5. During a further period of 5 minutes (without further pumping of air) the pressure
should not fall below 75 mm.
6. Release of the air pressure shall be carried out by removal of the stopper at the
end of the pipeline away from the manometer which will remain connected. Failure
to carry out the air pressure release in this manner shall render the test invalid.
7. The Contractor will not be permitted to commence testing later than 4 hours after
sunrise or earlier than 4 hours before sunset during the summer period unless
Water Test (Final Test)
After backfilling the length of pipeline under test, it shall be given the following final test:
1. All branches and open ends shall be closed with suitable stoppers, secured with
longitudinal braces before testing commences.
2. Water shall be filled from the lowest point and air allowed to escape. No
entrapped air shall remain in the pipeline while testing.
3. An internal pressure equivalent to a head of water of depth to invert of the pipeline

plus 1.25 m, or 4 m head whichever is greater shall be maintained for 30 minutes
to allow for initial absorption of water.
4. After that, the test pressure shall be maintained for 60 minutes and water added
shall be measured.
5. Pipeline shall be treated as passed if water consumption in 60 minutes does not

exceed 7.5 litres per metre of diameter per 30 m of length of pipeline under test.
Where in the opinion of the Engineer's Representative the above test is not sufficiently
indicative of water tightness by reason of high ground water levels the test will not be
applied. Acceptance of the pipelines will then depend on satisfactory inspection or
testing for infiltration as referred to below, and air test of the pipeline in manhole lengths.
The Engineer may require any length of pipe suspected of being damaged to be retested
by the water test at any time during the contract period.

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Infiltration Test
After completion of backfilling and restoration of normal subsoil conditions, all gravity
pipelines and manholes shall be examined for infiltration as follows:
1. All inlets to the system shall be closed sufficiently to prevent the entrance of water.
2. Pumping of groundwater shall be discontinued for at least 3 days prior to the test
for infiltration.
3. The section of the pipeline under test, including manholes, shall be accepted as
satisfactory if the infiltration does not exceed 1.00 litre per hour per metre of pipe
line per metre of nominal internal diameter.
Notwithstanding the satisfactory completion of the infiltration test, if there is any

discernible flow of water entering the pipeline at a point which can be located either by
visual or closed circuit television inspection, appropriate measures shall be taken to stop
such infiltration.
6.2.3 Testing of Pressure Pipelines
All pressure pipelines of 675 mm or more internal diameter shall have each joint
individually tested by means of an approved joint testing apparatus.
Pipelines of less than 675 mm shall be subjected to a preliminary air test as soon as a
length of pipe has been laid and before backfilling. Pressure pipelines shall
then be given a final test using water after they have been backfilled, cleaned and
inspected.
Preliminary pressure testing of pipelines may be carried out if so required by the

Engineer with partial backfill only and exposed joints, but the stability and safety of the
Works must be ensured at all times.
Each test shall be restricted to pipes of one class. Pipelines shall be tested in sections
not exceeding 500 metres or between valve positions. In addition the whole pipeline
shall be tested upon completion. Particular care must be taken to isolate air valves, etc.,
not to apply higher pressure than specified at any point on the pipelines and to ensure
that the pipelines are adequately anchored before any test is carried out.
Gauges used for testing pressure pipelines shall be capable of reading increments of 0.1
metre head. Before any pressure gauge is used, the Contractor shall arrange for it to be
checked independently and a dated certificate of its accuracy shall be provided to the
Engineer. Calibration of pressure gauges shall be carried out at regular intervals as
required by the Engineer
As soon as a length of pressure pipe has been laid and before backfilling, when
applicable and when ordered it shall be subjected to the following preliminary test:

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5. The test will not be satisfactory if the air pressure falls to less than 275 mm during
a period of 5 minutes without further pumping of air.
Pressure pipelines shall be given the following final test using water after they
have been backfilled, cleaned and inspected:
1. All the joints of the pipeline shall be left open for the purpose of inspection for
leakage if any, where practicable or instructed by the Engineer.
2. Pipe ends shall be closed with suitable stoppers, secured with longitudinal
braces/thrust block, before testing commences.
3. Water shall be filled slowly (to prevent possible water hammer) from the lowest
points and air allowed to escape through an air vent fixed for the purpose at the
highest points of the pipeline section under test. No entrapped air shall remain in
the pipeline while testing.
4. Pressure in the pipeline shall then be raised steadily upto and maintained at the
rated pressure for a period of 30 minutes to allow for absorption and achieve
conditions as stable as possible for testing.
5. If no leakage has been observed, pumping shall then be resumed and the
pressure slowly raised to the specified test pressure.
6. Unless specified elsewhere or directed otherwise by the Engineer, the test

pressure shall be 900 KN per square metre (91.8 m head of water).
7. Test pressure shall be continuously maintained by the use of the pump for a period
of 60 minutes and the amount of makeup water required to maintain the pressure
shall be accurately measured (to the nearest 1/8 litre).
8. Pipeline shall be deemed to have passed the test if all the following conditions are
satisfied:
a. No water is visible coming out of the pipe or joints at any point;
b. Amount of make-up water required does not exceed 1 litre per hour per
100 mm diameter per kilometer of pipeline under test;
c. The loss of the pressure during the test period does not exceed 70KN per
square metre.

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6.3 TESTING OF VALVES
Valves and all pipelines appurtenances shall be hydraulically tested together with the
pipeline in which they are installed. Valves shall be tested for operation under working
pressure and shall be adjusted so that they operate smoothly, seat properly and are
installed to tolerances recommended by the manufacturer.
6.4 TESTING OF RENOVATED AND REPLACED PIPELINES
All non-pressure pipelines renovated or replaced by slip lining, soft lining, or pipe
bursting methods shall be given an air test or water test per Clause 6.2.2 in the presence
and to the satisfaction of the Engineer.
6.5 TESTING OF WATER RETAINING STRUCTURES
All water retaining structures shall be visually inspected to confirm that there is no
infiltration. Where it is required by the Engineer, water retaining structures shall be tested
for watertightness. The structure shall be filled with water and shall stand for a period of
three days, to allow for absorption. The structure shall be considered satisfactory if,
subsequent to this period, there shall be no fall in level over a period of 24 hours (after
making the allowance for rainfall and evaporation) and there shall be no visible leaks, or
damp surface areas.
This shall be carried out before any backfilling and before the application of any external
concrete protection has taken place. Any damages revealed as a result of such tests
shall be made good to the satisfaction of the Engineer.

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SECTION 7 – Not Used

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SECTION 9 - CORROSION PROTECTION AND ODOR CONTROL
9.1 MATERIALS
9.1.1 Corrosive Environments
Corrosion protection systems and surface coatings shall in all cases be suitable for
exposure to their contact with environmental conditions which may include any or all
of the following :-
(1) The climatic conditions prevailing in the project area with particular emphasis on
temperature variations, high surface temperatures and high humidities.
(2) Septic sewage with a pH value of less than one.
(3) Sulfuric acid solution in sewage slimes in concentrations up to 15 % by weight.
(4) Hydrogen sulfide and other gases emanating from sewage, septic sewage and
sewage sludges.
(5) Saline groundwater with high chloride or sulphate contents both below the water
table and in soil zones above the water table where capillary action and the
presence of oxygen may cause extremely severe conditions.
(6) Wind blown chlorides.
(7) Wind blown abrasive sands.
9.1.2 Paint
Protective and decorative paint systems including primers and undercoats shall be
obtained ready mixed for use. All containers of paints and other coating systems shall
show date of manufacture, shelf life and pot life where applicable. Paint shall be
applied as per Clause 9.2.2 (refer to Clause 19.4 for schedules of protective coatings
and surface preparations).
The Contractor shall only be allowed to use paints which are delivered to the site in
sealed cans or drums bearing the name of the manufacturer and properly labeled.
Tints and shades of final coats shall be advised by the Engineer or his
Representative.
9.1.3 Impervious Tanking Membrane
Membrane used for tanking to concrete structures shall be impervious, self-adhesive

and covered with a release agent.
Rubber bitumen/PVC membrane shall have a minimum bitumen thickness of 2.0 mm

and PVC thickness of 0.3 mm.

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9.1.4 PVC Sheet Lining Materials
PVC sheet materials to be used for lining concrete structures and pipelines internally
shall be manufactured from polyvinyl chloride, plasticisers and pigments to make
permanently flexible sheets.
The colour of the sheet shall be approved on site.
The PVC sheet shall have a minimum thickness of 1.5 mm and shall be formed by
extrusion to have on one side locking keys or ribs of either ‘T’ or diamond section at
centers not greater than 75 mm. It shall be capable of forming a continuous 100%
effective seal with the use of welding strips or other approved method and shall be
supplied with all materials and tools for making the joints.
The tensile strength of the material shall be not less than 17000 kN/m2.
All weld strips, patches and other sheets used in the permanent fixing of the ribbed
sheet shall be of a material having the same composition as the ribbed sheet.
9.1.5 Reinforced Plastic Liners
Reinforced plastic liners to be used for lining pumping stations and manholes shall
be manufactured (as per Clause 19.1.4) to the dimensions given on the Drawings,
within the following tolerances :-
(1) The work size, which is defined as the internal diameter as specified by the
manufacturer, shall be declared and shall not differ from the normal diameter by
more than ± 1%.
A manufacturing tolerance on the work size of 10 mm will be allowed provided

that a tight fit is achieved between the liner and the slab liner.
(2) Liners shall be supplied in lengths to suit requirements with a resin-rich finish to
internal surfaces.
(3) Minimum thickness shall be 7 mm for sewerage work and 5 mm where
approved for drainage work.
(4) The out of squareness shall not be greater than 10 mm.
(5) The deviation from straightness of the bore of the liner shall not exceed 20 mm.
Although the liners are not designed to be structural, they shall have a sufficient
stiffness to withstand :-
(1) Buckling or distortion in transit or storage.
(2) A hydrostatic head of 8 metres without distortion damage, leakage or

permeation.
(3) Grouting pressures.

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Prior to grouting of the manhole liner at least 24 hours shall be allowed for
temperature equalization between the manhole structure and the reinforced plastic
liner.
The manufacturer shall provide shop drawings of the proposed top slab liners prior to
manufacture for approval.
The manufacturer shall stipulate the maximum deflection of the slab liner permitted
without causing surface cracking to the gel coat. The Contractor must take care not to
exceed this limit, and any surface cracking that occurs will be repaired.
9.1.6 In-Situ Laminations
The Contractor shall apply either of the following systems of laminations to renovate
the manholes:
(1) Epoxy resin mortars and laminating systems.
(2) Lamination using glass chopped strand mats impregnated with isophthalic resin
and with vinylester resin.
(3) Bisphenol polyester resin with heavy duty glass cloth inclusion.
Epoxy Resin System
A mortar consisting of an epoxy resin and hardener shall be mixed with a filler
material to produce a thixotropic dense trowel suited mix.
The mortar shall be manually applied to all internal surfaces and left at least 15
minutes.
A minimum of 7 mm of GRP laminate shall then be applied in two layers. The

benching laminate shall be sealed on to the in-situ channel liner with an approved
compatible material. The top surface of the benching shall be treated to produce a
non-slip finish.
Isophthalic and Vinylester Resin System
Firstly the surface of the manhole walls and the surface of the cover slab soft,
benching and channel (concrete) shall be coated with isophthalic resin.
Three layers of 600 gm/m2 glass chopped strand mat shall then be applied and
impregnated with isophthalic resin to provide an approximate thickness of 5 mm.
Next one layer of 600 gm/m2 and one layer of 300 gm/m2 glass chopped strand mat
shall be applied and impregnated with vinylester resin.
Following this two layers of glass veil shall be applied and impregnated with vinylester
resin.
Finally a coating of vinylester resin with paraffin wax shall be applied to provide a total
minimum thickness of 7 mm.
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Bisphenol Polyester Resin with Heavy Duty Glass Cloth Inclusion System
All cleaned surfaces shall be primed with a polyester based primer to seal the surface
and aid the application of the lining.
The base coat of resin reinforced with filler shall be trowel applied to approximately
1.5 mm thick. The reinforcing cloth shall be consolidated into the first trowel coat with
particular attention being paid to ensure that the cloth is fully wetted out. This
application shall be allowed to cure overnight before applying the top coat of resin.
This resin reinforced with the same filler shall be troweled on and dressed with a
rolling aid.
9.1.7 Epoxy Mortar
Where indicated on the drawings or specified to use epoxy mortar for benching and
channels in any manhole or any other structure such as chambers, pump station
wet-well, etc., they shall be formed to have a min. of 10 mm thickness of an approved
epoxy-resin mortar system.
The epoxy mortar system shall be a trowellable, two component epoxy resin system
consisting of a prefilled base and unfilled reactor which when mixed shall produce a
high strength, impermeable and chemically resistant mortar.
The epoxy mortar system shall have excellent chemical resistance to sodium chloride
and sulphuric acid (shall pass the relevant chemical resistence test), and shall have
high impact resistance. Typical properties are given in the following table:
Table 3-7. Properties of Two Component Epoxy Mortar

Property Test Method Limit
Sag at 10 mm thickness - None

Working Time ASTM C308 > 90 min. at 25C
Full Cure at 25C - 3 to 7 days
Setting Time at 25C - 30 to 45 min.
Water Absorption ASTM C413 < 0.07 %
Compressive Strength BS 6319:Part 2 > 40 N/mm2 at 25C,
7 days cure
Flexural Strength BS 6319:Part 3 > 3 N/mm2 at 25C,
7 days cure
Tensile Strength BS 6319:Part 7 > 8 N/mm2
Bond Strength BS 6319:Part 4 > 30 N/mm2
Density BS 6319:Part 1 1750 kg/m3
When placed on a concrete substrate the epoxy mortar system shall have an adhesive
strength of not less than the internal cohesive strength of concrete.
To achieve the necessary adhesion to the substrate an epoxy primer compatible for
use with the mortar and the substrate shall be applied.

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The epoxy mortar, or the primer where required, shall be suitable for application onto a
substrate with a moisture content of 4% or less as measured by the "wet-check"
Moisture Meter or other instruments approved by the Engineer.
The pot-life of the mixed mortar shall not be less than one hour at the temperature at
the place of application at the time of mixing. The Engineer may restrict application to
such time as the ambient temperature is sufficiently low for the specified pot-life to be
ensured.
There shall be strict control of surface cleanliness between primer and epoxy mortar
and between coats of the same. Vacuum removal of dust and sand shall be employed
and water soluble contamination shall be removed as specified above. Where dirt or
dust has become trapped in the primed surface it shall be removed with suitable
abrasive paper. The surface being primed shall be free of visible moisture throughout
these operations.
The mortar manufacturer shall stipulate primer and epoxy re-coat intervals for all
curing temperatures likely to be encountered and these shall be adopted with a
maximum tolerance of +4 hours. Where this is exceeded the surfaces to be re-coated
shall be suitably abraded to remove gloss.
Mixing of the components shall be strictly in accordance with the Manufacturer's

recommendations and care shall be taken to avoid the entrainment of air in the mixes.
Wet thickness gauge shall be used by the mortar applicators continually to check that
sufficient mortar is being applied to achieve the required dry thickness.
9.1.8 Bituminous Emulsion
Bituminous emulsion shall be to the approved standard and shall not contain less
than 53 % of bitumen.
9.1.9 Waterproof Paper
Waterproof building paper shall be to the approved standard. For roadworks it shall
be Class B.
9.1.10 Protective Materials for Wrapping Pipeline Components
The protective materials for wrapping pipeline components shall comprise a rust
inhibiting compound for the bolts, a mastic or comparable filler which will not harden
for moulding over the assembly, and a waterproof tape for wrapping.
9.1.11 Approved Paint Suppliers
The following paint systems have been successfully used in sewage environments in
Dubai. Reference to these systems in no way precludes the use of similar or superior
systems by other suppliers.

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Supplier Paint System
1. Colebrand Limited Epoxy Prefabrication Primer: CXL 100.

Colebrand House Epoxy Resin Solvent Free Coating : CXL 115.
20 Warwick Street High Build Epoxy Airless Spray Coatings.
Regent Street CXL 141 for temperate climates applications.
London WIR 6BE CXL 140 for hot climates applications.
England
2. Corroless International Limited Corroless T .

Berk House, Basings View Corroless Epoxy.
Basingstoke
Hampshire RG 21 2HW
England
9.2 INSTALLATION OF PROTECTIVE COATINGS AND LINERS TO CONCRETE
9.2.1 General
Concrete structures shall be protected both internally and externally where indicated
on the Drawings and by the methods detailed.
9.2.2 Protective Coatings/PVC Liners
All protection systems shall be applied strictly in accordance with the manufacturer's
instructions, two copies of which shall be included with the Contractor's application for
the approval of the material, and when approved will be deemed to be part of this
specification unless stated otherwise.
The permissible rate of permeation of all protection systems shall not exceed 0.0027
per inches (ASTM, 1 per inch = 1 gramme of water per hour per square foot (0.0929
m2) per mil (0.0254 mm) of thickness for a 1 inch (25.4 mm) difference in Hg vapour
pressure on each side of a membrane.
Coatings shall not be applied at expansion, contraction or construction joints which

incorporate a sealant.
(1) External Buried Surfaces
The external surfaces of concrete substructures shall be protected or "tanked" by one

of the following methods which will be indicated on the Drawings.
a) An approved impervious bituminous waterproof membrane:
The membrane shall be tropical grade, cross laminated to have high tear
strength; and puncture and impact resistance and shall be chemically resistant
for protection against aggressive soils and contaminated groundwater.

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The membrane shall comply with the following :-
Property Test Method Typical Results
Tape Strength ASTM D638 Long 4.2 N/mm²

Trans 4.8 N/mm²
Tensile Strength ASTM D638 Long 42 N/mm2

Trans 48 N/mm2
Elongation Film ASTM D638 Long 210 %

Trans 160 %
Tear Resistance ASTM D1004 Long 340 N/mm²

Trans 310 N/mm²
Adhesion to Self Concrete ASTM D1000 1.8 N/mm2
Puncture Resistance ASTM E154 220 N 65mm²
Water Resistance : ASTM D570

After 24 hours 0.14 %
After 35 days 0.95 %
Environmental Resistance ASTM D543 Conforms
Moisture Vapour ASTM E96 0.3 g/m² / 24 hrs.

Transmission Rate
The membrane shall be laid on to smooth concrete blinding surface free from
sharp edges and projections and on to walls primed with an approved primer and
applying the performed membrane, sticky side downwards, laid strictly in
accordance with the manufacturer's instructions. The minimum over laps shall be
50 mm side and end.
During the backfilling operation around all tanked structures, the waterproof
membrane shall be protected from damage by the use of an approved protection
board. The board shall be manufactured from graded and selected kork granules
bound with modified bitumen and encased between two layers of tough asphalt
paper. The board shall be light weight and capable of providing protection against
abrasive backfilling. The board may be stored outside, but shall be kept flat on
original pallets.
b) A brush applied bituminous emulsion:
The surface shall first be wire brushed and all dust and loose scale removed.
Three coats of bituminous rubber emulsion paint shall then be applied. The
second coat shall not be the same colour as either the 1st or 3rd.
Both methods of protection shall totally enclose the substructure within a

waterproof membrane to the limits shown on the Drawings.
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(2) Internal and External Exposed Surfaces
Where exposed surfaces of concrete structures are not protected by reinforced plastic
liners one of the following systems will be indicated on the Drawings where required.
a) An epoxy resin, acrylic, polyester or latex paint system:
The surface shall first be wire brushed and all dust and loose scale removed
(refer to Clause 19.4 for schedule of surface preparations). An epoxy resin or
other primer/sealer (for concrete and allied substrates) shall then be applied
followed by coats of high build epoxy airless spray or other coatings to give a
minimum dry film thickness (dft) of 300 microns. Freedom from pinholes shall
be established by use of a spark tester. The approved paint system must have
adequate flexibility to suit the thermal movements of the concrete without
cracking whilst maintaining an effective bond.
b) A PVC sheet lining system :
The PVC sheet lining shall be fixed such that the keys or ribs are cast into the
concrete surface. The lining shall be capable of taking up the same profile as
the concrete substrate as indicated on the Drawings.
Site operatives for employment on this work shall be certified by the

manufacturer as trained to a satisfactory standard in fixing and welding
techniques.
After completion of either of the linings or systems as described in sub-clauses (a)

and (b) above they shall be offered for inspection and testing. Two sets of testing
equipment, e.g. feeler probes and spark testing, shall be provided and be
maintained and available at all times for the sole use of the Engineer's
Representatives.
Only linings or systems completely free from pinholes will be accepted.
9.2.3 Reinforced Plastic Liners
The construction methods employed shall be so as to ensure that a completely

water and gastight seal is made preventing any exposure of the concrete surround
to the corrosive liquids and gases present as detailed below and in Clauses 15.5.4
and 15.5.5.
In particular:-
Reinforced plastic liners shall be handled in the same manner as reinforced plastic
pipes. In addition, extra care shall be taken to avoid damage to the liners which are
not designed to carry loads.
The manufacturer shall visit the site to demonstrate to the Contractor in the
presence of the Engineer's Representative the methods of handling and lifting,
including formation of the joints between the chamber liner.
The Contractor is reminded that these liners are not designed to withstand pressure
exerted by the concrete during construction.
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9.2.4 Cutting and Sealing of Reinforced Liners
Where the Contractor is required for any reason to cut reinforced plastic liners, he
shall seal the exposed ends with an approved resin before incorporating the cut
reinforced plastic in the work. No cut reinforced plastic shall be used until the resin
has cured.
The resin shall be as recommended by the manufacturer of the reinforced plastic

item and shall be pigmented so that the areas where it has been applied are easily
identifiable.
It shall be delivered to site in sealed containers bearing the name of the

manufacturer and properly labelled as to its content and shelf life.
9.3 ODOR CONTROL FACILITIES
9.3.1 General
The Contractor shall provide the labor, materials and equipment necessary to install
and test the odor control facilities as shown on the Contract Drawings and as
specified herein. The odor control units shall be either of the activated carbon filter
types or of the natural soil filter bed types as indicated in the Drawings.
9.3.2 Soil Moisture and pH Probes
Moisture and pH probes shall be able to continuously measure percent moisture and
pH in the soil. All components shall be highly resistant to corrosion due to sewage
and very high concentration of hydrogen sulfide and other gases. Soil moisture
probes shall measure moisture on a percentage basis in the full range of soil
moisture (0-100 percent). pH probes shall at a minimum be accurate within the 4-10
standard unit range. All probes shall be designed for maintenance and replacement
with minimum soil disturbance.
9.3.3 Activated Carbon Odor Control Filter
The activated carbon odor control filter shall be furnished and installed in
accordance with Clause 17.2.48. The air blowers for the odor control unit shall be as
specified in Clause 17.2.17.
9.3.4 Natural Soil Odor Control Filter
9.3.4.1 Materials
HDPE (High Density Polyethylene) Liner
The HDPE liner shall be furnished and installed in accordance with Clauses 19.3.4
and 19.2.13 and as shown on the Contract Drawings.
Washed Stone

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Stone for the air plenum shall be washed, rounded, uncrushed, well graded in size
from 20 mm to 25 mm and consisting of clean, and durable particles free from dirt,
vegetation or other objectionable matter and free from an excess of soft, thin
elongated, laminated or disintegrated pieces. The Contractor shall submit a sample
of the stone to the Engineer for approval prior to placement.
Wood Chips
Wood chips shall be obtainefrom hardwood and shall be of 10 mm to 50 mm

diameter. Not more than 2 percent shall consist of leaves, twigs or shavings. They
shall be free of extraneous materials, stone and debris. The Contractor shall submit
a wood chip sample to the Engineer for approval prior to placement.
Soil Filter
The soil filter shall be a mixture of approved natural sand or sandy loam and treated
compost. The compacted soil/compost mix shall have a 50 percent porosity. The
compost shall be a product of thermophilic aerobic stabilization. It shall be
adequately stabilized, so as to be completely free of any odors. The compost shall
be friable, pass through a 13 mm mesh screen, and be free of stones, stocks and all
objectionable debris. Compost shall have a pH of 5.5 to 8.0 and no less than 25
percent volatile solids. The compost source is subject to the review of the Engineer.
All compost shall be "cured" to the point that it is no longer self heating.
The Contractor shall place the stone, wood chips, soil and compost in layers of
uniform thickness as indicated on the Contract Drawing(s) or as directed by the
Engineer. The stone, wood ships, soil and compost shall be placed so as not to
damage the aeration piping. Damaged piping is to be replaced by the Contractor at
no additional cost to the owner.
9.3.4.3 Monitoring
The Contractor shall perform the following selected soil and atmospheric analyses at
the direction of the Engineer, but not more than once per week with the exception of
soil moisture and pH, for the length of the natural soil filter maintenance period. The
results of the analyses shall be recorded and presented to the Engineer at the end
of each month. Soil samples must be taken so as not to disrupt the even distribution
of air through the odor control filter.
Atmospheric Hydrogen Sulfide
Hydrogen sulfide (H2S) gas concentrations shall be measured in the atmosphere

directly over the filter bed with a probe placed immediately above the surface of the
natural soil filter. The H2S levels shall be monitored and recorded continuously.
Soil Moisture and pH
Soil moisture and pH shall be monitored and recorded continuously at a depth of

0.75 meters from the natural soil filter surface using the soil moisture and pH probes
as specified in Clause 9.3.2.
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Chlorides, Sulfides and Biological Analysis
Chloride and sulfide concentration shall be measured from soil sample collected at a
depth of approximately 0.75 meter from the natural soil filter surface. A biological
analysis shall be performed on the same soil samples to identify biological organism
in the filter media. The samples for these analyses shall be taken once per month
unless otherwise directed by the Engineer.
9.3.4.4 Maintenance
Where excessive settling or discontinuities have occurred in the soil filter media, the
Contractor shall replace the entire soil/compost media or add additional soil/compost
mixture at the direction of the Engineer.
9.3.4.5 Acceptance Test
The Contractor shall test the porosity of the compacted soil/compost mixture before
placement and provide the results of the test to the Engineer.

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SECTION 10 - BUILDING SPECIFICATIONS PIPELINE RENOVATION, REPLACEMENT

AND ABANDOMENT
10.1 GENERAL
10.1.1 Renovation, Replacement and Abandonment Works
The Contractor shall provide the labor, material and equipment and perform the
work necessary to renovate, replace or abandon the sewers indicated on the
Contract Drawings and as directed by the Engineer.
Where down sizing has been indicated the renovation of existing sewers or rising
mains shall be undertaken using slip-lining technology. Alternatively subject to
the approval of the Engineer and prior to mobilization to the works site,
renovation of the pipeline may be by using either a deformed pipe lining system
or an inversion type soft lining system.
Where up-sizing or replacement has been indicated the existing pipeline may be
replaced using conventional open cut methods or where such methods are
unacceptable or impractical, a non-disruptive method using pipe bursting
techniques shall be adopted.
All renovation or replacement operations shall be conducted from within existing

manholes without long lead in trenches unless otherwise approved by the
Engineer. The selection of insertion and reception locations shall be such as to
minimize disruption of normal traffic and inconvenience to the public.
Design calculations and method statement for each method proposed shall be
submitted to the Engineer at least 35 days prior to the intended date of
commencement of the work on site.
The Contractor shall inspect each location for proposed pipeline renovation to
confirm or determine the following:
1) The length and size of pipeline to be renovated.
2) The access available to the pipeline at either manholes or chambers.
3) The location of existing services together with any additional services not
4) The number of house connections to the pipeline and their location.
Where there is infiltration of groundwater at pipe joints, cracks and other defects,
the infiltration shall be sealed off prior to the installation of any lining. The
materials and method of sealing shall be submitted to the Engineer for approval.

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10.1.2 Use of Approved Specialist Firms / Sub-Contractors
The Contractor shall engage specialist Firms/Sub-Contractors to carry out/

execute each of the specialized category of works such as:
a) Pipeline Renovation - Slip lining, deformed pipe lining, and soft lining.
b) Pipeline Replacement - Pipe bursting
All specialists Firms/Sub-Contractors are subject to approval for each aspect of

work on this project in the field of their respective specialization. Only those
companies that can demonstrate successful experience on projects similar to
that required for this work (scope, size, conditions, and program) shall be
proposed by the Contractor for consideration and approval. Companies proposed
for approval shall demonstrate the necessary registration as a Contractor
licensed to work in Dubai either directly or through a legal association with a
registered Contractor.
10.1.3 Health and Safety
The Contractor shall provide and agree with the Engineer a written statement
detailing safe systems of work (see clause 9.4 ‘Safety Procedures’ of the General
Specification).
The Contractor shall provide and maintain on site suitable and sufficient safety
equipment and the necessary personnel trained in its use, for the safety and
protection of employees, the general public and systems and property of Dubai
Municipality.
The Contractor is responsible for the safety of all personnel as well as for the
safety of the public during the performance of the work and is responsible for
maintaining safe conditions in and around the work area. This is specified in
more detail in Section 9.
10.1.4 Materials
10.1.4.1 Polyethylene and uPVC Pipe
a) General
uPVC sewer lining pipe shall comply with the provisions of clause 4.1.4 of
this specification.
Polyethylene (HDPE or HPPE) sewer lining pipe shall comply with the
relevant provisions of Clause 4.1.7 of this specification.
Short length sections shall be used for slip lining and pipe bursting
technique between manholes where no long lead in trenches is permitted.
The short sections shall be of such a length as to enable insertion from

within the smallest diameter manhole in the applicable sections of the
sewerage system.
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Winching forces on PE and uPVC pipes during jointing and installation

processes shall be restricted so as not to exceed the maximum
permissible short term tensile stress specified by the pipe manufacturer at
the appropriate temperature.
b) Storage, Handling and Transport
uPVC, HDPE or HPPE pipe shall be stored, handled and transported

generally as specified in clause 4.2.3 for Thermoplastic pipes.
Black polyethylene pipe may be stored either under cover or in the open.
Natural polyethylene pipe, however, shall be stored under cover and
protected from direct sunlight.
Straight lengths shall be stored on horizontal racks giving continuous

support to prevent the pipe taking on a permanent set.
If, due to unsatisfactory storage or handling, a pipe is damaged or kinked,

the damaged portion shall be cut out completely.
Transport vehicles shall be provided with a flat bed free from nails or
other projections which might cause damage to the pipe by abrasion.
All lining pipes shall be inspected before being taken into store and again
before being taken underground for infiltration.
c) Jointing
Short section pipes shall be capable of jointing by fusion welding

techniques or, alternatively, by mechanical type joints including screw
type joints or snap on locking connectors. Details of jointing systems shall
be provided to the Engineer prior to procurement of the pipe.
Linings shall be cut using methods approved by the Engineer.

Precautions shall be taken to avoid delaminating or spalling.
Jointing - Butt Fusion Welding
The Contractor shall supply the Engineer with the pipe manufacturers
welding instructions.
Welding shall be undertaken in clean conditions and an appropriate cover

shall be provided to prevent rain or airborne particles from contaminating
the pipe faces prepared for welding. If necessary, the pipe ends shall be
plugged or covered to prevent internal cooling. Only electric heating
plates shall be used for butt fusion welding.
Pipe jointing shall conform to the pipe manufacturers recommended

procedures. The weld bead is to be checked to ensure that it is uniform in
shape, smooth in appearance and bead width conform to the
manufacturers allowable limits. The bead height shall not be greater than
half the bead width.

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Any unacceptable weld, and at least 250mm length of pipe on either side
of that weld, shall be cut off and discarded.
Internal and external weld beads shall be removed to a minimum

protrusion of 1mm from the pipe wall after the outside of the joint has
cooled to 35°C or below.
Welds shall be sampled, as directed by the Engineer, and shall meet the
requirements of PE tensile weld test.
Jointing - Mechanical Type
The Contractor shall use either Snap Lock, Clear line or other approved
mechanical joint system and shall satisfy himself that loads applied during
the slip lining operation are within the accepted limits for the joint as
provided by the manufacturer. The joint shall be capable of withstanding
the grouting pressure or the standard pipeline water or air test, whichever
is greater.
The Contractor shall provide calculations of the loads expected during

installation and during service and the manufacturers recommended
allowable loads to the Engineer prior to purchase of the pipe.
10.1.4.2 Annulus Grout
a) General
Cement for annulus grout mixes shall be sulphate resisting Portland

cement complying with the provisions of BS 4027. The use of pfa with
sulphate resisting cement shall not be permitted.
Sand for annulus grout mixes shall meet the relevant requirements of
BS 882 or BS 1200.
Admixtures for annulus grout mixes shall meet the relevant requirements
of BS 5075, but shall not be used without the written approval of the
Engineer.
Any admixture shall be measured using a proprietary dispenser and shall

be mixed with the full amount of water required for each batch and the
combined water/admixture mixed with the dry constituents.
Admixtures shall be stored and used strictly in accordance with the

manufacturer’s instructions.
Mixing water for annulus grout mixes shall be of potable quality.
Full details of the proposed grout mix shall be submitted to the Engineer
for approval.
Trial mixes of the grout type proposed shall be undertaken to establish

the properties of the grout. The following properties shall be determined
and the results shall form the control values for quality control purposes.
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1) Density using the Baroid Mud Balance or similar approved equipment.
2) Workability using either the Concrete Flow Trough or the Marsh Cone
with 10mm orifice.
3) Compressive strength. Grout cubes shall be prepared and tested as

follows:
Cube moulds shall be 100mm or 70.7mm with all joints sealed to prevent
leakage. Moulds shall be overfilled and air bubbles removed by lightly
tapping the mould. After leaving for 30-60 minutes, the excess grout shall
be struck off and the moulds covered with plastic sheeting. Moulds shall
be stored at 20°C± 5°C for 24 hours or until the grout has attained
sufficient strength to allow the cube to be stripped from the mould
whichever is the greater.
The cubes shall be removed from the moulds, marked and stored in water
at a temperature of 20° C± 1°C until tested. The Contractor shall test the
grout cubes at 28 days after casting. Grout cubes shall have a minimum
compressive strength of 3N/mm2.
4) Bleeding. The amount of bleed water shall be determined by filling a

100mm diameter container to a depth of 100mm with grout, covering to
avoid evaporation and removing the bleed water after 3 hours. The
amount of bleed water shall be expressed as the percentage ratio of the
volume of bleed water to the original grout sample volume. The
percentage by volume of bleed water after 3 hours shall not exceed 5
percent (5%).
b) Grouting
Grout shall be injected from the downstream end of the renovated sewer.
A minimum of two air vents shall be provided. Vent holes shall be

plugged when all air, water and contaminated or watery grout has been
released. The pressure shall be continuously monitored by a suitable
gauge fitted at the injection nozzle. The injection pressure shall not
exceed 50kN/m2. The gauge shall have a full-scale reading of not more
than 200 kN/m2.
Means of immediate communication between the nozzle operator and the

pump operator shall be maintained during the grouting and a means of
rapidly stopping the grout flow shall be provided.
The quantity of grout injected at each injection point and the maximum
pressure at the nozzle at each injection point shall be recorded and the
records made available to the Engineer.
The grout shall be mixed in the proportions specified in Clause 3.2.8 for
Class G3 cement grout.

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The dry constituents shall be thoroughly mixed using the minimum

quantity of water to ensure the necessary fluidity and to render it capable
of penetrating the work. All grout is to be used within one hour of mixing.
Sulphate resisting cement shall not be used as a constituent of grouts

containing pfa. Immediately after each grouting operation, the Contractor
shall inspect the pipeline and clean out any excess grout. All excess grout
shall be disposed of in a manner acceptable to the Engineer such that it
does not contaminate any sewer or watercourse.
Unacceptable grout and any grout wash water shall be disposed of by the
Contractor in a manner acceptable to the Engineer such that it shall not
contaminate any sewer or watercourse.
The Contractor shall make three (3) grout cubes from samples taken from
every 5m3 of grout or after every 50 meters of grouted pipe, whichever is
the smaller, as detailed in the previous section.
The density and workability of every batch shall be determined. The

density shall not differ by more than 5 percent from the specified density.
The workability shall not differ by more than 125mm or 5 seconds
(through or Cone test respectively) from the specified workability.
10.1.5 Diversion of Sewage Flows
The Contractor shall provide the equipment, materials and labor necessary to
divert flows around the work site during the lining operation. The pipe section to
be lined shall be isolated from sewage flow by plugging or blocking the line in the
upstream and downstream manholes.
The flow diversion system shall be designed and installed in such a manner as to
minimize disruption of traffic and inconvenience to the public. The Contractor
shall submit his proposed diversion details to the Engineer for approval prior to
mobilizing onto the site.
10.1.6 Flow Control
The Contractor shall use flow control methods and procedures as required to
ensure the safety or personnel and to facilitate completion of the work. Control
measures shall include plugging or blocking of the sewage flow or bypass
pumping where appropriate. The Contractor shall provide, operate and maintain
all equipment needed to properly control flows during the work.
Where the flow is to be blocked or plugged temporarily, the equipment shall

remain in place until the work has been completed and inspected. It is to be
removed in such a manner that permits sewage flow to gradually return to normal
without surge, surcharging or causing other disturbances downstream.
The Contractor shall provide, operate and maintain a bypass system to conduct
sewer flows around the work area when flow cannot be controlled by blocking or
plugging or when it is necessary to maintain system sewer flow around the work
area.
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The bypass system is to be of sufficient capacity to handle existing normal sewer

flows plus any additional flow, which may occur during a rain event should the
work take place during the rainy season.
Flow control and bypassing methods and procedures must result in minimum
inconvenience and disturbances to the public, and prevent damage to public and
private property due to flooding, surge or excessive surcharging.
10.1.7 Maintaining Clean Conditions
As noted elsewhere in this Section, the Contractor shall maintain clear conditions
in and around the work area at all times. All material removed from the manholes
shall be taken from the site immediately and disposed of in a safe and approved
manner. Removed material and debris shall not be stored at the work area. The
manner and location of disposal of material shall be approved by the Engineer
and employer prior to the commencement of work.
Construction material and equipment shall be brought to the work area only as
needed and shall be stored on site in a safe and proper manner. The Contractors
equipment and material at the work site shall result in minimum inconvenience
and disturbance to the public.
During the performance of the work, the Contractor shall ensure that no removed
materials or debris, nor any construction material or equipment is permitted to
enter the sewerage system. The Contractor shall provide suitable screening and
other means of trapping and blocking as required in the downstream manhole to
prevent material from passing downstream.
The screened, trapped or blocked material shall be promptly removed from the
manholes by suitable means, placed in suitable containers, removed from the
site and disposed of properly.
10.1.8 Sewer Pre-Renovation Surveys
The existing sewer shall be CCTV surveyed prior to any renovation or repair work. Refer to
Section 10.7 for CCTV survey requirements.
10.1.9 Cleaning of Sewers
All deposits of debris that are likely to jeopardize the performance of the lining operation or
of the finished pipe lining shall be removed. This may include, but not be limited to sand,
grease accumulations, construction rubble and other debris in the sewers as well as root
and other hard protrusions. Cleaning shall be carried out by approved methods.
All debris removed from the sewer shall be disposed of in a safe manner. The method and
location of disposal shall be submitted to the Engineer for approval prior to beginning
cleaning operations. The Contractor shall take all precautions to prevent debris from being
carried down stream of the work place. Refer to Section 10.7 for Sewer Cleaning
Requirements.

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10.1.10 Traffic Control and Diversion
The Contractor shall submit his plans for the diversions of traffic around the site
of the work to the Dubai Municipality and the Dubai Traffic Police for approval
prior to mobilizing on site. The Contractor shall provide all traffic barricades,
lights, signs and all other equipment or personnel necessary to control traffic
safely around the work site. For road-diversions and road-signs refer to Appendix
1 and Appendix 4, Part 3 of 3 of the Specifications.
10.1.11 Manhole Connections
Where a renovated or replacement sewer connects to a manhole the channels

and benching shall be modified in accordance with Section 11.2 ‘Manhole
Renovation to suit the new pipe sizes and / or arrangements.
The design and installation shall be such as to ensure that groundwater is not
permitted to enter the sewer or manhole.
Compatibility between materials for sewer renovation or replacement works and

manhole materials shall be ensured.
10.1.12 House Connections
House connection work including the re-routing of existing house connections is

not shown on the drawings.
All house connection work shall be designed by the Contractor and approved by
the Engineer. This design work shall include a full survey and investigation for
each individual house connection together with drawings and calculations for
submission to the Engineer for approval.
House connections to existing manholes that will be abandoned shall be re-

routed to the most suitable alternative new or existing manholes.
Where the main sewers to be renovated or replaced have house connections

directly connected to the sewer by a “Y” connection, the existing house
connections shall be abandoned and replace with new house connections and
transition chambers, if necessary. The new house connections shall be
constructed connecting to the nearest existing manhole or house connection
chamber. House connections and chambers shall conform in shape, size,
dimensions, materials and other aspects to the details indicated on the Contract
Drawings or as ordered by the Engineer.
House connection works shall be carried out in accordance with Section 4 of the
Specification.
10.2 PIPELINE RENOVATION - SLIPLINING
10.2.1 General
The renovation of existing sewers or rising mains where down-sizing has been
indicated shall be undertaken using slip-lining technology; The slip-lining pipe is
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to be manufactured from unplasticised polyvinyl chloride (uPVC), high density

polyethylene (HDPE) or high performance polyethylene (HPPE). The annular
space between the existing pipe and the new slip-lined pipe shall be filled with
grout.
The slip lining work shall include, but not be limited to the following operations.
1) Initial sewer cleaning prior to CCTV Survey

2) Initial CCTV survey and logging
3) Submission by Contractor to Engineer of proposed slip lining method
based on the initial CCTV survey and minimum disruption.
4) Full sewer cleaning prior to slip lining.
5) Slip lining
6) Grouting
7) Manhole Refurbishment as per clause 10.1.11
8) Testing of slip lined pipe
9) Temporary blocking off and over pumping and diverting of all contributing
flow as required during operations (1) through (8) above.
proving pig down the length to be relined to confirm the minimum annulus
size.
10.2.2 Slip-Lining Execution
Slip-lining shall use uPVC, HDPE or HPPE pipe lining.
Immediately prior to installation of the pipe lining, the Contractor shall pass a
proving pig down the length to be relined to confirm the minimum annulus size.
The proving pig shall have solid ends of sufficient rigidity and length to be
representative of the proposed lining system.
The pipe lining shall be installed by winching (or other approved method) the
assembled pipe through the existing sewer. Details of the proposed method of
winching must be submitted to the Engineer for approval at least seven (7) days
before the proposed insertion date.
The joints shall be watertight during winching of the pipes and in their final
positions.
The joints shall be designed to withstand the external pressure applied to the
joint during annulus grouting and to prevent any leakage of grout into the liner
pipe.
The winch shall be fitted with a direct reading load gauge to measure the
winching load. At the end of each days winching, the Contractor shall provide the
Engineer with copies of the forces recorded in winching or each approved
method at the start of any pull and during the pull at increments of 20 meters of
winching distance and at any restart after temporary stops.
The Contractor shall supply sufficient cable in one continuous length so that the
pull may be continuous between approved winching points.
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The winch cable and cable drum must be provided with safety cage and supports
so that it may be operated safely without injury to persons and property.
The Contractor shall provide a system of guide pulleys and bracings at each
intermediate manhole to minimize cable contact with the existing sewer between
manholes.
A nose cone shall be fixed to the first pipe to be inserted and shall be fitted with a
swivel attachment to reduce the twist transmission between the winch cable and
nose cone.
Lubrication to ease the pull will only be permitted with the written approval of the
Engineer and shall be water and / or bentonite.
Linings shall be cut using methods as recommend by the manufacturer or

approved by the Engineer. Precautions shall be taken to avoid de-lamination or
spilling.
10.2.2.1 Grouting
The annular space between the existing sewer pipe and the newly installed lining
is to be filled with cementitious grout as per clause 10.1.4.2. The Contractor shall
take all necessary precautions to ensure continuous operations between
manholes or drive pits and that any delay due to blockage or mechanical
breakdown is minimized so as not to affect the performance of the placed grout.
The selection of the grout material and the method for grouting the annular space
shall be such as to prevent the flotation of the pipe during the grouting operation.
As a minimum, the newly installed pipe lining, shall be capped and filled with
water.
10.2.2.2 Treatment of End of Lining
At the upstream end of the lining, the existing invert is to be broken out and the
lining lay on a suitable mortar bed so that the inverts are level. At all other points,
the existing sewer shall be suitably prepared and a smooth transition made with
suitable mortar.
Where existing benching and channels require modification to suit the new pipe
sizes and arrangements, then prior to sewer lining being carried out, the manhole
shall be thoroughly cleaned; the existing benching and channels scrabbled. All
loose scale aggregate and dust removed and any large holes filled with 3:1 sand
cement mortar.
The channel invert and sides shall be broken out to a depth sufficient to permit a
minimum of 10mm thickness of epoxy mortar or 7mm thickness of GRP laminate
to be applied in accordance with clause 11.2.8 after completion of the renovation
works.
Alternatively, with the approval of the Engineer, the benching and channel may
be broken out and reconstructed with Class 30/20 concrete to profiles suitable for
the new pipe sizes and arrangements and which will enable application of the
minimum thickness of laminate as detailed in clause 11.2.8.
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10.3 PIPELINE RENOVATION - DEFORMED PIPE LINING
10.3.1 General
Where down sizing has been indicated on the Drawings and where the existing
pipe is not suffering from excessive deformation, the Contractor may propose to
renovate the existing sewer using deformed pipe lining systems. In such
instances, the Contractor must indicate which line he proposes to renovate using
deformed pipelining techniques and obtain approval from the Engineer prior to
mobilizing labor, materials and equipment to the work site.
The deformed pipe lining works shall include but not be limited to the following
operations:
1) Initial sewer cleaning prior to CCTV survey.
2) Initial CCTV survey
3) Submission by Contractor to Engineer of proposed deformed pipe lining

process to be used based on the initial CCTV survey.
4) Preparation of manhole per clause 10.3.7
5) Full sewer cleaning prior to deform pipe sewer lining.
6) Deformed pipe sewer lining.

7) Testing of lined pipes.
8) Final jetting and CCTV survey
9) Temporary blocking off, over pumping and diverting of all contributing

flows as required during operations (1) to (8) above.
10.3.2 Materials - HDPE or HPPE Pipe
Pipeline renovation by deformed pipe techniques shall use high-density

polyethylene (HDPE) or high performance polyethylene (HPPE) pipe as specified
in Clause 4.1.7 of these specifications.
The HDPE or HPPE pipe shall be supplied in coils or on reels as recommended

and provided by the manufacturer.
10.3.3 Further Site work Preparation
The Contractor shall obtain the field measurements of the existing pipe profiles at
the accessible points such as manholes.
In addition to vertical and horizontal measurements of the pipe diameters, the

Contractor shall obtain measurements of the inner circumference of the pipe.
From the inner circumference measurements a round pipe theoretical outer
diameter shall be computed and compared to measured diameters. The
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horizontal and vertical diameters measured shall be used by the Contractor to

make necessary decisions about the overall conditions for the new pipe cross
sections.
The Contractor will make a determination concerning the lower and upper ranges
of the pipe’s diameters. The Contractor shall use the circumferences measured
from inside the pipe as a governing measure while the two perpendicular
diameters will be used as supporting measurements. The Contractor shall
compare the inside circumference of the pipe with the outside circumference for
the liner pipe. By subtracting one from the other, the Contractor will determine
what matching pipe should be selected for the work.
The Contractor shall ensure that the replacement pipe shall match the existing
pipe to provide a tight fit after the deformed pipe has been reverted to its full size.
The pipe shall be determined and ordered in the cold state and the Engineer
shall approve the size requirements for the pipe using the methods described
above.
10.3.4 Pipeline Obstructions
The Contractor shall repair or remove from the pipeline all obstructions (e.g.
sediments, protruding service laterals and collapsed pipe sections), that can
prohibit insertion of the pipe. A high speed rotating hydraulic cutter shall be used
to cut protruding service laterals, offset joints, roots, barnacles, concrete or other
obstructions. The cut will be made flush with the wall of the pipe to be restored
and the debris will be flushed down the pipe to the downstream manhole. If an
obstruction cannot be removed by conventional methods and/or mechanical
equipment remotely controlled, then the Contractor shall, by excavation, remove
or repair the obstruction. Such excavation shall be considered as separate
measurement item and must be approved in writing before commencement. The
difficult or special cases shall be evaluated by the Engineer and Contractor prior
to excavation. All loosened material must be removed at the downstream
manhole.
The pipeline shall also be checked immediately before lining for the presence of
collapses occurring subsequent to cleaning by passing sewer rods between
manholes, shafts or chambers. If a collapse is detected its position shall be
determined and an additional shaft shall be excavated if the debris cannot be
removed.
Where a collapse has occurred subsequent to cleaning the cost of excavation to

clear the blockage shall be paid at the appropriate billed rates.
If deformed pipe lining is delayed for a period in excess of 7 days after cleaning
and initial inspection the pipeline shall be reinspected. The cost of this work will
be borne by the Contractor if he is responsible for the delay as determined by the
Engineer.
10.3.5 Sewer Lining Execution

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All blocking off of sewers and house connections and over pumping shall be
carried out to the approval of the Engineer.
10.3.5.1. Pipe Insertion
The pipe reel or coil shall be positioned at the upstream manhole. The pipe will
be installed by pulling it, through the pipe to be restored, directly from the reel or
coil, through the upstream manhole in one single section without any excavation.
The pipe shall be winched through the existing pipe with due care to avoid
snagging or damage to the manholes. Guides or rollers shall be fitted within the
manholes to avoid the risk of snagging.
If it is necessary to reclaim the pipe from its position in the pipeline, this should
be done immediately the decision is made. Preferred methods are vacuum
collapsing the pipe or mechanically pulling the pipe, if the friction is not
prohibitively high. Excavation should be used as a last resort in the process of
recovering the pipe.
10.3.5.2 Manifold Installation
Processing manifolds to enable head and steam to revert the deformed pipe shall
be fixed at each end of the pipe.
10.3.5.3 Processing the Pipe
The Contractor shall install temperature and pressure measuring devices at the
upstream and downstream manholes. The temperatures sensors shall be fixed
as far as possible inside the pipe at the inlet and outlet points. A steam heat
source, operated in conjunction with the pressure, such as is generated from the
steam generator, shall be utilized to supply steam to the pipe during the
processing period. The steam generating equipment shall have a capacity of not
less than 102C (215F) nor more than 177C (350F). This capacity should be
sufficient to reach a downstream manhole. These measurements will be gauged
at the upstream manhole. The internal pressure range, which will be used in the
pipe’s processing, will not be less than 1.36 bars (20 psi) or more than 1.70 bars
(25 psi) for normal processing. The equipment must have the capacity to provide
at least this quoted pressure range.
10.3.5.4 Cooling Process
After the pipe has been fully processed or it has reverted to its circular shape
pressurized air shall replace steam at a gradual rate. Further cooling shall be
carried out using water.
10.3.5.5 Finishing Work
The pipe shall be cut flush at the inlet and outlet prior in the manhole by using the
rotary cutter.
10.3.5.6 Equipment General Specifications

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Steam rated pressure and temperature gauges to be fitted to the steam

generator and processing gauge stations and manifold shall be at least 125mm
in diameter and shall be clearly readable at a distance of 2 meters. All such
gauges shall have the capacity to measure from 10 to 260C.
The remote steam gauges shall be attached to the downstream processing

gauge station.
The high pressure steam hoses and fittings shall be rated for 200 psi or higher
working steam pressure.
The pulling winch shall be equipped with a tension gauge, capable of running at
constant and controlled speed. The operator must have the ability to increase or
decrease the pulling speed. The Contractor will prepare computations for
approval by the Engineer of the size of the winch necessary for a particular job.
10.3.6 Guarantee
The Contractor must provide a 10 year guarantee for the deformed pipe sewer
lining.
10.3.7 Finishing to Manholes
A. Prior to deformed pipe lining work being carried out, the manholes shall
be thoroughly cleaned, the existing benching and channels scrabbled and
all loose scale, aggregate and dust removed and any large holes filled
with a 3:1 sand cement mortar. The invert and sides of the main channel
shall be broken out to a minimum depth of 10mm with a chase 75mm x
15mm deep being formed in the sides of the main channel just before
springer level. A layer of epoxy mortar 10mm thick shall be formed in the
main channel up to springer level to give a uniform fall across the
manhole.
B. On completion of the deformed pipe sewer lining process and removal of

equipment, the lining pipe shall be neatly cut and trimmed to suit the
benching profile in each manhole. The free edge of the cut liner shall be
dressed with epoxy mortar into the performed chase in the channel sides
and a 10mm minimum thickness of epoxy mortar or 7mm thickness of
GRP laminate shall be applied to the whole of the benching and exposed
channel and over the free edge of the cut pipe as specified in clause
11.2.8
C. At the point of entry of the lining pipe to a manhole the lining pipe is to be
cut at the crown 25mm from the inside of the manhole finish and the
junction between the pipe and manhole lining is to be sealed with a
compatible material giving a similar degree of protection to the manhole
liner.
D. In manholes where two dissimilar lining pipe section adjoin, the channel
between the lining pipes shall be broken out to a depth to allow 10mm
minimum thickness of epoxy mortar or 7mm minimum thickness of GRP
laminate to be applied between the lining pipes, and a 75mm wide 15mm
deep chase shall be formed around the channel into which the bonding
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edge of the lining pipe shall be dressed with epoxy mortar or GRP
laminate. The entire channel shall then be applied with a minimum of
10mm of Epoxy Mortar or GRP laminate as per clause 11.2.8
10.4 PIPELINE RENOVATION - INVERSION OF SOFT LINING
10.4.1 General
Where down sizing has been indicated on the drawings and where the existing
pipe is not suffering from excessive deformation, the Contractor may propose to
renovate the existing sewer using inversion type soft lining techniques. In such
instances, the Contractor must indicate which lines he proposes to renovate
using inversion lining techniques and obtain approval from the Engineer prior to
mobilizing labor, materials and equipment to the work site. The inversion sewer
lining works shall include, but not be limited to the following operations:

2) Initial CCTV survey.
3) Submission by Contractor to Engineer of proposed liner design based on
the initial CCTV survey.
4) Full sewer cleaning prior to lining.
5) Inversion sewer lining.
6) Testing of soft lined pipes.
7) Manhole refurbishment as per clause 10.4.8.
8) Final jetting and CCTV Survey.
flows as required during operations (1) to (8) above.
10.4.2 Materials
The inversion type soft lining pipe material shall be of the following types:
1) A composite tube, consisting of one or more layers of polyester or acrylic

needle felt with an integral external coating of polyurethane, polyethylene,
PVC or nylon, impregnated with an approved thermosetting resin, which,
after inversion into a pipe, will bed against the pipe wall with the coating
on the inside.
2) On or more layers of a continuous glass fiber reinforcement impregnated

with an approved thermosetting resin, which, after inversion into a pipe
will bed against the pipe wall.
For the purposes of this project, only soft lining systems which provide
structural strength liners capable of resisting ground and traffic or groundwater
loadings as necessary upon curing will be considered. The resin system and the
lining thickness shall be selected to meet the chemical resistance and structural
requirements for the lining.
A trial section must be carried out and test performed as detailed in clause 10.4.3
to prove the Contractor’s proposed resin, handling technique, and the amount of
resin required.

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The Contractor must supply the Engineer with full details of recommended
usage, curing method, pot times, life, mechanical properties and chemical
resistance or the resin he proposes to use.
The Contractor must provide evidence that the proposed resin or polyethylene
material will have strength, stability and resistance to corrosion in an environment
which may comprise any combination of the following factors for a design life of
50 years:
1) Immersion in septic sewage at up to 35C.
2) Exposure to hydrogen sulphide gas derived from septic sewage to

temperatures up to 35C.
3) Immersion in saline water at temperatures up to 35C.
4) Deposits of free sulphur on exposed surfaces.
5) Exposure to 10% sulphuric acid at up to 35C.
Note: For items 1 through 3, refer to the 100-day ASTM test C581.
A preliner shall be used to prevent migration of resin into connections. The

preliner shall be composed of a polymeric membrane and may be integral with
the in-situ tube. This form of construction will be used in all applications of
inversion type lining systems.
10.4.3 Inversion Type Resin System
The inversion type soft lining systems shall use a resin system using an
isophthalic polyester resin or a proven alternative with equivalent or higher
performance characteristics than the isophthalic polyester resins. The resin
systems may contain only those additives approved by and only up to the limits
defined by the resin manufacturer to control viscosity and pot life.
The thermosetting resin system shall cure with a minimum of volumetric

shrinkage and shall have viscosities suitable for good impregnation and defined
processing characteristics at ambient temperatures between 20-50C (Middle
Eastern and tropical conditions must be accommodated).
The resin system shall cure under water and must also cure in the presence of
tar residues and dirt in the pipelines. The resin system shall not be affected by
sun radiation usually prevailing when inverting the impregnated felt tube. In
addition to the requirements of BS3532 the heat distortion temperature of
castings of fully cured resin (as opposed to felt/resin matrix) when determined in
accordance with BS2782: Method 121A shall be not less than 20C above the
expected maximum service temperature of the lining.
10.4.4 Tests

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The Contractor shall, when directed, periodically provide results of tests carried
out on the cured in-situ lining material by an approved testing laboratory. These
tests are to confirm the physical properties of the cured in-situ lining material.
Tests shall be carried out in accordance with the Specifications. The properties to
be tested are given below:
• Flexural modulus
• Flexural strength at first break
• Tensile strength
• Compressive strength
The Contractor will be required to initiate with an approved testing laboratory a

test to substantiate the 50 year creep modulus of the In-situ form material at the
working temperature in the pipe.
10.4.5 Soft Lining Design
Following the initial CCTV survey the Contractor shall supply calculations to
demonstrate the ability of the in-situ pipe to withstand design loading. These
calculations shall be comprehensive and should not be based on empirical
relationships found by the Contractor. They shall be based on a design life of 50
years. They shall cover all pipe diameters noted in the contract documents. The
liner shall be designed assuming no adhesion between the cured liner and the
walls of the existing pipe.
Approval by the Engineer of the use of any particular in-situ pipe thickness shall
not release the Contractor from his obligations under the Contract.
10.4.5.1 Liner Thickness Design
The liners for soft lining shall be designed as structural liners i.e. as chemically
protective liners with structural capability to withstand continuous inside and
outside pressure at an elevated temperature of up to 50C.
The following parameters shall be reviewed from CCTV survey record for
evaluation of the existing sewer as to its soundness structurally.
1) Infiltration of ground water accompanying soil, bedding material through

joints, open joints, breaks and missing sections.
2) Degree of corrosion due to corrosive effluent and corrosive environment.
3) Overall condition of the sewer - any visible cracks, protrusion of rubber

rings at open joints, intrusion of the tree roots etc.
The finished cured liner thickness design shall be based on:
1) Loading criteria such as ground and water pressures, highway loading.
Note: Water pressure shall be assumed to be from ground level. Highway loading
shall be assumed from Sewer Rehabilitation Manual.
2) A Standard Dimensional Ration (SDR) as shown:

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Nominal Inner
Pipe Diameter SDR
(mm dia)
250 35 - 40
300 40 - 50
350 40 - 50
400 40 - 50
500 40 - 50
750 50 - 60
1000 40 - 55
Note: For pipes less than  250mm, the liner (cured) thickness shall be minimum
4mm, but shall not exceed 6mm.
10.4.5.2 Liner Tube Fabrication
The lining bag or tube shall consist of one or more layers of needle interlocked
polyester felt or woven glass fiber and shall be fabricated to provide the required
length and thickness of in-situ pipe and shall be of a diameter such that on
inversion it expands to fit the profile of the pipe to be renovated. The required
thickness of liner tube may be achieved by fabrication in successive layers each
formed by sewing or flame bonding. Where the liners thickness is built-up using
more than one layer of polyester felt, the joints in the felt shall be offset to
prevent excessive thickening on the completed lining. The thickness of the
finished pipe shall be at least minimum specified and may be up to 15% greater,
except where felt layers overlap in which case it may exceed this value. The
outer layer shall be made from coated felt and a covering strip shall be bonded
over the flame bonded or sewn seams. The diameter of the tube shall allow for
any variation in the diameter of the pipe to be lined such that voids or wrinkles do
not occur in the finishing lining.
10.4.6 Sewer Lining Execution
All blocking off of sewers and house connections and over pumping shall be
carried out to the approval of the Engineer.
Pipe connections (if any) protruding into the sewers to be renovated shall be cut
off neatly using an approved cutting technique.
10.4.6.1 Equipment
The Contractor shall provide the expertise, personnel and equipment necessary
to perform in-situ soft lining of sewer pipes. The Contractor shall be responsible
for the provision, transport, storage, and insertion and curing of the pipe lining as
specified. The Contractor shall supply all equipment, tools, materials and labor
required to efficiently perform the soft lining work within the specified schedule.
10.4.6.2 Impregnation
The liner tube shall be laid flat and a vacuum applied by means of a vacuum
pump and the resin injected. The resin shall be impregnated evenly throughout

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by means of rollers. Both ends of the in-situ tube shall then be sealed. The
volume of resin shall be such that on completion of inversion and curing the
specified in-situ pipe thickness is achieved.
Immediately after impregnation the liner tube shall be placed in storage at or

below a maximum temperature recommended by the resin manufacturer and
approved by the Engineer and this temperature shall be maintained until the
inversion procedure commences on site using ice and cold storage vehicles as
necessary. The maximum time of storage after impregnation shall be as
recommended by the resin manufacturer and approved by the Engineer.
10.4.6.3 Transport and Storage
The lining system materials shall be transported to the site under controlled
environmental conditions according to the manufacturer’s recommendations.
The lining manufacturer shall be familiar with the changes in viscosity, gel time,
etc., which may occur during transport and storage of the resin, especially in the
climatic conditions in the U.A.E., and shall make appropriate allowances in the
lining manufacturing process. Resin stored in original, unopened containers shall
not be used after the resin manufacturers stated keeping period.
10.4.6.4 Inversion and Curing
The lining shall be inverted into the prepared pipeline using the unheated water
or compressed air. The medium used for the insertion should be as cool as
possible considering the climatic conditions in the U.A.E. and may require timing
the insertion during the night time hours and providing means for keeping the
insertion water cool.
Equipment shall be such that there is adequate head to ensure proper inversion
of the in-situ tube.
The in-situ tube shall be clamped around the inversion ring or elbow and inverted
into the pipe. Water or compressed air shall be pumped into the in-situ tube at a
rate such that inversion proceeds under an adequate head.
A water hose with discharge holes along its length, or a draw rope for
subsequently pulling in light cure lamps shall be attached to the in-situ tube rope
end so that on completion of the inversion it shall occupy the full length of pipe
being renovated.
On completion of inversion, curing shall be effected by the application of heat or

by the application of ultra violet light of the correct wavelength and intensity.
Heat shall be applied by means of circulating the water contained in the in-situ
pipe through a boiler and the water hose until the optimum curing temperature is
attained throughout the length of the pipe being renovated. The rate of
temperature rise and fall shall not exceed 10C/min. The optimum curing
temperature is to be as recommended by the manufacturer and approved by the
Engineer. The water temperature shall be automatically controlled. The resin
temperature shall be monitored using thermocouples on the inner and outer
faces of the lining installed where applicable. The boiler inlet and outlet water
temperature shall be recorded. During cure, the curing reactions become
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exothermic which may show up on the temperature monitor as a peak. The

curing temperature shall be maintained until the exothermic reaction is
witnessed, indicating a properly cured liner.
Ultra violet light shall be applied by drawing suitable lamps along the length of
the in-situ tube at a rate compatible with the resin system. For all installations the
curing parameters required must be agreed with the resin manufacturer and
After curing, the water in the in-situ pipe shall be released provided that the
temperature of the water is within 10C of ambient and provided always that this
temperature is within the safe permissible limits of temperature to allow the
Contractors employees to carry out this work in safety. The curing water must be
allowed to cool naturally and the full inversion head must be maintained
throughout cooling.
In the event that local repairs to the in-situ pipe are required the Contractor shall
submit proposals for such repairs to the Engineer. The Contract shall however
take all necessary steps and precautions to obviate the need for such repairs
during manufacture and installation of the liner.
10.4.7 Guarantee
The Contractor must provide a 10-year guarantee for the in-situ sewer lining. The
Contractor should note, however, that the design life of the lining should be 50
years as stated in clause 10.4.1
A. Prior to in-situ lining work being carried out, the manholes shall be
thoroughly cleaned, the existing benching and channels scrabbled and all
loose scale, aggregate and dust removed and any large holes filled with a
3:1 sand cement mortar. The invert and sides of the main channel shall be
broken out to a minimum depth of 10mm with a chase 75mm x 15mm deep
being formed in the sides of the main channel just above springer level. A
layer of epoxy mortar 10mm thick shall be formed in the main channel up to
springer level to give a uniform fall across the manhole.
B. On completion on the in-situ sewer lining process and removal of inversion

equipment, the in-situ pipe shall be neatly cut and trimmed to suit the
benching profile in each manhole. The free edge of the cut in-situ liner shall
be dressed with epoxy mortar into the preformed chase in the channel; sides
and a 10mm minimum thickness of epoxy mortar or a 7mm minimum
thickness of GRP laminate shall be applied to the whole of the benching and
exposed channel and over the free edge of the cut in-situ pipe as specified
in clause 11.2.8
C. At the point of entry of the in-situ pipe to a manhole the in-situ pipe is to be
cut at the crown 25mm from the inside of the manhole finish and the junction
between the in-situ pipe and manhole lining is to be sealed with a
compatible material giving a similar degree of protection to the manhole
liner.
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D. In manholes where two dissimilar in-situ pipe sections adjoin, the channel
between the in-situ pipes shall be broken out to a depth to allow a 10mm
minimum thickness of epoxy mortar or 7mm minimum thickness of GRP
laminate to be applied between the in-situ pipes, and a 75mm wide 15mm
deep chase shall be formed around the channel into which the bonding edge
of the in-situ pie shall be dressed with epoxy mortar of GRP laminate. The
entire channel shall then be applied with a minimum of 10mm of epoxy
mortar or 7mm of GRP laminate as per clause 11.2.8.
10.5 PIPELINE REPLACEMENT - PIPE BURSTING
10.5.1 General
The Contractor shall select a suitable pipe bursting method and equipment to
perform the specified pipe upsizing and replacement. The Contractor shall
specify the method and equipment to be used in his tender submittal.
Pipe bursting operation shall be conducted from within existing manholes without
long lead in trenches unless otherwise approve by the Engineer. The selection of
drive and reception locations shall be such as to minimize disruption of normal
traffic and inconvenience to the public.
The Contractor’s design shall include for all dewatering or other ground water
and soil support systems, necessary to prevent any adjacent ground from being
adversely affected during and after pipe bursting activities.
The pipeline replacement by pipe bursting works shall include, but not be limited
to the following operations:
2) Initial CCTV survey.
3) Submission by Contractor to Engineer of proposed pipe bursting

technique based on the initial CCTV survey.
4) Full sewer cleaning prior to pipe bursting.
5) Preparations of manholes prior to pipe bursting.
6) Pipe replacement by pipe bursting.
7) Testing of new pipes.
8) Manhole refurbishment per clause 10.5.3.
9) Final jetting and CCTV survey.
flows are required during operations (1) to (9) above.

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10.5.2 Pipe Bursting - Execution

The details of the method of pipe replacement to be used shall be submitted by
the Contractor to the Engineer in the form of a detailed method statement for
approval prior to mobilization to the site. The details shall include but not be
limited to the method of pipe bursting, method of jointing and if necessary,
debeading the pipe internally and externally, the location of driving and reception
pits and the necessary temporary work.
Pipe bursting shall use HDPE or HPPE pipe. HDPE or HPPE pipe shall be
installed by winching (or other approved method) the pipe bursting assembly and
jointed pipe through the existing sewers. Details of the proposed method of
winching must be submitted to the Engineer for approval at least 7 days before
the work is intended to be performed.
The winch shall be fitted with a direct reading load gauge to measure the
winching load. At the end of each working day, the Contractor shall provide the
Engineer with copies of the winching forces recorded for each approved method
at the start of any pull and during the pull at increments of 20 meters of winching
distance and at any restart after temporary stops.
The Contractor shall supply sufficient cable in one continuous length so that the
pull may be continuous between approved winching points.
The winch cable and cable drum must be provided with safety cage and supports
so that it may be operated safely without injury to person and property.
The Contractor shall provide a system of guide pulleys and bracings at each
intermediate manhole to minimize cable contact with the existing sewer between
manholes.
The pipe bursting assembly shall be fixed to the first pipe to be inserted and shall
be fitted with a swivel attachment to reduce the twist transmission between the
winch cable and nose cone.
Lubrication to ease the pull will only be permitted with the written approval of the
Engineer and shall be water and / or bentonite.
Cutting of Linings
Linings shall be cut using the methods approved by the Engineer. Precautions
shall be taken to avoid delaminations or spalling.
A. Prior to pipe bursting work being carried out, the manholes shall be
thoroughly cleaned, the existing benching and channels scrabbled, and all
loose scale, aggregate and dust removed and any large holes filled with a 3:1
sand cement mortar. The invert and side of the main channel shall be broken
out to accommodate the outer dimensions of the new pipe to be installed plus
a minimum additional 10mm depth. A layer of epoxy mortar 10mm thick shall
be formed in the main channel up to springer level to give a uniform fall
across the manhole.
B. Prior to pipe bursting work being carried out, the existing pipe penetrations
through the manhole wall shall be broken out to accommodate the outer
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dimensions of the new pipe to be installed. The Contractor shall prevent

groundwater flow into the manhole by the use of hydrophilic gel injection
around the existing pipe penetrations or by dewatering around the manhole,
or by such other method as shall be approved by the Engineer.
C. On completion of the pipe bursting process, and removal of the equipment,
the new pipe shall be neatly cut and trimmed to suit the benching profile in
each manhole. A 10mm minimum thickness of epoxy mortar or a 7mm
minimum thickness of GRP laminate shall be applied to the whole of the
benching and exposed channel and over the free edge of the new pipe as
specified in clause 11.2.8
D. At the point of entry of the new pipe into a manhole, the new pipe is to be cut
at the crown 25mm from the inside of the manhole finish and the junction
between the new pipe and the manhole lining is to be sealed with a
compatible material giving a similar degree of protection to the manhole liner.
10.5.4 Obstructions
The Contractor may encounter section of existing pipe where a concrete

surround has been used. In these situations, the pipe bursting technique may not
be capable of fracturing the pipe and concrete surround. The Contractor shall
endeavor to identify the possible locations of such obstructions through review of
Dubai Municipality records and discussions with Municipality personnel.
Where obstructions are known to exist, or where such obstructions are

encountered during the execution of pipe replacement work, the Contractor shall
excavate at the site and remove the obstruction. Following completion of the pipe
replacement through the affected section, the Contractor shall place pipe
bedding and backfill and complete reinstatement of pavements.
10.5.1.2 PIPELINE ABANDONMENT
10.5.1.3 General
The Contractor shall clean and fill by the method of continuous grout injection,
the asbestos cement sewer pipelines to be abandoned as indicated on the
Contracts Drawing(s) and as specified herein. uPVC pipes to be abandoned will
be fully cleaned as per Section 10.7 and left in place. The abandonment works
must be scheduled and co-ordinate with the renovation of existing sewers and
construction of new sewers so as to avoid conflicts between work crews, to
facilitate rapid completion of the work, and to limit disturbances to the area.
10.6.2 Grout and Grouting for Abandoned Pipeline
Grout for abandoned pipeline shall be as the annulus grout specified in clause
10.1.4.2
The asbestos cement sewers to be abandoned will be fully cleaned as specified

in Section 10.7 immediately prior to grouting.

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10.6 SEWER CLEANING AND CCTV SURVEY
10.6.1 GENERAL
The Contractor, where required to conduct a closed-circuit television survey

(CCTV) of sewers, shall perform a series of surveys as detailed below:
10.7.1.1 Extent of the Survey
The Contractor shall conduct an initial CCTV survey and logging on all existing
gravity sewers within the project area prior to the renovation and replacement of
any line. A (Post Renovation) survey shall be conducted on completion of
renovation and replacement operations all as described herein.
Initial Survey/Condition Survey
An initial survey shall be carried out on all pipelines to be renovated or replaced or

as otherwise required by the works. This survey shall be carried out as soon as
possible to check the condition of the pipe and to confirm proposed method of
replacement. This survey shall be carried out in addition to the survey immediately
prior to renovation/replacement whilst the sewer is operating under actual flow
conditions. The maximum flow in the pipe should be not more than 10%.
A light source shall be placed at the other end of the line to be surveyed to verify
the alignment of the pipe. The light may be removed once observed by the
camera, the location in the pipe length from which the light is first observed shall
be recorded.
Pre-Renovation Survey
Immediately prior to the renovation of any pipe, a CCTV survey (Pre-

Renovation Survey) shall be conducted.
Post Renovation Survey
As soon as practical after the renovation/replacement of the pipe a CCTV Survey

(Post Renovation Survey) shall be carried out..
10.7.2 SEWER CLEANING
All sewers including manholes prior to rehabilitation, renovation, replacement or

abandonment shall be cleaned as per the requirements of this section.
a) Prior to beginning the CCTV survey in any section of sewer, the Contractor
shall have the sewer section including manholes thoroughly cleaned and
prepared for the survey. The Contractor shall provide all necessary vehicles,
equipment, materials and labor, in proper condition and in sufficient
numbers, to carry out the cleaning of the sewers and manholes in a timely
and expeditious manner.
The Contractor shall arrange for the disposal of all material and debris in a
safe manner, as approved by the Engineer and the relevant authorities.
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b) Sewer and manhole cleaning shall be carried out mainly by water jetting.
Water jetting shall be carried out using purpose built jetting tankers. Jetting
tankers shall be equipped with at least 150m of suitable 25mm diameter
hose with jetting heads. The water pressure at the jetting head shall be
variable between 100 bars and 170 bars. The minimum flow rate at 100 bars
will be 2.5 l/s.
The hose shall be mounted on a power operated drum reel having variable
speed and direction controls. The hose system shall incorporate a suitable
method of meterage indication. A calibrated hose is an acceptable method
for measuring meterage. The hose must be equipped with a variety of
nozzles, including rear jets only (15½ to 30½), rear plus forward jets, and
rear plus side jets or other configuration to ensure adequate cleaning of the
pipelines.
Manhole jacks and hose guide rollers shall be used to prevent damage to
the hose.
c) Along with water jetting, sewer and manhole cleaning shall include the
following:
• Blocking off sewer lengths and over pumping where required
• Bucket and winch dredging where required
• Flushing from downstream manhole only using potable water. Debris

and sand jetted or dredged from the sewers shall be collected by silt
traps or screens installed in the downstream manhole.
• Removal and disposal of all collected debris and sand.
• Wire brushing of manholes
• Such other methods and works as may be required to clean the

sewers and manholes to a satisfactory standard.
d) Initial sewer cleaning, prior to the initial CCTV survey, shall be carried
out in such a manner as to avoid damage to the sewers, which are likely
to be in poor structural condition. Jetting pressure will be limited to 100
bars for initial cleaning.
During initial cleaning sewers must be cleaned to a standard such that

an effective CCTV survey of their structure can be carried out. Manholes
shall be similarly cleaned to permit visual surveys.
e) Full cleaning shall be performed prior to lining or abandonment of

sewers and manholes and will include all operations necessary to
remove all grease, slime and loose material from the pipes and
manholes.

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Sewers and manholes must be cleaned to a standard such that the

sewer lining can be effectively installed.
Where the initial CCTV survey indicates that the sewers are in poor
structural condition jetting pressure will be limited to 100 bars. Care
must be taken, generally, to avoid damage to the sewers. Any sewer
collapses caused by jetting shall be rectified by the Contractor
immediately at his cost.
10.7.3 SURVEY AND OPERATIONAL EQUIPMENT
The surveying equipment shall be capable of surveying a section of sewer up to

350 meters in length where entry to the sewer may be obtained at each end, up to
30 meters by rodding. Where entry is at one end of the section only, the equipment
shall be capable of surveying a section of sewer up to 150 meters in length using a
self-propelled unit.
The Contractor shall maintain this equipment in full working order and shall satisfy
the Engineer at the beginning of each working shift that all items of equipment
have been provided and are in full working order.
Each survey unit shall contain a means of transporting the CCTV camera in a
stable condition through the sewer under inspection. Such equipment shall ensure
that the CCTV camera position is maintained on or near to the central axis of the
sewer.
Where the CCTV camera is towed by winch and bond through the sewer, all
winches shall be stable with either lockable or ratcheted drums. All bonds shall be
steel or of an equally non-elastic material to ensure the smooth and steady
progress of the CCTV camera. All winches shall be inherently stable under loaded
conditions.
Each survey unit shall carry sufficient numbers of guides and rollers such that,
when surveying, all bonds are supported away from pipe and manhole structures
and all CCTV cables and/or lines used to measure the cameras location within the
sewer are maintained in a taut manner and set at right angles, where possible, to
run through or over the measuring equipment.
Each unit shall carry a range of flow control equipment, as opposed to over
pumping equipment, for use in controlling flow during the survey. A minimum of
one item of each size of equipment ranging from 150 mm to 450 mm diameter
inclusive shall be carried.
10.7.4 PERFORMANCE OF SURVEY
10.7.4.1 Camera Position
The camera lens shall be positioned centrally within the sewer, looking along the
axis of the sewer. A positioning tolerance of ± 10 % of the vertical sewer
dimension shall be allowed.
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10.7.4.2 Camera Speed
The speed of the camera in the sewer shall be limited to 0.1m/s for sewers of
diameter less than 200 mm, 0.15 m/s for sewers of 200 mm diameter up to 315
mm diameter, and 0.20 m/s for sewers exceeding 315 mm in diameter. The
camera shall be stopped whenever defects are being noted or photographed.
10.7.4.3 Linear Measurement
The CCTV monitor display shall incorporate an automatically updated record, in

meters and tenths of a meter, of the linear measurement of the camera position
from the cable calibration point.
The Contractor shall use a suitable metering device, which enables the cable
length to be accurately measured, with a tolerance of ± 1% or 0.3m, whichever is
greater. The Contractor shall demonstrate that this tolerance is being complied
with using one or both of the following methods:
• Use of a cable calibration device, or
• Use of a tape measurement of the surface between manholes.
If the Contractor fails to meet the standard of accuracy, the Engineer shall instruct
the Contractor to provide a new metering device and may, at his discretion,
instruct in writing, the Contractor to resurvey those lengths of sewer first inspected
with the original metering device.
10.7.4.4 Data Display, Video Recording and Start of Survey
At the start of each sewer length being surveyed, the length of sewer from zero
chainage up to the cable calibration point shall be recorded and reported in order
to obtain a full record of the sewer length.
The meter reading entered on to the data display at the cable calibration point
must allow for the distance from the start of the survey to the cable calibration
point such that the meterage at the start of the survey is zero. In the case of a
survey through a manhole where a new header sheet is required, the meterage
shall be set at zero with the camera focused on the outgoing pipe entrance.
The camera operator shall ensure that the meterage counter starts to register
immediately the camera moves.
At the start of each manhole length, a data generator shall electronically generate
and clearly display on the viewing monitor and video recording a record of data in
alpha-numeric form containing the following minimum information:
• Automatic update of the camera's meterage position in the sewer line from
adjusted zero,
• Sewer dimensions,
• Sewer use,
• Manhole reference numbers,
• Date of survey,

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• Road name and planning area number,

• Direction of survey, and
• Time of start of survey.
The size and position of the data display shall be such as not to interfere with the
main subject of the picture.
Once the survey of the manhole length is under way, the following minimum data
shall be continuously displayed:
• Automatic update of the cameras meterage position in the sewer line from
adjusted zero,
• Sewer dimensions,
• Manhole reference number, and
• Direction of survey.
Correct adjustment of the recording apparatus and monitor shall be demonstrated

by use of the test tape or other device approved by the Engineer. Satisfactory per-
formance of the camera shall then be demonstrated by the recording of the
appropriate test device at the commencement of each day for a minimum period of
30 seconds.
The test device(s) shall be provided on site at all times to enable practical
demonstration of compliance with the requirements of this section.
All video cassette tapes shall be supplied by the Contractor and shall be best
quality high grade (HG) new and unused prior to the recording and shall be of a
Video Home Systems (VHS) format.
10.7.5 SURVEY DATA REPORTING
The Contractor shall record and present the survey data in a format acceptable to
the Engineer. The report should generally be in accordance with the format
presented in the WAA/WRC "Manual of Sewer Condition Classification" 2nd
Edition, published 1988.
The Contractor shall supply the various numbers of copies and types of report for
each item listed, within the time period stated in the schedule for each section of
sewer.
Reports submitted by the Contractor shall be prepared by a qualified, trained and

certified Operator. The Operator shall be a signatory to each report.
10.7.6 DRAWINGS
One clean set of drawings showing manhole reference numbers which coincide
with the reporting format and tapes, shall be returned to the Engineer at the
completion of each section of the survey and shall be clearly annotated to show
any significant errors noted in the course of the survey. Such errors shall be
brought to the attention of the Engineer during the survey.

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10.7.7 METRIC MEASUREMENT
All dimensions shall be metric. For the purpose of metrication, inch sizes shall be
converted on the basis of 1 inch = 25.4 mm. Measurement shall be on nominal
diameter dimensions quoted to the nearest mm.
10.7.8 PHOTOGRAPHS
The Contractor shall provide color photographs. The photographs shall be durable
and shall be approximately 89 mm X 125 mm. Photographs should be high
resolution and computer generated by the CCTV system and printed on
photographic quality paper.
Photographs shall be taken of the internal condition of the sewers at the following
locations:
• All defective junctions and connections,

• At defects including cracks, fractures, broken pipes, deformations, collapsed
pipes and severe joint displacement,
• For continuous defects, at the beginning and end of the defect,
• Wherever else the Engineer may direct.
Where photographs are not otherwise required, general condition photographs

shall be taken of each manhole length.
The photographs must clearly and accurately show what is displayed on the
monitor, which shall be in proper adjustment.
Photographs must be clearly identified in relation to the location, survey direction,

meterage, photograph number and date when the photograph was taken. The
annotation shall be clearly visible and in contrast to its background, shall have a
figure size no greater than 5 mm and shall be type printed. The annotation shall be
so positioned so as not to interfere with the subject of the photograph.
The photographs shall be supplied in suitable A4 sized plastic holders and bound
in ring binders or lever arch files. The photographs shall be presented in
chronological order and each file shall contain a contents page providing clear
cross-referencing to the report.
10.7.9 EQUIPMENT STANDARDS

10.7.9.1 Picture Quality
The Contractor will provide a color CCTV system.
The electronic systems, television camera and monitor shall be of such quality as
to enable the following to be achieved:
• Shades of Grey. The grey scale shall show equal changes in brightness
ranging from black to white with a minimum of five clearly recognizable
stages.

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• Color. With the monitor control adjusted for correct saturation, the six
colors plus black and white shall be clearly resolved with the primary and
complementary colors in order of decreasing luminance. The grey scale
shall appear in contrasting shades of grey with no tint.
• Linearity. The background grid shall show squares of equal size, without
convergence or divergence over the whole of the picture. The centre circle
should appear round and have the correct height to width relationships
within a tolerance of ± 5 percent.
• Resolution. The live picture must be clearly visible with no interference

and must be capable of registering a minimum number of TV lines per
picture height lines. In the case of a tube camera, 350 lines, and in the
case of a CCD type camera, 250 lines.
• Color constancy. To ensure the camera shall provide similar results when
used with its own illumination source, the lighting shall be fixed in intensity
prior to commencing the survey. In order to ensure color constancy,
generally no variation in illumination shall take place during the Survey.
The Contractor shall note that the Engineer may periodically check both the live
and video picture color consistency against the color bar. Any differences will
necessitate re-survey of these new length affected at the Contractor's expense.
10.7.9.2 Video Playback
Video playback shall be capable of a resolution of a minimum of 250 lines

recorded at standard VHS speed.
10.7.9.3 Focus, Iris and Illumination Adjustment
The camera shall have pan and tilt facilities with zoom; capable of 360 rotation.
The adjustment of focus and iris shall allow optimum picture quality to be achieved
and be remotely operated. The adjustment of focus and iris shall be suitable for
conducting a 360 rotational joint survey for a minimum pipe diameter of 150 mm.
The range shall extend to infinity. The distance along the sewer in focus from the
initial point of observation shall be a minimum of twice the vertical height of the
sewer.
The illumination shall be such as to allow an even distribution of the light around
the sewer perimeter without loss of contrast, flare out of picture or shadowing.
10.7.9.4 Equipment Testing
All equipment used shall be factory calibrated and conduct a self-test on start-up.
The self-test should confirm all aspects of picture quality and general operation. In
the event of calibration discrepancies, the Contractor shall resurvey all affected
lines at his own expense.

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10.7.10 QUALITY CONTROL
10.7.10.1 Contractor's Quality Control Procedure
The Contractor shall operate a quality control system, to be approved by the

Engineer, which will effectively gauge the accuracy and consistency of the survey
report produced by the operator from the monitor picture.
The system shall be such that the accuracy of reporting shall be a function
particularly of:
• The number of faults not recorded (omissions),
• The correctness of the coding and classification of each fault recorded.
The Engineer shall be entitled to audit periodically the control system and be
present when assessments are being computed.
When requested by the Engineer in writing the Contractor shall forward to the
Engineer sufficient details and information for this audit assessment.
If any report fails to achieve the specified percentages for a particular sewer
length, the Engineer shall require the Contractor to re-code and re-submit the
report. If the accuracy check fails, the Contractor shall repeat the full quality control
check on 10 surveys, 5 surveys either side of the survey which has failed. If any
further failures are found to be outside the tolerances laid down in clause 14.7.10.5
within these additional checks, the process shall be repeated until the acceptable
standard has been reached. Any reports that have failed shall be re-coded by
another Water Training qualified surveyor and submitted to the Engineer to
replace those in his possession.
10.7.10.2 Random Selection
Quality selection shall be achieved by using two parameters:
• Population: the anticipated number of surveys carried out by one surveyor

over a
period of time.
• Sample size: the number of surveys required to be checked to satisfy the

quality
control validity.
The sample surveys for quality control shall be selected by the use of computer
generated random numbers (ERNI) or other such equivalent method and shall be
5% of the total population. Each surveyor shall have a different set of random
numbers, which are sorted into chronological order, and are renewed once the
population size has been reached. The random numbers shall not be disclosed to
the surveyor until they have been used up.
10.7.10.3 Survey Extraction

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On site the surveyor shall log the information on the surveys and the "in-office"
staff shall then count through the surveys that have taken place and copy those
reports that coincide with the random numbers.
A copy of the relevant section of video tape shall also be made.
Information on the new tape and its contents shall be entered on a survey
selection log.
10.7.10.4 Checking
Header information - All header information shall be checked to ensure that left
and right justified entries are correctly entered, alpha or numeric symbols are
correctly used and all compulsory boxes filled in. The percentages of accurate
entries shall be ascertained and any that fall below the value stated in clause
14.7.10.5 shall be rejected. All decimal percentage points shall be rounded down
to the nearest whole number.
Detail information - Each error/omission shall be treated on an equal basis whether

or not it is a minor or major error or omission. During the checking each
error/omission shall be highlighted on the report from which the following totals
shall be calculated for each survey report:
• The number of actual entries that should have been made.

• The number of actual errors/omissions made.
These totals shall be entered on the right of the survey report being checked.
Individual column totals shall also be calculated and entered on to the survey
accuracy log.
The accuracy of each survey shall be arrived at by taking the number of actual
errors/omissions away from the number of actual entries that should have been
made and dividing the result by the number of actual entries that should have been
made and multiplying by 100 to create a percentage.
Note:
The Contractor shall have the option to employ quality control methods other than
those outlined in clauses 14.7.10.2 through 14.7.10.4 of this specification with the
10.7.10.5 Accuracy for Quality Control
The minimum level of accuracy to be obtained under the quality control

procedure shall be as follows:
Standard for this Contract:
• Header accuracy 95%
• Detail accuracy 85%
• Lowest acceptable tolerance 75%

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SECTION 12 - SAFETY PROCEDURES
12.1 GENERAL
The Contractor shall be responsible for the safety of personnel and the public during
the contract period and compliance with safety requirements stated herein shall not
relieve the Contractor of his responsibility or liability under the Contract.
Prior to the commencement of the Works, the Contractor shall submit a safety policy
for the Contract detailing all proposed specific safety arrangements for the agreement
of the Engineer. This shall include but not be limited to the requirements set out in this
section.
If at any time safety requirements are not being met by the Contractor, the Engineer
shall have the right to instruct the Contractor on the necessary safety provisions and
the Contractor shall comply with such instructions forthwith.
The Contractor shall notify the Engineer immediately of any accident that occurs
whether on or off site in which the Contractor is directly involved which results in any
injury to any person whether directly concerned with the site or whether a third party.
Such initial notification may be verbal and shall be followed by a written comprehensive
report within 24 hours of the accident.
12.2 FAMILIARISATION WITH SAFETY PROBLEMS
The Contractor shall make himself familiar with the condition of the site before
tendering in order to assess the nature of safety problems he is likely to encounter and
the safety requirements.
12.3 SAFETY OFFICER
The Contractor shall appoint a Safety Officer who shall be responsible for all aspects of
safety. He shall be conversant with and experienced in all general civil engineering
construction and sewer safety techniques and emergency procedures, and shall be on
site at all times operatives are working. He shall enforce and supervise the safety
procedures at all places of works and make sure that adequate safety equipment,
required under Clause 12.5, is available in good working condition and at all places of
works at the time works are on-going.
The Safety Officer shall also be responsible for organizing, implementing and
maintaining any road closures, traffic diversions, removal of parked cars causing an
obstruction, etc., in adequate time to ensure compliance with the Contract programme.
12.4 SAFE WORKING CONDITIONS AT THE SITE
The Contractor shall provide Method Statements detailing proposed safe methods of
work with the Tender. The methods should generally follow the recommendations of
the following publications :
1) Code of Construction Safety Practice as published by the Dubai Municipality.

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2) Administrative Order No. 330 in connection with Safety Manual of Dubai

Municipality.
3) Health and Safety Guideline No. 2, Safe Working in Sewers and at Sewage
Works as published in the United Kingdom.
Accident procedures and emergency procedures shall be fully detailed.
No persons shall be allowed to enter a confined space until the safe methods of work
have been agreed upon and fully implemented to the satisfaction of the Engineer.
12.5 SAFETY EQUIPMENT
The Contractor shall make sure, prior to commencement of works on site, that
adequate safety equipment, apparatus and devices are available, and that as a
minimum the following equipment and devices are available at each entry point to a
confined space:-
Type of Equipment No. Required
a. Safety harness and ropes 2

b. Lifting frame and tackle for safety harness 1
c. Gas detector (suitable for H2S) 2
d. Approved mechanical air blower and power supply 1
e. Emergency breathing apparatus 2
f. Atmosphere monitoring device, capable
of monitoring oxygen levels, and levels
of toxic and flammable gas 1
g. Washing facilities with disinfectants,
toiletries As Required
h. Communication facilities As Required
i. Lighting (explosion proof) As Required
All personnel working on, visiting or inspecting any part of the Works shall be provided
with and be required to wear appropriate protective clothing or apparatus.
This may include:-
Safety helmets, coats, gloves, footwear, goggles, ear muffs, breathing apparatus and
any other protective apparel or any other equipment deemed necessary by the
Engineer.
Every hoist, lift, sling, chain, rope, pulley block and any other lifting tackle, used in the
Works shall be thoroughly examined by a competent person at least once every 6
months and shall be test loaded to 150% of the safe working load and shall then be
tagged with the safe working load and the date of successful testing by an authorised
testing authority.
All parts and working gear whether fixed or movable, including the anchoring and fixing
appliances of every crane and lifting machine shall be of good construction, sound
material, adequate strength and shall be properly maintained. All parts and gear shall
be examined at least once every twelve months.
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A register of all such equipment and examinations shall be kept up to date by the
Contractor and be available for inspection by the Engineer.
12.6 SAFETY PROCEDURES
12.6.1 General
All excavation shall be adequately supported against collapse and provided with
protective safety barriers and appropriate warning signs and bunting. Suitable and
sufficient scaffolds shall be provided and properly maintained for all work that cannot
safely be carried out from the ground or from part of the structure or from a ladder.
Every scaffold shall be of good construction, of suitable and sound material and of
adequate strength for the purpose for which it is used. Unless designed as an
independent structure, every scaffold shall be rigidly connected to a part of the
structure which is of sufficent strength to afford safe support. Protective headgear shall
always be worn.
All manufacturer’s instructions and recommendations for the use, application, erection
or construction of any material or item of equipment or plant shall be followed precisely.
Special care shall be taken to protect all employees when using power tools or
materials which will produce a fine dust and in particular all asbestos based products.
The operator should stand upwind of the operation and wear an approved respirator
and goggles. Wherever possible overalls should be worn and should consist of 60%
polyester fibre and 40% cotton.
Transportation of any material by the Contractor shall be in suitable vehicles which
when loaded do not cause spillage and all loads shall be suitably secured. The
Engineer shall have the right to instruct the withdrawal from the site of any vehicle
which does not comply with these requirements or any of the Dubai or UAE traffic
regulations and laws.
The Contractor shall adopt the safety procedures as proposed by him as per Clause
12.4 for entry into a manhole or other confined space. However, the following safety
procedures are outlined as a guide only. The Contractor shall, where appropriate, use
these procedures in addition to his proposed procedures while entering into a manhole
or a confined space. Also included are additional information on safety procedures for
manhole entry in Appendix 3 contained in Part 3 of 3 of these Specifications for his
guidance and use where appropriate.
It shall be explicitly understood that safety is the responsibility of the Contractor and
use of any of these procedures as outlined under this clause or in Appendix 3 shall not
relieve him of any of his contractual responsibilities.
a) The manhole or confined space shall be thoroughly vented by mechanical air

blower prior to entry.
b) A full gas check is to be undertaken prior to entry. If the level of toxic or explosive
gases is above the safe level (maximum acceptable for hydrogen sulphide is 10
ppm) or the level of oxygen is below a safe level (18%) then entry is not permitted
without the use of full breathing apparatus.

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c) All persons entering a manhole or a confined space shall wear a safety harness
properly rigged to the lifting frame.
d) The mechanical air blower shall be kept close by the manhole or confined space
which has been entered.
e) The hydrogen sulphide level in the manhole or confined space shall be
continuously monitored. If the level rises above 10 ppm then the manhole or
confined space shall be evacuated immediately.
f) At least two people shall be available close to the point of entry to operate the air
blower and lifting tackle in the event of an emergency and who shall note the
location of the nearest telephone in working order and the telephone number of the
nearest hospital before entry is permitted.
g) No smoking shall be permitted and ‘no spark’ tools shall be used.
12.6.2 Atmosphere Monitoring

When any person is in a confined space, the atmosphere at the work place and at the
base of the access manhole or pit shall be continuously monitored by a Monitoring
Device to detect oxygen deficiency, flammable gas and toxic gases. The monitoring
equipment shall be designed to be lowered into the work place or access manhole and
shall not depend on a sample draw tube from the surface. The monitoring equipment
shall be the first piece of equipment to be lowered into the place of work and shall be
the last piece of equipment removed.
The Contractor shall provide, maintain and calibrate the approved monitoring
equipment in accordance with the manufacturer's instructions. The Contractor shall
provide adequate numbers of monitoring devices to fully cover all proposed work
places and open manholes or access pits with adequate spare devices, parts and
batteries as needed to ensure complete monitoring of all sites of work at all times
throughout the construction period. No entry into a confined space shall be allowed
until the monitoring devices have been properly placed at the work place or access site
and the readings indicate that the atmosphere is safe. Operatives are to be fully
trained in the use of the monitoring equipment and in the necessary response to alarm
conditions.
12.6.3 Atmosphere Ventilation

Before any person is allowed to enter a confined space, the atmosphere shall be
adequately ventilated. As a minimum, both ends of the sewer section or work place
shall be opened to the atmosphere either by removing the manhole covers or through
open access pits. Positive ventilation shall be provided at all times when a person is in
a confined space, even if the atmosphere monitoring equipment indicates that the
atmosphere is safe for access.
12.6.4 Safety Harness
Each person entering a confined space shall wear a harness at all times. The harness
shall be designed such that it will enable an unconscious person to be lifted to the
surface in a vertical posture.
12.6.5 Emergency Breathing Apparatus

Each person in a confined space shall have emergency breathing apparatus available
and ready for use within the confined space. The breathing apparatus shall have a
minimum capacity of 2 litres and a working pressure of 200 bar and shall be tested
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daily, prior to starting work.
12.6.6 Active Confined Space Entry

Before any person is allowed to enter a confined space that is in active service, the
Contractor shall ascertain the schedule of sewage flows which can be anticipated over
the duration of the work. This shall include average and peak gravity sewage flows and
the discharge flows from all upstream pumping stations. Should the combined gravity
and pumped flows exceed safe working conditions at the work place, then the
Contractor shall prepare a plan for the control and diversion of flows around or away
from the work place. The method of flow diversion shall be as approved by the
Engineer and by the Dubai Municipality. A "permit to work" system shall be employed
for work on sewers where incoming flows (from pumping or diversion) are controlled by
people remote from the work site.
12.6.7 Washing Facilities
Every work place where persons are entering a confined space, shall be provided with
facilities for washing.
12.6.8 Communication
The Contractor shall provide a means of communication, appropriate to the safe

system of work, between ground level and any work place within the confined space.
12.6.9 Lighting
When permanent works are being constructed or inspected, the confined space shall
be adequately lit. The lighting apparatus shall operate at a voltage not exceeding 50
Volts. The circuit shall be protected against overload. No transformers, switches, fuses,
contact breakers, etc., shall be taken into the confined space. Bulbs shall be protected
against damage.
12.7 TRAFFIC CONTROL

Prior to initiating any work at a site, the Contractor shall prepare, for the approval of the
Engineer, a plan for the diversion and control of traffic around the work site. The
approved traffic control plan shall be submitted to the Dubai Municipality Roads
Department and Dubai Traffic Police for review. Work at the Site may not commence
until the traffic control plan has been approved by the Dubai Municipality Roads
Department and Dubai Traffic Police.
The traffic control plan shall include a street plan of the work site showing all traffic
lanes and building access drives that will be affected by the work. The proposed
system of traffic diversions and the manner of control shall be clearly illustrated,
including the location and types of traffic cones, warning signs and warning lights to be
used. The plan should indicate the anticipated schedule of works for which traffic must
be diverted. Road diversions and road signs shall conform to Clause 1.3.4 and to
Appendix 1 contained in Part 3 of 3 of the Specifications.
The traffic control plan shall take into consideration the requirements of the work crew
for access to the work site, for positioning and parking of vehicles needed for the work
and for the temporary storage of equipment and materials.

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SECTION 16 - MICRO-TUNNELLING AND PIPE JACKING
16.1 GENERAL
The Contractor shall furnish all labour, tools, materials and equipment required to
design and complete the installation of pipelines using micro-tunnelling or pipe
jacking methods as and where indicated on the Drawings and as specified,
including surveying, instrumentation and dewatering. The Contractor may also
elect to use micro-tunnelling methods to install those pipelines where the
installation method has been left to the option of the Contractor.
The method selected by the Contractor shall be capable of maintaining the

stability of the tunnels when accounting for soil and groundwater conditions and
shall take into account the types of soil likely to be encountered during
construction and the likelihood of encountering caprock or cobbles.
The options available to the Contractor can include the following:
a. Micro-tunnelling Method. The Contractor may select either the auger type
system or the slurry type system depending on his evaluation of the
tunnelling conditions based on the site investigations.
b. Pipe Jacking Method. The pipeline can be installed either by jacking the
tunnel shield or by jacking the entire tunnel shield and pipe string. The
selection of jacking method is dependant on the type of micro-tunnelling
system to be used.
The Contractor shall decide the excavated dimensions of the drive and reception
shafts at the locations shown on the Drawings and as required for the
micro-tunnelling method selected. Minimum shaft dimensions shall be used at all
locations.
Caisson-type manholes may be used where possible to minimize drive and

reception shaft dimension and traffic disruption.
The Contractor shall also determine the necessary horizontal alignment of the
tunnel and the locations of any additional shafts that his approved construction
method may require. The Contractor's work shall at all times remain within the
road right-of-way and the selection of shaft locations shall be such as to
minimize disruption of normal traffic and inconvenience to the public.
The Contractor's design shall include for all dewatering or other groundwater and
soil support systems, necessary to prevent any adjacent ground from being
adversely affected by shrinkage movement or loss of fines during and after the
construction of shaft and tunnels.
The Contractor's design shall include for all ground stabilization measures either
in advance or during micro-tunnelling operations.

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The Contractor's design shall include formulation of construction procedures to

minimize ground movement and prediction of movement during shaft and tunnel
construction.
The settlements arising from the construction of the works shall be limited to the
following:
a. Ground or roadway surface above the pipe center line: 5 mm.
b. Front face of adjacent structures: 5 mm.
Safety measures are of paramount importance. Tunnelling through sands below

the water table is a potentially dangerous situation. A comprehensive statement
of safety policy related to these micro-tunnelling works shall be submitted prior
to commencement of works.
It is emphasized that in general no open trenching shall be allowed due to the

congested nature of the area and that sheeting shall have to be provided for all
open excavations when such open excavation is unavoidable. However, the
number and size of all proposed shafts shall be kept at a minimum.
The proximity of buildings is such that the driving of steel sheet piles to shafts is
not permissible, nor is any construction noise greater than 70 dB. All
constructional plant forming part of the micro-tunnelling system is to be
electrically driven, either by mains supply or on-site generation.
Before commencing on site the Contractor shall submit a full Method Statement
indicating how all the measures required in this Specification are to be
accommodated including details of the sizes and type of micro-tunnelling
equipment proposed and the disposal of waste materials including any slurry.
This method statement shall be in addition to, and in conformity with any other
method statement(s) the Contractor is required to submit for micro-tunnelling at
the time of tendering.
The pipes and joints proposed for use in micro-tunnelling item(s) shall, as a
minimum, comply with the appropriate standards set for pipes and joints (refer
to sub-section 4.1) used in conventional (open-trench) pipeline construction in
all respects including materials of manufacture, tolerances, minimum strengths,
etc. In particular, the pipes and joints must comply with the details of Clause
4.1.6 for use in micro-tunnelling or similar jacking operations. The Contractor
shall satisfy the Engineer that the proposed pipes and joints shall adequately
withstand the temporary loads applied during installation.
If the Contractor elects to propose GRP pipes with concrete surround for micro-
tunnelling, he shall submit along with his Tender, comprehensive material
standards and complete specifications for these pipes for review and
consideration of the Engineer. He shall also provide evidence of successful use
of such materials elsewhere in a similar construction method and in areas of
similar soil conditions including the highly saline nature of the groundwater as in
Dubai.

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16.1.1 List of Approved Specialist Firms/Sub-Contractors
Included below is the list of specialist Firms/ Sub-Contractors who are approved to work
for Micro-tunnelling on this project. The Contractor shall be required to select and
engage specialist Firm(s)/Sub-Contractors(s) from the approved list to carry out all the
Micro-tunnelling works of this project (except where the Contractor himself is included in
the approved list):-
1. Euro-Iseki Ltd. (U.K.) 2. Foundation Engineering (U.A.E.)/

Avonbrook House, Masons Rd. Laserbore (U.K.)
Stratford-Upon-Avon C/O Foundation Engineering
Warwickshire CV37 9LQ P.O. Box 2526
United Kingdom Dubai, U.A.E.
Tel. : 44(0) 789 292227 Tel. : 04-450247
Fax : 44(0) 789 268350 Fax : 04-457641
Telex : 312440 PBSSPAG
3. M.C. Clancy (U.K.) 4. Dutco (U.A.E.)/

Clare House Coppermill Lane Brochier (Germany)
Harefiled, Middlesex UB96HZ P.O. Box 233
United Kingdom Dubai, U.A.E.
Tel. : 0044 5825263 Tel. : 04-851445
Fax : 0895 825263 Fax : 04-852103
16.2 SURVEY CONTROL
16.2.1 General
The Contractor shall set out the works and establish the laser guidance system for the
micro-tunnelling machine using survey stations given on the Drawings or indicated by
the Engineer on site. Any temporary control points are to be recorded and notified to the
Engineer for checking.
16.2.2 Survey References
The laser guidance system for the micro-tunnelling machine shall be such that the
machines position can be continuously monitored. Any deviations from line or level shall
be recorded as each new pipe is inserted.
16.2.3 Structural Survey
A pre-construction survey of all structures within 4 times the depth of micro-tunnel on

each side of the tunnel centerline shall be completed within 30 days before the start of
the micro-tunnelling activities. The Contractor shall submit a report containing
photographs and descriptions of the structures.

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Concurrently, a level survey on these structures and the surfaces of the roadway within
the above mentioned envelope shall be completed. All these survey data shall be
submitted to the Engineer prior to any construction.
16.2.4 Site Investigations
The Contractor shall engage a competent geotechnical firm to design and conduct a
comprehensive soil investigation program along the route of all lines to be constructed
using micro-tunnelling methods.
Boreholes shall be sunk adjacent to all proposed shaft locations. Due to the variability of
soil, rock and groundwater conditions, boreholes should also be sunk at intermediate
locations. It is recommended that boreholes be sunk at a maximum intermediate spacing
between shafts of 50 meters. In any case, it shall be the responsibility of the Contractor
to adequately familiarize himself with the ground conditions along the pipeline routes and
to assure himself that the selected construction method is appropriate and safe. This
data is also vital to the proper selection of cutting head for the tunnelling machine.
The boreholes shall be sunk at least 2.0 meters below the level of the proposed works or
at least 50 percent deeper than the proposed works, whichever is deeper and shall be
sited at least 2 metres off the proposed tunnel line to avoid creating areas of weakened
ground.
The following parameters shall be determined from undisturbed samples taken at

different depths, particularly at the tunnel depth:
- Standard penetration tests,

- Liquid and Plastic limits (Atterberg limits),
- Particle Size distribution,
- Shear strength,
- Moisture content,
- Height of water table, and
- Chemical composition of the groundwater
The boring logs, results of the laboratory tests and a discussion of the results as they
pertain to the selection of micro-tunnelling method and the selection of cutting head shall
be compiled in a "Soils Investigation Report" and submitted to the Engineer prior to
commencing micro-tunnelling work on any section.
16.3 GEOTECHNICAL INSTRUMENTATION
The Contractor shall engage a geotechnical firm to design, install and operate a
geotechnical monitoring program. The monitoring program shall include:
- Optical survey for layout and verification of all instrument locations and
elevations.
- Borehole drilling for installation of settlement anchors, observation wells and,

if requested by the Engineer, inclinometer casings.
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- Furnish, install and grout observation wells and, if requested by the Engineer,
inclinometer casings including sensor and readout unit, and furnish and
install settlement anchors and settlement markers.
- Furnish and install surface settlement points on existing structures.
The observation wells, settlement anchors, settlement points and inclinometer casings (if
requested) shall be installed and monitored for 14 days prior to advance of the tunnel
heading to the station of the instrumentation, or to the start of shaft excavation or to the
Monitoring Schedule
Activity Instrument Reading Frequency
Tunnelling Piezometer and Daily while heading is within 100 feet

Obs. Wells of instrument. Weekly while heading
is 100 to 500 feet from instrument.
Inclinometer, Daily while heading is within 50 to

Settlement 500 feet of instrument. After each
anchors and advance of 5 feet, when heading is
settlement points within 50 feet of instruments.
Excavations Obs. Wells Daily from start of dewatering to

system shutdown.
Inclinometer Daily from start to completion of

excavation.
Weekly until backfill completed within

50% of final grade.
Monthly until backfill completed.
start-up of a dewatering system.
The geotechnical firm shall read and record data in accordance with the schedule below
and report data from the geotechnical instrumentation within 24 hours to the
Engineer during the course of the work for eeeeo-tunnelling or shaft excavations.
6.3.1 Settlement Points
The geotechnical firm shall determine optimum location of settlement points to monitor
existing structures as acceptable to the Engineer.
He shall provide settlement points on the road surface and within existing structures.
Settlement points in the vicinity of the shafts will be agreed with or at the direction of the
Engineer.
He shall monitor all settlement points with reference to benchmarks located outside the
area of influence of the works. Monitoring shall demonstrate repeatability to 0.01 foot.
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16.3.2 Settlement Anchors
The geotechnical firm shall install settlement anchors and reference head in drill hole in
accordance with manufacturer’s instructions. Anchors shall be grouted in place with
cement/bentonite grout mix. Proportions by weight shall be 1 part of cement to 3 parts of
bentonite to 3 parts of water, (1:3:3).
16.3.3 Inclinometers (If required)
The Contractor (or his specialist sub-contractor as per Clause 16.3.4) shall install
inclinometer casings at locations as directed by or agreed with the Engineer. The
geotechnical firm shall supervise installation and testing of all devices and provide
qualified personnel for the proper operation and maintenance of the installation and shall
take field measurements for lateral deformation both perpendicular and parallel to
adjacent structure.
16.3.4 Groundwater Observation Wells
Prior to the installation works of the Groundwater Observation Wells, the Contractor
shall submit a detailed method statement for the installation works to the Engineer for
approval. The Contractor may engage a specialist sub-contractor with the approval of
the Engineer for the installation of Groundwater Observation Wells. In any case the
Contractor shall hire the services of a Geotechnical firm who shall inspect the installation
and shall monitor the wells at a set frequency and prepare reports on the impact of
dewatering and ground movements. Such data and reports shall be submitted to the
Engineer on a regular basis.
16.3.5 Optical Surveys
The geotechnical firm shall reference all instrument locations and elevations to existing
benchmarks and line monumentation. He shall establish elevations on all instrument
reference points to a minimum accuracy of 0.01 foot.
He shall locate all instruments by coordinate and survey ties to permanent topographic
features to minimum accuracy of 0.10 foot.
16.4 DEWATERING
The Contractor shall submit to the Engineer a method statement for dewatering along
with necessary sketches indicating any dewatering route, etc., and shall proceed with
installation of dewatering system only with the approval of the Engineer of the method
statement and the dewatering route(s).
The Contractor shall supply all equipment, tools, materials and labour for dewatering and
control of groundwater using dewatering systems consisting of well points and/or deep
wells. The system shall include any system required to recharge the groundwater so that

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adjacent structures are not affected with any additional piezometers and observation
wells.
Once dewatering has begun, it shall continue 24 hours per day for extent of time shaft
excavations are open. Water levels shall be maintained at least 0.6 meter below shaft
excavations and as required by the approved tunnelling method. In event of disturbance
of foundation soils or movement of existing structures in excess of limits stated in Clause
16.1, or movements of embankments, roadway or sheeting towards open excavation
caused by an inadequate or interrupted dewatering system, the Contractor shall
immediately notify the Engineer and take all corrective measures necessary at no
additional compensation.
The corrective measures shall include modification to the dewatering system to correct
the deficiency and repair of any associated damage at no additional compensation. If the
corrective measures prove unsatisfactory to the Engineer and results in damage to an
existing structure, all expenses incurred in any redesign of foundation or remedial
measures to repair damage to structure and in any related construction shall be
reimbursed by the Contractor. The Contractor shall take out adequate insurance for this
risk and produce evidence of it to the Engineer upon request.
16.4.1 Submittals
The Contractor shall submit detailed dewatering plans to indicate proposed type, depths,
installation locations and method of water disposal from the work sites, including
locations of piezometers, observation wells and reinjection wells, if required.
16.5 SITE INVESTIGATION
The Contractor shall avail himself of all available information concerning ground
conditions to determine the appropriate cutting head compatible with the expected
conditions.
The position of drive and reception shafts should be checked on site by the Contractor to
ensure that the design has provided sufficient working space which will cause the least
disruption to the flow of traffic.
Any alterations to the designed position of shafts must be approved by the

Engineer.
16.6 QUALITY CONTROL
The Contractor shall retain the services of a qualified specialist to supervise the
assembly, operation and maintenance of the equipment required for the selected method
of micro-tunnelling.
The finished micro-tunnelled pipe centerline shall have the following tolerances:
a. Horizontal : ±50 mm per 100 m sewer length
b. Vertical : ±25 mm per 100 m sewer length

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16.7 EQUIPMENT
The equipment utilized to perform this work shall be designed and provided so as to
carry out the micro-tunnelling work efficiently. It shall be able to handle the ranges of
ground conditions indicated by the boreholes and groundwater level information, with
excess capacity. The equipment shall be able to maintain stability of the tunnel when
taking into account the soil and hydrostatic loads as well as any surcharges imposed by
vehicular traffic.
The Contractor shall be capable of lubricating the pipe as it is advanced. The equipment
shall include a system for handling and transporting the excavated material from the
tunnel face, through the tunnel and via the drive shaft to the ground surface. The
excavated material, and the bentonite or similar slurry, if used, shall be properly
disposed of by the Contractor.
The equipment shall include a laser guidance system to permit continuous controlling,
monitoring and adjustment of the alignment and grade. The laser shall be mounted
independently of the thrust block. The tunnelling machine shall be fitted with a calibrated
laser target, robustly constructed and rigidly secured to the tunnelling machine.
16.8 EXECUTION
Prior to the start of work on any pipe section, assemble all material, equipment and tools
necessary to conduct tunnelling work continuously until that section is completed.
Institute approved traffic control and diversion program including required traffic barriers,
lights and signs. The traffic control program for each work area is to be submitted to the
RTA and to the Dubai Traffic Police for approval prior to mobilizing to the site.
Excavate the required shafts to complete the micro-tunnelling operations in accordance

with the approved schedule. The pipeline will be driven using the method proposed by
the Contractor and as agreed by the Engineer. While the tunnel is being advanced, the
Contractor shall monitor the ground and building levels and geotechnical instrumentation
as required.
The sewer lines are located such that manmade obstructions should not be
encountered. However, the Contractor should have contingency methods available to
remove natural or manmade obstructions should they be encountered including the
facility to withdraw the micro-tunnelling machine along the line of the tunnel drive if
obstructions or changes in ground conditions are encountered within 30 metres, to allow
a different micro-tunnelling machine to be used.
The tunnel shall be excavated to a size such that the overbreak is kept to a minimum.
The overbreak occuring shall be filled with a suitable slurry to keep ground movements
within the tolerances given in Clause 16.1. Slurry pressure or mechanical earth pressure
shall be maintained to ensure a positive pressure on the working face at all times.
At all times when the tunnel is being advanced, a field supervisor with extensive
experience in the operation of the equipment being used shall be present.

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The setting of the laser and target and the alignment of the tunnel relative to the laser
beam shall be continuously monitored (refer to Clause 16.2.2) to ensure compliance with
the horizontal and vertical tolerances as specified in Clause 16.6.
16.9 TESTING
All pipelines constructed by micro-tunnelling shall be inspected and tested in accordance

with Clauses 6.1 and 6.2 for new pipes.
16.10 SAFETY
The Contractor is responsible for the safety of all personnel as well as for the safety of
the public during the performance of the work and is responsible for maintaining safe
conditions in and around the work area. This is specified in more detail in Section 12.

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SECTION 17 - GENERAL, ELECTRICAL AND MECHANICAL SPECIFICATION
17.1 ELECTRICAL AND MECHANICAL PLANT TO BE SUPPLIED
Electrical and Mechanical plant shall be supplied and installed as detailed and in
accordance with sections 17 through 20 of the specification.
Specification section 17 through 20 shall also be applicable to temporary plant required

throughout the duration of the contract.
Particular care shall be taken to ensure that all components are suitable for the corrosive
climatic and environmental conditions prevailing in Dubai.
17.2 DRAWINGS AND INFORMATION REQUIRED FOR ELECTRICAL AND

MECHANICAL PLANT
As well as complying with the specified procedures for approval the following
documentation shall be supplied and procedures followed for all items of electrical and
mechanical plant in the Contract.
17.2.1 At the start of the Contract
Within 30 days of the Engineer’s order to Commence the Works the Contractor shall
submit the specified request for approval which shall include :-
(a) Detailed drawings (6 No.) of the general arrangements and specifications of

all electrical and mechanical plant showing all apertures, holes, chases,
trenches and ducts required in associated structures.
(b) Drawings (6 No.) of electrical and electronic equipment and specifications

giving details, dimensions, circuitry, component details and schematic
diagrams with a legend of symbols used and a written description of the
operation of the circuits marked thereon.
(c) Any additional drawings of particular items, called for by the Engineer.
The manufacture of items of Plant, shall not be commenced until written approval of all
relevant drawings and specifications have been obtained.
If the drawings are not approved one copy will be returned to the Contractor marked to
indicate the alterations required.
Upon final approval one copy will be marked Approved and returned.
After approval of drawings a further six copies shall be provided to the Engineer.

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17.2.2 As Built Record Drawing
During the course of the Works the Contractor shall maintain a detailed record of all
changes in order to facilitate accurate preparation of “As Built Record” drawings and to
ensure that these drawings are in all respects true record of the installation.
The Contractor is at liberty to apply for copies of the Engineer’s drawings which he
considers will assist him in the production of the ‘As Built Record drawings required to be
supplied by him, providing the Engineer is satisfied the request is reasonable, copies will
be provided by the Engineer at cost. The Contractor shall treat the copies of the
Engineer’s drawings as confidential matter and shall not use them other than for the
purpose for which they are provided.
The final record drawings shall be prepared by the Contractor and shall show the
complete Works including the sizes and routes of all ducts, pipework and cables. The
scales used shall be such that all details are legible when reduced for inclusion in the
Operation and Maintenance manuals. All drawings shall show scale bars as
appropriate.
The drawings shall clearly show the names of the plant manufacturers, giving model and
type numbers, and all details of plant and machinery duty ratings, sizes, current settings,
fuse ratings, etc. of all items of plant including electrical distribution cabling and wiring
installations.
The Contractor shall provide three prints of all drawings and schedules correctly
modified as final record drawings. These shall be submitted to the Engineer for approval
before the issue of a Taking Over Certificate and shall be a complete record of the
Mechanical and Electrical installation.
If the drawings are not approved, one copy shall be returned to the Contractor with
marked indications of the alterations required.
Upon final approval, one copy of the drawings or document shall be stamped “Approved”
and returned to the Contractor.
One set of the approved record drawings on paper shall be included in each of the
Operation and Maintenance manuals. These may be full size drawings folded and
inserted into clear plastic sleeves bound directly into the document. Reduced size
drawings shall be legible in all respects, and the actual reduced scale clearly marked on
the drawings.
1 No. copy on magnetic disc or tape, digital drawings in AutoCAD release 13, Intergraph
or DXF file as appropriate and three full size sets of approved record drawings on
polyester film or other approved reproducible film shall be handed to the Engineer. The
Engineer will not issue a Taking Over Certificate for the Works until all approved record
drawings have been received.
17.2.3 Prior to Delivery of the Plant
Before plant is delivered the Contractor shall provide for the use of the Employer and the
Engineer :-

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(a) Copies of all Test Certificates demonstrating compliance with the

specifications.
(b) Two copies of Draft Instructions for the Operation of the Plant which shall
describe the installation as a whole and shall give step by step procedures for
every operation in the running of the Plant. All necessary drawings and
sketches shall be included.
(c) Two copies of Draft Instructions for the Maintenance of the Plant. These
instructions shall include charts showing lubrication, checking, testing and
replacement procedures to ensure trouble free operation.
A separate section of these Instructions shall be devoted to a complete parts list based
on sectional arrangement drawings of the Plant. The maker’s name, address and
catalogue/serial numbers shall be given for each component of the Plant supplied.
Recommendations for consumable supplies, e.g. lubricants, packings etc. shall be

included.
The Contractor shall obtain the Draft Instructions from the suppliers, check them for
accuracy and shall bind each Instruction Book in Uniform bindings, the cover of which
shall be finished with a black and greaseproof material and the title printed on the front
and the spine including the word ‘Draft’.
The Instructions shall be specific to this Contract, a collection of manufacturer’s

descriptive leaflets will not be acceptable.
The Plant shall not be considered to be completed for purposes of delivery until the
above information has been provided.
17.2.4 Prior to the Issue of the Taking-Over Certificate
Before the Taking-Over Certificate is issued the Contractor shall provide for the use of
the Employer and the Engineer :-
(a) Three copies of Approved Instructions for the Operation of the Plant which
shall describe installation as a whole and shall give step by step procedures
for every operation in the running of the Plant. Copies of the as built record
drawings¤ and sketches shall be bound in the document.
(b) Three copies of Approved Instructions for the Maintenance of the Plant.
These instructions shall include charts showing lubrication, checking, testing
and replacement procedures to ensure trouble free operation.
(c) 1 No. copy on magnetic disc & tape on digital drawings in AutoCAD release
13, Intergraph or DXF file as appropriate and two hard copies of the following
As Built Record drawings¤ for approval :-
(a) Drawings showing the internal construction of the major items, with parts
list and reference numbers for ordering spares.
(b) Complete assembly drawings of machinery and ancillary plant showing all
pipe connections and fittings.
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(c) General arrangement drawings showing all equipment, cabling, traywork,

etc.
(d) Detailed arrangement of any conduit work buried in floors, walls or

ceilings, in any structure.
(e) Detailed wiring diagrams of the main circuits.
(f) Diagrams of connections between all items of equipment (e.g. main and
auxiliary switchboards, generators, control boards, motors, starters,
batteries, meters, instruments, relays, and allied equipment, etc. with
component values
(g) Three copies of detailed revised Specifications and Schedules of the

Plant as actually installed.
When (a), (b), (c), (d), (e) and (f) have been approved by the Engineer, the Contractor
shall provide two prints of each drawing or detail on thick paper for the use of the
Purchases, and one 35 mm photographic negative of each drawing or detail mounted in
a card frame 187 mm x 83 mm for the use of the Engineer.
A separate section of these Instructions shall be devoted to a complete parts list based
on sectional arrangement drawing of the Plant. The maker’s name, address and
catalogue/serial numbers shall be given for each component of the Plant supplied.
Recommendations for consumable supplies, e.g. lubricants, packings etc. shall be

included.
The Contractor shall bind each Approved Instruction Book in uniform bindings, the cover
of which shall be finished with a black and greaseproof material and the title printed on
the front and the spine including the word ‘Approved’.
The Contract shall not be considered to be completed for purposes of the issue of the
Taking-Over Certificate until the above information has been provided.
17.2.5 During the Maintenance Period
The Contractor shall be responsible for the complete maintenance (preventive and
corrective) of the plant for one year and shall supply at his own cost all spare parts
required during this period (The maintenance period). The maintenance period starts
from the successful inspection and commissioning of the plant and acceptance by the
Employer. The plant shall be re-inspected by the Employer at the end of the
maintenance period and any item found defective during the maintenance period shall
be replaced by the Contractor free of cost. The Contractor shall submit to the Engineer
a copy of the approved preventative maintenance schedule proposed for the installed
equipment.
17.3 WORKMANSHIP AND DESIGN OF PLANT
(1) The Plant shall be new, of sound workmanship and of robust design.

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(2) The general electrical and mechanical design of the Plant and particularly
that of the bearings, contacts, and other wearing parts, shall be governed by
the need for long period of service without frequent maintenance and
attention being necessary.
(3) Unless otherwise specified, all items of Plant shall be rated for continuous
service at the specified duties under the prevailing atmospheric and
operational conditions on site.
(4) All component parts of the Plant shall be manufactured to a strict system of
limits and complete inter-changeability of similar parts is required.
(5) All items of Plant for which spare parts may be required shall have attached
to them untarnishable serial numbers and basic information as to rating, etc.
in sufficient detail to allow the unit or assembly to be identified in
correspondence and when ordering parts.
(6) All parts subject to wear shall be readily accessible.
(7) Provision shall be made for taking up wear in all bearings and other wearing
parts or for easy replacement if adjustment is not practicable.
(8) If any moving parts show, in the opinion of the Engineer, signs of undue wear
or unsuitability for the purpose for which they were installed, they shall be
deemed to be defective materials, workmanship or design and shall be
replaced.
(9) Suitable packers and/or shims shall be fitted for ease of adjustment and re-
alignment of all machinery units. Particular attention shall be given to
combined sets.
(10) Where fitted bolts, spigots or other means for precise location are not
employed in the assembly of the Plant, locating dowels shall be fitted, on
completion of erection, to the satisfaction of the Engineer.
(11) The equivalent control panel reference shall be prominently inscribed on

each item of plant in a manner to be approved by the Engineer.
17.4 LUBRICATION OF PLANT
(1) Adequate and, as far as is practicable, automatic means of lubrication shall

be provided for all moving parts.
(2) The positions of all greasing and oiling points shall be arranged so as to be
readily accessible for routine servicing. Where necessary, to achieve this,
suitable extension pipes shall be fitted.
(3) Lubrication grease points shall comprise hexagon headed nipples except
where the lubrication required is of a special nature. In such event they shall
be fitted with metal labels to indicate the special lubricant required.
(4) Where continual grease or oil feeding is required the capacity of the reservoir
shall be sufficient for not less than seven days continuous services.
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17.5 INITIAL CHARGES OF OILS AND OTHER CONSUMABLES
The Contractor shall supply the initial charges of oil, grease electrolyte and similar
materials necessary for the correct setting to work and operation of the Plant.
17.6 SPARES
(1) Spares shall be readily interchangeable with the parts they replace, and shall
comply with the specification.
(2) Schedules shall be included for all spares recommended by the

manufacturers to cover periods of 2 and 5 years operation of the Plant. The
Engineer will determine the actual spares to be provided.
(3) Spares shall be packed and protected for storage to the appropriate
standard. Electrical equipment shall be sealed in polythene or similar bags
with a liberal supply of desiccant. Other items shall be protected so as to
avoid corrosion and spoilage for a minimum of twelve months after handover
to the Client. Machined surfaces of all mechanical components shall be
further protected by the application of a protective coating which may be
easily removed at the time of installation. Each package shall have attached
to it an untarnishable metal plate giving information for identification. This
shall include the maker’s name and reference description as shown on the
marked-up drawings supplied.
(4) The packages of items of spares shall be collected together by the Contractor
into consignments of reasonable size and then packed in secure cases each
of which shall contain a contents list. Where electrical items are involved the
cases shall be of tongue and groove boarding. Each case shall be durably
marked with the Contract number and site address, and shall be sent to site
after detailed instructions have been received. Each package shall be
clearly identified as to its contents in both English and Arabic.
(5) The Contractor shall provide the detailed agreed schedule in duplicate of the
spares supplied one copy to be retained by the Engineer after checking the
goods.
17.7 TOOLS AND LUBRICANTS
(1) A schedule is included to cover all special tools necessary for the proper
maintenance of the Plant. The Engineer will notify the Contractor which tools
shall be included in the Contract. These tools shall not be used for the
purpose of erecting the works.
(2) The Engineer may require to inspect the tools and packaging before dispatch
and the Contractor shall hold them at his works and not allow them to be sent
by suppliers direct to site.

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17.8 DELIVERY OF SPARES, TOOLS AND LUBRICANTS
Spares and tools shall only be dispatched to site after instructions for their reception
have been applied for and obtained from the Engineer.
The Contractor shall provide a lockable metal tool box to contain two sets of tools as
required by (1) above together with two sets of steel combination spanners to fit every
nut/bolt size on the plant including the holding down bolts and unions, plus other tools of
a special nature necessary for general maintenance.
A supply of the recommended lubricants sufficient for a period of two year's running shall
be supplied for the plant. This does not relieve the Contractor of the responsibility of
ensuring that all grease lubricants have been filled and the grease-gun applied to all
nipples before starting up the plant.
Lubricants or their equivalents shall be those obtainable in the Dubai markets.
The Contractor shall provide a detailed schedule in duplicate of the tools and lubricants
supplied one copy to be retained by the Engineer after checking the goods.
17.9 PROTECTION AND PACKING FOR SHIPMENT/STORAGE
(1) All Plant shall be adequately protected and packed in accordance with the
approved standard. In addition the Plant shall be so protected as to be safe
from spoilage and corrosion until installation or in the case of spare parts for
a period not less than 12 months from its date of handover to the Client.
(2) Items of plant which are finished painted at the manufacturer’s works such as
switchboards, shall be suitably encased in wood (such as hardboard secured
by screws to a wood framework) for their protection before dispatch.
(3) Particular care shall be taken in the packing of electrical apparatus. It shall
be packed separately in sealed polythene or similar approved bags (including
a liberal supply of desiccant) taking all precautions to exclude moisture.
(4) Packing cases shall be strongly constructed using tongued and grooved
boards with internal and external battens. Each packing case shall be
durably marked with the Contract number and site address and such other
marking as may be directed.
(5) The Contractor shall make good to the satisfaction of the Engineer any
deterioration of the protective coatings, paintwork, etc., which may occur
during transportation.
17.10 AUTOMATIC CONTROL OF PLANT
(1) The system of control and protection for unmanned automatically controlled
Plant shall be such that the Plant is protected against further damage should
any piece of apparatus fail and shall be capable, should the electricity supply
fail, of re-starting correctly on resumption of supply.

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(2) Each starter shall be provided with an individual fuse for the control circuit
deriving its control supply from the live and neutral in its associated cubicle
unless otherwise specified. Indicating lamps shall be controlled by separate
auxiliary contacts.
(3) In multi-unit installations the control arrangements shall provide staggered

starting and stopping of the Plant, so that not more than one unit starts or
stops at a time, to minimise electrical and hydraulic surges on the systems.
(4) The duty change to stand-by pump shall be signaled by a suitable lamp
labeled ôSTAND-BY PUMP IN USE¤ and unless otherwise specified an
alarm relay with a minimum of four contacts shall be provided to initiate such
alarms as may be specified or required to be fitted at a later date.
(5) Each pump level float switch shall be separately provided with its own low
voltage supply transformer to avoid all pumps being cut out should one
transformer fail.
17.11 INSTRUCTIONS AND TRAINING OF EMPLOYER’S STAFF
The Contractor shall provide qualified engineer(s) to instruct and train the Employer’s
staff in the operation and maintenance of the plant.
After the equipment has been installed, tested, adjusted and placed in the satisfactory
operation the Contractor shall provide the services of the manufacture's representatives
to instruct the Employer's operating personnel in the use and maintenance of the
equipment. An instruction and training programme shall be conducted for up to 6
operators designated by the Employer. The Contractor shall give the Employer at least
two month's written notice of the proposed instruction and training programme.
Instruction and training covering basic system operation theory, routine maintenance and
repair, and "hands on" operation of equipment shall be included. The duration of the
instruction and training period shall be based on the complexity of equipment involved
and the equipment manufacturers recommendations. The Engineer's/ Employers
acceptance of the adequacy of training received must be obtained before terminating the
programme.
17.12 MAINTENANCE OF PLANT
The Contractor shall be responsible for the maintenance of the plant for one year from
the date of Taking Over and shall supply at his own cost all spares required during this
period.
The Contractor shall carryout weekly, monthly, quarterly and yearly inspection and
preventive maintenance schedules of the plant and any other maintenance schedules of
the plant as recommended by the supplier of the plant. The Contractor shall respond
immediately to all plant alarms which take place during the maintenance period. The
Contractor shall make all arrangements for the complete re-inspection of the plant by the
Employer/Engineer at the end of the maintenance period and any item found defective
during maintenance period shall be replaced by the Contractor at his own cost. The
warranty period for any component/item found defective and/or repaired/ replaced during
maintenance period shall be agreed by the Engineer/Employer.

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Plant keys shall be handed-over to the Sewerage System Section of the Dubai
Municipality Drainage & Irrigation Department at the end of the one year maintenance
period.
17.13 RETURN TO SITE
Eleven months after the Plant has been in operation, a visit to site shall be made by an
experienced fitter, of the Contractor or the Manufacturer, who shall service all the Plant.
The service shall comprise tracing and correction of all faults and replacement of any
item of plant found to be defective which the Engineer considers to be the Contractor’s
liability.
17.14 OPERATING AND MAINTENANCE MANUALS
17.14.1 Introduction
The Operating instructions shall be prepared in English in such a way as to provide a

step by step description of the preparation and setting to work of the whole of the Plant
and its shutting down.
The Maintenance Instructions shall be in English and include the following :-
a) Schedules of routine maintenance to be carried out for each item of Plant

installed. 1 copy of the appropriate schedules and instructions shall be
mounted on neatly finished plywood boards suitably protected by clear
varnish or other approved material. and fixed on the wall adjacent to the item
of plant to which they refer.
b) Schedule of equipment supplied giving manufacturer's name and appropriate

Make/Model No./Cat. No.
c) Schedule of spares supplied.
d) Schedule of tools supplied.
e) Sectional arrangement drawings of major items of Plant i.e. pumps valves

etc. with dismantling instructions.
f) Plant layout drawings showing the "as erected" installation.
g) General arrangement and schematic diagrams of the "as installed" control

panel.
h) "As wired" diagrams of all electrical connections between the control panel
and installed loads.
i) Full and comprehensive instructions for the maintenance of all items of

equipment installed.
j) Test certificates for motors, pumps, compressors, pressure vessels, lifting

equipment, transformers, electrical installation and other items where
appropriate.
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k) Pump performance curves as tested.
l) System curves.
m) Schedule of recommended lubricants and their equivalents.
17.14.2 General Requirements and Contents
i) General
a) The Contractor shall provide 3 No. fully detailed manuals including all
mechanical, electrical and electronic equipment.
b) Two copies of the draft manuals shall be submitted to the Engineer for
review and approval as required by Clause 17.2.3, before delivery of the
equipment.
c) The final copies of the manuals shall be provided to the Engineer within
60 days of the commencement of the maintenance period. They shall
include all revisions and comments made be the Engineer and any
revisions or corrections necessitated by changes made during installation
and testing.
d) Manuals shall be contract specific, and be fully indexed and sectioned, for
allocation and distribution to the specialist staff involved on the particular
plant and equipment.
e) Where several sub-contractors and manufacturers have supplied

equipment the Contractor shall provide a complete integrated manual
which clearly demonstrates the inter-relation of the equipment.
f) Manuals shall be provided in durable hard backed A4 sized loose-leaf

four ring binders. Lever arch binders are not acceptable
g) The manuals shall enable the client to safely operate, maintain,

dismantle, reassemble and adjust all part of the works.
h) Original copies of leaflets and instructions provided by the specialist

manufacturers shall be provided. Superfluous information shall be clearly
deleted and relevant information referred to separately in the text.
i) All instructions and manuals shall be written in accordance with

appropriate National Standards and other recognised guidelines on
technical manual writing.
ii) Contents
a) These shall comprise a number of volumes, dependent on the amount

and technical content of the equipment installed. The operating
instructions shall always form a separate volume. Manuals shall include
sections containing information as described in the following paragraphs.

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b) Introduction. the name, address, telephone and fax numbers of the Site,
the Engineer, the Consultant, the Contractor, Sub-contractors,
Manufacturers and their Agents. The date the Contract commenced, and
the date of the Taking Over certificate. A brief description of the plant
provided and the contractual scope of the work, with descriptions of any
work subcontracted.
c) General description of equipment
i) General process description. This shall provide information on

treatment standards, flows and a general description of the treatment
processes provided, process P&I drawings shall be included with the
manual.
ii) Process design parameters. This shall provide information on the

performance of the individual processes.
iii) General description of the mechanical equipment. This shall provide

a brief description of all mechanical plant provided.
iv) General description of the electrical equipment. This shall provide a

brief description of the equipment provided, listing individual control
panel compartments and the remote controls.
d) Detailed description of the mechanical equipment. This shall provide

details of all the mechanical equipment including manufacturer type,
rating, duties, characteristic performance curves and schedules for all
components stating serial numbers.
e) Detailed description of the electrical equipment. This shall provide details

of all electrical equipment and cables including information on the control
panel(s), listing the display and controls available for each compartment
and stating the rating, manufacturer and supplier of main components,
and full component schedules with serial numbers, calibration procedures
a schedule of input and output signals, detailed number, signal type,
polarity, digital open or closed state and analogue range.
f) Operating instructions. These shall provide details of how each piece of

plant is controlled and operated in both automatic and hand modes,
including the control philosophy and its interrelationship with other
interdependent plant. Details of plant operation under non-routine
conditions and details of start-up and shut-down procedures with any
associated safety checks shall be provided.
g) Inspection and maintenance instructions. These shall provide schedules

recording the time interval for routine inspection, maintenance and
lubrication tasks, with reference to individual manufacturer's instruction
manuals for full details. They shall describe briefly the more complex
tasks that must be under taken at irregular intervals. In addition to the
routine operating and maintenance task this section should identify the
following:

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i) more complex tasks, involved with plant shut-downs, fault rectification

to components level, fault diagnostics, overhauls, etc.
ii) specific hazards associated with operating and maintaining the plant
,e.g. auto starting, high voltage, noise levels.
iii) highlight any particular complex or critical tasks over the above
normal requirements.
iv) measurements and guidance on limits of acceptable wear for all items
subject to wear.
h) Fault finding and correction. This shall provide a guide to first line checks
that can be undertaken in the event of plant failure without the need for
reference to the detailed instructions. A detailed guide of more complex
checks shall be provided in Section (g).
i) Inventory of installed plant. A schedule of this shall be provided.
j) Drawings list. A list of the ‘As-Built’ drawings shall be provided.
k) ‘As Built drawings’. Approved copies of all "As-Built" drawings shall

be included for the following:-
i) process and instrumentation diagram

ii) site layout showing main works operational features
iii) equipment and machinery layout
iv) mechanical and electrical details
v) electrical power circuit diagrams
vi) control schematic diagrams
vii) HV and LV distribution single line diagrams
viii) HV and LV cable routes
ix) PLC programmes or computer programmes
x) one master copy of the proprietary software package shall be
provided to the Engineer within one week of Contract completion.
All software licenses and/or registration requirement must be
forwarded promptly to the Engineer for subsequent registration
with the manufacturer. Sole rights to all software developed and
written on all schemes financed by the Engineer shall be retained
by the Engineer.
xi) assembly drawings shall clearly show the construction details and
be in sufficient detail to facilitate re-assembly.
xii) cable schedules shall include cable reference numbers and core
reference numbers relating to power circuit diagrams.
i) The above are to be supplied to the satisfaction of the Engineer. The

Contractor shall provide the Engineer black and white prints of each
on thick paper and one ISO size A2 (594 x 420) negative of each. All
drawings shall be prepared on a CAD system and printed on ISO
standard sized paper A1 unless specifically requested otherwise.
Each drawing shall be marked with the Engineers Consultant's,
Contractor's and manufacturers names and references, drawing
number, title, scales, date of completion and a full description and
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date of all amendments, and shall be certified 'As-built'. The project

title shall be included in a box at the bottom right had corner of each
drawing.
17.15 WORKS TESTING AND INSPECTION OF MANUFACTURED ITEMS
All manufactured items for incorporation in the Works shall be offered for inspection,
examination and witness testing and shall be supported by certificates to demonstrate
compliance with this specification and with the approved manufacturing and testing
standards specifications.
Where manufactured items are to be shipped the packaging shall also be offered for
inspection before dispatch.
Inspections when required shall be carried out by the Engineer or his appointed
Inspecting Engineer. A schedule of proposed equipment to be witness tested is included
in the Contract Documentation.
The Contractor shall give to the Engineer and the Inspecting Engineer reasonable
notice, which shall normally be of two weeks, of the date and place at which plant will be
ready for prescribed testing.
If the tests are beyond the resource of the manufacturer he shall make arrangements for
these to be carried out elsewhere. Any variation of this requirement shall be agreed and
confirmation in writing shall be obtained from the Engineer.
The Contractor shall supply four unpriced copies of all sub-orders for manufactured
items. Two copies of each of these sub-orders shall be forwarded to the Engineer and
two to the appointed Inspecting Engineer at the time the sub-orders are placed. The
sub-order shall indicate the Works for which the item is required, state in detail the
inspection and test requirements, give sufficient information for ready identification and
shall state that these items will be subject to witness testing and inspection.
Four copies of all test certificates and, where relevant, curves shall be supplied to the
Inspecting Engineer within two weeks of completion of any witnessed tests.
Where witness tests are not required or instructions to waive witness tests have been
issued, the test certificates and curves shall be forwarded to the Inspecting Engineer
within two weeks of the date of testing.
On each test certificate sufficient information including the Contract Number and details
shall be given for ready identification of the material or equipment to which the certificate
refers.
No inspection or passing by the Engineer, of plant or materials covered by this Contract,

whether carried out or supplied by the Contractor, shall release him from any of his
obligations under the Contract.
The Contractor shall be entirely responsible for complying with the above testing and
inspection requirements, including the provision of test certificates, curves and any other
information required by the Engineer and shall ensure that due care is taken by himself
and his Sub-Contractors or suppliers before presenting the Plant for inspection or test. If
unauthorised delivery has taken place the Contractor may be required to arrange for the
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Plant to be returned to the manufacturer for inspection and/or witness testing by the
Inspecting Engineer.
All apparatus, instruments and connections required for the tests shall have been tested
for accuracy within the preceding 12 months.
Any equipment used in the testing of the Plant shall in all respects comply with the
appropriate safety regulations and/or requirements regarding electrical apparatus for the
safety of the Plant and the men working therein.
The Contractor shall carry out tests as stated in the approved standard; performance
tests and such other tests as are necessary, in the opinion of the Engineer, the
Engineer’s Representative or his Inspecting Engineer, to determine that the Plant
complies with the Specification either under test conditions in the manufacturer’s works,
on site or elsewhere or in the ordinary working.
Where pumps are included in the Contract, at least one unit of each size shall be tested
with the suction rigged to conform to site conditions.
All cast metal components designed for the retention of liquids, e.g. pump casings, gear
boxes, engine crank cases, etc., shall be checked for soundness after machining etc.,
but before assembly or painting by treating with paraffin or similar method.
Where tests and inspection have been completed to the Engineer’s satisfaction, and
when the test certificates, curves etc., have been checked, the Engineer will confirm
acceptance in writing. Plant shall not be incorporated in the work or delivered until this
acceptance has been received.
17.16 TESTING AND CERTIFICATION OF MOTORS
Witness testing may be waived on standard types of small motors from recognised
manufacturers and on small components used in the manufacture of units of plant.
Motors of 15kW and above shall be witness tested for performance to the approved
standard.
Type test certificates shall be provided and shall include the following information for all
motors :-
(1) Approved standard of manufacture
(2) Class of insulation
(3) Size and type of cable fittings
(4) Type of bearings, sizes and lubricant
(5) Type and rating of heaters
(6) Brush sizes and maker (if fitted)
(7) Line current all phases
(8) Phase current balance
(9) Efficiency and P.F. at 100%, 75% and 50% of Full load
After initial witness testing each motor shall be combined with its driven units and
witness tested to demonstrate satisfactory performance, correctness of assembly and
ease of re-assembly at site. The assembled units shall be adequately marked and
dowelled.
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17.17 SITE TESTING AND COMMISSIONING OF ELECTRICAL AND MECHANICAL PLANT
(1) Cables laid underground shall be tested in accordance with the appropriate
standard specification and to Dubai Electricity & Water Authority - Electricity
Division's requirements for insulation resistance, and continuity of earth
circuit in the presence of the Engineers’ Representative before the cable
trenches are back-filled. All joints made during the installation of cables
which prove faulty when tested shall be remade and re-tested to the
(2) The connections of all electrical circuits shall be proved to be correct and the
whole installation shall be tested for insulation resistance and earth loop
resistance in the presence of the Engineer or the Engineer’s Representative
and Dubai Electricity & Water Authority - Electricity Division Representative
with instruments provided by the Contractor.
Any faults or defects shall be remedied at the Contractor’s expense.

Certificates in accordance with approved standard regulations of all service
authorities shall be issued to the Engineer.
(3) On completion of erection all pipelines shall be tested to ensure tightness of

joints and connections to a pressure agreed between the Contractor and the
Engineer. Test pressures will not exceed standard specification
requirements unless otherwise specified.
(4) Lubricating and fuel lines, sumps, tanks, etc., shall be adequately flushed to
remove any foreign matter before being put to use.
(5) On completion of erection of each item of Plant the Contractor shall test and
check it and as far as is possible proving it under working conditions.
(6) As soon as is practicable after erection the Contractor will be required to co-
operate under the supervision of the Engineer in test running the
completed installation (of which the Plant may form the whole or a part) and,
as far as is possible, proving it under working conditions.
(7) Following successful initial testing the installation shall be operated

continuously by the Contractor(s) for 24 hours, or such time as the Engineer
may specify, following the requirements of subclauses (8) thru (13) during
which time the Contractor will check that the installation is in safe working
order and fulfills the function for which it is intended.
(8) Operational demonstrations and system validation tests are required for all
mechanical and electrical equipment, Telemetry and SCADA systems
specified including all associated and related electrical systems and control
devices specified.
All costs for this shall be included in the Contract Price.
Materials, water, chemicals and electrical power for testing and

commissioning and validation shall be supplied by the Contractor.
Temporary facilities, storage, and similar facilities necessary for these shall

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be supplied by the Contractor. Testing and commissioning shall be

performed under continuous inspection by the Engineer. The Contractor
shall provide sufficient experienced skilled staff to carry out the testing and
commissioning. The various equipment manufacturers shall be present, if
specified.
All defects and malfunctions found by testing and commissioning shall be

corrected immediately, using approved method and new materials for repairs
as required. Interruption time necessary for corrective work may, at the
Engineer's discretion, be added to the specified testing and commissioning
period.
Satisfactory completion and approval of required commissioning and testing

is one of the conditions precedent to the Engineer's acceptance of the work,
but does not constitute final acceptance.
Testing and commissioning shall be in accordance with the Project

Specification, the relevant International Standards, DEWA requirements,
industry norms and to the Engineer's approval.
(9) Test Procedures
Testing shall be carried out in stages as follows :-
i) primary tests and checks

ii) unit testing
iii) system validation tests
iv) commissioning and setting to work
The Contractor shall not proceed from one stage to the next without the
Engineer's approval.
Consolidation of demonstration, testing and instruction requirements. Unit

and system validation testing, commissioning and instruction of the
Employer's personnel may be performed simultaneously but requires the
written agreement of the Engineer where this is at variance with requirements
specified elsewhere.
(10) Primary Tests and Checks
All component unit and complete systems shall conform to the Specification,
Drawing and the approved working drawings, samples, construction manuals,
materials lists, and other approved submittals.
All specified components and complete systems shall have been installed
satisfactorily and are operable.
All installation shall be safe to use. Temporary access, covers etc., will only
be permitted if approved by the Engineer.
All cleaning work shall be completed.

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Equipment shall be free from physical damage due to mechanical force,

exposure to the elements, incorrect connection etc.
(11) Unit Testing
Unit testing is defined as tests on individual equipment items such as pumps,

compressors, deodorisers, blowers, fans, conveyors and all similar
equipment item. Tests may be performed simultaneously on groups of
identical equipment, items, and groups of items supplied by one
manufacturer, if practicable.
Clean water shall be used to fill tanks, wells piping and systems that contain
water, sewage or sludge in normal operation. Where necessary specified
chemical shall be used for chemical systems but shall not exceed in-service
concentrations.
Tests shall show that all component units operate with the quantities,
efficiency, repeatability, and accuracy specified.
Tests shall be carried out continuously for a minimum period of 24 hours.
(12) System validation tests
System validation tests shall not commence until tests have been
satisfactorily completed.
This is defined as testing of complete systems that perform a discrete

process function such as autodesludging, pumping systems, emergency
power systems, Telemetry SCADA and similar systems. Each system shall
include associated structures tanks, piping, utilities, instrumentation and
controls, and like related items. Two or more separate systems shall be
validation tested simultaneously when necessary to validate an entire specific
function.
Clean water shall be used for system validation tests if it is possible to carry
them out satisfactorily with this medium. If the tests require use of the
medium used in service, then this shall be used.
Each system validation tests shall be carried out for minimum of 24 hours,
unless longer is needed to prove the performance of the system.
(13) Commissioning and Setting to Work
Commissioning is defined as testing all the equipment and system together

under actual operating conditions using all the mediums used in actual
operating conditions. Setting to work follows consecutively from this. Once
the equipment and systems are operating satisfactorily they are left to work.
Each system shall be tested including standby equipment by continuous

operation under the "in-service" condition for not less than 14 consecutive
days, with no interruptions except for normal maintenance or corrective work.
Where the in-service condition is an automatically controlled repair cycle with
on/off intervals it shall be so operated.
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Systems shall be operated continuously under constant inspection of trained

operators. System operation shall be cycled from full load to light load and
back to full load each 24 h. Variable speed equipment shall cycle through the
applicable speed range at a steady rate of change. Simulated alarm and
failure operating conditions shall be induced. Test controls and protective
devise shall be tested for correct operation in adjusting system functions or
causing system shutdown.
Subject to Contractor's request and Engineer's approval in each case, the

Contractor may simulate certain operating conditions relating to flow rates,
water levels, and malfunctions. Permission for simulations will be granted
only where it is unwise or impossible to obtain the conditions covered by the
capability of ranges or equipment. The simulation method shall reflect
reasonable anticipated operating conditions.
17.18 PLANT SUPPLIERS FOR THIS CONTRACT
In order to limit the number of manufacturers of electrical and mechanical equipment

used by Dubai Municipality and to simplify related maintenance, the following suppliers
have been selected for this Contract :-
Submersible Pumps: Stenberg Flygt AB

Suetsarevagen
S - 171 20 SOLNA 1
Sweden
OR ABS Pumpen GmbH

Postfach 1220
D5204 Lohmar 1
Scheiderhohe
West Germany
OR DAE Pumpen AS
Tolderlundsveg 3
DK - 5100
Odense C
Denmark
Klein, Schanzlin & Becker (KSB)

Aktiengesellschoft,
6710 Frankenthal (Pfalz)
Germany
HV Switchgear: South Wales Switchgear Ltd

Blackwood
Gwent NP 2XH
United Kingdom
OR ASEA Brown Boveri

P. O. Box 351 or P. O. Box 11070
Dubai, UAE
D - 6800 Manneheim 1,

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W. Germany
OR Groupe Schneider
P. O. Box 43103
Abu Dhabi
UAE
Electrical Control Panels and LV Switchgear:
Binghalib Engineering
P.O. Box 6969
Sharjah
United Arab Emirates
OR Siemens Aktiengesellschaft
Werrer-von-Siemens-Strasse 50
Power Engineering Group
E5 Division
D8520 Erlangen
Federal Republic of Germany
OR Blackburn Starling Ltd.

Queens Drive
Nottingham
United Kingdom
The Contractor shall be responsible for liaising with the suppliers, obtaining, checking for
accuracy and issuing all drawings and other documents and for co-ordination of supply
and installation.
17.19 CLIMATE
All plant and materials used shall be suitable for the climatic conditions described below.
Meteorological and Ambient Conditions Prevailing in Dubai:
Maximum Ambient Temperature 52oC
Minimum Ambient Temperature 1oC
Design Ambient Temperature 55oC
Maximum Surface Temperature

(recorded under direct sunlight) 85oC
Minimum Barometric Pressure 998 mb
Maximum Ambient Humidity 100%
Minimum Ambient Humidity 20%

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Design Ambient Humidity 100% Maximum
Design Wind Velocity 160 km/hr
Average Yearly Rainfall 80 mm - 150 mm
The climate in Dubai is relatively mild from November to April, and hot from May to
October with high relative humidity.
Under certain combinations of the above climatic conditions, considerable condensation

may take place.
Particular attention should be paid to the prevailing corrosion conditions. A considerable

amount of salt is contained in the atmosphere which together with the extremely high
ambient humidity can produce severe corrosion.
Distribution of rainfall is irregular, and the precipitation amounts are normally of no

significance. However, sudden heavy rainfall can occur in a very short period of time.
The prevailing wind directions are from the North and West. Strong winds are common
with maximum velocities exceeding 160 km/hr and sand storms occur in the summer
months.
17.20 ELECTRICITY SUPPLY
The electricity supply available from the Dubai Electricity & Water Authority - Electricity
Division network is 3 phase 220/380 volts, 50 Hz 4 wire.
17.21 DERATING DUE TO THE CLIMATIC CONDITIONS
The minimum derating for all electrical equipment including cables shall be in
accordance with the relevant Electrical Standards appertaining to the climatic conditions
referred to in Clause 17.19.
Switchboards, motor control centres, and electrical equipment shall be suitable for
continuous operation in an ambient temperature of 55oC. The fact that switch gear,
control rooms, pump rooms may be air conditioned shall not be taken into account when
rating equipment.
17.22 TROPICALISATION
17.22.1 General
In choosing materials and their finishes due regard shall be given to the conditions under
which equipment is to work. Tropical duty materials shall be used wherever possible.
17.22.2 Metals
Ferrous metals shall be prepared and coated in accordance with the painting
specification. Small iron and steel parts (other than stainless steel) of all instruments
and electrical equipment the cores of electromagnets and the metal parts of relays and
mechanisms shall be treated in an approved manner to prevent rusting.

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Cores etc. which are built up of laminations or cannot for any other reason be anti-rust
treated shall have all exposed parts cleaned and heavily enamelled or lacquered.
When it is necessary to use dissimilar metals in contact these shall be selected such that
the electro-chemical potential difference is not greater than 250 mV and if practicable the
two metals shall be insulated from each other by an approved insulating material or by a
coating of approved varnish compound.
17.22.3 Screws, Nuts, Springs, Pivots etc.

The use of iron and steel shall be avoided in instruments and electrical relays wherever
possible. Steel screws when used shall be zinc, cadmium or chromium plated or when
plating is not possible owing to tolerance limitations shall be of corrosion resisting steel.
Springs shall be of bronze or non-rusting material. Pivots for which non-ferrous material
is unsuitable shall be of an approved rustless steel where possible.
Testing of Thickness of Coating (Galvanized Steel) shall be checked with Dubai Central
Laboratory.
17.22.4 Wood
The use of wood shall be avoided as far as possible. When used it shall be of an
approved type to resist termite attack and fungal decay.
17.22.5 Electrical Insulating Materials
The use of hygroscopic insulating materials shall not be permitted except where
immersed in oil or suitably sealed to prevent ingress of moisture.
17.23 WORK IN DANGEROUS AREAS
The Contractor shall comply with any safety precautions called for by the Engineer such
as a "Permit to Work" system for access to designated high risk areas including wet
wells, sumps, valve chambers sewers and buildings in addition to Electrical Danger
Areas.
A minimum of 21 days notice in writing shall be given when requesting Permits to Work.
No unauthorised interruptions to the plant operations will be tolerated. The applications
for permits to work/plant shutdowns shall be accompanied by approved method
statements addressing all working practices, operational implications, safety procedures,
hazards and risks.
The "Permit to work" system will be administered by the Engineer.
17.24 CLASSIFICATION OF HAZARDOUS AREAS
The wet wells of pumping stations and raw sewage open channels to a height of one
metre above coping level shall be classified as Zone 2; in accordance with BS 5345.
17.25 HEALTH AND SAFETY AT WORK, ETC. ACT 1974
The entire installation and apparatus shall comply with the Health and Safety at Work,
etc. Act 1974 (incorporating provisions of the UK Factories Act) which lays down
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standards of safety and shall also be in accordance with the current Institution of
Electrical Engineers (UK) Regulations for the Electrical Equipment of Buildings.
Copies may be obtained from the Government Bookshop, P.O. Box 569, London SE1
9NH, UK.
17.26 PROGRESS REPORTS
The Contractor shall furnish a progress report for the ME&I Works at the end of each
month utilising software generated CPM planning and reporting methods The Contractor
shall in his report state the details with dates of the submission, approval, manufacture,
works testing, shipment, installation, site testing & commissioning of the proposed
equipment.
17.27 QUALITY ASSURANCE AND STANDARDS
All equipment furnished under this specification shall be new, and wherever possible,
shall be a standard product of an approved or experienced manufacturer, assembled
from standard components readily available in the market.
Equipment shall conform to the applicable requirements of the particular and general
project specifications and reference standards.
Manufacturer's, manufacturing premises, sub-contractors and suppliers shall operate on

an internationally recognised and approved quality system, or an equivalent in-house
quality system approved by the Engineer. The Contractor shall, if required supply full
details of the quality system to the Engineer for his review and approval.
17.28 ADAPTATION OF EQUIPMENT
No responsibility for alteration of a planned structure to accommodate substitute

equipment shall be taken by the Engineer. Equipment which requires alteration of the
structures will be considered only if the Contractor assumes all responsibility for making
and co-ordinating all necessary alterations, at no additional cost to the Employer. All
modifications to structures, mechanical, electrical, or other work made necessary by
such substitution shall require the approval of the Engineer. The cost of this work shall
be made at the Contractor's expense.
After approval of the mechanical and electrical drawings the Contractor shall prepare
and submit to the Engineer revised drawings showing any necessary revisions to the
proposed building and civil structures. The location, size and details of box-outs and
fixings for mechanical and electrical and other equipment shall be shown on the revised
drawings and the Contractor shall be responsible for providing in the civil structures the
correct location and size of the box-outs and fixings shown on the approved mechanical
and electrical drawings. The Contractor shall prepare at his own cost the necessary
revised civil drawings and detailed structural and other design calculations and submit
them to the Engineer for approval. The Contractor shall not be entitled to an extension
of time for completion for any delays from the preparation of such revised drawings. The
Contract price shall not be increased as a result of any changes in the civil structure from
that designated unless such changes are the result of variation properly ordered by the
Engineer.

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17.29 GUARANTEE
The Contractor shall provide a guarantee for the maintenance period for all equipment in
accordance with the General Conditions of Contract. In addition to the general
guarantee requirements, equipment warranty shall cover:
a) faulty or inadequate design

b) improper assembly or erection
c) defective workmanship or materials
17.30 CO-ORDINATION
The Contract Drawings show in a general arrangement form the layout desired for the
principal equipment, piping, and similar appurtenances, and shall be followed as closely
as possible. Proper judgment shall be exercised in carrying out the work to secure the
best possible headroom and space conditions throughout, to secure neat arrangement of
all equipment and accessories, to overcome local difficulties and interference with
structural conditions wherever encountered.
The Contractor shall take all measurements for his work at the installation site, verify all
dimensions and conditions at the place of installation verify the sub-contractor's
drawings and be responsible for the proposed installation, of the equipment within the
available space specified and shown on the Drawings. Proposed deviations from the
Drawings and Specification shall be submitted to the Engineer in writing giving full details
and reasons for the requests. The Engineer’s approval must be obtained for any
modification of the original works.
17.31 TESTING AND COMMISSIONING PROCEDURES AND DOCUMENTS
This clause is supplemental to Clause 17.17 Site Testing and Commissioning of

Electrical and Mechanical Plant.
a) Test procedures Method Statement. At least 45 days before testing and

commissioning is to be performed, a detailed and comprehensive method
statement shall be submitted for the performance of each separate test. Each
method statement shall describe and itemise the involved system including
associated electrical equipment, instrumentation and control system. Evidence
of an organised step-by-step procedure, properly co-ordinating the efforts of
the various trades and manufacturers representative involved, and of the
operations of the facilities should be provided. Method Statements shall
include an estimated duration and commencement date for each procedure
and a schedule of personnel and equipment required.
b) Method Statement information. Each method statement shall include the

following information, as applicable :
i) description of temporary procedure facilities, including drawings and

sketches as necessary to fully illustrate the requirements.
ii) list of test materials and estimated quantities
iii) list of instruments, measuring and recording devices, and other test
equipment, whether a part of the equipment or furnished separately for

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temporary use. Copies of calibration certificates shall be submitted for any

test equipment.
iv) names of supervisor and participating personnel
v) recording intervals.
c) Record materials. Samples shall be submitted of the forms, charts, and other
materials to be used when recording demonstration and validation test results.
Wherever possible, standard forms shall be used.
d) Test recording. Neat and comprehensive records of each test shall be

maintained by the Contractor. Each portion of the test procedure shall be
described with all components itemised. Records shall be prepared on forms
in a step-by-step fashion paralleling the approved method statement. Forms
shall list for each test or check the following :
i) check/list taken
ii) result anticipated
iii) result obtained
iv) if incorrect, corrective action taken
v) re-test/check result
vi) steps (iv) and (v) shall be repeated until all systems operate as required.
Instruments, gauges, and other sensors and display devices forming a
part of the various systems shall be employed for data acquisition where
applicable. The Contractor shall furnish all other instruments, gauges,
recorders and test devices as required, types conforming to the approved
method statements.
vii) The names of the personnel conducting the tests and the serial numbers
of any measurement equipment employed.
All applicable data such as, but not limited to, water and other liquid levels,
flows, pressures, head differentials, duration of runs, instrument readings,
voltage settings, drive speeds, motor running currents, torque, voltages and
related information, as applicable, and in accordance with approved test
procedures shall be recorded at the start and finish of each operational
demonstration and at 30 minute intervals during system validation tests, unless
other intervals are specified.
e) When a repeat of the same demonstration or validation test is required to verify

the results the repeat procedure shall be indicated on the recorded data by
numerical indication, data and time.
f) Test and commissioning reports including results, final settings and

adjustments made shall be provided in a separately bound volume of the
Operations and Maintenance Instruction Manuals.
17.32 SITE RELIABILITY TRIALS
This Clause is supplementary to Clauses 17.17 and 17.31
The Site Reliability Trials shall be carried out as follows under the control of the
Contractor's staff and the supervision of the Engineer. The purpose of these trials shall
be as follows:-
(i) To confirm the results of the Works Tests.

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(ii) To confirm the performance guarantee figures.
(iii) To provide a comprehensive record of machinery performance, bearing

temperatures and alignment at the time of commissioning.
The Contractor will be responsible for the following:-
a) To provide all necessary measuring instruments, indicators, temporary

pipework, temporary pumping plant and all other apparatus necessary to
carry out tests as detailed herein. The Contractor shall provide all necessary
skilled personnel and testing water and fuel for the Site Reliability Trials.
b) To liaise with his sub-contractors associated with the completion of any part
of the Works to ensure that all parties concerned are present during any tests
to carry out their responsibilities within the defined limits of their individual
sub-contracts.
c) To provide Test Certificates in quadruplicate giving a detailed record of all

electrical and mechanical tests carried out on the plant and cabling under the
Contract both in the manufacturers works and at site. Test certificates for the
cable installation shall be issued with the Record Drawings.
The Site Trials shall be carried out under the control of the Contractor's staff and the
supervision of the Engineer. The Contractor shall provide all of the necessary labour
and instrumentation to conduct the test.
Failure of one of the elements during the test run shall invalidate the test run, and test
runs shall be repeated until a continuous uninterrupted test run of all equipment has
been obtained.
The Site Reliability Trials, as applicable shall include the following:-
(i) A record of bearing, coupling clearances, protective device settings and

alignments shall be tabulated to show the "as-built" condition of each pump
set and drainage equipment machinery.
(ii) A record of all limit switches, overloads, relay and protective settings etc.
shall be tabulated to show the "as-built" condition of each applicable part of
FBA’s and other electrical switchgear and include a discrimination chart.
(iii) All cables shall have an insulation test to confirm the integrity of the
insulation. A tabulated record of results shall be made. Every cable shall be
subject to the following tests after installation:-
Witnessed high voltage pressure tests shall not be carried out on

P.V.C/S.W.A/P.V.C. control cables, but it shall remain the responsibility of the
Contractor to test the insulation of these cables both between cores and
between cores and earth during installation with a 500 volt insulation tester.
The Contractor shall test all cables after installation to ensure phasing out of
cores and continuity of cores sheath and armour over the whole length of the
cable.

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(iv) All earthing systems shall be tested to demonstrate the resistance of the
electrodes to earth and the earth conductor continuity is in accordance with
the Specification. The tests shall be made on completion of the installation.
Tests shall also be performed to prove earth loop impedance for all circuits.
Calculations shall be produced in accordance with the IEE regulations to
support the relevance of the impedance measured.
(v) The control centres, control panels and instrumentation shall be statically
tested with motors disconnected to confirm the correct sequence and
functional operation.
(vi) Each pump shall be operated individually over the range from closed valve to
maximum emergency top water level on a re-circulation basis using fresh
water. During this test the following parameters will be recorded:-
a) Motor current and voltage.
b) Pump and sewage treatment machinery outputs.
c) Ambient and Test Water temperatures.
d) Rotational and linear speeds, noise generated
e) Process product composition.
f) Sampling, Process and Dynamic Instrumentation settings.
(vi) All equipment subject to water pressure shall be hydraulically tested to at

least 8 bar, 1.5 times the maximum working pressure, twice the closed valve
pressure or 1.5 times the surge pressure whichever is the greater.
The hydraulic tests shall also be applied to the above ground pipework at Site
after erection. The Contractor shall provide the necessary equipment
including any temporary blank flanges which may be required to isolate
equipment.
(vii) All cranes shall be tested at works with a load 25% in excess of the rated
load.
The tests shall be repeated at site when erection is complete using test
weights to be provided under the Contract.
Certificates shall be provided for both tests and these shall include details of
centre span deflections recorded during the test procedure.
After all the deficiencies apparent during the site reliability trials have been
rectified to the Engineer's satisfaction, apart from necessary retesting, the
following test shall be carried out:-
(viii) Circuit Breakers and Control Gear:

Routine tests including H.V. pressure tests, and mechanical tests.
(ix) Protection and Control Circuits:
(x) All inter-tripping circuits in conjunction with other items of plant supplied
under separate contracts and controlled by others under the supervision of
the Engineer.
All testing and commissioning records shall be bound into a separate volume
of the Operations and Maintenance Manual.
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SECTION 18 - ELECTRICAL SPECIFICATON
18.1 HV AND LV FACTORY BUILT ASSEMBLIES (F.B.A.'s)
HV FBA's shall comply fully with the requirements of an approved International

Standard for metalclad switchgear and control gear.
LV FBA's shall comply with the requirements of an approved International

Standard for Type Tested Multi-cubicle-type Assemblies in order to provide fully
segregated self contained compartments.
18.1.1 Construction
Switch and control boards shall be factory built assemblies (FBA) and be
constructed and certified by an approved short-circuit testing authority. They shall
normally be of steel, flush fronted cubicle type, and of rigid construction, the sheet
steel being not less than 2 mm. Each FBA shall be multi-cubicle or multi-box type
form 4 with a separate compartment for the busbars and for each functional unit or
group. The protective conductor shall not be exposed. Unless otherwise detailed
they shall be self standing and have front access. Each enclosure shall be suitably
protected to an approved International Standard against dust, damp & vermin .
Removable back and other plates, where fitted shall be provided with suitable
gaskets or inserts.
Each door shall be :
(a) hung on substantial stainless steel hinges secured with SS bolts.
(b) secured with a corrosion resistant, lockable handle, operating at a sufficient

number of points to ensure firm pressure on the gaskets around the whole
periphery. Lock and handle shall be heavy duty and approved by the
Engineer and shall have common keys, and be compatible with existing RTA
lock types.
(c) interlocked with a fuse-switch disconnector, moulded case circuit breaker so

that, unless otherwise detailed, it cannot be opened unless all the equipment
contained in the cubicle is completely isolated from all supplies.
A circuit diagram and diagram of connections of permanent nature shall be

mounted inside the termination enclosure.
Steel used for the construction of boards shall be zinc sprayed or equally
protected. Bolts, nuts, washers, etc. shall be of stainless steel. Small fixing
screws and other similar items shall be of non-ferrous metal. Screws, bolts etc. on
the face of boards shall be of stainless steel. Painting shall be to final coat of stove
enameled grey gloss finish for external surfaces, unless otherwise detailed, and
stove enameled white gloss finish for internal surfaces. Each coat to be individually
stoved on. All paints shall be applied to the directions of the paint manufacturer.
Surfaces of boards which will be in contact with or close to structures shall, in
addition, be coated with bituminous paint or equal.
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18.1.2 Earthing Bar
Boards shall be properly earth bonded and provided with a tinned and sleeved
copper earthing bar of minimum size 300 mm2 running the full length of the board
and supplied with terminals of adequate size for connection to the station earthing
system.
18.1.3 Terminals
All internal connections, terminals, and metal supports for equipment and cables
shall be included.
Cables, unless otherwise detailed, shall enter through the underside of the board
via approved cable glands secured to a blank steel glanding plate. Space shall be
provided to accommodate cable glands of appropriate size for incoming and
outgoing circuits. Direct termination on equipment such as distribution board fuses
or miniature circuit breakers is not acceptable. Undrilled non-ferrous gland plates
bolted into position shall be provided where single core cables are terminated.
All gland plates and trays shall be earthed.
Termination blocks shall not be more than 400 mm from the gland plates. They
shall be referenced, readily accessible, of adequate size and suitable for
accommodating surge diverters.
18.1.4 Busbars
Bus bars and connections shall be identified by phase colour marking and
adequately supported by suitable insulators the whole to be mechanically and
electrically designed to withstand the full fault capacity as specified herein.
Busbars shall be rated at 50 kA for 1 sec as minimum of solid rectangular section

copper, rigidly supported and extending for the full length of the board. They shall
be of uniform cross sectional area throughout. They shall be separately housed,
arc protection shields being provided at each cubicle division. Access covers shall
carry warning labels. Connections to the busbars shall take the form of rigidly
supported copper strip and the mechanical and dielectric strength of busbars and
supports shall be capable of withstanding the worst conditions of electrical surge
which can occur in the installation. All bare copper shall be tinned. Busbars and
connections to busbars shall be protected by flame retarded cold shrink or heat
shrinkable tubing.
18.1.5 Anti-Condensation Heaters
Anti-condensation heaters shall be provided unless otherwise detailed. They shall

normally be of enclosed tubular pattern each served from a service fuse by a front
of board rotary switch and shall be controlled via a humidistat.

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The capacity of the anti-condensation heaters shall be considered at 10 watts per

square metre of cubical surface area, excluding the base with a minimum of 20
watts and shall be of available standard range of watts as follows :-
STANDARD RANGE OF WATTS STANDARD VOLTAGES

20, 30, 40, 60, 80, 100, 120 110, 220V, 380 Volts
18.1.6 Indicating Lamps

Indicating lamps shall be housed in flush mounted, square or circular lamp units,
measuring not less than 25 mm across the smallest dimension. Bezels shall be of the
non-metallic rustproof type. All indicating lamps shall be low voltage with self contained
transformer. Bulbs shall be voltage rated higher than the transformer secondary to
ensure long life.
Indicating lamps shall be supplied from individually fused circuits.
Lamps shall be well ventilated and the design shall permit removal of lamp glass and
bulbs from the front of the unit.
All pilot lamp bulbs shall be of the same voltage regardless of transformer primary
voltage.
18.1.7 Indicating Instruments
Indicating instruments shall be as Clause 18.18
18.1.8 Motor Starter Isolation
Each motor starter shall be provided with its own MCCB or fused switch, which shall be
suitable for padlocking in the "off" position.
18.1.9 Control Circuit Protection
Separate short circuit protection devices shall be provided for each circuit and shall be
clearly marked to show the circuit that is protected.
18.1.10 Rotor Resistances
Rotor resistances shall normally be contained in separate enclosures adequately

ventilated to dissipate heat generated and arranged so that the grids are accessible. If
resistance is installed in the starter section, then a thermostat shall regulate the
temperature of the starter section.
18.1.11 Socket Outlets
Socket outlets where detailed, shall be of low voltage not exceeding 220 V fed from a
suitable double wound and fused transformer with earth leakage protection. They shall
be 3 pin 16 ampere flush socket outlets with flaps.
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18.1.12 Metering
When provision for the Dubai Electricity Water Authority (Electric Division) metering
equipment is specified the Contractor shall obtain details of the equipment and shall
submit drawings of the arrangements to be provided for approval. The approved
arrangements shall be incorporated and annotated in the drawings submitted to the
Engineer. When the KWH meter is supplied by the Control Panel Manufacturer, the
meter shall be forwarded to the Dubai Electricity Water Authority (Electric Division) for
calibration tests prior to installation. The calibration certificates shall be included with the
documentation.
18.1.13 Labeling
Labels shall be colourless transparent plastic material not less than 3mm thick with
beveled edges to half the thickness. Each shall be reverse engraved in Arabic and
English the engraving being filled white and the reverse side painted blue unless
otherwise detailed. Main labels shall be provided as detailed and subsidiary labels be
provided for each item on the face of the board, stating what it indicates or controls. Any
item which is not isolated at the board shall, in addition, be provided with a warning label
"Danger Live Terminals Isolate Before Maintenance" with flash and voltage in red letters
on white background in Arabic and English. A drawing giving label sizes and a list of
inscriptions shall be submitted to the Engineer for approval before manufacture. All
labels shall be fixed before taking-over tests are carried out.
All external labels shall be affixed with chrome plated nuts and bolts with slotted holes to
allow for expansion of the label. All internal labels shall be engraved multi-layered
plastic to an approved design affixed with chrome plated nuts and bolts or a permanent
adhesive.
18.1.14 Spares
The spare parts list for the FBA’S shall be as approved by the RTA.
A complete spare set of all fuses and indicating lamp bulbs in each cubicle shall be
provided suitably marked and clipped in readily accessible positions, preferably inside
the door; in each cubicle.
18.1.15 Future Equipment
Where provision for future equipment is detailed the arrangement shall be such that
equipment can be installed safely without interfering with the operation of the existing
plant. Cubicles provided for future equipment shall be complete with busbars and
isolators.
18.1.16 Standby Generator Connection
Each panel shall have provision for standby generator incoming supply as an alternative
to the main supply as follows:-
(a) For a load of 125 Amps or less, a suitably rated three position change over
switch with indicator lights shall be provided.

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One No. 3 phase, weatherproof neutral and earth, 5 pole male socket for the
connection of a standby power generator supply shall be flush mounted on the
L.H. bottom section of the panel. Where the panel is located inside of a weather
proof kiosk. A lockable door shall be provided to afford direct access to the
socket. Each socket shall be complete with a female plug for the termination of
the generator supply cable. The socket shall incorporate a mechanically
interlocked mechanism to ensure that the plug is fully/correctly inserted into the
socket prior to switching on the supply. The fitting shall be rated at 125 A, 600
V and shall be compatible with the existing fittings. Each socket shall be
complete with a secured cover which may be placed in position when the plug is
removed, and as detailed on the single line diagram.
(b) For a load higher than 125 Amps appropriate termination and change over
arrangements shall be provided, and as detailed on the single line diagram.
18.1.17 Weatherproof Switchboards
Panels for use in locations exposed to the weather shall be installed within Fibre Glass
Kiosks.
(a) All fixing screws, bolts, etc. shall be of stainless steel.
(b) Each push button shall operate through a suitable shroud covering the whole of
the button and forming a barrier between the button and the interior. All
operating spindles on isolators, etc. shall enter their enclosures through packed
glands or similar, to exclude moisture.
(c) Each board shall be protected by an outer shell.
Hinges for kiosks shall be of an approved grade of Stainless Steel and robust in design.
Lock and handle shall be heavy duty and approved by the Employer and all locks shall
have common keys. Door restrainers shall be of an approved grade of Stainless Steel
and of adequate cross section (min. 6 mm x 35 mm). The clear space between the front
of the control panel and the kiosk shall not be less than 650 mm, clearance to the rear
and sides shall be a minimum 300 mm and a maximum of 500 mm for enclosures with
front access only. For enclosures with front and rear access the minimum clearance to
the rear and sides shall be 600 mm.
A generator plug and socket enclosure shall also be provided on the L.H.S. of the kiosk.
The enclosure shall be fitted inside the kiosk, mounted flush with appropriate opening
and lockable doors.
18.1.18 Panel Wiring
Joints of main or control wiring between the components are not permitted. All control
panel wiring, motor starters, control gear and the like shall be carried out in a neat and
systematic manner with cables supported clear of the panels and other surfaces at all
points to obtain free circulation of air. Claw washers shall be used to terminate all small
wiring. Insulating bushes shall be provided where necessary to prevent chafing of
wiring. Neoprene will not be used with PVC wiring. All panel wiring shall be in PVC
sheathed cable or fire-resisting cable of approved type.

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All control panel wiring, motor starters, control gear and the like shall be carried out in a
neat and systematic manner with cables supported clear of the panels and other
surfaces at all points to obtain free circulation of air. Claw washers shall be used to
terminate all small wiring. Insulating bushes shall be provided where necessary to
prevent chafing of wiring.
All circuits above 200 Volts shall be wired in 450 / 750 Volt grade cable but circuits at
200 Volt and below in 300 / 500 Volt grade cable. The conductors shall be of copper
and shall have a minimum cross sectional area of 1 mm2.
All wire ends shall be tinned before termination and all terminals shall be protected by
PVC sleeves or flame retarded cold shrink or heat shrinkable tubing. All wires shall be
fitted with numbered ferrules of approved type at each termination.
Crimped lugs shall be fitted to all wires and cables for termination.
18.1.19 Thermal Overload Relays

Thermal overload relays shall be temperature compensated (-10oC/80oC) sensitive to
phase failure, adjustable and be calibrated in terms of motor full load current. Auxiliary
volt free contacts shall be fitted for remote indication circuits.
Relays shall be manually reset by means of integral push-buttons or levers. A testing

facility shall also be provided. Terminals shall be of the pinch screw pattern.
18.2 CIRCUIT BREAKERS
18.2.1 H.V. Circuit Breakers
Circuit breakers for use in AC circuits of rated voltage above 1 kV shall be of either the
SF6 insulated, vacuum type or air break type. They shall comply with an approved
International Standard and be suitable for use with the voltages and fault levels
anticipated.
18.2.2 Air Break Circuit Breakers
Circuit breakers of rated voltage below 1 kV shall be of the air break type and shall be
suitable for controlling loads as indicated in the schedules. They shall comply with an
approved International Standard and be suitable for use on systems with voltages and
faults levels anticipated.
18.2.3 General
The circuit breakers should be horizontally isolated, horizontal drawout pattern air break
type. The closing and tripping mechanism shall be as detailed in the relevant Clauses or
schedules.
The operating mechanism shall have a mechanical ON/OFF indicator and a manual trip
device fitted with means for locking test terminal blocks healthy trip lamp (coloured
white) and associated push-buttons set of auxiliary switches SUPPLY AVAILABLE

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lamps (blue) (on incoming units only) and cable boxes complete with glands of suitable
size for the accommodation of the incoming and outgoing cables entering from below.
Each circuit breaker shall be provided with an operations counter.
Closing solenoids shall be suitable for operation at 80% of the nominal supply voltage.
Closing and tripping batteries shall comply with Clause 18.16.

Auxiliary contacts for the indication of breaker state for use at 24V DC shall be provided.
Circuit breakers shall be designed and constructed such that inspection maintenance
and replacement of the main fixed and moving contacts shall be easily possible on site.
Detailed manufacturer’s instructions shall be incorporated in the maintenance manuals.
Breakers requiring their complete return to the manufacturers for service will not be
acceptable.
All circuit breakers shall be provided with interlocks to ensure that:-
Circuit breakers cannot be plugged in or isolated when it is closed.
The circuit breaker cannot be closed until it is fully plugged in or completely isolated.
The circuit breaker cannot be closed in the service position without completing the
auxiliary circuits between the fixed and moving positions.
Facilities shall be provided for testing the circuit breaker operation when in the isolated
and withdrawn position. Auxiliary jumper connections if necessary shall be included.
The incoming circuit breakers should be fitted with over current tripping and earth fault
relays with auxiliary relay for instantaneous remote trip and indication.
If transformer protection relays are to be located on the LV breakers an intertrip relay

shall be provided to trip the HV breaker on operation of transformer protection device.
All incoming circuit breakers shall be fitted with a voltmeter with a selector switch to read
voltage of the line and line to neutral.
Ammeters shall be fitted on the bus bar side voltmeters on the line side of the incoming
circuit breaker trips.
The LV circuit breaker shall trip every time its associated HV circuit breaker trips.
Any other interlocking shall be provided as necessary to ensure the safe operation and
maintenance of all electrical equipment provided under the Contract.
All components of the switchgear including bus bars and cable boxes shall be capable of
withstanding the tests outlined in the approved International Standards.
18.3 EARTH LEAKAGE CIRCUIT BREAKERS AND SWITCH DISCONNECTORS
Earth Leakage circuit breakers and fuse-switch disconnectors or switch disconnectors

shall, unless otherwise specified, be of front access type. They shall be of the horizontal
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draw-out triple pole type, provided with a detachable neutral link suitable for the system
voltage and capable of withstanding the fault current of the system.
Contacts shall be of robust design, of adequate cross sectional area, capable of carrying
the full load current for an indefinite period and shall be readily renewable. The fixed
contacts shall be shrouded.
The switching mechanism shall be of a well proven type, interlocked to prevent access
under energised conditions and shall incorporate a mechanical switch position indicator
labeled "ON" and "OFF".
18.4 FUSE-SWITCHES AND FUSE-SWITCH DISCONNECTORS

(1) All fuse-switches and fuse-switch disconnectors shall be capable of
withstanding the fault level of the system.
(2) Unless otherwise called for in the detailed specification the following
standards sizes shall be employed throughout :-
60, 100, 150, 200, 300, 400, 500, 600 and 800 A.
60 A units shall be suitable for adapting carriers to accept 30 A fuses.
(3) The switch action shall be parallel, giving a simultaneous make and break
action on all contacts.
(4) Moving contacts shall be provided with suitable fillets between phases with
fixed contacts fully shrouded.
(5) The construction of fuse-switches and fuse-disconnectors shall be suitable

for easy removal of contacts and all moving parts under site conditions.
18.5 FUSES
Fuses for systems of up to and including 1,000 Volt pressure, shall be of the HRC
cartridge type to approved International Standards.
Control circuit fuses, alarm indicator fuses, semi-enclosed fuses, domestic consumer
unit fuses and high voltage fuses shall be manufactured to an approved International
Standard.
18.6 CURRENT TRANSFORMERS
Current transformers shall be manufactured to an approved International Standard.
18.7 INSTRUMENT VOLTAGE TRANSFORMERS
Voltage transformers shall be manufactured to an approved International Standard.
18.8 ISOLATING TRANSFORMERS
Isolating transformers shall be manufactured to an approved International Standard.

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18.9 SELECTOR SWITCHES
(1) Selector switches shall be of robust design and construction and rotary in
operation. Bezels shall be of non-metallic rust-proof type.
(2) Switches for voltmeters shall be capable of selecting :-
R-B, B-Y, Y-R, R-N, B-N, Y-N and OFF
(3) Switches for ammeter
18.10 EARTHING
All switchboards and control boards shall be provided with a proper system of earthing,
suitable for connection to all protective conductors and metallic sheathing of all
associated cables, so as to be effectively connected to the general mass of earth at the
sub-station from which the installation is supplied, in accordance with approved
regulations and codes of practice as required by the supply authority and to the
18.11 AC MOTORS
(1) AC motors shall be continuously rated to S1 duty and performance and be

suitable for 15 starts per hour.
(2) Conditions of operation and type of protection shall be as given in the

detailed specification.
(3) Frame sizes shall be in accordance with an approved International Standard.
(4) Commutator segments shall be constructed from hard drawn copper or equal
approved and of ample cross-section with sufficient depth to permit
"skimming".
(5) Brushes where applicable shall be of standard sizes. They shall be mounted
in holders with springs such that the correct pressure is applied and no
portion of the load current is carried by the springs. An alternative device
which ensures constant pressure at the brushes throughout their life may be
offered. The whole brush assembly shall be continuously rated for the duty
and so constructed that it can be conveniently removed.
(6) Windings shall be designed to give an even temperature distribution, free

from hot spots.
(7) Temperature sensitive thermistor devices shall be embedded in each phase

winding for motors of 7.5 kW and above unless otherwise specified.
(8) The rotor assembly shall be statically and dynamically balanced, vibration
shall not exceed the limits set out in the approved International Standard or
such finer limits as defined in the detailed specification. Bearings shall have
lubricators suitable for ensuring an adequate supply of lubricant at all times.

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For motors of 37 kW and above the bearings shall have plugged pockets
suitable for insertion of thermometers or temperature probes.
(9) Moving parts of the motor shall be provided with guards and where
appropriate hinged doors shall be provided for easy access to commutator
and brush gear.
(10) Unless otherwise specified, heaters shall be incorporated to prevent moisture

condensation when the motors are stationary. Where heaters are not fitted
the motor shall have a suitable drain hole in the casing.
(11) Terminal boxes shall be conveniently located and of adequate size to

accommodate all connection requirements. The heater and thermistor
connections may be located in the starter box provided they are isolated from
other connections, shrouded, and clearly marked. Alternatively separate
boxes with non-interchangeable covers may be provided for the heater and
thermistor connections. Terminal boxes shall be provided with removable
plates suitable for drilling and tapping by others unless details of the required
drillings are given in the detailed specification.
(12) Each motor shall be provided with a suitable external earthing terminal.
(13) Each motor shall have a rating plate with the following information:-
(a) Manufacturing standard reference.

(b) Maker’s name and motor type number.
(c) Frame size.
(d) Rating.
(e) Class of insulation.
and, where significant
(f) Ambient working temperature.

(g) Type of coolant.
(h) The permissible overspeed.
In addition motors of 7.5 kW and above shall have individual identification

numbers.
18.12 MOTOR STARTERS
18.12.1 General
The starter cubicles as required are to form part of the FBA and as such circuit
connections protection devices and the like shall comply with the approved International
Standards appertaining to the FBA’s . The cubicles shall be easily accessible for
maintenance purposes and shall be damp-proof and dust-proof. The motor starter shall
comply with an approved International Standard and shall be suitable to carry the full
load current of its rated duty at its most severe load conditions. All starters shall be
capable of at least 20 starts per hour at 100% full load torque. Motor starters shall be
dust-proof. Motors up to and including 11 kW shall be started direct on line. Motors
above 11 kW shall be started in accordance with applicable clauses detailed herein.
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18.12.2 L.V. Starters
Each starter shall be housed in a separate compartment which shall contain the
following:-
a) 1 No. triple pole MCCB or fuse switch externally operated and interlocked
with the cubicle door. There shall be provision for padlocking in the OFF
position.
b) Contactors selected from one of the following types:-
i. 1 No. TP contactor for switching direct-on-line (DOL) in accordance with

an approved International Standard and fitted with auxiliary contacts.
ii. Closed transition star-delta starting
iii. For auto-transformer starting there shall be provided magnetically

operated starting, accelerating and running contactors operating under
mechanical or pneumatic timing devices. The auto-transformer shall limit
the starting current to 4 times full load current (FLC) with 60%, 70% and
80% tappings.
iv. For slip ring rotor resistance starting there shall be provided magnetically
operated starting, accelerating and running contactors operating under
mechanical or pneumatic timing devices.
v. Contactors shall be selected for AC4 duty.
vi. For Solid State Reduced voltage Starting there shall be provided a micro-
processor based electronic logic module and a 3 pole, 6 thyristor (SCR)
full wave power section together with the following features:-
(1) Turn on current adjustment - 100 to 400% FLC.

(2) Pulse start adjustment - 0 to 2 seconds.
(3) Adjustable current ramp time - 2 to 30 seconds.
(4) Starting current limit adjustment - 100 to 400% FLC
(5) Over temperature protection.
(6) Fan assisted cooling above 11 kW.
c) 1 No. Electronic Motor Protection Relay with the following features:-
Protection Against:
overcurrent unbalance
single phase
earth fault
Digital Indication of:
relay settings
% of FLC that the motor is taking
continuous monitoring of thermal capacity of motor
thermal capacity used during start of motor
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if tripped, how much time before restart to take place

stall or short circuit trip
earth fault trip
starting
Documentary evidence must be produced showing the current/time characteristic of

each overload at its setting (hot/cold for the thermal overload) overlaid on the motor
manufacturers thermal stability time/current characteristic for comparison. Consideration
must be given as to the requested method of starting (DOL, auto transformer etc.).
d) 1 Set of auxiliary relays and timers required to provide the necessary

indication and control sequence.
e) Motor starter TEST switch to allow operation of the starter with no supply to
the associated motor.
f) 1 Set of main motor terminals and auxiliary terminals for remote controls and
indicators all complying with clause 18.1.3.
g) 1 Set terminals for remote lock-off stop push buttons.
h) 1 No. 220/110V 50 Hz double wound single phase transformer with earth

screen and of suitable capacity to supply all pilot lamp requirements. The
control and pilot lamp circuits shall be fuse protected on both sides. The
transformer secondary shall be centre tapped and earthed via a removable
bolted earth link. The transformer primary shall be supplied through a
suitably rated fuse and neutral link via auxiliary contacts of the main fuse
switch with a suitably wired switch marked "TEST" for the purpose of
conducting functional tests to the control circuit whilst the main fuse switch is
isolated.
The switch shall be interlocked so as to prevent the closing of the cubicle

door with the said switch in the "ON" position.
i) 1 No. anti-condensation heater (off when starter contactor is closed). The

heater shall be separately fused.
j) 1 Set of power factor correction capacitors with fuses for all corrected drives.
k) 1 Adjustable thermostat to be mounted in the starting resistance cubicle and

protecting the resistance from overheating by tripping the main contactors.
(Resistance and auto-transformer starting).
The following equipment shall be mounted on the door of the starter cubicle:-
l) 1 No. ammeter fitted with suppressed scale to read motor running and
starting current.
m) 2 No. pilot lamps to indicate "SUPPLY ON" (green) and "MOTOR RUNNING”
(Red).
n) 1 No. pilot lamp to indicate "MOTOR FAILED" (Amber).

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o) 1 No. Blue pilot lamp to show automatic operation has been selected.
p) Pilot lamps shall comply with Clause 18.1.6.
q) 1 No. "HAND/OFF/AUTO" selector switch.
r) 1 Local/remote selector switch as required.
s) 1 set "START/STOP" push button.
t) 1 No. externally operated overload reset push button.
u) 1 No. motor and cubicle heater "OFF/AUTO" control switch.
v) 1 No. hour counter reading to 9999 hours.
w) 1 duty label.
1 No. digital display unit.
Volt-free N/O and N/C auxillary contacts wired to terminals for remote indication of motor
running, motor stopped, hand and automatic selected, shall be provided for all starters.
18.12.3 H.V. Starters
All H.V. starters shall be generally equipped as L.V. starters except as detailed below.
i) 1 No. TP externally operated load isolating switch mechanically interlocked

with the cubicle doors and electrically interlocked with the main contactor.
The isolator shall have three positions: closed, open and earthed position.
There shall be provision to lock the isolating switch in the OFF & Earth
position.
ii) 1 No. Externally hand operated shrouded control isolator with the above unit
to provide a contactor test facility.
iii) 3 No. bolt on type HRC fuses suitably fault rated.
iv) 1 No. Triple pole H.V. vacuum contactor which shall comply with
requirements of an approved International Standard and be designed to
minimise the mean currents chopped and transient over voltages to those
which could occur with an equivalent air contactor. Continuous vacuum
monitoring facilities shall be provided and interlocked with the contactor coil.
The contactors shall be suitable for mechanical duty in accordance with an approved
International Standard.
18.12.4 Slip Ring Rotor Resistance Motor Starters
18.12.4.1 General

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Where slip ring rotor resistance motor starters are employed the rotor resistance
shall be of the metal grid type and shall limit the starting current to that specified for
the size of drive.
Rotor resistance shall be mounted in floor standing units, panel top units or integral
panel units.
18.12.4.2 Floor Standing units
The rotor resistance may be mounted within floor standing cubicles constructed of
2mm (minimum) thick sheet steel of welded construction. The cubicles shall be
provided with adequate ventilation louvers and access to the resistance units shall
be by means of a lockable, hinged front door. The cubicle shall be arranged for
cabling from below.
Both the exterior and interior of the cubicle shall be stove enameled to in Grey to
an approved International Standard. Warning notices to indicate electrical hazard
within shall be fixed to all access panels.
Each cubicle shall be equipped with a heater which shall be continuously "on"
while the associated resistance bank is de-energised.
18.12.4.3 Panel Top Units
The rotor resistance may be mounted within separate cubicles mounted on top of
the control panel. These cubicles shall be identical in construction to the control
panel and dummy cubicles shall be provided as necessary to ensure uniform
height of the entire control panel.
The cubicles shall be provided with adequate ventilation louvres and access to the
resistance units shall be by means of a lockable, hinged front door. Cable
connections to the main control panel shall be via suitable cable glands to maintain
the integrity of the control panel enclosure.
Each cubicle shall be equipped with a heater which shall be continuously "on"
while the associated resistance bank is de-energised.
18.12.4.4 Integral Panel Units
The rotor resistance may be mounted within a cubicle within the control panel itself
provided that:-
(a) The resistance cubicle is adequately ventilated front and rear.
(b) The resistance cubicle is provided with suitable cable gland entries to
maintain the integrity of the control panel enclosure.
(c) The resistance cubicle is located so that no electrical components are

mounted above it.
(d) The motor starter equipment is located in a separate, totally enclosed cubicle
within the control panel.

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(e) 1 No. TP wound magnetic overload relay fully adjustable but set at the actual
current setting required to trip under a stalled motor condition within the
maximum time that the motor characteristic permits this condition to exist.
18.13 MOULDED CASE CIRCUIT BREAKERS (M.C.C.B'S)
(1) M.C.C.B's shall withstand the system short circuit current of not less than 30
KA.
(2) M.C.C.B's shall accommodate the maximum number of poles available.
(3) The rated voltage insulation shall not be less than 600 V AC and the rated
operation voltage shall not be less than 380 V AC.
(4) The rated operational current for uninterrupted duty shall meet loading
requirements.
(5) The switching mechanism shall be fully interlocked with the compartment
door to prevent entry by personnel while the M.C.C.B is in the energised
position.
(6) All contacts shall be shrouded to prevent accidental contact by operations

and maintenance personnel.
(7) Thermal and magnetic settings shall be adjustable.
(8) Volt free contacts shall be provided for ON/OFF indication, contacts shall be
wired to case mounted terminals.
18.14 PUMP CONTROLS
The control unit shall be suitable for operation on 220 V AC supply and in the ambient
conditions prevailing in Dubai. It shall contain a built -in battery with a minimum life of 2
years. Stored data shall be protected from being lost in the event of a power failure. The
unit shall record the time taken to empty the sump and calculate the idle time to
continuously adapt the operation of the pump(s) to the station inflow to achieve the most
economical operation. The current sensors for use in conjunction with the computer logic
system shall be either a current transformer or a low level sensor and shall be installed
in the control panel.
The current transformer primary current shall be as close to the pump's operating current
as possible.
The control system shall have the following facilities:-
(1) The pumps shall be controlled automatically by a computer logic system

installed in the control panel using signals received from float level switches
on a 1st duty, 2nd duty/standby (2 pumps only) and 3rd duty/standby (3
pumps) to chamber of pumps basis with a common stop. The duties shall
alternate automatically.
(2) Each pump shall be capable of selection for manual/auto duty.

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(3) The automatic duty shall be selected by an auto/hand selector switch.
(4) Each pump in manual shall be controlled by start/stop push button.
(5) Individual pump start delay to reduce starting current surges.
(6) The emergency stop (low level) float shall be in circuit for both manual and
auto modes of operation and shall stop all the pumps.
(7) A high level in the pump shall be indicated in the panel through a float switch
and a continuously rated flasher light mounted on top of the kiosk marked
'HIGH LEVEL IN SUMP'.
(8) Reset button to erase all stored operating data from the memory.
18.15 TELEMETRY SYSTEM
The objectives and key features of the telemetry system will be as follows:
(1) The monitoring and remote control of automatically operating plant from a
central point.
(2) To provide operational data for both normal and fault conditions including the
initiation of alarms in order to minimise the frequency of visits and to provide
a prompt response to faults.
(3) To collect, store and process operational data for management purposes.
The system shall make use of the public telephone network.
Sufficient space shall be provided in the control panel for the telemetry system. The
Contractor will be provided with outline requirements for the system and will be required
to then offer detailed proposals and specifications for the plant and equipment to be
supplied.
The specifications, plant and equipment etc. shall be subject to the approval of both the
Employer and the Engineer.
During the commissioning/start up period of the system it will be necessary to provide

appropriate training and instruction in the operation and maintenance of the system for
the Employer's operations staff.
18.16 BATTERY UNITS
The battery and charger shall be housed in a single sheet steel floor mounted ventilated
cabinet with batteries housed in the lower part of the cubicle.
The unit shall be complete with a self adjusting constant potential trickle charger suitable
for operating from a 220V single phase AC supply. The charger shall be rated to
continuously energise relay coils and lamps as applicable. The charger shall be
designed to maintain a constant voltage within 3% irrespective of mains voltage or
frequency variation. Booster charge facilities shall be included.
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The unit shall be fitted with the following:-
1 No. Supply ON indicating lamp

1 No. ON/OFF switch
1 No. Charger ammeter
1 No. OFF/FLOAT/BOOST switch
1 No. Charger failure alarm relay and lamp
1 Set of cable terminals and fuses.
All battery cells shall be either nickel iron or nickel cadmium structure with an alkaline
electrolyte and be provided with a suitable drip tray to protect the cabinet from corrosion
caused by accidental spillage of the battery medium.
Batteries shall be 30V or 110V DC and of suitable ampere hour capacity to operate
the closing and tripping coils motor of the circuit breakers. Dual duty batteries (i.e.
for engine starting and for tripping circuit breakers) will not be acceptable.
18.17 TRANSFORMERS
18.17.1 Standards
Transformers shall be manufactured to an approved International standard and be of

the Naturally Air Cooled Oil Filled Hermetically Sealed type. Transformer oil shall be as
recommended by the manufacturer for the local conditions.
18.17.2 Windings
The windings shall be connected delta-star with group 4 phase displacement primary to
secondary vector group reference DY11 (plus 30o) with the star point of the secondary
winding brought out through the tank and suitably terminated in a separate housing for
solid earthing in addition to the neutral connection. Provision shall be made for current
transformers for fault protection to be mounted on both neutral and earth connections.
The percentage value of the equivalent impedance of each transformer shall not be less
than that required to restrain the secondary voltage fault level to the maximum permitted
by the switchgear.
Solid insulation material for immersed type transformers shall be as defined in an

approved International Standard modified as necessary for service in an ambient
temperature of 50oC.
The high voltage windings shall be provided with tapping at +5%, +2.5%, -2.5%, -5%
with constant flux voltage variation as defined in an approved International Standard.
Tap selection shall be by means of an externally operated manual control off-circuit

tapping selector. A mechanical tap position indicator shall be provided and the selector
shall be capable of being padlocked in any position.
The tap changing selector shall be located below the oil level inside the tank and the
selector operating rod shall extend outside the tank.

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18.17.3 Construction
The core shall be constructed from cold rolled steel laminations manufactured to an
approved International Standard. The laminations shall be insulated from each other by
means of a suitable temperature resistant oil proof coating.
The windings design and construction shall provide adequately designed and located
coolant flow ducts so that possible hot spots are eliminated. Windings shall be braced to
withstand dynamic stresses due to short circuit conditions. Full details shall be provided
of arrangements for taking up or eliminating coil shrinkage during service. The core and
winding shall be designed so that the iron loss is at a minimum but the ratio of copper
loss to iron loss shall be in accordance with an economic design and the manufacturer
shall state the ratio used.
The arrangement of internal connections shall be such that the transformer core and
winding may be lifted bodily from the tank without disturbing the cable boxes or
insulators.
The transformer tanks shall be constructed from high grade steel with electrically welded
seams. The structure of the tank shall enable it to be handled whilst filled with oil and
shall be pressure tested to 70 kN/m2.
Tank shall be fitted with skids and four removable rollers and lifting eyes suitable for the
mass of the transformer and oil.
The tanks shall be provided with external cooling tubes to provide natural cooling under
the climatic conditions.
All terminals shall be brought out through oil tight insulating glands into respective
disconnecting terminal chambers to facilitate cable testing.
The tanks shall be non-breathing hermetically sealed type.
The tank covers shall be of such construction as will prevent the accumulation of
moisture and shall be bolted to a flange on the tank top to form a weather-proof seal. All
gaskets shall be of synthetic rubber and cork compositions. The tank tubes and all
steelwork shall be shot blasted internally and externally before painting and a rust
inhibiting paint shall be applied to both external and internal surfaces before applying a
final finish. The exterior shall be given an additional coat on Site of a durable oil and
weather resisting paint of an approved colour.
The design and construction of the transformer core winding and tank shall ensure that
the noise level at full load is kept to the minimum consistent with economic design. The
tank shall be reinforced or braced where necessary to reduce the noise level.
The complete transformer arranged for service shall be capable of withstanding the
specified impulse voltage on the H.V windings.
All windings, winding terminals and connections shall be fully immersed in oil under all
operating conditions and materials shall be suitable for this duty and not be subject to
deterioration from contact with oil.

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The windings shall be thoroughly dried out under vacuum at the manufacturer's works
and shall be delivered to Site filled with oil to the normal level and ready for service.
18.17.4 Fittings
The following fittings are required:-
(a) Thermometer pockets, one for oil and one for winding temperature.
(b) 200 mm diameter dial type oil and winding temperature indicators each fitting
with 2 No. sets of adjustable contacts for alarm and trip functions.
(c) Rating and diagram plate complying with an approved International Standard
and of a durable and non-corrodable material.
(d) Oil gauge clearly visible from ground levels.
(e) Pressure relief valve with alarm contacts.
(f) Separate neutral earthing terminal with independent access cover enclosed
with a weather-proof housing for the restricted earth fault current transformer.
(g) Earthing terminal.
(h) Marshalling box for overtemperature, pressure alarm and trip contacts.
(i) Large identity labels shall be affixed to each transformer identifying their
primary circuit breaker.
(j) H.V and MV disconnecting chambers where compound filled cable boxes are
provided.
All joints shall be arranged so that they may be tightened externally.
A H.V compound filled cable sealing box complying with an approved International
Standard shall be provided. Large filling orifices and adequate expansion space shall be
provided. The necessary compound shall be included.
The cable boxes shall be completely detachable from the transformer without breaking
the cable termination. Suitably drilled cable sockets shall be provided.
18.18 INSTRUMENTS, INDICATORS AND TRANSMITTERS
Where not specified elsewhere, the following shall apply:-
18.18.1 General
All instruments, gauges and control equipment shall be to approval, and those which
perform similar duties shall be of uniform type and manufacture throughout the scheme
in order to facilitate maintenance and the stocking of spare parts. Moving parts and
contacts shall be adequately protected from the ingress of dust, and all instruments shall
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be protected by moisture and dustproof cases including those mounted in panels. All
equipment shall be suitable for its environment and of industrial quality.
Panel mounted receiving instruments shall be of the electrically operated miniature flush
mounting type unless otherwise stated.
Where applicable each instrument chassis shall be easily withdrawable from its housing
for maintenance without interrupting its signal.
All instrument bezels shall be finished in black
Main indicating instruments shall be of 140 mm minimum diameter. Secondary indicating

instruments shall be of 75 mm minimum diameter. Scales shall be clearly marked with
black lettering and graduations on a white background. Instruments of the same type
and range have identical scales. Ranges shall be selected to show normal plant
operation between 50% and 75% of the instruments range.
18.18.2 Instrument Ranges
Indicating instruments shall be selected to operate using the following units:-
Flow l/s Litres per second

Level m Metres
Pressure m.hd Metres head of water
o
Temperature C Degree Centigrade
p.p.m Parts per million
Concentration
Mg/l Milligram per litre
Current A Amperes
Voltage V Volts
Power W Watts
Electrical Energy Whr Watt-hours
Frequency Hz Hertz
Speed r.p.m. Revolutions per minute
Standard S.I. multipliers shall be used (kilo-, milli- etc.).
18.18.3 Field Mounted Instruments
Field mounted instruments shall, where possible be hermetically sealed. If this is not
possible they shall be of weatherproof construction with heavy cast metal cases.
Transmitters and similar equipment shall be further enclosed in purpose made

weatherproof, glass reinforced fire-retardant polyester resin cabinets.
Particular regard shall be paid to the ease of access to all instruments. Serial
number/calibration plates shall be visible when the instrument is in its cabinet.
Locally mounted indicating instruments shall be mounted in viewable positions.
Field mounted instruments shall be complete with all mounting brackets, pillars, sun
shades, fittings and fixings to complete the installation.

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18.18.4 Panel Mounted Instruments
Panel mounted instruments shall where possible be hermetically sealed. If this is not
possible they shall be enclosed in moisture and dust proof cases.
18.18.5 Indicators
All indication instruments shall have performances and scale markings in line with an
approved International Standard.
Level indicators shall be scaled vertically, alarm levels being indicated by red areas.
Motor current ammeters shall have red lines or adjustable movable pointers to indicate
motor full load current.
18.18.6 Digital Indicators
Digital flow indicators shall be three figure electronic digital display type. Precaution
shall be taken to ensure that fluctuation in the signal, however caused, does not render
the last figure to unstable and unreadable during normal running when updating of
readings at three second intervals.
Indicators shall read zero at “no flow” condition.
Direct readings shall be displayed without use of conversion factors other than multiples
of ten, which shall be clearly indicated. Display figures shall be 14 mm gas discharge
and visible from 12 metres distance.
18.18.7 Integrators
Flow integrators shall be six figure non-resettable mechanical impulse counters with a
minimum figure size of 9 mm x 4.5 mm.
Electronic counters may be employed providing precautions are taken to maintain the
count during power failure.
Integrators must not record under “no flow” condition.
Direct readings shall be displayed without use of conversion factors other than multiples
of ten which shall be clearly indicated.
18.18.8 Chart Recorders
All chart recorders for use in control and instrument panels, desks, consoles, etc., shall
comply with the following unless specified elsewhere.
Maintain accuracy of quantity and time measurement to an approved International

Standard.
Have a separate scale plate for each signal channel.

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Have a linear scale not less than 100 mm long with clear graduations and markings.
Have the units of the measured variable and any multiplying factor clearly marked on the
scale plate.
Be flush mounting with black bezel.
Be designed so that the chart may be withdrawn from the front and replaced without
interrupting the indicating section.
Have a plug-in chassis which may be withdrawn from the front leaving the housing in
position, without interrupting its signal.
Have a minimum chart speed of 20mm per hour and a minimum chart duration of 4
weeks.
Have charts with printed calibration of 0-100% and 24 hr. time marks.
Have a window of anti-glare or low reflectivity glass in a hinged, lockable door which
opens a full 180o, with adequate window and door sealing to prevent the ingress of dust
and reduce the ingress of moisture to an absolute minimum.
Match all other meters and instruments (including indicating meters, meter relays,
integrators etc.) on the same panel, and on similar panels in the same room, as regards
style, finish and appearance.
The Contractor shall ensure that all meters intended for installation on inclined surfaces
are suitable for that application, and that when so mounted the accuracy will be
maintained over the whole range.
Sufficient charts shall be provided for two year operation at the time of take-over.
18.18.9 Transmitters
Transmitters shall provide 4 mA to 20 mA output signals proportional to the measured

conditions. They shall operate on a 2 wire system receiving their power from the
residual 4 mA in the transmission signal. They shall be fitted with output meters to give
an approximate indication of transmitter output scaled 0 - 100%.
Differential pressure transmitters which shall have capacitance or inductive type sensing
elements shall be fitted with direct mounted, stainless steel, 3 valve manifolds. Pressure
and level transmitters shall be fitted with two valve manifolds.
Transmitters shall be manufactured from materials suitable for use with the process
medium and for the site ambient conditions and this shall be approved by the Engineer.
Pipework shall be run in copper or stainless steel pipe as appropriate with a minimum
gradient of 1 in 12 after an initial rise (gas) or fall (liquid) of 300 mm.
Transmitter equipment should be supplied and installed complete in all detail including
pipework, stop cocks, drain cocks and any similar ancillary items of equipment.

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Process data, calibrated span, range, output, protection, accuracy and connection
details shall be as necessary to satisfy the particular specification requirements.
The transmitter shall have non-interacting external zero and span adjustment and shall
have facility for an optional external damping adjustment.
Each transmitter shall be equipped with a stainless steel nameplate, permanently

attached, indicating the following specified data as a minimum:-
1. Transmitter tag no.

2. Purchase order no.
3. Name and address of manufacturer
4. Type/Model no.
5. Serial no.
6. Calibrated range
7. Range and maximum working pressure, temperature, speed, vibration level
etc.
8. Materials of construction
9. Electrical protection classification.
18.19 FLOW MEASURING EQUIPMENT
18.19.1 Electro Magnetic Flow Meters
Magnetic flow meters shall be provided in accordance with the following:-
Meters shall be of the short form, having a modulated, direct current excitation and
inherent total zero stability.
The power consumption shall not exceed 16 watts per 100 mm of diameter.
The output shall be 4-20 mA and the system accuracy shall be within 0.75% of the flow
rate. Test Certificates shall be provided.
The field coils shall be fully encapsulated.
The equipment shall be guaranteed suitable for the ambient and process liquid
temperatures and the atmospheric environment.
Each flow-meter primary element shall be supplied with a Teflon liner and electrodes of
material best suited to the particular process fluid.
Primary units shall be as follows:-
Suitable for accidental submergence to a depth of 3 metres.
Have flanges in accordance with the relevant mechanical clauses relating to pipes,
flanges, fittings etc.,
Rated well in excess of the maximum possible fluid pressure, including possible surge
pressures.

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Be supplied and installed complete with Flange Adaptor coupling or similar approved
arrangement to permit removal for repair or inspection.
Incorporate electrodes to detect when the pipe is not full. The detectors output shall
control circuits within the converter to short out the analogue signal and initiate an
indication of the "pipe not full" condition.
a. Complete with amplifier (converter), drive unit (if applicable) and all cable for
connecting between the components. Where this equipment is exposed to the
environment it shall be housed in a GRP enclosure.
The amplifier/converter shall be:-
Fully screened to prevent interference from adjacent equipment.
Incorporate voltage stabilisation to ensure maintenance of system accuracy with a

supply variation of +10%.
b. Each installation shall be provided with Ultrasonic electrode cleaning equipment

or inherent protection against sludge build up. This facility shall include
equipment for hand and automatic operation, and shall be installed complete
with the necessary switches, push-buttons, timers etc.
c. Where the flow-meter is exposed to the environment provision shall be made to

protect the detector head from direct sunlight. The protective device shall be
secure with ease of removal for maintenance purposes.
18.19.2 Ultrasonic In-line Flow Meter
Ultra-sonic flow measuring equipment for "in-pipe" applications shall operate on the
phase difference technique employing 2 No. ultra-sonic probes displaced longitudinally
and mounted on opposite sides of the pipe to detect the difference between the
upstream and downstream flight times. The equipment shall include acoustic
transducers and a transmitter, and shall be installed complete with all necessary fittings,
cables and connectors.
The acoustic transducers shall be non-intrusive and arranged so that they may be
removed without shutting down the process line.
All materials in contact with the process liquid shall be approved for use in the specified
application.
All items of equipment attached to the pipe and/or pipe insert shall be of non-corrosive
material, designed to withstand continuous submergence to a pressure of 3m head and
guaranteed suitable for the temperature and process pressures, including maximum
possible surge pressures.
The transmitter shall process the signals from the acoustic transducers and shall:-
(i) provide an output of 4 - 20 mA proportional flow,
(ii) be suitable for direct or wall mounting with up to 30m of cable,incorporate

contacts to initiate an alarm in the event of mal-function,
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(iv) include facilities for field checking and zero adjustment.
The complete system shall operate with a minimum accuracy of ±1.5% of full scale
deflection over the full ambient temperature range. A test certificate shall be provided for
each set of equipment.
18.19.3 Ultrasonic Open Channel Flow Measuring Equipment
Where ultra-sonic equipment is specified for measuring flow in open channels, the
equipment shall be supplied and installed in accordance with the above Clause 18.20.1,
except that in this application the control unit shall be micro-processor based
incorporating algorithms for converting level to flow, as appropriate and shall provide a 4-
20 mA output proportional to flow. The system accuracy shall be within ±1.0% of the
instrument span over the range 5% to 100% flow
18.19.4 Installation of Ultrasonic Sensors
Each ultra-sonic sensor shall be installed on a robust, rigid structure provided for the
purpose under this Contract. The structure shall include a means of leveling the sensor
so that the transmitted beam is perpendicular to the liquid surface and shall provide a
safe and easy access to the sensor for servicing and maintenance.
The Contractor shall, where applicable, provide a canopy around and/or above the sensor
and/or the control unit to provide a protection from direct sunlight.
18.20 LEVEL MEASURING & CONTROL EQUIPMENT
18.20.1 Ultrasonic Level Measuring Equipment
Where ultra-sonic level measuring equipment is specified , level measurement shall be

accomplished by the use of non-contact, echo-time measuring equipment operating at
ultra-sonic frequency. The equipment shall transmit pulses which are reflected back to the
sensor from the surface of the liquid whose level is being measured.
The equipment shall consist of a hermetically sealed sensor incorporating both transmitter
and receiver, together with a separate control unit.
The equipment shall be provided with automatic temperature compensation, shall be

suitable for operation in the designated application under the prevailing climatic and
environmental conditions.
The sensor shall be suitable for mounting in the open, or within an enclosed tank, and
shall be totally enclosed and hoseproof with environmental protection appropriate for the
installed location.
The control units shall incorporate facilities for adjusting independently both zero and
span, and shall have an output of 4-20 mA proportional to level.
The overall accuracy of the level measurements shall be within ±1.0% of the instrument
span.

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The connection between the sensor and control unit shall be via a single length of
commercially available screened cable, and the equipment shall operate with up to 150
metres of such cable. Cable connections / joints will not be permitted above the
processing liquor.
The Contractor shall ensure that all equipment is suitable for the application, particularly
with regard to the blocking distance and transmitted beam angle / cone.
18.20.2 Pressure Level Measuring Equipment
Where pressure level measuring equipment is specified in the relevant application clause,
level measurement shall be accomplished by the use of a chemically inert high density fine
ceramic transducer.
The equipment shall be provided with automatic temperature compensation, shall be

suitable for operation in the designated application under the prevailing climatic and
The sensor shall be hermetically sealed and suitable for mounting in sewage. It shall be
readily removable.
The control units shall incorporate facilities for adjusting independently both zero and
span, and shall have an output of 4-20 mA proportional to level.
The overall accuracy of the level measurements shall be within ±1.0% of the instrument
span. The connection between the sensor and control unit shall be via a single length of
commercially available screened cable, and the equipment shall operate with up to 150
metres of such cable. Cable connections / joints will not be permitted above the process
liquor.
18.20.3 Float Level Control Equipment

Where float level equipment is specified, level control shall be accomplished by the use of
a plastic encapsulated float switch. The float switch shall operate at 24V AC for irrigation
installations and 48V AC for sewerage installations. The Float casing shall be
manufactured of polypropylene supported by a Stainless steel suspension chain.
18.21 GENERAL DESCRIPTION OF LIGHTING AND SMALL POWER INSTALLATIONS
The Contractor shall provide and install all the necessary fittings, sub-distribution boards,
contactors, etc. for the complete small power and lighting installations as follows:-
18.21.1 Small Power Installations
18.20.1.1 General
Low voltage supplies required for illumination and power supplies etc. shall be as
follows:-
Socket outlets shall be manufactured from polycarbonate and protected from the
ingress of dust and moisture to an approved standard. All socket outlets shall be
colour coded in compliance with an approved International Standard. Each socket
shall be provided with a plug.
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All handlamps shall be 25V and the socket outlets colour coded violet.
220V socket outlets colour coded blue.
380V socket outlets colour coded red.
Small Power Installations shall be provided so that the following facilities are
available in each area.
a) Motor Room
16 amp 250 V 3 pin un-switched socket outlets (sufficient quantities to ensure

that any extension cable used does not exceed 3m).
16 amp 25 V socket outlets (sufficient quantities to ensure that any extension

cable used does not exceed 3m).
32 amp 380 V TP&N socket, switched and mechanically interlocked.
b) Control Rooms
A minimum of 4 No. twin 13 amp 220 V switched socket outlets; final numbers
and arrangement are subject to approval.
c) Exterior to Wet Well
32 amp TP&N socket, switched and mechanically interlocked
d) Pump Chamber Dry Well
As motor room.
e) GRP Kiosks (for control panels)
As motor room with sockets at each panel end.
f) Accommodation
A minimum of 2 No. Twin 13 amp 220 V switched socket outlets to an

approved International Standard to each habitable room and kitchen.
18.21.2 Lighting Installations
General
Lighting installations shall be provided to give minimum illumination levels as detailed

below. Lighting levels will be measured at a plane 1000 mm above ground/ floor/ access
level. Two way switching will be included for areas where access may be gained via two
physically separate points.

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The Contractor shall prepare lighting layout drawings of sufficient detail to enable duct
requirements to be ascertained prior to the casting of roof beams and columns. Lighting
conduits shall be surface mounted on ceilings and walls except in tiled areas where the
conduits shall be concealed beneath the tiles.
The lighting shall be located in easily accessible positions for the purpose of
maintenance. If this is not possible the Contractor shall advise the method for
undertaking maintenance and if this requires special equipment such as scaffolding,
hoists or access tower, this shall be provided by the Contractor at no extra cost.
The Contractor shall submit his proposed scheme together with details of the fittings he
proposes to use and his calculations of illumination levels for the Engineer’s approval.
The following lighting levels shall apply:
a) Motor Room
350 lux using energy efficient anti-corrosive fluorescent fitting with polycarbonate
diffuser;
b) Dry Well
350 lux using energy efficient watt anti-corrosive fluorescent fitting with
polycarbonate diffuser;
c) Control Rooms
400 lux using energy efficient fluorescent fittings with easy clean antiglare
diffusers.
d) Wet Well
As dry well, all fittings to be approved for Zone 1 environment.
e) External Lighting
Over each external entrance door there shall be installed 1 No. 250 watt high
pressure sodium floodlights controlled by an external weather-proof switch.
On the exterior of building mounted on each corner shall be polycarbonate vandal

proof light fittings controlled by a light sensitive cell with manual override. This
system shall be fully automatic and be mounted in the FBA.
f) Access/Car Park Areas
An average illumination of 20 lux shall be achieved.
g) Miscellaneous
GRP Kiosks (for control panels)
As motor room to provide sufficient lighting to be able to maintain the FBA at night.

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External Maintenance Areas

Sodium weather-proof floodlighting to provide 50 lux at the working height. Final
locations of these units to be agreed at site.
Accommodation
Each room to contain sufficient 100 Watt light fittings with opaque white glass to
achieve the illumination level defined in an approved International Standard as
appropriate for the intended use of the room.
18.21.3 Emergency Lights
Emergency lights shall be wall-mounted, twin lamp units arranged to give at least 3
hours illumination in the event of main power supply failure. The units shall include
integral battery, battery charger and battery status indicator. A lamp test facility shall be
included. Emergency light units shall be connected to a dedicated electrical circuit
separate from all other lighting or small power supplies.
Lamps shall be provided as follows:
Motor Room - 1 No. unit adjacent to each access door;
Dry Well - 1 No. unit at each stairway landing plus 1 No. unit at pump level.
Control Room - 1 No. unit adjacent to each access door.
Accommodation - 1 No. unit adjacent to each access door.
18.22 PORTABLE PLANT
The Contractor shall supply for each pumping station:
1 No. Gripper Type handlamp with wire cage and 25 V, 40 watt B.C. rough service lamp
complete with 30 metres of 3 core tough rubber sheathed cable and plug suitable for low
voltage socket outlets;
1 No. 500 watt, 220 V, 50 Hz weather-proof portable floodlight complete with stand, 30
metres of 3 core T.R.S. cable with plug suitable for 220 V volt socket outlet;
18.23 WIRING & CABLING ACCESSORIES
Generally for all small power and lighting installations the following Clauses shall apply:-
18.23.1 Wiring
Wiring shall be carried out in PVC cable enclosed in conduit. The minimum copper
conductor size used shall not be less than 1.5mm2. The use of junction boxes between
fittings shall be kept to a minimum and where practicable all connections shall be made
at the fitting. Where used junction boxes shall be rectangular pattern and where
possible their position shall be hidden from immediate view but not made inaccessible.
Circuit wiring shall not be connected directly onto the terminals of lighting fittings but
shall be made off in point boxes consisting of a standard box containing porcelain
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shrouded pinch screw connectors to which connections shall be made to the light fitting
by heat resistant flexible cables.
18.23.2 Distribution Boards

All distribution boards shall be of the totally enclosed metal clad pattern (500 V rating)
manufactured in accordance with an approved International Standard.
The enclosure shall be made from zinc coated mild steel formed to a clean line and
complete with a lockable hinged cover with gasket. Removable plates with conduit
knockouts shall be provided at top and bottom.
All distribution boards shall be complete with a Residual Current Circuit Breaker. The
circuit breaker shall be rated and have the same number of phases as the circuit from
which it is fed.
Doors shall be fitted with gaskets and shall be easily removable to preserve the finish
and simplify installation. Each distribution board shall be arranged for top and bottom
cable entry and shall be provided with an ample cable termination plate and chamber to
enable cables to be neatly glanded with tails grouped and terminated onto appropriate
internal termination's. Distribution boards shall be wall or floor mounted and shall when
specified incorporate on-load isolators which shall be front of panel operated with
ON/OFF indicator and capable of being padlocked in the OFF position. Distribution
boards shall incorporate HBC cartridge fuses or combinations of single pole and neutral
and triple pole miniature pole circuit breakers (MCB's) as specified.
Each bank of MCB's/fuses shall be clearly identified with its appropriate phase colour
code and the mounting framework for the banks of MCB's/fuses shall be easily
removable to simplify installation. Adequate phase barriers and shields shall be fitted to
ensure that after installation and wiring all bare terminals and wires are covered to
prevent accidental contact with live conductors during the normal procedure of fuse
changing and resetting of MCB's.
All distribution boards shall have a fusing factor of 1.5 to afford "close" overcurrent
protection to circuits.
All neutral bars shall have a separate terminal for each fuseway within the distribution
boards.
The termination of the circuit cables at distribution boards shall be neat and slack left at
each fusebank or neutral bar to enable the complete assembly to be removed for
inspection without disconnection. Neutral conductors shall be connected to the bar in the
same order as the phase conductor to the fuseway.
Each distribution board shall be complete with a permanent circuit identification chart
preferably mounted within the front door. This chart shall be permanently and legibly
filled in as circuits are completed with the circuit description including the fuse rating.
Painting of distribution boards shall be in approved colours.
18.23.3 Socket Outlets
Socket outlets shall be connected to a ring circuit with each 30 amp circuit feeding a
maximum floor space of 50m2. All socket outlets shall be switched and of the shuttered

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type. They shall accept 13 amp. square plugs and comply with an approved International
Standard. They shall be selected from one of the following types.
(a) Surface and externally mounted socket outlets shall be manufactured from
polycarbonate and protected from the ingress of dust and moisture to an
(b) Flush mounted socket outlets shall be of the grid switch pattern with matt
hrome heat cured powder lacquer finish covers.
18.23.4 Switches
Switches shall be of the "multiple phase" type incorporating phase barriers with the
switches arranged in multigang boxes. They shall be one of the following types:-
a) Surface and externally mounted switches shall be manufactured from

polycarbonate and protected from the ingress of dust and moisture to an
b) Flush mounted switches shall be of the grid switch pattern with matt chrome
heat cured powder lacquer finish covers.
Special care shall be taken to ensure that all switches are securely fixed truly
vertical and that flush mounted switches are flush with the wall finish so that
the overlapping cover plates seat onto the rims of the boxes.
18.23.5 Lighting Fittings
Lighting fittings shall be complete with all supports, suspensions, flexible cables,
pendants and plugs. They shall be connected to the main circuit wiring with heat
resisting flexible cables of a minimum conductor size of 1.5m2 insulated with silicon
rubber.
Break joint rings shall be used in conjunction with batten holders, ceiling roses or back
plates mounted onto a flush installation.
The earthing of all pendant or semi-pendant fittings shall be by a separate core in the
connecting flex or cable securely bonding the earth terminal on the fitting to the glanded
joint of interconnecting cables. In no case shall pendant chains or conduit support tube
be used as a means of earthing.
Standard fluorescent lighting fittings shall have two suspension or fixing points.
Lampholders for flexible pendants, batten or wall mounting shall be of the all insulated
skirted pattern with cord grips. All lampholders shall be of the bayonet cap pattern.
The point box suspensions and other parts of the lighting fittings shall be erected at
times to suit the building programme for decoration. The glassware, diffusers, shades,
lamps and tubes shall not be fitted until all building work is complete.
All fittings shall be left clean inside and outside ready for use. All fluorescent fittings shall
be suitable for instant start.
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All fluorescent tubes shall be of an approved manufacture and standard white in colour.
They shall be suitable for the lighting fittings in which they are installed and of the correct
voltage. Diffusers on fluorescent fittings shall be polycarbonate.
All incandescent lamps shall be of an approved manufacture with metal coil filaments
gas filled pearl in standard sizes with standard caps to suit the fittings in which they are
installed.
The Contractor shall supply and install all lamps for the entire lighting installation and
shall replace all burned out lamps up to the time that the Employer takes final
acceptance of the works.
18.24 CABLES
18.24.1 General
All multi-cored cables on low voltage installations shall be 600/1000V grade.

Manufacturer's test certificates shall be submitted to the Engineer for approval of the
material before commencing cable installation.
Where a neutral conductor is required this conductor shall be in the form of a core of the
same section as the other cores.
The Contractor shall ensure that each cable is of sufficient rating for its normal and fault
conditions. To assess the rating and cross section required for each cable the following
factors shall be considered:-
(a) Fault level.
(b) Conditions of ambient temperature relevant to method of laying.
(c) voltage drop.
(d) Voltage drop in motor circuits due to starting.
(e) Overcurrent settings of circuit breakers.
(f) Disposition of cabling whether in air, ducts or ground.
Cable ratings shall be calculated in accordance with an approved procedure.
The Contractor shall submit details of the cable sizes for the Engineer's approval before
ordering.
The Contractor shall be responsible for measuring the length of cable required.
Each cable shall be supplied in a suitable length, continuous through its run. Through
joints will not be permitted without the written permission of the Engineer.
The earthing conductor shall be of adequate cross sectional area and shall either be one
core of a multicore cable or a separately run single core cable. The use of conduit,
water or other service pipes in any part of the earth continuity conductor is strictly
prohibited.
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The Contractor shall supply and install all necessary cable glands and sealing boxes
required to complete the installation.
The cores of each cable shall be taken direct to the terminals of the equipment to be
connected. Cable ends shall be sealed in suitable chambers bolted to terminal boxes.
The general routing of cables is indicated on the Drawings but the final routes shall be
agreed with the Engineer before any work in connection with the cable installation is
commenced. All cables shall be installed in strict accordance with the requirements of
this Specification.
Cables with a conductor size of less than 1.5mm2 section shall not be used in the
installation.
All cables used shall bear the manufacturer's original guarantee and all cables shall be
delivered to Site in their original wrappings. The Contractor shall obtain the permission of
the Engineer before removing wrappings and commencing installation.
The Contractor shall ensure that the installation is installed so that no more than one
phase will occur at switch lighting or power outlets where these outlets are less than
2.5m apart unless guarded by a wall partition or other barrier. If this is impracticable the
Contractor shall obtain the advice of the Engineer before proceeding.
The scheme of wiring shall conform to the colour code requirements of an approved
A minimum tail length of 250mm shall be left on all cables at outlet positions for
connection of the apparatus fed by the outlet.
The installation of multi-core and single core cables or bunching of cables in conduit is to
be carried out on the assumption that such cables will carry alternating current.
The excessive bunching of small cables in large conduits will not be permitted.
The Contractor shall include for terminating each cable in excess of 30 amp current
carrying capacity in a pressure operated mechanically crimped leg terminal or terminal
socket.
18.24.2 PLYSW & PVC Oversheath Cables
PVC insulated and sheathed galvanised steel wire armour cable with an overall PVC
sheath (PVCSWA PVC) shall conform to an approved International Standard. They shall
be of approved manufacture of 600V or 1000V grade with copper conductors.
All such cables shall be terminated with mechanical glands in accordance with an
International Standard and shall be of a type to provide adequate mechanical support by
locking on the armour, with outer seal, shroud and earthtag.
18.24.3 PVC SWA PVC Cables

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PVC insulated and sheathed galvanised steel wire armour cable with an overall PVC
sheath (PVC SWA PVC) shall conform to an approved International Standard. They
shall be of 600V/1000V grade with copper conductors from an approved manufacturer.
approved International Standard. The gland shall be of a type to provide adequate
mechanical support by locking on the armour, with outer seal, shroud and earthtag.
18.24.4 XLPE PVC SWA PVC Cables
XLPE insulated and PVC sheathed galvanised steel wire armour cable with an overall
PVC sheath (XLPE PVC SWA PVC) shall conform to an approved International
Standard. They shall be of 600/1000V grade with copper conductors from an approved
manufacturer.
approved International Standard. The gland shall be of a type to provide adequate
mechanical support by locking on the armour, with outer seal, shroud and earthtag.
18.24.5 PVC Insulated Cables
Single-core PVC insulated cables shall comply with an approved International Standard
and shall be 450V/750V grade.
Multi-core PVC insulated cables shall comply with an approved International Standard
and shall be 600V/1000V grade.
The cable used shall not be less than 1.5mm2 cross-sectional area.
18.24.6 PVC Insulated MICC Cables
PVC MICC insulated cables shall comply with an approved International Standard and
shall be 600V/1000V grade. The cable used shall not be less than 1.5mm2 cross-
sectional area.
For fire alarms and associated uses they shall be coloured orange
18.25 CABLING METHODS
18.25.1 General
All cables shall be either clipped to walls or ceilings of structures or run in ducts and
trenches. All cable hangers, cleats, saddles, brackets and similar supporting devices
shall be of an approved type and of adequate strength for the cable they are supporting.
They shall be non-ferrous and so treated as to withstand site conditions without
corroding.
Every cable whether in or out of sight shall be neatly run vertically horizontally or parallel
to adjacent walls, beams or other structural members.
Bending of cables shall be in accordance with the following table:-

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Minimum
internal radius
of bend (times
Insulation Finish Overall overall
diameter diameter* of
cable)
Rubber or PVC(Circular Not exceeding 10
or circular stranded Unarmoured mm 3(2)+
copper or aluminium Exceeding 10 mm,
conductors) but not exceeding 25
mm 4(3)+
Exceeding 25 mm 6
Armoured Any 6
PVC or XLPE (SAC Armoured or 8
or shaped copper Unarmoured Any
conductors)
Copper sheath 6
with or without
Mineral PVC covering Any
* For flat cables, the factor is to be applied to the major axis.

+ The figures in parentheses relate to single core circular conductors of stranded
construction installed in conduit or trunking.
Spacing of clips, saddles and cleats shall be such to prevent sagging of the cables at all
times during their installed life.
Cables run in indoor trenches shall be segregated and run on trays or brackets secured
to the trench wall. No cables shall be run on the bottom of these trenches.
Where a number of cables are terminated to any particular item of equipment then
special care shall be taken to ensure that the cables finally approach the equipment from
a common direction and are individually terminated in an orderly and symmetrical
fashion.
The Contractor shall prepare drawings showing his precise requirements for cable
trenchwork detailing the width and depth of trenches and indicating the road crossing
cable ducts required. These drawings shall be prepared in consultation with the
Engineer and be approved before issue.
The sanding and laying of cables shall satisfy the following requirements:-
(a) Cables shall be laid at a depth of 750mm for LV and 1000mm for H.V cables.
The depth shall be assessed from finished ground level unless otherwise
Generally LV and H.V cables should not be run in the same trench but should
be laid staggered. However where necessary to pass through ducts it may
be necessary to lay one above another and H.V cables should be laid first
and sanded before laying the LV cables.

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(b) Before laying cables the Contractor should inspect the trenchwork to ensure
that the bottom of each trench is firm and of smooth contour and free from
broken stones or rock.
(c) 75mm of riddled sand shall be placed in the trench to form a bedding for the
cables.
(d) Cables up to and including 50 mm cross-sectional area may be hand-drawn.
Heavier cables shall be treated as follow :-
(1) They shall be laid using rollers not more than 3 m apart and where drawn
round corners skid plates and additional rollers shall be used.
The cable shall be pulled by means of a suitable winch with a pulling eye and
cable-sock or equal approved device to ensure even load distribution on the
cable.Cables shall be laid with adequate separation and shall be gently
"snaked" to avoid tension during backfilling and subsequent settlement.
(e) Before sanding and backfilling all laid cables shall be inspected by the
Engineer.
(f) After cables have been laid they shall be covered with a further 75mm of
riddled sand which shall be well tamped around the cables. Mechanical
punners shall not be used for this work.
(g) The Contractor shall supply cable cover tiles. These shall be of the precast
concrete type complying with an approved International Standard and
engraved "Electricity".
(h) After sanding cable covers shall be placed in position to overlap the cables
by a minimum of 50mm either side of the cables.
(j) A second inspection following sanding and tiling shall be made by the
Engineer before backfilling.
(k) The Contractor shall carry out backfilling and be responsible for ensuring that
tiles are not disturbed and that no large rocks or stones are dropped on tiles
or included in the backfill material.
(l) After backfilling the Contractor shall reinstate to finished ground level.
(m) The Contractor shall supply and lay in position the necessary cable route
marker posts at a maximum of 10 metres apart and at any change in
direction of cable route.
Where cables enter or leave buildings the ducts shall be sealed at the points of entry into
the building. The Contractor shall include for caulking with an approved compound,
followed by not less than 40mm of bitumen compound or a weak sand/cement mixture
as directed by the Engineer. Care must be taken to ensure that the PVC sheathing of
cables is not damaged during caulking due to excessive temperature if heated
bituminous compound is employed.

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Wherever it is necessary to remove the PVC sheath of cable (e.g. at a joint) the
minimum length necessary shall be removed and the exposed copper sheath or
armouring shall be adequately covered by a PVC tape or sleeve or other suitable means.
All cable shall be delivered on robust cable drums with cable ends treated to form an
effective seal. When a cable is cut from a drum the cable end left on the drum shall be
immediately sealed in an approved manner to prevent the ingress of moisture.
Each and every cable shall be permanently identified at each end by its cable number.
Cable markers shall comprise oval markers with semi-rigid black PVC carrier strip and
shall be fixed axially by means of two PVC covered aluminium strips with buckles. Cable
markers shall also be installed at entry and exist points of buried ducts, exits from
buildings and in such other positions as are necessary to identify and trace the route of
any cable.
All power shall be connected to main switchboards and other items of plant so that the
correct phase sequence colour coding are preserved throughout the system. All such
cables shall be identified with phase colours for 3 and 4 wire systems and blue and
brown for single phase. On rotating plant, where to achieve the required direction of
rotation it is necessary to connect the phase cores to the appropriately identified
terminals, special core ferrules shall be fitted to identify each core with the terminal to
which it is finally connected.
In addition control cables shall have individual cores identified by means of suitable
permanent ferrules bearing the same numbers at both ends. Core identification shall
occur at every point of termination using an approved system of ferrule markers.
Numbering shall read from the terminal outwards on all cores. At those points of
interconnection between wiring where a change of number cannot be avoided double
ferrules shall be provided on each wire. The change of numbering shall be shown on the
wiring diagrams of the equipment at which the change is made.
Where the termination of control cable cores or the supervision of termination of cores is
specified as being the responsibility of another party (e.g. the termination of certain
control and instrumentation cables) any necessary temporary means of core
identification shall be agreed with that party. Should the Contractor propose to use
junction boxes in auxiliary control cable circuits for the purpose of marshaling a number
of cables feeding to a common item of equipment full details shall be given to the
Engineer and the Contractor shall only proceed after receipt of the Engineer's written
approval. Any such junction box shall be of the wall mounting pattern with double
terminals, with cores ferruled and identified in accordance with the system schematic
and cable diagrams.
18.25.2 Conduit System and Associated Cables
All conduit systems and their component materials shall comply with an approved
Conduit shall be neatly run on the surface or buried. Ways shall be provided for
additional conduits at all distribution boards. The size of conduit shall be as detailed for a
particular position or as determined by the number of cables to be drawn in. In no case
shall conduit less than 20mm diameter be used. Sunken and concealed conduit
systems shall support fittings independently of any false ceiling.
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All conduits shall be installed in an approved manner and arranged with adequate
ventilation and drainage where necessary. All bends or sets shall be formed in the
conduit itself. The Contractor shall ensure that conduit draw-in boxes and junction boxes
are of sufficient capacity to allow all cables to be installed.
The whole of the conduit system shall be completely swabbed through to remove any
loose matter or dirt before cables are drawn in. Where conduits connect to switch
boxes, draw-in boxes and the like, the conduits shall have a machined faced socket
screwed on to the end which when tightened is flush with the outside of the box. The
conduit is then to be secured to the apparatus by means of a hexagon smooth bore
brass bush screwed from the inside of the apparatus into the conduit socket in order to
make a sound and tight mechanical joint.
All horizontal runs shall be supported at no more than 900mm. Vertical runs shall be
supported at no more 1200mm. Where directional changes occur support shall be
provided at no more than 150mm either side of the bend.
Bending of conduit shall be carried out as follows:-
a. PVC - a bending spring of the correct size shall be used in all cases. The heat
source shall be provided by a hot air torch. When the conduit is in a pliable
state it shall be bent around a suitable former and held in position until the
conduit has set. No other method will be approved.
b. Steel - Purpose manufactured bending machine complete with formers.

Bending blocks may be used at the discretion of the Engineer for special
applications.
Only couplers, bends and spouted fittings supplied by the manufacturer shall be used.
Expansion couplers shall be used in surface installations where straight runs exceed 8
metres and at all expansion joints in the structure.
Standard junction or adaptable boxes shall be provided at all junctions and at sharp
changes of direction in addition to any special positions where they are called for by the
Engineer. Inspection couplers may be used in long runs to facilitate drawing in cables.
All junction boxes must be accessible in the completed works.
Particular care must be taken to ensure that no water is allowed to enter the conduit at
any time and all conduits shall be arranged with adequate ventilation and drainage
where necessary or as directed by the Engineer.
For buried conduit continuous lengths shall be installed between boxes. Positioning of
joint boxes within floor screeds is not permitted.
The ends of conduits laid or set in formwork prior to concreting shall be temporarily
sealed off with a coupler and a plug.
Fixing to surfaces of walls shall be by spacer bar saddles securely fixed by screws.
Where conduits are concealed or laid in structural floors they shall be held in position
with substantial fixings of make and pattern to be approved by the Engineer.
Weather-proof boxes and accessories shall be used outdoors where agreed on Site by
the Engineer or where indicated in this Specification or on the Drawings.
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Conduit shall be installed such as to permit complete rewiring without the need to carry
out builders work.
No single conduit serving phase socket outlets lighting points and switches shall contain
more than one phase.
Wiring shall be carried out on the looping-in system and no joints other than at looping-in
points will be allowed.
18.25.3 Flexible Conduit
Where the conduit system terminates at any equipment requiring a non-rigid connection
a flexible conduit shall be installed of the PVC sheathed metallic type fully watertight with
factory made connection adapters.
Each flexible connection shall include not less than 400 mm length of flexible conduit
and a separate earth conductor shall be run within the conduit connected to the earth
terminals in the equipment and the fixed conduit run. The flexible conduit shall not be
used as an earth continuity conductor.
18.25.4 Cable Trunking and Associated Cables
The trunking shall be manufactured, as specified, from either heavy gauge continuous
hot dipped galvanised steel, stainless steel or heavy duty rigid unplasticised PVC ( self
extinguishing, and unaffected by sunlight and/or water; the material shall be suitable for
continuous ambient temperatures of 65oC). Each length shall be supplied with the
necessary connection sleeves and shall have joggled sides to allow flush fitting.
Each length of trunking shall be fitted with easily removable covers attached to the
trunking by an efficient fixing.
The trunking system shall be complete with purpose made angle and set accessories
designed to afford easy installation of and to avoid tight right angle bends in the circuit
cables installed in the trunking. All trunking accessories shall be complete with
removable covers. No site made mitred joints will be allowed.
Where cable trunking is installed in vertical runs efficient circuit cable clamps are to be
installed at not greater than 500mm intervals.
The Contractor shall ensure that the size of the trunking is adequate for the number of
cables passing through it but as a minimum the size should be 50mm x 50mm. All
bends tees and intersections shall be of the gusset type and manufactured by the maker
of the trunking and to similar standard.
18.25.5 Cable Tray
Cable tray shall be manufactured as specified from heavy duty perforated galvanised or
stainless steel or rigid unplasticised PVC with deep flanges (PVC shall be self
extinguishing and non-inflammable and shall be unaffected by sunlight or water; It shall
be suitable for continuous ambient temperatures of 65oC).
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The cable tray shall be complete with approved type fixings while cleats shall be of the
aluminium or nylon pattern. Cables which shall be attached to cable tray or structure by
saddles or cleats respectively shall be spaced to ensure compliance with an approved
International Standard. The spacing of supports shall be 1200mm in all cases where
cables are supported by cable tray and 750mm where supported from tray or by cleats.
All cables shall be saddled or cleated in position as they are installed along the route. All
cable tray changes in direction or level shall be made via sets and adequately sized
angles to provide a support to the cables. The cable runs on trays shall be fixed to the
tray by purpose made approved fixing clamps. Cable trap brackets shall be of
galvanised steel. Site manufactured bends and junctions will not be permitted.
18.26 EARTHING
The earthing system shall comply with the requirements of an approved International
Standard and the Dubai Electricity and Water Authority regulations.
Earth tapes on 11 kV 6.6 kV and 3.3 kV plant shall comprise a minimum of 50mm x 6mm
copper tape and on 380V equipment, a minimum of 38mm x 4mm copper tape.
The metalwork of ALL items of electrical equipment provided under the Contract shall be
securely bonded to earth. Earthing shall be effected by means of the metal sheath of
cables which shall be securely bonded to the metalwork of the apparatus concerned at
each end or a separate earth conductor. A separate conductor shall be provided for all
items of plant rated 20 kW or greater.
Armour wires on main cables shall be solidly bonded as additional earth paths but cables
from standby generators shall be insulated or bonded to the main earth system
depending on instructions received from the Engineer. Particular care shall be taken on
cable termination boxes to ensure that the cable sheath and armour is adequately
bonded to the associated item of plant. If continuity is inadequate copper connections
shall be made between the apparatus frame and the cable sheath.
Where the cable sheath and armour is used as the earth path return then it shall be
established that the impedance is sufficiently low to carry the fault current and
disconnect the equipment. If not a separate copper earth conductor shall be installed.
Particular care shall be taken to ensure earth continuity across items of equipment
situated within a cable run, should the design of such equipment not give adequate and
lasting continuity through its structural body then additional earthing clips and conductors
shall be provided to independently bond the cable sheaths together. Similarly additional
earthing clips shall be provided to bond the cable sheaths to any piece of apparatus
fitted with a special earth terminal should the earth connection of the terminating gland
prove inadequate. Any additional clips shall be contained within the apparatus wherever
possible.
The earth tapes shall be protected against corrosion and be complete with test links.
Earth tapes shall be held in position by saddles screw fixed to the substrate.
Connections shall be sweated and riveted and shall be electrically and mechanically
continuous. Joints between the main conductor and the earth electrodes shall be readily
accessible for periodic inspection and shall be protected against damage and corrosion.

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Where rigid or flexible conduit and/or trunking is incorporated into the Works a separate
internal earth conductor shall be run which shall be securely bonded to the terminating
apparatus by means of a special earth terminal.
When instructed by the Engineer an earth electrode system shall be installed. This will
comprise a system of vertically mounted rods. Leads from each electrode shall be
brought to concrete disconnection chambers to enable each electrode to be
disconnected for testing purposes. Each electrode shall be capable of providing an
effective earth within the limits specified. The earth pit containing the earth rods shall be
of the preformed type with concrete inspection covers.
When standby generators are specified it may be necessary to install two earth electrode
systems, depending upon local conditions.
Earth rods shall be copper or steel cored with a metallic bonded copper outer surface.
Rods shall be internally connected via threaded connections forming part of the earth rod
and provided with special hardened tips and caps to avoid distortion when driven into the
ground. Approved non-ferrous clamps for connecting the rod to the copper strip shall be
provided.
All excavation trenches and disconnecting chambers will be the responsibility of the
Contractor including the supervision of the backfilling of trenches setting and alignment
of disconnection and inspection chambers.
On completion of the earth installation the Contractor shall demonstrate to the Engineer
that the resistance of the electrodes and the earth network is within the specified limits.
Test equipment shall be supplied by the Contractor.
18.27 ELECTRIC ACTUATORS
Where required valves and penstocks shall be operated by means of electrically driven
actuators with integral reversing starters.
Actuators shall be suitable for use with a nominal 380 volt 3 phase 50 Hz power supply
and shall incorporate a motor, integral reversing contactor starter, local control facilities
and terminals for remote control and indication connections.
The actuator shall be capable of opening or closing the valve or penstock against an
unbalanced head equal to the maximum working pressure.
The safety margin of motor power available for sealing and unsealing the valve or
penstock shall be sufficient to ensure torque switch trip at maximum valve torque with
the supply voltage 10% below nominal. The operating speed shall give valve opening
and closing at approximately 300mm per minute.
The actuator shall be capable of functioning at ambient temperature ranging from 0o to

55oC for twice the valve stroking time at an average load of at least 33% of maximum
valve torque. Where actuators are required for modulating purposes continuously rated
motors shall be provided.
Overload protection shall be provided by a direct sensing thermostat embedded in the

motor windings.
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The gearbox shall be of the total enclosed oil bath lubricated or grease filled type
suitable for operation at any angle and provided with appropriate filling and drain plugs.
The drive shall incorporate a lost motion hammer blow feature. The output shaft shall be
hollow to accept a rising stem and incorporate thrust bearings of the ball or roller type.
The design shall permit the gear case to be opened for inspection or disassembled
without releasing the stem thrust or taking the valve out of service.
All operating spindles, gears and headstocks shall be provided with adequate points for
lubrication.
A handwheel shall be provided for manual operation engaged when the motor is
declutched by a lever which shall be padlockable in either position. The drive shall be
restored to power automatically by starting the motor. The handwheel drive must be
mechanically independent of the motor drive, and any gearing should be such as to
permit emergency manual operation in a reasonable time. Clockwise operation of the
handwheel shall give closing movement of the valve or penstock. The effort required for
manual operation shall not exceed 250N.
Handwheels shall be clearly marked with the words "OPEN" and "CLOSE" and arrows in
the appropriate directions. The rims of handwheels shall have a smooth finish.
The actuator shall be fitted with a drive bushing which is easily detachable for machining
to suit the valve stem or gearbox input shaft. Bushings shall be fitted in the base of the
actuator to enable standard length valve stems to be used.
Transparent PVC covers shall be fitted to protect the threads of rising spindles.
Actuators shall be provided with open and close torque and/or position limit switches as
required by the type of valve or penstock plus two additional limit switches at each end of
travel for remote indication and interlocking. A mechanical latch shall be provided to
prevent the open torque switch tripping while the initial unsealing hammer blow is
applied. Two additional sets of limit switches consisting of 3 switches per set shall be
provided. Each set shall be independently adjustable to any valve or penstock position.
Switch contact ratings on inductive circuits shall be 5 amp. AC up to 440V, 50 watts DC
up to 250V.
An illuminated mechanical dial indicator shall be provided to show continuous movement

valve position, and the actuator shall incorporate a sealed potentiometer of at least 3
watts rating for continuous remote position transmission.
The reversing contactor starter and local controls shall be integral with the valve actuator
and housed to prevent breathing and condensation build-up. The starter shall be
suitable for 60 starts per hour and shall comprise mechanically and electrically
interlocked reversing contactors of approximate rating to the motor size with coils fed
from a 120V control transformer of 40VA minimum rating. The common connection of
the contactor coils at the transformer shall be grounded so that the contactors drop out
on the event of leakage to earth. The primary winding shall be separated from the
secondary by a grounded screen and shall be protected by two easily replaceable
cartridge fuses. Secondary windings shall also be protected by cartridge fuses.
Local controls shall comprise push-button switch for Open, Close and Stop, and a
Local/Off/Remote selector switch padlockable in any one of three positions:-
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(a) Local control only.
(b) Off/On electrical operation.
(c) Remote Control with local stop.

It shall be impossible to operate both open and close pushbuttons
simultaneously. Stop pushbuttons shall be mushroom headed "Stay-put"
type.
Each actuator shall incorporate the following:-
(a) Easily replaceable phase discriminator to prevent starting with an incorrect

phase rotation or dead phase.
(b) Plug-in interposing relays with dust covers for Open/Close/Stop control from
a specified remote DC supply.
(c) Plug-in instantaneous reversal monitor relay with normally open contacts and
having its coil energised from the control transformer only when the
Local/Off/Remote switch is in the remote position to show that the actuator is
electrically operable by remote control.
Internal wiring shall be of a tropical grade PVC insulated stranded cable of 5 amp.
minimum rating for control circuits and appropriate size for the motor 3 phase power.
Each wire shall be clearly number identified at each end. The terminal compartment
shall include a moulded "transfer back" terminal block of the stud type the 3 phase power
terminals being segregated by a separate insulating cover. The terminal compartment
shall include a double O-ring seal to provide a watertight barrier to the electrical
enclosure so that electrical components are protected from moisture ingress while the
terminal cover is removed.
The actuator enclosure shall be watertight and where specified shall be explosion-proof
to an approved International standard.
The actuator starters shall be integrally housed with the actuator in robustly constructed
totally enclosed weatherproof housings. The motor starters shall be capable of starting
the motors under the most severe conditions.
The starter housing shall be fitted with internal heaters so as to provide protection
against damage due to condensation. Heaters shall be suitable for single phase
operation. The heaters shall be switched "on" when the actuator is stopped and shall be
switched "off" when the actuator is running.
18.28 PLC’S AND MICROPROCESSOR EQUIPMENT
i) Microprocessors and PLC Equipment
All telemetry, micro-processor and PLC equipment shall comply with this Clause,
and the relevant clauses in Section 17 to 20.
For telemetry, computers, micro-processors and similar solid state equipment,

status inputs and outputs shall be isolated by opto-isolators or an approved

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alternative and analogue inputs shall be as differential circuits. Individual noise

filtering shall be provided as necessary for each application. Series mode rejection
and over-ranging protection shall be fully adequate.
Where applicable components shall be mounted on high grade flame retardant

printed circuit boards which shall comply with the relevant part(s) of BS 4584, have
gold plated edge connections, be equipped with test points to facilitate checking of
major functions and have mechanical keying to prevent accidental insertion of an
incorrect card.
The equipment shall accept status inputs from site and panel mounted volt free
contacts and 4-20 mA analogue signals from site and panel mounted transmitters.
Analogue inputs shall be scanned into a 10 bit binary analogue to digital converter
with buffered inputs.
Status outputs shall be suitably rated for switching filament indicator lamps,
connecting into alarm systems, operating hardwire control circuits or other
switching functions in accordance with the requirements of the application Clauses.
Analogue outputs shall be 4-20mA suitable for driving control circuits, indicating
meters, recorders and integrators. The overall accuracy of transmitted analogue
signals shall be within ±0.5% of FSD over the operating temperature range of 0oC
to 50oC.
The power supply unit shall be suitable for operation on a supply having a voltage
variation ±6% and a frequency variation of ±2%. The power unit shall have an
isolated output and incorporate protection against voltage spikes on the mains
supply, over-voltage and short circuit.
The equipment shall maintained in operation during a period of mains failure, either
drawing power from the main instrumentation and control battery/charger system
or from a separate UPS system, as appropriate.
Each system unit shall include spare installed capacity of not less than 15% of
each type of input and out put module, together with a minimum of 20% spare
system logic capacity.
All systems and equipment shall include diagnostic and automatic self test routines
with volt-free contacts to initiate an alarm in the event of malfunction.
As far as possible all computers, micro-processors, plc’s and similar system

elements provided throughout the whole system shall operate with similar
protocol/language so as to provide a compatible system with all peripherals,
programs, program development units, file management routines, data storage
facilities and similar facilities being common to all elements.
All equipment shall be fully programmed in accordance with the requirements of

the application Clauses. All programs, in the form of flow diagrams or logic circuits
shall be submitted to the Engineer for approval not less than 6 weeks before the
equipment is to be inspected.

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In all cases the facility shall be provided for modifying the program, altering set
points and adjusting time settings while the equipment is "on line". There shall be
a permanently connected means of accessing set points and timer settings.
All equipment associated with an operator interface shall utilise a high level,
engineer orientated language to permit programming, editing and similar functions
by engineers and operators.
ii) PLC’s
All PLC's shall be provided with the following facilities/accessories unless specified
elsewhere
Program to be stored on an EPROM
EPROM eraser
3 No. Spare EPROM's
Serial Computer Interface
Hand held programmer for local programming
Computer Software for programming
Computer interface and EPROM programmer to enable programs prepared on the
computer program to be transferred and stored on the EPROM.
Local battery backup for RAM.

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SECTION 19 - MECHANICAL SPECIFICATION
19.1 FINISH
All covers flanges and joints shall be properly faced, bored, fitted, fixed, hollowed
moulded or chamfered as the case may be according to the best approved practice. All
working parts of the plant and other apparatus shall in like manner be well and
accurately fitted, finished, fixed and adjusted.
19.2 MATERIALS
All materials incorporated in the Works shall be the most suitable for the duty concerned
and shall be new and of first class commercial quality, free from imperfection and
selected for long life and minimum maintenance.
19.3 VALVES
19.3.1 General
Valves and penstocks shall be capable of withstanding corrosion in the ambient

conditions.
Nylon or other thermoplastic materials liable to attack shall not be used where hydrogen
sulphide is likely to be present.
All valve waterways shall be coated internally with a solvent free epoxy or polyester
lining of 100% solid content to be applied at the place of manufacture. The lining shall
be of 250 micron nominal thickness and holiday free.
All valves and penstocks will normally be witness tested at works.
Unless otherwise specified all valves and penstocks shall be anti-clockwise opening and
the maximum effort required, applied at the circumference of the hand wheel to operate
the valves against the maximum unbalanced head shall not exceed 55kg.
All hand wheels shall have the words "to open" and "to close" in Arabic and English with
arrows indicating the direction of rotation cast on and shall be coated in plastic, nylon or
other approved materials in order to withstand the ambient conditions.
Unless otherwise specified or agreed spindles and extension spindles shall be of

stainless steel Grade 316 S16.
Extension spindles, where required, shall be connected by suitable muff type couplings
manufactured from stainless steel grade 315S16. The muff couplings shall be supplied
drilled with nuts and bolts for connection to the spindles.
A clear polycarbonate tube shall be securely fitted to protect the thread of rising spindles.
The nuts shall be of gunmetal or synthetic material and mating surfaces of gates and
bodies shall be of gunmetal, copper alloy or synthetic material.

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All fixing brackets, bolts and nuts, washers, etc. shall be SS grade 316 S16.
Where "Operation by Tee Key" is specified the valve or penstock shall be supplied with a
suitable yoke with a squared cap of standard size to receive the tee key.
The key shall be supplied at the rate of one key per two valves or two penstocks unless
the valve or penstock is to be installed in an isolated location in which case one key shall
be supplied for each fitting location.
Before delivery to site all working surfaces shall be thoroughly cleaned, and, if metal,
protected by grease.
Packing must be sufficient to ensure complete protection of the fitting during transit and
storage.
Valves under 300 mm diameter together with all hand wheels and other easily
detachable items on both valves and penstocks are to be packed in timber packing
cases and properly bound with steel packing bands.
All valves of 300 mm and over are to be protected with wood or plywood discs or flanges
together with straw rope and hessian wrapping.
19.3.2 Non-Return Valves
Unless higher pressure ratings are required for the pipelines non-return valves shall
have a pressure designation of 10 bar which shall be marked on the valve body. Unless
detailed to the contrary to suit existing pipework, flanged valves shall have their flanges
to a pressure of 10 bar and be drilled accordingly. The face to face lengths of the valves
shall be either 2 x ND + 100 mm or to an approved international standard, the longer
length to be allowed for in all cases using make up pieces where necessary to achieve
the required lengths.
Non-return valves shall be manufactured to conform to the requirements of an approved

international standard. Valves shall be of the single door swing check type and shall
have bodies of cast iron with copper alloy seatings and resilient faced disks. Valve
spindles and all construction bolts shall be stainless steel grade 316 S16. Door to
spindle connections shall incorporate a keyway.
All valves shall be clearway, and lugs provided on screwed seats, etc., for assembly
purposes shall be removed.
Valves shall, unless impracticable through size or otherwise specified shall be capable of
passing 90 mm dia solids.
Valves shall be provided with a removable cover on top of the body casting, to enable
the hinge and door to be inspected or removed.
The door opening shall be restricted to a maximum angle of 700 at the hinge, measured
from a plane passing through the hinge at right angles to the axis of flow. Valves shall
be provided with extended door spindles fitted with lever arms suitable for balance
weights.

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There shall be enough space between reflux valve and the wall of the valve chamber so
that the valve spindle could be withdrawn to the sides for repair/maintenance of swing
door without removing valves.
When specified limit switches, operated by external cams rigidly attached to the door
spindles shall be provided. The limit switch shall operate when the valve door has
moved through an angle of approximately 100. The switch shall provide normally open
and normally closed electrically separated contacts of the make before break type.
19.3.3 Gate Valves for Sewage and Related Fluids
Unless higher pressure ratings are required for the pipeline, gate valves shall have a
nominal pressure designation of 10 bar which shall be marked on the valve body.
Unless detailed to the contrary to suit existing pipework, flanges shall have a nominal
pressure designation of 10 bar and shall be drilled accordingly. The face to face lengths
of the valves shall be in accordance with an approved international standard.
Gate valves shall be manufactured to conform to the requirements of an approved

international standard and shall normally be metal seated with valve bodies of cast iron
and the seatings copper alloy faced. The gates shall be of wedge pattern, copper alloy
faced with inside screw non-rising stems of forged bronze or stainless steel grade 316
S16. They shall have a packed gland stuffing box seal.
Where resilient seated gate valves are detailed the valve bodies shall be cast iron. The
gates shall be of cast iron and wedge pattern with nitrile rubber covering and with inside
screw non-rising stems of stainless steel or forged bronze. They shall have a seal of
nitrile rubber ‘O’ rings to an approved international standard.
Actuator operated valves larger than 300 mm dia. shall have copper alloy faced guides
and slippers. 300 mm dia. and smaller actuator operated valves installed other than in a
vertical position shall have machined guides and gates.
Valves shall normally be provided with drain plugs.
All cast iron shall be to an approved international standard.
19.3.4 Air Valves
Unless higher pressure ratings are required for the pipeline, or otherwise indicated in the
Contract Documentation air valves shall have a nominal pressure rating of 10 bar which
shall be marked on the valve body and shall be designed for a liquid temp. of 500C and
air temp. of 700C.
Air valves for pumped pressure pipelines shall be the special high pressure ‘Dual’ large
orifice type. The following shall be used as a guide for the general sizing of large orifice
air valves :-
Pipeline (mm) 200 300 350 450 600 900 1000*

Bore
Air Valve (mm) 20 25 50 80 100 150 200
size
Ball size (mm) 100 100 100/125 100/125 125 125/200 150/200

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* For larger mains air valves may be fitted in clusters of two or more as required.
For other duties, such as distribution mains single, small orifice type standard air valves
having a nominal 25mm male thread inlet and with a ball size of 100 mm shall be used.
The test pressure for different components of the air valves shall be as follows:-
Body Seat Ball/Float
20 bar 10 bar 10 bar
The materials of construction for air valves shall be as follows :-
Body, Cover : Cast Iron to an approved international standard

& Duct Cover
Ball/Guide : Polypropylene
Seat : Nitrile Rubber
Air Release : Moulded Rubber

Nipple
All Bolts : Stainless Steel, Grade 316 S16
All components shall be highly resistant to corrosion due to sewage and very high
concentrations of H2S and other gases. All internal components shall be strong in
design and of stainless steel grade 316 S16.
The access cover for air valves shall be in such a position that the valves could be
easily removed for repair/maintenance.
The siting of the air valves shall be at locations shown on the drawings, as
recommended by the pipeline surge analysis or as decided by the Engineer on site.
19.3.5 Flush Valves
An automatic flush valve shall be attached to the pump volute to provide a flushing
stream from the pump’s discharge to flush the station sump and to keep it free from
sludge build up. The valve shall close after a predetermined period of time or when the
pump stops whichever occurs first and shall be totally leak proof in the closed position.
The valve shall open automatically in readiness for the next pumping cycle.
The valve shall be suitable for operation based on the ejector principle utilising a ball as
the closing device or shall be suitable for operation on AC supply.
The material of construction for the flush valve shall be of cast iron to an approved
international standard.
19.3.6 Flap Valves

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Metal Flap Valves
Flap valves shall be designed for a nominal pressure rating of 10 bar which shall be
marked on the valve body, and a liquid temperature of 500C.
Flaps and frames shall be of cast iron to an approved international standard with end
flange faced and drilled to an approved international standard. Mating surfaces of flaps
and frames shall be of an approved non-ferrous metal machined to ensure a watertight
fit in the closed position.
Hinge pins shall be of phosphor bronze to an approved international standard all flaps
shall be double hung and seated off the vertical.
Springs shall be of stainless steel, grade 316 S16.
All cast iron surfaces shall be cleaned by grit or shot blasting to be free from grease,
then coated as specified for the environment. Hinge pins and mating surfaces shall be
smeared with grease.
Plastic Faced Flap Valves
Flap valves shall be faced in an approved synthetic material so as to be corrosion-free in

the ambient conditions. The flap shall be weighted to assist closing and shall be suitably
braced and reinforced.
Hinge pins shall be of stainless steel and all flaps shall be double hung and seated off
the vertical.
Mating surfaces shall be accurately moulded or machined to ensure a watertight fit in the
closed position.
19.4 PUMPS
19.4.1 General Requirements
Rotary Pumps are required to pump storm/groundwater or raw sewage containing rags,
fibrous material and general waste matter including grit and other abrasives, partially
treated sewage, sewage sludges and/or grit laden sewage.
Pumps shall be designed to pump satisfactorily solids of 90 mm diameter unless

otherwise specified. Freedom from choking is essential and is more important than high
pumping efficiency.
Pumps unless otherwise specified shall be designed to have stable head/quantity

characteristics, so as to avoid large changes of quantity with small changes of head.
The pumps shall be capable of operating with the sump surcharged to its maximum level
and the Pump motors shall be rated accordingly.
The fluid velocity at entrance to pump impellers shall not exceed 3.6 m/s for pumps with
suction pipework larger than 200 mm dia. nor 5.5 m/s for smaller pipework. The fluid
discharge velocity shall not exceed 3.6 m/s for all pumps.

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Pump bodies, covers, brackets, bearing housings, wearing plates, eye rings, support
brackets, etc., shall be manufactured from close-grained cast iron or nickel iron.
Pump castings shall be of substantial construction to give long life under abrasive
conditions and to enable them to withstand shock loads caused by solids in suspension.
Impellers shall be of best quality close-grained cast iron or nickel iron for sewage pumps
and stainless steel grade 316 S16 or equal for storm/groundwater pumps.
Impellers shall be keyed onto shafts.
Shafting shall be of stainless grade 316 S16 or equal of adequate size to avoid the
possibility of fatigue failure. The duty speed range shall be well below the first critical
speed. At any change in diameter of the shaft the shoulder shall be generously radiused
to reduce stress concentration.
The rotating elements shall be dynamically balanced before final assembly.
Pump casings shall be hydraulically tested before assembly to a pressure of 1.5 times
the closed valve head of the pump plus the maximum suction pressure.
Cathodic corrosion protection shall be provided for the storm/ground water pumps.
Pumps shall be performance witness tested at the manufacturer’s works by the Engineer
in accordance with the appropriate standard using clean cold water. Unless otherwise
specified pumps shall be tested with the motor which will drive them after installation.
Mass produced pumps shall be tested to prove the duty/guarantee point.
Special pumps (ie. those for which the impeller is specially trimmed or otherwise
designed) shall be tested to prove the duty/guarantee point and to develop
Quantity/Head, Quantity/Power, Quantity/Efficiency curves for the pump at operating
speed, or if the pump is multi or variable speed, at maximum and minimum speeds.
19.4.2 Submersible Pumps
Submersible pumps shall comply with the General Requirements for Pumps.
They shall be close coupled units comprising a single, stainless shaft, a squirrel cage
electric motor and a single entry, end suction pump.
Stainless steel lifting frames or eye bolts shall be fitted to casings for connection of lifting
chains.
Motors shall have IP68 protection and be continuously rated for use both when
submerged in sewage or storm/ground water at ambient temperature and when in air.
Motor windings shall be fitted with normally closed thermistors complying with relevant
specifications and providing protection when the pump is running.
Motors above 30 kW rating shall also be fitted with a lower bearing temperature monitor
and stator housing liquid level monitor. The monitoring equipment shall be designed and
installed so that automatic re-starting of the motor is not possible in the event of a fault.
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The monitoring units shall be manufactured by the pump supplier and supplied as free
issue to the control panel manufacturer to form part of the control panel.
Two mechanical seals shall be fitted on the shaft between the electric motor and the
pump impeller. The space between these two seals shall be oil filled.
Motor feed cables shall be ethylene propylene rubber insulated flexible cable, with each
power core of tinned copper wire nylon earth screened and polychloroprene sheathed
overall. Suspension of motor cables shall be via stainless steel cable socks from
suspension brackets.
Discharge bends shall be of close grained cast iron or stainless steel and shall provide
both pump support and lower guide rail/rope location. The pump discharge connection
system shall be designed so that the weight of the pump provides a clamping force.
Sealing between the pump and bend shall be achieved by the weight of the pump and
there shall be no leakage at the joint between the faces.
Mounting brackets for the pump shall be of Grade 316 S16 Stainless Steel.
Guide rails and holders shall be manufactured from stainless steel grade 316 S16 rigidly
supported at both ends. Alternatively stainless steel guide wire arrangement with
stainless upper guide holder may be used.
Lifting chains shall be of stainless steel and shall include shackles for connection to
pump lifting points. They shall be at least 1.50 m longer than the guide rails.
The lifting chain shall be fitted with a stainless steel tag detailing the safe working load,
the test load, the date of testing and the name of the testing authority.
Pump materials shall be according to Table 19-1
Table 19 - 1 Schedule of Pump Materials
Cast parts Cast iron
Studs, nuts, screws Stainless steel

and washers
Lifting handle Stainless steel
O-rings Nitrile rubber (700 IRH)
Stationary wear ring Nitrile rubber-clad steel
Rotating wear ring Stainless steel
Upper Mechanical shaft seals Tungsten carbide/Tungsten carbide
Lower mechanical shaft seals Tungsten carbide/Tungsten carbide
Impeller for Storm/Ground water Stainless steel

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Impeller for Sewage Cast Iron
Shaft Stainless steel
19.5 PRESSURE AND COMPOUND GAUGE FOR SEWAGE AND SLUDGE
Pressure gauges for use with sewage and sludge shall be Bourdon gauges. The
pressure transmission system shall be of the air-filled or oil-filled sealed type
incorporating reinforced plastic or stainless steel capillary tubing and diaphragm
transmitter.
For the air-filled system, the diaphragm shall be mounted in a clean-out housing. The
transmitter housing shall be mounted directly onto a 25 mm or greater bore straight
through isolating cock. The cock shall be mounted directly onto the pressure tapping.
Where the gauge is mounted directly on the pressure tapping a Schaffer diaphragm
gauge may be used. Schaffer diaphragm gauges shall be fitted with 20 mm or greater
bore straight through isolating cocks.
Gauges shall be graduated in metres of water and bars gauge, together with vacuum
where appropriate. The accuracy of the system shall be  1.50% of range or  2.50m
bar.
Gauges shall have 150 mm diameter circular faces. Gauge graduations shall be such
that the gauge is never used continuously beyond 60% of the maximum graduation.
The gauges shall not be connected to air release pipes or auxiliary suction pipes.
The gauges shall be fitted with a pressure snubber to dampen pressure pulsation.
The face shall have a warning label marked in red “IMPORTANT - TURN OFF WHEN
NOT IN USE” both in English and Arabic.
Before delivery, each gauge shall be tested in accordance with an approved international
standard and the test certificate sent the Engineer.
19.6 CENTRIFUGAL FANS (AIR BLOWERS)
Centrifugal Fans to be used as air blowers shall be of heavy duty, single inlet direct drive
type. They shall be suitable for handling temperature upto 800C, dust free air, and
aggressive gases and moisture normal to the sewage environment. The fan shall be
low-noise, explosion proof and corrosion resistant.
The blower shall be designed to handle, as a minimum, the rated air volume against the
stated head, as indicated in the Contract Documentation.
General Construction
Mating flanges and/or flexible connection, as appropriate, shall be provided for the inlet
and outlet.

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The fan shall be mounted together with motor support pedestal on a common base
frame. Fan blades, casing and other parts normally in contact with gases shall be of
stainless steel or plastic construction.
The fan shall have a backward curved centrifugal impeller which shall be overhung on
the motor shaft.
Driving motors shall be of well known manufacture with protection and insulation
appropriate to their location.
Blower Enclosure
Enclosure panels shall be of GRP modular construction materials consisting of chopped

strand mats, roving and unsaturated polyester resin to approved international standards.
The GRP material shall be composed of :- 0.5 mm minimum thickness gelcoat to provide
chemical resistance, layers of chopped strand mat reinforcing in resin content 60-70% by
weight. Woven roving glass fabric layers to provide strength and rigidity with resin
content 45-55%, surface layers shall consist of “C” glass surface mat (45-50 gm per
square metre) with resin content of 90% by weight.
All cut edges shall be made smooth using a resin top coat and are to be gel coat sealed.
Rigidity of the enclosure can be increased by adding sufficient stiffeners.
The enclosure shall be U.V. resistant, have high impact resistance, high abrasion
resistance, low sound absorption dB 10-15 in the 100 - 500 Hz range, low thermal
conductivity of 1.4 W/m2 0C and be non combustable.
19.7 SUPPORTS AND FIXINGS
Unless otherwise specified all supports, fixing bolts, screws, etc., and other fixings shall
be provided, shall be of minimum Grade 316 S16 stainless steel and shall be as follows;
i) Threaded and fitted with 3mm thick washers beneath bolt and nut. The
length shall be such that when tightened down with a nut & bolt the threaded
portion will not protrude more than half a diameter of the bolt.
ii) When fastening galvanised components or aluminium alloy components.

PTFE washers shall be fitted beneath the stainless steel washers for both
bolthead and nut.
iii) Stainless steel grade 316S31 shall be used for construction of pumps,
fastening galvanised or aluminium alloy components, holding down and
anchor bolts.
Not withstanding the above, the Contractor shall consider galvanic corrosion between
various metals when selecting materials for proposal.
19.8 SETTING OF MACHINERY
The machinery shall be mounted on flat steel packings of thickness selected to take up
variations in level of the concrete foundations.
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The packings shall be bedded by chipping or grinding of the concrete surface.
Packing shims of the appropriate thickness shall be located adjacent to each holding
down bolt. The number of shims shall not exceed three at each location.
The machinery shall be aligned, levelled and pulled down by the nuts of the holding
down bolts with a spanner of normal length. No grout shall be applied until the
machinery has been run and checked by the Engineer for stability and vibration.
Where specified an approved high performance non shrink grout shall be poured to bed
the equipment.
19.9 SUPPORT OF PIPEWORK AND VALVES
All necessary supports, saddles slings, fixing bolts and foundation bolts shall be supplied
to support the pipework and its associated equipment in an approved manner. Valves,
meters, strainers, and other devices mounted in the pipework shall be supported
independently of the pipes to which they connect.
All brackets or other forms of support, which can conveniently be so designed, shall be
rigidly built up of sections.
No point of passage of pipes through floor or walls shall be used as a point of support,
except with the approval of the Engineer.
19.10 PENSTOCKS
19.10.1 General
Fixings shall be of the drilled anchor type and made of stainless steel.
All penstocks shall be suitable for an on/off seating head of 10m minimum but in no
instances shall be less than 1.5 the maximum working head.
Penstocks shall conform to the following specifications:
(i) Austenitic Ni Resist Cast iron
(ii) Stainless Steel
(iii) Plastic
The size of penstock to be used in any particular location shall be as described in the
Contract Documentation and approved by the Engineer.
The frame, doors, sealing faces and spindles of each type of penstock shall be as
specified in the appropriate clauses herein.
Unless otherwise described in the Contract Documentation all penstocks shall be

provided with handwheels of adequate diameter with suitable gearing where necessary
to ensure that the required operating force applied by hand does not exceed 55 kg.
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Handwheels shall have the works “To open” and To close” in Arabic and English with
arrows indicating the direction of rotation cast on them. The direction of closing shall be
clockwise and a vandal/weatherproof, clear polycarbonate tube cover shall be securely
fitted to protect the thread of rising spindles. The tube shall be clearly and permanently
engraved to indicate the position of the penstock.
Spindles shall have machine cut robust trapezoidal or square form threads as
necessary. They shall be of stainless steel. Extension spindle coupling shall be of the
muff type and they shall be drilled and provided with a stainless steel nut and bolt for
securing the spindle to the penstock spindle head which likewise be drilled to take the
bolt.
All penstocks shall be of the rising type unless otherwise stated. Headstocks shall be
provided except in cases where the handwheels can be mounted on the penstock
frames. Unless otherwise stated for penstocks of 300mm (square or circular) or more
thrust tubes shall be provided. For all motorised/actuator operated penstocks thrust
tubes shall be provided between the penstock frame and headstock in order to absorb
the thrust in both directions of operation. Thrust tubes shall incorporate all necessary
fixing brackets and spindle guide plates.
Permissible rates of leakage under the specified working head shall be as follows;
On seating installation : - 5 litres per meter of slide perimeter per hour.
Off seating installation: - 30 litres per meter of slide perimeter per hour.
The slide perimeter shall be measured as the total length of contact faces between the
gate and frame in the closed position.
All materials used in the manufacture of penstocks shall conform to approved

international standards.
19.10.2 Austenitic Ni Resist Iron Penstocks

The frames, doors and stems guides for iron penstocks shall be made from austenitic Ni
resist iron. The penstocks shall be designed so as to ensure tight closure while
maintaining freedom of door movement during operation and minimising sliding wear of
the sealing faces. They shall incorporate adjustable wedges manufactured from a
material that shall not be susceptible to corrosion.
Non-ferrous metal sealing faces shall comprise accurately machined phosphor strips
bedded and fixed to the frame and door. The strips shall be secured by countersunk
screws that shall not be susceptible to corrosion. The faces of the strips shall then be
brought together in the operating position and hand scraped to a water-tight finish.
Non-ferrous metal strips shall be fitted to the frame guides and gate.
Penstocks shall be prepared and painted in accordance with painting specification.
19.10.3 Stainless Steel Penstocks
The frames and doors of stainless steel penstocks shall be of Grade 316 S31. The
design of the doors shall be such that the required working pressures can be withstood

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without deflection or distortion that would affect the operation of the penstocks. Any
strengthening of doors by the provision of ribs and gussets shall be carried out by
welding and not by bolting.
The side sealing faces may consist of simple metal to metal contact between the door
and frames or by synthetic rubber seals and plastic guides as necessary to withstand the
required working pressure without leakages.
Spindles shall be manufactured in stainless steel grade 316 S31.
19.10.4 Plastic Penstocks
The frames of plastic penstocks shall be made from continuously welded stainless steel.
Frames shall be reinforced and gusseted to ensure rigidity without dependence upon the
bridge which shall be bolted for ease of removal.
The doors of plastic penstocks shall be made from sheets of approved rigid cellular
polymer sandwiched between sheets of approved rigid compressed composite plastics.
The linear coefficient of thermal expansion of the material shall not be greater than 1.6 x
10 per oC. No PVC or GRP materials shall be used. The doors thus formed shall have
sufficient strength to withstand the required working pressures without deflection,
distortion or that would affect the water-tightness of the penstocks. Totally enclosed
steel matrices shall be incorporated in the door construction to ensure adequate rigidity.
The sealing faces and side guides shall be to the approval of the engineer and shall
consist of plastic strips having a high resistance to sliding wear and a coefficient of
friction of less than 0.10. The sealing strips shall be securely fixed to the inner faces of
the frames and shall incorporate removable stainless steel adjusting devices.
Spindle operating nuts shall be of gunmetal or manufactured from an approved ultra high
molecular weight polyethylene material. The operating nuts for the spindle retaining
blocks shall be fixed in a visible position inside a separate gate lifting bracket bolted on
to the top of the door with stainless steel fasteners. The operating nut or spindle
retaining block shall not be contained within the door.
All plastic materials shall be non toxic ultraviolet stabilised and shall have fire resistance
in accordance with an agreed internationally approved standard.
19.10.5 Actuators
Where electric actuators are required for valves or penstocks they shall comply with the
requirements of Section 18 the Electrical Specification.
19.11 LIFTING EQUIPMENT
19.11.1 Electrically Operated Traversing Cranes
Cranes shall be electrically operated traversing type and be complete with gantry rails
and all accessories including a set of slings.

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The gantry joists and rails shall be provided with provision for jointing and fix to the
structure. The lifting capacity of the apparatus shall be sufficient for the heaviest load
which will be obtained when erecting or dismantling the plant or other parts of the
installation. The capacity of the cranes proposed shall be stated in the equipment supply
schedule.
The crane shall be tested at the makers works at 25% above the rated load, and test
certificates shall be provided.
The crane shall be of the double girder travelling type. The traveller carriage shall run on
bridge rails which shall be securely fixed to the gantry.
The crane shall be provided with a maintenance platform over the full span. The
maintenance platform shall be provided with double handrails throughout and a fixed
ladder access.
Longitudinal and traverse motions shall be provided for the crane and shall be such that
operation is speedy without impairing safety in working. The hook and load chains shall
be such that the hook will reach to the maximum depth.
Ball or roller bearings shall be employed on all motions and the load hook shall revolve
on a ball swivel. All gears shall be machine cut and all runway wheels machined.
A reliable braking and locking arrangement shall be provided.
The crane structure shall be designed in accordance with the requirements of an

approved international standard.
Two hoist speeds shall be provided, not exceeding 3 m/min across the working range of
the crane. Cross travel speeds shall be approximately 15 m/min. All motions shall be
electrically driven. The speeds of all motions shall confirmed in the appropriate
schedule the speeds on all motions.
The load shall be carried on a flexible steel wire rope coiled onto a cast iron barrel
having right and left hand machine cut spiral grooves to ensure a true vertical lift. The
load rope shall be of sufficient length to reach the maximum depth. The load hook shall
comply with an approved international standard and shall revolve on a ball swivel. A
safety catch shall be fitted to the hook.
The crane shall be remote controlled on all motions from a non-metallic pendant push
button station. Buttons shall be of the hold-to-operate type. The pendant enclosure
shall give protection to IP54 requirements. Operation of the crane shall be possible from
any position across the full span. The pendant legends shall be inscribed in English and
Arabic.
The power supply to the hoist shall be of festooned cable type running on a rigid support
system. An earth conductor shall also be provided.
The electrical equipment shall be controlled at 110 volts. The transformer shall be
protected by HRC fuses on both primary and secondary circuits.
A main supply isolator shall be provided and mounted at operating height from ground
level. Three sets of red "conductor alive" warning lamps shall be provided.
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All motors and electrical equipment shall be rated in accordance with the climatic and
other Specification requirements.
The integrity of the hermetic seal to the box girders is to be maintained. All cables shall
be enclosed in a steel conduit which is to fastened to the exterior of the girder.
19.11.2 Manually Operated Lifting Equipment
A close lift, hand operated gear driven lifting block, on a single runway beam, shall be
provided when specified in the Contract Documentation. The Safe Working Load of block
and beam shall be at least 25% above the weight of the heaviest item which will require
lifting for maintenance purposes. Equipment shall have the following minimum ratings:
500 kg for the hoist and 1000 kg for the beam.
The whole assembly including beam, gear driven travelling trolley, pulley block and
chains shall be subject to a capacity test carried out on site by an approved independent
body. The proof load applied for certification shall be 50% in excess of the Safe Working
Load (SWL) shall be clearly marked on the lifting block and on the runway beam. The
test date is to be displayed on the runway beam.
The bottom block shall be of the steel fully swivelling type with a safety catch fitted to the
hook.
A secondary load chain/cable and hook shall be supplied, suspended from the trolley.
The chain/cable shall be fixed length so that the hook is suspended approximately 1000
mm below the bottom flange of the beam. The hook, and chain/cable shall be tested to
the same safe working load as the main hoist. The secondary load chain/cable shall be
used to support a lift at intermediate levels whilst the main load chain is reslung.
19.11.3 Lifting Frames
Lifting Frames shall comprise an "A" frame or portal supporting a composite beam over
the lift centre lines which will carry a hoist block with traverse. The composite parts of the
device shall comply with the relevant specification clauses.
19.11.4 Lifting Davits
Lifting davits shall comprise of a simple single mounting; capable of traversing the uispan of
the area of lift and be fitted with a chain block as Clause 19.11.2 above. A socket shall be
provided which is to be cast into the reinforced concrete of the associated structure.

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APPROVED INTERNATIONAL STANDARDS
ASTM C418
BS 466
BS 476
BS 970
BS 1452
BS 1780
BS 2061
BS 2374
BS 2494
BS 2573
BS 2853
BS 2903
BS 3243
BS 3468
BS 3499
BS 3532
BS 3643
BS 3691
BS 4504
BS 5153
BS 5163
DIN 1690
DIN 1691
ISO 5752
ISO 5996

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SECTION 20 - MISCELLANEOUS ELECTRICAL AND MECHANICAL
20.1 METAL AND PLASTIC MATERIALS
20.1.1 Aluminium Alloy
Aluminium alloys shall be selected as having properties appropriate to the duty of the
unit, the method of fabrication and the environmental conditions.
The materials shall be manufactured in accordance with an approved International

Standard and shall be anodised when specified.
Alternative alloys may be proposed by the Contractor if the manufacturer considers its
properties more appropriate to the application, the environmental or the physical
conditions prevailing.
20.1.2 Steel
Steelwork shall be manufactured/fabricated in accordance with an approved international

standard. Where specified or detailed steel work shall be hot dipped galvanised in
accordance with an approved International Standard at the place of
manufacture/fabrication.
20.1.3 Stainless Steel
Stainless steel shall have the following composition with mechanical properties to the
appropriate approved standard.
Table 20-1. Required Properties for Stainless Steel
Percentage Chemical Composition
Element Welded Fabrication Cold Fabrication

% minimum % maximum % minimum % maximum
Carbon - 0.03 - 0.07
Silicon 0.20 1.00 0.20 1.00
Manganese 0.50 2.00 0.50 2.00
Nickel 11.00 14.00 10.00 13.00
Chromium 16.50 18.50 16.50 18.50
Molybdenum 2.25 3.00 2.25 3.00
Sulphur - 0.03 - 0.03
Phosphorous - 0.045 - 0.045
Alternative, higher grade, stainless steel may be proposed by the Contractor if the
manufacturer considers its properties more appropriate to the environmental or physical
conditions.

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20.1.4 Reinforced Thermosetting Plastics
Reinforced plastic shall be as follows unless otherwise agreed in writing by the Engineer.
(1) Manufacturing Standards
The specification for design, materials, construction, inspection, and testing

of plant manufactured from reinforced plastics shall conform to the
appropriate sections of the approved standard.
(2) Resins
(a) Isophthalic, Terephthalic, Bisphenol and Vinyl Ester resins may be

specified and they shall comply with the approved standard. The resins
used shall have a minimum strain to failure of cured cast resin of 2%.
(b) Pigments or fire retardant resins (or fillers) shall only be used when
specified or ordered in writing.
(c) Additives shall not be included in the resins unless they are required for
viscosity control.
(d) Due attention must be paid to preclude the possibility of air inhibition
occurring on the laminate surfaces. The inclusion of paraffin wax, etc.,
must be in accordance with resin suppliers recommendations.
(e) Where protection against Ultra Violet light degradation is required, a

translucent UV inhibitor should be included in the outer layers of the
laminate.
(3) Curing
Curing systems shall be in accordance with the Resin Manufacturer's

recommendations. The manufacturer of the laminate shall demonstrate that
the laminate has been adequately cured prior to its acceptance at the
laminator's works.
(4) Reinforcement
(a) 'E' type glass chopped strand mat reinforcement shall be to the
approved standard and shall be to a maximum unit weight of 600
gm/m2.
(b) 'E' type glass woven roving fabrics shall be to the approved standard
and shall be to a maximum unit weight of 800 gm/m2.
(c) 'C' type glass veil (or synthetic fabric veil, where use is agreed by the
Engineer), shall be used to reinforce all surface sealing resin layers on
laminates.
(d) Use of 'ECR' Corrosion Resistant glass will be permitted.
(5) Structural Design

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(a) The laminate shall be designed to withstand all the loadings normally
carried by the laminates.
(b) Under the worst combination of loading conditions, a maximum strain of

0.2% shall be permitted in the laminate.
(c) A minimum laminate thickness of 6 mm shall be maintained for all GRP

laminates including the facings over or under stiffener sections.
(d) Stiffener sections may be used to increase the rigidity of a structure.

The minimum glass reinforcement content shall be 1.2 kg/m2 in these
areas. Stiffener sections may be manufactured from the following
materials.
(1) Polyurethane Foam

(2) Marine Plywood
(3) Other material agreed in writing
Stiffener sections shall not be made from steel or metal sections unless
written consent has been previously obtained. Where stiffening
sections are employed they shall not be construed as adding to the
strength of the section to which they are added.
(6) Moulds
Moulds shall be of adequate rigidity to retain dimensional stability and permit

a high level of laminate consolidation., The mould surfaces shall be of a
quality which will ensure the surface finish of the product.
(7) Fabrication Methods
Manufacture shall be by approved mechanical methods wherever possible.

Items produced by hand lay-up processes will only be permitted if a suitable
mechanically manufactured product is not available. If deposition of resin by
gun is used, this must be carried out by airless spray technique.
(a) Unreinforced gel coats shall have a maximum thickness of 0.5 mm.
Unreinforced flow (top) coats shall be fully brushed out to remove resin
rich areas. The flow coat shall not exceed 0.3 mm in thickness.
(b) Surface veil or synthetic fabric reinforced layers shall consist of

approximately 90% resin by weight. The thickness of this reinforced
layer shall not exceed 0.5 mm.
(c) Chopped strand mat layers shall have a resin content of between 65%
and 75% by weight.
(d) Woven roving glass fabric layers shall have a resin content of between
40% and 60% by weight.
(e) Where edges of laminates are cut or exposed these shall be sealed
with a continuous layer of fully cured resin.

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(f) Bisphenol or vinyl ester protective layers to isophthalic/terephthalic

laminates, shall be applied with a 'C' type glass veil (or synthetic fabric
veil) reinforcement after hardening of the substrata. When this has
sufficiently cured to prevent movement, a continuous flow (top) coat of
bisphenol or vinyl ester resin shall be applied and fully cured. In such
cases it is anticipated that an appropriate paraffin wax additive will be
required to prevent air inhibition of the surface.
(8) Samples
(a) A sample measuring 1 metre square and typical of each different

laminate proposed shall be submitted for approval together with a
detailed descriptive specification at least 4 weeks prior to the
commencement of manufacture.
(b) Production samples measuring 300 mm square and typical of each

different section of laminate shall be submitted to the Engineer's duly
authorised Inspecting Engineer throughout the period of manufacture
for the purpose of testing.
(c) Samples of liquid and cast resin together with reinforcements and
surfacing veils (or fabrics) required to manufacture the samples
indicated in (b) above shall also be made available to the Engineer.
Failure to provide any of the samples designated in (a), (b) and (c)
above shall be construed as representing a delay in completion of the
Contract under the terms and conditions contained therein.
(9) Tolerances for Moulded GRP
Table 20-2 Thickness Tolerances for Moulded GRP
Nominal thickness Moulding from open Moulding from closed Matched metal
(mm) mould. mould mouldings
(mm) (mm) (mm)
Up to but not p 0.50  0.20  0.18
including 1.5
1.5 to but not  0.75  0.30  0.20
including 3.0
3.0 to but not  1.10  0.50  0.30
including 6.0
6.0 to but not  1.50  0.75  0.40
including 12.0
12.0 to but not  2.00  1.40  0.50
including 25.0
25.0 and over  3.00  1.90  0.65
(10) Quality Control and Testing
(a) The following tests for inspection and quality control shall be carried out:-

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(1) The laminate shall be fully cured and shall show full resistance to a
commercial acetone sensitivity test.
(2) The laminate shall give Barcol Hardness of at least 90% of the resin
manufacturer's recommendations. The measurement of hardness
by means of a Barcol Impressor shall be carried out in accordance
with the approved standard.
(b) Resin burn off tests shall be performed on cut-outs, where no such cut-
outs exists the Engineer reserves the right to have 50 mm diameter cut-
outs for checks to be made on local glass reinforcement content. The
tests shall be conducted in accordance with the approved standard and
the result shall define glass content.
(c) The following strengths of the laminate shall be determined in accordance

with the approved standard.
(1) Ultimate tensile unit strength
(2) Flexural strength
(3) Lap shear strength
(4) Shear and Peel strength of bond between thermoplastic linings and
laminate shall be at least 95% of the minimum value specified by
the laminate manufacturer.
(d) Where a laminate has been designed to take bolts in the make up of the
structure tests for bolt bearing strength shall be performed. Bolt bearing
strength tests shall be performed in accordance with the approved
standard.
(e) Where a laminate is to be used in conjunction with electrical control

equipment all or part of the following additional tests may be called up
which shall be carried out in accordance with the approved standard.
(1) Electrical strength of sheet parallel to the plane of the sheet.
(2) Electrical strength of sheet normal to the plane of the sheet.
(3) Electrical strength of casting laminating resin system.
(4) Insulation resistance of laminated sheet using IEC taper pins.
(f) Additional tests may be called up at the discretion of the Engineer.
(g) (1)Test Certificate shall be obtained from the resin supplier for the heat
distortion temperature of resin and the unreinforced resin extension to
failure.
(2) Test Certificates shall be obtained from the glass reinforcement

manufacturer for each grade and type of glass employed in the
fabrication of the laminate.
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(h) All the tests referenced in (a) to (f) above shall be witnessed by the
Engineer or his Representative unless waived in writing by the Engineer.
(11) Trial Election
A sufficient proportion of the fabricated sections of the structure must be trial

assembled to demonstrate the correctness of fit of the various sections.
20.2 METAL AND PLASTIC PREFABRICATED ITEMS
20.2.1 Ladders and Safety Hoops
Ladders and safety hoops shall be manufactured from either stainless steel or glass
reinforced plastic, as specified in the contract documentation.
The materials and manufacture of ladders and safety hoops shall be in accordance with
an approved international standard.
For all stainless steel ladders the stringers shall be 65 mm by 12 mm and spaced 375
mm apart. The rungs shall be 25 mm dia. reduced to 20 mm dia. at the ends and
rivetted over. They shall be spaced at 225 mm centres. The ladders shall be provided
with fixing brackets or the ends of the stringers shall be turned over to form fixings. The
fixings shall be drilled for 16 mm diameter bolts.
Stainless steel safety hoops shall be of circular pattern fabricated from 50 mm by 10 mm

flats. Fixing shall be by 12 mm dia. countersunk screws with washers and nuts, the
screws being inserted from the inside of the ladder stringers.
Glass reinforced plastic ladders shall be dimensionally similar to stainless steel ladders
for rung widths and spacings. The treads of rungs shall be roughened.
All fixing brackets, screws, bolts and nuts, etc. shall be SS grade 316 S16.
20.2.2 Underground Hydrants and Covers
Underground Hydrants shall be of the screw-down pattern manufactured in accordance

with the approved International Standard.
20.2.3 Open Mesh and Chequer Plate Flooring
Open mesh and chequer plate flooring shall be of mild steel, aluminium or reinforced
plastic as specified in the Contract Documentation.
Unless higher loadings are called for floorings shall be designed to take pedestrian
loading based on a central point load of 100 kg under which the deflection shall not
exceed span/200 for metal flooring and span/100 for reinforced plastic flooring.
Reinforced plastic flooring shall have a non slip tread surface.
Unless a higher grade of protection is detailed all mild steel flooring shall be hot-dipped
galvanised after fabrication.

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20.2.4 Galvanised Steel Guardrailing
Tubular handrails and standards shall be of 10 gauge thickness 32 mm nominal internal

diameter steel tube. Solid handrails shall be 25 mm diameter and solid standards 32
mm diameter. The balls on the standards shall be of adequate size to accommodate
the rails which shall be fixed by grub screws for tubular rails and by welding for solid rails
or by similar approved fixings.
Heights of rails, overall dimensions and details of the bases for the standards, fixing
bolts and any other special requirements relating to the guardrailing are shown on the
drawings.
All components shall be galvanised after fabrication.
20.2.5 Aluminium Guardrailing
Unless otherwise specified or ordered, aluminium guardrailing shall be constructed with

tubular rails fixed to double ball pattern solid forged standards. Both rails and standards
shall have a minimum outside diameter of 38 mm.
The rails and standards shall be of aluminium alloy anodised after fabrication. The
standards shall be fitted with base plates approximately 150 mm x 65 mm x 16 mm thick.
Heights of rails, overall dimensions and details of the bases for the standards, fixing bolts
and any other special requirements relating to the guardrailing are shown on the drawings.
20.3 ODOUR CONTROL EQUIPMENT
20.3.1 Design Parameters
The Tenderer shall submit detailed proposals for the effective control of odours emitted
from wet wells.
Concentrations of H2S are likely to be as high as 250 ppm under natural ventilation
conditions with an average concentration of 50 ppm.
The odour control system shall be based on the use of bulk activated carbon of the
regenerative type. The system shall be designed for regeneration of the carbon without
the removal of any part of the plant from site.
Performance guarantees to reduce the H2S levels at 1.5 m above ground level to 0.1
ppm and in the Wet Well to 3 ppm shall be included in the proposals and shall be binding
on the successful Tenderer.
The Deodoriser shall be designed during normal operation to give a minimum of 16 air
changes per hour.
A warning light of the flashing beacon type shall be placed at the entrance to the wet well
which shall operate if the system fails. It shall operate on the fail safe basis and
additional signage is to be provided warning operators not to enter if the flashing/warning
light is illumated. Safe working practices shall be followed before any entry. A notice
shall be placed underneath the warning light and shall read as follows:-
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DANGER VENTILATION
FAILURE
DO NOT ENTER WHEN THE RED LIGHT IS FLASHING
20.3.2 Description and Arrangement of Plant
20.3.2.1 General
The odour control plant shall comprise a rechargeable activated carbon bulk plant
with pre-filter as follows:-
Filter media housing

Sufficient Activated Carbon to give continuous operation for five years
(Inclusive of regeneration)
A. Pre-filter inclusive of housing, washable nylon filter etc.
B. Extract fan (s)
C. H2S monitor
D. Differential pressure gauge
E. Interconnecting pipework and valves
F. Ductwork between sump, fan(s), carbon filter and pre-filter
20.3.2.2 Filter Media Housing
The filter media housing shall be manufactured in uPVC and wrapped externally
with glass reinforced white pigmented polyester resin (GRP) in accordance with the
general specifications. Conductive resin strips behind weld lines shall be included
to alleviate static build up and be bonded to earth.
It shall consist of a vertical cylindrical sections with flat base as follows:
Flanged access covers

Discharge stack
Connections for earth bonding, pre-filter inlet, differential pressure detector, H2S
monitor etc.
All materials shall be resistant to corrosion from chemicals encountered in the

process.
Design calculations shall be submitted in respect of the stack height required to

prevent down-draft occurring due to the possible effect of adjacent structures.
20.3.2.3 Filter Media
The filter media shall be activated carbon and must be effective in dealing with
odours arising from concentrations of Hydrogen Sulphide gas.
A full specification of the type and grade of activated carbon proposed is to be

included with the Tender.
The Contractor shall state the expected life of the activated carbon and guarantee
sufficient supplies for five years of operation.

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The activated carbon shall be suitable for insitu regeneration by water wash. For
which all necessary equipment shall be provided.
20.3.2.4 Extract Fans
Extract fans shall be provided as necessary in the system prior to the main filter to
transfer foul air as described previously.
Each fan shall be of the multi-vane centrifugal type and fabricated from stainless
steel Gr. 316S31
A direct coupled drive is preferred but alternatives will be considered providing it

can be shown that belts and pulleys are fully protected.
Motors shall be in accordance with the electrical section of the specification. They
shall be suitable for continued operation within the hazardous location.
20.3.2.5 Differential Pressure Switch
An air pressure switch for detection of the efficiency of filters shall be provided. It
shall be of the differential pressure type and be protected for the environment. The
switch shall be intrinsically safe and shall be arranged to initiate an alarm one week
before filters require cleaning.
20.3.2.6 H2S Monitor
H2S Monitor for deodorising plants shall be of the "sensitised pad" type enclosed in
a factory manufactured clear UV protected housing mounted in a clearly visible
location on the filter media housing. The sampling point shall be in the air stream
just above the carbon bed level such that it detects the level of H2S that is emitted
from the filter.
The sensitised pad shall change colour relative to its exposure to H2S. A colour
chart with H2S (ppb) graduated against time (min) shall be supplied for
comparison.
20.3.2.7 Ductwork
Ductwork, casings, sun covers, louvers etc. shall be constructed of chemically

reinstated glass reinforced plastic or Upvc, or stainless steel as specified and
comply with the following:-
Comply with HVAC and SMACNA or similar approved publications
Obtrusions to air flow with the exception to dampers, vanes, splitters will not be
accepted.
All joints, fittings, support etc. shall have all sharp edges removed.
Where ductwork passes through ceilings, roofs, walls etc.; purpose made vermin
proof fittings are to be used.

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Connection of individual components between an assembly and ductwork shall be

carried using angled flange joints.
Ducts in close proximity to walls and ceilings shall be mounted in such a way as to
exclude vermin runs.
Flexible joints are to be provided at all fan inlets and outlets
Where uPVC is exposed to direct sunlight it shall be enclosed in GRP for

protection.
The external noise levels due to the operation of the ventilation equipment shall be
unobtrusive at all times.
20.3.2.8 Filters
The filter designed should be as follows:-
Filters shall be installed at all points of entry to ventilation and air conditioning
systems. To reduce the ingress of dust around the frame to a minimum and so
constructed to facilitate maintenance.
Manufactured from approved corrosion resistant material.

Have a Minimum efficiency of 95%.
Have a maximum air velocity of 2.5 m/sec.
Provided with drainage points as necessary
Pressure of clean air > 90 Pa for 95% efficiency & > 125 Pa for 98% efficiency.
20.3.2.9 Flexible Joints
Flexible joints shall have the effective cross sectional area as adjoining ductwork or
fan housing and shall be manufactured from material with a 15 minute fire
penetration time.
20.4 VENTILATION
20.4.1 General
Ventilation equipment shall be supplied and installed for the areas specified.
The noise level due to ventilation equipment shall be no greater than sound power level
65 dB(A) re 10-12 watts.
The Contractor shall include for sound absorbers and anti-vibration mountings as
necessary.
All inlets and outlets through the roof shall be fitted with approved GRP or Aluminium
cowls and bird screens. All inlets and outlets through walls shall be fitted with sand
trapped de-mountable aluminium louvers. All materials used for external fittings shall be
highly resistant to ultra-violet light degradation.
All louvers shall be of the sand trap type and shall be fitted with internal sand filters and
mosquito screens.

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20.4.2 Extract Fans
Extract fans shall be roof, wall or duct mounted electric motor driven axial flow type. They
shall be complete with weather protecting cowls of GRP or aluminium if mounted externally,
and any necessary ductwork.
Extract fans shall be sized to provide the minimum number of air changes per hour for the
area specified:-
Toilets 12
Stores 6
Workshops 15
Garages/Car park areas 8
Messes (two speed) 6-20
Motor Room 10 - 20
Dry Well 20.
20.4.3 Wet Well Ventilation
Refer to odour control equipment
20.4.4 Dry Well Ventilation
Ventilation equipment shall provide 20 air changes per hour to the dry well area.
The system shall operate on the principle of forced draught outlet/ natural ventilation inlet
via the stairways and other apertures.
20.4.5 Motor Room Ventilation
Ventilation equipment shall be two speed to provide 10 or 20 air changes per hour to the
Motor Room area.
The system shall operate on the principle of forced draught outlet/ natural ventilation inlet
via inlet louvers. All inlet louvers shall be fitted with 50mm thick metallic washable filters.
Access shall be provided for cleaning/changing filters.
20.4.6 Fans
Fans shall be of the axial flow or centrifugal types suitable for handling air of high
humidity and having concentrations of hydrogen sulphide.
They shall be of non-ferrous construction or be protected with suitable epoxy resin

coatings.
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Wet well fans shall be constructed entirely from stainless steel to an approved
All bearings shall be of the roller or ball race type and shall be sealed for life.
20.4.7 Fan Motors
Fan motors shall be suitable for continuous operation in hot, humid atmospheres at an
ambient temperature of up to 55oC at 100% humidity.
The degree of protection provided shall be appropriate to the installed location and
All motors shall comply with the requirements of the electrical section of the Specification
insofar as it applies.
20.4.8 Ducting
Ventilation ducting shall be of GRP, Reinforced uPVC or Stainless Steel. Material

thickness, stiffening and joint arrangements shall be in accordance with an approved
Ducting shall be complete with all necessary supports. Stainless steel nuts and bolts shall
be used for all ducting joints and all Supports and brackets shall be galvanised except
where otherwise specified. All supports, brackets and fixings in wet wells shall be stainless
steel.
Ducting shall be sized so that the air velocity within the ducts shall not exceed 5.5 m/s.
Flexible connections and anti-vibration mountings shall be provided as necessary between

the ductwork and fans and provision shall be made for thermal expansion.
Where ducts pass through walls roof or floor slab the gap shall be sealed with a non
degradable approved material.
20.5 AIR CONDITIONING
20.5.1 Wall Mounted Air Conditioning Units
Air cooled 'window-type' air conditioning units, as supplied by an approved and accepted
manufacturer, shall be installed in positions approved by the Engineer. They shall be
provided complete with slide out chassis and frame, suitable for clear openings set not
higher than 1.5m above floor level. They shall be suitable for continuous efficient
operation in the climatic conditions prevailing and the materials of construction
(particularly concerning the fins or extended surfaces of the refrigerant to air heat
exchangers) shall be subject to the Engineer's approval.
Both fresh air and re-circulated air shall be filtered and the filter shall be arranged for
ease of removal from the main unit for cleaning and replacement.

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Depending on the size of the room space and the heat load therein, the air conditioning
units shall be of 1 ton, 1.5 tons or 2 tons refrigeration capacity (equivalent to an air
cooling capacity of 13,250; 19,880 or 26,500 B.T.U.’s per hour) or multiples thereof.
Each unit shall be provided with a manually adjustable thermostatic air temperature
control and such other controls necessary to allow the following modes of operation:-
1. Off.
2. Fan only with two speeds.
3. Cooling at two possible fan speeds.
4. Re-circulation of air from room, through unit and back to room.
5. Part re-circulation of air with some exhaust airflow.
6. Part re-circulation of air with some fresh air inlet flow.
Each unit shall also be fitted with an automatic delay timer in the compressor control
circuitry to prevent the compressor having to start against gas pressure in the event of
an interruption in the power supply or the cooling mode being switched off and on
rapidly.
20.5.2 Centralised Air Conditioning Systems
Centralised air conditioning systems shall comply with the requirements of the Particular
Specification.
The system shall be complete with all necessary ductwork, diffusers, air grilles etc. Two
single package units shall be provided and installed. Each unit shall be capable of
providing 60% of the total cooling load.
Machinery shall be from an approved manufacturer, of types readily available in Dubai

and suitable for installation in direct sunlight. Filters, re-heaters and/or humidifiers shall
be provided as necessary to maintain the condition of the equipment.
Supply and return air ducting shall be run in the void above the suspended ceiling where
applicable. Air vents to conditioned areas shall be via slot diffusers integral with the
suspended ceiling. The whole system shall be designed to give an even temperature
distribution throughout the air-conditioned areas.
Single package units shall be of the type with two compressors and split coils arranged
so that the failure of a compressor shall not lead to total failure of the air conditioning to
any area. The two units shall be identical to limit the quantity of spares.
Work on installation of air conditioning systems is only to be undertaken by an approved

local air conditioning contractor or by an international air conditioning contractor who is
associated with an approved local air conditioning contractor.
It is recommended that the Contractor engages the services of an air conditioning

specialist who is familiar with local requirements and conditions to design and specify the
system and liaize with Dubai Electricity and Water Authority, regarding approvals and
inspections.
Copies of the design calculations, unit specifications and system descriptions and
drawings are to be submitted to the Engineer for approval by the Dubai Municipality who
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will finally be responsible for the air conditioning system. The Dubai Municipality will
require two additional copies of the operating manuals for the air conditioning system.
Representatives of the Dubai Municipality will require to be in attendance during
commissioning.
A five year guarantee shall be provided against all malfunctions of the compressor by the
Dubai Electricity and Water Authority approved local air conditioning contractor
appointed.
20.5.3 Split Unit Air Conditioners
All materials used in the manufacture of the units shall be produced to approved
International Standards. The cooling tubes shall be manufactured from solid drawn
copper and shall be tested to 20 bars. Fins shall be of Aluminium and shall be
permanently bonded to the tube. Cabinets shall be manufactured from pre-galvanised
sheet steel and the outer panels electro-statically powder coated with epoxy and stoved.
Panels shall be removable for access.
Condensate trays shall be fitted and the outlets piped to a suitable drain point.
Fans shall have corrosion resistant steel impellers. Motors shall comply with the
relevant parts of the Specification. Anti-vibration mountings shall be provided.
Air filters shall be fitted having 90% efficiency. If they are of the throw-away type a five
year supply of spare elements shall be provided.
The condenser unit shall be suitable for outdoor installation.
The coils shall be pressure tested to 20 bars and fins shall be permanently bonded to
them.
Motors shall be weatherproof and shall comply with the relevant parts of the
Specification.
Compressors shall be hermetically sealed. Crank-case heaters and anti-vibration

mountings shall be provided.
High and low pressure switches and overload protection shall be provided and also an
anti-recycling timer.
The units shall be sized to maintain a dry bulb temperature of 26oC and a relative
humidity of between 40% and 60% when the external shade temperature is 52oC and
the external relative humidity is 50%.
20.6 STANDBY DIESEL GENERATING PLANT
20.6.1 Application
The diesel generating plant is required to provide a standby source of power and shall
be suitable to start and take-up continuous full load after lengthy periods of standing un-
operated. It is the supplier's responsibility to ensure that the plant is fully suitable for this
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class of duty and suitable for the electrical loads to be applied to the plant. The
equipment shall be suitable for operation at a temperature of 50oC and should be
derated accordingly.
20.6.2 General Description Of The Plant
The engine and alternator shall be mounted upon a purpose built one piece robust rolled
steel fabricated baseframe which shall be provided with lifting lugs complying with an
approved international standard. Steel support channels shall be cast into the concrete
base slab to which the base frame shall be bolted. Jacking points and dragging points
shall also be provided.
Anti-vibration mountings (oil resistant) may be included below the baseframe if the
Tenderer considers these desirable but the inherent vibration level of the complete unit
from zero to 10% above working speed should not necessitate anti-vibration mounting.
Oil drip trays, with drainage facility, shall be provided below the engine to prevent floor
contamination.
The Contractor shall supply the first fill of lubricating and fuel oil as well as any
necessary consumables for testing.
20.6.3 Engine - General
The engine shall be as follows:-
Rated for kW loading of the applied load with consideration given to sizing in such a way
that it is not subject to running for long periods of time under light loading.
Of four stroke, compression ignition, self- lubricating, water cooled type complying with
approved international standard, as is applicable, running at a nominal speed not
exceeding 1500 rpm and shall be suitable for operating on automotive diesel fuel. The
rating shall suit the load requirements in the ambient conditions stated.
The following shall be incorporated in the design:-
Replaceable plated cylinder liners

Replaceable valve seats
Replaceable valve guides. Replaceable
silicon bronze small ends Valve gear shall
be of the enclosed pattern
Cam shaft and crankshaft to be supported by lined steel shells
Crankcase pressure relief breather to be of the closed circuit type.
Air filter of the extra heavy duty “Desert” centrifugal type
The engine shall directly drive the generator with the coupling arrangement being
flexible. A flywheel shall be fitted to ensure stable operation. Means shall be provided
for manual barring of the engine for maintenance purposes.
All exposed rotating or moving parts shall be protected by suitable guards with brackets
and securing arrangements of substantial construction and shall comply with an
approved international standard. Special attention shall be given to guarding the
flywheel-coupling and the radiator fan drive.
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The guards shall be readily removable for plant maintenance purposes as necessary.
Lifting eyes or lugs shall be provided on the cylinder head blocks if necessary. The
Tenderer shall include with the offer a drawing showing all necessary lifting requirements
with unit weights both for installation and maintenance.
Remote alarm contacts, where referred to, shall be voltage free SPDT suitable for 1 amp
at 24 V DC/220 V A.C.
20.6.4 Engine - Lubrication
The lubricating system shall be of the closed circuit type suitable for fast automatic start
of the unit. The oil shall be pumped round the oil circuit by an engine mechanically
driven pump having a suction strainer and the oil system shall not require priming prior to
starting the engine.
The oil pump shall have associated with it a pressure regulating valve and a separate
over pressure relief valve. Large capacity dual filters with auto bypass shall be fitted
immediately after the oil pump. The filters shall be of the replaceable type. Each filter
shall be fitted with a pressure gauge and drain cock. The oil cooler shall use the coolant
of the engine cooling system.
The lubrication system shall be designed to allow at least 400 hours of continuous
running between oil and filter changes and shall be provided with a filler cap, dipstick
and plugged oil drainage valve.
Dial type gauges showing the oil pressure and temperature after the filters shall be
provided.
20.6.5 Engine - Fuel System
This shall include a fuel tank with the necessary mounting brackets, and pipework
(including a flexible connecting pipe if the tank is not engine mounted). The tank shall be
of sufficient capacity for 8 hours continuous operation or as specified at full load and
shall be complete with a fuel shut off valve, a dial type level indicator, minimum and
maximum level switches having SPDT contacts suitable for 24 V DC/220 V A.C. at 1
amp (for filling control and alarm), a protected vent, an overflow connection and a
plugged drain valve.
A fuel feed pump driven from the engine shaft shall be provided, together with a hand
priming pump, also dual filters and a drip tray to collect any fuel spill or leakage. The
drip tray to have a drainage cock and flexible draw-off pipe.
A dial type gauge showing the pressure after the filters shall be provided.
20.6.6 Engine - Cooling
The coolant shall be a proprietary anti-corrosive type in a closed circuit system with a
radiator mounted on the engine bedplate and having an engine driven cooling fan
arranged to discharge the cooling air to the outside of the enclosing structure.

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A mixture of coolants, rust inhibitor recommended by the generator manufacturer for the
climatic conditions prevailing in Dubai shall be used. Quantities and mixture ratios shall
be clearly identified in the Operational Manuals provided for the project.
A flexible connection shall be provided between the radiator and the surround opening to
prevent hot discharge air escaping backwards. The opening shall be large enough to
allow installation and removal of the generator plant and shall have an external rain
protecting removable grille.
The radiator shall be sized to allow for the ambient conditions and the plant layout at
110% of the engine full load rating.
The coolant shall be circulated by an engine driven pump having a pressure gauge on
the outlet pipework. The cooling system shall incorporate a thermostatic valve to bypass
the radiator to provide rapid warm up and automatic temperature control. A dial type
indicator showing the coolant temperature at the hottest point of the cooling system shall
be provided.
The coolant system shall include at the highest level in the system a volume capacity
either in the upper part of the radiator or by a separate header tank to allow for coolant
expansion and make-up. A coolant level indicator shall be fitted.
The cooling system shall be provided with plugged valves as necessary to enable all
parts of the system to be drained.
20.6.7 Engine - Exhaust System
Each plant set shall be complete with all exhaust pipework including stainless steel
flexible exhaust piping or stainless steel bellows pieces from the engine and suitable
silencers either mounted above the engine or complete with the necessary brackets and
hangers for supporting from the enclosing structure.
The exhaust system shall be complete with all pipework, fittings and mountings to carry
the exhaust gases away from the enclosing structure. All pipework within the enclosing
structure shall be provided with efficient lagging.
The engine exhaust system shall be fitted with temperature indicators at the outlet of
each cylinder block manifold arranged so that the indicators may be satisfactorily
observed from floor level.
20.6.8 Engine - Speed Control
An electronic governor system shall be fitted to maintain engine speed and recovery time
within the limits of an approved international standard. The system shall be arranged
such that an adequate range of speed together with fine speed adjustment is obtained.
Means shall be provided for electrical remote control of the speed over a range of +5%
of the normal speed.
An entirely independent overspeed trip shall be fitted to shut down the engine if the
speed exceeds 10% above the normal speed. This device shall not operate if full load is
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suddenly thrown off the engine. Provision shall be included to provide a remote
electrical alarm. This overspeed safety trip shall be hand reset at the engine.
20.6.9 Engine - Starting
The engine may be started either electrically or by means of compressed air.
The starting system capacity shall be adequate to allow 6 consecutive start attempts
each of 15 seconds with 1 minute intervals.
After receipt of the starting signal, the starting system shall carry out all sequential
operations necessary to drive the unit up to normal voltage and frequency. In the event
of failure to start on the first starting control signal, the system shall automatically initiate
the starting sequence two further consecutive times with the appropriate time spacing.
Should no result be obtained the system shall prevent further starting attempts and actuate
a circuit to provide a 'Failure to Start' alarm.
It shall be possible by means of a selector to alter the starting sequence to provide a

single start attempt of up to 1 minute before lockout and alarm.
An engine shut down solenoid shall be fitted, this shall be of the "energised to run type"
for operation from the engine control system battery. An emergency stop push button
shall be provided.
Stopping shall be attained by interrupting the shut down solenoid circuit and this shall
also cancel any outstanding repeat start attempts.
If compressed air starting is provided, an electrically driven air compressor shall be

provided capable of recharging the air bottles automatically within 15 minutes. A hand
start diesel or petrol engined standby re-charging compressor shall also be provided.
The air system shall be complete with all valves, gauges and stainless steel or copper
pipework. The air supply vessel shall be located off the engine bed and shall comply
with an approved international standard. Means shall be provided whereby any
condensed water is automatically drained from the system. A pressure switch shall be
incorporated to provide a low air pressure alarm.
With air starting, an Alkaline type battery unit shall be provided suitable to energise the
diesel plant control system continuously for a minimum of 24 hours. This battery unit
shall be fitted with a voltmeter and means to provide remote alarm in the event of low
battery volts. Mains operated automatic high-low rate charging shall be included having
a charging ammeter to show high rate with an adjacent push switch which when held
depressed changes to low rate scale. A "No Charge" remote alarm circuit shall be
incorporated to operate after 15 minutes delay.
If electric starting is used an Alkaline type battery shall be provided together with rapid
recharge by means of an engine driven charging generator with automatic charging
control and cut-out and including a generator charging ammeter (which may be on the
'Engine Panel', referred to elsewhere). An automatic mains operated constant potential
type battery charger shall also be provided incorporating self- protecting current limiting
arrangements and shall also be suitable to remain connected to the battery when
charging is proceeding by the engine generator. The battery unit shall be fitted with a
voltmeter also a mains charging ammeter to show high rate with an adjacent push switch
which when held depressed changes to low scale. Means to provide remote alarm of
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low battery volts and "No Charge" shall be incorporated to operate after 15 minutes
delay excepting that the "No Charge" alarm shall not be given when generator charging
is proceeding.
The interconnecting cables between the starting battery and the engine starter shall be
provided.
The battery used for electric starting may also be used to energise the diesel plant
control system but shall have enough capacity remaining after three engine start
attempts to energise the control system continuously for 24 hours.
The control system shall be suitable to continue operating correctly during the voltage
dips occurring on the battery during the engine starts.
20.6.10 Engine Panel
A panel shall be provided on the engine unit, supported on anti- vibration mountings at a
convenient height and position for observation and operation and shall have on the panel
face:-
1. Lubricating oil pressure gauge

2. Lubricating oil temperature indicator
3. Fuel line pressure gauge
4. Coolant system temperature indicator
5. Engine stop push button
6. Charging Ammeter (Engine Generator)
7. Engine Speed Indicator with non-re-setable hours counter
(Mechanical Tachometer).
20.6.11 Engine - Safety Devices
The following safety devices shall be fitted and arranged to stop the engine:-
1. Oil pressure low

2. Oil temperature high
3. Coolant temperature high
4. Over speed
5. Fuel low.
20.6.12 Engine Wiring
All wiring associated with the engine shall be insulated with heat resistant type insulation
to an approved international standard for use at temperatures of up to 85oC 600/1000
volt grade. Conductor section shall be stranded and to suit the currents involved at the
ambient temperatures arising but not less than 1.5 mm2 excepting special types such as
compensated or screened cables.
All wiring on the engine (excluding starting cables) shall be brought out to a common
shielded terminal board mounted on the engine. Starting cables may be connected
directly to the items concerned on the engine.

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20.6.13 Alternator Output
The output shall be suitable for the load after the alternator has provided for its own
auxiliaries, and shall have an overload capacity of 10% for one hour at the ambient
conditions.
20.6.14 Alternator Construction

The alternator shall comply with an approved international standard and be of the
brushless self excited type fitted with heavy duty lubricant packed ball or roller bearings
to give at least 4000 hours running without attention. The machine shall be screen
protected and drip-proof to an approved international standard. The cooling air inlets
shall be screen protected at the end remote from the engine and shall be designed to
deflect and remove dust from the incoming air stream so that, as far as possible, it shall
be prevented from entering and accumulating within the ventilation spaces or elsewhere
where a build up of dust may be deleterious to the performance or reliability of the
machine. When specified outlet ducting shall be provided to duct the alternator cooling
air out of the building.
The frame of the alternator shall be fitted with lifting lugs or eye bolts to an approved
international standard.
20.6.15 Alternator - Terminals

Main terminal boxes shall be mounted on the alternator and shall contain both phase
and neutral terminals. The neutral end of each phase shall be brought to a separate
neutral terminal to facilitate testing of the windings and a neutral link bar provided. The
terminal box shall meet the requirements of an approved international standard.
The alternator frame shall be provided with a bolted earthing lug.
20.6.16 Alternator - Insulation
The alternator windings insulation and temperature rise shall be in accordance with an
approved international standard and de-rated to allow for the ambient conditions.
20.6.17 Alternator - Heaters
The alternator shall be fitted with 110V anti-condensation heaters. The connections to
these heaters shall be brought to a separate terminal box (or a separately enclosed
section in the main terminals box) and conspicuously marked to indicate the danger that
the terminals are likely to be alive from a separate supply.
20.6.18 Alternator - Waveform, Regulation and Radio Frequency Interference
The alternator waveform shall meet the requirements of an approved international

standard. Voltage regulation shall be controlled by an electronic type automatic voltage
regulator, the regulation shall be in accordance with an approved international standard.
Provision shall be included to ensure adequate excitation of the alternator under electrical
fault conditions such that the output current would be not less than 250% of full load
current to ensure the tripping of protective devices.
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Provision shall also be made for manual adjustment of the regulated output voltage over
the range of 10% above and 10% below the normal specified voltage.
Radio frequency interference suppression equipment shall be included as necessary for

electrical parts of the generator to ensure that interference levels conform to an
approved international standard.
20.6.19 Control Panel Construction
The panel shall be constructed generally as described for FBA’s and shall be suitable for
indoor installation in the ambient conditions separately specified, its construction shall be
such as to allow full accessibility from the front and to be suitable for mounting against a
vertical wall with no rear access. Floor fixing bolts shall be provided.
The panel shall be sealed so as to be substantially dust and vermin proof to the
requirements of an approved international standard. Cables will enter and leave from
the bottom. The panel shall be provided with a removable rustproof plated gland plate.
The Contractor shall provide and fit all necessary cable glands. The control panel shall
comply with the specification for FBA's as and where applicable.
20.6.20 Control Panel - Front Panel
The following shall be mounted on the front face of the panel at suitable viewing and
operating heights:-
1. Voltmeter and selector switch
2. Ammeter and selector switch (Suitable current transformers are to be provided

by the Contractor and located to suit the general layout, typically in the
alternator cable box).
3. Frequency meter (47 - 53 Hz)
4. Voltmeter for battery voltage

Ammeter for Battery Charge
Push switch for range change (If not fitted on a separate charging unit)
5. Selector switch, key operated, having positions:-
'Local' - 'Locked Out' - 'Remote' (Key to be removable in the 'locked out'

position only)
6. 'Raise/Lower' Alternator Voltage adjuster
7. Push buttons:-
'Increase Speed' (White)

'Decrease Speed' (White)
'Start' (Green)
'Stop' (Red)
'Sequence Reset' (White)
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'Lockout Reset' (White)

'Check Alarm' (Orange)
'Lamp Test' (White)
The 'start' push button to be functional only when the control selector switch is
at the 'Local' position.
8. Lamp Indications:-
'Alarm Checked' (Orange)

'Incomplete Starting Sequence (White)
'Overspeed' (White)
'Fuel Low Level' (White)
'Coolant High Temperature' (White)
'Lubricant High Temperature' (White)
'Lubricant Low Pressure' (White)
'Charging Fail' (If not on a separate charging unit) (White)
Push buttons and lamp indicators may be combined together where

appropriate (i.e. 'Check Alarm'/'Alarm Checked').
20.6.21 Control Panel - Alarm Annunciator

All alarms shall be displayed on an alarm annunciator which shall be mounted at the
front upper part of the panel. The alarm system shall be of the "first up" type and each
alarm shall be provided with a volt free SPDT contact for remote repeat alarm.
The annunciator shall be generally as described elsewhere.
20.6.22 Control Panels - General
Important Instruction
Generators shall not be provided with the manufacturers standard control panel. Printed
circuit boards and electronic components shall be kept to a minimum. All control
functions shall be effected by eight or eleven pin plug in relays and all push buttons,
lamps and fuses shall be as described else where. All control components such as
Automatic Voltage Regulator, Speed Controller, Frequency Controller, Over/Under Voltage
Controller, Pressure and Temperature Controllers, Level Controllers, Timers, Counters etc.
shall be separate, independent items fixed to the back plate and prominently labelled.
Each unit shall be individually removable and 100% spare units shall be provided. Under
no circumstances will a PCB or control unit which controls more than one function or
variable be acceptable.
The panel shall be designed and constructed such that a general electrician with no
electronics experience or knowledge and with the use of standard multimeter type
instrumentation only can carry out fault finding, maintenance and repair work with the
guidance of the Operation and Maintenance Manual.
The control panel shall contain the following items:-
1. Automatic voltage regulator (unless mounted on the generator unit) to be self

protected against under and over voltage and frequency.
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2. Battery charger (unless a separate unit).
3. Contactor for alternator anti-condensation heaters.
4. Emergency engine shutdown from alarms as listed elsewhere. Engine to be

'locked out' until the 'Lockout Reset' push button is operated. Lockout, to
provide contacts for the tripping of the generator (remote) circuit breaker.
5. Monitoring and control relays as necessary.
6. MCB cut-outs, fuses etc. as necessary.
7. Terminals as necessary, including for remote stop/start operation and

indication, remote speed control and voltage adjust and remote circuit
breaker trip, also terminals for anti-condensation heater and local supply
(separately enclosed and with warning label). All terminals to be coded in
accordance with an approved international standard.
8. Wiring, as necessary, PVC insulated of not less than 1.5 mm2. copper cross
section, to an approved international standard, with each conductor reference
coded at both ends for identification Green colour to be used for earth
circuits only.
20.6.23 Bulk Fuel Tanks
Bulk fuel tanks shall be as follows:-
i) Sufficient quantity to provide approximately seven days operation
ii) Manufactured in accordance with an approved international standard and be

fabricated from good commercial quality mild steel plate of minimum 5 mm
thickness, ends dished and flanged, electrically welded throughout and spatter
removed.
iii) Provided with a 480 mm diameter raised manhole with joint and 8 mm thick
bolted on cover.
iv) Provided with galvanised access ladder and platform to manhole
v) BSTP connections shall be provided for fill, vent, outlet and drain.
Receive approved corrosion protection appropriate to its location.
20.6.24 Fuel Transfer Pumps
Electric fuel transfer pumps, if necessary shall be of the progressive cavity type, self
priming and capable of achieving a suction lift of at least 7 metres. They shall be
capable of pumping approximately 400 litres of diesel fuel per hour from the bulk fuel
tank to the day tank. Two number shall be provided for each installation located
immediately below the day tank. They shall operate in an automatic duty/standby mode
with automatic interchange of duty to equalise wear.
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Manual fuel transfer pumps shall be of the self priming diaphragm type with detachable
handle arranged to pump diesel fuel from the bulk fuel tank to the day tank.
Provision shall also be made to pump fuel from the day tank to the bulk fuel tank to
empty the day tank for maintenance purposes.
20.6.25 Fuel System
The fuel system shall comprise the following:-
Fuel transfer pumps controlled by a float type level switch in the day tank.
Overflow back to the bulk fuel tank to be provided to guard against float switch failure.
Mesh type filters not coarser than 120 mesh to be provided on the draw-off line.
Free-fall fire shut-off valves to be fitted operated from the local fire alarm system (where
applicable) or a wire rope and heat sensitive fusible link.
Daily service tank to accommodate fuel for 8 hours running at full load.
Fuel supply piping system to be in suitably sized copper tubing.
20.6.26 Enclosure
Where specified the diesel generator shall be housed in a purpose built GRP enclosure
as follows:-
GRP fabrication as described elsewhere.
Protection against the ingress of dust and moisture to an approved international

standard.
Provide ample access for maintenance by way of hinged and removable covers
Controls, indication etc. to be enclosed in an integral panel with a polycarbonate hinged

clear cover.
Small power & lighting system as per GRP enclosures described for submersible
pumping stations.
In all cases the maximum sound level shall not exceed 85dbA at 1m radius from the
generator and/or enclosure.
20.7 FIRE ALARM AND EXTINGUISHING SYSTEMS
20.7.1 General
The Contractor shall arrange for an approved Sub-Contractor who shall be on the list of
Approved Contractors, to supply, install, wire and commission the complete
manual/automatic fire alarm system comprising manual fire alarm call points, alarm bells
and sounders, smoke and heat detectors and control panels as indicated on the
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drawings. The fire alarm system equipment shall be selected from equipment approved
by the Fire Department. The system shall be installed and maintained in accordance with
the recommendations of an approved international standard. The wiring shall be 1.5
mm2 MICC/PVC for bell and battery circuits.
20.7.2 Manual Fire Alarm Call Point

Manual fire alarm call points shall consist of a die cast plastic cover locked in position
with screws. The enclosure shall house a micro switch. The micro switch plunger shall
bear onto an inset break glass panel fixed into the cover. The call point shall be
arranged for surface mounting. The cover and the enclosure shall be self coloured red.
The words “BREAK GLASS FOR ALARM” shall be printed on the frangible glass. A
testing facility using a special key shall be provided to enable the call point to be tested
without breaking the glass and the frangible glass shall be covered with plastic film to
prevent injury when the glass is broken. The mounting height shall be 1500 mm above
finished floor level.
The switching unit contacts shall be gold or silver plated or an alloyed metal which will
not corrode when left unattended in a highly polluted environment. Contact blades and
other metal parts of the switching unit shall also be constructed from plated or alloyed
metal which will not corrode when left unattended. Contacts shall be normally open or
normally closed to suit the alarm monitoring system. The voltage and current rating of
the contacts shall be marked within the enclosure.
The call point shall comply with an approved international standard :Specification for
manual call points”.
The call point shall be resistant to the ingress of dust and water, and shall be suitable
for operation in the environmental conditions at the site of installation.
20.7.3 Optical Smoke Detector
Optical smoke detectors shall comply with an approved international standard.
20.7.4 Detector Base
An operation indicator lamp of the light emitting diode type and a time delay unit to
override spurious alarms shall be fitted to the base.
20.7.5 Fire Alarm Panel
The fire alarm panel shall be wall mounted adjacent to the motor control centre. The fire
alarm system shall protect risk areas within the premises by giving warning of a fire
condition relayed by an automatic detector or by the operation of a break glass callpoint.
Operation of an individual detector is to be displayed by an indicator fitted into the base
of the detector. This indicator will illuminate when its detector goes into alarm. Fixed
temperature heat detectors will not have this local indication facility. Upon receipt of an
alarm, the control units shall perform the following actions:
a) Illuminate fire zone detector

b) Activate alarm warning devices within the building
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c) Operate internal fire sounder

d) Operate ancillary devices as appropriate
Alarm warning devices shall be de-activated by operation of the “Silence Alarms” switch.
The internal sounder will continue to operate and the fire indicators remain lit until the
key switch controlled push switch is operated. This should only be achieved if the alarm
initiating device is no longer in alarm.
Reset of the controller, after the fire incident has been investigated, will be achieved by
operation of the “Reset” switch.
The enclosures of the panels shall be fabricated from sheet steel, minimum thickness
1.5 mm and shall be provided with a hinged lockable door. Protection to an approved
international standard shall be provided.
The control unit should be designed to comply with the compulsory requirements of an
approved international standard, relating to “Automatic fire alarm systems in buildings,
control and indicating equipment”.
Alarm panels shall as a minimum requirement be equipped with the following:
a) Mains supply on indicator

b) DC supply on indicator
c) DC supply faulty indicator
d) Alarm indicator for each zone
e) Alarm accept push-button to acknowledge fire alarm signals, silence external
audible alarms and energise as internal bleeper unit.
f) Reset push-button to restore monitoring systems to the quiescent condition
g) Integral sealed battery and trickle battery charger where appropriate
h) Alarm transmission facilities via the telephone alarm system
i) Terminations for incoming and outgoing wiring systems
j) Voltage free normally closed circuits which shall open in the event of an alarm
to shutdown ventilation and air conditioning equipment in the immediate
vicinity.
k) Suitable fault indication both visual and audible.
Alarm indicators shall be of the light emitting diode type. Indicators shall be provided in
pairs for each function.
Alarm panels shall continuously monitor all alarm circuits, including wiring and control
devices. When a fault monitoring circuit has been energised it shall not reset until the
fault condition is cleared.
Batteries shall be of the sealed lead acid type and shall have a capacity capable of
maintaining the system in normal working condition for at least 24 hours without
recharging and subsequently to operate in the alarm condition for at least one hour.
Battery charging to be of sufficient capacity to power the system whilst recharging a fully
discharged battery. The battery shall be fully charged within 8 hours.
Monitoring circuits shall utilise solid state components. Output relay contacts shall be
gold or silver plated and shall be rated for the circuit conditions into which they operate.

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Alarm bells shall be of the gong type with a minimum diameter of 200 mm. They shall be
continuously rated and be mounted 2200 mm above finished floor level.
Bells shall be marked with the words “FIRE ALARM”.
20.7.6 Fire Extinguishing Equipment

The Contractor shall supply and install in the respective positions:
2.5 kg hand held CO2 operated for extinguishers and 4.5 kg hand held dry powder type
fire extinguisher, suitable for Class A, B and C fire risks, flammable liquid, and fires from
electrical sources. The extinguisher shall comprise a light alloy or steel cylinder finished
in blue epoxy resin fitted with a controllable brass valve with pressure gauge or
aluminum head cap for CO2 operated cylinders. Valves to be fitted with safety pin
lever.
All equipment supplied shall be suitable for the high temperatures, humidities, and dusty
atmospheres experienced in Dubai, with a minimum jet range of 5-7m discharging in
approximately 15 secs.
All equipment supplied under this section shall be obtained from a company regularly
engaged in the manufacture and supply of fire protection equipment. It shall essentially
be a duplicate of equipment that has been in satisfactory use for not less than five years
prior to the bid date and be supported by an approved service organisation capable of
carrying out regular inspection and maintenance of fire protection systems.
All portable fire extinguishers shall be manufactured in accordance with an approved

international standard and are to be wall mounted on secure brackets with the base
approximately 760 mm above floor level.
Fire extinguishing devices shall be clearly and indelibly labelled with clear instructions for
their use in English, Arabic and pictorial form.
20.8 ACCESSORIES
The Contractor shall supply and install where specified the items listed below:
a. FIRST AID BOX - wall mounted first aid box marked with a red crescent and
containing:
40 nr individually wrapped adhesive dressings

2 nr sterile eye pads and bandages
2 nr sterile triangular bandages
6 nr safety pins
6 nr sterile unmedicated dressings No. 8
2 nr sterile unmedicated dressings extra large
1 nr roll elastic bandage 2 inch
1 nr pair scissors
1 nr eyebath
1 nr bottle eye wash solution
25 g cotton wool
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1 nr bottle antiseptic
1 nr card or booklet giving simple instructions
b. ELECTRIC SHOCK FIRST AID INSTRUCTION - Instructions in both English

and Arabic for the treatment of persons suffering from electric shock. The
instructions shall be printed on a substantial wall mounted plate with a wipe
clean surface.
c. DANGER NOTICE - Danger notices inscribed “DANGER DO NOT

OPERATE - MAN WORKING ON EQUIPMENT” in both English and
Arabic. The plates shall be of laminated plastic with white letters on a red
background and arranged to hang on isolator handles.
d. RUBBER GLOVES - One pair of heavy duty insulating rubber gloves. The
gloves are to be stamped with their date of manufacture and shelf life.
20.9 GAS DETECTORS
20.9.1 Portable Gas Detectors: General
The detector shall be housed in a robust case sealed to comply with an approved
international standard. The case shall be provided with harness-type straps to allow the
equipment to be worn. Alternatively, a purpose-made carrying case, also with harness
straps, shall be supplied. In use, such a carrying-case shall allow the display to be
clearly visible.
The detector shall be explosion proof with an internationally recognised certification as

“intrinsically safe” allowing use in hazardous areas. The detector shall be suitable for
gas groups commonly found at sewage treatment works.
The detector shall be powered by a rechargeable nickel cadmium battery pack which
shall be replaceable. A fully charged battery pack shall operate the detector continously
for a minimum of 10 hours. In use, low battery power shall initiate an audible alarm.
The detector shall incorporate sensors to detect gas concentrations and initiate alarms
as follows:
Mode display range alarm initiate

combustible gas or 0 - 100% by volume of air, calibrated > 20%
vapour for methane
hydrogen sulphide 0 - 25 ppm >10 ppm
Oxygen 0 - 25% by volume of air >24%
<19%
The display may be switchable between the three modes. However, should any one of
the three gas hazards occur, a warning lamp shall light and an audible alarm shall
sound, irrespective of the position of the switch.
Due to the limited life of gas sensor cells, the cells in the detector or any spare cells
provided shall be less than 3 months old at the time of handover to the employer. Each
cell shall have its date of manufacture indicated on its cover.

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The detector shall be provided with an extension tube 2 m long and manual pump for
sampling inaccessible places.
Only equipment which is supported by a service workshop in Dubai authorised by the

manufacturer shall be provided.
20.9.2 Portable Gas Detector
One complete set of portable gas detection equipment shall comprise:
1 nr Portable gas detector complete with sensors for combustible gas,

hydrogen sulphide and oxygen, and including rechargeable battery pack,
harness/carrying case and extension tube.
1 nr Single way charger to suit above battery pack
1 nr Stainless steel probe for extension tube
Test gases in 20 litre canisters:
1 nr 2.5% methane in air
1 nr 25 ppm hydrogen sulphide in air
1 nr 17% oxygen in nitrogen
1 No. box to house above equipment, suitable for wall mounting and labelled
“Portable Gas Detector”.
20.10 SURGE
The Contactor shall be responsible for supplying suitable pumping plant and surge
suppression equipment (if any) to ensure that transient pressure surges do not exceed
the following limits:
a) less than – 5m head at any point along the pumping main
b) greater than 50% of the pressure rating of pipes and fittings installed on the
pumping main.
These limits shall not be exceeded under any condition of normal working or power
failure.
The Contractor shall include for all necessary surge suppression equipment. The
equipment (if any) should be compatible with the characteristics of the pumping plant
proposed. It is therefore recommended that the Contractor should perform his own
assessment of the pressure transients.
To confirm the results of his initial assessment, the Contractor shall instruct the pump
manufacturer to carry out a comprehensive pressure surge analysis on the complete
hydraulic pumping system under all operating conditions, and submit three copies of a
report and calculations on the surge in the system within 3 months of contract
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commencement to enable surge suppression equipment to be manufactured in time for

delivery and installation if found necessary.
APPROVED INTERNATIONAL STANDARDS
BS 649
BS 800
BS 2594
BS 2869
BS 3116
BS 4278
BS 4999
BS 5000
BS 5169
BS 5266
BS 5304
BS 5345
BS 5420
BS 5423
BS 5445
BS 5472
BS 5501
BS 5514
BS 5559
BS 5839
BS 6746
BS 6899


DISTRICT ONE – PHASE 3B – 3B EXTENSION AND 3C
ROADS AND UTILITIES

VOLUME 2 – PART IV
APPENDIX TO DUBAI MUNICIPALITY SEWERAGE AND
DRAINAGE SPECIFICATIONS

20010410
JUNE, 2022
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications


Architectural
Volume 5 Soil Investigation Report and Project Environmental

and Health & Safety Requirement
AE7 PROJECT NO. 20010410 ii REV 1 – ISSUED FOR CONSTRUCTION

VOLUME 2 – PART IV DATE OF ISSUE: 16 JUNE, 2022
APPENDIX TO DUBAI MUNICIPALITY
SEWERAGE AND DRAINAGE SPECIFICATIONS
DUBAI – UAE
MEYDAN GROUP LLC
Project: 20010410
Roads and Utilities
Volume 2 – Part IV

Table of Contents
APPENDIX NO.2 - TESTING AND WORKMANSHIP OF IN-SITU LINING MATERIALS ......... 1

1. PERFORMANCE REQUIREMENTS ...................................................................................... 1
2. TYPE TESTS ............................................................................................................................... 1
2.1 GENERAL ................................................................................................................................. 1
2.2 SHORT TERM FLEXURAL (BENDING) PROPERTIES ................................................. 1
2.3 FLEXURAL CREEP MODULUS........................................................................................... 2
2.4 TENSILE PROPERTIES ........................................................................................................ 2
2.5 COMPRESSIVE PROPERTIES ........................................................................................... 2
3. QUALITY CONTROL TESTS ..................................................................................................... 2
3.1 GENERAL ...................................................................................................................................... 2
3.2 SAMPLES FOR QUALITY CONTROL TESTS.................................................................. 3
3.4 WALL THICKNESS ................................................................................................................. 3
3.5 TENSILE PROPERTIES ........................................................................................................ 3
3.6 SHORT TERM FLEXURAL (BENDING) PROPERTIES ................................................. 4
4. CONTROL OF TEST CONDITIONS ....................................................................................... 4

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4.1 TEST CONDITIONS ............................................................................................................... 4

4.2 SPECIMEN CONDITIONING................................................................................................ 4
5. WORKMANSHIP, INSPECTION AND CERTIFICATION ................................................... 4
5.1 WORKMANSHIP ..................................................................................................................... 4
5.2 5INSPECTION .......................................................................................................................... 5
5.3 5CERTIFICATION.................................................................................................................... 5
6. 5REFERENCES ....................................................................................................................... 5
APPENDIX NO.3 MANHOLE ENTRY ............................................................................................... 7
3.1 LIFTING MANHOLE COVERS ............................................................................................. 7
3.2 ENTERING MANHOLES - RAT POISON .......................................................................... 8
3.3 ENTERING MANHOLES ....................................................................................................... 8
3.4 ENTERING LOW RISK MANHOLES .................................................................................. 9
3.5 ENTERING HIGH RISK MANHOLES ............................................................................... 10
3.6 ACCESS TO ELEVATED MANHOLES AND SEWERS ................................................ 11
3.7 MANHOLE ENTRY - EMERGENCY PROCEDURE ...................................................... 11
3.7A PUMPING STATION CHAMBERS AND SUMP ENTRY ........................................... 13
3.8 ESSENTIAL MINIMUM SAFETY EQUIPMENT .............................................................. 14
3.8.1 FOR LIFTING MANHOLE COVERS ............................................................................. 14
3.8.2 FOR ENTERING LOW RISK MANHOLES OR WATERCOURSE CULVERTS
WITH OPEN ENDS. .......................................................................................................................... 14
3.8.3 FOR ENTERING HIGH RISK MANHOLES AND CONFINED SPACES
ASSOCIATED WITH ........................................................................................................................ 14
PUMPING STATIONS ...................................................................................................................... 14
3.8.4 FOR ENTERING SEWERS ............................................................................................. 15
3.9 HIGH PRESSURE WATER JETTING ............................................................................... 15
3.9.1 EQUIPMENT ...................................................................................................................... 15
3.9.2 PROTECTIVE CLOTHING .............................................................................................. 16
APPENDIX N0.4 ................................................................................................................................... 17
STANDARD DETAILS FOR SEWERAGE & DRAINAGE .............................................................. 17
01. GENERAL NOTES 1 .................................................................................................................. 17
02. GENERAL NOTES 2................................................................................................................... 18

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100. FLEXIBLE PIPE INSTALLATION ......................................................................................... 18

201. SEWERAGE MANHOLE SELECTION AND DIMENSIONS .............................................. 19
202. GENERAL SEWERAGE MANHOLE DETAIL ..................................................................... 20
203. SEWERAGE MANHOLE TYPE 'SPECIAL' PLAN ............................................................. 21
204. SEWERAGE MANHOLE TYPE 'SPECIAL SECTION A- 1 ............................................ 23
205. SEWERAGE MANHOLE TYPE ‘SPECIAL’ STRUCTURAL REINFORCEMENT ....... 24
206. SEWERAGE MANHOLE TYPE ‘A’ PLAN ........................................................................... 25
207. SEWERAGE MANHOLE TYPE 'A' SECTION A-A............................................................. 26
208. SEWERAGE MANHOLE TYPE ‘A’ STRUCTURAL REINFORCEMENT ...................... 27
209. SEWERAGE MANHOLE TYPE ‘B’ PLAN ........................................................................... 28
210.SEWERAGE MANHOLE TYPE 'B' SECTION B-B ...................................................... 29
211. SEWERAGE MANHOLE TYPE 'B' SECTION C-C............................................................ 30
212. SEWERAGE MANHOLE TYPE 'B' STRUCTURAL REINFORCEMENT ...................... 31
213. SEWERAGE MANHOLE TYPES 'C' & '0' PLAN .............................................................. 32
214. SEWERAGE MANHOLE TYPES 'C' & 'D' SECTION D-D ............................................... 33
215. SEWERAGE MANHOLE TYPES 'C' & 'D' SECTION E-E ................................................ 34
216. SEWERAGE MANHOLE TYPES 'C' & 'D’ STRUCTURAL REINFORCEMENT (SHEET
1 OF 2) ................................................................................................................................................ 35
217. SEWERAGE MANHOLE TYPES 'C' & 'D’ STRUCTURAL REINFORCEMENT (SHEET
2 OF 2)................................................................................................................................................. 36
218. SEWERAGE MANHOLE TYPES 'E' & 'F'- PLAN ............................................................ 37
219. SEWERAGE MANHOLE 'E' & 'F' - SECTION F-F ............................................................ 38
220. MANHOLE TYPES 'E' & 'F' STRUCTURAL REINFORCEMENT (SHEET 1 OF 2) ... 39
221. MANHOLE TYPES ‘E' & 'F' STRUCTURALREINFORCEMENT (SHEET 2 OF 2)
.............................................................................................................................................................. 40
222. SEWERAGE MANHOLE COVER INSCRIPTION.............................................................. 41
223. TYPICAL BACKDROP CONNECTION ................................................................................ 42
224. INTERNAL BACKDROP CONNECTION ............................................................................. 43
301. HOUSE CONNECTION CHAMBER TYPE 'A' ................................................................... 44
302. HOUSE CONNECTION CHAMBER TYPE 'B' .................................................................. 45
303. HOUSE CONNECTION CHAMBER TYPE 'B' STRUCTURAL REINFORCEMENT . 46

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304. HOUSE CONNECTION CHAMBER TYPE 'C' ................................................................... 47

305. HOUSE CONNECTION CHAMBER TYPE 'C' STRUCTURAL REINFORCEMENT .. 48
306. VENT PIPE ARRANGEMENT................................................................................................. 49
401. STORM WATER DRAINAGE PIPE INSTALLATION ........................................................ 50
402. SLOTTED LAND DRAIN WITH GRAVEL TRENCH .......................................................... 51
403. LAND DRAIN AND CARRIER MAIN IN A COMMON TRENCH ..................................... 52
404. STORM DRAIN MANHOLE WITH LAND AND CARRIER MAIN ...................................... 53
501. STORM WATER DRAINAGE MANHOLE SELECTION AND DIMENSIONS ................. 54
502. STORM WATER DRAINAGE GENERAL MANHOLE DETAIL ....................................... 55
503. STORM WATER DRAINAGE MANHOLE TYPE 'G' PLAN ............................................. 56
504. STORM WATER DRAINAGE MANHOLE TYPE 'G' SECTION A-A .............................. 57
505. STORM WATER DRAINAGE MANHOLE TYPE 'G' STRUCTURAL
REINFORCEMENT .......................................................................................................................... 58
506. STORM WATER DRAINAGE MANHOLE TYPE ‘H’ PLAN.............................................. 59
507. SECTION SECTION B-B ........................................................................................................ 60
508. STORM WATER DRAINAGE MANHOLE TYPE 'H' SECTION C-C .............................. 61
509. STORM WATER DRAINAGE MANHOLE TYPE 'H' STRUCTURAL
REINFORCEMENT ........................................................................................................................... 62
510. STORM WATER DRAINAGE MANHOLE TYPES ‘I' & 'J' PLAN ............................... 63
511. STORM WATER DRAINAGE MANHOLE TYPES 'I' & 'J' SECTION D-D .................. 64
512. STORM WATER DRAINAGE MANHOLE TYPES 'I' & 'J' SECTION E-E .................... 65
513. STORM WATER DRAINAGE MANHOLE TYPES 'I' & 'J’ STRUCTURAL
REINFORCEMENT ........................................................................................................................... 66
(SHEET 1 OF 2) ................................................................................................................................ 66
514. STORM WATER DRAINAGE MANHOLE TYPES 'I' & 'J' STRUCTURAL
REINFORCEMENT (SHEET 2 OF 2) ......................................................................................... 67
515. STORM WATER DRAINAGE MANHOLE TYPES 'K' & 'L' PLAN .................................. 68
516. STORM WATER DRAINAGE MANHOLE TYPES 'K' & 'L' SECTION F-F.................... 69
517. STORM WATER DRAINAGE MANHOLE TYPES 'K' & 'L' STRUCTURAL
REINFORCEMENT (SHEET 1 OF 2) ............................................................................................ 70
518. STORM WATER DRAINAGE MANHOLE TYPES 'K' & 'L' STRUCTURAL
REINFORCEMENT (SHEET 2 OF 2) ............................................................................................ 71

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600. GULLY AT UPSTAND KERB .................................................................................................. 72

601. REMOVABLE BASKET ........................................................................................................... 73
602. UPSTAND KERB ...................................................................................................................... 74
603. KERB SECTION WITH SIDE ENTRY GULLY .................................................................... 75
604. GULLY CONNECTED TO CARRIER W/ TRAFFIC LOAD................................................. 76
605. GULLY CONNECTED TO LINE W/O TRAFFIC LOAD .................................................... 77
701. CONCRETE BED AND SURROUND TO PIPES ............................................................. 78
702. CONCRETE SURROUND FOR PIPES WITH COUPLINGS .......................................... 79
703. PROTECTION SLAB TO PIPES .......................................................................................... 80
704. PIPE CONNECTION AT STRUCTURES ............................................................................ 81
705. EXTERNAL WATERPROOF TANKING TO MANHOLES ....................................... 82
706. WATERPROOF TANKING DETAILS TO MANHOLES (SHEET 1OF 2) ........... 83
707. WATERPROOF TANKING DETAILS TO MANHOLES (SHEET 2 OF 2) ..................... 84
708. SAFETY CHAIN ........................................................................................................................ 85
709.PROTECTIVE WARNING TAPE ....................................................................................... 86

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APPENDIX NO.2 - TESTING AND WORKMANSHIP OF IN-SITU LINING MATERIALS
1. PERFORMANCE REQUIREMENTS
The lining shall meet the minimum requirements given in Table 1 when tested in
accordance with those clauses indicated.
Minimum Test
Property Requirements Clause
Short term 2200 MPa 2.2

bending modulus
--------------------------------------------------------------
50 year flexural As agreed with 2.3
creep modules purchase but not
less than 500 Mpa.
2. TYPE TESTS
2.1 General
The test given in 2.2 to 2.5 shall have been satisfactorily completed before lining
can claim to have met this specification. All combinations of wall thickness,
constituent materials, material proportions and curing methods shall be tested.
Should there be any modifications to these, the tests must be repeated.
The Quality Assurance Schedule of the quantity system (see 3.1) may require type
tests to be repeated at specified intervals.
All tests are the responsibility of the Contractor. Details and results for type tests
relevant to each material composition and manufacturing process shall be made
available to the Engineer or his representative on request.
Samples used for testing should be flat and formed in moulds but otherwise must be
manufactured and cured in an identical manner to the lining with which they are to
be identified or taken from site on the intermediate manholes.
2.2 Short term flexural (bending) properties
The initial tangent flexural modules of elasticity, flexural stress and strain at failure
shall be determined in accordance with the procedure described in BS 2782:
Method 335A using a cross head displacement rate of 10 mm/min.
Each test piece shall be tested with the impermeable membrane in contact with the
load bearing supports.
The flexural properties of each test piece shall not be less than the following
requirements:

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Initial tangent flexural modulus 2600 MPa
Flexural stress at first break * 50 MPa
Flexural strain at first break * 1.0% to 2.5%
(* as indicated by the first discontinuity of the force/extension curve).
2.3 Flexural Creep Modulus
The lining material shall meet the requirement of Table 1 when tested under
aqueous conditions in accordance with the method described in Clause 7 of IGN-4-
34-04.
2.4 Tensile Properties
The tensile strength, initial tangent modules of elasticity and elongation at first break
shall be determined in accordance with BS 2782: Method 1003 using Type II or
Type III test pieces, a grip separation rate of 2 mm/min. and either an optical or
strain gauge extensometer.
The tensile properties of each test piece shall not be less than the following
requirements:
Initial tangent tensile modulus 1700 MPa
Tensile stress at failure 25 MPa
Elongation at first break * 1.0 %
(* as indicated by the first discontinuity to the force/extension curve).
Results from samples breaking within 10 mm of the grips shall be discarded and the
test repeated with the occurrence being recorded.
2.5 Compressive Properties
The compressive strength shall be determined in accordance with BS 2782 :

Method 345A using Type IV tests pieces and a cross head displacement of 0.5h
mm/min where h is the height of the test sample in mm. The compressive strength
shall not be less than 60 MPa.
3. Quality Control Tests
3.1 General
The test requirements of 3.2 to 3.6 are necessary in order to demonstrate a

continuing satisfactory level of production and installation quality in day to day
production. The Contractor shall establish a quality system to meet the
requirements of BS 5750: Part 2.
Quality control tests shall be carried out by the manufacturer on each lining length
after it has been installed and cured. If any of the tests are failed the Engineer shall
be informed immediately.
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3.2 Samples for Quality Control Tests
3.2.1 For each lining length one sample shall be fabricated and cured in a clamped
mould using the methods detailed in Clause 8 of IGN 4.34.04.
When curing of the lining has been completed the mould samples shall be
removed and subjected to quality control testing. With the exception of the wall
thickness requirement (3.4), if all tests are passed then no further quality control
testing is required.
3.2.2 Unless otherwise approved by the Engineer, provision shall be made to suitably
support the lining bag either at the ends or at intermediate manholes. In cases
where disagreement or dispute exists over the results obtained from the clamped
sample, these samples or samples cut from the installed lining (removed at the
Contractor's cost) shall be used for repeat testing as required in 3.6.2. For test
purposes attention is drawn to the curvature limitations and orientation
requirements of samples taken from linings.
All cut away material shall be marked to indicate its place of origin and shall be
stored until the linign length has been tested and accepted as meeting the quality
control test requirements.
3.2.3 Should there be any disagreement following testing performed on samples

described in 3.2.2 then at the Contractor's discretion and cost either:
(a) the creep modulus shall be validated against the Contractor's creep data
obtained for 2.3 using an abridged creep test on material removed from the
lining, or
(b) the lining shall be replaced.
3.3 Visual Examination
After installation each lining shall be visually examined by CCTV. The

installation lining shall have a smooth internal surface which shall be generally
free from wrinkles.
3.4 Wall Thickness
The minimum wall thickness shall be determined at a minimum of five locations

on a cut section of the lining using a method of measurement accurate to the
nearest 0.1 mm. The minimum value shall meet the requirements of
Specification Clause 14.3.4.1.
Samples from the clamped mould shall also meet the requirements of
Specification Clause 14.3.4.1.
3.5 Tensile Properties
The tensile strength, initial tangent modulus of elasticity and elongation at first
break of at least five samples shall be determined in accordance with BS 2782:
method 1003 using Type II or Type III test pieces, a grip separation rate of
2mm/min. and either an optical or strain gauge extensometer. The tensile
properties shall not be less than the minimum requirements set down in 2.4.

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3.6 Short Term Flexural (bending) Properties
3.6.1 For normal quality control testing using clamped mould samples:-
A minimum of five samples shall be tested by the method prescribed in 2.2 with
the impermeable membrane of the sample in contact with the load bearing
supports.
The samples shall comply with the requirements of 2.2.
3.6.2 For repeat testing referred to in 3.2.2.:-
Where practicable, unless otherwise approved by the Engineer,a minimum of

five test pieces shall be prepared.
Wherever possible, samples for test purposes shall have a radius of curvature
not less than 250mm and be taken from the hoop direction. However, for linings
where hoop samples cannot meet the curvature requirements, samples may be
taken from the longitudinal direction.
When tested by the method prescribed in 2.2 with the impermeable membrane
in contact with the load bearing supports, the samples shall comply with the
requirements of Table 1.
4. CONTROL OF TEST CONDITIONS

4.1 Test Conditions
Unless otherwise required by this specification the test measurements shall be

conducted at a temperature of 33 ± 2 C.
4.2 Specimen Conditioning
4.2.1 For type in air (or in any case of disagreement) specimens shall be kept in air at
23 ± 2 C for not less than 88 hours prior to testing.
4.2.2 For quality control testing, specimens shall be kept in air at 23 ± 2 C for not
less than 12 hours after they are considered to be cured.
4.3 Test Specimen Preparation
For mechanical tests, specimens shall be machined following the

recommendations of BS 2782: Method 930A.
5. WORKMANSHIP, INSPECTION AND CERTIFICATION
5.1 Workmanship
All raw materials shall be tested at a frequency sufficient to ensure consistency

and compliance with this specification.
The Contractor shall adequately supervise all stages of production and keep
records of the raw material batches used and products made each work shift or
day.

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Manufacture shall be under environmental conditions compatible with producing

satisfactory lining and raw materials shall be stored and used in accordance
with the recommendations of their manufactures.
The lining manufacturer shall be familiar with the changes in viscosity, gel time,
etc., which may occur during storage of the resin and make appropriate
allowance in the lining manufacturing process. Resin stored in original
unopened containers shall not be used after the resin manufacturer's stated
keeping period required by clause 4 of BS 3522: 1962. The guidance of the
resin manufacturer shall be sought and followed for the useful life of resin
delivered by tanker. Tanks used for bulk storage of polyester resin must be
inspected regularly and checked for contaminants.
Note:(For guidance only) A well cured polyester in-situ lining would be

expected to have a Barcol hardness of not less than 35 when tested in
accordance with BS 2782: Method 1001. Lining samples should be abraded to
remove the soft impermeable membrane and to produce a flat surface before
testing.
5.2 Inspection
In addition to the Contractors own inspection and supervision, the Engineer
shall have access at all reasonable times to those parts of the manufacturer's
works engaged on production and testing of linings and to all relevant test
records.
5.3 Certification
The Contractor shall, on request, furnish the Engineer with copies of signed
certificate for each size and classification of lining, stating that the construction
and testing of the lining supplied comply with the requirements of this
Specification and giving details of minimum performance parameters. If
required by the Engineer, the quality control test results or a suitable summary
shall be provided with the certificate.
6. REFERENCES
This specification makes reference to the latest editions of the following
publications (except where otherwise indicated) including all addenda and
revisions:
BS 2782 Methods of testing plastics

Method 121A Determination of temperature ofdeflection under
a bending stress of 1.8 MPa, of plastics and ebonite.
Method 335A Determination of flexural properties of rigid

plastics.
Method 345E Determination of compressive properties by

deformation at constant rate.
Method 432B Determination of the acid value of unsaturated

resins.
Method 432C Determination of the hydroxyl value of

unsaturated polyester resins.
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Method 620A Determination of density of solid plastics

excluding cellular plastic (immersion method).
Method 930A Preparation of test specimens by machining.
Method 1003 Determination of tensil properties
BS 3532 Unsaturated polyester resin systems for low

pressure fibre reinforced plastics.
BS 4618 Recommendations for the presentation of
plastics design data.
Sub-section 1.1.2:1976. Creep in flexure at low strains.

BS 5750 Quality Systems
Part 2 : Specification for manufacture and installation.
IGN 4.34.04 - Specification for Polyester Insituform

Sewer Linings

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APPENDIX No.3 MANHOLE ENTRY

(INCLUDING ELEVATED MANHOLES AND ACCESS TO ELEVATED SEWERS)
In deciding manning levels account must be taken of the location of manholes

and sewerage facilities in relation to availability of means of summoning
assistance in emergencies.
3.1 Lifting Manhole Covers
Place traffic signs in accordance with regulations if the cover is in the Highway.
Unattended open manholes must be safely protected by suitable barriers.

Remember that some people are visually handicapped.
Whenever possible covers shall be lifted using lifting keys and proper lifting and
handling techniques or by the use of a hydraulic or other approved manhole
lifting device.
Many accidents have been caused due to the misuse of tools while attempting
to free tight covers. A large proportion of these accidents have been associated
with the misuse of chisels and hammers. Sledge hammers should only be used
to 'shock' a cover into vertical movement by blows to the cover, they should
never be used to hit chisels, etc. Chisels, should not be allowed to become
burred over.
The following is the approved method for lifting tight covers:-
a) Clean out any gap between cover and frame and clean keyholes using
suitable handtools without the application of force in the form of
hammering unless a seaming chisel is used with a small hammer in
order to clear the gap.
b) Strick the cover using a sledge hammer in order to move the cover and
assist penetration of the water and/or using a properly tempered (not
brittle) chisel, hammer the chisel into the gap between cover and frame
using a lump hammer of no more than 4 lb. weight. The striker of the
chisel must hold the chisel with one hand. Do not strike a chisel held by
someone else and do not strike a chisel when it is wedged to the point
where it is under great stress signified by rapid increased in the pitch of
the sound when it is struck. When using a chisel always wear safety
goggles, and ensure that other persons are not exposed to danger or
loss.
c) Apply the hydraulic lifter or other approved lifting equipment and attempt
to lift the cover. If the cover does not lift repeat the above procedure.
Extra lift can also be achieved by the use of a long bar (about 1.2m long)
passing through the eye of the ring type manhole keys and levering onto
a block of wood resting on the ground adjacent to the cover.

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Patient application of the above will safely remove most covers. If a cover
does not lift after applying the above procedure several times the cover
needs to be dug out.
When lifting covers wear protective clothing as specified.
3.2 Entering Manholes - Rat Poison
Protective clothing should be worn when entering manholes and a watch

should be kept for any poisons. On no account should rat bait be touched. If
protective clothing is accidentally contaminated wash the clothing down
thoroughly before removal and do not touch the contaminated parts with
exposed skin. If rat bait is seen and work cannot be completed without risk of
contacting the bait the manhole should be first jetted clean before entering. If
rat bait is removed, the Contract manager shall be informed. Wear appropriate
clothing. Do not touch dead rats, remove with a shovel and bucket.
3.3 Entering Manholes
The entry requirements for manholes and chambers have been selected on a
basic risk element and are divided into two types entitled 'Low Risk' and 'High
Risk'.
Low Risk
Access applies to shallow manholes with small diameter pipes where there is
little risk of falling or being swept away.
High Risk
Access applies to deep manholes with any pipe size or shallow manholes with
a large diameter pipe where there is a greater risk of falling or being swept
away.
The factors differentiating between 'Low' and 'High' risk entry is as below and all
the listed conditions must apply.
Low Risk Conditions
i) Chambers with good access

ii) Depth not exceeding 3.0m (10')
iii) Sewers not exceeding about 375mm (15") diameter or up to 1.5m
(5')diameter if the flow is very low in both depth and velocity.
High Risk Conditions
i) Chambers with poor access

ii) Depth greater than about 3.0m (10') but less than about 7.0m (22'6")
iii) Sewers exceeding about 375mm (15") diameter
Note:All Trunk Sewers 1.5m (5') diameter or over and manholes deeper that
7.0m (22.'6")require a Permit to Work.
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3.4 Entering Low Risk Manholes
i) With approved winching system
Where entry into low risk manholes require the operative to work at the
point of entry the operative must be attached to an approved winching
system at all times.
Minimum number of men 2.
ii) Without approved winching system
Lifting Manhole Covers, Entering Manholes and Chambers with good

access not exceeding 3.0m (10') deep on sewers not more than 375mm
(15") in diameter.
a) Locate nearest usable telephone or if available usable radio

telephone set, before entering the manhole.
b) Lifting Cover - comply with Sections 3.1 and 3.2.
c) Before entering the manhole ensure that the cover has been
removed to give natural ventilation for a minimum of 5 minutes.
d) Test for Toxic and Flammable Gases, and Oxygen deficiency, using
approved detector. If Toxic and Flammable Gases or Oxygen
deficiency is detected do not enter manhole and inform your
Supervisor.
e) When in the manhole keep the gas detector, with you (switched
on). Leave the manhole immediately if the alarm sounds and inform
your Supervisor.
f) Wear protective clothing as appropriate.
g) Use safety equipment as specified.
h) Do not enter the manhole if access is bad. Take the following

factors into account when considering access:-
i) Size of access hole and shaft.
ii) Presence of standing water in manhole.
iii) Structural condition of manhole.
iv) Visibility in manhole.
v) Position and condition of step irons/ladders.
If access is bad or there are other reasons for not entering the
manhole report to your Supervisor who if necessary will assign
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another man or appropriate equipment to your gang so that

manhole entry can be attempted using the working methods
specified in Section 3.5. A permit to work may be required.
i) It is essential that rapid egress from the manhole can be achieved

without panic if the gas alarm sounds. If the manhole is on a storm
overflow chamber or other lateral chamber the chamber itself should
only be entered providing there is no appreciable fall risk and
providing a source of fresh air can be contacted within a few
seconds of the gas alarm being sounded.
j) Particular care should be taken in entering manholes. The next

foothold should be tested with a large proportion of bodyweight
before relinquishing a firm support from other points.
k) If the manhole is less than approximately 3m (10') deep and has

good access but a pipeline of 375mm (15") or more in diameter, the
manhole itself can be entered providing the above is complied with
and providing the sewer is not steep and is dry or almost dry.
3.5 Entering High Risk Manholes
Entering Manholes and Chambers more than 3m (10') deep or with poor
access or on sewers of 450mm (18") or more in diameter.
a) Comply with 3.4 a),b),c),d),e) f), g), h) and i).
b) When entering the manhole wear full safety harness and line supported
by two topmen or by one topman and approved winching system.
c) Only relinquish the security of your lifting line where:-
i) No fall risk is present.
ii) There is no danger of being swept downstream.
iii) Safety chains (where available) have been fixed or alternatively

mechanical struts have been placed across sewer entrances.
d) Do not at any time leave the manhole bottom without being attached to
your lifting line unless you have a source of fresh air available within a
few seconds. This means that if you leave the security of your lifting line
wear approved BA escape equipment.
e) Do not enter any sewers.
f) The topman/men must remain at the top of the manhole at all times
when a person is in the manhole.
g) Do not enter any manhole over approximately 7m (22'6") deep
- Permit to Work required.

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h) Do not enter a manhole where visibility is bad due to steam, spray,

etc. Report this to your Supervisor.
i) Do not enter any manhole without step irons or fixed ladder unless a
ladder can be placed. If there are no or few step irons and a ladder
cannot be placed, a Permit to Work is required.
3.6 Access to Elevated Manholes and Sewers
a) Elevated Manholes
When elevated manholes require to be entered suitable and safe

access to the cover must, so far as is reasonably practicable, be
provided. Generally, this will apply to manholes protuding above ground
level by more than one metre and will take the form of scaffolding
erected in accordance with regulations.
b) Elevated Sewers
When a sewer is at such a level above ground as to make it

unreasonable to work on the sewer while standing at ground level then
a ladder must be used.
If the height is such (1.98m [6'6"]) that a ladder cannot be used than
scaffolding must be used.
If this is not practicable then slung or suspended scaffolds, boatswains

chairs or similar must be used.
In all the above cases the Construction Regulations 1961 and 1966
must be observed. Supervisors must have a copy of the Construction
Regulations Handbook.
3.7 Manhole Entry - Emergency Procedure
NOTE:This emergency procedures assumes that approved working methods

have been used and that personnel are wearing specified safety
equipment, and using and/or deploying safety equipment as required by
the appropriate safe methods of working.
The following emergency situations:-
a) The presence of flammable and toxic gases or Oxygen Deficiency

Alarm.
b) Collapse of person at bottom of manhole.
are considered below where the approved response is

described in different working circumstances.
a) Work Circumstance - Low Risk Manhole Entry
1. Emergency - Flammable and toxic gases or Oxygen

Deficiency Alarm.
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Response - i) Bottom man must don Escape Set

immediately and leave manhole.
ii) Report alarm to supervisor or to base and warm

anyone else known to be working in the vicinity.
2. Emergency - Collapse of Operative
Response - If an operative collapses a rapid assessment by

the topman needs to be carried out. This
assessment will be based upon two prime factors
a) If the casualty is conscious
b) If the casualty is unconscious
a) If the casualty is conscious
i) Topman to inform emergency services immediately.
ii) Topman to monitor and reassure the casualty.
iii) When emergency services arrive, topman to give details of

situation.
b) If the casualty is unconscious
i) If the gang consists of two men then an approved winching

system must be used. The topman must immediately winch
the casualty clear of the confined space and place him in a
safe area.
ii) If the gang consists of three men without an approved

winching system the two operatives must remove the casualty
to a safe area.
iii) Once the casualty is clear of the confined space a rapid

assessment must be made of his condition i.e. ascertain as to
whether he is breathing, or his heart has stopped.
NOTE: Operators should be trained in basic first aid and

resuscitation.
iv) An operative must then radio or telephone for ambulance

assistance and return to casualty.
b) Work Circumstances- High Risk Manhole Entry -

Three Man Gang Plus Approved
Winching System
1) Emergency - Gas or Oxygen Deficiency Alarm
Response -
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i) Bottom man must don mask of Escape Set and must leave
manhole immediately.
ii) Report alarm to supervisor or to base and warn everyone

else known to be working in the vicinity.
2) Emergency - Collapsed Person at bottom of Manhole
Response -
i) The topman must immediately winch the bottom man out of

the manhole and pull him onto the ground adjacent to the
manhole.
ii) If the man recovered from the manhole is not breathing,

artificial respiration must be applied.
iii) Ensure that the casualty is laid on his side in a safe

comfortable position, with the head in such a position that
breathing is easy, is not slumped forward or back.
iv) Where the casualty cannot be winched out of th manhole, and

has stopped breathing, resuscitation should be applied. An
operative should stay with the casualty with gas detector
continuously monitoring and breathing apparatus to hand until
the emergency services arrive.
v) The topman must radio or telephone for Ambulance

assistance. See below "Communicating with Base or
Ambulance in an Emergency".
Communicating with Base or Ambulance in an Emergency
The most direct method of communicating with the Ambulance is by

telephone, this is therefore the preferred method where a telephone is
available. If a telephone is not available near at hand a vehicle equipped with
radio must be used or the workgroup must be supplemented by extra personnel
and/or transport in order to give quick access to an available telephone.
3.7a Pumping Station Chambers and Sump Entry
a) Any manhole, tank, dry or wet well or enclosed space at a Pumping

Station which normally has sufficient ventilation and in which gas has
not previously been detected should be treated as a 'High Risk' manhole
entry (see Section 3.5).
b) Any manhole, tank, dry or wet well or enclosed space at a Pumping

Station which does not normally have adequate ventilation, or if
hazardous or toxic gas has previously been detected, the person
entering the confined space must wear and use a BA set providing the
person entering is suitably trained.

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c) Except in an emergency, no confined space shall be entered where gas

has been detected, and then only if suitable approved BA is worn. This
does not include an Escape Set.
EQUIPMENT
3.8 Essential Minimum Safety Equipment
3.8.1 For Lifting Manhole Covers

a) Appropriate safety footwear
b) Suitable and sufficient signs to enable compliance with signing

requirements.
c) First Aid Kit.
d) Retro reflective clothing.
e) Gloves/goggles.
3.8.2 For Entering Low Risk Manholes or Watercourse Culverts with Open Ends.
a) Appropriate safety footwear.
b) Hard hat, gloves.
c) Gas detection equipment and line.
d) Barrier cream.
e) First Aid Kit.
f) Washing Facilities
g) Intrinsically safe lamp
h) Air line* or approved BA escape set.
i) Full safety harness.
j) (16mm)Polypropylene rope of adequate length with nonferrous spring

shackle at one end and non-ferrous eye at the other.
k) Approved winching system (dependant on number of operatives).
l) Oxygen resuscitator
* Not for watercourses.
3.8.3 For Entering High Risk Manholes and Confined Spaces Associated with
Pumping Stations
a) As for 3.8.2 plus :-
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b) Rescue set
c) Approved winching system.
3.8.4 For Entering Sewers
a) For manhole entry part of job as 3.8.3.
b) For entry to sewer :-
i) Appropriate safety footwear.
ii) Hard hat, gloves.
iii) Intrinsically safe lamp.
iv) Full safety harness.
v) Gas detection equipment
vi) Escape BA set (one per person to enter).

vii) To be deployed on surface :-
a) Full breathing apparatus (minimum of two).
b) Spare lifting line.
3.9 High Pressure Water Jetting
Only personnel who have been adequately instructed or are under instruction
and are familiar with this Code of Safe Practice shall operate High Pressure
Water Jetting Equipment. All operations shall be controlled and supervised by a
competent person.
The term High Pressure Jetting covers all operating pressures above 50 bars
(700 psi).
WARNING - THE WATER PRESSURE DELIVERED AT THE NOZZLE CAN

CAUSE VERY SERIOUS INJURY AND POSSIBLE DEATH, UNDER NO
CIRCUMSTANCES MUST THE NOZZLE BE ALLOWED TO POINT AT
ANYONE.
3.9.1 Equipment
Equipment comprises of the following:-
a) Pressuring Pump - This delivers the water at various pressures. The

lowest pressure should always be used compatible with the work to be
done.

DUBAI – UAE
b) Fail Safe Valve - This, when released, immediately diverts the water from
the hose or lance and releases the pressure from the pump
completely.
c) Long Lances - These vary in length and are used for internal pipe or
tube cleaning and surface cleaning when fitted with an 'in line' valve,
they shall be manufactured from solid drawn tube and be of one
complete length, i.e. Not coupled lengths.
d) Short Lances - These are used mainly for surface cleaning and can be
fitted with a pistol grip valve in lieu of remote 'in line' valve.
e) Flexible Hoses - Used for internal cleaning in pipework where it is

necessary for the nozzle to navigate bends and contours.
f) Nozzles - There are different types and sizes of nozzles and those used
should be suited to the machine and application required.
g) High Pressure Hoses - Used for connecting the High Pressure Pump to
the jetting nozzle or working lance. Such hoses shall be restricted to the
manufactures maximum recommended working pressure.
h) Any fault or problems with the equipment must be reported at once to

the appropriate supervisor.
3.9.2 Protective Clothing
Wear protective clothing as appropriate.

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APPENDIX N0.4
STANDARD DETAILS FOR SEWERAGE & DRAINAGE
01. General Notes 1
I.ALL DIMENSIONS SHOWN ON STANDARD DEAlIL DRAWINGS ARE IN MILLII.IETRES UNLESS OTHERWISE
INDICATED
2. AI..L CONCRETE SHALL BE CLASS 'A' UNLESS OTHERWISE INDICATED.SULPHATE RES

ISTING PORTLAND
CEMENT <TYPE VICOMPLYING WITH ll.S.4027 SHALL llE USED IN ALL CONCRETE MIXES.
3. STEEL REINFORCEIIIENT SHALL BE GRADE 460 IBS4449) STEEL BARS OR AS SPECIFIED.
4. AI..L REINFORCEI.IENT IN MANHOLES/CHAMBERS SHALL BE EPOXY COATED AS SPECIFIED.
5. MINIMUM COVER TO REINFORCEMENT SHALL BE 50mm.
13. EXTERNAL CONCRETE SURFACES BELOW GROUND SHALL BE PROTEC TEO WITH BITUMINOUS
WATERPROOF TANKING t.IEMBRANE AS SPECIFIED.
7. INTERNAl.. BACKDROP CONNECTIONS SHALL BE PROVIDED FOR SEWERS AND HOUSE CONNECTIONS ONLY
WHERE EXTERNAL CONSTRUCTION IS NOT POSSIBLE.
8. DIMENSIONS AND CONSTRUCTION OF' BACKDROP CONNECTIONS SHAI..L BE AS SHOWN ON DETAIL DRAWING.
THE DROP PIPE SHIILL HAVE THE SAME DIAMETER AS THE SEWER DISCHARGING INTO THE MANHOLE.
9. BACKDROP CONNFCTIONS SHAl l NOT BE PROVD

I FD FOR STORM WATFR CARRIFR DRAINS UNIFSS
INSTRUCTED BY THE ENGINEER.
10. A BACKDROP OR BRANCH SEWER INLET SHAILL HAVE LEVEL SOFFITS WITH A LARGER PIPE DIAMETER.
THE BACKDROP OR BRANCH SEWERS SHALL HAVE INVERT LEVELS AT MAIN SEWER SPRING LINES
ON PPI ES OF THE S.<WE DIAMETER.
11. GRANOLITHIC CONCRETE SHALL BE FORMEDIN /ILL MANHOLE CHANNELS TO PROVIDE A SMOOTH
TRANSITION OF SIZE AND GRADIENT FROIII THE INLETISl TO THE OUTLET SEWER INVERTS.
12. AI..L FOUL SEWER MANHOLE CONCRETE BENCHN

I CS AND CHANNELS SHALL BE PROTECTED WITH
GRP LAMINATION.
13. AI..L DRAINAGE MANHOLE BENCHN

I G AND CHANNELS SHALL BE FORMED WITH EPOXY MORTAR OR
WITH GRANOLITHIC CONCRETE PROTECTED WITH GRP LAMINAT
ION.
14. INTERNAL CEMENT MORTAR JOINTS OF SEWERAGE MANHOLE EXTENSION RINGS SHALL BE RAKED OUT
AND ALL EXPOSCD <ACCS SII/ILL (J[ LAMN
I ATCD WITII GRP.
15. AI..L SEWERAGE MANHOLES AND INSPECT

ION CHAMBERS SHALL BE FT
I TED WITH HEAVY DUTY 0.1.COVER
MID rRAMFS WITH A CLFAR OPFMNG OF 600 x 600mm (QOUBLF T RIANGliLAR fOR MANHOIFSIAND
600 x 600mm SOUE FOR INSPECTION CH.M1BERS AS SPECIFIED.
1B.. ALL DRAINAGE MANHOLES AND CHAMBERS SHALL BE FITTED WITH HEAVY OUTY D.l.COVER J>K)
F'RAME HAVING A CLEAR OPENING OF' 600mm OIA.ftS SPECIF'IEO.
17. GRP LINERS SHALL HAVE A loiiNIMUM THC

I KNESS OF 6.5mm AND BE CONSTRUCTED AS SPECIFIED.
18. GR? BANDAGES TO LINERS SHALL EXTEND 100mm EITHER SIDE OF A J NT.
19. GRANULAR !lEO AND SuRROUND TO PIPES SHALL llE ENCLOSED IN GEOTEXT LE AS SPECIFED
WHERE PIPELINES ARE BELOW THE WATER TABLE AND AS DIRECTED BY THE ENGINEER.
20. ANY PIPELINE BELOW GROUND LEVEL ENTER NG OR PROTRUDING FR•OM ANY STRUCTURE SHALL HAVE
TWO FLEXIBLE JOINTS ADJACENT TO THE STRUCTURE AS S?i:C
IFIED UNLESS INDICATED OTHERW
ISE.
21. PROTECTION SLABS SHALL BE PROVIDED OVER GRAVITY SEWER PIPELINES WI-ERE COVER IS LESS THAIN
1.2 METERS.
22 PROTECTION SLABS SHALL BE PROVIDED OVER uPVC HOUSE CONNECTION PIPELINES WHERE THE
COVER IS LESS THAN 0.9 METRES AND WHERE INSTRUCTED BY THE ENGINEER.
Qlli REVISION I
;::.
DURAl MUNICIPALITY
(I
DltAlNAOK • IR.RIOATION DRPT.
GENERAL NOTES 1
-- Ser.ic• I ,.,.;;--1 Datai!No.

SEW I N T S I 01

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02. General Notes 2

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201. Sewerage Manhole Selection and Dimensions

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202. General Sewerage Manhole Detail

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203. Sewerage Manhole Type 'Special' Plan

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204. Sewerage Manhole Type 'Special Section A- 1

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205. Sewerage Manhole Type ‘Special’ Structural Reinforcement

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206. Sewerage Manhole Type ‘A’ Plan

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207. Sewerage Manhole Type 'A' Section A-A

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208. Sewerage Manhole Type ‘A’ Structural Reinforcement

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209. Sewerage Manhole Type ‘B’ Plan

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210.Sewerage Manhole Type 'B' Section B-B

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211. Sewerage Manhole Type 'B' Section C-C

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212. Sewerage Manhole Type 'B' Structural Reinforcement

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213. Sewerage Manhole Types 'C' & '0' Plan

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214. Sewerage Manhole Types 'C' & 'D' Section D-D

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215. Sewerage Manhole Types 'C' & 'D' Section E-E

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216. Sewerage Manhole Types 'C' & 'D’ Structural Reinforcement (Sheet 1 of 2)

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217. Sewerage Manhole Types 'C' & 'D’ Structural Reinforcement (Sheet 2 of 2)

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218. Sewerage Manhole Types 'E' & 'F'- Plan

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219. Sewerage Manhole 'E' & 'F' - Section F-F

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220. Manhole Types 'E' & 'F' Structural Reinforcement (Sheet 1 of 2)

Y16 0150 C/C TII.B

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221. Manhole Types ‘E' & 'F' StructuralReinforcement (Sheet 2 of 2)
--·--I .. .. _.. . ...I

SEW NTS 221
, ........................

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222. Sewerage Manhole Cover Inscription

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223. Typical Backdrop Connection

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224. Internal Backdrop Connection

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301. House Connection Chamber Type 'A'

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302. House Connection Chamber Type 'B'

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303. House Connection Chamber Type 'B' Structural Reinforcement

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304. House Connection Chamber Type 'C'

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305. House Connection Chamber Type 'C' Structural Reinforcement

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306. Vent Pipe Arrangement

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401. Storm Water Drainage Pipe Installation

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402. Slotted Land Drain with Gravel Trench

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403. Land Drain and Carrier Main in a Common Trench

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404. Storm Drain Manhole with Land and Carrier Main

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501. Storm Water Drainage Manhole Selection and Dimensions

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502. Storm Water Drainage General Manhole Detail

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503. Storm Water Drainage Manhole Type 'G' Plan

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504. Storm Water Drainage Manhole Type 'G' Section A-A

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505. Storm Water Drainage Manhole Type 'G' Structural Reinforcement

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506. Storm Water Drainage Manhole Type ‘H’ Plan

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507. Section Section B-B

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508. Storm Water Drainage Manhole Type 'H' Section C-C

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509. Storm Water Drainage Manhole Type 'H' Structural Reinforcement

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510. Storm Water Drainage Manhole Types ‘I' & 'J' Plan

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511. storm Water Drainage Manhole Types 'I' & 'J' Section D-D

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512. Storm Water Drainage Manhole Types 'I' & 'J' Section E-E

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513. Storm Water Drainage Manhole Types 'I' & 'J’ Structural Reinforcement
(Sheet 1 of 2)

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514. Storm Water Drainage Manhole Types 'I' & 'J' Structural Reinforcement (Sheet
2 of 2)
D•/Dlii&J11!15m ll£TI!lGW5Wrl/DT M.DCN ll1121l00

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515. Storm Water Drainage Manhole Types 'K' & 'L' Plan

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516. Storm Water Drainage Manhole Types 'K' & 'L' Section F-F

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517. Storm Water Drainage Manhole Types 'K' & 'L' Structural Reinforcement (Sheet
1 of 2)

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518. Storm Water Drainage Manhole Types 'K' & 'L' Structural Reinforcement (Sheet
2 of 2)

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600. Gully at Upstand Kerb

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601. Removable Basket

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602. Upstand Kerb

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603. Kerb Section with Side Entry Gully

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604. Gully connected to carrier W/ Traffic Load

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605. Gully connected to line W/o Traffic load

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701. Concrete Bed and Surround to Pipes

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702. Concrete Surround for Pipes with Couplings

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703. Protection Slab to Pipes

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704. Pipe Connection at Structures

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705. External Waterproof Tanking to Manholes

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706. Waterproof Tanking Details to Manholes (Sheet 1of 2)

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707. Waterproof Tanking Details to Manholes (Sheet 2 of 2)

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708. Safety Chain

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709.Protective Warning Tape


ROADS AND UTILITIES

VOLUME 2 – PART V
PARTICULAR SPECIFICATIONS FOR IRRIGATION WORKS

20010410
JUNE, 2022
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications


Architectural
Volume 5 Soil Investigation Report and Project Environmental

and Health & Safety Requirement

DUBAI – UAE
MEYDAN GROUP LLC
Project: 20010410
Roads and Utilities
Volume 2 – Part V
PARTICULAR SPECIFICATIONS FOR IRRIGATION WORKS
CONTENTS
1.0 IRRIGATION / AUTOMATIC IRRIGATION SYSTEM............................................................ 1

1.1 SUBMITTALS ............................................................................................................................ 2
1.1.1 MATERIALS AND EQUIPMENT SCHEDULE................................................................... 3
1.1.2 NO OBJECTION CERTIFICATES ...................................................................................... 3
1.1.3 SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS ......................................... 3
1.1.4 MANUFACTURERS CERTIFICATIONS............................................................................ 4
1.1.5 RECOMMENDATION OF THE MANUFACTURERS ...................................................... 4
1.1.6 SPARE PARTS ...................................................................................................................... 4
1.1.7 INSTALLATIONS AND TESTING ....................................................................................... 4
1.1.8 PROGRAM/PROGRESS REPORTS ................................................................................. 5
1.1.9 MANUFACTURER'S LITERATURE ................................................................................... 5
1.1.10 CIRCUIT DIAGRAM ................................................................................................................ 5
1.1.11 AS-BUILT DRAWINGS AND OPERATION & MAINTENANCE MANUAL A. AS-
BUILT DRAWINGS ............................................................................................................................... 5
1.1.12 SILENCE OF SPECIFICATION ............................................................................................ 7
1.1.13 SYSTEM EXPLANATIONS ................................................................................................... 7

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1.1.14 LAYOUT OF WORK................................................................................................................ 7

1.1.15 CLEAN-UP ............................................................................................................................... 7
1.1.16 WARRANTY ........................................................................................................................... 8
1.1.17 PRODUCT STORAGE AND HANDLING ............................................................................ 8
1.1.18 Operation & Maintenance of the system ............................................................................ 8
1.2 IRRIGATION SYSTEM, MATERIALS ....................................................................................... 9
1.2.1 PIPES AND FITTINGS ......................................................................................................... 9
1.2.1.1 uPVC PIPE AND FITTINGS.......................................................................................... 9
1.2.1.2 POLYETHYLENE PIPE AND FITTINGS ................................................................... 10
1.2.1.3 STEEL PIPE AND FITTINGS ...................................................................................... 11
1.2.1.4 THREADED STEEL PIPES & FITTINGS (FOR 3” AND BELOW) ........................ 11
1.2.1.5 DUCTILE IRON PIPE AND FITTINGS ...................................................................... 11
1.2.1.6 ASBESTOS CEMENT PIPES ........................................................................................ 12
1.2.1.7 GRP PIPES AND FITTINGS .......................................................................................... 12
1.2.1.8 DUST CAP ..................................................................................................................... 16
1.2.1.9 STAPLE STAKE ........................................................................................................... 16
1.2.2 VALVES ......................................................................................................................... 17
1.2.2.1 SOLENOID VALVES .................................................................................................... 17
1.2.2.2 CHECK VALVE ............................................................................................................. 17
1.2.2.3 GATE VALVE ................................................................................................................ 17
1.2.2.4 AIR VALVE .................................................................................................................... 18
1.2.2.5 ELECTRICALLY ACTUATED BUTTERFLY VALVE ............................................. 18
1.2.2.6 PRESSURE REDUCING, PRESSURE SUSTAINING & CHECK VALVE ........... 19
1.2.2.7 PRESSURE RELEASE VALVE .................................................................................. 19
1.2.3 VALVE BOXES .................................................................................................................... 19
1.2.4 WATER METERS & STRAINERS .................................................................................... 20
1.2.4.1 BASKET STRAINER............................................................................................................. 20
1.2.4.2 BRONZE STRAINER ............................................................................................................ 20
1.2.4.3 WATER METER .................................................................................................................... 20
1.2.5 DRIP TUBES, EMITTERS .................................................................................................. 21
1.2.5.1 PRESSURE COMPENSATING EMITTERS .................................................................... 21

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1.2.5.2 PRESSURE COMPENSATING DRIPPERLINE: ............................................................. 21

1.2.5.3 SUBSURFACE DRIP SYSTEM FOR GRASS AREAS ................................................ 22
1.2.5.3.1 Subsurface Drip Tubing: ................................................................................................... 22
1.2.5.3.2 Automatic Flushing Valve: ................................................................................................. 23
1.2.5.3.3 AirVent/Vacuum Relief Valve: .......................................................................................... 23
1.2.5.3.4 Check Valve: ....................................................................................................................... 23
1.2.5.3.5 Operation Indicator: ........................................................................................................... 24
1.2.6 PRESSURE COMPENSATING BUBBLERS (not applicable) ...................................... 24
1.2.7 POP-UP SPRAYERS.......................................................................................................... 24
1.2.8 ROTOR POP UP SPRINKLERS ....................................................................................... 25
1.2.9 PUMPS ................................................................................................................................. 26
1.2.9.1 MAIN IRRIGATION PUMPS (VARIABLE SPEED) .................................................. 26
1.2.9.1.1 Material of Construction ............................................................................................... 26
1.2.9.1.2 Pump base ..................................................................................................................... 27
1.2.9.1.3 Motor............................................................................................................................... 27
1.2.9.1.4 Valves & Piping ............................................................................................................. 27
1.2.9.1.5 Control System .............................................................................................................. 27
1.2.9.1.5.1 General.............................................................................................................................. 27
1.2.9.1.5.2 Electrical Installation ........................................................................................................ 28
1.2.9.1.5.3 Pump set Controls ........................................................................................................... 28
1.2.9.1.5.4 Data Log ........................................................................................................................... 29
1.2.9.1.5.5 Menu Structure................................................................................................................. 29
1.2.9.1.5.6 Ambient Requirements ................................................................................................... 29
1.2.9.1.5.7 System Security ............................................................................................................... 29
1.2.9.1.5.8 Outputs .............................................................................................................................. 30
1.2.9.1.5.9 Inputs ................................................................................................................................. 30
1.2.9.1.5.10 Telemetry ........................................................................................................................ 30
1.2.9.1.5.11 Quality Requirements ................................................................................................... 30
1.2.9.1.5.12 Documentation ............................................................................................................... 30
1.2.9.1.5.13 Compliance Table .......................................................................................................... 31
1.2.10 STORAGE TANK .................................................................................................................... 31

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1.2.10.1 General .................................................................................................................................. 31

1.2.11 FILTERS ............................................................................................................................... 31
1.2.12 PRESSURE GAUGES ......................................................................................................... 32
1.2.13 UNDERGROUND WARNING TAPE .................................................................................. 32
1.2.14 ELECTRICAL EQUIPMENT ................................................................................................ 32
1.2.14.1 ELECTRICAL WIRE FOR SOLENOID VALVES AND SATELLITES ........................... 32
1.2.14.2 WIRE CONNECTORS .................................................................................................... 33
1.2.14.3 ELECTRIC PRESSURE SWITCHES ........................................................................ 34
1.2.14.4 FLOW SENSING AND CONTROL SYSTEM ........................................................... 34
1.2.14.4.1 ELECTROMAGNETIC FLOWMETER FOR TREATED SEWAGE EFFLUENT
(TSE). .................................................................................................................................................... 34
1.2.15 SYSTEM CONTROLLING EQUIPMENT ......................................................................... 36
1.2.15.1 ELECTRICAL CONTROL PANEL .............................................................................. 36
1.2.15.2 IRRIGATION CONTROLLERS ................................................................................... 37
1.2.15.3 FILTER CONTROLLER ............................................................................................... 37
1.2.16 CHAMBER IDENTIFICATION PLATE .............................................................................. 37
1.2.17 DUCTING ............................................................................................................................. 38
1.2.18 EXHAUST FAN .................................................................................................................... 38
1.2.19 FERTILIZER INJECTION UNIT........................................................................................... 38
1.2.20 SURGE ANTICIPATOR RELIEF VALVE ........................................................................... 38
1.2.21 DOSING PUMPS................................................................................................................... 39
1.2.22 RUBBER EXPANSION JOINTS (RUBBER BELLOWS) ................................................. 39
1.3 IRRIGATION SYSTEM, EXECUTION ......................................................................................... 43
1.3.1 EXCAVATION AND BACK-FILLING ................................................................................ 43
1.3.2 PVC PIPE INSTALLATIONS ............................................................................................. 44
1.3.3 DRIP LINE PIPE .................................................................................................................. 45
1.3.4 VALVES ................................................................................................................................ 45
1.3.5 IRRIGATION EQUIPMENT ................................................................................................ 45
1.3.6 IRRIGATION CONTROL EQUIPMENT ........................................................................... 45
1.3.7 TESTING .............................................................................................................................. 45
1.3.7.1 PIPELINE PRESSURE TEST ............................................................................................ 45
1.3.7.2 PAINTING ...................................................................................................................... 46
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1.3.8 ROAD CROSSINGS ........................................................................................................... 46

1.3.9 THRUST BLOCKS .............................................................................................................. 47
1.3.10 ELECTRICAL CODES .......................................................................................................... 47
1.3.11 ELECTRICAL TESTS ........................................................................................................... 47
1.3.12 ELECTRICAL INSTALLATIONS ......................................................................................... 47
1.3.13 CONTROL PANEL INSTALLATIONS ................................................................................ 48
1.3.14 CONTROLLER INSTALLATIONS ...................................................................................... 48
1.4 AUTOMATIC IRRIGATION SYSTEM, COMMISSIONING ................................................. 49
1.4.1 FIELDWORK ........................................................................................................................ 49
1.4.2 IRRIGATION CONTROL SYSTEM................................................................................... 49
1.4.3 OPERATION AND MAINTENANCE MANUAL ............................................................... 49
1.4.4 AS-BUILT DRAWINGS ....................................................................................................... 50
1.5 IRRIGATION SYSTEM, CIVIL WORKS ................................................................................. 50
1.5.1 EARTHWORK AND EXCAVATION.................................................................................. 50
1.5.1.1 PRE-EXCAVATION...................................................................................................... 50
1.5.2 CONCRETE ......................................................................................................................... 51
1.5.2.1 GENERAL ............................................................................................................................. 51
1.5.2.2 MATERIALS ........................................................................................................................... 52
1.5.3 CONCRETE MIXING .......................................................................................................... 54
1.5.4 CONCRETE TESTING ....................................................................................................... 54
1.5.5 TRANSPORTATION ........................................................................................................... 54
1.5.6 CASTING OF THE CONCRETE ....................................................................................... 54
1.5.7 CONCRETE COMPACTION ............................................................................................. 54
1.5.8 CURING OF THE CONCRETE ......................................................................................... 54
1.5.9 MOVEMENT AND CONSTRUCTION JOINTS ............................................................... 54
1.5.10 DEFECTIVE CONCRETE WORKS .................................................................................. 55
1.5.11 FORM WORK AND SUPPORTS ........................................................................................ 55
1.6 SWEET SOIL FILLING, CONTOURING AND PLANTATION ............................................ 56
1.6.1 SWEET SOIL FILLING. ...................................................................................................... 56
1.6.2 CONTOURING .................................................................................................................... 56
1.6.3 GRAVEL ............................................................................................................................... 56

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1.6.3.1 WHITE GRAVEL ................................................................................................................... 57

1.6.3.2 WADI GRAVEL ....................................................................................................................... 57
1.6.4 GEOTEXTILE FILTER FABRIC......................................................................................... 57
1.6.5 MODIFICATION TO EXISTING CHAMBERS ................................................................. 57
1.7 ANCILLARY WORKS ................................................................................................................ 57
1.7.1 PAVING DESCRIPTION .................................................................................................... 57
1.7.2 PAVING BLOCKS ............................................................................................................... 57
1.7.3 OVERALL REQUIREMENTS FOR PAVINGS BLOCKS ............................................... 58
1.7.4 BLOCK LAYING REQUIREMENTS ................................................................................. 58
1.7.4.1 LAYING COURSE .......................................................................................................... 58
1.7.5 KERBS DESCRIPTION ...................................................................................................... 59
1.7.6 MATERIALS AND MANUFACTURE OF KERBS ........................................................... 59
1.7.7 GEOTEXTILE FILTER FABRIC ........................................................................................ 59
1.8 AIR CONDITIONING.................................................................................................................. 60
1.8.1 WALL MOUNTED AIR CONDITIONING UNITS ............................................................. 60
1.8.2 CENTRALIZED AIR CONDITIONING SYSTEMS .......................................................... 60
1.8.3 SPLIT UNIT AIR CONDITIONERS ................................................................................... 61

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1.0 IRRIGATION / AUTOMATIC IRRIGATION SYSTEM
Scope
The contract shall include for the complete supply of material, installation completion,
testing, commissioning and one year maintenance of the irrigation system summarised
below and as per this specification – MOHAMMED BIN RASHID AL MAKTOUM CITY
Phase 1.
The work shall comply with the Dubai Municipality standards for material and quality of
workmanship.
1. Installation of primary distribution mains with chambers, ducts, future connections, etc.
2. Laying of Ducts for Mains, Sub-mains, Laterals and Control Cables and spare ducts for
current and future development under footpaths and roads.
3. Relocation of existing mains, valve chambers, if required.
4. Removing existing trees and shrub lines where it is affected by new road layout and
close co-ordination with Dubai Municipality Horticultural Department representatives.
5. Excavation to foundation level for sweet soil filling including excavation of plant pits and
removal of unwanted excavated material.
6. Reinstatement of the affected areas as and when required during the progress of the
project.
7. Testing & commissioning of the system and demonstration of automatic operation.
8. Operation and maintenance of complete irrigation system for a period of one year after
commissioning of the system including trained operator and labours.
The Contractor shall include for all materials, labour, plant and tools and preparation of
detailed and co-ordinated shop drawings.
Backfilling and road base to be tested by an approved independent laboratory at least one
test per 200 mtr. Interval or as per the request at specific location by the Client and by the
Engineer.
The Contractor shall be responsible for maintaining the main irrigation system in the
contract area and for existing plantations.
General concept of the Design shall be as follows:

1. Water requirement for the plantation shall be as follows:
a. Palm trees ...................... 227 lit/day
b. Ornamental trees ............ 100-120 lit/day
c. Grass................................ 15 lit/m2/day
d. Shrubs & hedges.............. 25 lit/day
e. Ground covers, Flowers & creepers 15 lit/m2/day
2. Maximum Daily Operation timing for Irrigation system to be as follows

a. Palm Trees ...........................................30 minutes
b. Ornamental Trees, shrubs, Ground
Covers, Seasonal Flowers,
Creepers & Hedges..............................1 to 2 Hours
c. Grass Area......................................... Between 20 minutes to 2 Hours
depending on type of Sprayer and Sprinklers.

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3. Type of Irrigation System for each type of Plantation shall be as per the Section 2
(Irrigation System, Materials) of this specifications and contract drawings for
Installation Details.
4. Contractor can arrange the area in different blocks with individual solenoid valve.
Each block (solenoid Valve) shall serve only one type of plantation.
5. Daily Operation time for the proposed irrigation system shall not exceed 11 hours.
6. For pipe sizing mean velocity of flow in Main or lateral pipes shall not exceed 1.5
m/sec. The total head loss in Main line not to exceed 4.0 meter. Contractor to provide
ring Main with suitable no. of isolation valves to the approval of the Engineer
7. Total Friction loss from the far end of the lateral up to solenoid valve shall not exceed
2.5 metre. The total head loss in solenoid valve assembly not to exceed 3.0 meter.
8. The total head loss in Pump/filtration complex not to exceed 5.0 meter. Pump Station/
Filtration Station Manifolds shall be of GRP, uPVC and Epoxy coated steel schedule
80.
9. Arrangement of Sprayers shall be in such away that water spray for sprayer should
not hit the stems of the palm trees.
10. All materials and execution of the works shall be as per DM Drainage and Irrigation
Department Specifications and standards and to the approval DM Irrigation Engineer,
The Contractor shall include for all materials, labour, plant and tools.
Contractor shall propose and construct pump & filtration room as per drawings and should
make the connections to the project main irrigation network complete with all fittings to the
approval of the Engineer. Treated Sewage Effluent (TSE) is available from DM irrigation
networks. Location of Filtration Room should be approved by engineer. The size,
placement and orientation of Pump and Filtration Room, Valve chambers etc. has to be in
such a way that sufficient room for laying other services are maintained. Power supply to
pump and filtration room distribution board will be connected to the proposed pocket sub-
station Connection of power supply for pump and filtration room from this distribution board
is part of the contract. Approval of DEWA for using the sub-station should be arranged by
the contractor. (Please note that as per DEWA regulations laying of power supply cable up
to Main control panels of Pump/Filtration chamber shall be DEWA approved sub-contractor
through DEWA.)
All crossings across major roads/dual carriageways and U-turns shall be either through
ducts or no dig method.
It shall be done strictly as per DM specifications and to the Approval of the Engineer. Back
filling and road base to be tested by an approved independent laboratory at least one test
per 200 mtr. Interval and part thereof & 30 mtr interval and part thereof respectively or as
per the request at specific location by the Engineer.
The contractor to modify all the existing manhole chambers; in the proposed Landscape
area (if required); to the approval of the Engineer and the concerned service authorities; in
order to match its top levels with the proposed landscaping levels.
The contractor shall reinstate all roads and footpath where affected by the installation of
irrigation system to the approval of the engineer.
1.1 SUBMITTALS
The Contractor shall submit to the Engineer the following documentation for review and
approval, before commencing work.

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1.1.1 MATERIALS AND EQUIPMENT SCHEDULE
All catalogue cuts, diagrams, samples, drawings and such other data as may be required
to demonstrate compliance with the specification.
1.1.2 NO OBJECTION CERTIFICATES
Prior to start of any work at site the contractor has to approach all Service Authorities in
Dubai to get their no objection for the work included in this contract and record drawings for
their existing services. Copy of these drawings and no objection certificate should be
submitted to the Engineer before starting the actual work at site.
Trial Trenches: Contractor to make detailed survey of project area, note existing
levels in the project area and take trial trenches for all the locations where plantation and
irrigation system has been proposed.
All these details to be submitted to the Engineer along with digital format.
Based on the information of existing levels and trial trenches made Contractor to propose
final location of tree plantation and irrigation services and submit shop drawings.
1.1.3 SHOP DRAWINGS AND VERIFICATION OF DIMENSIONS
Please note that the contractor to make detail survey of existing levels in the contract area.
Trail pits should be taken at every 50 meter interval, mark all the existing services in
reference to the road edge & building line along with its depth from existing the ground level
& the proposed Landscape finish level. Contractor to check availability of all the existing
ducts that are marked on the tender drawings. Contractor to propose the route of Irrigation
piping based this information. All this information regarding trial pits, existing and proposed
levels, availability of existing ducts shall be made available to DM Engineer within
mobilisation period of the contract. All this information shall be made available on hardcopy
& in Digital format to DM as it is required for adjusting landscape and pipes/services
alignment.
Any delay to provide the above-mentioned information regarding trial trenches, existing
services & levels which affect the progress of works shall be the responsibility of the
Contractor. The Dubai Municipality keeps the right to take necessary action and penalise
the Contractor in such circumstances.
The successful Contractor shall submit shop drawings, for approval by the Engineer, for
the following:
a) In case of any conflict between contract drawings and any existing or future services
which may necessitate re-routing proposed irrigation Main or laterals, the contractor
has to prepare the shop drawings accordingly and submit it to the Engineer for
approval. This should be considered as integral part of the contract.
b) The Pump/Filtration Station/chambers mechanical, electrical and civil/structural works

shop drawings. Necessary modifications to the existing feeding chambers (civil and
mechanical). Valve chambers including valves, pipe works and civil works. Electrical
control equipment with circuit diagrams.
c) Details of mainline, lateral pipes and other typical connections.

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d) Wiring diagrams including conduits, pull boxes, sizing and calculations to verify that
cable sizing is in accordance with DEWA regulations and equipment manufacturer’s
recommendations.
e) Electrical power and control wiring diagrams for irrigation controllers, field wiring and
grounding and CCU system including all decoders and interfaces.
f) Sketch plans for drip line layout and bubbler layout.
g) Sketch plans for sprayer and sprinkler layouts.
h) Detail of valve chambers and any modification to the existing feeding chambers.
The approval shall not relieve the Contractor of any of his responsibility under the contract
for successful completion of the work.
1.1.4 MANUFACTURERS CERTIFICATIONS
a) uPVC Pipe and fittings

Certification by a recognized certification mark scheme such as "The Kitemark" or by
an independent third party testing organization approved by the Engineer, that
production has been carried out under a system for supervision, control and testing,
applied during manufacture, in accordance with BS 5750 or an approved equal
procedure.
b) Valve, and Special Steel Fitting

Manufacturer's certificate for pressure testing, and coating, including holiday and DFT
test reports for each valve, fitting, spool if applicable.
c) Emitters
Certification of coefficient of manufacturer's variation.
1.1.5 RECOMMENDATION OF THE MANUFACTURERS
The Contractor shall submit manufacturers' recommendations for installation and

commissioning of each material or piece of equipment for approval prior to commencing
work. Recommendations shall include testing methods, storage requirements, (if
applicable) maintenance and operational data. The contractor shall have a copy of the
manufacturers' instructions available on site at all times while work is in progress and shall
follow these instructions unless otherwise authorized to deviate by the Engineer.
1.1.6 SPARE PARTS
The Contractor shall submit manufacturer's list of spare parts for approval prior to
commissioning any piece of equipment. Recommendations shall include stocking
recommendations, exploded assembly diagrams illustrating location and spare parts to be
utilized and all relevant operational data.
1.1.7 INSTALLATIONS AND TESTING
The Contractor shall submit his proposed work method statement for approval prior to
commencing work. The statement shall detail proposed sequence of work, hold points,
testing frequency and document control.

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1.1.8 PROGRAM/PROGRESS REPORTS
The Contractor shall submit a program of works as per Clause of the condition of the
contract for approval.
The Contractor also shall submit monthly progress report at the end of each month
including all the works constructed during the month with photographs, numbers of staff
and labourers, cash flow, test reports, overall progress and general details as per engineer
approval.
1.1.9 MANUFACTURER'S LITERATURE
At such time as the list of materials has been approved by the Engineer, the Contractor
shall provide four (4) sets of manufacturer's technical and maintenance literature to the
Engineer. Data sheets shall provide sufficient technical information to identify each product
and shall include the name and the address of the nearest supply firm, which should have
a local representative in the Emirates of Dubai.
1.1.10 CIRCUIT DIAGRAM
Contractor must submit all circuit diagrams of electrical installation along with samples and
specifications of materials proposed in order to obtain approval prior to fabrication or
installation.
1.1.11 AS-BUILT DRAWINGS AND OPERATION & MAINTENANCE MANUAL A. AS-BUILT

DRAWINGS
The Contractor shall maintain one set of contract drawings for the sole purpose of
recording accurate changes made as the work progresses ("As-Built" conditions) of the
irrigation system. All changes previously approved and all completed work shall be
recorded on these drawings.
The Contractor shall prepare as-built drawings clearly showing all location, depths, slopes,
heights, shapes and dimensions of all works as executed. All valve locations and piping
shall be dimensioned and recorded (except that wire locations, common to pipe ditches,
need not to be dimensioned). The Contractor must submit as-built drawings for all electrical
installations. The contractor should clearly mention location of lines, chambers etc. in
reference to building line and centre line of the roads. The contractor must submit as built
drawings for all electrical installations.
Sizes of all the as-built drawings should be the same as that of DM Drainage & Irrigation
Department Standard (approx. 120cm x 60cm) size.
All as-built drawings should be prepared using Microstation program (latest version for
Windows). Mainline layouts should be submitted on DM Survey sheets (scale 1:1000) as
per Dubai Municipality Drainage & Irrigation Department requirements and the Client
approval. As-built drawings of mainline layouts of Automatic Irrigation system Main and
Irrigation Network Mains should be on separate drawings for each.
Contractor should prepare and submit as-built drawings for the pipeline profiles of the
Mainlines. Pipeline profile drawings should be in Horizontal scale of 1:1000 and Vertical
scale of 1:100. Pipeline profiles to be submitted on separate drawings with clear
references to mainline layout drawings marked on the same.

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Chambers schedule are to be prepared indicating all relevant construction items and giving
co-ordinates for each manhole in compliance with DM grid system.
The Contractor must submit as-built drawings for all the electro-mechanical installations.
All the details of the installed equipments regarding manufacturer, model no., type, size,
etc. shall be provided in the legend of the drawings.
Lateral line layouts for sprinklers/sprayers drip and bubblers shall be in scale 1:500. All the
Layout drawings should be shown on background of light colored Landscape as-built, for
easy reference
The Contractor should follow the Standards (regarding legend, line styles, colors, levels,
size of drains, title block etc.) of DM Drainage and Irrigation Department while preparing
As-Built Drawings.
After final approval to the As-Built Drawings, Contractor to submit the following before the
final taking over of the project.
1) Three complete sets of “As-Built Drawings” folded properly and provided in plastic
folders as a part of Operation and Maintenance Manual;
2) A set of Mother Prints (on Heavy grade Polyester) and;
3) A copy of computer discs, CDs (with proper titles and plastic enclosure box) please
note that zip files will not be accepted.
Provisional acceptance will not be considered unless Contractor submits all the above said
As-Built Drawings.
Notes:
1) Contractor to check all existing irrigation system within the contract area (along with
existing filtration chambers) and shall record those details in the as-built drawings of
the project.
2) Contractor to prepare & submit the detailed records results of trial pits and trenches. All
such information shall be submitted to DM in digital format and hard copies.
3) Contractor to prepare and submit the detailed results of trial pits and trenches. Record
of all trial holes executed under this contract shall be made available in the form of
drawings (Scale 1:1000 for Plans & 1:100 for sections) to be the part of as-built set of
drawings. These drawings shall be made available to Services Co-ordination Unit of
Roads Department, Dubai Municipality. All such information shall be submitted to DM
in digital format and hard copies.
B. OPERATION AND MAINTENANCE MANUALS
01 Assemble three (3) copies of manuals containing Operating & Maintenance instructions
for each piece of equipment and systems requiring service and Prints of As-Built
drawings as described above. O & M Manuals shall be bound in a hard cover 3-ring
binder of suitable size and properly indexed. Cover and Manual shall be as per DM
standards and to be approved by the Client. Contractor should also submit digital copy
of Maintenance Manual on CD.
02 O & M Manuals shall include the following information:-
a. Description of equipment
b. Operation of equipment
c. Maintenance of equipment and lubrication schedule

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d. Servicing of equipment
e. Control Diagrams
f. Irrigation Valve Operation Schedule c/w Controller Station no., valve no., valve
size, flows, operating time, etc.
g. Diagrams of the system
h. Logic of operation of the systems
i. Valve charts
j. Performance characteristics: Curves and charts for equipment (Data shall refer to,
and identify specific modeling service and shall not be general advertising data).
k. Spare parts list
l. Names, contact numbers and addresses of spare part suppliers.
m. Test reports
n. Certificates
o. Bill of Quantities of Material used in the Contract
p. Letter of Satisfaction
q. Guarantees.
A digital copy (on computer CD) of Operation & Maintenance manual complete
with Valve operation Schedule, Circuit & control diagrams shall be submitted to DM
along with As-built drawings
03 Submit one copy of the manual to the Engineer for review and three final copies to the
Client after the final approval of the Engineer. Provisional acceptance will not be
considered unless Contractor submits completed O & M manuals and as-built
drawings.
1.1.12 SILENCE OF SPECIFICATION
The apparent silence of the specification, drawings or other contract documents as to any
detail or the apparent omission from them of a detailed description concerning any point
shall be regarded as meaning that only the best general practice is to be used. All
interpretations of the specifications will be made by the Engineer on this basis.
1.1.13 SYSTEM EXPLANATIONS
During site visits by the Engineer, operation of the system will be delineated to all
authorized persons desiring such information.
Three copies detailed system operation and maintenance brochure will be provided to the
Client at the completion of the project by the Contractor.
1.1.14 LAYOUT OF WORK
The Contractor shall stake out the irrigation system in accordance with the scaled plans.
Staking shall be erected in such a manner as to insure permanency of the staked locations
until such time as the irrigation system is installed. Stakes shall be placed to show location
of valves, pipelines and control head. Stakes shall be flagged with bright flagging for ease
of location. All staking by the Contractor shall be subject to approval of the Engineer.
The Contractor shall stake the landscape patterns as shown on the landscape drawings.
These patterns shall be marked with lime powder and nylon ropes for future use section
during plantation phase.
1.1.15 CLEAN-UP

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During the course of construction, the Contractor shall remove waste material from the site
continually as is necessary to keep the site in an orderly manner. Waste material shall be
removed from the work site and not to be used as back-fill material. Upon completion of the
contract, the Contractor shall remove all waste equipment and parts and leave the site in a
neat and orderly condition.
1.1.16 WARRANTY
All work included under this Contract shall be warranted by the Contractor against all
defects and malfunction of materials and workmanship for a period of one year from the
date of completion of works. Should problems arise with the system during the warranty
period, all necessary repairs and/or replacements shall be made by the Contractor in an
expedient manner at no additional cost to the Client.
The Contractor shall be responsible for operation and maintenance of the system for a
period of one year from the completion date.
1.1.17 PRODUCT STORAGE AND HANDLING
All products shall be delivered in the manufacturers' original protective packaging and shall
be inspected at time of delivery. Any product, which are damaged and not in accordance
with specifications, or date stamp expired, shall be immediately removed from the site and
replaced.
Evidence must be submitted to verify materials, such as uPVC pipes, solvent cement,
rubber gaskets etc., have been properly protected during transport and storage prior to
delivery to the site.
All products shall be handled and stored in accordance with printed recommendations of
the manufacturer.
All site storage areas shall be shaded at all time. Pipe stacks shall be designed to ensure
that pipes and especially pipe sockets are not deformed during storage and/or affected by
sunlight.
Precautions shall also be taken to protect items sensitive to sunlight or heat prior to
backfilling operation. uPVC pipes shall on no account be exposed to sunlight for more than
two days in summer, or one week in winter. Any pipe, whether installed or not, which is
observed to be sunburn, or oval, shall immediately be removed from the site and replaced.
1.1.18 Operation & Maintenance of the system
The Contractor shall be responsible for operation and maintenance of the system till the
completion of End of Defects Liability period.
The Contractor will be responsible for operation, scheduling, and inspection of the system.
Contractor should be provide a skilled operator, a pipe fitter and a helper who are
experienced in widely varying irrigation requirements over various planting times and
climatic conditions for the optimal performance of the irrigation system. All these staff
should be available for full time on the site. Operating the system should be combined with
the instructions of the designer to formulate a set of standard operating procedures for the
system. During the planting and establishment time of the plantation Irrigation operation
should be provided as per the requirements of Horticulture Department in co-ordination
with DM Irrigation Maintenance Section and Client

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Complete inspections are necessary during the operation of the irrigation system as
follows:
Inspections of all the irrigation equipments line sprayers, sprinklers, Dripper lines,
bubblers, valves, pressure regulators, filters, pumps, flow/pressure sensors, fertiliser
injection system etc. should be done regularly during the operation of the system for their
proper & optimal operation. Each zone should be inspected for excessively wet areas that
might indicate leaks and dry patches which indicate improper coverage of the
sprayers/sprinklers.
Equipments should be adjusted and corrected to give the optimum performance.
Drip lines, and irrigation pipes should be inspected for breakages and attended
immediately to repair the same.
Arc and throw of sprayers and sprinklers should be inspected and adjusted in such way
that it will not throw the water on the roads and stems of the palm trees. All the pressure
regulators of solenoid valves should be adjusted to give the recommended pressures.
Filters and Basket Strainers must be inspected and cleaned periodically.
1.2 IRRIGATION SYSTEM, MATERIALS
Scope
The scope of this section includes a description of materials and methods for the hydraulic
element of the system.
All materials covered by this specification shall be from an approved local representative in
the Emirate of Dubai qualified to provide the appropriate level of technical support.
All equipment, fittings and accessories shall be suitably rated to comply with the system
design and operating parameters.
Note: Following are general specifications for the Irrigation materials, the items which are
not required in this project shall not be considered in the scope of the works.
1.2.1 PIPES AND FITTINGS
1.2.1.1 uPVC PIPE AND FITTINGS
uPVC piping shall be fabricated from unplasticized polyvinyl chloride according to BS

3505:1968 and BS 3506:1969. Rating and size shall be as shown on the drawings but not
less than class D. Pipe shall be supplied in lengths no smaller than six (6) meters. Each
length of pipe shall bear markings of identify type and grade. All piping shall show no
evidence of blisters, grooves or other extrusion marks. The Contractor shall provide three
(3) samples of each size, one meter in length for approval prior to supply and installation.
All pipes three inches (3") and above to be with Lock Ring Socket. The socket to be
integral part of the pipe and in accordance to BS 4346 Part 2: 1970 and it should
incorporate a triple compression rubber seal complying with BS 2494: Part 2 and when
jointed offers three-fold hydraulic security under both positive and negative pressure
heads. The socket should have the same wall thickness as the pipe with an extra sleeve to
maintain the correct pressure rating at the joint.

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All joints in pipe shall be made by solvent welding using adhesive solvent and primer as
recommended, in writing, by the manufacturer and approved by the Engineer. All cans of
solvent and primer shall have labels intact and shall be stamped with date of manufacture.
No cans dated over two years old will be permitted. No thinning of solvent or primer will be
permitted. Lubricant and solvent cement used to make joints shall be approved in writing
by the pipes manufacturer or his designated representative and the Engineer. Only male
joints may be used up to 2". Joints larger than 2" shall not be threaded. All threaded joints
shall be made up using PTFE tape or an approved equal thread sealant.
Pipes sized 1-1/4 " and larger shall be of class D (12 bars working pressure) and smaller
pipes shall be class E (15 bars working pressure). Fittings shall be fabricated from uPVC
according to BS 4346.
For sizes up to 8” uPVC fittings shall be used. All uPVC pipes and fittings should be
covered by licensed Kite mark. All uPVC fittings shall be of pressure ratings not less than
16 bar at 20 deg. Celsius and 9 bar at 50 deg. Celsius.
For sizes above 8”; GRP fittings with 15 bar pressure ratings shall be used in chambers.
On no account shall saddle and cross type connections be made to uPVC pipe. All pipes
passing through ducts shall be solvent weld joints.
Flange couplers shall be PN 16 and in accordance with BS 4504. Bolts and nuts (whether
part of the coupler or for fixing) shall be A4 – 70 stainless steel.
Threaded riser pipe used to support valves and sprinklers and fittings may be galvanized
steel, or brass. All galvanizing shall be carried out after threading.
All valves chambers above 8” shall have GRP fittings.
1.2.1.2 POLYETHYLENE PIPE AND FITTINGS
Polyethylene pipes for drip lines shall be manufactured from linear low-density
polyethylene incorporating a minimum of 2.8% carbon black and shall have a working
pressure of 4 kg/cm2.
Random samples of drip pipes shall be subjected to the Teepol crack resistance test. The
samples shall be immersed in a bath containing a solution of 10% Teepol and 90% water
maintained at 50 degrees C. The pipe should resist the solution without showing any
fatigue or crack for a period of 150 hours.
The test should be carried out in an independent laboratory within U.A.E.
All fittings for drip line shall be compression type. Insert barbed type fittings secured by
plastic ratchet clips shall not be used.
For the trees planted (in planters) in the tiled areas; a common drip line (with a drip line
riser for several trees) running through conduit is not allowed. A separate drip line riser
from PVC lateral line shall be provided for each tree/planter.
The pipes for bubbler and drip line risers connections shall be as per BS. 1972-67 class C.
The fittings for the above pipes should be of compression quick joint type with minimum 12
bar nominal pressure.

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1.2.1.3 STEEL PIPE AND FITTINGS
Steel pipe shall conform to API standard schedule 80 or other equal and approved.
Welded fittings shall be schedule 80 and weld neck. Flanges shall be in accordance with
BS4504 PN16. All bolts, nuts and washers used for flange assembly or integral with bolted
couplers shall be stainless steel (A4 - 70).
All Pipes and fittings to be coated inside and outside by electrostatic fusion bonded epoxy
to average DFT 150 microns, or by fusion bonded plastic powder coating to average DFT
500 microns.
1.2.1.4 THREADED STEEL PIPES & FITTINGS (FOR 3” AND BELOW)
Threaded steel pipes and fittings used for risers shall be hot dip galvanized mild steel class
(C) in accordance with BS 1387.
All G.I. & Steel Pipes and fittings to be coated, inside and outside with electrostatic fusion
bonded epoxy to average DFT 150 microns or by fusion bonded plastic powder coating to
average DFT 500 microns.
Any galvanized pipe installed in contact with the soil shall be wrapped with at least two
layers of an approved petrolatum impregnated tape of min. thickness of 1.15mm and
applied with 50% over lap. The wrapping tape shall extend a minimum of 100 mm above
the soil. Steel piping and fittings shall only be installed above ground or otherwise
specified.
Joints shall be threaded and sealed with PTFE tape or some other approved method.
Connections to the flanged equipment shall be via threaded flanged adopters. All bolts,
nuts and washers used for flange assembly or integral with bolted couplers shall be
stainless steel A4-70.
1.2.1.5 DUCTILE IRON PIPE AND FITTINGS
Ductile iron pipe and fittings shall be in accordance with BS 4772 or ISO 2531. They shall
be supplied by an internationally known and approved manufacturer. Ductile iron pipes and
fittings shall be supplied, stored, laid, and back-filled and tested in accordance with CP
2010. The pipes shall not exceed 5.5 meters in length and push-in or flexible mechanical
joints shall be used unless otherwise stated.
Where flanged joints are used, the flanges shall be faced and drilled to PN16 as defined in
BS 4504, unless directed otherwise. Flanged joints shall be made with inside bolt circle
gaskets as described in BS 4865 part 1, and gaskets from plain rubber to BS 1737. Bolts
shall be stainless steel Grade A4-70, complete with nuts and washers. The threaded
portion of bolts shall be of such length that at least two threads shall protrude beyond the
nut when tightened.
Pipe barrels shall be class K9, tapers, bend and pipes with cast on flanges shall be class
K12, and tees shall be class K14.
The internal and external surfaces of all-ductile iron pipes and fittings shall be coated
according to one of the following methods:
i) Fusion Bonded Plastic Powder Coating (average 500 microns)

ii) Fusion Bonded Epoxy Coating (minimum 300 microns)

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1.2.1.6 ASBESTOS CEMENT PIPES
Asbestos Cement pipes shall be class 18 confirming to the requirements of ISO 160:1980
or BS EN512 with 5m length. Pipes shall be BS kite marked. The cement shall be sulphate
resistance to BS 4027. The joints shall be of Reka type coupling or approved equal. All AC
pipes and joints shall be coated externally with bitumen.
Couplers shall be made from the same materials as the pipe and shall be flexible allowing
a deviation of 1 to 5 degrees under normal circumstances. Jointing couplers shall be multi-
toothed EPDM rubber seal. Rubber seals should conform to BS 2494.
Copies of all test reports and certificates of compliance shall be submitted to the Engineer
for each consignment delivered to the site. Witnessing of factory testing by the Engineer
may be required prior to delivery. The AC pipes and couplers should be manufactured by
the same manufacturer in Dubai Emirate and to be approved be the Engineer.
1.2.1.7 GRP PIPES AND FITTINGS
All pipes and fittings shall have a resin rich inner layer, having a minimum thickness of 1.0
mm and a resin rich outer layer having a minimum thickness of 0.25mm incorporating one
layer of "C" glass. The remainder of the liner shall consist of at least one layer of 450 g/m
powder bound acid resistant chipped glass strand mat having a glass content between 25
and 30 % by weight.
All glass reinforcement shall be of the "ECR" type. All pipes and fittings shall have a
stiffness of not less than 10,000 N/m2 and satisfy the requirement of ASTM D 3262-87.
Pipes shall withstand longitudinal tensile force of 100 N/mm of circumference. All the
flanges shall be PN16.
All fittings (including bends, tees, reducers and flanges) used with GRP pipelines shall be
GRP (glass fibre reinforced plastic) fittings and shall comply with the following specification:
AWWA C 950 - 95 AWWA Standards for “Fibreglass”

(Glass Fibre Reinforced Resin) Pressure Pipe
BS 5480 : 1990 Glass Fibre Reinforced Plastics (GRP) pipe and

Fittings for use for water supply Sewerage; parts 1&2.
01 - General
This specification covers the design manufacture and testing of glass fibre reinforced
plastic (GRP) pressure fittings for use with GRP pressure pipe in nominal sizes 200mm
and larger. GRP fittings and pipe shall be designed and manufactured in accordance with
AWWA C 950-95 and the requirements herein. All components shall be produced by one
manufacturer.
The manufacturer shall be approved by Dubai Municipality and must demonstrate the
experience and capability to produce fittings of the same diameter and pressure range as
those required. The manufacturer shall be certified to ISO 9002 or BS 5750 Part : 2. Full
range of fitting diameters used for the project must be manufactured and delivered by the
same manufacturer.
02 - Construction
GRP fittings shall have the following principal construction:

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A corrosion resistant, resin rich having a minimum thickness of 0.5mm. The liner surface in
contact with water shall be reinforced with “C” glass veil or mat impregnated with Vinylester
or Epoxy Resin. The liner shall be continuous along the circumference of the pipe and shall
be of uniform thickness and composition.
A structural wall consisting of continuous glass filament findings and/or woven roving and
chopped glass reinforcement and may include fine fillers, all impregnated with Isophethalic,
Vinylester or Epoxy resin as required.
A resin-rich exterior surface having a minimum thickness of 0.025mm.
No dark pigments shall be allowed in the GRP fittings.
03 - GRP fittings and flanges shall be designed in accordance with AWWA C950 for service at
the following conditions:
Maximum operating pressure 16 Bar

Maximum allowable vacuum -1 bar
Minimum depth of water 1.0 meter
Maximum depth of cover 3.0 meters
Truck loading (wheel load) 90 KN
Service temperature (Maximum) 40 deg. C
Flange X flange fittings shall be designed for installation above ground (in chambers)
without thrust blocks. Flange branches on Spigot Tees shall be designed to resist end
thrust from closed valves.
Spigot joints, where specified shall have the same outside diameter (OD) as approved by
Dubai Municipality for GRP pipe to which it is to be joined. The joint dimensions and
tolerances shall be equal to GRP pipe spigots such that joint remains watertight under all
normal operating and surge conditions. The spigot ends shall be clearly marked with a
“homeline” indicating the proper insertion limit for the GRP couplings. The spigot width
shall not be less than half the GRP coupling joint width.
Flanged joints, where specified shall be GRP filament would flanged manufactured from
Epoxy or Vinylester resin and glass reinforcements. Flanges shall be flat faced and drilled
to BS 4504 PN 16 drilling pattern.
GRP Flange gasket (full face) design and thickness shall be as recommended by the GRP
fitting manufacturer. Hand lay-up flanges shall not be acceptable.
Laminated or Adhesive joints used in the fabrication of fittings shall be equal or superior in
strength to the sections they join. The thickness of laminated joints shall not be less than
the wall thickness of the adjoining pipe section. All hand laminations or windings shall
utilize only one type of resin throughout.
04 - Chemical Requirements
GRP fittings shall be not impart any date, odour or colour to drinking water. GRP
pipe/fittings shall be certified and listed for portable water use by the water research center
(WRC) U.K., in accordance with BS 6920 or by the National Sanitation Foundation (NSF) -
USA in accordance with NSF standard 14.
05 - Dimensions

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GRP fittings shall be produced in Metric sizes and shall be classified by their nominal
inside diameter (ND). The actual fitting inside diameter shall not be less than that shown in
the table below:
Nominal Diameter (ND) Minimum inside Diameter

mm mm
80 78
100 98
150 148
200 198
225 223
250 245
300 298
350 348
400 397
450 447
500 497
550 547
600 597
700 696
800 795
900 895
1000 995
1200 1195
All standard fittings up to and including diameter 300mm used in the distribution system
shall be filament wound on precision steel moulds. Standard 90 and 45 degree bends of
nominal diameter 300mm and smaller shall be of the smooth radius type, having a turning
radius of 1.5 times the bend nominal diameter. Fittings diameter 350mm and larger may be
of moulder or mitered (manufactured from GRP pipe sections) construction and internal
surfaces shall be finished smooth.
The thickness of GRP flanges shall not be less than shown in the table below:
Nominal Diameter (ND) Minimum GRP Flange Thickness

mm mm
80-100 38
150-200 44
225 46
250-350 54
400 58
450 64
500-600 68
700 72
800 78
900 85
1000 88
1200 108
The wall thickness of GRP fittings shall be determined by the manufacturer to meet the
design requirements of these specifications but shall in no case be less than the minimum
thickness shown in the table below:

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Nominal Diameter (ND) Minimum Pipe Thickness

mm mm
80-400 6.0
450 6.7
500 7.5
550 8.2
600 9.0
700 10.5
800 12
900 13.5
1000 15
1200 18
Flange drilling shall be as per BS 4504 PN 16
06 Mechanical Properties
GRP fittings shall meet the following minimum strength requirements:
Property Test Method Minimum Value as per Table
1. Hoop Tensile Stress ASTM D2290 Portable 10 of AWWA C950 for class 250
psi
2. Axial Tensile Stress ASTM D 638 Portable 11 of AWWA C950 for class 250
psi
3. Axial Tensile Stress for

flg. X flg. Fittings ASTM D638 70 MPa
4. Stiffness (E1/D3) ASTM D2412

Dia  300 1000 Pa
Dia  300 5000 Pa
07- Visual Requirements

GRP fittings shall be free from delamination, crazing, dry areas or cracks. Spigot ends shall
be free from end delamination, torn edges and gauges and shall be finished smooth to
ensure water tightness. All laminates shall be fully cured with a minimum Barcol hardness
of 33 when tested in accordance with ASTM D2583.
08 Testing
1. Routine Tests
The following test shall be carried out by the GRP pipe/fittings manufacturer at the
frequency specified. Test results and certificates shall be submitted to the Engineer for
each consignment delivery. Witnessing of factory testing by the Engineer may be required.
The Dubai Municipality and the Engineer shall have the right to retain up to 2% of the
material delivered back to the factory for inspection and /or testing by their representative
at no additional cost. Test method shall be in accordance with AWWA C 90 5480.
Test Frequency
i. Visual Inspection Every item
ii. Dimensions Every item
iii. Hydraulic pressure at 24 bars Once per 10 Flg. x Flg.
for 30 seconds items
iv. Stiffness Once per 100 items

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v. Barcol hardness (resin cure) Every item

vi. Axial & Hoop Tensile stress Once per 100 items
vii. All GRP pipe used for fitting fabrication shall be factory
pressure tested at 24 bars for 60 seconds.
2. Qualifications (Type) Tests

The following tests shall be carried out on actual pipe/fittings produced by the manufacturer
to establish and accept the design basis for the products. These testes are not routine
quality control tests.
a) Long Term hydrostatic design pressure of the GRP pipe or fitting shall be established in
accordance with AWWA C950 Section 2.4.2.
b) Short term hoop tensile strength shall be within the ultimate strength of the pipe fittings.
Laminated joints and flanged joints shall withstand a hydrostatic test pressure of 3.5 times
the rated working pressure with no signs of leakage or weep. For Flanges joints, the
flanges shall be blinded and the ends unrestrained during the test.
09- Submittals/Drawings
Prior to start of production, the fittings manufacturer shall submit to the Engineer detailed
drawings of each fitting required for approval. Design calculations, samples and sample
testing may also required by the Engineer for approval at no extra cost to the client.
For flanged fittings, the manufacturer shall submit before delivery, the recommended
gasket details, the bolt torque sequence and maximum recommended torque for each
flange shall be supplied.
10 - Markings
Each fitting shall be indelibly marked with the following:
- Manufacturer’s name or trade mark
- Nominal diameter (ND) in mm (inside and outside)
- Pressure rating in bars
- Manufacturing date, month & year
- Inspection mark
- Coupling “homeline”, “position” position on spigot end.
11 – Tangential Flanged Tee: this shall be used as Washout tee which shall have a bottom
tangential flanged outlet. Tee shall be Spigot X spigot X Branch Flange. The size and the
configuration of the Tee shall be as detailed on the drawings. The detail of the product and
engineering data shall be submitted.
1.2.1.8 DUST CAP
Dust cap should be fixed at the end of each 4mm tube to prevent insects and dirt from
entering the tube. The cap should be durable plastic and heat resistant.
1.2.1.9 STAPLE STAKE
All drip tubes shall be held on the soil by Staple stake. The stake should be polypropylene,
minimum 220mm long, durable and heat resistant. Tails of the stakes shall be provided
with integral barb type flaps to increase retention in soil. The drip line shall be holding on
the soil by the same length staple stake at 10 m interval. The stake shall be featured
separated surface to grip the drip line.

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1.2.2 VALVES
1.2.2.1 SOLENOID VALVES
Automatic remote control valves shall be of the sizes prescribed on the plan. The valves
shall be normally closed diaphragm type with slow opening and closing action for
protection against surge pressure. Actuation shall be by encapsulated type solenoids and
rated 24 volts, 50 cycles unless otherwise specified.
The valve shall able to operate under very low flow and pressure conditions.
Construction shall provide for convenient access to functional parts without removal of
valve from system plumbing. A manual flow control adjustment, with shut-off capability,
shall be furnished on all valves. Valve pressure rating shall not be less than 200 PSI.
The diaphragm shall be of nylon reinforced BUNA-N rubber, and provide for a positive seal
between bonnet and body. The solenoid functional parts shall be of stainless steel, brass
or bronze for corrosion resistance. Diameter shall be as shown on plan. A mechanism
shall be provided for bleeding of the diaphragm chamber for manual operation. Valves shall
be fabricated from heavy cast brass or bronze. The valve shall be capable of working
under dirty (Treated sewage) water conditions. Inlet and outlet shall be threaded B.S.P.
All valves shall be provided with a pressure regulator capable of regulating downstream
pressure between 15 to 100 PSI (within an accuracy of +or- 5PSI) regardless of upstream
pressure. It shall provide full and accurate pressure regulating capabilities irrespective of
whether it is operated electrically or manually. The pressure measurement should be
possible via Schrader valve or integral pressure gauge.
1.2.2.2 CHECK VALVE
Check valves three inches (3") and above shall be double flanged single door swing type
having ductile iron body and gunmetal seat to BS1400. Pressure rating is to be PN 16 or
more. All valves shall be coated with epoxy internally and externally to average DFT 300
microns for protection against corrosion of body components. All nut bolts to be of stainless
steel grade 316/ A4-70.
Check valves of two inches (2") and smaller shall be spring type manufactured from Brass
or Bronze. Inlet and outlet to be BSP female threaded. The spring to be of stainless steel.
Pressure rating to be PN16 or more.
1.2.2.3 GATE VALVE
Gate valves three inches (3") and larger shall be double flange, ductile iron waterworks
valves, with wedge type gate and non-rising stem. Valves shall be manufactured in
accordance with DIN3352. All valves shall be coated with epoxy internally and externally to
average DFT 300 microns for protection against corrosion of body components. Valves
installed below ground shall be provided with stem cap for key operation.
Valves to have non-rising stem of stainless steel, stem nut brass or cast aluminium bronze
with gun metal. Body components shall be of ductile cast iron SG GGG-50. Stem sealing
by elestomer/ NBR rubber ‘O’ rings.
Up to size DN 400 resilient seated Gate valves are preferred with ductile iron wedge fully
covered with special grade elastomer EPDM rubber. Heavy duty steel keys with head

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configuration to fit operating nut and handle length as required for proper above ground
operation shall be provided in numbers specified by the Engineer.
Valves above ground shall be provided with hand wheel. Nominal pressure for the valves
shall be 16 bar or more. All bolts and nuts to be stainless steel grade A4-70.
Gate valves two inches (2") in diameter and smaller shall have non-rising stem and be
manufactured from brass or bronze according to BS 5154. Inlet and outlet to be screwed
BSP. Rating to be PN16 or above.
1.2.2.4 AIR VALVE
Provide automatic double orifice air vents at all high points at all high points on the
pressure mains. Air valves and other similar items shall confirm to BS 2591. Automatic air
valves shall have non-corrosive floats in chambers with clear space ensuring blockage free
operation. All components for the air valve actuating mechanism including lever shall be
stainless steel.
The body and cover of the valve should be of bronze or ductile iron with phenolic primer
coating. Nozzles with seals and actuating mechanism to be located in the removable upper
plate connected to the valve body using stainless steel (grade 316/A4) bolts. Valves shall
be coated with epoxy internally and externally to average DFT 300 microns for protection
against corrosion of body components. All nut bolts to be of stainless steel grade 316/ A4-
70.
Pressure rating of the valve shall be 16 bars. The internal components shall be stainless
steel. The valve size and installation shall be as per site conditions and engineer
instruction.
1.2.2.5 ELECTRICALLY ACTUATED BUTTERFLY VALVE
Electrically actuated Butterfly valves shall comply in all respects with DIN 3354 - PN16
Body of Ductile cast iron SG GGG-50 Valve disc shall be of Stainless steel 316.
All valves shall be coated with epoxy internally and externally to average DFT 300 microns
for protection against corrosion of body components.
Valves shall be flanged type or mounted between flanges to DIN 250, part 1 for PN 16,
face to face dimensions to DIN 3202-K1 corresponds to ISO 5752, concentric type,
streamlined design.
With replaceable seat ring, fusion bonded on backing ring, leak tight closure on both
directions. For operation at differential pressure at maximum 16 bars with operating gears
with electric part turn actuator.
Variant DN-40-300, K1, Seat ring NBR (BUTA N), Shaft S.S. 1.4005, Maximum working
temperature +80 degree Celsius with maximum working pressure 16 bars.
All nut bolts to be of stainless steel grade 316/ A4-70.
Electric actuators shall have to open and close of at least 60 seconds and shall be
provided with an auxiliary operating wheel. The motor control should allow for stepped
closing of valve pausing at ½ closed and ¼ closed.

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Motor and electrical protection shall be in strict accordance with the electrical specifications
and DEWA regulations; motors shall be rated to operate at an ambient temperature of 50
degrees centigrade, and a relative humidity of 100 %.
Electrical components shall be protected from condensation.
Electrically actuated butterfly valve shall be connected to low pressure cut-off switch for
automatic closing of valve in case of low pressure (down stream of valve) due to any
breakage in the system. But valve should not be closed if both downstream and up-
stream pressure is low.(due to shutdown/ breakage of TSE Network Main). For this
purpose Contractor should arrange a differential pressure switch and arrange required
control in combination with other controls.
Complete control of the valve including partial closing of valve should be possible.
1.2.2.6 PRESSURE REDUCING, PRESSURE SUSTAINING & CHECK VALVE
These valves shall be installed as indicated on drawings to maintain a constant

downstream pressure regardless of demand fluctuations. The valve shall be automatic,
fluid actuated, with a flexible non-wicking, FDA approved, nylon fabric reinforced elastomer
diaphragm. The pilot shall be brass and tubing of copper/brass. The valve shall be flanged
and of ductile iron body. All internal and external exposed surfaces shall be FDA approved
epoxy coated to minimum DFT 300 microns. Valve sizes 4” and above shall be standard
with an externally mounted Y strainer for protection of control circuit and ball valves to
isolate the pilot system from Main valve. All nut bolts to be of stainless steel grade 316/ A4-
70.
The valve shall open and close in modulating action. On pressure reversal, valve shall
close tightly. Adjustable pressure range shall be from 1.0 kg/cm2 to 8.5 kg/cm2.
1.2.2.7 PRESSURE RELEASE VALVE
These valves shall be installed in the pump room as shown on drawings to release excess
pressure away from the system.
The valve shall be flanged, diaphragm type, hydraulically operated, pilot controlled, and
modulating type. The pilot shall be brass and tubing of copper/brass. The valve shall be
fast opening and slow closing. The valve shall be flanged and of ductile iron body. All
internal and external exposed surfaces shall be FDA approved epoxy coated to minimum
DFT 300 microns. All nut bolts to be of stainless steel grade 316/ A4-70.
1.2.3 VALVE BOXES
Air valves (1" or smaller only), quick coupling valves, solenoid valves and wires pull boxes
to be installed in an access box of sufficient size to permit ready removal of the valve inner
assemblies without removing the box from the ground. Valve names and numbers must be
clearly marked inside and outside of the box with permanent plastic tags.
Valve boxes shall be fabricated from reinforced plastic and minimum recommended size
COVER DEPTH
Q.C.V. 250mm (dia) 230mm

Pull box, Air valve 1” & 430 x 295mm 300mm
Flush valve

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Solenoid valves up to 2” 590 x 349mm 380mm

Solenoid valves above 2”
and Isolation valves up to 3” 825 x 495mm 450mm
Measurements are taken from the top of boxes. Covers shall be secured by stainless steel
(A4-70) bolts.
Please note- Installation of plastic valve boxes in Paved areas and Sikkas are not allowed.
All the valve chambers/pullboxes in paved areas and sikkas shall be in RCC and with
heavy duty ductile iron manhole covers.
1.2.4 WATER METERS & STRAINERS
1.2.4.1 BASKET STRAINER
Ductile iron basket strainer with bolted cover, inlet and outlet to be flanged and drilled to
PN 16. The strainer should be stainless steel with 1/8 inch perforations. Working pressure
is 150 psi. All bolts and nuts to be stainless steel grade 316/A4-70. The basket strainer
shall be coated internally and externally with coal tar epoxy 300 DFT micron.
1.2.4.2 BRONZE STRAINER
For sizes 2" and below, "Y" type threaded end bronze strainers should be used for
protecting the performance of pipeline equipment by Removal of debris from the water.
The strainer should PN16 rating with Bronze body material and screen should be
of Stainless steel 316.
1.2.4.3 WATER METER
Water Meters should be horizontal Woltman-type meter designed for installation where
occasional low and moderate to high sustained flows are demanded. Accuracy should be
maintained in both forward and reverse flow directions.
Water meter should comply with all relevant international quality standards, substantially
exceeding ISO4064 BS5728 Class B specifications for forward flow installations in
horizontal, vertical and inclined pipelines.
The meter should have robust shroud and copper can register for long life and clear
readability, optimum accuracy. The Meter should given reading in cubic meter and/or US
gallons.
The meter shall be suitable for installation in horizontal, inclined or vertical lines.
The meter to be suitable for use up to 120° F (50°C) and working pressures up to 230 psi
(16 Bar). The meter will perform with accuracy registration of 100% ± 2% within normal
flow*. The Meter should be certified by manufacturer in factory for both pressure loss and
accuracy tests before shipment. No adjustments need to be made before installation.
The main case to be of cast iron with raised characters showing size and direction of flow.
Meter body and cover are epoxy powder coated for protection in all environments.
Thrust pads and stub spindles are manufactured in tungsten carbide and jewelled rotor
bearings are used for maximum wear life.

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The measuring element assembly should consist the rotor, straightening vanes, accuracy
regulator, spindles and gears. The measuring element is attached to the underside of the
cover with three stainless steel screws and washers. The main case and cover are
assembled with an o-ring gasket and stainless steel nuts, bolts and washers. The
register/pulser assembly is secured to the cover with a lock wire and lead seal.
An in-line strainer should be installed proior to the meter to protect the rotor and help
reduce the effect of turbulence.
The meter should be capable of being easily fitted with pulser output feature on site; when-
ever required in future without disturbing the calibration seal or interrupting the water
supply; for providing pulser-out for automatic water reading through central control system.
Pulse out-put should be possible by two types of pulsers: opto-electronic and reed switch
1.2.5 DRIP TUBES, EMITTERS
1.2.5.1 PRESSURE COMPENSATING EMITTERS
Emitters shall be constructed from durable black-heat resistant plastic. The emitters shall
be of barbed configuration which can be inserted easily in to Polyethylene tubing. Pressure
compensation shall be achieved by a flexible orifice located in resilient Silicone Elastomer
diaphragms. The orifice should be self-flushing type and shall clean itself during each
irrigation cycle at the start up and the shut down. The emitters should have manual flushing
capability also. The emitter exponent shall be 0.10 or less. The body and the diaphragm
should be resistant to high concentration of Chlorine, fertilizers and pesticides.
1.2.5.2 PRESSURE COMPENSATING DRIPPERLINE:
Irrigation equipment - Dripperline shall consist of linear low density Polyethylene tubing
with pressure compensating, self flushing type integral drip emitters. The tubing shall have
an minimum outside diameter (O.D.) 16mm and thickness of 1.1 mm + 0.05mm. Pipes for
drip lines shall be manufactured from low density polyethylene incorporating a minimum of
2.8% carbon black, antioxidants in an amount not exceeding 0.5% and shall have a
nominal pressure PN 6.
Random samples of drip pipes shall be subjected to the Teepol crack resistance test. The
samples shall be immersed in a bath containing a solution of 10% Teepol and 90% water
maintained at 50 degrees C. The pipe should resist the solution without showing any
fatigue or crack for a period of 150 hours.
The test should be carried out in an independent laboratory within U.A.E.
All fittings for drip line shall be compression type.
The emitters must be pressure compensating according to ISO 9260 and emission rate of
the emitter shall remain constant at varying water pressure from 1bar to 4.5 bar. The flow
path in emitter must ensure turbulent flow and emitter must confirm to excellent pressure
compensation and self-cleaning/Flushing mechanism. The emitter must be clogging
resisting and the filtration requirement not more than 150 mesh. Coefficient of variation
shall be less than 5%. The flow of emitter must remain same/constant at temperatures
varying from 0 to 60 deg. Celsius.
The product must have warranty against cracking and performance for 7 Years.

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No. of dripline risers shall be as per Engineer’s approval. Separate dripline risers shall be
for each planter. Each tree in grass areas shall be provided with separate dripline riser.
Drip stakes shall be provided at each point of change in direction of drip line and spacing
between drip stakes shall not be more than 10.0 meters. Drip stakes shall be provided at
each point of change in direction of drip line and spacing between drip stakes shall not be
more than 10.0 meters.
The capacity and spacing of the inbuilt emitters in the dripperline shall be as follows:
For ground covers: Emitter discharge rate shall be 0.9 GPH and spacing between
emitters shall be 50 cm in dripperline and 50cm between dripperlines.
For seasonal flowers: Emitter discharge rate shall be 0.6 GPH and spacing between
emitters shall be 50cm in dripperline and 30cm between dripperlines.
For hedge: Emitter discharge rate shall be 0.6 GPH and spacing between emitters In
dripperline shall be 50 Cm.
For trees: A loop of dripperline (around tree) with 0.9 GPH in line emitter at every 30 cm
length of dripperline in a loop shall not be less than 3.2 metre.
For shrubs: 2 Nos in line PC emitters (each emitter 0.9 GPH) per plant shall be used for
shrubs if spacing between shrubs is less than or equal to 1.5 metre. A loop of dripperline
with 3 Nos inline P.C. emitters (each emitter 0.9 GPH) per plant shall be used for shrubs (if
spacing between shrubs is more than 1.5 mtr).
For bougainvillea: 2 nos. in line p.c. emitters (each emitter 0.6 gph) per plant
1.2.5.3 SUBSURFACE DRIP SYSTEM FOR GRASS AREAS
1.2.5.3.1 Subsurface Drip Tubing:
Irrigation equipment- Subsurface Drip tubing shall consists of linear low density
Polyethylene tubing with pressure compensating, self flushing type integral drip emitters.
The Tube shall be suitable for subsurface installation in grass areas.
The drip tubing shall be a pre-bonded emitter type. The tubing shall have emitters spaced
at 12 inches (30 cm) and in flow rates of 1.0 gallons per hour (GPH) with a coefficient of
variance (Cv) less than 0.05. The spacing between the drip tubing should not be more
than 12"(30cm).
Maximum length of run of the drip tubing (for relatively flat levels/grade) from drip line riser
point should not be more than 55 mtr.
Water distribution shall be via an integrated turbulent flow path emitter with dual discharge
ports on opposing sides of the tubing. The tubing shall consist of nominal-sized, linear,
low-density 5/8" (15,8mm) polyethylene with an outside diameter (O.D.) of approximately
.710" (18mm) and an inside diameter (I.D.) of approximately .620" (16mm). The emitters
shall be molded from virgin polyethylene impregnated with TREFLAN(R) to inhibit root
intrusion. The tubing shall be available in pressure-compensating type. The pressure-
compensating type shall incorporate a circular silicon rubber disk designed to flush at start
up, shutdown and during the irrigation cycle to inhibit debris collection.

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The tubing shall have at least seven-year warranty for root-intrusion protection.
1.2.5.3.2 Automatic Flushing Valve:
The flushing valve shall be with inlet size minimum 1/2" MPT. The flushing valve shall be
entirely of non-corrosive plastics. Maximum Flow rate should be 15-20 gpm. Line Flushing
Valves should be used to provide a cleansing action in the sub-surface drip tubing each
time the zone is turned on. The Line Flushing Valve should have ability to dump water
which allows the velocity of water inside the drip tubing to increase momentarily during
turn-on. This action should move sediments out of the system through the Line Flushing
Valve. Place a Line Flushing Valve (one per 15 GPM of zone flow) as far away from the
source as possible. This should typically be somewhere along the exhaust header. Note:
Where Center Feed layouts are used, install one Line. Flushing Valve on each exhaust
header.
Line Flushing Valves should be buried in a valve box with a gravel sump adequate to drain
approximately 1 gallon of water as shown on the details drawing. Installation of the Line
Flushing Valve should be in an inconspicuous area as far away from the source (solenoid
valve) as possible.
1.2.5.3.3 AirVent/Vacuum Relief Valve:
Air/Vacuum Relief Valves should be provided for two reasons:
1. To freely allow air into a tubing after shutdown. This ensures a vacuum doesn’t draw
debris into the drip tubing.
2. To provide a means of releasing air from the drip tubing when the zone is turned on,
thus eliminating air pockets.
Air/Vacuum Relief Valves are installed at the highest point(s) of a subsurface drip-tubing
zone. Instillation of Air/Vacuum Relief Valves should ensure all rows of drip-tubing can take
advantage of the Air/Vacuum Relief Valve, install it on a line perpendicular to the dripline
rows. This may be an exhaust header, or a special lateral connecting all the rows of drip-
tubing such as going over a berm.
The air vent/vacuum relief valve shall be an O-ring seal type with inlet threads of 1/2"
(16mm) MIPT capable of venting air until 4 psi (0,27 Bar) is achieved at system startup,
and vacuum relief when 4 psi (0,27 Bar) is reached during system shutdown. The air
vent/vacuum relief valve shall be rated at a maximum operating pressure of 100 psi (6.8
Bar). The air/vacuum relief valve body and shuttle shall be constructed of corrosive-proof
engineering thermoplastics. The seal shall be a rubber O-ring. Air/Vacuum Relief Valves
should be installed in a valve box with a gravel sump as per details drawings.
1.2.5.3.4 Check Valve:
On slopes in line spring check valves should be installed to avoid wet areas in the lowest
areas in that zone due to low line drainage.
The check valve shall be a preset, adjustable type with 1/2" (16mm) female slip inlet and
outlet capable of eliminating reverse water flow when the system is depressurized. The
check valve body shall be molded from polyvinyl chloride (PVC) capable of being solvent-
welded to any appropriate PVC pipe or fitting. The check valve seat shall be constructed of
rubber. All internal metal components shall be constructed of stainless steel. Opening
pressure of the check valve should be 5 psi (0.3 Bar) and be capable of maintaining

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elevation change up to 12' (3,6m)
1.2.5.3.5 Operation Indicator:
Provide at least one operation indicator per zone. The operation indicator shall include two
feet of 1/4" (6,4mm) blank tubing with a pre-installed barbed coupling. The operation
indicator's stem shall extend to 9" (229mm) with 10 psi (0.68 Bar) of working pressure.
1.2.6 PRESSURE COMPENSATING BUBBLERS (not applicable)
Bubblers shall be constructed from UL stabilized engineering grade plastic and rubber,
delivery shall be pressure compensating in the range of 2.00 to 5.00 bar, delivery shall be
umbrella pattern, flow shall be 1gpm. Inlet shall be ½ inch female threaded.
Stakes for bubblers shall be constructed from strong temperature resistant polypropylene
plastic construction with protective stop collar, length shall be 12 inches each side of inlet
with barbed side inlet suitable for class “C” polyethylene pipes, and outlet shall be ½ inch
external male thread.
2 NOS. BUBBLERS SHALL BE USED FOR EACH PALM TREE, EACH 1 GPM
1.2.7 POP-UP SPRAYERS
The sprayers shall have a high level impact strength corrosion resistant body, stem and
nozzle. Pop - up height should be 4". The sprayer shall have a heavy-duty stainless steel
retraction spring and piston with slip clutch to facilitate nozzle positioning. The sprayer shall
incorporate a wiper seal to protect the internal mechanism against ingress of foreign
material and prevent pressure blow out and shall have an easily accessible under nozzle
screen. The wiper seal should be co-molded type that ensures flow-by of less than 0.10
US. GPM at low pressure and complete sealing at pressure greater than 10 psi. The
sprayer shall have 12mm (1/2") threaded inlet.
ALL SPRAYERS SHOULD BE PROVIDED WITH BUILT-IN SEAL-A-MATIC CHECK

VALVE AND IN STEM PRESSURE REGULATOR TO MAINTAIN CONSTANT OUTLET
PRESSURE OF 30 PSI.
The sprayer shall have the following performance specification at 2 bar operating pressure:
The nozzles shall have precipitation rates matched across sets and across patterns. The
standard nozzle shall be capable of covering 4.5 metre radius at 2.0 bar pressure.
Spacing for the sprayers with standard nozzle shall be 4 meters. For small areas sprayers
with low flow nozzles shall be used as shown on drawings.
Standard Sprayers shall have the following performance at 2.0 bar and 30 trajectory:
Type Radius (m) Flow l/s
Full Circle 4.5 0.23
Three Quarter 4.5 0.17
Half Circle 4.5 0.11

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Quarter Circle 4.5 0.06
Low angle/low gallon age sprayers shall have the following performance at 2.0 Bar and 15
trajectory:
Type Radius (m) Flow l/s
Full circle 3.0 0.10
Half 3.0 0.05
Quarter 3.0 0.03
All nozzles for standard and low angle shall be MPR. Sprayers / sprinklers should be
installed in such a way that water will not hit the stem of the palm trees.
Sprayers and sprinklers shall be installed 30cm away from heel kerb / edge of footpath.
1.2.8 ROTOR POP UP SPRINKLERS
Turbine or gear drive rotor pop up sprinklers, full and part circle operation with Memory-Arc
to automatically return nozzle stream to set arc. Part circle adjustment shall be from
minimum 40 deg. to 350 degrees. All adjustments of the sprinklers shall be from the top.
The internal mechanism is water lubricated. Heavy duty plastic case with multi-function
wiper seal and heavy duty retraction stainless spring. All sprinklers should be provided with
seal-A-matic check valve. Bottom inlet to be 3/4" BSP female threaded. Pop up height to
be not less than 3 5/8". The nozzles of all the sprinklers shall be low pressure models for
proper performance even at low pressures.
The sprinkler shall approx. match the following performance specification at 3.0 bar
operating pressure:
A) Standard (25 deg Trajectory)
Type Radius (m) Flow (GPM)

Three Quarter Circle 12.0 4.4
Quarter circle 9.7 1.6
Spacing for these sprinklers shall not be more than 10.0 meters.
B) Low angle (15 deg Trajectory)
Type Radius (m) Flow (GPM)

Three Quarter Circle 6.5 2.46
Quarter circle 6.5 0.92

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Spacing for these low angle sprinklers shall be not be more than 6.5 meters.
Sprinklers in tree areas should be with low trajectory angle.
1.2.9 PUMPS
Contractor shall be responsible for:
1. Integrity of the system after installation of piping and equipment inside the pumping
station.
2. Entire piping system shall be restrained and/or protected against unbalanced forces.
3. Stress analysis shall be carried out by specialist engineer to design appropriate
supporting system and to maintain loads on pipes and equipment within allowable limits.
1.2.9.1 MAIN IRRIGATION PUMPS (VARIABLE SPEED)
Main Irrigation pumps (variable speed) shall be vertical multi-stage, cast iron body and
base. Jockey Pump (variable speed) shall be vertical multi stage, stainless steel body and
base. The pump section (shaft, impellers, guide vanes and chambers) shall be of stainless
steel. The mechanical shaft seal shall have diamond polished Tungsten Carbide or Silicon
Carbide seal faces and heat resistant O-ring. Thrust bearing shall have ample capacity to
carry the weight of all rotating parts plus the hydraulic thrust of the impellers. Motors shall
be closed coupled type.
Pumps shall be suitable for Treated Sewage/Brackish Water
The inlet and the outlet shall be flanged PN 16.
During normal operation system shall allow for 30-40m head pressure for each automatic
irrigation connection point for streets, open areas and lease lots.
Motors shall nominally 1460 RPM, TEFC Class F, manufactured generally in accordance
with DEWA regulations and electrical specifications. The power rating for the electric motor
should be 30% above the rated power shown in the manufacturer catalogue.
Supply and install packaged pump set for irrigation water supply, designed for the total
system capacity as shown in the pump schedule. The system shall be completely factory
assembled, tested and shipped to the job site as an integral unit ready to receive suction
and discharge piping and incoming electric power.
Package pump set along with the variable speed derive control panel to be assembled
either by the pump manufacturer or by their local representative. Local assembling facility
should be minimum ISO9002 certified for manufacturing and servicing of packaged pump
set and variable speed drive unit.
1. Pump shall be selected for non-overloading characteristics, and the contractor shall
submit performance curve on pumps proposed for installation. Select pumps to operate
near their point of peak efficiency, flexible coupled to an electric motor and mounted on
common steel base plate.
2. Pump shall be of multi stage vertical mounting type to suit the specified capacity.
1.2.9.1.1 Material of Construction

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Material of construction shall be in accordance with ASTM standard / relevant BS

standards
Casing - Stainless Steel (jockey) & Ductile iron (main pumps)
Impeller - Stainless Steel
Shaft - Stainless Steel
Seal type - Mechanical
1.2.9.1.2 Pump base
The pump set shall be mounted on the fabricated M.S channel base frame duly painted.
The base shall be sufficiently rigid to support the pump and motor without the use of
additional support or members.
1.2.9.1.3 Motor
The pump shall be connected to a totally enclosed fan ventilated motor with class F
insulation. Motor shall be in accordance with latest NEMA / BS standards and shall have
following characteristics.
Motor speed - 1460 RPM

Power supply - 400V/3Ph/50Hz
Each motor shall have a sufficient horsepower rating to operate the pump at any point on
the pump’s flow-head curve without over loading the name plate horsepower rating of the
motor. The motor shall be suitable for continuous duty and variation of + 5% in voltage.
1.2.9.1.4 Valves & Piping
Piping shall be GRP, with isolating cast iron epoxy coated gate valve on each pump
suction and discharge, cast iron check valves on each pump discharge, strainer on the
suction of each pump, flexible connectors on suction and discharge of each pump. Provide
pressure gauge in suction and discharge header.
1.2.9.1.5 Control System
1.2.9.1.5.1 General
Pump set to be suitable for 400V/3Ph/50Hz power supply and 240V/1Ph/50Hz control.
The control system shall enable the pumps to maintain a set point pressure with variable
flow rates utilizing pressure sensing to vary the pump speed to suit the flow.
The controller shall utilize a VFD frequency inverter to modulate the speed pump. The
operation shall be controlled by a pressure transducer to determine the actual pressure
and compare the pressure with a reference pressure set in the controller.
The control shall be a purpose built microprocessor dedicated to pump control. PLC control
units shall not be considered.
When the system pressure drops below the System Cut In pressure the controller shall
signal the VFD to run. The pump will ramp up in speed until the Set Point pressure is
reached. The controller shall then modulate the speed of the VFD pump to maintain this
pressure.
On the sensing of no flow the controller shall check that:

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The pump is at minimum frequency

The system is at or about the Set Point pressure
Once these criteria are satisfied then the pump shall shut down.
1.2.9.1.5.2 Electrical Installation
1. All electrical works must be installed to international standards and comply with regional
power authorities requirements. It shall be the contractors responsibility to obtain
permits and inspections from those authorities where required.
2. The Control Switchboard shall be located in a position protected from direct sunlight and
the elements.
3. All equipment mounted within the switchboard shall have all wiring numbered and
confirmed to an `AS BUILT’ Circuit Diagram.
4. The control power supply shall be 240V AC 50Hz with suitable protection to stop
unauthorized access to the high voltage areas.
5. All control wiring shall use multi-strand multi-cored shielded control cable of at least
1mm2.
6. Pressure input shall be via a pressure transducer. The controller shall be suitable for any
full scale pressure transducer that still satisfies the hydraulic requirements.
7. The switchboard shall have Din rail terminals located in the bottom half with the following
inputs/output sized for 2.5mm building wire with auto-isolation of the input voltages to
the main control board.
Pause switch input contacts

System fault output
System Paused output
8. All wiring shall be numbered and conform to the as built circuit diagrams.
9. The switchboard shall be manufactured from 2mm thick mild steel with exterior quality
powder coating applied to prepared surfaces. The Ingress protection shall be to IP54
minimum with removable filter pads for dust ingress protection.
1.2.9.1.5.3 Pump set Controls
MANUAL-OFF-AUTO switches shall be installed for each pump located on the front of the
switchboard with the pump number clearly labeled adjacent to this switch.
Provision shall be made for the control of pump operations as follows:-
MANUAL - run pump irrespective of all other commands
AUTO - Modulating control for the selected pump.
OFF - Selected pump remains isolated at all times
Selection of any of the above functions will not effect the operation of other pumps.
After restoration of power following a power failure the system shall power up to normal
operation with the system operating with the previously set parameters. Power up to
DEFAULT parameters shall not be acceptable.
Any failure of the VFD shall not preclude the MANUAL operation of the system.
The control of the pump set shall incorporate the following protection features.

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For individual pumps-

Thermal overload shut down
For pump system-

Low system pressure shutdown
High system pressure shutdown with programmable restart options
System pause activated by external input with both emergency and controlled pause
options
High pressure limit which trips pumps at a controlled rate and decelerates the VFD at max
to obtain a lower pressure.
Individual protection for each pump with associated delay timer.
PID adjustment on the controller for reaction tuning
Selectable lead pump options with external lead pump selection or time based lead pump
rotation
3 set points
Optional pressure trips for external control of other devices.
The shutdown events must be resettable by any operator & a relay shall be available to
drive an indicator such as a dome light in case of a shutdown occurrence.
1.2.9.1.5.4 Data Log
The control system must log data for display on the screen. The items to be logged are:
Hours run per pump
Flow rate
Total flow
Fault history
Resetting of these items to zero shall be made from screen key presses.
1.2.9.1.5.5 Menu Structure
The controller shall have a nested menu structure that allows access to specific areas for
site tuning. The menus shall be in English text. Abbreviations shall not be accepted.
1.2.9.1.5.6 Ambient Requirements
All control equipment shall be rated to a minimum of 50 deg. C & 90% humidity without
causing any shutdown. The unit shall be cooled by means of an internal fan sized to
maintain lower than maximum temperatures within the unit. The control box shall be
mounted under cover away from any direct sunlight with access denied to unauthorized
personnel.
The enclosure shall be rated to IP54 with forced cooling fans designed to handle heat
extraction of suitable capacity assuming a 3% VFD power loss. This calculation shall be
made with an ambient temperature of 46 deg.C. Calculations shall be provided if requested
to prove this capacity.
1.2.9.1.5.7 System Security
The control system shall have the feature of selective entry for personnel based on key
press. Sensitive areas of adjustment shall be accessed by a security code. All areas that
would effect the configuration of the system shall be security protected.

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1.2.9.1.5.8 Outputs
The controller shall have 4 programmable outputs that can be selected to any of the
functions listed below but not limited to these options. They shall be rated to 10 amps
240VAC with change over contacts.
Shutdown Fault
Low Pressure Fault
High Pressure Fault
High Pressure Alarm
Pump Run
Pump Shutdown
System Paused
Any pump shutdown
Any pump running
No Flow Shutdown
VFD Fault
Pressure Trip
1.2.9.1.5.9 Inputs
The controller shall have 4 fixed voltage free inputs and a minimum of 8 programmable
inputs. The programmable inputs shall have the following options:-VFD Fault
Set Point 2
Soft Pause
Pump Protection
Pump Stop
Phase failure
Fire Mode
Pump Manual Run
Cycle pumps
Shutdown No Flow
1.2.9.1.5.10 Telemetry
The controller shall be capable of communicating with an external telemetry system based
on digital Inputs and Outputs from a remote source.
1.2.9.1.5.11 Quality Requirements
The following documentation is required as a minimum.

Pump system Test Report showing testing of:
Set point
Loss of prime
Alarm functions
System security
Shutdown functions
Phase failure test
1.2.9.1.5.12 Documentation
The contractor shall provide the following documentation prior to Practical Completion
being awarded:
- Instruction manual for the controller
- As-built drawings of the mechanical components in AutoCAD format copied to DVD

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- A1 sized drawing of the as built pump station.

- Full set of circuit diagrams on AutoCAD 2000 format
- Bound copy of as built circuits with pump station showing all circuits, exterior
dimensions and components, detail of all components used within the switchboard by
Make & model.
- VFD instruction manual
1.2.9.1.5.13 Compliance Table
All items on this compliance table must be satisfied to accept the offer.
ITEM COMPLY
Control features Yes No
IP Compliance Yes No
Switchgear included Yes No
Pump protection Yes No
Input capacity Yes No
Output capacity Yes No
Set points – 2 off Yes No
Data log suitability Yes No
Switchgear standard Yes No
VFD type Yes No
Cooling capacity Yes No
Telemetry serial communications Yes No
TEMPERATURE RATING 40degC Yes No
OUTPUTS Yes No
Documentation Yes No
QA compliance Yes No
1.2.10 STORAGE TANK
1.2.10.1 General
Aboveground GRP water storage tank shall be installed for the project and to be connected
to the pump room.
1.2.11 FILTERS
Automatic self-cleaning filters specifically designed for use with organic contaminants.
Cleaning shall be effected by a hydraulically powered suction scanner, automatically
activated when the differential pressure across the filter reaches an adjustable level,
nominally 5 psi.
The screen shall be stainless steel grade 316 with 200 micron mesh size. Flushing line to
be connected to the soak pits or nearest storm water manhole.
The control system shall feature a fail safe timer to prevent continuous flushing due to
malfunction.
The control System for the filters should be such that it will not flush the filters if the pumps
and/or irrigation system is not operating. Filters should flush; only during the operating
hours of the Irrigation System.

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All the filters shall have isolation valves in the suction as well as delivery side for easy
maintenance. The controller for the filters shall be equipped with timer and pressure
differential control unit. Controller will be fixed in the Electric control panel.
All nuts and bolts shall of stainless steel grade 316 or A4-70.
The filter body and internal parts including flanged connection shall be stainless steel.
Pressure gauges to be connected to suction and delivery side of each filter, pressure
gauges to be mounted in the Electric control panel in isolated compartment.
1.2.12 PRESSURE GAUGES
Pressure gauges for filtration chambers shall be stainless steel, direct reading, Glycerin
filled capable of 0-10 kg/cm2 register with 0.25 graduations. Gauge shall be of glass or
Plexiglas faced drip-proof and minimum dia. of 50 mm. Gauge cock shall be of same size
as pressure gauge and be fabricated from stainless steel.
1.2.13 UNDERGROUND WARNING TAPE
Warning tape shall be laid above main pipes. Tapes shall be durable and detectable by
Electro-Magnetic means using low output generator equipment. They shall remain legible
and color fast in all soil conditions at PH values of 2.5 to 11.0 inclusive.
The tapes shall be flexible and subject to the Engineer's approval. Width of the tape should
be at least 6"(150 mm.).
Tape shall be Orange color with Black text in Arabic and English as “CAUTION:
IRRIGATION PRESSURE MAIN BELOW ". The text on the tape shall be permanent ink
bonded to resist prolonged chemical attack by corrosive acids and alkaline with message
repeated at a maximum interval of two meters. The tapes shall be laid 300 mm above the
pipeline.
The tape shall be continuous over pipelines and at joints there should be a minimum of one
meter over lapping.
1.2.14 ELECTRICAL EQUIPMENT
All electrical equipments shall be in accordance with DEWA regulations and electrical
specification. Enclosures shall be protected in accordance with IP55 for equipment
installed above grade and IP58 for equipment installed below grade.
Wiring to and from control panels shall be routed in PVC conduit below the ground. Above
grade conduit to be liquid tight flex, or galvanized steel, provision to be made for inspection
tee's and ells to facilitate removal in the future.
Name of approved manufacturers for electric components are as follow:
1. SIEMENS
2. LEGRAND
3. ABB.
1.2.14.1 ELECTRICAL WIRE FOR SOLENOID VALVES AND SATELLITES
All electrical wire for underground use shall be single core solid "Underground Feeder" type
insulated with a flame-retardant thermoplastic compound, rated for 600 volts and direct

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burial. The Contractor shall prepare a wire-sizing chart with effective lengths of each
station and common wires, which shall be submitted, for approval prior to commencement
of work. Cable markers shall be used for indicating valve number each cable at both ends
as well as at splices. Cables shall be laid in PVC conduits.
Two-way signal cables should be laid in separate conduits between irrigation Controller
and Main control panel for future use. Separate wire to be laid for each solenoid valve, and
valve combination to be arranged at the respective Irrigation Controller. Power cables for
Irrigation controllers shall be armoured cables without any conduit for it.
Two-way Signal wire between the Main Control Panel and the Irrigation controllers should
be doubling jacketed, two conductor cables intended for future central control system.
The cable manufacturer should certify that the insulated conductors have been tested for
and meet the requirements of U.L.
The two conductors shall be color coded with one conductor BLACK and the other RED.
The conductors shall be tin coated, soft drawn, annealed solid copper conforming to the
requirements of ASTM -33.
The cable shall be suitable for direct burial in the earth, whoever it is required to be
installed in ducts or conduits.
Pull boxes shall be provided at every place of change in direction of conduit piping, near to
solenoid valves. In any case spacing between adjacent pull boxes in a line shall not exceed
50 meters.
Size of the cable depends on the distance between the Main Control Panel and the field
Controllers and according voltage loss calculations.
Sizes of the conduits should be as follows.

1” up to 4 wires
1 1/2” up to 8 wires
2” up to 15 wires
3” up to 30 wires
4” more than 30 wires
Provide minimum one spare cable for every five cables.
Irrigation control cables shall be color coded as follows
1. Common wire ....................Black

2. Drip valve wire ………..….Blue
3. Bubbler valve wire …… Red
4. Spray valve wire … … Yellow
5. Sprinkler valve wire … … Orange
6. Spare wire……………… White
SEPARATE PULL BOXES SHOULD BE USED FOR POWER CABLES AND MAXI COM
SIGNAL CABLES.
1.2.14.2WIRE CONNECTORS
All wire connections at electric remote control valves and all splices of wire in the field shall
be made using wire connectors. The wire connectors shall be specifically designed to

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ensure waterproof underground wire connections. The connectors shall be under-writers

laboratories listed water-resistant wire connectors; rated 600 volts for PVC insulated
copper wire with insulation temperature rating of 105 degree C.
The connector shall be insulated with color coded, pliable, vinyl skirt. They shall feature
alive spring which assures a tight grip even on small wire combinations.
All wire connections to be arranged in plastic pull boxes at fixed interval distances of max.
100 meters and/or at any change of direction.
All valve combinations shall be arranged at the controller.
1.2.14.3 ELECTRIC PRESSURE SWITCHES
Pressure switches shall be fabricated from die cast aluminium per ASTM B-85 and
designed to meet IP65 specifications. Transducers shall be fabricated from brass and buna
N.
The pressure switches shall incorporate an alternating fulcrum balance plate allowing
independent adjustment of both set and reset point over the full range.
Both set and reset points shall be adjustable 1.40 to 14 bar, having a minimum dead band
range less than or equal to 1.40 bar. Repeatability shall be +/-0.5% to 2% of full scale.
Switches shall be vibration resistant and shall have front access to electrical connections
and adjustment nuts.
1.2.14.4 FLOW SENSING AND CONTROL SYSTEM
Flow sensing and control system to sense the flow data and display that data as both flow
rate and volume on digital indicator.
Sensor should be Flanged Electro-magnetic type as specified below.
Digital Indicator displays for both flow rate and total volume to be provided and to be
mounted inside the panel. The digital indicator unit should be powered with external 220
volts AC power supply and rechargeable Lithium battery. The unit can run of internal or
external power and should have automatic changeover switch which is activated during a
power failure. The battery will be automatically recharged during normal mains operation.
Flow sensing and control system should sense high flow rate (above the max. flow rate for
any combination of valves) and close the butterfly valve in filtration chamber.
1.2.14.4.1 ELECTROMAGNETIC FLOWMETER FOR TREATED SEWAGE EFFLUENT (TSE).
1. General
Flow meter shall comprise of a flow sensor and a transmitter unit. The Transmitter and
Display unit shall be remotely mounted in a dedicated Control Panel. The flow meter shall
be microprocessor based modular design. Total measuring system shall be suitable for a
minimum ambient temperature of +60º C. Each meter shall be provided with the validation
on site without removing the sensor. Flow meter processor unit must be digital to reduce
noise level. All inputs, outputs and power supply shall be galvanically isolated. Overall
accuracy should be +/- 0.5% and repeatability shall be 0.1% or +/- 0.5 mm/s (or = of
reading).

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Each unit shall have electromagnetic compatibility with more than 10 V/m and shall
withstand an isolation test up to 1600 V for 2 sec. min. Complete flow meter should have
good resistance to shock and vibration. It should withstand acceleration of 2g/2h per day,
10-100 Hz.
2. Sensor
Submersible, flanged process connection of carbon steel material with Zink aluminium alloy
coating rated suitably for TSE application. Metering tube shall be at least SS 304. Each
sensor should have 2 measuring electrodes, 1 empty pipe detection electrode and 1
reference electrode. It is essential to have additional empty pipe detection electrode for
proper detection of pipe condition. Electrodes material shall be stainless steel SS 316.
Sensor housing material should be powder coated die-cast aluminium. Sensor lining shall
be polyeurethane, abrasive resistant, suitable for TSE & potable water. Each sensor shall
be protected to IP 67 or IP 68 as required. If the sensor is installed in a flow chamber
sensor must be IP 68. Also, IP 68 protection shall be from the manufacturer, without using
any external kit or gel locally. The connection cable between the sensor and transmitter
should be original and fitted and potted from manufacturer. The coil cable shall be 2x0.75
mm2 PVC braided copper shield and the signal cable shall be 3x0.38 mm2 PVC braided
copper shield.
In case of non conductive pipe materials grounding rings shall be used for proper
grounding or complete meter must be isolated.
3. Transmitter.
The transmitter must be microprocessor based remote wall mounting type. It shall have
modular design and field configurable by its built-in buttons via matrix. Transmitter housing
shall be robust powder coated diecast aluminium construction with IP 67 protection. It is
essential that the transmitter is of modular design for ease of maintenance and future
expendability. In case of any fault in the transmitter one should be able to change
individual modules. The flow meter shall have 4-20mA DC (into a minimum 1,000-Ohm
load) HART and Pulse (frequency) analog output suitable and compatible with the project
SCADA system. Relay output – 8SPDT contacts rated 8A at 250VAC.
It should have 2-line, 16-character LCD display for flow rate and totalized flow indication
with LED back lighting. Transmitter should be configurable for error messages, empty pipe
detection, flow direction etc.
The sensor and transmitter shall be connected with 10m cable from the manufacturer. The
coil cable shall be 2x0.75 mm2 PVC braided copper shield and the signal cable shall be
3x0.38 mm2 PVC braided copper shield. The meter should be able to operate at the
voltage range of 100-260 VAC, 45-65 Hz supply.
Digital indicator displays for both flow rate and total volume to be provided and to be
mounted inside the panel. The digital indicator unit should be powered with external 220 /
230 volts AC power supply and rechargeable lithium battery, which can operate
continuously for five hours. The unit can run of internal or external power and should have
automatic changeover switch which is activated during a power failure. The battery will be
automatically recharged during normal mains operation.
Flow sensing and control system should sense high flow rate (above the max. flow rate for
any combination of valves).
4. Other Requirements.

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Factory calibration shall be provided with a Flow meter.
Installation of all equipment and components shall be in accordance with approved shop
drawings and installation instructions furnished by the equipment manufactures.
The Flow transmitter, controller and indicator to be installed remotely for easy access and
maintenance. Sunshade protection to be for all equipment if required.
Suitable connections shall be provided and allowed for future interface with a general
project SCADA monitoring system.
Recommended manufacturers: Krohne, Endress+Hauser, Sparling, Foxboro,

Schlumberger or equal approved.
1.2.15 SYSTEM CONTROLLING EQUIPMENT
1.2.15.1 ELECTRICAL CONTROL PANEL
All control panels should be assembled by one of the following approved companies:
1 - BLACKBURN STERLING.
2 - SCIENTECHNIC.
3 - BIN GHALIB.
4 - ABB.
5 - DANWAY
6 – AL GHANDI SWITCHGEAR INDUSTRY
A - MAIN CONTROL PANELS
Electrical control panels for this project shall be constructed of mild steel sheet enclosures
with stainless steel 316 lock and hinges front opening door having a protection range not
lower than IP 65 according to IEC and to be class 3. The panel shall have provision for
connecting to generator.
The Control Panel For Filtration Chamber shall be Form 2 and that for pumping station,
Class 3 ( Form 4 ) and all the control panels to be fixed in GRP kiosk on concrete base
(300 mm above ground level).
The panels to be fixed beside the filtration chamber/pump room as per the Engineer’s
approval and shall include the followings:
1- IRRIGATION PUMPS CONTROL SYSTEM

2- FLOW METER DISPLAYS.
3- EXHAUST FAN CONTROL.
4- BUTTERFLY VALVES CONTROL GEAR.
5- LIGHTING SYSTEM
Panel shall have main circuit breaker for the power main and earth leakage protection.
Each power circuit should have circuit breaker, earth leakage protection and power
indication lamp. Each switch and light on the exterior of the panel shall be marked with an
engraved plastic name identifying each item. Truncking shall be used when wiring the
panel. The panels shall have serially numbered terminals for terminating all incoming and
outgoing cables. Anti-condensation heaters should provide inside the panel. The panel
shall be installed above Pump or filtration chamber. Pump or filtration system Control
panels shall strictly be as per DEWA and /or DM standard Specifications in all aspects and
subject to the Engineer’s approval.

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B – CONTROL PANEL FOR FERTILIZER INJECTION UNIT
Same as above to accommodate the control system and injection pump switch gear.
1.2.15.2 IRRIGATION CONTROLLERS
The Irrigation controllers shall be solid state type and shall have 220 Volts power input and
26.5 Volts, 50 cycles.
If the input Voltage to the controller is other than 220 Volts AC, the Contractor must ensure
continuous regular Voltage to controllers’ equivalent to the input Voltage marked out on the
controllers. If Voltage fluctuations are noted, controllers must be equipped with automatic
voltage regulations.
The controllers shall have 24 stations as mentioned on drawings. The controller should be
weatherproof lockable cabinet with minimum one meter high stainless steel pedestal. The
pedestal to fixed on proper concrete base, 300 mm above ground level. All irrigation
Controller(s) shall be installed in GRP Kiosk enclosure.
The two way signal cables from the controllers shall be laid up to the Main electric control
panel for future use. The power supply for all Controllers on a pumping station / filtration
chamber should be taken from single source.
Power supply to the controllers should be by armoured cables. No conduit is required for
these armoured power cables. Contractor to provide calculations for cable sizing for the
Engineer's approval. Size of the power cables should not be less than 2.5mm2 X 4 cores.
Cables laid under ground should be tested in accordance to IEC standards and DEWA's
standards for insulation resistance, continuity etc. in presence of DM and the Engineer
before the backfilling of the cable trenches
The contractor has to check the number of electric valves connected to each station, if
number exceeds the manufacturer recommendation a multi-station relay has to be included
with the corresponding controller. Lightening protection shall be provided for all controllers.
1.2.15.3 FILTER CONTROLLER
Allow cascade flushing of filters if differential pressure exceeds 0.30 bar, or on command
from central controller. Flush time to be adjustable. Control panel to be provided with a
flush counter (reset able) and a selector switch to allow manual flushing, and/or cancelling
each automatic function.
Controller to be provided with circuits to flow switch mounted in the flush lines to detect any
flow of water after the flushing cycle has ceased, and linked to the alarm circuit, time delay
2.00 minutes. The controller will be mounted inside the electric control panel.
1.2.16 CHAMBER IDENTIFICATION PLATE
Chamber Identification plate is to be made to sizes shown on drawing and shall be of

"Admiralty Brass" BS Code No.CZ III BS 2871. The plate to be 5 mm thick with two lags
150 mm long 20 mm wide by 5 mm thick welded at the back. The plate is to have
engraving 2 mm deep as shown on the drawings for each relevant chamber.

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1.2.17 DUCTING
uPVC ducts shall be class B to BS3506 pressure tested. Duct markers shall be used and
should be aluminium and shall clearly indicate the name in Arabic and English: IRR ".
1.2.18 EXHAUST FAN
Extra heavy duty industrial type Aluminium body exhaust fan to be fixed in the Pump
Room.
1.2.19 FERTILIZER INJECTION UNIT
The fertilizer/chemical injection unit shall comprise of 1000 litre rigid polypropylene make
tank with reinforced ribs mounted on a pedestal and a suitable dosing pump complete with
valves and fittings, filters and connecting pipes.
The elevated make up tank shall have level marks molded into the side of the tank. A
second outlet complete with stop-cock shall be provided in bottom of tank for draining and
washing out. An agitator shall be provided to ensure that there is no separation of liquids.
The agitator unit shall be removable to allow access for cleaning the tank.
The dosing pump shall be constructed of corrosion resistant material, close coupled to a
suitable splash proof electric motor. The unit shall have an operating head of 70m over the
full flow range. The injection rate shall be set manually to required flow.
The Fertiliser tank should be fixed to ground using stainless steel straps and nut/bolts
(grade 316) which will keep the tank at its place in case of flooding.
1.2.20 SURGE ANTICIPATOR RELIEF VALVE
Surge anticipator relief valves shall be fluid actuated and have a single moving assembly.
A flexible, non-wicking, FDA approved, nylon fabric reinforced synthetic elastomer
diaphragm shall be integral with this assembly to form a sealed chamber, operating free of
drag or wear. The diaphragm shall not be used as a seating surface. This assembly shall
have a stem which is fully guided by separate upper and lower bearings to preclude
bending or deflection. When the valve is in the closed position sealing at the seat shall be
accomplished by the contact and a smooth seat surface. The seat design shall be
removable and shall not have edges that will induce seal cutting, or wear at low flows.
Progressive throttling of flow shall be accomplished by a characterized profile quad ring
retainer washer. The valve body and cover shall be of ductile iron / cast iron. An FDA
approved fusion bonded epoxy coating shall be applied to the internal and external
exposed surfaces of these components after cleaning and degreasing. This coating shall
be standard on all basic valves. All internal valve components shall be removable and
repairable while the valve body remains in the line. Packing glands and/or stuffing boxes
are not permitted and there shall be no pistons operating the valve or controls. Valve sizes
2-3” shall be standard equipped with a flow-clean strainer mounted in the inlet supply port
of the main valve. Valve sizes 4” and larger shall be standard with an externally mounted y-
strainer for protection of the control circuit and WATTS ball valves to isolate the pilot
system from the main valve.
The valves shall open on a low or high pressure wave. The high pressure relief pilot shall
be set to open at any pressure above the normal operating pressure of the system. The
high pressure control shall be adjustable, spring loaded, normally closed, direct acting,

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diaphragm valve designed to permit flow when controlled pressure exceeds the spring
setting. The low pressure pilot shall be set to open the main valve at any pressure below
normal system operating pressure.
It shall be an adjustable spring loaded, direct acting, normally open, diaphragm actuated
valve. The low pressure control shall control the filling of a hydraulic accumulator which
opens the main valve and prevents the main valve from remaining open an excess amount
of time. The control system shall have adjustable opening and closing speed needle
valves. The specification shall note when valve 6” and larger are to be installed with the
system in a horizontal position.
All valves shall have a drain plug at the bottom of the body.
1.2.21 DOSING PUMPS
Dosing pumps shall be of the diaphragm type and shall have the following as a minimum
standard:
i) Hypalon chemical diaphragm

ii) PVC-U metering head
iii) Viton valve seats
iv) PTFE faced working diaphragm
v) Caustic soda stainless steel valve balls
vi) Sulphuric acid and sodium hypochlorite – glass valve balls
vii) Capability of altering dosing rate from 10-100%
viii) Integral pressure relief valve
ix) Pulsation dampers
1.2.22 RUBBER EXPANSION JOINTS (RUBBER BELLOWS)
1. The rubber expansion joints shall be used for absorption of vibration in pipes,
absorption of all type of movements such as axial compression, axial elongation,
lateral and angular deviation, connection of pipes which are not properly lined up,
water hammer reduction etc.
2. It shall be PN10/PN16/PN25 as per piping design. Generally it shall be PN10 but

tenderer/supplier to verify.
3. Technical Details:
TYPE: SINGLE ARC WITH VACUUM RING WITH TIE

RODS
FLANGE DRILLING PN10/PN16 PATTERN TO BS4504
WORKING PRESSURE. 1OBAR/16BAR
AXIAL COMPRESSION AS WRITTEN IN TABLE
AXIAL ELONGATION AS WRITTEN IN TABLE
LATERAL DEFLECTION AS WRITTEN IN TABLE
ANGULAR MOVEMENT AS WRITTEN IN TABLE
TORSION MOVEMENT 1-5˚
TIE RODS 8NOS or AS PER REQUIREMENT with
LOCKNUT, SPHERICAL WASHERS AND
SEATS

DUBAI – UAE
VACUUM RING ONE IN THE ARC and TWO

RINGS AT THE CORNER
ORIGIN: WESTERN EUROPE/ USA
4. Materials of construction:
Bellow : EPDM rubber combining different layers of fabrics to get the Desired
flexibility as well as a long resistance to aging. It shall be on full face of
flange. Part face on flange is not acceptable
Backing Flange: Carbon steel – with rust preventive treatment of zinc plated. Tie
Rods : Carbon Steel – with rust preventive treatment of zinc plated
5. Flange drilling pattern shall be as per BS 4504 PN10/16/25
6. Nuts, bolts and washers and all fasteners shall be AISI type 316.
7. It shall be single arc designed type double flanged (flange/flange) rubber expansion joint
and suitable for flanged pipe work of water pumping stations.
8. The fluid is potable water of maximum temperature of 50˚C. The fitness certificate in
contact with potable water up to minimum 50 degree C shall be submitted from Water
Regulation Advisory Scheme (WRAS), U.K. or equivalent authority.
9. The material shall be high quality Rubber with necessary reinforcement to

withstand abnormal sudden pressure change inside the pipeline and vibration.
10. The rubber material shall be suitable for use under direct sunlight associated with ultra-
violet radiation and protection against ozone evolved from electrical motors or other
sources and special coating for U.V. and ozone protection shall be provided
11. The rubber flange shall be supported from the back by a zinc electroplated/
stainless steel flange. The joints have to be provided with galvanized/ stainless steel
Tie rods against the back of the flanges and through to the mating flanges of the pipe. One
metal reinforcing ring of stainless steel has to be provided at the base of the arch to add
strength between the convolutions and two rings at the corner. All rings shall be
embedded inside rubber.
12. The supplier have to provide Hydraulic test certificates during delivery of material.
13. Marking:
The following marking shall be provided on the body of the Expansion Joint.
• Manufacturer name/ origin / Trade mark.
• Nominal Diameter in mm.
• Pressure rating in Bars.
• Date of manufacture.
14. Submission:

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• The supplier have to provide full technical details of the Expansion joints including original
catalogues and production shop drawing from the manufacturer along with their offer.
• Details of Tie rods brackets for Tie rods.
• Service, Installation & Maintenance Manual during the delivery of the material.
15. WARRANTY:
The supplier and manufacturer have to provide at least 24 months of service warranty of
rubber joints along with their offer. During this period if any failure occurs the
supplier/manufacturer/contractor have to replace the same at free of cost.
16. It shall have following dimensions and movements
Dia. - face to face Working Movements Axial Lateral Angular

DN dimension - pressure Axial Tension deflection deflection
L - PN compressio
mm m bar mm (-) mm(+) Mm(±) degree(±)
300 25 10/16 4 20 20 10
450 30 10/16 4 15 30 6
500 30 10/16 4 15 30 6
600 30 10/16 4 15 30 6
700 30 10/16 4 15 30 6
800 31 10/16 4 15 30 6
900 31 10/16 4 15 30 6
1000 31 10/16 4 15 30 6
1100 35 10/16 4 15 30 5
1200 35 10/16 4 15 30 5

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1.3 IRRIGATION SYSTEM, EXECUTION
1.3.1 EXCAVATION AND BACK-FILLING
Prior to trenching all services crossing or running close to the line of the trench shall be
identified and exposed. In addition the line of the trench shall be swept using an approved
detection device, capable of detecting both live and 'dead' cables.
Trenches shall be made as narrow as practicable, but not less than the pipe diameter plus
300mm, and shall provide sufficient room for lying jointing and testing. The width of the
trench at the crown of the pipe shall not exceed the pipe diameter plus 600mm. Sheeting,
bracing and shoring shall be used to provide for the safety of all personnel for all trenches.
The trench bottom shall be composed of stable uniform sand with no protuberances that
might cause point loading of the pipe. The trench formation shall be trimmed to an even
finish which will provide continuous support for the pipe. Additional excavation shall be
carried out at the position of the pipe socket to ensure proper joint assembly and pipe
support.
If the existing formation is unsuitable for direct laying, the pipes shall be laid on a bed of
imported sand 100 mm thick (minimum). This sand may be sourced from sieved excavated
material, but should not contain any particles larger than 5 mm, and should have good self
compacting properties.
De-watering shall be provided to remove any surface or ground water entering the
excavations. Ground water level shall be maintained at least 100 mm below the bottom of
each excavation.
The trench should not be excavated more than 3 days production rate in front of pipe
laying.
Pipes shall be center loaded leaving joints exposed within three days of laying. Initial back-
fill shall be by hand in 300 mm lifts, and carried out in such a manner as to ensure adequate
support under the pipe and distributed evenly to ensure there are no voids under or to the
side of the pipe.
Back-fill material shall be sand and shall be compacted by water tamping once the level of
back-fill reaches the crown of the pipe.
For pipe sizes 4" ( dia ) and above , back-fill material shall be deposited in 300 mm lifts in
general areas and compacted to relative degree of compaction of 95% ( by approved
method )and tested by large pouring method. In paved areas layers shall be 150 mm
and back-fill shall be compacted layer by layer to reach relative degree of
compaction of 95% to DM roads department approval. Mechanical compactors shall not
be used until there is a minimum of 300 mm above the crown of the pipe.
Back-fill material shall be sand and shall not contain any particles larger than 25 mm for the
first 100 mm above the pipe; thereafter back-fill material shall contain no particles larger
than 50 mm.
Whenever ambient temperatures exceed 35 degrees centigrade, center loading for PVC
pipes greater than 3" shall only be carried out in the early morning, or shall alternatively be
preceded by cooling of the pipe string by application of water.
For pipe sizes of 3" and below compaction as mentioned is not required.

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1.3.2 PVC PIPE INSTALLATIONS
PVC pipes shall be stored on site in a covered pipe store. Pipe stacks shall not be greater
than seven layers or two meters high. Pipes shall be shielded from the sun at all times and
shall be placed on a sand bed, or on supports at least 75 mm wide and placed not greater
than 1.50 m apart; side supports shall be similarly constructed and placed not greater than
3.00 m apart. The pipe store shall allow for circulation of air. Rubber sealing rings shall be
stored inside closed boxes in a shaded place, and shall on no account be exposed to
sunlight for more than a few hours.
Pipes shall be transported on the site on a flatbed trailer, and should never be dropped or
dragged along the ground.
Spigot ends of all pipes shall be chamfered to a depth of half the wall thickness at an angle
of 15 degree. Pipes cut on site should be cut square to the pipe axis with a fine toothed
saw. All swarf and burrs should be removed from the pipe prior to assembly of joints. Pipe
cutters may be used for 1" pipe. Spigot insertion depth shall be measured and marked on
all pipe larger than 3" using indelible ink to allow checking at a later date.
Ring joints shall be made using an approved non ionic lubricant compatible with the sealing
ring. Pipes sized up to 8" may be jointed using a crowbar and a timber protection piece,
joints larger than 8" shall be assembled using a clamped lever device. Before back-filling
joints shall be checked to ensure that the spigot is inserted to at least 90% of the socket
depth in all circumstance.
Solvent welding shall be carried out by experienced fitters who fully understand the
technique, and have successfully made a solvent weld joint in the presence of, and to the
approval of the Engineer. Helpers brought up on site may only be allowed to make solvent
joints after inspection of their technique by the Engineer.
Solvent welded joints made on pipe 3" and above shall be preceded by lightly sanding both
surfaces to be jointed using a medium glass paper or clean emery cloth. Solvent "cleaner"
shall be applied to all mating surfaces using a dauber or brush (application using rags will
not be allowed). After ensuring that mating surfaces are clean and dry solvent cement shall
be applied in sufficient quantities to ensure bonding, but not in excessive quantities that will
leave appreciable residues inside the pipe.
Brush size shall be 3/8" round for 1" pipe, 1" flat for 1-1/2" pipe and 2" flat for larger pipes.
Solvent cement should be applied by two people simultaneously for pipe 3" and above.
Immediately after application of solvent cement pipes shall be pushed together in a smooth
continue motion, that ensures that the spigot is at least 90% inserted into the socket, the
joint shall be held for a minimum of 20 seconds after insertion, and then surplus cement
shall be cleaned from the outside of the pipe using a rag or paper. Solvent cement and
cleaner shall be provided in tins with brush or dauber fixed to the lid of the tin. The lids shall
be firmly closed at all times except when the joint is being made. Any tins of solvent cement
that become viscous or hardens shall be disregarded.
On no account shall brushes on which solvent cement has hardened be used for making
joints. All fitters involved in solvent cement jointing shall be provided with safety gloves that
prevent solvent touching the skin, gloves shall be kept in good condition and shall be
replaced periodically.
Jointing shall not be carried out in windy conditions (wind speeds greater than 18 km/hour).
All lines shall be capped at the end of the days work.

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uPVC mains with sizes 8" and above shall have minimum cover of 1.2 mete over the top of
the pipe. Mainline sizes 6" and below should have minimum cover of 1.0 meter. Pipes
should be laid in such a way it should have minimum clear space as per DM standards &
requirements from other services and trees.
Please note that uPVC lateral lines should have minimum cover of 60 cm over the crown of
the pipe. Laterals should be laid in such a way it should have minimum clear space as per
DM standards & requirements from other services.
Minimum distance of uPVC Lateral lines for drip and bubblers system from the centre
line of trees shall be as follows.
Palm Trees ------------------------------------------------------- 2.0 metre.
Trees---------------------------------------------------------------- 1.5 metre.
Shrubs------------------------------------------------------------- 1.0 metre.
1.3.3 DRIP LINE PIPE
Drip line pipe shall be installed above ground as shown on the drawings and shall be
anchored to the ground with staple stake at every 10m.
1.3.4 VALVES
Butterfly valves, Gate valves, air valves and solenoid valves shall be installed as shown on
the drawings. Installation shall be neat tidy. Valve boxes shall be installed level and aligned
with the pavement.
Cover of the valve chambers and valve boxes shall be level and aligned with pavement as
instructed by the Engineer.
1.3.5 IRRIGATION EQUIPMENT
Equipment shall generally be installed to achieve optimal irrigation efficiency and to

accommodate the requirements of the landscaping. All irrigation equipment such as spray
heads and emitters shall be installed only after all the laterals and risers are flushed
thoroughly. The half circle spray heads should be installed at least 50 cm away from kerb
stone.
1.3.6 IRRIGATION CONTROL EQUIPMENT
The Contractor has to follow strictly the instruction of the suppliers and provide the Engineer
with all technical information related to this equipment.
1.3.7 TESTING
1.3.7.1 PIPELINE PRESSURE TEST
The length of test section shall be maximum 500 m or as directed by the Irrigation Engineer.
The pipe length to be tested may be blanked off using a blank iron or steel flange previously
drilled and tapped for test equipment connection and strutted as necessary against end
thrust. The blank flange may be attached to the pipeline by a V.J. flange adopter or similar
fitting.
Testing should not be carried out against closed valves. All charging and testing should
preferably be carried out from lowest point of the under test section and all testing
equipment should be located at this point.
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The pressure gauge also should be located at the lowest point or adjustment must be made
for the level of the pressure gauge relative to the pipes location.
Prior to testing, care should be taken to ensure that all anchor blocks have attained
adequate maturity and that any solvent welded joints included in the pipe system have
developed full strength. Correct support and anchorage of any above ground sections of the
pipeline is also necessary. Underground pipelines should be back-filled, taking particular
care to consolidate around lengths which may have been deflected to negotiate curves.
All joints should be left exposed until testing is completed.
The main pipe should be charged slowly, preferably from the lowest point with any air cock
in the open position. They should be closed in sequence from the lowest point only when
water visibly free from aeration is being discharged through them.
Satisfactorily charged, the main should be allowed to stand overnight to allow any residual
air to settle-out. Reventing is then necessary and any water deficiency should be made-up.
Pressure testing can then begin by pumping slowly until it reaches to 9 bars. This pressure
shall be kept for 24 hours.
A permissible water loss of 3 liters per 1000m length per 25 mm nominal bore per 24 hours
shall be considered reasonable for PVC pipe.
For AC pipes the pressure test should be according the manufacturer's recommendation.
1.3.7.2 PAINTING
Dry film thickness (DFT) of all painted valves and spool pieces shall be measured on
delivery to site. DFT shall be the average of no less than three measurements, with no one
measurement less than 75% of nominal average DFT. Holiday tests shall be carried out on
internal and external surfaces on delivery, and also on external surfaces prior to back filling.
1.3.8 ROAD CROSSINGS
All crossings across major roads/dual carriageways and U-turns shall be either through
ducts or no dig method.
Where it is necessary to cross roads in order to complete the work, the Contractor should
first obtain N.O.C. from service companies and submit where appropriate for road cutting to
DM's road Department. The Contractor should follow strictly DM's regulations. Ducts to laid
at least 100 cm below tarmac surface.
Road cutting will only be permitted if it can be proved that all forms of non disruptive method
of crossing is possible. In the event of road cutting is permitted, the reinstatement of wearing
course shall be extended to 15m from each side of the disturbed edge of trench.
Traffic diversions shall be carried out in accordance with the requirements and approval of
Roads & Transport Authority Roads Department & Dubai Traffic Police. If trench is left open
overnight, proper lights & caution lights shall be provided.
Trenches to be back filled with fine gravel around ducts to minimum depth of 50 cm.
Remaining depth to be back filled with 15 cm thick layers of Subkha or sub grade material
with minimum 30% CBR properly compacted & tested by approved Independent
Laboratory.

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Asphalt re-instatement shall be as specified by the Municipality Roads Department.

Sketches on traffic diversion shall be provided including road signs to be used and
distances between such signs.
Only a Dubai Municipality Roads Department approved sub-Contractor shall be permitted to

carry out Road reinstatement works (sub-base, base, wet-mix, asphalt, road marking etc.)
and non disruptive crossing works such as the thrust boring, directional drilling etc.
All ducts should be at least 50 mm larger than pipe size.
Road crossings for the main and lateral pipes or cables should be carried out preferably by
horizontal drilling. Wherever it becomes impossible to drill because of existing services or
any other reasons acceptable by Irrigation Engineer, the road cutting shall be done as
specified above.
Any tiled area damaged during construction, drilling or road cutting should be reinstated.
Separate ducts shall be used for irrigation pipes, electrical cables, control wires and maxi-
com signal wire.
1.3.9 THRUST BLOCKS
At each bend, diversion or at the end of pipeline, a thrust block shall be provided. Heavy
duty polyethylene sheet shall be used to wrap the pipe at the point of contact between
pipeline fittings and the thrust block. Design of the thrust blocks shall be done by the
Contractor and to be approved by the Engineer.
1.3.10 ELECTRICAL CODES
All the electrical installations shall operate at a system voltage of 380 volts AC three phase
four wire 50 cycles.
The entire works shall be carried out in strict accordance with this specification and
instruction as issued by the Dubai Electricity and Water Authority.
1.3.11 ELECTRICAL TESTS
Each electrical equipment, cable and complete system shall be thoroughly inspected and
tested before finally placing in service under the full responsibility of the Contractor. All
tests shall be made in compliance with respective regulations, recommendations and
standards. Any modifications or repairs deemed necessary upon completion of the tests
shall be executed at the Contractor's expenses. Further tests shall be carried out on any
modified or repaired equipment until it is certified trouble free and acceptable for its
intended service. All testing shall be demonstrated to the Engineer in a manner to be
agreed later.
1.3.12 ELECTRICAL INSTALLATIONS
All electrical equipment under these contract documents shall have passed adequate
routine factory tests. Field tests shall be made by qualified personnel, approved by the
Engineer. The Contractor shall furnish all apparatus, material, labour and facilities for
performing the required tests. Unless otherwise specified the individual electrical equipment
shall undergo the following tests in accordance with the IEC recommendations or other
approved standards.
In Workshop:
- High voltage test
- Check on mechanical function
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- Pre-test of functional sequences

At Site:
- Visual inspection
- Insulation test (megger test)
- Check of functional sequences
The Contractor shall submit to the Engineer acceptance test certificates of all tests carried
out in his workshop including all measuring data and subsequent evaluation.
The following tests are to be carried out for all cables as a minimum:
- Resistance measurements
- Insulation test with specified AC power frequency test voltage
- Insulation resistance measurement of every individual cable length at site
- Electrical continuity test for all controls.
The following test shall be carried out upon completion of the earthing system:
- Measurement of the conductance of the earthing wires

- Measurement of the intermediate resistance of the earthing electrodes
The Contractor shall provide at his expense the necessary qualified personnel and
measuring instruments of the above measurements.
1.3.13 CONTROL PANEL INSTALLATIONS
Panels shall be installed onto concrete bases (300mm above ground level). Control wire
shall be color coded, and provided with tags. Control cable shall be bundles and tied with a
plastic cable tie at least every 5 meters, installation of cable bundles in conduit shall be
carried out in such a way as to preclude the possibility of stretching the cable, or damaging
the insulation. All cable splices shall be waterproof, and made inside valve or conduit
boxes, leaving at least one meter of spare cable neatly coiled at each joint, and bend.
Panels shall be individually earthed by an approved copper clad grounding rod minimum
length 15 mm x 3 meter rod driven down into the water table and connected to the controller
by a brass clamp and a 4 mm2 grounding wire as per DEWA and engineer approval.
All stages of the control system installation shall be supervised by a factory-trained

engineer, recommended by the manufacturer who has previously been in charge of all
aspects of installation of a similar control system and approved by the engineer.
1.3.14 CONTROLLER INSTALLATIONS
The field satellite controllers shall be installed near the Pump/Filtration Chamber. Controller
shall be installed on the concrete bases (300mm above ground level) and shall be in
pedestal enclosure as specified, control wire shall be color coded, and provided with tags.
Control cable shall be bundles and tied with a plastic cable tie at least every 5 meters,
installation of cable bundles in conduit shall be carried out in such a way as to preclude the
possibility of stretching the cable, or damaging the insulation.
All cable splices shall be waterproof, and made inside valve or conduit boxes, leaving at
least one meter of spare cable neatly coiled at each joint, and bend.
Controllers shall be individually earthed by an approved copper clad grounding rod

minimum length 15 mm x 3 meter rod driven down into the water table and connected to the
controller by a brass clamp and a 4 mm2 grounding wire. Decoders, encoders, and
terminators shall be installed in plastic valve boxes, and their function and reference
number shall be clearly indicated in indelible ink.

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1.4 AUTOMATIC IRRIGATION SYSTEM, COMMISSIONING
1.4.1 FIELDWORK
Commissioning of fieldwork and equipment shall include all works required to bring the
system into service, and to make sure that it is operating efficiently, and shall include but
not be limited by the following:-
1. Adjust valve outlet pressure +/- 10% of nominal.
2. Measure head loss from first to last sprayer in up to 50 different cases.
3. Adjust sprayer to ensure spray onto pavement and paths is minimized. Replacing any
spray nozzles that have uPVC burrs or sand lodged inside. Adjust spray patterns to
ensure optimal coverage.
4. Ensure that all sprayers and valve boxes are flush with the finish grade.
5. Replacing any clogged or partially clogged emitters (delivering less than 50% of
nominal flow) or any emitter overflowing by more than 50% (squirting). Carrying out
emission uniformity test involving at least 40 emitters on up to 10 valves, as directed by
the Engineer.
6. Controllers shall be adjusted to give an optimal flow regime, generally in accordance

with the drawings and as instructed by the Engineer. Valves sequence may be
modified to ensure that valves operate in a logical sequence to facilitate maintenance
operations.
7. Irrigation cycles for sprinklers and sprayers should be programmed during night time
and early morning (from 12 mid night up to 5 am).
A full cycle shall be run four times, and total system flow rates shall be recorded, and
stations shall be adjusted in accordance with the instructions of the Engineer, base on the
results of these trials.
Trials shall only be carried out after all valve's pressure have been adjusted. During these
trials main line head losses shall be verified by installing pressure recorder at the start and
the end of the main line.
1.4.2 IRRIGATION CONTROL SYSTEM
Three standard irrigation schedules shall be developed in accordance with the requirements
of the Engineer, and tested per controller schedule as above. Each particular function of
the system shall be demonstrated in accordance with an approved commissioning
procedure developed by the Contractor.
1.4.3 OPERATION AND MAINTENANCE MANUAL
Operational and maintenance manuals shall be prepared and submitted for approval in
draft form prior to commencement of commissioning. Manuals shall contain comprehensive
operational schedules, recommended spare parts list, manufacturers' operating data,
Catalogues and exploded parts diagrams where applicable for the entire irrigation scheme.
The materials used for the system shall be listed in the manual.
Manuals shall be revised in accordance with Engineers instructions, and reflect, and record
the results of the commissioning procedures described above. Three bound copies of the

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manual shall be delivered to the Engineer prior to the date of substantial completion
certificate issuing.
1.4.4 AS-BUILT DRAWINGS
The Contractor must submit As-Built drawings for all works included in this contract.
Completion certificate will not be issued unless the contractor submits the As-Built
drawings.
Three complete set of "As Built" drawings along with a negative and all diskettes should be
submitted before handing over of the project.
1.5 IRRIGATION SYSTEM, CIVIL WORKS
The civil works of the project shall be carried out by Main contractor or an approved sub-
contractor as per general specifications of Dubai Municipality and subject to approval of the
Engineer.
1.5.1 EARTHWORK AND EXCAVATION
1.5.1.1 PRE-EXCAVATION
a) Excavation site shall be surrounded by new painted fence of corrugated galvanized or

plywood sheets. Fence sides shall be properly supported; such supports shall not project
outside the site.
b) Contractor shall check with all the concerned Service Authorities for any existing buried
plants inside the excavation site. Contractor shall be responsible for any damages of
service plants caused by excavation.
c) Ground levels shall be agreed at suitable intervals with the Engineer.
d) Top soil and other surfacing materials shall be stopped and stored separately from the
subsoil. Subsequent spreading of top soil shall be as directed on site.
1.5.1.2
inconvenience as possible. Different classes of material shall be handled and deposited
separately.
1.5.1.3
Excavated material for use as back-fill shall be as approved, and shall be kept in a suitable
safe place and surrounded by a suitable fence as directed by the Engineer.
1.5.1.4
Where ordered if necessary for reasons of limited access or any other reason, excavation
shall be carried by hand.
1.5.1.5
All excavation shall be kept free of water. In addition, precautions shall be taken to prevent
floatation of partly built structures, completed structures to be filled on commissioning of
the works and unback-filled pipelines. All necessary precautions shall be taken to prevent
any adjacent ground from being adversely affected by loss of fines through any dewatering
process.
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1.5.1.6
The sides and or the bottom of excavation shall be adequately supported.
1.5.1.7
Back-filling shall be carried using selected excavated materials and in layers not greater
than 150 mm thick (compacted thickness) and compacted such that throughout each layer
placed the dry density is not less than 95% of the site dry density of the soil prior to
excavation. Back-filling shall be tested to ensure the specified compaction.
1.5.1.8
All surplus material shall be either spread on site or shall be removed and disposed off the
approved Municipality tips, immediately after excavation as directed by the Engineer.
1.5.1.9
In case of extra excavation deeper than the level required by the Engineer, Contractor shall
fill the same with selected well-compacted material or plain concrete as directed by the
Engineer.
1.5.1.10
Excavation to the required level shall be carried out by the contractor as part of the contract
regardless of the kind of soil strata or rock to be excavated.
1.5.1.11
Contractor shall bear the responsibilities and consequences of any damage caused by the
excavation to the adjacent structures, roads or plants.
1.5.1.12
Contractor shall take all the necessary precautions at the excavated sites to protect his own
staff, Engineer's representative, site visitors, pedestrians, traffic movement by supporting
excavation sides, providing proper guard rails fences, cones, warning tapes and traffic
signs, and by keeping 24 hrs. Guard attendance to all excavated locations.
Contractor shall bear all the legal responsibilities in case of accidents caused by lack of
safety precautions.
1.5.2 CONCRETE
1.5.2.1 GENERAL
a) All materials forming the concrete mix shall be approved by the Engineer.
b) Complete detailed design of all the reinforced concrete structures shown on drawings
shall be carried out by the Contractor following the relevant British Standard. Drawings
and calculation shall be submitted to the Engineer and subject to his approval.
However, it shall be understood that the Engineer's approval of the design and
calculation does not release the Contractor from his responsibility in case of any
structural failure due to design faults.
c) The Contractor may use premixed concrete from an approved source.
d) Concrete used shall conform to the following:

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GRADE
-------------------------------------------------------------------------------------------------------
B C
------------------------------------------------------------------------------------------------------
NOMINAL MAX. 20 20
AGGREGATE SIZE mm
------------------------------------------------------------------------------------------------------
CEMENT CONTENT kg/m3 of
FINISHED CONCRETE
MINIMUM 370 300
MAXIMUM 400 400
-------------------------------------------------------------------------------------------------------
MAX. WATER CEMENT RATIO 0.45 0.45
-------------------------------------------------------------------------------------------------------
MIN. MEAN CUBE STRENGTH N/mm2 35 25
-------------------------------------------------------------------------------------------------------
FINE AGG./TOTAL AGG.% MAX. 35 35
-------------------------------------------------------------------------------------------------------
e) Immediately following the land excavation to formation level for floor where shown on
the drawing or as ordered by the Engineer, a sealing coat of 75 mm minimum thickness
of concrete grade "c" shall be placed on polyethylene sheet (1000 gauges) placed on
the surface of the formation a carefully spade finished to an even surface floors shall be
laid on the sealing coat as soon as may be practicable and if required by the Engineer,
the sealing coat shall be kept thoroughly damp by watering.
f) Unless tolerances for particular surfaces are specifically shown on drawings, they shall
be as follows:
1) FLOORS: The level of the surface at any point shall be plus or minus 5 mm of the level
desired from drawings.
2) WALLS: The position of the face at any point shall be within 10 mm of its position
desired from the drawings. There shall be no irregularity exceeding 3 mm in 3 meter
template.
3) CURVED SURFACES: Shall be within plus or minus 2 mm of the level desired from the
drawings.
g) Concrete shall not be placed when the sheds temperature exceeds 40 degrees C.
The temperature of batched concrete at time of placing shall not exceed 30 degrees C.
1.5.2.2 MATERIALS
a) AGGREGATES:
Coarse aggregate shall consist of crushed stones free from salt and clay or any other
materials harmful to the concrete such as organic, coal, mica, gypsum and fines. In any
case the percentage of fines shall not exceed 1% of the dry weight.
Fine aggregate shall consist of Natural Sand with hard grains of any other similar inert
material. Sand shall be free from organic, salts, clay, mica and fossils. It shall also be
sieved and washed.

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Percentage of Sulphate and Chloride in aggregates shall not exceed the figures listed in the
following table:
MATERIALS MAX. % OF DRY WEIGHT
Sulfate as SO3 0.04 %
Chloride as Na Cl 0.01 %
Chloride as Cl 0.06 %
Aggregates shall be well guarded to the Engineer's approval.
b) CEMENT:
Cement shall be supplied from approved factories in closed bags. In case of bulk cement
supply, it shall be delivered using special containers for the same purpose. Cement shall
always be accompanied with its origin certificate showing its test results and date of
manufacture.
When stored on site, cement shall be kept in a dry place raised above the floor and not
touching the walls of the store. It shall not be allowed to use the cement which is more than
2 months old, nor that which has hardened in the form of grains regardless of its age.
Ordinary Portland cement shall be used for all concrete works unless it is otherwise
specified in any of the contract documents.
c) WATER:
Water used for the concrete mix and aggregate washing and cleaning of formwork and
curing of casted concrete shall be potable water. In any case it shall comply with the
following conditions:
1) Should be clean and free from oil, organic, metals, acids and bases.
2) Should not contain more than 600 mg/l of Chlorides or 500 mg/l of Sodium Sulphate.
3) PH should be between (7-9).
4) Should not contain more than 0.25% by weight of suspended solids.
In general, mixing water shall not contain any harmful materials which are sufficient to
change the concrete setting time by more than 25% or to decrease the concrete
compressive strength by more than 20% of that which is made of distilled water.
d) ADMIXTURES:
Concrete admixture shall be used in case it is specified in any of the contract documents.
In case the Contractor requires to use any of them (such as plasticizer and retarders), it
shall be subject to the Engineer's approval who might require a modified concrete mix
design to suite the used admixture.
e) REINFORCING STEEL:
Reinforcement shall be epoxy coated and free from rust or other extraneous matters. They
shall be cut and placed as detailed in the drawings and as approved by the Engineer.

DUBAI – UAE
1.5.3 CONCRETE MIXING
Concrete shall be mechanically mixed until getting a homogeneous viscosity and color mix.
Mixing time shall not be less than two minutes or twenty revolutions of the mixing machine
or which ever is greater. Mixing time is considered to start when all the contents of the
concrete mix including the mixing water are loaded inside the mixer. Concrete mix
unloading shall be carried out in such a way that will not cause separation of the mix
contents.
1.5.4 CONCRETE TESTING
Contractor shall make the standard concrete cubed and test them as directed by the
engineer for all the structural concrete elements.
Number of cubes and method of their making and testing shall comply with the relevant
British Standard.
1.5.5 TRANSPORTATION
In case of pre-mixed concrete, the concrete shall only be transported to the casting site,
using special containers equipped for the same purpose to prevent the separation of the
materials forming the concrete mix.
1.5.6 CASTING OF THE CONCRETE
Concrete casting shall always be subject to the written approval of the Engineer on the
reinforcing steel and suitability of the concrete mold and formwork and supports.
Reinforcement and mold shall be sprayed with water prior to casting. It shall not be allowed
to cast the concrete which was mixed before more than 30 minutes unless plasticizing
agents are used, in such cases the time allowance shall be decided by the Engineer.
1.5.7 CONCRETE COMPACTION
All concrete works shall be compacted during casting using mechanical vibrator. Care shall
be taken so that the vibrator's rod does not touch the reinforcements or the mold. In any
case, the casted concrete which has started setting should not be distributed as a result of
casting or working nearby.
1.5.8 CURING OF THE CONCRETE
Exposed concrete surfaces shall be completely covered with polyethylene sheeting

immediately after placing and within two or three hours this shall be quickly replaced by wet
hessian covered with polyethylene. The hessians shall be wet damp continuously using
water for a period of at least 7 days or such period as the Engineer may direct. Approved
curing compounds may be applied earlier to supplement use of wet hessian and
polyethylene.
1.5.9 MOVEMENT AND CONSTRUCTION JOINTS

1.5.9.1 Movement joints or construction joints in concrete shall be provided as directed by the
Engineer.
1.5.9.2 Water Bars shall be manufactured of extruded PVC or of nitrite rubber. They shall be of the
types and general shape indicated on the drawings and shall have the minimum
characteristics:

DUBAI – UAE
DENSITY: 1300 kg/m3
TENSILE STRENGTH (25 degree C): 13.7 N/mm2
ELONGATION AT BREAK (25 degree C): 285%
WEB THICKNESS: 10 mm
DIMENSION OF CENTRAL BULB: 18 mm
Water bars shall not be displaced during the placing of concrete which shall be fully
compacted around them. Jointing of water bars shall normally be carried out by clamping
and welding or adhesion and shall be in accordance with the recommendations of the
manufacturer. Water bars shall be arranged so that there is a minimum distance of 25 mm
from the water bars to the reinforcement.
1.5.9.3 Joint fillers shall be utilized as directed by the Engineer.
1.5.10 DEFECTIVE CONCRETE WORKS
1.5.10.1 Unless tolerances for particular surfaces are specifically shown on drawings, they shall be as
follows:
FLOORS: The level of the surface at any point shall be plus or minus 5 mm of the level
desired from drawings.
WALLS: The position of the face at any point shall be within 10 mm of its position desired
from the drawings. There shall be no irregularity exceed 3 mm in to 3 m template.
CURVED SURFACES: Shall be within plus or minus 2 mm of the level desired from the
drawings.
1.5.10.2 As directed by the Engineer, contractor shall repair or demolish and re-build the concrete
works which had any concrete quality or dimension or reinforcement or segregation defects,
or any other defects that the Engineer might decide they cause the concrete to be
unsatisfactory to its required purpose. In case of repair, its method and results shall be
subject to the Engineer's approval.
1.5.10.3 Where required by the Engineer, the Contractor shall fill cracks which have developed in
concrete structures using an approved resin based sealing compound. Method of injection
may include pressurized injection techniques.
1.5.11 FORM WORK AND SUPPORTS
1.5.11.1 Formwork shall be designed and constructed so that the concrete can be placed and
compacted without disturbing or displacing the reinforcement. It shall be firmly supported,
braced, guyed or tied back so that it is stable against vertical and horizontal formwork.
Internal spacers and ties shall be of approved types that do not produce holes completely
through the concrete. Joints in the formwork should be close fitting to prevent leakage.
The arrangement shall allow for removal of formwork from the sides and members without
disturbing soffit formwork. Rough faced formwork may be used for surfaces which are
normally never exposed to view.
Formwork shall be designed so that splays, fillets, chamfers and projection are cast as the
work proceeds. Unless specifically deleted all external angles on exposed concrete shall
have a 25mm x 25mm chamfer.
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Before placing concrete all extraneous material shall be removed from the interior of the
formwork and the faces in contact with the concrete shall be wetted or treated with a non-
staining composition to prevent adhesion.
Concrete shall be placed in the formwork only after examination and approval of the
formwork by the Engineer.
1.5.11.2 Formwork shall not be struck until the structure has attained sufficient strength and in no
case less than the period given below:
BEAM SIDES, WALL, COLUMNS: 2 days

SOFFITS TO SLABS OR BEAMS
(props left under): 5 days
PROPS TO SLABS OR BEAMS: 10-14 days
1.5.11.3 CONCRETE SPACERS AND COVERING BLOCKS The minimum possible number of
concrete spacers and covering blocks which provides the concrete covers for the
reinforcing steel, shall be made of concrete which has same compressive strength of that to
be cast.
1.6 SWEET SOIL FILLING, CONTOURING AND PLANTATION
1.6.1 SWEET SOIL FILLING.
For the planting areas, Contractor shall clear all rubbish and remove the existing topsoil and
dispose off as directed and prepare the area to receive sweet soil, in such a way that it will
below 60 cm than the proposed final level of landscape/existing and proposed footpath The
Contractor has to refer to the landscaping drawings. Leveling and contouring shall be done
as per the Landscape drawings and to the approval of the Engineer. The minimum
acceptable depth of sweet soil filling in proposed planting area is 50 CM. Sweet soil levels
should be10 cm below the existing/proposed footpaths and chamber levels
Contractor will remain responsible for maintaining the levels of sweet soil against wind
erosion till the final hand over of the project.
Contractor to make tree pits and fill them with fresh sweet soil. The size of tree pits to be as
follows:
Pits for Date Palms: 2m X 2m X 2m

Pits for Ornamental trees: 1.5m X 1.5m X1.5m
Pits for shrubs: 1m X 1m X 1m
THE EXISTING SWEET SOIL SHOULD NOT BE USED FOR FILLING THE TOP 50 CM
LAYER AND TREE PITS.
1.6.2 CONTOURING
The Contractor has to level the landscaped areas and bring it to the contours as shown in
the landscaping drawings. Contractor to make arrangements to prevent the loss/ drifting of
soil due to wind. Contractor will be responsible for maintaining the levels and contours of
the sweet soil till the Final Handing over of the project.
1.6.3 GRAVEL

DUBAI – UAE
1.6.3.1 WHITE GRAVEL
Gravel shall be white to light beige crushed gravel (to Engineer’s approval) size 10 - 20mm
to fill the areas as shown on the landscape drawings. The Depth of gravel mulch shall be at
least 10 cm.
1.6.3.2 WADI GRAVEL
Wadi gravel shall be naturally occurring water rounded stones of approved origin. Stones
shall range from 50mm to 100mm diameter and shall be washed and free of sand, debris
and fine material. Color shall be brown.
1.6.4 GEOTEXTILE FILTER FABRIC
A layer of geotextile filter fabric is to be installed on prepared ground formation below the
gravel bed layer/ gravel mulch in tree areas and where directed by the Engineer. A
minimum of 300mm overlap shall be provided at junctions between strips and roll ends. The
fabric shall be secured by steel pegs at maximum 3m intervals prior to covering with gravel
layer.
The geotextile filter fabric shall be U. V. resistant and resistant to all naturally occurring soil
acids and alkalis and be non degradable.
The fabric membrane shall be manufactured from bonded non-woven or woven continuous
filament synthetic fibers.
The fabric shall be pliable and strong enough not to be damaged during placement and
subsequent backfilling yet permeable without clogging by possible ingress of fine particles
and flying sand.
The geotextile filter fabric shall be approved by the Engineer. The fabric shall not be
punctured, torn or otherwise damaged in any way during installation.
1.6.5 MODIFICATION TO EXISTING CHAMBERS
The contractor shall modify the existing chambers in the proposed Landscape area (if
required) to the approval of the Engineer and the concerned service authorities in order to
match the proposed landscape levels.
The Contractor has to use cream white crushed gravel size 20mm to fill the areas as shown
on landscape drawings. Depth of filling with gravel shall be at least 10 cm. Gravel shall be
installed on Geotextile membrane.
1.7 ANCILLARY WORKS
1.7.1 PAVING DESCRIPTION
This works shall consists of covering certain areas (Top of filtration chamber and 1.0 meter
around and 0.6 metre wide strip by the side of road kerbs all around landscape areas) with
paving blocks and heel kerbs in accordance with specifications, the drawings and
1.7.2 PAVING BLOCKS
Paving blocks and heel kerbs shall be as per RTA standard Specification.
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Paving blocks type shall be matching type available in the vicinity and/or as approved by
relative authorities.
1.7.3 OVERALL REQUIREMENTS FOR PAVINGS BLOCKS
The materials, dimensions and tolerances, test for comprehensive strength, test for water
absorption and certificate of compliance for the paving blocks shall conform to the
requirements of Local Order of 44/90. Water absorption and abrasion resistance shall be
carried out in accordance with the requirements of particular specifications.
1.7.4 BLOCK LAYING REQUIREMENTS
1.7.4.1 LAYING COURSE
The laying course shall consists of sharp black sand containing not more than 3% silt and
clay by weight and not more than 10 % retained on 4mm sieve. The sand shall be obtained
from single source, allowed to drain before use and shall be covered with suitable sheets to
minimize moisture changes. Permissible sulphate (as SO3) and chloride (as Cl) shall not
exceed 0.3% and 0.5% respectively (expressed as a percentage by weight.).
1.7.4.2 The profile of laying course before compaction shall be similar to that of finished surface.
During laying, the sand shall be in uniform moisture content and screened carefully,
screened to form smooth compacted surface to receive the paving blocks. The maximum
deviation from design shall be 5 mm.
1.7.4.3 The edge restrained to the paved areas shall be laid in advance of the laying course and all
permanent obstacles within the area, such as manhole covers shall be adjusted to the
correct finished levels.
1.7.4.4 The paving blocks shall be laid on sand laying course in such a manner as not to disturb
the blocks already laid. Each block shall be placed firmly against its neighbour so that they
fit closely together. The joints between the blocks shall exceed 3 mm. Laying of paving
blocks shall commence at right angles to the main pavement axis starting at one end of the
area. The paving blocks shall be laid in a herringbone pattern unless otherwise shown on
the drawings or instructed by the Engineer at 45 deg angle to main pavement axis.
1.7.4.5 Where blocks do not fit the edge restraints or other obstructions such as manholes or
upstands the gaps shall be filled using cut blocks.
1.7.4.6 Blocks shall be cut only by using a mechanical block splitter.
1.7.4.7 Dimensional accuracy, uniformity of joint gaps alignment and squareness shall be checked
after laying the first three layers of the blocks and thereafter at regular intervals. If joints
begin to open, the blocks shall be knocked together using a hide mallet.
1.7.4.8 After every 20 sq. m or such areas that has been agreed with the Engineer, has been laid
the blocks shall be compacted to the required levels using plate vibrator.
1.7.4.9 The plate vibrator shall have a plate area of 0.2 to 0.35 m2. And have compaction force of
12-24 KN and a frequency of approx. 75 to 100 Hz.
1.7.4.10 A minimum of two passes of plate vibrator shall be made in each direction i. e. at 90 deg to
each other. Vibration shall continue until no further compaction of sand layer is apparent.
The laying course shall have compacted thickness of 50 mm. Fine dry sand with particle
size of 0.3 mm shall be then brushed over paving. And further passes of plate vibrator shall
be made in each direction, until sand is no longer absorbed in the joints.
DUBAI – UAE
1.7.4.11 The plate vibrator shall not pass closer than 1 mtr to a temporarily unrestrained edge during
laying.
1.7.4.12 No paving shall be left incompact overnight except for the 1mtr strip at the temporarily
unrestrained edge.
1.7.4.13 On compaction the finished surface level shall be within 5 mm of the design level and
maximum deviation within the compacted surface, measured by 3 mtr straight edge shall
not exceed 3mm. The level of any two adjacent blocks shall not differ more than 3 mm.
Any areas of paving which do not comply with these tolerances shall be removed. The sand
laying course adjusted and paving blocks re-laid to the correct levels.
1.7.5 KERBS DESCRIPTION
1.7.5.1 This work shall consist of the construction of kerbs in accordance with specifications and in
conformity with the lines grades and typical sections shown on the drawings or established
by the Engineer. These specifications refer to the following types of precast kerbs to be
constructed: Non mountable Kerbs, Dropped kerbs, Heel kerbs, Quadrants and Flush
kerbs. All kerbs and edgings shall be hydraulically pressed and shall comply with the
requirements of BS7263 Part 1. They shall be uniform in colour, free from cracks, flaws or
other defects and they shall have well defined arises.
1.7.6 MATERIALS AND MANUFACTURE OF KERBS
1.7.6.1 Materials shall confirm to the requirements specified in part 4 “concrete” of the
specifications and as specified here in.
1.7.6.2 As per RTA standard specifications.
The Kerbs shall be prepared with a concrete mixture containing not less than 400 kg/m3 of
sulphate resisting Portland cement. The aggregate shall meet the requirements of the
general Specifications and confirm to the required gradation.
1.7.7 GEOTEXTILE FILTER FABRIC
1.7.7.1 A Layer of geotextile filter fabric is to be installed on prepared ground formation below the
gravel bed layer/gravel mulch in areas shown on contract drawings and where directed by
the Engineer. A minimum of 300mm overlap shall be provided at junctions between strips
and roll ends. The fabric shall be secured by steel pegs at maximum 3m intervals prior to
covering with gravel layer.
The geotextile filter fabric shall be U.V resistant and resistant to all naturally occurring soil
acids and alkalis and be non degradable.
The fabric membrane shall be manufactured from bonded non-woven or woven

continuous filament synthetic fibers.
The fabric shall be pliable and strong enough not to be damaged during placement and
subsequent backfilling yet permeable without clogging by possible ingress of fine particles
and flying sand.
The geotextile filter fabric shall be approved by the Engineer. The fabric shall not be
punctured, torn or otherwise damaged in any way during installation.

DUBAI – UAE
1.8 AIR CONDITIONING
1.8.1 WALL MOUNTED AIR CONDITIONING UNITS
Air cooled 'window-type' air conditioning units, as supplied by an approved and accepted
manufacturer, shall be installed in positions approved by the Engineer. They shall be
provided complete with slide out chassis and frame, suitable for clear openings set not
higher than 1.5m above floor level. They shall be suitable for continuous efficient operation
in the climatic conditions prevailing and the materials of construction (particularly
concerning the fins or extended surfaces of the refrigerant to air heat exchangers) shall be
subject to the Engineer's approval.
Both fresh air and re-circulated air shall be filtered and the filter shall be arranged for ease
of removal from the main unit for cleaning and replacement.
Depending on the size of the room space and the heat load therein, the air conditioning
units shall be of 1 ton, 1.5 tons or 2 tons refrigeration capacity (equivalent to an air cooling
capacity of 13,250; 19,880 or 26,500 B.T.U.’s per hour) or multiples thereof.
Each unit shall be provided with a manually adjustable thermostatic air temperature control
and such other controls necessary to allow the following modes of operation:-
1. Off.
2. Fan only with two speeds.
3. Cooling at two possible fan speeds.
4. Re-circulation of air from room, through unit and back to room.
5. Part re-circulation of air with some exhaust air flow.
6. Part re-circulation of air with some fresh air inlet flow.
Each unit shall also be fitted with an automatic delay timer in the compressor control circuitry
to prevent the compressor having to start against gas pressure in the event of an interruption
in the power supply or the cooling mode being switched off and on rapidly.
1.8.2 CENTRALIZED AIR CONDITIONING SYSTEMS
Centralised air conditioning systems shall comply with the requirements of the Particular
Specification.
The system shall be complete with all necessary ductwork, diffusers, air grilles etc. Two
single package units shall be provided and installed. Each unit shall be capable of
providing 60% of the total cooling load.
Machinery shall be from an approved manufacturer, of types readily available in Dubai and
suitable for installation in direct sunlight. Filters, re-heaters and/or humidifiers shall be
provided as necessary to maintain the condition of the equipment.
Supply and return air ducting shall be run in the void above the suspended ceiling where
applicable. Air vents to conditioned areas shall be via slot diffusers integral with the
suspended ceiling. The whole system shall be designed to give an even temperature
distribution throughout the air conditioned areas.
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Single package units shall be of the type with two compressors and split coils arranged so
that the failure of a compressor shall not lead to total failure of the air conditioning to any
area. The two units shall be identical to limit the quantity of spares.
Work on installation of air conditioning systems is only to be undertaken by an approved

local air conditioning contractor or by an international air conditioning contractor who is
associated with an approved local air conditioning contractor.
It is recommended that the Contractor engages the services of an air conditioning specialist
who is familiar with local requirements and conditions to design and specify the system and
liaize with Dubai Electricity and Water Authority, regarding approvals and inspections.
Copies of the design calculations, unit specifications and system descriptions and drawings
are to be submitted to the Engineer for approval by the Dubai Municipality who will finally be
responsible for the air conditioning system. The Dubai Municipality will require two
additional copies of the operating manuals for the air conditioning system. Representatives
of the Dubai Municipality will require to be in attendance during commissioning.
A five year guarantee shall be provided against all malfunctions of the compressor by the
Dubai Electricity and Water Authority approved local air conditioning contractor appointed.
1.8.3 SPLIT UNIT AIR CONDITIONERS
All materials used in the manufacture of the units shall be produced to approve International
Standards. The cooling tubes shall be manufactured from solid drawn copper and shall be
tested to 20 bars. Fins shall be of Aluminium and shall be permanently bonded to the tube.
Cabinets shall be manufactured from pre-galvanised sheet steel and the outer panels
electro-statically powder coated with epoxy and stoved. Panels shall be removable for
access.
Condensate trays shall be fitted and the outlets piped to a suitable drain point.
Fans shall have corrosion resistant steel impellers. Motors shall comply with the relevant
parts of the Specification. Anti-vibration mountings shall be provided.
Air filters shall be fitted having 90% efficiency. If they are of the throw-away type a five year
supply of spare elements shall be provided.
The condenser unit shall be suitable for outdoor installation.
The coils shall be pressure tested to 20 bars and fins shall be permanently bonded to them.
Motors shall be weatherproof and shall comply with the relevant parts of the Specification.
Compressors shall be hermetically sealed. Crank-case heaters and anti-vibration

mountings shall be provided.
High and low pressure switches and overload protection shall be provided and also an
anti-recycling timer.
The units shall be sized to maintain a dry bulb temperature of 26oC and a relative humidity
of between 40% and 60% when the external shade temperature is 52oC and the external
relative humidity is 50%.


ROADS AND UTILITIES

VOLUME 2 – PART VI
PARTICULAR SPECIFICATIONS FOR FIRE FIGHTING WORKS

20010410
JUNE, 2022
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications


Architectural


VOLUME 2 – PART VI DATE OF ISSUE: 16 JUNE, 2022
FOR FIRE FIGHTING WORKS
DUBAI – UAE
MEYDAN GROUP LLC

Project: 20010410
Roads and Utilities
Volume 2 – Part VI
PARTICULAR SPECIFICATIONS FOR FIRE FIGHTING WORKS
CONTENTS
1.0 FIRE FIGHTING SYSTEM ....................................................................................................... 1

1.1 Scope of Work......................................................................................................................... 1
1.2 Related Sections..................................................................................................................... 1
1.3 References .............................................................................................................................. 1
1.4 Submittals for Review ............................................................................................................ 1
1.5 Quality Assurance...................................................................................................................... 1
1.6 Qualifications .............................................................................................................................. 2
1.7 Applicable Standards and Codes ............................................................................................ 2
1.8 Technical Requirements ........................................................................................................ 2
1.8.1 General ..................................................................................................................................... 2
1.8.2 Pipe Materials........................................................................................................................... 3
1.8.2.1 Pipe Classifications and Pressure Ratings ........................................................................ 3
1.8.2.2 Polyethylene Pipes (HDPE or HPPE) ................................................................................ 5
1.8.3 Storage and Handling of Pipes ............................................................................................... 6
1.8.3.1 General ................................................................................................................................... 6
1.8.3.2 Thermoplastic Pipes............................................................................................................. 7
1.8.3.3 Granular Material for Pipe Bedding .................................................................................... 7
1.8.3.4 Compaction Fraction Test ................................................................................................... 8
1.8.4 Deflection Measurements........................................................................................................ 8
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1.8.4.1 General ................................................................................................................................... 8

1.8.4.2 Deflection Measurements - Plastic Pipes .......................................................................... 9
1.8.4.3. Underground Services Warning Tapes ............................................................................. 9
1.8.4.4 Cleaning and Inspection of Pipelines ............................................................................... 10
1.8.4.5 Testing of Pipelines ............................................................................................................. 11
1.8.4.5.1 General .............................................................................................................................. 11
1.8.4.5.2 Testing of Pressure Pipelines......................................................................................... 12
1.9 TESTING OF VALVES.............................................................................................................. 13
1.10 FIRE HYDRANT ...................................................................................................................... 13
1.11 PUMPS .................................................................................................................................. 14
1.11.1 FIRE PUMPS ........................................................................................................................ 14
1.11.1.1 Material of Construction ............................................................................................ 15
1.11.1.2 Accessories ................................................................................................................ 15
1.11.1.3 Electric motor drive ................................................................................................... 15
1.11.1.4 Diesel engine drive ................................................................................................... 16
1.11.1.5 Control equipment .................................................................................................... 16
1.11.2 General .................................................................................................................................. 16
1.12 TYPES OF VALVES................................................................................................................ 17
1.12.1 VALVES CONTROLLING WATER SUPPLIES ............................................................... 17
1.12.2 POST INDICATOR VALVES .............................................................................................. 18
1.12.3 Location. ................................................................................................................................ 18
1.12.4 Arrangement. ........................................................................................................................ 18
1.12.5 VALVES PITS ....................................................................................................................... 18
1.12.6 SECTIONAL VALVES. ........................................................................................................ 19
1.12.7 IDENTIFYING AND SECURING VALVES....................................................................... 19
1.12.8 CHECK VALVES. ................................................................................................................. 19
1.13 PIPES AND FITTINGS. ....................................................................................................... 20
1.14 FIRE ALARM AND EXTINGUISHING SYSTEMS General ............................................ 21

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1.0 FIRE FIGHTING SYSTEM
1.1 Scope of Work
This specification covers minimum requirements for the construction, installation and testing
of High Density Polyethylene (HDPE) pipes and fittings to be used for transport and
distribution TSE water for firefighting purposes as described and specified within this
specification and drawings including route survey, row, excavation, stringing, joint fusion,
laying, backfilling, etc.
1.2 Related Sections
1.2.1 This schedule is intended to be used as a helpful indication of the related sections
within the Project Specifications. It is not necessarily comprehensive or complete and it
is the Contractor's responsibility to ascertain all applicable sections required to
understand the full Scope of Works intended.
1.2.2 The requirements of the NFPA and Local Civil Defence Authority Codes take
precedence over the above standard specifications.
1.2.3 The Contractor shall become familiar with other sections of the Specifications affecting
work of this trade.
1.3 References
1.3.1 The minimum standards for products specified in this section shall be those standards
referred to or relevant NFPA/BSI standards if no other standards are referred to. The
following NFPA /BSI standards specifically apply:
• NFPA 20, Standard for the Installation of Centrifugal Fire Pumps

• NFPA 22, Standard for Water Tanks for Private Fire Protection
• NFPA 24, Standard for the Installation of Private Fire Service Mains and their
Appurtenances
• BS 5306:Part 1: 2006 Hydrant Systems, Hose Reels and Foam Inlets
1.4 Submittals for Review
1.4.1 Submit samples of all products, preliminary drawings, coordinated installation drawings,
detailed schematic drawings, specifications, compliance statement, engineering
calculations, description of system and installation method in accordance with the
Contract Documents. Submissions shall indicate all dimensions, details of
construction, details of materials, details of installation, relation and connections with
adjoining work.
1.4.2 Drawings and calculations shall be to the standard defined in Chapter 8 of NFPA 13.
1.4.3 Submit evidence to prove that the specialist contractor employed to design, install test
and commission the fire suppression is approved to do so by Local Civil Defence
Authority and is licensed to design and install fire mains / hydrants to NFPA 13 and 14
or LPC.
1.5 Quality Assurance

1.5.1 Perform Work in accordance with relevant NFPA, British Standards and Industry
Standard Codes.

DUBAI – UAE
1.6 Qualifications
1.6.1 The entire installation shall be designed, installed, tested and commissioned by a
Specialist Contractor approved by local Civil Defence authorities. Specialist Contractors
shall provide references for successful project where they have completed design and
installation work for hydrant installation.
1.6.2 Workmen employed to install fire main, fire pump and hydrant services shall have
received appropriate training and shall have at least five years relevant experience.
1.7 Applicable Standards and Codes
Unless otherwise specified the works shall conform to the following standards and other
standards noted elsewhere in this specification.
• Polyethylene (PE) Pipes for firefighting - Specifications ISO 4427.

• Plastic Piping Systems for firefighting Polyethylene (PE) PR EN 12201.
• Pipelines on land - BS 8010: Part 1.
• Pipelines on land design, construction and installation - BS 8010: Part 2.
• Thermoplastic pipes for conveyance of fluids – nominal outside diameter and nominal
pressure- part 1: Metric series- ISO 161-1.
• Thermoplastic pipes for the conveyance of fluids – Resistance to internal pressure –
Test Method- ISO 1167.
• Plastic pipes – Measurement of dimensions- ISO 3126.
• Thermoplastic pipes – Universal wall thickness table- ISO 4065.
• Polyolefin pipes and fittings – Determination of carbon black content by calcinations
and pyrolysis – Test method and basic specification- ISO 6964.
• Thermoplastic pipes for the transport of fluids – Method of extrapolation of hydrostatic
stress rupture data to determine the long-term hydrostatic strength of thermoplastic
pipe materials- ISO 9080.
• Thermoplastic pipes for the conveyance of fluids – Dimensions and tolerances Part:
1: Metric series- ISO 11922-1.
• Thermoplastic materials for pipes and fittings for pressure applications –
Classification and designation – overall service (design) coefficient- ISO 12162.
• Plastic pipes and fittings – pressure reduction factors for polyethylene pipeline
systems for use at temperatures above 2000C- ISO 13761.
1.8 Technical Requirements
1.8.1 General
The Contractor shall prepare detailed Method Statements (MS), i.e. Construction Procedures,
for all described activities, and submit to the Engineer for approval.
The Contractor/Manufacturer shall design any HDPE pipe system including Surge Analysis
and Stress Analysis (Flexibility), Support Location/Function Analysis and the Conceptual
Support Design where necessary for the given design and routing.
These MS's shall describe in detail how the Contractor proposes to perform the various
activities to ensure compliance with the requirements as set forward in this Specification.
The Contractor shall execute the work, with due care and diligence, in compliance with
international practice and all local laws, by-laws, ordinances, regulations, etc., provide all
plant, services and labor, inclusive of supervision thereof, provide all materials, excluding the
materials indicated as materials furnished by the Engineer in the Agreement, and provide all
equipment, appliances or other articles of whatsoever nature required for the execution of the
work, whether of a temporary or permanent nature.
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1.8.2 Pipe Materials
1.8.2.1 Pipe Classifications and Pressure Ratings

GRE (Glass Reinforced Epoxy Resin)
DI (Ductile Iron)
Pressure pipes shall be supplied to the following rated pressure classifications:-

HDPE 20 bars (Class PE100 SDR 9)
GRE 20 bars
DI 20 bars
The type and class of pipe for a particular underground installation shall be determined
through consideration of the following factors:
(1) Fire resistance of the pipe
(2) Maximum system working pressure
(3) Depth at which the pipe is to be installed
(4) Soil conditions
(5) Corrosion
(6) Susceptibility of pipe to other external loads, including earth loads, installation
beneath buildings, and traffic or vehicle loads
The entire system shall withstand full vacuum (-1 bar).
HDPE fittings and flanges shall be of the following conditions:

- Max. Operating pressure 20 bars
- Max. Site pressure 30 bars
- Max. Allowable vacuum - 1 bar
- Min. Cover depth 1.0 meter
- Max. Cover depth 4 meter
- Truck loading (wheel load) 90 kN
- Max. Service temperature 50oC
Joint Requirements and Limitations

Unless pipes are detailed with rigid joints or are specified differently all pipelines shall be
jointed with approved mechanical, flexible joints with elastomeric joint rings. The whole joint
assembly shall be compatible with the pipe construction and with the specified performance
of the completed pipeline.
Flexible Joints
Flexible joints shall be as a separate sleeve coupling and double spigot assembly with two
sealing rings.

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Elastomeric joint sealing rings shall be manufactured to EN-681-1 from ethylene propylene
rubber (EPDM) and shall have a hardness measured in International Rubber Hardness
Degrees (IRHD) compatible with the pipe material.
Deflection: The completed joint shall be capable of accepting the following ranges of
deformation when subjected to internal pressure without losing its seal at the specified test
pressure, without direct contact between spigot and socket/coupling and without inducing
stresses or strains in the pipe material beyond the safe working limits.
Table 4-1. Minimum Allowable Angular Deflection for Flexible Joints
Angular Deflection
Pipe Material Pipe Diameter (mm) (Degrees)
All materials up to 200 3

(except concrete Over 200 to 500 1.75
and clay pipes) Over 500 to 1350 1
Over 1350 0.5
Straight draw: Not less than 10 mm or the following proportions of the

length of the longest pipe/unit at any joint:
1% for polyethylene pipes
0.5% for polypropylene, polybutylene or ABS pipes.
0.3% for GRE pipes
Shear: Pipe materials shall be subjected to a load of 17.5 N/mm of pipe

diameter in accordance with ASTM D-4161.
If the approved standard for a pipe material does not include a shear
test for the jointing system, this test shall be carried out in
accordance with test procedure of another appropriate pipe material
standard.
Flanged Joints
Flanged pipes shall incorporate an annular gasket at the Joints and these gaskets shall
be manufactured to BS 4865 from ethylene propylene rubber (EPDM) 3.0 mm thick and
shall be dimensioned to full face of the pipe flange and to suit the flange drillings. The
hardness of the rubber (IRHD) shall be to the manufacturer's recommendations to suit
the pipe material.
Flange Adaptors
The adaptors shall be manufactured from rolled steel or approved material with an
approved coating and be capable of withstanding the pressure tests of the pipeline in
which they are incorporated. The adaptors shall accommodate a deflection at least 3o
between adjacent pipes in any direction and they shall be capable of accommodating a
movement of 10 mm between the ends of pipes they connect.

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Bolted Couplings
Bolted couplings shall be flexible couplings and shall be capable of withstanding the
pressure tests of the pipeline in which they are installed. They shall also be capable of
accommodating the deflections and movements specified for flange adaptors.
Nuts and Bolts
All bolts, nuts and washers shall be of stainless steel grade 320S17 to BS 970: Part 1 or
DIN 17440:1.4571 and shall remain unpainted. PTFE washers shall be fitted beneath
stainless steel washers for both bolthead and nut.
Shipping and Handling
All elastomeric joint sealing rings and gaskets for flanged pipes shall be supplied and
transported in light proof packaging so as to prevent damage due to ultra violet radiation.
The Contractor shall provide suitable storage facilities to prevent ultra violet exposure
until use.
1.8.2.2 Polyethylene Pipes (HDPE or HPPE)
General
Polyethylene (PE) pipe, either high density polyethylene (HDPE) or high performance
polyethylene (HPPE) pipe shall be manufactured to conform to the requirements of CP
312 Part 1 and 3, and BS 6437 or DIN 8075. Where pipes are used for renovation work,
pipes shall be of short lengths or short length conforming to the requirements of the
method selected and the available working space in the manholes or drive shafts. Longer
lengths may be used for new installation where conventional open trench methods of
construction are employed.
The base polymer shall be polyethylene with a derived density greater than 930 kg/m3
when determined in accordance with the method required by BS 3412. The base polymer
shall be blended with additives that are necessary for the manufacture, storage and use of
PE pipes for pipelines, including antioxidants, carbon black and UV stabilizers.
The material in pipe form shall have a thermal stability of at least 15 minutes when tested
in accordance with the isothermal method for differential thermal analysis.
The ovality of pipes up to and including nominal size 250 mm shall not exceed 0.02 the
nominal size (mm). The ovality of pipes greater than nominal size 250 mm shall not
exceed 0.035 the nominal size (mm).
The ends of the pipe shall be cut, cleanly and squarely, to within the following tolerances:
Nominal Size (mm) Maximum Out of squareness
180 - 225 4 mm
250 - 355 5 mm

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The calculated 24 hour and 50 year creep module shall be not less than the values given
below when tested in accordance with either the pipe ring in tension or the three point
bend method.
Property Minimum Mean Requirement
Short term flexural creep

modulus (24 hour) Es 350 MPa
Long term flexural creep

modulus (50 year) El 130 MPa
The jointing system for polyethylene pipes and fittings shall be in accordance with the
pipe manufacturer’s recommendations subject to approval by the Engineer.
Wall Thickness
The polyethylene (HDPE or HPPE) pipe shall be Type PE100 SDR9 i.e. shall be designed
to sustain working pressure of 20 bars at 20°C. The wall thickness shall be based on a
nominal pressure rating (PN) of 20 bars.
Wall thickness shall manufactured in conformity with BS 6437.
1.8.3 Storage and Handling of Pipes
1.8.3.1 General
Method Statements must be approved for the transportation, handling and storage of pipes before
any pipes are delivered to site.
All pipes shall be handled and stored in compliance with the manufacturer's recommendations
subject to the following limitations:-
Pipes shall be transported, handled and stored with such packing and in such a manner that
damage does not occur and that contact is avoided with sharp edges which may cause damage.
During transit, pipes and fittings shall be well secured and adequately supported along their
length.
At every point of loading or unloading, all pipes or castings must be handled by approved lifting
tackle unless specified elsewhere. Unloading by rolling down planks or any other form of inclined
ramp will not be allowed. Pipes shall not be tipped or dropped.
Pliable straps, slings or rope shall be used to lift pipes, and steel cables or chains will not be used
without written permission.
Nesting of pipes for transportation will be permitted provided method statements demonstrate that
effective precautions will be taken to protect inner surfaces from damage.
All pipes and fittings shall be thoroughly inspected on arrival at site after off-loading and prior to
installation for detection of any damages.
Damages to coatings, if any, shall be made good in an approved manner. For other damages,
proposals for repairs shall be submitted in writing for the Engineer's approval. If in the Engineer's

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opinion the nature of any damage is such that the condition of a pipe has been impaired and
cannot be repaired, the pipe concerned shall not be incorporated in the Works.
Suitably smooth and level storage areas shall be provided at or near the site and made secure to
prevent unauthorised access.
Pipes of different sizes and thickness shall be stocked separately.
1.8.3.2 Thermoplastic Pipes
Pipes and fittings of plastic materials smaller than 300 mm diameter may be handled manually and
those equal or larger than 300 mm diameter shall be lifted using a single fabric or large diameter
rope sling. There shall be enough slack in the sling to keep the hook at least 600 mm over the
pipe. Use of wire rope chains and fork lifts shall not be permitted.
Care shall be taken to prevent distortion of the pipes during transportation, handling and storage.
They shall be stacked either on bearing timbers on a level surface staked to prevent movement, or
in suitable racks. Not more than two layers shall rest on the bottom layer, and for spigot and
socket pipes, sockets shall be at alternate ends so that no pressure comes on a socket. Bearing
timbers shall be spaced at not more than 1 metre and shall be wide enough to prevent denting of
the pipe wall. Sharp edges (e.g. of metal) shall be avoided. Similar care shall be taken with pipes
in transit.
Where shaped battens are used, they shall be at least 100 mm wide and not more than 1.5 meters
apart. The end pipes in each row shall be strapped to the battens. The pipe shall not be stacked
any higher than five (5) layers.
All thermoplastic pipes shall be shaded/protected from direct sunlight during handling,
transportation, storage and laying.
The Contractor shall ensure that thermoplastic pipes do not come into contact with bituminous or
other hydrocarbon based materials.
1.8.3.3 Granular Material for Pipe Bedding
Granular material for pipe bedding shall be free-draining, hard, clean, chemically stable gravel or
crushed stone to BS 882 and shall be graded in accordance with BS 882 : Part 2 as shown in the
following table:-
Table 4-3. Grading of Granular Material for Pipe Bedding

( mm) For Pipe For Pipe Diameters
Diameters up to 600 mm 400 mm and above
63 - -
37.5 - -
20 - 100
14 100 85 - 100
10 85 - 100 0 - 50
5 0 - 25 0 - 10
2.36 0- 5 -

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Notes:
1) For pipes 400 mm to 600 mm diameter, either grading is acceptable.
2) Total acid soluble content of the material when tested in accordance with
BS1377 shall not exceed 0.3 percent by weight of sulphate expressed as SO3
(sulphur trioxide).
3) The material shall have a Compaction Fraction value not exceeding 0.15.
1.8.3.4 Compaction Fraction Test
For testing pipe bedding material, a representative sample of about 40 kg shall be heaped onto a
clean surface and quartered to obtain approximately 10 kg. The moisture content of the sample
should not differ materially from that of the main body of material, at the time of use in the trench.
A 150 mm internal diameter open ended cylinder 250 mm high shall be placed on a firm flat
surface and loosely filled, without tamping, from the 10 kg sample. Any surplus material shall be
struck off level with the top of the cylinder. The area around the filled cylinder shall be cleared of
all surplus material and the cylinder then lifted clear of its contents and placed alongside the
material.
Approximately one quarter of the material shall then be replaced into the cylinder and compacted
by tamping vigorously with a 40 mm diameter metal rammer weighing about 1 kg until no further
compaction can be obtained. This operation shall then be repeated for each of the remaining
quarters, tamping the final surface as level as possible.
The distance from the top of the cylinder to the surface of final layer shall then be measured and
this value, divided by the height of the cylinder, shall be taken as the Compaction Fraction.
1.8.4 Deflection Measurements
1.8.4.1 General
HDPE pipelines will be subjected to in-situ deflection measurements. Any section of pipe failing to
meet the deflection criteria shall have its surround material re-compacted, such procedure being
repeated until the in-situ deflection is found to be satisfactory.
In the above paragraph deflection shall be considered as the maximum difference between the
measured in-situ diameter and the stated non-deflected diameter on any axis divided by the non-
deflected diameter.
For all pipes the horizontal and vertical deflections shall be measured at each end at points 100
mm and 1.5 m away from the joint and at 3.0 m intervals thereafter, or as directed by the
Engineer. For pipe lengths of less than 3.0 m these deflections shall be measured at each end at
a point 100 mm away from the joint and at the mid-point.
For smaller pipelines, deflections shall be checked by pulling through an approved cylindrical plug
dimensioned to suit the permissible minimum deflected diameter of the pipe.
Alternately, a deflectometer of a form that can be drawn through the pipeline and be capable of
measuring diametric dimensions both vertically and horizontally may be used for deflection
measurement of pipes of diameter less than 600 mm. The deflectometer shall be calibrated for
each diameter regularly in the presence of the Engineer to maintain the accuracy of the
instrument. The d e v i c e shall also provide a means of identifying where each
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deflection
measurement was taken along the length of a pipeline. This shall be in the form of either a
continuous printout or a visual display on a remote monitor.
The Contractor shall tabulate the results of the measurements and copies shall be submitted to
the Engineer immediately after each set of measurements has been taken.
1.8.4.2 Deflection Measurements - Plastic Pipes
The measurement shall be taken on at least two separate occasions:
1. As soon as a pipeline has been installed, tested and the trench backfilled, but before the
dewatering is removed.
If any of these tests indicate that the deflection may exceed the permitted values the pipe or
pipes shall be replaced. Any pipe removed for this reason shall be taken from site and not
incorporated in the permanent works.
All pipes replaced for any reason shall subsequently be subject to deflection checks as
described above. Deflection checks shall also be carried out on adjacent pipes for 20 m
either side of the removed pipes.
The permissible positive or negative deflections on the pipelines shall be as follows (a

reduction in the diameter is considered to be a negative deflection):-
After Initial Installation 3%

Long Term 5%
1.8.4.3. Underground Services Warning Tapes
Service protection tapes shall be installed above firefighting pipelines constructed or exposed
under this contract excluding individual service connections.
For pipelines with the top of the pipe barrel more than 900 mm below finished surface level
the tape shall be placed over the centerline of the pipeline at 600 mm below finished surface
level during backfilling and compaction operations. For pipelines with less than 900 mm
cover to the top of the pipe barrel the tape shall be placed over the centerline of the pipe at
300 mm above the top of the pipe barrel during backfilling, compaction and reinstatement
operations.
Tape shall be Orange colour with Black text in Arabic and English as "CAUTION: FIRE-
FIGHTING PRESSURE MAIN BELOW” for firefighting network. The text on the tape
shall be permanent ink bonded to resist prolonged chemical attack by corrosive acids
and alkaline with message repeated at a maximum interval of two meters. The tapes
shall be laid 300 mm above the pipeline.
The tape shall be continuous over pipelines and at joints between tapes from separate
rolls the joint shall be lapped a minimum of one metre.
Tapes shall be durable and detectable by electro-magnetic means using low output
generator equipment. They shall remain legible and colour-fast in all soil conditions at
pH values of 2.5 to 11.0 inclusive.

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The tape shall be minimum 150 mm wide and 250 micron thick and produced as a
strong composite laminate consisting of: -
(1) 30 Micron polyester film top layer

(2) 12 Micron detectable aluminium foil in between
(3) 208 Micron bottom layer polyethelene.
The thickness of the tape (250 micron / 1000 gauge) shall be measured in accordance
with BS 2782: Part 6. Method 630 A.
The following properties shall be demonstrated by appropriate tests:-
Physical properties :- (Average of 5 tests)
Tensile strength Longitudinal (MD): 160 N (Minimum)

(BS EN ISO 527 – 3: 1996 Transversal (TD): 150 N (Minimum)
Elongation (PE only)

(BS EN ISO 527 – 3: 1996 MD: 450%, TD : 550%
Tear strength MD: 640 gram force
BS 2782 Part 3, 360A: 1991 TD: 700 gram force Minimum
Dart Impact
BS 2782: P3: 352F: 1996 1000 grams minimum
Chemical resistance:-
The tape shall be remaining legible and colour fast in all soil conditions at PH 2.5 – 11.0,
inclusive. The tape shall not show any adverse effect when in contact with the sulphates,
chlorides and other minerals present in sub soil and water, oil, 5% Acetic Acid, 5%
NaOH and Alcohol mix, if any.
Detectability after installation and back filling
Text in Arabic and English indicating the protected services lying below the tape shall
be permanent ink bonded to resist prolonged chemical attack by corrosive acids and
alkalis with the message repeated at a maximum interval of two metres. Tapes shall be
colour as per Civil Defense specifications. The sign and styles of the text shall be
1.8.4.4 Cleaning and Inspection of Pipelines
The Contractor shall ensure during and after construction that the pipes remain clean
and free of all silt, mortar, debris and other obstructions, and if required by the Engineer,
the pipelines shall be cleaned out using approved methods and equipment which do not
damage the internal lining of the pipes. When work is not in progress the open ends of
the pipeline shall be securely plugged with an approved watertight plug or stopper to
prevent the ingress of deleterious matter into pipelines.

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After backfilling pipe trenches and completing chambers, hatch boxes, etc., and before
the trench surfaces are reinstated, the interior of pipelines shall be cleaned of silt and
debris by approved methods for inspection by the Engineer's Representative as follows:-
All newly constructed pipelines shall have a loose plug passed through them to show
that they are clear of obstruction and free from deflection. The loose plug shall be
dimensioned to suit the permissible minimum deflected diameter of the pipe. Alternately,
a deflectometer capable of measuring diametric dimensions both vertically and
horizontally may be used as specified.
All renovated or replaced pipeline shall after cleaning, be inspected from the inside using
CCTV inspection, as directed by the Engineer.
Pipelines, chambers/structures will be inspected again before being put in service or

taking over (whichever is sooner) and if required by the Engineer's Representative shall
be cleaned again in whole or in part by suitable means which may include, if directed,
flushing with clean water.
1.8.4.5 Testing of Pipelines
1.8.4.5.1 General
The Contractor shall make his own arrangements for the supply of water used for testing
and cleaning of pipelines which shall be obtained from a source approved by the
Engineer. All water required for testing and cleaning shall be provided by the Contractor
at his cost.
Prior to commencement of flushing or testing, approval shall be obtained to the methods

and programme for testing and to the method of disposal of all fluids used for flushing or
testing purposes.
If permission is given to use new or existing pipelines, which are not part of a live
system, they shall be thoroughly cleaned of any resulting damage made good after use.
If lagoons for the storage of such fluids are permitted, they must be suitably protected
with fencing and attended by day and night to prevent access by the general public and
will not be sited adjacent to buildings. Approved means of preventing the formation of
mosquito larvae on the surface of the lagoons will be employed.
Testing of pipelines shall in all cases be applied in the presence of the Engineer's
Representative. The Contractor shall notify the Engineer at least 48 hours before hand
of his intention to test a section of pipeline. The Contractor, at his own expense, shall
provide complete plant and all struts, thrust blocks, etc., as may be necessary for
effectively testing the pipelines to the specified pressures.
Pipelines shall be properly completed and supported before being put under test. No
testing will be permitted until seven days after thrust blocks and other holding down
works have been completed.
Should any inspection be unsatisfactory or any test fail the Contractor shall replace
defective pipes, leaking joints or otherwise re-execute defective work as instructed
following which cleaning and testing will be repeated until the Engineer's Representative
certifies the pipeline to be satisfactory.

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1.8.4.5.2 Testing of Pressure Pipelines
Pipelines shall be subjected to a preliminary air test as soon as a length of pipe has
been laid and before backfilling. Pressure pipelines shall then be given a final test using
water after they have been back filled, cleaned and inspected.
Preliminary pressure testing of pipelines may be carried out if so required by the

Engineer with partial backfill only and exposed joints, but the stability and safety of the
Works must be ensured at all times.
Each test shall be restricted to pipes of one class. Pipelines shall be tested in sections
not exceeding 500 metres or between valve positions. In addition the whole pipeline
shall be tested upon completion. Particular care must be taken to isolate air valves, etc.,
not to apply higher pressure than specified at any point on the pipelines and to ensure
that the pipelines are adequately anchored before any test is carried out.
Gauges used for testing pressure pipelines shall be capable of reading increments of 0.1
metre head. Before any pressure gauge is used, the Contractor shall arrange for it to be
checked independently and a dated certificate of its accuracy shall be provided to the
Engineer. Calibration of pressure gauges shall be carried out at regular intervals as
required by the Engineer
As soon as a length of pressure pipe has been laid and before backfilling, when
applicable and when ordered it shall be subjected to the following preliminary test:
5. The test will not be satisfactory if the air pressure falls to less than 275 mm during
a period of 5 minutes without further pumping of air.
Pressure pipelines shall be given the following final test using water after they have been
backfilled, cleaned and inspected:
1. All the joints of the pipeline shall be left open for the purpose of inspection for
leakage if any, where practicable or instructed by the Engineer.
2. Pipe ends shall be closed with suitable stoppers, secured with longitudinal
braces/thrust block, before testing commences.

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3. Water shall be filled slowly from the lowest points and air allowed to escape
through an air vent fixed for the purpose at the highest points of the pipeline
section under test. No entrapped air shall remain in the pipeline while testing.
4. Pressure in the pipeline shall then be raised steadily up to and maintained at the
rated pressure for a period of 30 minutes to allow for absorption and achieve
conditions as stable as possible for testing.
5. If no leakage has been observed, pumping shall then be resumed and the
pressure slowly rose to the specified test pressure.
6. Unless specified elsewhere or directed otherwise by the Engineer, the test

pressure shall be 900 KN per square metre (91.8 m head of water).
7. Test pressure shall be continuously maintained by the use of the pump for a
period of 60 minutes and the amount of makeup water required to maintain the
pressure shall be accurately measured (to the nearest 1/8 litre).
8. Pipeline shall be deemed to have passed the test if all the following conditions are
satisfied:
a. No water is visible coming out of the pipe or joints at any point;
b. Amount of make-up water required does not exceed 1 litre per hour per 100
mm diameter per kilometer of pipeline under test;
b. The loss of the pressure during the test period does not exceed 70KN per
square metre.
1.9 TESTING OF VALVES
Valves and all pipelines appurtenances shall be hydraulically tested together with the pipeline in
which they are installed. Valves shall be tested for operation under working pressure and shall be
adjusted so that they operate smoothly, seat properly and are installed to tolerances recommended
by the manufacturer.
1.10 FIRE HYDRANT
The Civil Defence requirements for fire Hydrants and its fittings are control by NFPA 24 standard
as stated below:
- Hydrants shall be of approved type and have not less than a 6-in. (152-mm) diameter
connection with the mains,
- A valve shall be installed in the hydrant connection,
- The number, size, and arrangement of outlets; the size of the main valve opening; and
the size of the barrel shall be suitable for the protection to be provided and shall be
approved by the authority having jurisdiction,
- Hydrants shall be provided and spaced in accordance with the requirements of the
authority having jurisdiction,

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- Hydrants shall be located not less than 6.0m from the buildings line to be protected,
and
- The centre of a hose outlet shall be not less than 18 in. (457 mm) above final grade or,
where located in a hose house, 12 in. (305 mm) above the floor.
Pillar type hydrants shall be to BS 750, cast iron body to BS EN 1561:1997 with 2 nos. x 65mm
diameter control valve with copper alloy to BS EN 1982:1999 female instantaneous outlet and
150mm diameter female suction.
A 150mm diameter isolating valve in an accessible builders work chamber shall be provided
upstream of the fire hydrant.
1.11 PUMPS
Contractor shall be responsible for:
1. Integrity of the system after installation of piping and equipment inside the pumping
station.
2. Entire piping system shall be restrained and/or protected against unbalanced forces.
3. Stress analysis shall be carried out by specialist engineer to design appropriate
supporting system and to maintain loads on pipes and equipment within allowable limits.
1.11.1 FIRE PUMPS
Pumps shall be cast iron body and base. The pump section (shaft, impellers, guide vanes
and chambers) shall be of stainless steel. The mechanical shaft seal shall have diamond
polished Tungsten Carbide or Silicon Carbide seal faces and heat resistant O-ring. Thrust
bearing shall have ample capacity to carry the weight of all rotating parts plus the hydraulic
thrust of the impellers. Motors shall be closed coupled type.
Pumps shall be suitable for Treated Sewage/Brackish Water
The inlet and the outlet shall be flanged PN 16.

During operation at fire time duty of each fire pump shall be 1000GPM at total head greater
than or equal to 90m.
Pump to be automatically switched on when any fire hydrant is in operation.
System shall allow for 90m head pressure and 1000GPM flow for two fire hydrants while
operating two at the time of fire.
Fire pump shall be local Civil Defense approved and manufactured by an approved
manufacturer. Packaged fire pump set along with the control panel to be assembled in an
ISO9002 Certified facility within the United Arab Emirates.
Each pump shall have capacities as shown in pump schedule, adjusted as necessary to suit
the hydraulic calculation.
Electric fire pump and Diesel driven pump shall be horizontal single stage or multistage
construction to suit the specified rating. The pumps shall be connected to the standpipe
system. The suction supply for the fire pump shall be from storage tank at a maximum
pressure of 1.0 bar. The pump casing shall be cast iron and rated to withstand at least 1.5
times the working pressure.

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1.11.1.1 Material of Construction
Materials of construction shall be in accordance with ASTM standard /relevant BS

standards or NFPA 20.
Casing - Cast Iron / Stainless Steel

Impeller - Stainless steel
Shaft - Stainless steel
Shaft sleeve - Bronze
The casing will be of the end suction design made of cast iron, designed for 1720 kPa
hydraulic test pressure. The casing shall have tapped and plugged holes for priming, vent
and drain.
The impeller shall be designed to give the characteristics outlined under “Performance”. It
shall be of the enclosed type, vacuum cast in one piece. It shall be furnished all over, the
exterior being turned and the interior being furnished smooth and cleaned of all burrs,
trimmings and irregularities. The impeller will be dynamically balanced. It shall be held
securely to the shaft by a key of ample size and impeller nut.
A stuffing box shall be provided, designed with sufficient area for incorporation of
mechanical seals.
Pumps shall have balanced mechanical seals. Mechanical seals shall be with carbon
rotating ring, stainless steel spring, ceramic seat and flexible bellows and gaskets.
The pump shaft shall be one -piece finished and polished on all sections. The shaft shall be
of ample strength and rigidity and the shortest practicable distance between bearings shall
be used to keep deflection and vibration to a minimum.
The pump shall be fitted with grease lubricated ball bearing.
A flexible coupling shall be provided to connect the pump shaft to the motor shaft. The
coupling shall be of an all metal type with a flexible rubber insert. The entire rotating
coupling element shall be enclosed by a coupling guard.
The pump, motor and diesel engine shall be mounted on a groutable steel base plate with
integral drip channels incorporated on each side. The base shall be sufficiently rigid to
support the pump and motor without the use of additional supports or members.
1.11.1.2 Accessories
The fire pump shall include the following accessories:
- Discharge header Steel Sch 80 epoxy coated

- Isolating valves on suction and discharge of each pump
- Non return valves on discharge of each pump
- Air release valve to be provided on the stand pipe
- Discharge pressure gauge.
1.11.1.3 Electric motor drive
The electric motor shall be totally enclosed fan ventilated, wound for 380/415V/3Ph/50Hz
current. The motor shall be such capacity that 115% of full load ampere rating shall not be
exceeded at any condition of the pump load. Acceptable suppliers shall be: Brook
Crompton (UK), General Electric (USA), Schoch, US motors or equal.

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Motor shall be IP55, class F insulated suitable for ambient temperature of 500C. Bearings
shall be anti friction ball or roller type.
1.11.1.4 Diesel engine drive
Diesel engine shall be provided with electric starting system. Engine shall be either radiator
cooled or heat exchanger type. In case of heat exchanger, the factory supplied heat
exchanger piping loop complete with required strainers, a pressure reducing valve and
bypass line shall be installed between the pump discharge head and engine heat
exchanger by the installing contractor. Each engine shall be furnished by a lead acid heavy
duty starting batteries, battery rack and cables, a flexible exhaust connector and industrial
type silencer.
1.11.1.5 Control equipment
The fire pump control panel shall be completely assembled, wired and tested by the control
manufacturer before shipment from the factory, and shall be labeled “Fire Pump Controller”.
The controller shall be located as close as practical and within sight of the motor, preferably
mounted on the pump skid. The controller shall be so located or protected that it will not be
damaged/effected by water escaping from the pump or connection. The controller shall be
of combined manual and automatic star delta type, and shall be complete with:
A. Star delta starter for main electric pump.

B. Star delta/DOL starter for jockey pump, if applicable.
C. Door interlocked isolator.
D. Triple pole thermal over load relay.
E. MCCB for main and jockey pump.
F. Terminal for pressure switch.
G. Terminal for float switch for dry run protection.
H. Low voltage supply for float switch.
I. Run Trip indication for main, jockey pump.
J. Hand-Off-Auto switches for main and jockey pump.
K. Main incoming Ammeter.
L. Panel alive lamp.
M. A/C control circuit healthy indication.
N. Delay timer to prevent motor from cycling.
ENGINE CONTROLS.
O. D/C control circuit healthy indication.
P. Run-Trip lamp for diesel engine.
Q Hand-Off-Auto switches for diesel engine.
R. Battery charger
S. Battery charger On-Off switch
T. Ammeter for battery charger.
U. High water temperature indication lamp.
V. Low oil pressure indication lamp.
W. Terminal for pressure switch.
All the above in IP55 enclosure.
1.11.2 General
Pump set with diesel and electric driven shall be complete with suction and discharge
header, pressure gauges, coupling guard and control panel.
Batteries shall furnish in a dry charge condition, with electrolyte liquid in a separate
container. Electrolyte shall be added and the battery given a conditioning charge at the time
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that engine is put into service. Batteries shall be located so as to be readily accessible for
servicing and at least 300 mm above floor level.
All wiring between controller and building fire alarm system shall be carried by the
contractor.
A wring diagram shall be provided inside of the control panel enclosure showing exact
wiring for the controller, including a legend of identifying number of individual components.
All wiring terminals shall be plainly marked to correspond with the diagram furnished.
Wiring elements of the controllers shall be designed on a continuous -duty basis. All wiring
leading from the panel to the engine and to the battery shall have adequate current carrying
capacity. Such wiring shall be protected against mechanical injury by conduit.
Prior to shipment, the pump set shall be thoroughly shop tested for leakage. Test pressure
shall be 1.5 times the working pressure.
Electric fire pumps shall be the lead fire pump. Diesel engine pump shall be backup fire
pump and shall only operate if the lead pump cannot maintain system pressure.
Pump and motor to be aligned by the pump supplier prior to commissioning using Laser
alignment equipment. Software generated alignment report to be submitted along with
commissioning report.
The pump driver all controls and necessary attachments specified herein shall be
purchased under a unit contract. Field wiring of fire alarm panels, installation and wiring of
fuel piping, wiring from the suction tank to the panel shall be provided by the contractor. The
pump manufacturer shall assume unit responsibility and shall provide the service of a
qualified engineer to supervise the installation and alignment of equipment. Field tests shall
be conducted in the field to satisfy Local Authorities having jurisdiction of satisfactory
operation of pump, driver and controller. The pump manufacturer’s engineer shall be at the
job site supervising the test. The control manufacturer shall have their representative at the
job site to train operators in the use of the controls.
1.12 TYPES OF VALVES
A. All valves controlling connections to water supplies and to supply pipes to sprinklers
shall be listed indicating valves.
B. Indicating valves shall not close in less than 5 seconds when operated at maximum
possible speed from the fully open position.
C. A listed underground gate valve equipped with a listed indicator post shall be permitted.
D. A listed water control valve assembly with a reliable position indication connected to a
remote supervisory station shall be permitted.
E. A nonindicating valve, such as an underground gate valve with approved roadway box,
complete with T-wrench, and accepted by the authority having jurisdiction, shall be
permitted.
1.12.1 VALVES CONTROLLING WATER SUPPLIES
1.12.1.1 At least one listed indicating valve shall be installed in each source of water supply.
1.12.1.2 No shutoff valve shall be permitted in the fire department connection.
1.12.1.3 Where more than one source of water supply exists, a check valve shall be installed in
each connection.

DUBAI – UAE
1.12.1.4 Where cushion tanks are used with automatic fire pumps, a check valve shall not be
required in the cushion tank connection.
1.12.1.5* In a connection serving as one source of supply, listed indicating valves or post
indicator valves shall be installed on both sides of all check valves.
1.12.1.6 In the discharge pipe from a pressure tank or a gravity tank of less than 15,000 gal
(56.78 m3) capacity, a control valve shall not be required to be installed on the tank
side of the check valve.
1.12.1.7* The following requirements shall apply where a gravity tank is located on a tower in
the yard:
(1) The control valve on the tank side of the check valve shall be an outside
screw and yoke or a listed indicating valve.
(2) The other control valve shall be either an outside screw and yoke, a listed
indicating valve, or a listed valve having a post-type indicator.
1.12.1.8* The following requirements shall apply where a gravity tank is located on a building:
(1) Both control valves shall be outside screw and yoke or listed indicating
valves.
(2) All fittings inside the building, except the drain tee and heater connections,
shall be under the control of a listed valve.
1.12.1.9One of the following requirements shall be met where a pump is located in a
combustible pump house or exposed to danger from fire or falling walls, or where a tank
discharges into a private fire service main fed by another supply:
(1)* The check valve in the connection shall be located in a pit.
(2) The control valve shall be of the post indicator type and located a safe
distance outside buildings.
1.12.1.10*All control valves shall be located where readily accessible and free of obstructions.
1.12.2 POST INDICATOR VALVES

1.12.2.1* General. Every connection from the private fire service main to a building shall be
provided with a listed post indicator valve located to control all sources of water supply.
1.12.2.2 Alternate Provision for Post Indicator Valves. The authority having jurisdiction shall be
permitted to waive the requirement for the post indicator valves..
1.12.3 Location.
1.12.3.1 Post indicator valves shall be located not less than 40 ft (12.2 m) from buildings.
1.12.3.2* Where post indicator valves cannot be located, they shall be permitted to be
located closer where approved by the authority having jurisdiction, or wall post
indicator valves shall be used, provided they are set in locations near blank walls
where the possibility of injury by falling walls is unlikely and from which people are
not likely to be driven by smoke or heat.
1.12.4 Arrangement.
1.12.4.1 Post indicator valves shall be set so that the top of the post is 36 in. (0.9 m) above
the final grade.
1.12.4.2 Post indicator valves shall be protected against mechanical damage where needed.
1.12.5 VALVES PITS

1.12.5.1 Where it is impractical to provide a post indicator valve, valves shall be permitted to be
DUBAI – UAE
placed in pits and shall be approved by the authority having jurisdiction.

1.12.5.2 Valve pits located at or near the base of the riser of an elevated tank shall be
designed in accordance with Chapter 9 of NFPA 22, Standard for Water Tanks for
Private Fire Protection.
1.12.5.3* Where used, valve pits shall be of adequate size and readily accessible for inspection,
operation, testing, maintenance, and removal of equipment contained therein.
1.12.5.4 Valve pits shall be constructed and arranged to properly protect the installed
equipment from movement of earth, freezing, and accumulation of water.
1.12.5.5 Depending on soil conditions and the size of the pit, valve pits shall be permitted to be
constructed of any of the following materials:
(1) Poured-in-place or precast concrete, with or without reinforcement
(2) Brick
(3) Other approved materials
1.12.5.6 Where the water table is low and the soil is porous, crushed stone or gravel shall be
permitted to be used for the floor of the pit.
1.12.5.7 The location of the valve shall be marked, and the cover of the pit shall be kept free of
obstructions.
1.12.6 SECTIONAL VALVES.

1.12.6.1 Large, private, fire service main systems shall have sectional controlling valves at
appropriate points to permit sectionalizing the system in the event of a break or to make
repairs or extensions.
1.12.6.2 A sectional valve shall be provided at the following locations:
(1) On each bank where a main crosses water
(2) Outside the building foundation(s) where a main or a section of a main runs
under a building.
1.12.7 IDENTIFYING AND SECURING VALVES.

1.12.7.1 Identification signs shall be provided at each valve to indicate its function and what it
controls.
1.12.7.2* Valves on connections to water supplies, sectional control and isolation valves, and
other valves in supply pipes to sprinklers and other fixed water-based fire suppression
systems shall be supervised by one of the following methods:
(1) Central station, proprietary, or remote station signaling service
(2) Local signaling service that causes the sounding of an audible signal at a
constantly attended location
(3) An approved procedure to ensure that valves are locked in the correct
position
(4) An approved procedure to ensure that valves are located within fenced
enclosures under the control of the owner, sealed in the open position, and
inspected weekly
1.12.7.3 Supervision of underground gate valves with roadway boxes shall not be required.
1.12.8 CHECK VALVES.

Check valves shall be installed in a vertical or horizontal position in accordance with their
listing.
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1.13 PIPES AND FITTINGS.
A. PIPES
1. Pipes and fittings shall be in conformance with the following specifications unless
specified otherwise by the Authority having jurisdiction. Obtain approval of local
Authorities before proceeding with the work.
2. Pipe shall be seamless UL, as per ASTM A 53 grade B, schedule 40.
3. When pipes are assembled by screwed fitting or by roll-grooved / cut-grooved, the

minimum thickness for a pressure up to 20.7 bar.
4. Seamless Steel pipes must have factory galvanized internal and external surfaces or
shall be shot blasted and immediate Electrostatic Powder coated with RAL 3000 finish on
external surfaces to prevent corrosion. The threaded extremities must be oil treated to
prevent corrosion and shall have a thickness of not less than 100 microns. The painted
pipes shall be subject to oven baking at 200 Deg.C. The paint powder used shall be UV
stabilized suitable for external weather condition and a certificate from manufacturers
must be submitted. The pipes must be well wrapped so it will not be scratched during
installation.
5. Diameters
• Minimum diameter is DN25
6. Pipes bending:
Schedule 40 Steel pipes bending is allowed if bending are executed with no defaults,
no diameter reduction and no significant deviation in the pipes circle symmetry.
The bending minimum radius must be:
• 6 pipe diameters for a diameter < 2 ‘’, and
• 5 pipe diameters for a diameter > 2 ½ ’’.

7. Pipes marking and identification
Firewater pipes in galvanised steel shall be marked to indicate it’s destination.
8. Pipes Drainage
For sprinkler system, pipe drainage shall be accomplished by sloping pipe to low point
with auxiliary drain as per NFPA13.
9. Special Requirements
Full flanges or plugs, according to the diameter shall be installed on the collector’s
extremities to flushing rinsing of the pipes
B. PIPE FITTINGS.
1. Fittings for piping 50mm and small shall be UL listed and FM approved. The fittings
shall be suitable for 300 psi working pressure. Fittings shall be ductile iron or cast iron
in black or hot dipped factory galvanized finish.

DUBAI – UAE
2. Fittings for piping larger than 50 mm shall be hot dipped factory galvanised
mechanical grooved fittings and mechanical joints. Fittings, gaskets and mechanical
couplings shall be UL listed and FM approved. The fittings shall be suitable for 300
psi working pressure.
3. Pipes welding shall not be carried out on site.
4. The galvanised steel fittings shall be Ul Listed and or FM approved.
5. Unions and Couplings
Screwed unions shall not be used for pipe grater than DN40. For pipes above, flanges
will be used.
6. Reducers and male/female reducers
• One piece reduced fitting must be used for each pipe diameter change.
• Reduced sleeve for the pipe continuity, and
• Male/female reducer for a direction change with reduction (T shape + reducer)
1.14 FIRE ALARM AND EXTINGUISHING SYSTEMS General

The Contractor shall arrange for an approved Sub-Contractor who shall be on the list of
Approved Contractors, to supply, install, wire and commission the complete manual/automatic
fire alarm system comprising manual fire alarm call points, alarm bells and sounders, smoke
and heat detectors and control panels as indicated on the drawings. The fire alarm system
equipment shall be selected from equipment approved by the Fire Department. The system
shall be installed and maintained in accordance with the recommendations of an approved
international standard. The wiring shall be 1.5 mm2 MICC/PVC for bell and battery circuits.
Manual Fire Alarm Call Point
Manual fire alarm call points shall consist of a die cast plastic cover locked in position with
screws. The enclosure shall house a micro switch. The micro switch plunger shall bear onto
an inset break glass panel fixed into the cover. The call point shall be arranged for surface
mounting. The cover and the enclosure shall be self coloured red. The words “BREAK
GLASS FOR ALARM” shall be printed on the frangible glass. A testing facility using a
special key shall be provided to enable the call point to be tested without breaking the glass
and the frangible glass shall be covered with plastic film to prevent injury when the glass is
broken. The mounting height shall be 1500 mm above finished floor level.
The switching unit contacts shall be gold or silver plated or an alloyed metal which will not
corrode when left unattended in a highly polluted environment. Contact blades and other
metal parts of the switching unit shall also be constructed from plated or alloyed metal which
will not corrode when left unattended. Contacts shall be normally open or normally closed to
suit the alarm monitoring system. The voltage and current rating of the contacts shall be
marked within the enclosure.
The call point shall comply with an approved international standard :Specification for manual
call points”.
The call point shall be resistant to the ingress of dust and water, and shall be suitable for
operation in the environmental conditions at the site of installation.

DUBAI – UAE
Optical Smoke Detector
Optical smoke detectors shall comply with an approved international standard.
Detector Base
An operation indicator lamp of the light emitting diode type and a time delay unit to override
spurious alarms shall be fitted to the base.
Fire Alarm Panel
The fire alarm panel shall be wall mounted adjacent to the motor control centre. The fire
alarm system shall protect risk areas within the premises by giving warning of a fire condition
relayed by an automatic detector or by the operation of a break glass callpoint. Operation of
an individual detector is to be displayed by an indicator fitted into the base of the detector.
This indicator will illuminate when its detector goes into alarm. Fixed temperature heat
detectors will not have this local indication facility. Upon receipt of an alarm, the control units
shall perform the following actions:
a) Illuminate fire zone detector
b) Activate alarm warning devices within the building
c) Operate internal fire sounder
d) Operate ancillary devices as appropriate
Alarm warning devices shall be de-activated by operation of the “Silence Alarms” switch. The
internal sounder will continue to operate and the fire indicators remain lit until the key switch
controlled push switch is operated. This should only be achieved if the alarm initiating device
is no longer in alarm.
Reset of the controller, after the fire incident has been investigated, will be achieved by
operation of the “Reset” switch.
The enclosures of the panels shall be fabricated from sheet steel, minimum thickness 1.5
mm and shall be provided with a hinged lockable door. Protection to an approved
international standard shall be provided.
The control unit should be designed to comply with the compulsory requirements of an
approved international standard, relating to “Automatic fire alarm systems in buildings, control
and indicating equipment”.
Alarm panels shall as a minimum requirement be equipped with the following:
a) Mains supply on indicator
b) DC supply on indicator
c) DC supply faulty indicator
d) Alarm indicator for each zone
e) Alarm accept push-button to acknowledge fire alarm signals, silence external audible
alarms and energise as internal bleeper unit.
f) Reset push-button to restore monitoring systems to the quiescent condition

DUBAI – UAE
g) Integral sealed battery and trickle battery charger where appropriate
h) Alarm transmission facilities via the telephone alarm system
i) Terminations for incoming and outgoing wiring systems
j) Voltage free normally closed circuits which shall open in the event of an alarm to
shutdown ventilation and air conditioning equipment in the immediate vicinity.
k) Suitable fault indication both visual and audible.
Alarm indicators shall be of the light emitting diode type. Indicators shall be provided in pairs
for each function.
Alarm panels shall continuously monitor all alarm circuits, including wiring and control
devices. When a fault monitoring circuit has been energised it shall not reset until the fault
condition is cleared.
Batteries shall be of the sealed lead acid type and shall have a capacity capable of
maintaining the system in normal working condition for at least 24 hours without recharging
and subsequently to operate in the alarm condition for at least one hour.
Battery charging to be of sufficient capacity to power the system whilst recharging a fully
discharged battery. The battery shall be fully charged within 8 hours.
Monitoring circuits shall utilise solid state components. Output relay contacts shall be gold or
silver plated and shall be rated for the circuit conditions into which they operate.
Alarm bells shall be of the gong type with a minimum diameter of 200 mm. They shall be
continuously rated and be mounted 2200 mm above finished floor level.
Bells shall be marked with the words “FIRE ALARM”.
Fire Extinguishing Equipment
The Contractor shall supply and install in the respective positions:
2.5 kg hand held CO2 operated for extinguishers and 4.5 kg hand held dry powder type fire
extinguisher, suitable for Class A, B and C fire risks, flammable liquid, and fires from electrical
sources. The extinguisher shall comprise a light alloy or steel cylinder finished in blue epoxy
resin fitted with a controllable brass valve with pressure gauge or aluminum head cap for CO2
operated cylinders. Valves to be fitted with safety pin lever.
All equipment supplied shall be suitable for the high temperatures, humidities, and dusty
atmospheres experienced in Dubai, with a minimum jet range of 5-7m discharging in
approximately 15 secs.
All equipment supplied under this section shall be obtained from a company regularly
engaged in the manufacture and supply of fire protection equipment. It shall essentially be a
duplicate of equipment that has been in satisfactory use for not less than five years prior to
the bid date and be supported by an approved service organisation capable of carrying out
regular inspection and maintenance of fire protection systems.
All portable fire extinguishers shall be manufactured in accordance with an approved

international standard and are to be wall mounted on secure brackets with the base
approximately 760 mm above floor level.

DUBAI – UAE
Fire extinguishing devices shall be clearly and indelibly labelled with clear instructions for their
use in English, Arabic and pictorial form.
All Fire Fighting and Fire Alarm systems shall have approval from the Civil Defence
Department of the Emirate of Dubai
ACCESSORIES
The Contractor shall supply and install where specified the items listed below:
a. FIRST AID BOX - wall mounted first aid box marked with a red crescent and
containing:
40 nr individually wrapped adhesive dressings
2 nr sterile eye pads and bandages
2 nr sterile triangular bandages
6 nr safety pins
2 nr sterile unmedicated dressings extra large
1 nr roll elastic bandage 2 inch
1 nr pair scissors
1 nr eyebath
1 nr bottle eye wash solution
25 g cotton wool
1 nr bottle antiseptic
1 nr card or booklet giving simple instructions
b. ELECTRIC SHOCK FIRST AID INSTRUCTION - Instructions in both English and Arabic
for the treatment of persons suffering from electric shock. The instructions shall be
printed on a substantial wall mounted plate with a wipe clean surface.
c. DANGER NOTICE - Danger notices inscribed “DANGER DO NOT OPERATE - MAN

WORKING ON EQUIPMENT” in both English and Arabic. The plates shall be of
laminated plastic with white letters on a red background and arranged to hang on isolator
handles.
d. RUBBER GLOVES - One pair of heavy duty insulating rubber gloves. The gloves
are to be stamped with their date of manufacture and shelf life.

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GAS DETECTORS
Portable Gas Detectors: General
The detector shall be housed in a robust case sealed to comply with an approved international
standard. The case shall be provided with harness-type straps to allow the equipment to be worn.
Alternatively, a purpose-made carrying case, also with harness straps, shall be supplied. In use,
such a carrying-case shall allow the display to be clearly visible.
The detector shall be explosion proof with an internationally recognised certification as “intrinsically
safe” allowing use in hazardous areas. The detector shall be suitable for gas groups commonly
found at sewage treatment works.
The detector shall be powered by a rechargeable nickel cadmium battery pack which shall be
replaceable. A fully charged battery pack shall operate the detector continously for a minimum of
10 hours. In use, low battery power shall initiate an audible alarm.
The detector shall incorporate sensors to detect gas concentrations and initiate alarms as follows:
Mode display range alarm initiate
combustible gas or vapour 0 - 100% by volume of air, calibrated > 20%

for methane
hydrogen sulphide 0 - 200 ppm >10 ppm
oxygen 0 - 25% by volume of air >24%
<19%
The display may be switchable between the three modes. However, should any one of the three
gas hazards occur, a warning lamp shall light and an audible alarm shall sound, irrespective of the
position of the switch.
Due to the limited life of gas sensor cells, the cells in the detector or any spare cells provided shall
be less than 3 months old at the time of handover to the employer. Each cell shall have its date of
manufacture indicated on its cover.
The detector shall be provided with an extension tube 2 m long and manual pump for sampling
inaccessible places.
Only equipment which is supported by a service workshop in Dubai authorised by the

manufacturer shall be provided.
Portable Gas Detector
One complete set of portable gas detection equipment shall comprise:
1 nr Portable gas detector complete with sensors for combustible gases, hydrogen
sulphide and oxygen, and including rechargeable battery pack, harness/carrying case
and extension tube. If the instrument has no built-in pump, a rubber bulb aspirator along
with suitable adaptor and extension tube shall be provided.

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1 nr Single way charger to suit above battery pack
1 nr Stainless steel probe for extension tube
Test gases in 20 litre canisters:
1 nr 2.5% methane in air tester / calibration bottle
1 nr 25 ppm hydrogen sulphide in air teser / calibration bottle
1 nr 17% oxygen in nitrogen tester / calibration botle
1 No. box to house above equipment, suitable for wall mounting and labelled “Portable
Gas Detector”.


ROADS AND UTILITIES

VOLUME 2 – PART VII
BUILDING GENERAL SPECIFICATIONS
CIVIL & ARCHITECTURAL

20010410
JUNE, 2022
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications

Volume 2 – Part VI Particular Specifications for Firefighting Works

Architectural

VOLUME 2 – PART VII DATE OF ISSUE: 16 JUNE, 2022
DUBAI – UAE
MEYDAN GROUP LLC

Project: 20010410
Roads and Utilities
Volume 2 – Part VII
Building General Specifications – Civil & Architectural
Table of Contents
DIVISION 1- GENERAL REQUIREMENTS .............................................................................................. 1

DIVISION 02 – SITE WORK ......................................................................................................................... 1
02220 EARTHWORKS PART I GENERAL............................................................................................. 1
1.01. DESCRIPTION OF WORK ....................................................................................................... 1
1.02. QUALITY ASSURANCE ........................................................................................................... 1
1.03. SUBMITTALS .............................................................................................................................. 1
PART 2 PRODUCTS ................................................................................................................................. 2
2.01. DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS MATERIAL
....................................................................................................................................................................... 2
2.02. SELECTED BACKFILL MATERIALS FOR STRUCTURES, FOUNDATION AND
SERVICE TRENCHES .............................................................................................................................. 3
2.03. NON-COMPLIANCE WITH CLAUSE 2.2 .............................................................................. 3
PART 3 EXECUTION ................................................................................................................................ 3
3.01. EXCAVATION LEVELS ............................................................................................................ 3
3.02. EXCAVATIONS BEYOND THE TRUE LINE AND LEVEL ................................................ 3
3.03. PROTECTION AND SAFETY OF EXCAVATIONS ............................................................ 4
3.04. DE-WATERING .......................................................................................................................... 4

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3.05 REMOVAL OF UNSUITABLE MATERIAL ............................................................................ 5

IN ................................................................................................................................................................... 5
SPECTION OF EXCAVATIONS ............................................................................................................... 5
3.06 SPOIL DISPOSAL ...................................................................................................................... 5
3.07 ................................................................................................................................................................ 5
3.08 REFILLING OF FOUNDATION PITS AND TRENCHES ................................................... 6
3.09 FORMING OF AREAS OF FILL .............................................................................................. 6
3.10 COMPACTION AND TREATMENT OF EXISTING SUB-GRADE ................................... 7
3.11 COMPACTING OF FILL MATERIAL ...................................................................................... 7
3.12 FILL ADJACENT TO STRUCTURES .................................................................................... 8
3.13 SLIPS ............................................................................................................................................ 9
3.14 TOLERANCE LIMITS ................................................................................................................ 9
3.15 ANTI TERMITE TREATEMENT .............................................................................................. 9
02760 AGGREGATE SUB BASES AND ROAD BASES .................................................................. 10
PART 1 GENERAL .................................................................................................................................. 10
1.01 DESCRIPTION OF WORK ..................................................................................................... 10
1.02 REFERENCE STANDARDS .................................................................................................. 10
1.03 QUALITY ASSURANCE ......................................................................................................... 11
1.04 SUBMITTALS ............................................................................................................................ 11
1.05 PRODUCT DELIVERY, STORAGE AND HANDLING ..................................................... 11
1.06 COMPACTED THICKNESS ................................................................................................... 12
PART 2 PRODUCTS ............................................................................................................................... 12
2.01 MATERIALS .............................................................................................................................. 12
PART 3 EXECUTION .............................................................................................................................. 16
3.01 CONSTRUCTION TRAFFIC ON PAVEMENTS UNDER CONSTRUCTION .............. 16
3.02 DRAINAGE ................................................................................................................................ 17
3.03 EARTHWORKS ........................................................................................................................ 17
3.04 TOLERANCES .......................................................................................................................... 17
3.05 CONSTRUCTION REQUIREMENTS .................................................................................. 18
DIVISION 3 – CONCRETE WORK ........................................................................................................... 19
03110 CONCRETE FORMS AND ACCESSORIES ........................................................................... 19

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PART 1 GENERAL .................................................................................................................................. 19

1.01 RELATED WORK ..................................................................................................................... 19
1.02 REFERENCES AND STANDARDS ..................................................................................... 19
1.03 SHOP DRAWINGS .................................................................................................................. 20
1.04 WORKMANSHIP - DEFLECTION AND CAMBER ............................................................ 20
PART 2 PRODUCTS ............................................................................................................................... 20
2.01 MATERIALS .............................................................................................................................. 20
PART 3 EXECUTION .............................................................................................................................. 21
3.01 FABRICATION AND ERECTION .......................................................................................... 21
3.02 SUPPORTS ............................................................................................................................... 22
3.03 JOINTS AND EDGES .............................................................................................................. 22
3.04 CLEANING AND TREATMENT ............................................................................................ 23
3.05 STRIKING .................................................................................................................................. 23
03210 CONCRETE REINFORCEMENT .............................................................................................. 25
PART 1 GENERAL .................................................................................................................................. 25
1.01 RELATED WORK ..................................................................................................................... 25
1.02 REFERENCES ......................................................................................................................... 25
1.03 SOURCE QUALITY CONTROL ............................................................................................ 25
1.04 SHOP DRAWINGS .................................................................................................................. 26
1.05 SUBSTITUTES ......................................................................................................................... 27
PART 2 PRODUCTS ............................................................................................................................... 27
2.01 MATERIALS .............................................................................................................................. 27
2.02 FABRICATION .......................................................................................................................... 28
PART 3 EXECUTION AND PROTECTION ........................................................................................ 28
3.01 CUTTING AND BENDING...................................................................................................... 28
3.02 PLACING REINFORCEMENT............................................................................................... 28
3.03 FIELD TOUCH-UP ................................................................................................................... 29
3.04 CLEANING................................................................................................................................. 29
3.05 FIXING ........................................................................................................................................ 29
3.06 SPLICES .................................................................................................................................... 29
3.07 MESH FABRIC.......................................................................................................................... 30

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3.08 WELDING .................................................................................................................................. 30

3.09 PROTECTION HANDLING AND STORAGE ..................................................................... 30
3.10 CONTACT BETWEEN DISSIMILAR METALS .................................................................. 30
3.11 STARTER BARS ...................................................................................................................... 30
3.12 COVER ....................................................................................................................................... 31
3.13 EMBEDDED ITEMS................................................................................................................. 31
3.14 DOWEL BARS .......................................................................................................................... 31
PART 4 EPOXY COATED REINFORCEMENT ................................................................................. 32
4.01 SCOPE ....................................................................................................................................... 32
4.02 GENERAL .................................................................................................................................. 32
4.03 EPOXY COATING OF REINFORCEMENT ........................................................................ 32
4.04 SITE INSPECTION AND REPAIR ON REJECTION OF DAMAGE TO EPOXY
COATING ................................................................................................................................................... 33
4.05 CUTTING AND BENDING OF REINFORCEMENT .......................................................... 34
4.06 SITE INSTALLATION AND HANDLING .............................................................................. 34
4.07 QUALITY CONTROL ............................................................................................................... 35
03310 CAST-IN-PLACE CONCRETE ................................................................................................... 36
PART 1 GENERAL .................................................................................................................................. 36
1.01 RELATED SECTIONS ............................................................................................................ 36
1.02 REFERENCES ......................................................................................................................... 36
1.03 SAMPLES .................................................................................................................................. 38
1.04 CERTIFICATES ........................................................................................................................ 39
1.05 QUALITY ASSURANCE ......................................................................................................... 39
PART 2 PRODUCTS AND STORAGE ................................................................................................ 40
2.01 MATERIALS FOR CONCRETE ............................................................................................ 40
PART 3 EXECUTION AND QUALITY ASSURANCE ....................................................................... 52
3.01 DESIGN OF CONCRETE MIXES ......................................................................................... 52
3.02 STRENGTH TESTS ................................................................................................................. 55
3.03 WORKMANSHIP ...................................................................................................................... 55
3.04 CONCRETING .......................................................................................................................... 57
3.05 DIMENSIONAL TOLERANCES ............................................................................................ 63
3.06 COMPLIANCE OF CONCRETE WITH SPECIFICATIONS ............................................ 64
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3.07 FINISHES................................................................................................................................... 66
3.08 CONSTRUCTION JOINTS A. Details .................................................................................. 68
3.09 MOVEMENT JOINTS .............................................................................................................. 70
3.10 JOINT FILLERS AND SEALANTS ....................................................................................... 70
PART 4 FLOOR SCREEDS ................................................................................................................... 70
4.01 SCOPE ....................................................................................................................................... 70
4.02 GENERAL .................................................................................................................................. 70
4.03 MATERIALS .............................................................................................................................. 70
4.04 SCREEDS LAID DIRECT ON IN SITU CONCRETE ........................................................ 70
4.05 SCREEDS LAID ON PRECAST CONCRETE UNITS ...................................................... 71
4.06 AERATED OR CELLULAR CONCRETE SCREEDS ....................................................... 72
PART 5 WATERTIGHT CONCRETE ................................................................................................... 72
5.01 SCOPE ....................................................................................................................................... 72
5.02 General ....................................................................................................................................... 72
5.03 MATERIALS .............................................................................................................................. 72
5.04 WORKMANSHIP ...................................................................................................................... 72
5.05 TESTING FOR WATERTIGHTNESS .................................................................................. 74
DIVISION 4 - MASONRY ............................................................................................................................ 76
04200 MASONRY ..................................................................................................................................... 76
PART 1: GENERAL .................................................................................................................................. 76
1.01 SCOPE OF WORK ........................................................................................................................ 76
1.02 RELATED WORK NOT INCLUDED .......................................................................................... 76
1.03 SUBMITTALS ................................................................................................................................. 76
1.04 MATERIAL DELIVERY, HANDLING AND STORAGE........................................................... 77
1.05 PROTECTION OF MATERIALS ................................................................................................. 77
1.06 PROJECT ENVIRONMENTAL CONDITIONS ......................................................................... 77
1.07 ADJUSTMENT AND CLEANING OF COMPLETED WORK ................................................ 78
1.08 PROTECTION DURING PROGRESS OF WORKS ............................................................... 78
1.09 PROTECTION OF COMPLETED WORK ................................................................................. 78
PART 2: MATERIALS .............................................................................................................................. 78
2.01 MATERIALS : .................................................................................................................................. 78

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2.03 MATERIALS - TIES ....................................................................................................................... 79

2.04 MATERIALS - MOVEMENT JOINTS ......................................................................................... 79
2.05 MORTAR MATERIALS ................................................................................................................. 81
PART 3: EXECUTION .......................................................................................................................... 82
3.01 MORTAR ......................................................................................................................................... 82
3.02 MASONRY - INSTALLATION...................................................................................................... 82
3.03 CLEANING ...................................................................................................................................... 85
3.04 FIELD QUALTIY CONTROL........................................................................................................ 85
DIVISION 5 – METALS ............................................................................................................................... 86
05500 MISCELLANEOUS METALS ......................................................................................................... 86
PART 1: GENERAL .................................................................................................................................. 86
1.01 SCOPE OF WORK ........................................................................................................................ 86
1.02 RELATED WORK NOT INCLUDED ........................................................................................... 86
1.03 SUBMITTALS .................................................................................................................................. 86
1.04 COORDINATION ............................................................................................................................ 86
1.05 REFERENCE SPECIFICATIONS ............................................................................................... 87
PART 2 : PRODUCTS ................................................................................................................................. 87
2.01 MATERIALS .................................................................................................................................... 87
2.02 STEEL ITEMS ................................................................................................................................. 89
PART 3: EXECUTION .............................................................................................................................. 90
3.01 FABRICATION ................................................................................................................................ 90
3.02 INSTALLATION ............................................................................................................................. 90
DIVISION 7 – THERMAL AND MOISTURE PROTECTION ................................................................ 92
07005 WATERPROOFING AND DAMPPROOFING ............................................................................. 92
PART 1: GENERAL .................................................................................................................................. 92
1.01 SCOPE OF WORK ........................................................................................................................ 92
1.02 GUARANTY ..................................................................................................................................... 92
1.03 APPLICATION SCHEDULE ......................................................................................................... 92
1.04 SUBMITTALS .................................................................................................................................. 92
1.05 DELIVERY, STORAGE AND HANDLING ................................................................................. 93
1.06 JOB CONDITIONS ......................................................................................................................... 93

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PART 2: MATERIAL AND LOCATION.................................................................................................. 93

2.01 Substructure .................................................................................................................................... 93
2.02 Underground Water Tank ............................................................................................................. 94
2.03 Wet Areas ........................................................................................................................................ 94
PART 3: EXECUTION .............................................................................................................................. 95
3.01 GENERAL ........................................................................................................................................ 95
3.02 SUBSTRATE SURFACE .............................................................................................................. 95
3.03 INSTALLATION .............................................................................................................................. 95
SECTION 07193 VAPOR BARRIER ........................................................................................................ 97
PART 1: GENERAL .................................................................................................................................. 97
1.01 SCOPE OF WORK ........................................................................................................................ 97
PART 2: PRODUCTS ............................................................................................................................... 97
2.01 MATERIALS .................................................................................................................................... 97
PART 3: EXECUTION .............................................................................................................................. 97
3.01 INSTALLATION .............................................................................................................................. 97
SECTION 07200 INSULATION ................................................................................................................. 98
PART 1: GENERAL .................................................................................................................................. 98
1.01 SCOPE OF WORK ........................................................................................................................ 98
1.02 RELATED WORK ........................................................................................................................... 98
1.03 SUBMITTALS .................................................................................................................................. 98
1.04 PRODUCT DELIVERY, STORAGE, AND HANDLING ........................................................... 98
PART 2: PRODUCTS ............................................................................................................................... 98
2.01 MATERIALS .................................................................................................................................... 98
PART 3 : EXECUTION .......................................................................................................................... 99
3.01 CLEANLINESS: .............................................................................................................................. 99
3.02 INSTALLATION OF EXTRUDED POLYSTYRENE BOARD : ............................................... 99
SECTION 07500 ROOFING SYSTEM ................................................................................................... 100
PART 1: GENERAL ................................................................................................................................. 100
1.01 SCOPE OF WORK ...................................................................................................................... 100
1.02 SUBMITTALS ................................................................................................................................ 100
1.03 DELIVERY, STORAGE AND HANDLING ............................................................................... 100

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1.04 PRE-ROOFING CONFERENCE ............................................................................................. 100

1.05 JOB CONDITIONS ....................................................................................................................... 101
1.06 GUARANTY ................................................................................................................................... 101
PART 2 : PRODUCTS ......................................................................................................................... 101
2.01 INSULATION MATERIALS ......................................................................................................... 101
2.02 WATERPROOFING MATERIALS ............................................................................................. 102
2.03 ACCESSORIES AND FASTENINGS MATERIALS ............................................................... 103
2.04 PROTECTION MATERIALS ...................................................................................................... 103
PART 3: EXECUTION ............................................................................................................................ 104
3.01 GENERAL ...................................................................................................................................... 104
3.02 SUBSTRATE SURFACE ............................................................................................................ 104
3.03 SCREEDING ................................................................................................................................. 104
3.04 ROOFING MEMBRANE INSTALLATION................................................................................ 104
3.05 EXTERNAL AND INTERNAL CORNERS ............................................................................... 105
3.06 LIGHTWEIGHT CONCRETE INSTALLATION ..................................................................... 105
SECTION 07900 CAULKING ................................................................................................................... 106
PART 1: GENERAL ................................................................................................................................ 106
1.01 SCOPE OF WORK ...................................................................................................................... 106
1.02 RELATED WORK ......................................................................................................................... 106
1.03 SUBMITTALS ................................................................................................................................ 106
1.04 PRODUCT DELIVERY, STORAGE, AND HANDLING ......................................................... 106
PART2: PRODUCTS ............................................................................................................................. 106
2.01 MATERIALS .................................................................................................................................. 106
2.02 PERFORMANCE AND DESIGN REQUIREMENTS ............................................................. 107
PART3: EXECUTION ............................................................................................................................ 107
3.01 JOINT PREPARATION ............................................................................................................... 107
3.02 SEALING ........................................................................................................................................ 108
DIVISION 8 - DOORS AND WINDOWS ................................................................................................ 109
SECTION 08120 ALUMINUM DOORS AND FRAMES ................................................................... 109
PART 1: GENERAL ................................................................................................................................ 109
1.01 SCOPE OF SECTIONS ............................................................................................................. 109

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1.02 RELATED SECTIONS ............................................................................................................... 109

1.03 REFERENCES ............................................................................................................................ 109
1.04 QUALITY ASSURANCE ............................................................................................................ 110
1.05 SYSTEM DESCRIPTION .......................................................................................................... 110
1.06 SUBMITTALS .............................................................................................................................. 111
1.07 MAINTENANCE DATA .............................................................................................................. 111
1.08 DELIVERY, STORAGE AND HANDLING ............................................................................. 111
1.09 WARRANTY ................................................................................................................................ 111
PART 2: PRODUCTS ............................................................................................................................. 112
2.01 MATERIAL DESCRIPTION ...................................................................................................... 112
2.02 ALUMINIUM ................................................................................................................................. 112
2.03 ASSEMBLY COMPONENTS ................................................................................................... 113
2.04 ADDITIONAL STEEL REINFORCING ................................................................................... 113
2.05 ADJUSTABLE ANCHORS ANDREINFORCING .................................................................. 113
2.06 GLASS TYPES ........................................................................................................................... 113
2.07 GLAZING MATERIALS ............................................................................................................. 113
2.08 GLAZING SALANTS .................................................................................................................. 114
2.09 ALUMINIUM DOORS, HINGED, EXTERIOR AND INTERIOR ......................................... 114
2.10 ALUMINIUM DOORS, SIDELIGHT AND SCREEN FRAMES, EXTERIOR AND
INTERIOR ................................................................................................................................................ 114
2.11 HARDWARE ................................................................................................................................ 115
2.12 SEALANT AND ACCESSORIES ............................................................................................. 115
2.13 FABRICATION ............................................................................................................................ 116
PART 3: EXECUTION ............................................................................................................................ 117
3.01 EXAMINATION............................................................................................................................ 117
3.02 COORDINATION ........................................................................................................................ 117
3.03 ERECTION .................................................................................................................................. 117
3.04 ALUMINIUM DOOR FRAMES, AND SIDELIGHT AND TRANSOM FRAMES,
EXTERIOR AND INTERIOR ................................................................................................................ 118
3.05 ALUMINIUM DOORS, EXTERIOR AND INTERIOR, HINGED ......................................... 118
3.06 ALUMINIUM SPECIFICATION ................................................................................................ 118
3.07 GLASS NOTES: .......................................................................................................................... 118
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3.08 GLAZING TYPES ....................................................................................................................... 119

3.09 GLAZING ...................................................................................................................................... 119
3.10 HARDWARE ................................................................................................................................ 119
3.11 CAULKING ................................................................................................................................... 120
3.12 CLEANING ................................................................................................................................... 121
3.13 CLEAN UP ................................................................................................................................... 121
SECTION 08710 HARDWARE ................................................................................................................ 122
PART 1: GENERAL ................................................................................................................................ 122
1.01 SCOPE OF WORK ........................................................................................................................ 122
1.02 RELATED WORK .......................................................................................................................... 122
1.03 SUBMITTALS ................................................................................................................................. 122
PART 2: PRODUCTS ............................................................................................................................. 123
2.10 HARDWARE FINISHES ............................................................................................................... 127
PART 3 : EXECUTION ............................................................................................................................. 127
3.01 INSTALLATION ............................................................................................................................. 127
3.02 ADJUST AND CLEAN .................................................................................................................. 128
SECTION 08800 GLAZING ..................................................................................................................... 130
PART 1: GENERAL ................................................................................................................................ 130
1.01 SCOPE OF WORK ...................................................................................................................... 130
1.02 RELATED WORK ......................................................................................................................... 130
1.03 SUBMITTALS ................................................................................................................................ 130
1.04 DELIVERY, STORAGE AND HANDLING ............................................................................... 130
PART 2 : PRODUCTS ......................................................................................................................... 131
2.01 GLASS TYPE ................................................................................................................................ 131
2.02 GLASS MATERIALS.................................................................................................................... 131
2.03 ACCESSORIES AND COMPOUNDS ...................................................................................... 131
PART 3 : EXECUTION ........................................................................................................................ 132
3.01 QUALITY OF WORK: .................................................................................................................. 132
3.02 FIXING GENERALLY .................................................................................................................. 132
3.03 GLAZING METHODS .................................................................................................................. 132
3.04 PROTECTION AND CLEANING ............................................................................................... 134

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DIVISION 9 - FINISHES ............................................................................................................................ 135

SECTION 09220 PORTLAND CEMENT PLASTER ........................................................................... 135
PART 1 GENERAL ................................................................................................................................ 135
1.01 SCOPE OF WORK ...................................................................................................................... 135
1.02 RELATED WORK ......................................................................................................................... 135
1.03 REFERENCES ............................................................................................................................. 135
1.04 SUBMITTALS FOR REVIEW ..................................................................................................... 135
1.05 QUALITY ASSURANCE ............................................................................................................. 135
1.06 MOCK-UP ...................................................................................................................................... 136
1.07 ENVIRONMENTAL REQUIREMENTS .................................................................................... 136
PART 2 : PRODUCTS ......................................................................................................................... 136
2.01 PLASTER BASE MATERIALS................................................................................................... 136
2.02 PLASTER FINISH MATERIALS ................................................................................................ 136
2.03 FURRING AND LATHING .......................................................................................................... 137
2.04 CEMENT PLASTER MIXES....................................................................................................... 137
PART 3 : EXECUTION ........................................................................................................................ 138
3.01 EXAMINATION ............................................................................................................................. 138
3.02 PREPARATION ............................................................................................................................ 138
3.03 INSTALLATION - LATHING MATERIALS ............................................................................... 138
3.04 INSTALLATION - ACCESSORIES ........................................................................................... 138
3.05 CONTROL AND EXPANSION JOINTS ................................................................................... 139
3.06 PLASTERING................................................................................................................................ 139
3.07 ERECTION TOLERANCES ........................................................................................................ 140
3.08 SCHEDULES ................................................................................................................................ 140
SECTION 09221 COLOURED PREMIX RENDER .............................................................................. 141
PART 1 GENERAL ................................................................................................................................ 141
1.01 SCOPE OF WORK ...................................................................................................................... 141
1.02 RELATED WORK ......................................................................................................................... 141
1.03 SUBMITTALS FOR REVIEW ..................................................................................................... 141
1.04 MOCK-UP ...................................................................................................................................... 141

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PART 2 : PRODUCTS ......................................................................................................................... 141

2.01 COLOURED RENDER MATERIAL .......................................................................................... 141
2.02 APPROVED MANUFACTURERS ............................................................................................. 142
2.03 FURRING AND LATHING .......................................................................................................... 142
2.04 RENDER MIXES .......................................................................................................................... 143
PART 3 : EXECUTION ........................................................................................................................ 143
3.01 EXAMINATION ............................................................................................................................. 143
3.02 PREPARATION ............................................................................................................................ 143
3.03 INSTALLATION - LATHING MATERIALS ............................................................................... 143
3.04 INSTALLATION - ACCESSORIES ........................................................................................... 144
3.05 CONTROL AND EXPANSION JOINTS ................................................................................... 144
3.06 RENDERING ................................................................................................................................. 144
SECTION 09300 CERAMIC TILE ........................................................................................................... 146
PART 1: GENERAL ................................................................................................................................ 146
1.01 SCOPE OF WORK ...................................................................................................................... 146
1.02 RELATED WORK ......................................................................................................................... 146
1.03 REFERENCES ............................................................................................................................. 146
1.04 SUBMITTALS ................................................................................................................................ 147
1.05 MAINTENANCE DATA ................................................................................................................ 147
1.07 QUALIFICATIONS ....................................................................................................................... 147
1.08 DELIVERY, STORAGE, AND HANDLING .............................................................................. 147
1.10 EXTRA MATERIALS.................................................................................................................... 148
PART 2: PRODUCTS ............................................................................................................................. 148
2.01 CERAMIC MANUFACTURERS ................................................................................................. 148
2.02 CERAMIC TILE MATERIALS ..................................................................................................... 148
2.03 BASE MATERIALS ...................................................................................................................... 149
2.04 STAIR MATERIALS ..................................................................................................................... 149
2.05 ADHESIVE MATERIALS............................................................................................................. 149
2.06 GROUT MATERIALS .................................................................................................................. 149
AE7 PROJECT NO. 20010410 xv REV 1 – ISSUED FOR CONSTRUCTION

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2.07 GROUT MIX .................................................................................................................................. 149

PART 3 EXECUTION ............................................................................................................................ 150
3.01 EXAMINATION ............................................................................................................................. 150
3.02 PREPARATION ............................................................................................................................ 150
3.03 INSTALLATION - THINSET METHOD ..................................................................................... 150
3.04 CLEANING .................................................................................................................................... 150
3.05 PROTECTION OF FINISHED WORK ...................................................................................... 150
SECTION 09410 TERRAZZO TILE ........................................................................................................ 151
PART1: GENERAL ................................................................................................................................ 151
1.01 SCOPE OF WORK ...................................................................................................................... 151
1.02 RELATED WORK ......................................................................................................................... 151
1.03 REFERENCES ............................................................................................................................. 151
1.04 SUBMITTALS ................................................................................................................................ 151
1.06 SAMPLE FLOOR AREA ............................................................................................................. 152
1.08 COORDINATION .......................................................................................................................... 152
1.09 PRODUCT DELIVERY, STORAGE AND HANDLING .......................................................... 152
PART2: PRODUCTS ............................................................................................................................. 152
2.01 MATERIALS .................................................................................................................................. 152
2.02 MORTAR MIXES .......................................................................................................................... 153
PART3: EXECUTION ............................................................................................................................ 153
3.01 GENERAL ...................................................................................................................................... 153
3.02 CONTROL JOINTS ...................................................................................................................... 153
3.03 INSTALLATION - FLOOR TILE ................................................................................................. 154
3.04 INSTALLATION - BASE .............................................................................................................. 154
3.05 APPLICATION - STAIRS ............................................................................................................ 154
3.06 CURING ......................................................................................................................................... 154
3.07 SURFACE FINISHING ................................................................................................................ 154
3.08 TOLERANCES .............................................................................................................................. 155
3.9 CLEANING AND PROTECTION ............................................................................................. 155
AE7 PROJECT NO. 20010410 xvi REV 1 – ISSUED FOR CONSTRUCTION

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SECTION 09600 STONE FLOOR AND WALL TILING ...................................................................... 156

PART 1: GENERAL ................................................................................................................................ 156
1.01 SCOPE OF WORK ...................................................................................................................... 156
1.02 RELATED WORK ......................................................................................................................... 156
1.03 REFERENCES ............................................................................................................................. 156
1.04 SUBMITTALS ................................................................................................................................ 157
1.05 MAINTENANCE DATA ................................................................................................................ 157
1.07 MOCKUP ....................................................................................................................................... 157
PART 2 : PRODUCTS ......................................................................................................................... 157
2.01 NATURAL STONE SLABS AND FITTINGS GENERALLY .................................................. 157
2.02 MARBLE AND STONE MATERIALS........................................................................................ 158
2.03 ADHESIVE MATERIALS ........................................................................................................... 158
2.04 MORTAR MATERIALS ............................................................................................................... 159
2.05 GROUT MATERIALS .................................................................................................................. 159
2.06 ACCESSORIES ............................................................................................................................ 159
2.07 MORTAR AND GROUT MIX ...................................................................................................... 159
2.08 STONE FABRICATION ............................................................................................................... 159
PART 3 : EXECUTION ........................................................................................................................ 159
3.01 EXAMINATION ............................................................................................................................. 159
3.02 PREPARATION ............................................................................................................................ 160
3.03 INSTALLATION - THINSET METHOD ..................................................................................... 160
3.04 INSTALLATION - MORTAR BED METHOD ........................................................................... 160
3.05 CLEANING .................................................................................................................................... 161
SECTION 09901 SURFACE PREPARATION AND SHOP PRIME PAINTING ............................ 162
PART 1: GENERAL .................................................................................................................................. 162
1.01 SCOPE OF WORK ...................................................................................................................... 162
1.02 RELATED WORK NOT INCLUDED ......................................................................................... 162
1.03 SUBMITTALS ................................................................................................................................. 162
PART 2: PRODUCTS ............................................................................................................................. 162
2.01 MATERIALS .................................................................................................................................. 162
AE7 PROJECT NO. 20010410 xvii REV 1 – ISSUED FOR CONSTRUCTION

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PART 3: EXECUTION ............................................................................................................................ 163

3.01 APPLICATION .............................................................................................................................. 163
SECTION 09902 PAINTING ................................................................................................................... 164
PART 1: GENERAL..................................................................................................................................... 164
1.01 SCOPE OF WORK ...................................................................................................................... 164
1.02 RELATED WORK ......................................................................................................................... 165
1.03 SUBMITTALS ................................................................................................................................ 165
1.04 DELIVERY AND STORAGE ...................................................................................................... 165
1.07 JOB CONDITIONS ....................................................................................................................... 166
PART 2: PRODUCTS ............................................................................................................................. 166
2.01 MATERIALS .................................................................................................................................. 166
PART 3: EXECUTION .............................................................................................................................. 167
3.01 INSPECTION .................................................................................................................................. 167
3.02 SURFACE PREPARATION........................................................................................................ 168
3.03 MATERILAS PREPARATION .................................................................................................... 169
3.04 APPLICATION .............................................................................................................................. 169
3.05 FILED QUALITY CONTROL ...................................................................................................... 171
3.06 CLEAN-UP AND PROTECTION ............................................................................................... 171
4.0 PAINT FINISH FOR GALVANIZED STEEL .......................................................................... 172
AE7 PROJECT NO. 20010410 xviii REV 1 – ISSUED FOR CONSTRUCTION

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DIVISION 1- GENERAL REQUIREMENTS
(Follow Main Contract)
DIVISION 02 – SITE WORK
02220 EARTHWORKS PART I GENERAL
1.01. DESCRIPTION OF WORK
A. This Section covers the excavation, filling and backfilling for general purpose sand
building construction.
B. Related Work Specified Elsewhere:
1. Refer to General Conditions and Appendices.
2. Demolition and site clearance is covered in Section 02210, Demolition and Site
Clearance.
1.02. QUALITY ASSURANCE
I. Tests
Testing will be undertaken by an independent testing laboratory proposed by the

Contractor and approved by the Engineer.
II. The British Standards referred to in this specification are listed below together with any
other references specified. Any differences between their requirements and this
specification shall be submitted to the Engineer for his ruling.
Standards
BS 1377 : 1990 Methods of test for soils for civil engineering purposes.
AASHTO T89 Liquid limit
AASHTO T90 Plasticity index
BRE Digest 250 Concrete in sulphate bearing soils and ground water.
1.03. SUBMITTALS
I. Test Reports:
1. All field and laboratory test results shall be submitted to the Engineer for
review.

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II. Surveying of Site:
1. The Contractor shall, before commencing any excavation or fill, survey and take levels on the
original ground surface, and shall prepare plans and sections accordingly. The plans and
sections shall, when finally and mutually agreed, be signed by the Engineer and Contractor
as truly representing the configuration of the areas in question at the commencement of work.
PART 2 PRODUCTS
2.01. DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS MATERIAL
1. Sweet Soil shall be fertile, friable soil obtained from well drained arable land and shall
be free-draining, non-toxic and capable of sustaining healthy plant growth.
2. Suitable Material shall comprise all material that is acceptable in accordance with the
Contract for use in the Works. Suitable material for earthworks shall be approved soil
obtained from excavations within the Works or from borrow pits approved by the
Engineer. It shall not contain an excess of fines or organic material.
Suitable Material Fill shall comply with the following limits:
Liquid Limit (AASHTO T89) 30% max.
Plasticity Index (AASHTO T90) 6% max.
Total Water Soluble Salts (BS1377) 5% max.
Minimum soaked CBR of 15% when the material is compacted to 95% of the MDD.
Maximum particle size to be not more than 100mm.
MDD is the maximum dry density by BS1377 Test 13.
CBR values are to be determined by BS 1377 Test 16.
3. Unsuitable Material shall comprise:
i. Organic material, stumps and other perishable material.

ii. Material susceptible to spontaneous combustion.
iii. Soils of liquid limit exceeding 30% and/or plasticity index exceeding 6%.
iv. Material with excessive moisture content.
v. Any other material which the Engineer may deem to be unsuitable for earthworks.
4. Rock shall mean those geological strata or deposits so designated on the Drawings and
any hard, natural or artificial material requiring the use of approved pneumatic tools for
its removal, but excluding individual masses less than 0.20 cubic metres.
5. Subkha Soil shall be obtained only from borrow pits approved by the Engineer. It shall
comprise a salt-bound silty or clayey sand and shall meet the following requirements:

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− not more than 30% by weight passing BS sieve No.200.

− CBR value at 95% maximum dry density (soaked)
not less than 30% when tested to BS 1377 test 16.
6. Soft Material shall mean "suitable material' with the exception of rock fill.
2.02. SELECTED BACKFILL MATERIALS FOR STRUCTURES, FOUNDATION AND SERVICE

TRENCHES
1. Except as noted in Clause 2.3 any fill material used within 500 mm of concrete structure
or cement bound materials shall not contain any chemical in sufficient concentration
such that it would, in the opinion of the Engineer, have a deleterious effect on the
concrete or cement bound material. The chemical composition of the fill shall be
determined by testing in accordance with BS 1377. The rate at which testing is to be
carried out shall be mutually agreed between the Contractor and the Engineer, but shall
not normally exceed a rate of one set of tests per day.
The backfill material shall be of class 3 or less in accordance with BRE Digest 250 and
must comply with Clause 2.1.2 of this Specification.
2.03. NON-COMPLIANCE WITH CLAUSE 2.2
1. If, at the Contractor's choice, fill is used within 500mm of concrete structures or cement
bound materials which does not conform to Clause 2.2, special precautions, to the
approval of the Engineer, shall be taken to protect the concrete or cement bound
material. All such precautions shall be at the Contractor's own expense and all
associated delay shall be the Contractor's responsibility and no claim for extension of
time shall be considered.
PART 3 EXECUTION
3.01. EXCAVATION LEVELS
I. All excavations shall be carried out to the lines and levels shown on the Drawings or to
such lines and levels as the Engineer may direct. The Contractor shall trim all
permanent excavations to the slopes and batters shown on the Drawings and he shall
leave the surfaces smooth and even unless ordered otherwise by the Engineer. Sides
of temporary and soft excavation, which, at the Contractor's choice, are excavated to
unstable slopes shall be adequately supported.
3.02. EXCAVATIONS BEYOND THE TRUE LINE AND LEVEL
I. If, from any cause whatsoever, excavations other than for concrete work are
carried out beyond their true line and level other than at the direction of the Engineer,
the Contractor shall at his own cost make good to the required line and level with
approved material and in such a manner as the Engineer may direct.

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II. If from any cause whatsoever excavations for concrete works are carried out beyond
their true line and level other than at the direction of the Engineer, the Contractor shall,
when directed by the Engineer, and at his own cost fill to the required line and level with
concrete similar in grade to that intended to be used in the true excavation unless
otherwise directed.
3.03. PROTECTION AND SAFETY OF EXCAVATIONS
I. Existing Utilities
Existing utilities remaining in service, including those remaining in service until after
relocation, and relocated utilities are shown on the drawings. The position of the
services shown on the drawings are approximate. The Contractor is to hand excavate
exploratory trenches, plot the positions of the existing services and submit to the
Engineer for approval record and shop drawings detailing the existing services and any
diversions and his proposals for protecting the work.
Within the limits of excavation the Contractor shall remove any existing piping, cesspits,
sub-soil drainage systems, conduit, manholes and related items which are to be
abandoned and plug open ends with concrete.
II. IExisting Structures
The Contractor shall submit, as soon as possible, information regarding the intended
procedures for excavation, dewatering, shoring and protection. The information to be
supplied shall include proposed procedures for recording the status of the existing
structures by daily photographs and monitoring of shorings and structures and other
alternative methods proposed.
The Contractor shall submit full details and shop drawings and calculations of all the
above procedures for the Engineer's approval before commencing the excavation.
Particular consideration shall be given to the possible effects on the neighbouring

structures of lowering of the ground water level. Proper shoring of the excavation next to
the adjacent structures, roads and walkways, shall be allowed in order to avoid any
lateral yield of the soils, loss of foundation support etc., and while the excavation
remains open, settlements and any lateral displacement of these structures, roads and
walkways should be monitored on a daily basis.
The Contractor shall be fully responsible for the strength and adequacy of retaining
structures, and for the safety and support of construction, utilities, roads or paving, and
for any movement, settlement or damage thereto.
The Contractor shall also be fully responsible for ensuring that adequate safety
measures are taken to protect site personnel and the general public from any
excavation hazard.
3.04. DE-WATERING
I. Where the excavation level is below the natural water table and it is necessary to pump
continuously from the excavation or to install a specialist form of dewatering
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equipment, around the perimeter of the site or excavation, the Contractor will be
responsible for ensuring that the equipment installed will allow the excavation and
subsequent construction to be carried out in dry conditions.
II. Continuous or permanent dewatering of the excavation or Site may not be undertaken
without the written approval of the Engineer to the work and the method to be
employed which shall also comply with Codes of Practice and Local Authority
requirements.
III. The water pumped from excavations or well points shall be pumped to disposal
points or sumps as approved by the Engineer and/or Local Authority and if so required
be passed through settling tanks before disposal. Under no circumstances must
water be disposed of in the Municipality's sewer system.
IV. The Contractor shall make good at his own expense any damage that may result from
his failure to keep the excavation free from water.
3.05 REMOVAL OF UNSUITABLE MATERIAL
I. The Engineer may order the excavation and removal of any material deemed
unsuitable for supporting the fills, pavements or structures to be placed thereon, and its
replacement by suitable fill material.
II. Where the excavation reveals a combination of suitable and unsuitable materials
the Contractor shall, unless otherwise agreed by the Engineer, carry out the
excavation in such a manner that the suitable materials are excavated separately for
use in the Works without contamination by the unsuitable materials.
3.06 SPOIL DISPOSAL
I. Excavated material from the Works selected by the Engineer for re-use shall be placed
directly in its final position or may be stocked on Site as directed by the Engineer.
II. No excavated suitable material other than surplus to requirements of the Contract shall
be removed from the Site except on the direction or with the permission of the
Engineer. Should the Contractor be permitted to remove suitable material from the
Site to suit his operational procedure, then he shall make good at his own expense any
consequent deficit of filling arising therefrom.
III. Suitable material and sweet soil surplus to the total requirements of the Works and all
unsuitable material shall be removed to sites approved by the Engineer. Such spoil
shall not be deemed permanently deposited elsewhere other than on such sites. The
Contractor shall trim and regulate the spoil tips to profiles and levels as directed by the
Engineer. He shall also maintain without interruption the flow of watercourses affected
by the tips and he shall observe any agreement concerning the site, existing
between the Employer and the persons or authorities concerned.
3.07 IN SPECTION OF EXCAVATIONS
A. The Contractor shall report to the Engineer when excavations are ready to receive

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permanent materials. No permanent materials shall be placed in the excavations until

the Contractor has obtained the Engineer's agreement that a secure foundation has
been reached and that the excavation has been carried out to the lines and levels
required.
3.08 REFILLING OF FOUNDATION PITS AND TRENCHES
A. Unless otherwise shown on the Drawings or directed by the Engineer, all filling for
this purpose shall consist of “suitable material” as defined in Clause 2.1.2 and shall also
conform to Clause 2.2 or 2.3. It shall be deposited and compacted by approved plant
in accordance with this Specification. Timber sheeting and other excavations supports
shall be carefully removed as the filling proceeds except where they are required by the
Contract to be left in position, but the removal of such supports will not relieve the
Contractor of his responsibilities for the stability of the Works.
Compaction of the material must meet the requirements of Clause 3.11.
3.09 FORMING OF AREAS OF FILL
The Contractor shall form filled areas and embankments to the slopes, levels, depths,
heights, lengths, widths and other requirements shown on the drawings or in accordance
with the Engineer’s instructions following the Contractor’s site survey.
A. All areas of fill shall be formed of material defined as "suitable material" or "rock fill".
Additionally when permitted by the Engineer, material wetter than the appropriate limit
provided by the Contractor under inclusion (c) of Clause 2.1.3 may be incorporated.
B. Placing of Fill
Areas of fill shall be built up over their full width and damage to the compacted layers due to
lack of control of construction traffic shall be made good by the Contractor.
1) Materials Other than Rock Fill
All material other than "rock fill" placed in areas of fill shall be deposited and
compacted as soon as practicable after excavation in layers not exceeding150mm
loose depth unless as a result of compaction trials the Engineer approves spreading
to a greater depth up to a maximum of 250mm loose depth.
The field density of layers not exceeding 150mm shall be tested in accordance with
BS 1377 Test 15A. For layers greater than 150mm BS 1377 Test 15B is applicable.
2) Rock Fill
Rock used in areas of fill shall, except for any specified external cover to slopes or
near formation level, be of such size that it can be deposited in horizontal layers each
not exceeding 450mm loose depth. Material shall be spread and levelled by a
crawler tractor weighing not less than 15 tonnes and compacted in accordance with
Clause 3.11. Each layer shall consist of reasonably graded rock and all surface
voids shall be filled with broken fragments before the next layer is placed. The top
surface and side slopes of fill areas so formed shall be thoroughly blinded
with approved fine graded material to seal the surface. Such material may on side
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slopes and verges be sweet soil as defined in Clause 2.1.1. Isolated boulders
each within the range 0.015 cu.m to 0.085 cu.m in size may be incorporated in full
areas not of rock fill at the discretion of the Engineer provided that the specified
compaction requirements are met and no stone exceeding 0.015 cu.m shall be
placed less than 600mm below finished level.
3.10 COMPACTION AND TREATMENT OF EXISTING SUB-GRADE
I. After clearance of site and removal of all unwanted materials and items and after
excavation to formation level if required, the profile of the existing sub-grade for all
external works, such as roads and footways, and for all structural works, as so exposed shall
be treated as though this is the uncompacted profile of a layer of fill material and the same
testing procedure analysis assessment of optimum moisture content and evolution of
compaction procedure shall be arranged for in order to provide proper compaction as
specified for suitable material for at least 300mm below the compacted profile of the existing
sub-grade. Compaction to meet the requirements of Clause 3.11.
II. Irregularities in profile may be made up to an approximately level grade only following this
initial compaction of the existing subgrade.
III. The Contractor should ensure that the finished subgrade is available for inspection by the
Engineer, together with the supporting test result prior to the placement of any material upon
it.
IV. If the existing subgrade material fails to achieve the requirements for suitable material
following the procedure described in Clause 3.10A, or if instructed by the Engineer then the
subgrade material shall be removed to a suitable depth as determined by the Engineer and
replaced with suitable material placed in accordance with the specification or otherwise as
3.11 COMPACTING OF FILL MATERIAL
All filling material used in earthworks shall be compacted to Specification and the Contractor
shall submit to the Engineer for approval his proposals for the compaction of each main type
of material to be used in the filled areas, the types of plant to be used, the number of passes
and the loose depth of layer. The Contractor shall carry out compaction trials for the
earthworks, supplemented by any necessary laboratory investigations, as required by the
Engineer using an approved procedure proposed by the Contractor and he shall satisfy
the Engineer that all the specified requirements regarding compaction can be
achieved. Compaction trials with the main types of materials likely to be encountered shall
be completed before the works, with the corresponding materials, will be allowed to
commence.
A. Compaction Requirements
Suitable fill material shall be compacted to 95 percent maximum dry density. Suitable fill
material placed within 300mm of formation level shall in addition have a minimum soaked
CBR Value of 15 percent (or as shown on the drawings) at 95 percent maximum dry density.
This is a percentage of a maximum dry density as determined by the modified AASHTO
tests carried out in accordance with BS 1377 (1975) Test No.13.
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B. Testing
During earthworks construction the Engineer shall instruct control tests to determine the
degree of compaction achieved. Tests shall include:
− Dry Density/Moisture Content BS 1377: Test 13 or Test 14, at a minimum rate of 3

tests per 500 square metres for each layer of fill.
− In-situ Dry Density BS 1377: Test 15, at a minimum rate of 3 tests per 500 square
metres for each layer of fill. (For compliance with this test the three results may at
the discretion of the Engineer be averaged. However no individual result is to be less
than 94%).
− California Bearing Ratio BS 1377: Test 16, as required by the Engineer.
The Contractor shall allow for the cost of all required testing by a laboratory approved by the
Engineer.
C. Procedure in event of compaction being unacceptable
If the material deposited as fill subsequently reaches a condition such that it cannot be
compacted in accordance with the requirements of the Contract the Contractor shall,
at the Engineer's discretion, either:
i. make good by removing the material either to tip or elsewhere until it is in a

suitable physical condition for re-use, and replacing it with suitable material;
or
ii. make good the material by mechanical or chemical means to improve its
stability; or
iii. cease work on the material until its physical condition is again such that it can
be compacted as described in the Contract.
D. Compaction during Overtime
Without prejudice to the provisions of Clause 45 of the Conditions of Contract and in order
that the Engineer may make proper provision for the supervision of compaction in the
Permanent Work, the Contractor shall, not less than twenty-four (24) hours before he
proposes to carry out compacting during periods of overtime, apply in writing to the Engineer
for permission to do so. If compaction is carried out during periods of overtime without such
permission the Engineer will require additional density tests to be carried out to determine
the state of compaction achieved. The results of these tests will be compared with the
results of similar tests made on approved work compacted under supervision. If the state of
compaction is thereby shown to be inadequate the Contractor shall at his own expense carry
out such further work as the Engineer may decide is required to comply with the terms of the
Contract.
3.12 FILL ADJACENT TO STRUCTURES
A. The filling immediately adjacent to structures shall be deposited and compacted in

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accordance with the requirements of this specification or as directed by the Engineer.
B. Backfilling Against Foundation or Walls
After completion of foundation walls and removal of forms, the excavation shall be cleaned
of all rubbish and debris before application of waterproofing and placement of backfill.
Symmetrical backfill loading shall be maintained and each layer compacted by hand tempers
or other suitable equipment.
When backfilling against foundations or walls, special care shall be taken to prevent
wedge action, eccentric loading or overloading of the structure by equipment used in
compacting backfilling material, and to prevent damage to waterproofing on walls.
3.13 SLIPS
A. The Contractor shall during his contract and as ordered by the Engineer make good any
damage or defect caused by slips to any cuttings, excavations or embankments and shall do
all necessary work to prevent or remedy the same.
3.14 TOLERANCE LIMITS
A. The tolerance limits for the permanent finished earthworks will be as follows:-
Horizontal dimensions will be within +75 mm and -75mm of the true dimensions shown on
the drawings.
For slopes to embankments or cuttings the horizontal deviation between the top and bottom
of the slope will be within +5% and -5% of the true horizontal component of the slope shown
on or calculated from the drawings.
Formation levels shall be within +0 mm and -25mm of the true levels shown on the drawings.
Other earthworks levels shall be within +0mm and -50mm of the true levels shown on the
drawings.
3.15 ANTI TERMITE TREATEMENT
Termite control treatment shall be carried out by an approved specialist subcontractor. The
Contractors shall submit full details of the specialist sub-contractor whom he proposes to use
for the approval of the Engineer.
The contactor shall submit a method statement to the Engineer detailing the most
appropriate method along with the rate of application for the existing site conditions and
taking into consideration the configuration and lay out of the building, for the approval of the
Engineer before commencing any work. The Contractor shall, also, furnish full details of the
chemicals he proposes to use along with all necessary documental evidence as required for
compliance with the regulations, local authorities requirements and proven track record.
The most appropriate method to be used shall be decided at the time of construction after
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considering all aspects.
The contractor shall follow the principle of creating a toxic barrier within the soil beneath and
around the buildings, through which termites cannot pass. All internal and external back
filling shall be treated prior to casting ground slabs.
Particular emphasis is to placed on site cleanliness during the works and the contractor is to
ensure that no timber cardboard or other cellulose containing materials discharged during
the work are left in or on the ground on completion of the project.
The Contractor shall ensure that the treated areas shall not be disturbed by reveling, digging
on earth filling once the treatment is completed as this will disturb the chemical barrier. In
case the treated areas are disturbed (in any way), the area shall be retreated to restore the
chemical barrier at his own expense.
The treatment shall have the guarantee that the building is safe from termite infestation for a
period of 10 years after completion of the works. The specialist Sub-contractor shall give an
undertaking that in case of infestation of the said structure he shall carry out such treatment
as may be necessary to render the structural fee from termite infestation without any extra
cost to the Employer.
The Contractor shall submit a counter-guarantee stating that the works have been carried
out in accordance with the drawings and specifications and shall be guaranteed free from
termite infestation for a period of ten (10) years from the issue of completion certificate.
02760 AGGREGATE SUB BASES AND ROAD BASES
PART 1 GENERAL
1.01 DESCRIPTION OF WORK
A. This section covers the construction of the base materials, above the subgrade, to
receive the finished masonry or asphalt pavement. This work includes, but is not
limited to subgrade preparation, and furnishing and installing the materials including
geotextile materials where appropriate.
B. Related work specified elsewhere
1. Subgrade preparation is specified in Section 02210, Demolition and Site Clearance

and Section 02220, Earthworks.
2. Finished paving products are specified in Section

02780, Masonry pavements and Concrete Kerbs.
3. Refer to General Conditions and Appendices.
1.02 REFERENCE STANDARDS

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The following British Standards shall be referred;
BS 812 Methods for Testing Aggregates
BS 882 Aggregates for Natural Sources for Concrete
BS 1377 Methods of test for Soils for Civil Engineering Purposes
BS 6906 Methods of tests for Geotextiles
BS 6100 Part 2 Civil Engineering
BS EN 965 Geotextiles and Geotextile-related products.

Determination of mass per units area.
Reference should also be made to AASHTO and ASTM where appropriate or as advised by
the Engineer.
1.03 QUALITY ASSURANCE
A. Testing Agency
Samples and tests, as required, are to be made by an independent testing laboratory

1.04 SUBMITTALS
A. Shop drawings in accordance with Volume 2, Part B, Annexure S, shall include but not be
limited to survey and proposed works plans showing grades and levels.
B. Samples:
1. Samples of the proposed aggregates intended to be used in the works shall be

provided in advance of that element of the work for testing of the same to be verified
in accordance with the specification by an independent testing laboratory. Regular
testing in accordance with this specification shall continue during the sequence of the
work. The source of aggregates, once approved by the Engineer, may not be
changed, without his written authority.
2. Four (4) 1 sq.m samples of any proposed geotextile material shall be provided for
approval and testing prior to inclusion within the works.
C. Test
1. Contractor shall submit all test certificate attesting conformance with the specification
prior to inclusion of the materials in the works.
2. Test reports shall be routinely submitted to the Engineer during the works.
1.05 PRODUCT DELIVERY, STORAGE AND HANDLING

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All materials delivered to site shall be delivered, handled and stored so as to prevent
contamination or degradation.
1.06 COMPACTED THICKNESS
Unless stated to the contrary, any thickness of material described means the thickness after
full compaction.
PART 2 PRODUCTS
2.01 MATERIALS
A. Aggregate Sub Bases
1. Granular Sub Base Type 1
a) Type 1 granular sub base shall comprise crushed rock or gravel. Water soluble
salts in coarse or fine aggregate shall together not exceed 1% by weight of
aggregate. The material shall have a ten percent fines value of not less than 50
kN when tested in accordance with BS 812, shall be well graded and lie within
the grading envelope of the following table.
BS sieve size Percentage by mass size passing
75mm 100
37.5mm 85 -100
10mm 40 - 70
5mm 25 - 45
600 micron 8 - 22
75 micron 0 - 10
The particle size shall be determined by Test 7A of BS 1377.
b) The sub base shall have a minimum soaked CBR value of 80% and the material
passing the 425 micron BS sieve shall be non-plastic, when tested in accordance
with BS 1377.
c) CBR to be determined at 95% of the maximum dry density.
d) The material shall be compacted to a field density of not less than 95 per cent of
the maximum dry density determined by the vibrating hammer test method of BS
1377. Field density tests shall be carried out at a frequency of 2 tests per 500
sq.m. laid, or as directed by the Engineer in accordance with BS 1377.
2. Granular Sub Base Type 2
a) Type 2 granular sub-base material shall comprise natural sands, gravel, crushed
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rock or crushed concrete. The material shall be well graded and lie within the
grading envelope of the following table.
BS sieve Percentage by mass size passing
75mm 100
37.5mm 85 - 100
10mm 40 - 100
5mm 25 - 85
600 micron 8 - 45
75 micron 0 - 10
b) Material passing the 425 micron BS sieve shall have a plasticity index of less
than 6. The sub base shall have a minimum soaked CBR Value of 30%, when
first tested in accordance with BS 1377, and a ten percent fines value of 50 kN or
more, when tested in accordance with BS 812 Part 111.
c) CBR to be determined at 95% of the maximum dry density.
d) The material shall be compacted to a field density of not less than 95% of the
maximum dry density determined by the vibrating hammer test method of BS
sq.m. of each layer and one test per 150 lin.m. of shoulder or footway, or as
directed by the Engineer and determined in accordance with BS 1377.
B. Aggregate Road Bases
1. Wet-mix Macadam Road Base
a) The coarse and fine aggregate for wet-mix macadam shall consist of crushed
aggregate, each particle having a minimum of one crushed face. Aggregates
shall consist of naturally occurring material complying with the requirements of
BS 882. Aggregates of marine origin may be used provided that the content of
chlorides salt in the aggregate expressed as the equivalent anhydrous calcium
chloride percentage by mass of the cement to be used in the concrete does not
exceed 0.5 per cent.
b) For the purpose of calculation the anhydrous calcium chloride content may be
taken as equal to the sodium chloride content or to 1.6 times the chloride ion
content as appropriate.
c) Flakiness index determined in accordance with BS 812 shall not exceed 35

for any size of course aggregate.
d) The material shall be well graded and lie within the grading envelope of the
following table and shall have a minimum soaked CBR value of 80% when
tested at maximum dry density in accordance with BS 1377.

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e) Visual examination will determine the percentage of partially crushed faces of

aggregate.
50mm 100
37.5mm 95 -100
20mm 60 - 80
10mm 40 - 60
5mm 25 - 45
2.36mm 15 - 30
600 micron 8 - 22
75 micron 0 - 10
f) The moisture content of the wet-mix macadam when compacted shall be within +
0.5 percent of the optimum moisture content as determined by the vibrating
hammer test method of BS 1377. Water shall be added at the mixing plant as
necessary, with due allowance for moisture loss during transportation and laying.
g) The material shall be laid and compacted in layers of not more than
200mm finished thickness to a field density of not less than 95 percent of the
maximum dry density determined by the vibrating hammer test method of BS
sq.m. of each layer or as directed by the Engineer and determined in accordance
with BS 1377.
h) Placing of wet-mix macadam by grader will not be permitted.
i) As soon as possible after compaction the wet-mix macadam shall be

sealed by the application of a prime coat as specified. Should the surface of
the material be allowed to dry out before the seal is applied, it shall be lightly
watered and re-compacted immediately prior to spraying with prime coat. Should
the full depth of layer be allowed to dry out, it shall be removed and replaced with
fresh material. Watering and re-mixing in place will not be permitted.
2. Aggregate Road Base (Dry Bound Macadam)
a) Aggregate road base material shall consist of natural mineral aggregate of the
specified grading.
b) Natural aggregate road base shall consist of coarse and fine aggregates
screened and blended to give a well graded material within grading envelope C of
the following table.
c) Crushed aggregate road base shall consist of crushed coarse aggregate and
crushed or natural fine aggregate screened and blended to give well graded
material within grading envelopes A or B of the following table.

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A B C
50mm 100 100 100
37.5mm 100 100 100
20mm 70 - 100 60-90 50 - 100
10mm 50 - 80 45-75 40 - 70
5mm 35 - 65 30 - 60 30 - 60
2mm 25 - 50 20 - 50 20 - 50
425 micron 15 - 30 10 - 30 10 - 30
75 micron 5 - 15 5 - 15 5 - 15
d) The type and grading of aggregate road base shall be as directed by the
Engineer from the gradings given in the above table or similar gradings. The
grading of test samples taken from the Works shall be such that the percentage
passing the No.4 sieve shall not vary by more than 7 percent from the sample
originally submitted and approved.
e) The material shall be clean and free from organic material, clay and other
extraneous or detrimental material. The fraction passing the 425 micron BS sieve
shall, when tested in accordance with BS 1377, have a plasticity index of less
than 6. The soaked CBR Value of the material, when tested at 95% maximum
dry density determined by the 4.5 kg rammer test method of BS 1377, shall be
not less than 80%.
f) The percentage of wear of the coarse aggregate fraction shall not exceed
40% when tested for resistance to abrasion by the Los Angeles Test (AASHTO
T96) and shall have a maximum sodium sulphate soundness loss of 12%
(AASHTO T-104).
g) The material shall, if necessary, be plant mixed to give the required grading
before delivery to the job site. Mixing of separate materials at the job site by
motor grader will not be permitted. Segregation shall be avoided and pockets
of coarse or fine material shall be discarded before spreading and compacting
the road base.
h) Material shall be spread on the road bed in layers such that the finished
compacted thickness of each layer does not exceed 150mm. The road base
shall be spread by finisher and/or grader and water added if necessary, such
that the moisture content of the layer when compacted is within -2% and +2% of
the optimum moisture content as determined by the 4.5kg rammer test of BS
1377.
i) The road base shall be compacted to a field density of not less than 100%
of the maximum dry density as determined by the 4.5 kg rammer test of BS
1377. Field density tests shall be carried out at a frequency of 2 test per 100
sq.m. of each layer and 1 test per 150 lin.m. of shoulder, or as directed by the
Engineer and determined in accordance with BS 1377.
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j) Roadbase which fails on testing to meet the above requirements shall be

reworked, watered and re-compacted to conform to specified requirements, or
shall be removed and re-placed with fresh material as directed by the Engineer.
C. Geotextile
1. The Contractor shall furnish and place the geotextile as specified and
directed by the Engineer. All geotextiles proposed by the Contractor must be
approved by the Engineer before they are incorporated in the works.
2. Geotextiles shall be woven or non-woven fabrics manufactured from polypropylene

fibres and be in the forms of thin permeable membranes.
3. All geotextiles shall have an design life of not less than 40 years.
4. The geotextile shall contain an ultra violet inhibitor and shall be inert to naturally
occurring acids, alkalis, sea water etc. To protect against mechanical or chemical
damage the geotextile shall not be uncovered between manufacture and
incorporation in the works. Temporary exposure shall not exceed 10 hrs.
5. The geotextile shall have a minimum tensile strength of 2.5 kN/m and a
minimum CBR puncture resistance of 1500 N when tested in accordance with BS
6906 : Part 4. In accordance with BS 6906 : Part 2, the geotextile shall have a size
distribution of pore openings such that the mean O90 is between 100 and 300
microns.
6. The geotextile shall allow water to flow through it normal to its principal plane at a
rate of not less than 10 litres/m2/second when tested in accordance with BS 6906 :
Part 3.
7. The surface on which the geotextile is to be placed shall not have protrusions or
sharp projections which are likely to damage the fabric during installation or service.
Operation of construction plant directly on the installed geotextile will not be
permitted and its covering with fill material shall take place immediately after its
laying. Adjacent sheets of geotextile shall be overlapped by a minimum of 300 mm in
the transverse direction and 600 mm in the longitudinal direction.
8. All geotextiles shall be tested by an independent laboratory in accordance with the

requirements of BS 6906 ‘Methods of tests for Geotextiles’.
PART 3 EXECUTION
3.01 CONSTRUCTION TRAFFIC ON PAVEMENTS UNDER CONSTRUCTION
Subject to the approval of the Engineer or as specifically stated in this Specification,

construction traffic may be permitted on pavements under construction, provided always that
the traffic will be suitable in relation to the course it traverses, that wheels of plant shall be
kept free from deleterious materials, and that all surfaces will be cleaned and repaired when
necessary as directed by the Engineer before subsequent construction.
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3.02 DRAINAGE
All drainage work under pavement construction shall be completed before any pavement
construction is started. Roads, car park and paved area gullies and their connections will be
included within the drainage works and shall be co-ordinated with the pavement works.
3.03 EARTHWORKS
All earthworks shall be in accordance with Specification 02210 and 02220. The preparation
of the formation shall be carried out after completion of any subgrade drainage and
installation of any gully connections and immediately prior to the laying of the first layer of
the pavement. The surface shall be cleaned and trimmed to shape before compaction. The
material shall be compacted to 95% of maximum dry density as determined from Proctor
compaction tests. The depth of effective compaction shall extend to one metre below
formation level for roadways and parking areas. The top 300mm below formation level shall
be compacted to 95% of MDD.
3.04 TOLERANCES
Horizontal alignments shall be determined from one side of the road surface, and as
constructed will be correct within +/- 6mm.
The level of the surface of any rigid pavement layer shall not deviate more than 3mm and
the level of the surfaces of flexible pavement layer will not deviate more than 6mm when
tested with a 3000mm long straight edge.
The level of any point on the surface of pavement courses shall on completion of
compaction, conform to that shown on the drawings within the following tolerances:
Surface of Course Tolerance from True

Surface L evel
Subgrade or Formation + 10mm

- 20mm
Sub-Base + 10mm
- 15mm
Base + 10mm
- 10mm
Base Course + 6mm

- 6mm
Wearing Course + 6mm

- 6mm
The surface of the completed pavement will be checked longitudinally and transversely for
smoothness with a 3 metre straight edge. The surface shall not vary more than 3 millimetres
in 3 metres parallel to the centre line and not more than 6 millimetres at right angles to the
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centre line.
3.05 CONSTRUCTION REQUIREMENTS
Vehicles transporting plant-mixed material shall have a capacity suited to the output of the
mixing plant and be capable of discharging cleanly. Material when mixed shall be removed
at once from the mixer, transported directly to the point of discharge and protected from
adverse weather conditions before tipping. The maximum distance from the mixing plant to
the point of discharge shall be approved by the Engineer.
All material shall be placed and spread evenly. Spreading shall be undertaken concurrently
or without delay. Road base material shall be spread using a paving machine or approved
spreader box with a mechanism for levelling off to an even depth. Except where otherwise
specified the material shall be spread in one layer so that after compaction the total
thickness is as specified.
Compaction shall be completed as soon as possible after the material has been spread and
levelled using either pneumatic-tyred rollers or smooth-wheeled steel rollers, with or without
vibration, to the specified degree of compaction.
Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and
transverse joints and the Contractor shall use additional, hand-operated compactors in
these areas as necessary.
The surface of any layer of material shall, on completion of compaction and immediately
before overlaying, be well closed, free from movement under compaction plant and free from
ridges, cracks or loose material. All loose, segregated, or otherwise defective areas shall
be removed for the full layer thickness, relaid with new material and re-compacted.
End of Section

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DIVISION 3 – CONCRETE WORK
03110 CONCRETE FORMS AND ACCESSORIES
PART 1 GENERAL
1.01 RELATED WORK
A. Section 03310 - Cast-in place concrete
B. Section 03210 - Concrete Reinforcement
C. Section 04051 - Masonry Procedure
D. Section 07212 - Board Insulated
E. Section 07712 - Prefabricated roof expansion joints
F. Section 09001 - Finishes Schedule
1.02 REFERENCES AND STANDARDS
A. The design and construction of formwork shall be carried out by competent persons
taking due account of the surface finish required. The formwork shall be sufficiently
rigid and tight to prevent loss of grout or mortar from the concrete at all stages and
for the appropriate method of placing and compacting.
B. The design and use of formwork shall be in accordance with BS 5975: 1982
Falsework.
C. Formwork (including supports) shall be sufficiently rigid to maintain the forms in their
correct position and to correct shape and profile so that the final concrete structure is
within the limits of the dimensional tolerances specified. The supports should be
designed to withstand the worst combination of self weight, formwork weight,
formwork forces, reinforcement weight, wet concrete weight, construction and wind
loads, together with all incidental dynamic effects caused by placing, vibrating and
compacting the concrete.
D. The formwork shall be so arranged as to be readily dismantled and removable from

the cast concrete without shock, disturbance or damage. Where necessary, the
formwork shall be so arranged that the soffit form, properly supported on props only,
can be retained in position for such periods as may be required by maturing
conditions or specification.
E. Formwork shall be provided with suitable means of access and safety

guardrails for operatives working above ground.
F. In addition to the above, formwork shall be provided to the top surface of concrete
where the slope or the nature of the work requires.
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G. Provisions shall be made for forming holes and chases for services and for building
in pipes, conduits and other fixings shown on the construction and plant
manufacturer's drawings.
H. The position of any ties passing through the concrete requires the Engineer's
approval. Where part of a metal tie remains embedded in the concrete it shall not
have less cover than the reinforcement. Any holes left after the removal of ties shall
be filled with concrete or mortar to the Engineer's approval.
1.03 SHOP DRAWINGS
A. Submit shop drawings for formwork and falsework in accordance with Section 01340
- Shop Drawings, Product Data, Samples and Mock-ups.
B. Indicate method and schedule of construction, shoring, stripping and re-

shoring procedures, materials, arrangement of joints, special architectural exposed
finishes, ties, liners, and locations of temporary embedded parts.
C. Indicate formwork design data, such as permissible rate of concrete placement,

and temperature of concrete, in forms.
D. Indicate sequence of erection and removal of formwork/falsework as directed by

Engineer.
1.04 WORKMANSHIP - DEFLECTION AND CAMBER
The Contractor shall make allowance for any deflection of formwork that is likely to arise
during construction, so that the hardened concrete conforms to the specified line and level.
In the absence of any specified camber, the soffit of all beams more than 5 metres in
span shall be laid to a camber where:
(with dimensions in mm)

Camber = (Span)2
7200 x depth
PART 2 PRODUCTS
2.01 MATERIALS
A. Formwork materials
1) For concrete without special architectural features, use plywood and wood
formwork materials to standard specified in this section.
2) For concrete with special architectural features, use

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formwork materials to provide the specified finish.
B. Pan forms
As required by the Engineer and the finishes schedule.
C. Tubular column forms
Round, steel, internally treated with release material. Spiral pattern not to show in
hardened concrete for areas require.
D. Form ties
1) For concrete not designated fair face finish, use removable or snap-off
metal ties, fixed or adjustable length, free of devices leaving holes larger than
25 mm dia. in concrete surface.
2) For Architectural concrete, use snap ties complete with plastic cones and light
grey concrete plugs.
E. Form liner
1) Plywood: high density overlay or edge 20 mm thick min. square edge.
F. Form release agent: chemically active release agents containing compounds that
react with free lime in concrete resulting in water insoluble soaps.
G. Form stripping agent: colourless mineral oil, free of kerosene, with viscosity between
70 and 110 s Saybolt Universal 15 to 24 mm/s at 40C, flashpoint minimum
150C, open cup, or
H. Falsework materials: to approval of Engineer.
I. Sealant: to Section 07900 - Joint Sealers.
PART 3 EXECUTION
3.01 FABRICATION AND ERECTION
E. Verify lines, levels and centres before proceeding with formwork / false work and
ensure dimensions agree with drawings.
F. Obtain Engineer's approval for use of earth forms framing openings not
indicated on drawings.
G. Hand trim sides and bottoms and remove loose earth from earth forms before placing
concrete.
H. Fabricate and erect false work in accordance with standards specified in this section.

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I. Refer to architectural drawings for concrete members requiring architectural exposed

finishes.
J. Provide site drainage to prevent washout of soil supporting mud sills and shores.
K. Fabricate and erect formwork in accordance with standards to produce finished

concrete conforming to shape, dimensions, locations and levels indicated within
tolerances required by the specified standard.
L. Align form joints and make watertight. Keep form joints to minimum.
M. Locate horizontal form joints for exposed columns 2700 mm above finished floor
levels (F.F.L).
N. Use 25 mm chamfer strips on external corners and/or 25 mm fillets at interior corners

of concrete members, joints, unless specified otherwise.
O. Form chases, slots, openings, drips, recesses, expansion and control joints as
indicated.
P. Construct forms for architectural concrete, and place ties as indicated and/or as
directed. Joint pattern not necessarily based on using standard size panels or
maximum permissible spacing of ties.
Q. Build in anchors, sleeves, and other inserts required to accommodate Work specified
in other sections. Assure that all anchors and inserts will not protrude beyond
surfaces designated to receive applied finishes, including painting.
3.02 SUPPORTS
Props and supports shall be designed to allow the formwork to be adjusted accurately to line
and level and to be erected and removed in a sequence without damage to the concrete.
3.03 JOINTS AND EDGES
A. All joints in formwork shall be close-fitting to prevent bleeding of cement paste from
the concrete.
B. At construction joints formwork shall be tightly secured against previously cast or

hardened concrete to prevent the loss of grout or the formation of steps or ridges in
the concrete.
C. Formwork shall be constructed to provide straight and true angles, arises or edges.
Where chamfers are called for, the fillets shall be accurately sized to provide a
smooth and continuous chamfer.
D. Formwork panels shall have true edges to permit accurate alignment of their sides
and to provide clean lines at construction joints and shall be fixed with joints either
vertical or horizontal, unless otherwise specified.
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E. The type and treatment of any lining (plywood, metal, plastics, etc.) to the forms shall
be appropriate to the concrete finish required.
F. Where holes are needed on forms to accommodate projecting reinforcement or fixing

devices care shall be taken to prevent loss of grout. Special care shall be taken
when stripping in order not to break off the edge of the concrete adjacent to the
projecting reinforcement.
3.04 CLEANING AND TREATMENT
A. The formwork that will be in contact with the concrete shall be clean and treated with
suitable release agent before fixing reinforcement. All rubbish and water shall be
removed from the interior of the forms before the concrete is placed.
B. Release agents for formwork shall be approved by the Engineer and shall be
carefully chosen for the particular conditions they are required to fulfil. Where a
concrete surface is to be permanently exposed only one agent shall be used
throughout the entire area. Release agents shall be applied evenly and contact
with reinforcement and concrete at construction joints avoided. Where the surface is
to receive an applied finish, care shall be taken to ensure the compatibility of the
release agent with the finish.
C. Surface retarding agents shall not be used.
D. Damaged or distorted formwork shall not be used
3.05 STRIKING
A. The formwork shall be removed slowly as the sudden removal of wedges is

equivalent to a shock load on the partly hardened concrete.
B. Materials and plant shall not be stacked on any newly constructed floor
without the permission of the Engineer.
C. Provided the concrete strength is confirmed by tests on cubes stored as far as

possible under the same conditions as the concrete in the member under
consideration, formwork supporting cast in-situ concrete in flexure may be struck
when the cube strength is 10N/sq.mm or twice the stress to which it will then be
subjected whichever is the greater provided that such earlier striking will not result in
unacceptable deflections due to shrinkage, creep, etc. The Contractor shall submit
calculations and cube test results to prove compliance with this Clause.
D. In the absence of cube test results the periods before striking given below shall be
used:
TYPE OF FORMWORKS MINIMUM PERIOD B

BEFORE STRIKING
Vertical formwork to columns, walls 24 hrs.
and large beams

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Soffit formwork to slabs 4 days

Props to slabs 11 days
Soffit Formwork to beams 8 days
Props to Beams 15 days
E. When formwork is removed within the seven (7) days curing period, particular care
shall be exercised to avoid damage to the concrete, especially to arises and features.
The provision of suitable curing methods shall immediately follow the removal of the
formwork and the concrete shall be protected from high temperatures by means of
suitable shielding.
F. Concrete shall not be cured by the application of cold water. Where the finished
surface has re-entrant angles formwork shall be removed at the earliest time possible
to avoid shrinkage cracks.
G. In multi storey construction the Contractor shall submit his proposed sequence of
removal of props taking into account the above minimum details for striking
formwork. Reference can be made to BS 5975 "Falsework".
End of Section

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03210 CONCRETE REINFORCEMENT
PART 1 GENERAL
1.01 RELATED WORK
A. Section 03310 - Cast-in place

concrete.
B. Section 03110 - Concrete form work and
accessories C. Section 03450 - Plant-Precast
Architecture concrete. D. Section 04051 - Masonry
procedure.
E. Section 08920 - Glazed Curtain

walls.
1.02 REFERENCES
A.
General
All reinforcement for use in the permanent works shall be specified on

the drawings and shall comply with the British Standard as indicated in 9.1.2.
B. Type of
Reinforcement
The reinforcement shall comply with the relevant British Standards as given below:
1. Mild steel, plain rolled bars BS 4449
2. High yield steel hot rolled deformed bars BS 4449
3. High yield steel, cold worked deformed bars BS 4449
4. Fabric reinforcement, indented or deformed welded wires BS 4483
5. Cold reduced steel wire BS 4482
6. Deformed bars shall have a Type 2 bond classifications.
1.03 SOURCE QUALITY CONTROL
A. Provide the Engineer with certified copy of mill test report of reinforcing steel,
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showing physical and chemical analysis, minimum 8 weeks prior to commencing

reinforcing work.
B. Inform the Engineer of proposed source of material to be supplied.
C. Two copies of certificates verifying that the reinforcement complies with this
Specification shall be given by the Contractor to the Engineer in accordance
with the British Standard as appropriate for each consignment of reinforcement
from each source.
D. All testing for reinforcement shall be carried out in a laboratory acceptable to the
Engineer. The frequency of testing shall be as set out in BS 4449 or as directed by
the Engineer.
1.04 SHOP DRAWINGS
A. Submit shop drawings including placing of reinforcement in accordance with

Section 01340 - Shop Drawings, Product Data, Samples and Mock-ups.
B. Indicate on shop drawings, bar bending details, lists, quantities of reinforcement,

sizes, spacings, locations of reinforcement and mechanical splices if approved by the
Engineer, with identifying code marks to permit correct placement without reference
to structural drawings. Indicate sizes, spacings and locations of chairs, spacers and
hangers. Prepare reinforcement drawings in accordance with the Engineer
instructions.
C. Detail lap lengths and bar development lengths. Provide tension lap splices where
indicated.
D. Bar Schedules
1) The Contractor shall schedule the reinforcement in accordance with BS 8110

and BS 4466 and the information on the Drawings, this Specification and
subsequent instructions.
2) The Contractor shall include for all necessary chairs and spacers, and his
price and rates for steel thus shown shall include for these.
3) The Contractor shall prepare reinforcement detail drawings and other relevant
shop drawings on reproducible negatives to the following scales:
Walls and slabs 1:50

Beam and column elevations 1:20
Beam and column sections 1:20 or 1:10
4) Sketches will not be acceptable.
5) These drawings shall show all openings for services, upstands or

plinths for equipment and cast-in items.
6) Bending schedules and reinforcement detail drawings shall be

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submitted for the Engineer’s approval. Two weeks shall be allowed for his
consideration of this initial submission.
7) The Contractor shall correct these schedules and resubmit as reasonably

required to ensure a high standard of work. He shall programme his work
and submit schedules for approval allowing time for such verification,
rectification and resubmission as necessary. Such approval shall not relieve
the Contractor of his responsibility for the accuracy of such schedules.
8) No concreting shall be allowed to proceed until such a time that the

drawings and bending schedules for that particular section of works are
approved. Any delay incurred in obtaining approval shall be the Contractor’s
responsibility.
E. Supplementary Drawings
The Contractor shall prepare any additional shop and fabrication drawings and other
details necessary to instruct his staff on the positioning, bending, supporting of
reinforcement and association works. Two copies of such drawings and details shall
be submitted to the Engineer with the bar schedule.
1.05 SUBSTITUTES
Substitute different size bars only if permitted in writing by the Engineer.
PART 2 PRODUCTS
2.01 MATERIALS
A. Reinforcing steel to standards identified in this section (see 1.2 above)
B. Where reinforcement couplers are specified or are permitted by the Engineer they
shall be used in accordance with the manufacturer recommendations.
The tensile strength and the fatigue performance of coupled sections of bar should
comply with the relevant British Standard for the type of bar(see Clause 7.9.1.2).
C. Tying Wire: tying wire shall be 1.6mm diameter black annealed mild steel wire. The
use of any other type requires the approval of the Engineer. The ends of the wire
shall be bent back away from the surface of the member to avoid rust staining.
D. Spacers: the type of spacer requires the approval of the Engineer. They shall be of
durable material and shall be designed to avoid corrosion of reinforcement and
spalling of concrete.
Concrete spacer blocks shall be made from cement, sand and small size coarse
aggregate. The mix proportions shall match those of the surrounding concrete and
the blocks shall be comparable to the surrounding concrete in strength, durability and
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appearance.
The spacer blocks, their positioning and fixing shall be in accordance with good
practice as recommended by the Concrete Society in their publication “Spacers for
Reinforced Concrete”
2.02 FABRICATION
A. Fabricate reinforcing steel in accordance specified standards.
B. Obtain the Engineer's approval for locations of reinforcement splices other than
those shown on placing drawings.
C. Upon approval of the Engineer, weld reinforcement in accordance with approved

standards.
D. Ship bundles of bar reinforcement, clearly identified in accordance with bar bending
details and lists.
PART 3 EXECUTION AND PROTECTION
3.01 CUTTING AND BENDING
A. The Contractor shall cut reinforcement to length and bend it to the shape shown on
the schedules within the dimensional tolerances given in BS 4466. Bars shall be
bent cold by the application of slow steady pressure. Hooks or right angle bends
shall be formed where called for by the schedules and to the dimensions and
tolerances specified in BS 4466. In the unlikely event of temperatures
below
5°C, in certain locations during the winter months, the rate of bending shall
be reduced if necessary to prevent fracture of the steel.
B. High tensile bars shall not be bent after placing in the works, unless shown otherwise
on the drawings or specifically approved in writing by the Engineer.
C. After bending, bars shall be securely tied together in bundles or groups and legibly
labelled as set out in BS 4466
3.02 PLACING REINFORCEMENT
D. Place reinforcing steel as indicated on reviewed approved placing drawings and in

accordance with specified standards.
E. Use plain round bars as slip dowels in concrete. Paint portion of dowel intended to
move within hardened concrete with one coat of asphalt paint. When paint is dry,
apply a thick even film of mineral lubricating grease.
F. Prior to placing concrete, obtain the Engineer's approval of reinforcing material and
placement.

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G. Ensure cover to reinforcement is maintained during concrete pour.
H. Protect coated portions of bars with covering during transportation and handling.
3.03 FIELD TOUCH-UP
I. Touch up damaged and cut ends of epoxy coated or galvanized reinforcing steel with
compatible finish to provide continuous coating.
3.04 CLEANING
J. All reinforcement shall be cleaned to ensure it is free of all oil, dust and deleterious
material. Concrete shall be subsequently placed within 24 hours. Cleaning shall be
by wire brushing or grit or sand blasting to the Engineer's satisfaction. If blasting is
required the blasting medium shall be clean and salt free. If at any time the
Engineer is not satisfied with the result of mechanical cleaning he may require the
Contractor to adopt an alternative method.
K. Water cleaning of reinforcement to remove chloride contamination shall be carried

out at the Engineer’s discretion prior to pouring of concrete. Cleaning water shall
comply with clause 3.1.E of specification 03310
3.05 FIXING
A. Reinforcement shall be securely fixed in position within a dimensional tolerance

stated in clause 3.12 of this specification.
B. Unless otherwise agreed by the Engineer, all intersecting bars shall either be tied
together with 1.6mm diameter black annealed mild steel and the ends of the wire
clipped short or turned into the body of the concrete, or shall be secured with a wire
clip of a type agreed by the Engineer.
C. Spacer blocks shall be used for ensuring that the correct cover is maintained on the
reinforcement. Blocks shall be as small as practicable and of a shape agreed by the
Engineer. Wires cast into the block for tying in to the reinforcement shall be 1.6mm
diameter annealed mild steel. Special provisions shall be made where special
finishes are required and exposed spacer blocks not permitted.
D. Reinforcement shall be rigidly fixed so that no movement can occur during concrete
placing. Any fixings made to the formwork shall not be within the space to be
occupied by the concrete being currently placed.
3.06 SPLICES
A. No splices shall be made in the reinforcement except where shown on the

Drawings or agreed by the Engineer. Splice lengths shall be as shown on
the Drawings or as otherwise directed by the Engineer
Mechanical splices shall not be used unless the Engineer agrees otherwise in writing.
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3.07 MESH FABRIC
A. Sheets of steel mesh fabric reinforcement shall overlap each other by at least twice
the wire spacing in the direction of the lap or as shown on the Drawing's and shall
be securely fastened at the ends or edges.
3.08 WELDING
A. Reinforcement shall not be welded except where required by the Contract or agreed
by the Engineer. If welding is employed, the procedures shall be as set out in BS
2640 for gas welding or BS 7123 for metal arc welding. Full strength butt welds shall
only be used for steel complying with BS 4449. If high yield deformed bars are to
be welded they shall have a carbon equivalent of the steel less than 0.51% and a
nitrogen content less than 0.007%
3.09 PROTECTION HANDLING AND STORAGE
A. The Contractor shall ensure that reinforcement left exposed in the Permanent Works
shall not suffer distortion, displacement or other damage. When it is necessary to
bend protruding mild steel reinforcement aside temporarily, the radius of the bend
shall not be less than four times the bar diameter. Such bends shall be carefully
straightened before concrete placing continues, without leaving residual kinks or
damaging the concrete round them.
B. Reinforcement shall be stored on site in racks within a building enclosure at a

minimum of 150mm above the ground and shall be protected from wind-blown dust,
sand and sea salts.
C. Reinforcement shall also be protected from the weather. Any reinforcement which
has become corroded or pitted to an extent which in the opinion of the Engineer will
substantially affect its properties or its long term durability shall be removed from site.
3.10 CONTACT BETWEEN DISSIMILAR METALS
A. Where concrete members contain galvanised or stainless steel reinforcement or

embedded items as well as ordinary uncoated mild or high-yield steel reinforcement
then contact between dissimilar metals shall be prevented, if necessary by inserting
electrically insulating material between them. Starter bars shall be protected from
wind blown dust, sand and sea salts.
3.11 STARTER BARS
A. Starter bars shall be protected from wind-blown dust, sand and sea salts by wrapping
with polythene sheet or other approved means.

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3.12 COVER
A. The required cover specified on the Drawings is the nominal cover. Nominal cover is
the design depth of concrete cover to all steel reinforcement, including links
(stirrups). The sizes of spacers and the dimensions of all reinforcement shall be
based on this nominal cover. The fixing of reinforcement and formwork shall also be
such as to maintain the nominal cover.
B. The actual concrete cover to all steel reinforcement shall not be less than the
required nominal minimum cover minus 5mm.
Where reinforcement is located in relation to only one face of a member (e.g.

a straight bar in a slab) the actual concrete cover shall be not more than the
required nominal cover plus:
• 5mm on bars up to and including 12mm size.
• 10mm on bars over 12mm up to and including 25mm size,
• 15mm on bars over 25mm size.
Cover shall be maintained to all embedded fixings, conduits, etc., and all chases and
pockets.
C. Spacers, chairs, together with such other supports as may be necessary, shall be
used to maintain the reinforcement in its correct position. In a member
where the nominal cover is dimensioned to the links, spacers between the link
and the formwork shall be the same dimension as the nominal cover.
D. The position of reinforcement shall be checked before and during concreting,

particular attention being paid to the position of top reinforcement in cantilever
sections.
3.13 EMBEDDED ITEMS
A. All embedded items shown on the drawings shall be fixed in the positions shown
within the specified tolerances.
B. Where this necessitates the modification or displacement of the reinforcement the

Contractor's proposals for such work shall be approved by the approval of the
Engineer.
C. Embedded items shall not be supported by welding to reinforcement.
3.14 DOWEL BARS
A. Unless specified otherwise, dowel bars shall be straight round smooth mild steel bars
complying with BS 4449. The free end shall be sawn and free from burrs or other
irregularities.
B. Where shown on the Drawings, dowel bars shall be debonded with an approved
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debonding compound or proprietary dowel bar sleeve. The Engineer may require the
Contractor to demonstrate the efficiency of the method of debonding by carrying out
the test described below.
The average bond stress on debonded bars cast into concrete specimen and
subjected to pull out tests at 7 days shall not exceed 1.4MN/sq.m and the total
movement of the dowel bar relative to the concrete shall be not less than
0.25mm at the stress. The concrete specimens shall be 150mm x 150mm in section
and 450 mm long and made with the same mix proportions as used in the Works.
The number of tests will be at the Engineer's discretion.
C. Compressible Caps
Caps shall be securely fixed and shall permit free movement of one end of the bar.
D. Workmanship
Dowel bars shall be rigidly supported so that they are correctly aligned.
PART 4 EPOXY COATED REINFORCEMENT
4.01 SCOPE
This part deal with Fusion Bonded Epoxy coated reinforcement applied by the electrostatic
spray method.
4.02 GENERAL
The requirements of Specification 03210 shall apply except as varied herein.
4.03 EPOXY COATING OF REINFORCEMENT
A. Where shown on the drawings, reinforcement with a fusion bonded epoxy coating
shall be supplied. The coating shall be applied and rested in accordance with ASTM
A775/A775M-84 except as amended in the following clauses:
Clause
5.1
The surface preparation of the reinforcement shall be cleaned to a visual standard in

accordance with SIS 05 59 00 Sa2.5
Clause
6.1
The coating shall be applied within 4 hours of reinforcement being blast cleaned.
Clause
7.3.1

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The bend test for adhesion of the coating shall be made at uniform rate and shall
take 20 seconds to complete.
Clause
8.2.1
Tests for thickness of coating shall be made on a minimum of 3 bars of each size
from each production shift but not less than:
10 bars for every 5 tonnes of reinforcement for bars of less than 20mm
diameter.
5 bars for every 10 tonnes of reinforcement for bars of 20mm diameter or greater.
Clause
8.2.2
Bend tests for adhesion of coating shall be conducted on a minimum of 2 bars

of each size from each production shift, but not less than:
6 bars for every 5 tonnes of reinforcement for bars of less than 20mm
diameter.
3 bars for every 10 tonnes of reinforcement for bars of 20mm diameter or

greater.
B. The supplier of the epoxy resin shall obtain the Engineer's approval of the
compliance of their material with the requirement of the annex to ASTM A775-84.
Patching material compatible with coating material shall also be supplied.
The contractor shall supply the certificate noted in ASTM A775 Clause 4.2 and the
samples noted in ASTM A775 Clauses 4.3 and 4.4.
Clause
7.1
Add 'No measurements shall be less than 3 mils'. Clause

9.1
If a specimen for coating thickness or for adhesion fails to meet the specified
requirements, 3 re-tests on samples from this same batch shall be conducted
for each failed test. If the results of all the re-tests meet the specification
requirements, the coated bars represented by the samples shall be accepted.
4.04 SITE INSPECTION AND REPAIR ON REJECTION OF DAMAGE TO EPOXY COATING
E. Bars shall be inspected for damage at the following

times:
1. Immediately after initial unloading at the site.
2. During and after fixing of the reinforcement when access is available.

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3. Immediately prior to the pour.
F. Criteria and method of repair:
All coating damage i.e., cracking with exposes bare steel, cutting or abrasion of the
coating shall be repaired.
The damaged areas shall have all rust removed using a wire brush and emery paper.
The repaired areas shall be recoated with the approved patching material to a
minimum thickness of 4 mils, and in accordance with the manufacturer's
recommendations to the satisfaction of the Engineer.
Bars which have damage in excess of 2% of the bar surface area in the form of an
evident rust layer shall be rejected from site and replaced with an acceptable bar.
Bars showing debonding of the coating shall be rejected and removed from site.
Bars which have damaged areas in excess of 2% of the bar surface area per
300mm length shall be rejected and removed from site.
Repairs shall not be carried out when moisture is present on the surface of the bar.
4.05 CUTTING AND BENDING OF REINFORCEMENT
All reinforcement shall be bent cold unless otherwise specifically permitted by the Engineer.
Wooden mandrels or steel mandrels with nylon collars shall be used and the minimum
internal radius of bending shall be 4 bar diameters for both High Yield and Mild Steel
Reinforcement. No plain unribbed reinforcement shall be used unless specifically permitted
by the Engineer.
4.06 SITE INSTALLATION AND HANDLING
Reinforcement of all types shall be stored on site in protection racks above ground in an
approved manner so as to avoid damage to the coating. Direct metal to coating contact
should be avoided wherever possible.
The reinforcement shall be lifted with nylon slings in accordance with Clause 10.1 of ASTM
A775. Steel slings shall not be used to lift Epoxy coated reinforcement. Equipment for
handling Epoxy coated bars shall have padded contact areas.
Any coating damage due to handling, transporting and placing shall be repaired. All chairs,
tie-wires or other devices used to connect, support, secure or fasten epoxy coated
reinforcement shall be made of, or coated with, dielectric material such as nylon, epoxy or
plastic. All bundles shall be identified at the factory with durable tags to allow checking of
coating quality or rebent in a manner which may cause injury to the material.
The Engineer is to be notified of all errors and omissions prior to the cutting, bending and f
ixing of the reinforcement.

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The Contractor shall provide adequate scaffold boards or similar to ensure that the coating is
not damaged during fixing and the reinforcement is not displaced by being walked upon
during the placing of the concrete or other operations. Prior to concreting the Contractor
shall ensure that the reinforcement is cleaned of all concrete from previous pours and any
damage to the coating is repaired.
The Contractor's workforce must be competent in the use, handling and protection of epoxy
coated reinforcement.
4.07 QUALITY CONTROL
The coating applicator's authorised representative shall be required to attend the Site at
regular intervals, to be agreed with the Engineer to inspect all aspects of the works to ensure
that the product is being stored and handled in full accordance with the coating applicator's
recommendations and their specification. The inspections shall include the storage, lifting,
general handling, fixing, tying, repairing etc. of the epoxy coated reinforcement.
END OF SECTION

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03310 CAST-IN-PLACE CONCRETE
PART 1 GENERAL
This section describes all the cast-in-place concrete work required under this contract.
1.01 RELATED SECTIONS
A. Section 03110 - Concrete Forms and Accessories.
B. Section 03210 - Concrete Reinforcement.
C. Section 03361 - Concrete Floor Hardeners.
D. Section 03362 - Concrete Floor Treatment.
E. Section 03450 - Plant-Precast Architectural Concrete and Panel Types.
F. Section 04050 - Blockwork.
G. Section 05500 - Metal Fabrications.
H. Section 07121 – Membrane Water Proofing.
I. Section 07128 – Fluid Applied Water Proofing
J. Section 07210 – Building Insulation.
K. Section 05810 - Expansion Joint assembly.
L. Section 07900 – Caulking and Sealant.
M. Section 09001 - Finishes Schedule.
N. Section 09200 - Lath & Plaster
1.02 REFERENCES
The Standards referred to in this Specification are listed below, together with any other
References specified. The latest editions shall be used, including all current amendments
and additions. Any difference between their requirements and this Specification shall be
submitted to the Engineer for his ruling.
Standards
ACI 305 Hot Weather Concreting
ASTM C 87 Effect of organic impurities in fine aggregate on strength of mortar.

ASTM C 142 Clay lumps and friable particles in aggregates.
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ASTM C 227 Potential Alkali reactivity of cement - Aggregate combinations (Mortar

bar method)
ASTM C 289 Test for potential reactivity of aggregates (chemical method)
ASTM C 232 Bleeding water test.
BS 12 Portland cement
BS 812 Testing aggregates
BS 882 Aggregates from natural sources for concrete
BS 1014 Specification for pigments for Portland Cement
BS 1305 Batch type concrete mixers
BS 1377 Method of test for soils for civil Engineering purposes
BS 1881 Testing concrete
BS 3148 Methods of tests for water for making concrete
BS 3892 Pulverised fuel ash
BS 4027 Sulphate-resisting Portland cement
BS 4449 Carbon steel bars for the reinforcement of concrete
BS 4466 Bending dimensions and scheduling of bars for the reinforcement of

concrete
BS 4483 Steel fabric for the reinforcement of concrete
BS 4550 Part 2 Methods of testing cements - chemical tests
BS 5075 Part 1 Accelerating admixtures, retarding admixtures and water

reducing admixtures
Part 2 Air-entraining admixtures
Part 3 Super plasticisers
BS 5328 Part 1 Guide to specifying concrete
Part 2 Method for specifying concrete mixes
Part 3 Specification for the procedures to be used in producing and

transporting concrete
Part 4 Specification for the procedures to be used in sampling, testing

and assessing compliances of concrete.
BS 5975 Code of Practice for falsework

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BS 6100 Glossary of building and civil Engineering terms
BS 7123 Metal Arc Welding of Steel for Concrete Reinforcement
BS 8004 Foundations
BS 8007 Design of concrete structures for retaining aqueous liquids
BS 8110 The structural use of concrete
DD 147 Method of test of curing compounds for concrete
A. Building Research Establishment
BRE Digest 357 Shrinkage of Natural Aggregates in Concrete

BRE Digest 330 Alkali Aggregate Reactions in Concrete
B. Concrete Society
Technical Report 30 Alkali Silica reaction - minimising the risk of damage to

concreteSpacers for Reinforced Concrete.
All structural concrete work shall be designed and constructed in accordance with the
requirements of BS 8110 and/or BS 8007 where appropriate except where otherwise
listed in the Specification or on the Drawings. Concrete Specification shall comply
with BS 5328. Any differences between these requirements and this Specification
shall be submitted to the Engineer for his ruling.
C. Hot Weather
Hot weather shall be defined as any combination of high air temperature, low relative
humidity and wind velocity tending to impair the quality of fresh or hardened
concrete. The climatic factors affecting concrete in hot weather are high air
temperature and reduced relative humidity, the effects of which may be considerably
more pronounced with increases in wind velocity. The effects of hot weather on
concrete are most critical during periods of rising temperature, falling relative
humidity or both.
1.03 SAMPLES
A. Submit samples in accordance with Section 01340 - Shop Drawings, Product

Data, Samples and Mock-ups.
B. At least 4 weeks prior to commencing work, inform Engineer of proposed source of

aggregates and provide access for sampling.
C. At least 4 weeks prior to commencing work, submit to Engineer samples of following

materials proposed for use:
1. 10 kg of each type of Portland cement.

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2. 3 kg of each type of supplementary cementing material.
3. 10 kg of each type of blended hydraulic cement.
4. 5 L of each admixture.
5. 5 L of curing compound.
6. 1 m length of each type of joint filler.
7. 1 m length of each type of waterstops.
1.04 CERTIFICATES
A. Minimum 4 weeks prior to starting concrete work submit to Engineer

manufacturer's test data and certification by qualified independent
inspection and testing laboratory that following materials will meet specified
requirements:
1. Portland cement.
2. Blended hydraulic cement.
3. Supplementary cementing materials.
4. Grout.
5. Admixtures.
6. Aggregates.
7. Water.
8. Waterstops.
9. Waterstop joints.
10. Joint filler.
B. Provide certification that mix proportions selected will produce concrete of quality,
yield and strength as specified in concrete mixes, and will comply with standards
defined in this section.
C. Provide certification that plant, equipment, and materials to be used in concrete

comply with requirements of this section.
A. Minimum 4 weeks prior to starting concrete work, submit proposed quality

control procedures for Engineer's approval for following items:
1. Formwork erection.
2. Hot weather concrete.
3. Curing.
4. Finishes.
5. Formwork removal.
6. Joints.
B. Definitions

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For the purpose of this Specification the definitions given in BS 2787 and BS 6100
shall apply.
C. Testing
The Contractor shall be responsible for all testing. Testing laboratories require the
Engineer’s approval. The Engineer shall be permitted access to the laboratories to
witness any tests and he may request further tests if necessary. Two copies of all
test results shall be submitted to the Engineer within 48 hours.
The Contractor shall demonstrate to the Engineer’s satisfaction that the production of
concrete cubes and the measurement of slump are being carried out only by persons
competent in the required techniques.
D. Approval of the Engineer
Wherever the Contractor is required to obtain the approval of the Engineer, this shall
be requested in writing and written approval obtained at least 24 hours before the
work concerned is put in hand.
E. Rectification
All work which fails to comply with this Specification shall be rectified promptly
by a procedure approved by the Engineer. In particular making good of concrete
shall be carried out within 7 days of removal of the formwork. Work which
cannot be rectified shall be broken back and reconstructed to the specified standard.
PART 2 PRODUCTS AND STORAGE
2.01 MATERIALS FOR CONCRETE
D. Initial approval
Prior to starting work on the contract the Contractor shall submit to the Engineer for
approval details of the proposed sources of all materials he proposes to use for
making concrete. No concrete shall be placed in the Permanent Works until the
Engineer has approved the materials of which it is composed. Approved materials
shall not thereafter be altered or replaced by other materials without the consent of
the Engineer.
E. Certification
Two copies of Certificates verifying that the materials comply with this Specification
shall be submitted promptly by the Contractor at the following intervals:
- Aggregates - corresponding to the test frequency in table 1.
- Cement - each consignment.
- Water - at commencement of work, then monthly.

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- Admixtures, curing compounds and other materials - each consignment.
Where certificates are not available for admixtures, technical data sheets
shall be submitted instead.
F. Cement
1. General Requirement
The cement to be used throughout the work shall be Portland Cement

obtained from manufacturers approved in writing and shall be as described
under one of the following headings:
i. Ordinary Portland Cement (OPC)
Cement complying with either BS 12 or ASTM C150 Type I but

containing not less than 7% and not more than 12% by weight of tri-
calcium aluminate (C3A).
ii. Moderate Sulphate Resisting Portland Cement (MSRPC)
Cement complying with BS 12 or ASTM C150 Type II but

containing not less than 4% and not more than 8% by weight of
tricalcium aluminate (C3A). In either case the cement shall not contain
more than 2.7% by weight of sulphur trioxide (SO3).
iii. Sulphate Resisting Portland Cement (SRPC)
Cement complying with either BS 4027 or ASTM 150 Type V, but

containing not more than 4% by weight of tricalcium aluminate (C3A).
2. Additional Requirement
In addition to the requirements in 3.1.C.1 for cement to be used in permanent

Works the acid soluble alkali level measured as (Na2O + 0.658 K2O) shall
not exceed 0.6% by weight.
Also the heat of hydration at 7 days in accordance with ASTM C-186 shall not
exceed 290 kJ/kg and the fineness (specific surface) in accordance with BS
4550 shall not be less than 280 m²/kg.
Cement shall be free flowing and free of lumps. It shall be supplied in the
manufacturer's sealed and unbroken bags or in bulk.
Cement which has become hardened or lumpy or fails to comply with this
Specification in any way shall be removed from the site.
High alumina cement shall not be used.
3. Cement Delivery and Marking
Cement shall be obtained from a manufacturer or supplier approved by the

Engineer delivered direct to the site whether in bulk or in sealed bags.

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When cement is delivered in bags the following particulars should be marked

on each bag, both in English and local language.
i. type of cement
ii. the number and date of the standard the cement conforms to
iii. the net weight of cement contained therein
iv. the name, trade name of the manufacturer
v. the country of origin
vi. the date of manufacture.
Similar information shall be provided in the invoice documents accompanying

the shipment of bulk cement.
Cement in bags shall be transported in vehicles provided with effective means

of ensuring that it is protected from wet weather and high humidity.
Bulk cement shall be transported in containers built and equipped for the
purpose.

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TABLE 1 - FREQUENCY OF ROUTINE TESTS ON AGGREGATE
Sr. Kind of Requirement – Test Method Test Frequency Rate

No.
1 Grading – BS 812 Part 103 Each two weeks or per 100m3
whichever is more frequent
2 Material finer than 0.075mm - do -
BS 812 Part 103
3 Clay lumps and friable particles - do -
ASTM C142
4 Organic impurities - BS 1377 Test B Each month or per 200m³ whichever is
more frequent
5 Water absorption - ASTM C128/C127 - do -
6 Specific Gravity - ASTM C128/C127 - do -
7 Shell content - BS 812 Part 106 Each two months or per 100m³
whichever is more frequent
8 Particle shape - BS 812 Parts 105.1, - do -
105.2
9 Acid soluble chlorides, C1
Qualitative - BS 812 Part 117 App A/ On each delivery to site
Qualitative - BS 812 Part 117 App C Each week if result is more than 75%
of the limit and
Each month if result is less than 75%
of the limit.
10 Acid soluble sulphates, SO3 Each 2 weeks if result is more than
75% of the limit and each 2 BS 812
Part 118 months if the result is less
than 75% of the limit.
11 Soundness, mgSO4 (5 cycles) - ASTM
C88 Each two months
12 Mechanical strength
10% fines of impact value - BS 812 Each three months
parts 111, 112
Los Angles abrasion - ASTM C131/C535 -do-
13 Moisture variation in sand by Moisture Twice daily
Meters
NOTE: Drying shrinkage and potential reactivity of aggregates shall be determined

initially at the start of the project or whenever there is a change in the source of supply.

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TABLE 2 - LIMITS OF PHYSICAL, CHEMICAL AND MECHANICAL PROPERTIES

OF AGGREGATE FOR CONCRETE
Sr. Kind of Requirement Test Methods FInes Permissible

No. BS 812 ASTM Limits Coarse
1. Grading Part 103 Standard Standard
2. Material finder than 0.075mm Part 103
Natural, uncrushed / crushed Max 3% Max 1%
Crushed rock Max 7% Max 1%
3 Clay lumps and friable particles Max 1% Max 1%
C142
4 Light weight pieces C123 Max 0.5% Max 0.5%
5 Organic impurities, Test 8 of BS Max 0.05%
1377
6 Water absorption C128/C127 Max 2.3% Max 2%
7 Specific Gravity (apparent) C128/C127 Min 2.6 Min 2.6
8 Shell content in aggregate Part 106
Coarser than 10mm Max 5%
Between 5mm and 10mm Max 5%
Between 2.36mm and 5mm Max 10%
Finer than 2.36mm Note 1
9 Particle Shape
Flakiness index Part 105.1 Max 25%
Elongation index Part 105.2 Max 25%
10 Acid soluble chlorides, C1 Part 117,
For reinforced concrete made with Appendix 'C'
SRPC cement Max 0.03% Max 0.01%
OPC and MSRPC cements Max 0.05% Max 0.02%
For mass concrete made with

SRPC cement Max 0.03% Max 0.02%
OPC and MSRPC cements Max 0.05% Max 0.04%
For pre-stressed concrete and Max 0.01% Max 0.01%

steam cured concrete
11 Acid soluble sulphates, , SO3 Part Max 0.3% Max 0.3%

118
12 Soundness, MgSO4 (5 cycles) C88 Max 12% Max 12%
13 Mechanical strength
10% fines value Part 111 min 100 kN
or impact value Part 112 Max 30%
Los Angles abrasion C131/C535 Max 30%
14 Dry shrinkage Part 120 max 0.05%
15 Potential reactivity, Note 2
Note: 1. There is no requirement of shell content in sands passing 2.36mm size sieve.
2. See 2.1.D.5.
4. Cement Storage
Cement in bags shall be stored in a suitable weatherproof structure of which

the interior shall be dry and well ventilated at all times. The floor shall be
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raised above the surrounding ground level and shall be so constructed that no
moisture rises through it.
Each delivery of cement in bags shall be stacked together in one place. The
bags shall be closely stacked but shall not be stacked against an outside wall.
If pallets are used, they shall be constructed so that bags are not damaged
during handling and stacking. No stack of cement bags shall exceed 3m in
height. Different types of cement in bags shall be clearly distinguished by
visible markings and shall be stored in separate areas of the store.
Cement from broken bags shall not be used in the Permanent Works. Cement
in bags shall be used in the order in which it is manufactured
(by date)
Bulk cement shall be stored in weatherproof purpose built silos which shall
bear a clear indication of the type of cement contained in them. Different
types of cement shall not be mixed in the same silo. Cement stored in
silos shall be adequately protected against rain humidity and dewfall. Silo
charging and discharging points shall be properly sealed. Silo aeration
equipment shall, if necessary, incorporate de-humidifiers. Cement silo
charging pipes shall be clearly marked with the cement type. Precautions
shall be taken to reduce the effect of solar radiation on the temperature of the
silos.
The Contractor shall provide sufficient storage capacity on Site to ensure that
his anticipated programme of work is not interrupted due to lack of cement.
The temperature of cement shall not exceed 65C at the time of

incorporation within the mix.
5. Cement Sampling and Testing
All cement used in the Permanent Works shall be tested by the manufacturer
or the Contractor in a laboratory acceptable to the Engineer. In addition to
tests carried out by the manufacturers the Engineer shall from time to time
require tests to be carried out in accordance with BS or ASTM methods, at
the Contractor's expense.
Tests shall be carried out for the following properties:
• fineness
• setting time
• loss on ignition
• compressive strength
• heat of hydration
• soundness
• acid soluble alkali level
• chloride content
• insoluble residue
• C3A content
• SO3 content
Methods of testing cement shall be in accordance with BS 4550 Part 1 for

sampling, BS 4550 Part 2 for chemical test and BS 4550 Part 3 for physical
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property test except for the following where ASTM test methods shall be
used:
• Method C204 - Fineness by air-permeability

• Method C151 - Soundness, autoclave expansion
• Method C186 - Heat of hydration.
The Contractor shall supply two copies of each test certificate to the
Engineer.
Each set of tests carried out by the manufacturer or Contractor shall relate to
not more than one day's output of each cement plant, and shall be made on
samples taken from cement which is subsequently delivered to the Site.
Cement which is older than three months and stored on Site for longer than
one month in bags or two months in silos shall be retested in a
laboratory acceptable to the Engineer at the rate of one set of tests for each
type of cement, and at monthly intervals thereafter. The following routine
tests shall be carried out for assessing its quality before it is approved for use
in the works:
• fineness
• setting time
• loss on ignition
• compressive strength
Cement which does not comply with the Specification shall not be used in the
permanent works.
Any consignment of cement not used within 6 months from the date of
manufacture shall not be used in the works.
The Contractor shall keep full records of all data relevant to the manufacture,
delivery, testing and use of all cement used in the Permanent Works and shall
provide the Engineer with two copies thereof.
G. Aggregates for Concrete
Aggregates for concrete shall conform to the requirements for fine and coarse
aggregates in BS 882. Aggregates subject to high drying shrinkage such as quartz
shall not be used. Fine and coarse aggregates shall separately conform to the
requirements set out in Table 2.
1. General Requirements
Aggregate shall be clean, hard, durable and shall not contain iron pyrites, iron
oxides, mica, shale, coal or other laminar, soft or porous materials or hollow
shells.
2. Gradings
As a minimum requirement, fine aggregate shall conform to BS 882

Table 5. The grading shall not cross from one side of the envelope to the
other between any three adjacent grading points. In order to achieve an
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acceptable grading it may be necessary to blend materials from more than

one source. Grading percentage by weight passing sieve no. 100 shall not
exceed 10% for natural sand and 15% for crushed rock.
Coarse aggregate shall be supplied in the nominal sizes specified and shall
be graded in accordance with BS 882 for single sized aggregates. A
coarse aggregate shall be predominantly angular, rounded or irregular as
defined in BS 812, Part 1.
3. Physical, Chemical & Mechanical Properties Requirement
The limits for physical, chemical and mechanical properties of aggregates for
concrete and the test method to ensure compliance shall be as summarised
in Table 2.
4. Total Chloride and Sulphate Content
The total chloride content arising from all ingredients in a mix including
cement water and admixtures shall not exceed the limits set out in
3.1.E.
The total sulphate content expressed as SO3 of all the ingredients in a mix
including cement, water and admixtures shall not exceed the limits set out in
3.1.E.
5. Alkali Reactive Minerals
No part of the aggregates shall contain any mineral known to have a potential
to cause alkali silica, alkali silicate, alkali carbonate, or any other damaging
chemical reaction between alkalis and aggregates. (see Concrete Society
Technical Report 30 and BRE Digest 330).
The Contractor shall demonstrate to the Engineer's satisfaction that the matrix
will be stable and not liable to excessive internal expansion due to alkali-
aggregate reaction. The Contractor's proposals for demonstrating this shall
be submitted and shall take account of the time necessary for any testing.
The demonstration may be based on previous long term experience of the
materials or on a programme of tests. The Contractor shall, if a test
programme is carried out, submit to the Engineer test certificates from an
independent testing laboratory for the tests stated below:
i) The aggregate source shall be inspected for lihtological diversity and

the findings interpreted.
ii) Petrographic examination of the aggregates in thin section shall be

carried out by a suitably qualified person using a sample of the
aggregate crushed to pass a 4.75mm sieve. The reuslts shall be
interpreted.
iii) The material as dug if a sand, or crust to pass a 4.75mm sieve, shall
be tested according to the specification given in ASTM C1260-94.
The results shall be interpreted with the aid of petrographic study of of
the tested mortar. If the result shows a marginal expansion in the
range 0.08 to 0.12% expansion at 14 days the test shall either be
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repeated, continued for 56 days and/or intrepreted in the light of a

petrographic study of the mortar.
iv) If the petrography indicates that rocks potentially alkali-carbonate

reactive are present, these shall be analysed cehmically for CaO,
MgO, A12O3 and insoluble residue and be tested by ASTM C-586
rock cylinder method and the results interpreted.
An interpretive report shall be submitted to the Engineer for approval.
If the aggregate/cement combination is deemed acceptable for the

intended purpose, then a programme of inspection shall be
established to ensure that no adverse materials appear in the product.
6. Delivery and Storage of Aggregates
Aggregates shall be delivered to Site in clean and suitable vehicles. Different

types or sizes of aggregates shall not be delivered in one vehicle.
Aggregates shall be stored on a hard, dust-free surface and shielded from

dust and the direct rays of the sun. If dust-free environment cannot be
achieved rescreening and washing of aggregates shall be carried out prior to
their use.
Aggregates of each grade and type of material shall be kept separate until
batched. Segregation in each stock-pile shall be prevented. Stockpiles
shall be protected against contamination from soil, evaporate salts,
vegetable matter or other deleterious material. The floors of bins shall be
75mm thick mass concrete (or similar and approved) and shall be laid to fall
to the outer edge or provide a free draining apron.
7. Testing Aggregates
i) Acceptance Testing
The Contractor shall deliver to the Engineer samples containing not

less than 5 kg of any aggregate which he proposes to use in the
Permanent Works and shall supply such further samples as the
Engineer may require. Each sample shall be clearly labelled to show
its origin and shall be accompanied by all the information called for in
BS882.
Tests to determine compliance of the aggregates with all the

requirements of Clause 3.1.4 shall be carried out by the Contractor in
a laboratory acceptable to the Engineer. If the tested materials fail to
comply with the Specification, further tests shall be made in the
presence of the Contractor and the Engineer and acceptance of the
material shall be based on such tests.
The acceptance tests carried out by the Contractor shall generally be

on three representative samples of fine and coarse aggregates
taken in the presence of the Engineer. Total numbers of tests
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required for acceptance are as follows:-
TEST FINE COARSE

AGGREGATE AGGREGATE
Water Absorption 3 3*
Flakiness index 3 3*
Shell Content 3 3*
Determination
Test for shell 3 1
Content 3 3*
10% Fines Test or 3 3 on each
Aggregate Impact nominal size
Gradings 3* 3*
3* 3*
Chloride Content - 3*
Sulphate Content As required As required
Soundness Minimum 3 Minimum 3
Petrographic 3 3
Examination
3 3
Clay, Silt and dust
Determination
Organic impurities
* One test on each sample
Testing shall also be carried out to establish the relationship between

Quantab and Volhard results for the aggregates
If at any time a significant physical or chemical change in the nature of

the coarse or fine aggregate occurs, or a new source of aggregate is
used, the Engineer may direct that some or all of the acceptance
testing is repeated.
ii) Routine Testing
The Contractor shall carry out routine testing of aggregates in

accordance with Table 1 for compliance with the Specification during
the period in which concrete is being produced for the Permanent
Works.
The Contractor shall take account of the fact that when the chloride
content is variable it may be necessary to test every load in order to
prevent excessive amounts of chloride contaminating the concrete.
For this purpose the Contractor shall use the rapid field test (Quantab
test). In the event of disagreement regarding the results of the field
test, the chloride content of the aggregate shall be determined in the
laboratory as described in BS 812 (the Volhard test).
H. Water for Concrete
Water shall be clean and free from salt and other impurities to the satisfaction of the
Engineer. It shall be tested in accordance with BS 3148 or ASTM C94.
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Water used for mixing and curing of concrete shall have a pH value in the basic
range of 7 to 9 and the soluble solids shall not exceed the following limits:
Total dissolved solids 2000 mg/l

Chlorides (NaCl) 250 mg/l
Sulphate (SO3) 350 mg/l
Alkali Carbonates & Bicarbonates 500 mg/l
Water for concrete making shall be kept shaded from the sun and appropriate
measures shall be taken to ensure that the water temperature is kept as low as
possible. Where flaked or crushed ice is added to the water for concreting, it shall
have completely melted prior to the addition of the water to the concrete mix.
Such ice shall be sampled and tested in accordance with BS
3148 or ASTM C94 for compliance with the above criteria.
I. Admixtures
1. The Contractor shall obtain the Engineer's approval prior to the use of
admixtures in each mix. The suitability of admixture shall be verified by trial
mixes.
2. Admixtures shall be stored to avoid deterioration and segregation.
3. Admixtures shall be used strictly in accordance with the manufacturer's

instructions unless directed otherwise by the Engineer.
4. Neither calcium chloride nor any admixture containing chloride shall be used.
5. Both the amount of admixture to be added and the method of use require the
approval of the Engineer, for whom the following data shall be provided:
i) the chemical name(s) of the main active ingredient(s) in the admixture;
ii) whether or not the admixture contains chlorides;
iii) the typical dosage and detrimental effects of under-dosage and over-
dosage;
iv) whether or not the admixture leads to the entrainment of air when
used at the manufacturer's recommended dosage;
v) long-term and short-term effects of the admixture on concrete, and the

effect of different types of cement and aggregate;
vi) storage life and any special storage requirements;
vii) safety precautions in handling;
viii) availability of on-site technical service.
ix) alkali content.

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6. Admixtures shall comply with one of the following British Standards: BS1014,
BS3892 or BS 5075 as appropriate. Certification of compliance with the
appropriate British Standards shall be provided by the Contractor.
7. Air entrainment agents shall be such that the air content can be
maintained within the limits specified even if the mixing time is extended
to 30 minutes.
8. If two or more admixtures are proposed to be used in any one mix, the
manufacturers of each shall be consulted and their advice passed to the
Engineer.
J. Microsilica (Condensed Silica Fume)
1. Origin
The Microsilica shall originate from specified Ferrosilicon or Silicon Plants

where the Silicon content of the primary alloy produced (not the microsilica
produced) is greater than 85%.
2. Frequency of Supplier Testing
The manufacturer shall maintain a testing frequency at the production plant at

least once every 100 Tons of microsilica produced.
3. Compositional Analysis
The microsilica shall have the following minimum and maximum composition in
its powder form.
Min Max
SiO2 85% -
Fe203 - 1.5%
SO3 - 1.0%
Na2O+K2O - 2.0%
C1 - 0.05%
C - 1.5%
Loss on ignition ASTM C311 - 2.0%
Coarse particles >44µmASTM C311 - 1.5%
Moisture content ASTM C311 - 1.5%
BET Fineness m²/kg DIN 66132 20,000
4. Documentation
The contractor shall submit to the Engineer authentic original
documents relating to:
a) The origin of the microsilica by country and location of plant.

b) The silicon content by percentage of the primary alloys produced
at the nominated plant and any variations during the supply
period.
c) method of shipment
and d) the compositional analysis with every delivery of microsilica to the
project.
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5. Storage
a) Dry microsilica powder in bags shall be stored under shaded cover and be
isolated from the ground or floors by pallets.
b) Dry microsilica powder shall be stored in clean dry rust free silos and
protected from contamination.
6. Method of Addition to Concrete
a) Microsilica powder shall be slurrified into a 50% (by weight) water slurry
before addition to the fresh concrete mix.
b) The slurry shall be accurately dispensed into the concrete mix either
manually or by automatic equipment designed for the purpose to an
accuracy of +3%.
c) The addition of powder directly to the concrete mix shall be approved only
at the discretion of the Engineer.
7. Curing
Wet curing shall be maintained for a minimum period of 10 days after

placement. Under no circumstances shall the concrete be allowed to dry out
during the wet curing period.
PART 3 EXECUTION AND QUALITY ASSURANCE
3.01 DESIGN OF CONCRETE MIXES
A. General
The grades of concrete are shown on the Drawings by reference to the 28-day
characteristic compressive strength in N/sq.mm and, when necessary, followed by
the nominal size of the coarse aggregate in millimetres - for example C40-20.
Design of mixes shall comply with the requirements of BS 5328. The Contractor's
mix proposals for each mix require the Engineer's approval. Existing data provided as
evidence of satisfactory previous performance shall include the workability and
water/cement ratio. During production the Contractor shall inform the Engineer of all
changes in sources of materials or cement content. Trial mixes shall be made
initially as well as before any substantial change is made. No changes shall be
made without the Engineer's approval.
Based on the results of the tests on the trials mixes, the Contractor shall submit two
copies of the full details of his proposals for mix designs to the Engineer, including
the type and source of each ingredient, the proposed proportions of each mix and the
results of the tests on the trial mixes (see sections 3.1.G).
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B. Cement Content
The cement content of structural concrete shall not be less than 350 kg/cu m unless
directed otherwise. A cement content in excess of 420 kg/cu m shall not be used
without the specific approval of the Engineer.
C. Water/Cement Ratio
The maximum free water/cement ratio shall be 0.42 unless shown otherwise on the
drawings. Free water/cement ratio shall be as defined in BS 5328 Part
4 Clause 3.14.2.
D. Air Content
The average allowable air content of the fresh concrete (other than those
incorporating air-entraining agents) shall be no more than 2%.
E. Total Content of Acid Soluble Chlorides and Sulphates
The total content of acid soluble chlorides (expressed as Cl) in concrete containing
Ordinary Portland Cement shall not exceed 0.20% by weight of cement. For
prestressed concrete, this limit is reduced to 0.08%.
The total content of acid soluble chlorides (expressed as Cl) in concrete containing
Sulphate Resisting Cement shall not exceed 0.06% by weight of cement.
When measuring soluble chloride dissolved in water the result shall be calibrated
against the above limit.
The total content of acid soluble sulphates (expressed as S03) shall not
exceed 3% by weight of cement.
The limits for acid soluble salt contents of aggregates specified in Table 2 may need
to be reduced to comply with the overall limit above.
F. Total Alkali Content
The alkali content (Na2O and K2O) of the concrete shall not exceed 3 kg/m³.
G. Performance Testing of Trial Mixes
The following testing shall be carried out at the trial mix design stage and periodically
during production to verify the mix design.
1. Workability
The workability shall be measured by slump cone. Workability shall be

sufficient to suit the methods of transport, placing and compaction which are
to be used. The slump of the final agreed mix shall be the control slump for
concrete to be incorporated into the works. For mixes with slump in excess of
150mm, a flow table shall be used in place of the slump cone. Slump shall be
not less than 25mm nor more than 75mm (or not more than 125mm for
pumped concrete) unless permitted otherwise by the Engineer.
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2. Segregation and Bleeding
The proportions of the ingredients of the concrete, including the water, shall
be so chosen that the concrete will be workable enough to be fully compacted
and not be prone to segregation or bleeding.
The mix shall be such that there will not be excess water on the top surface
after compaction. It may be necessary to reduce the water content of batches
at the top of deep lifts to compensate for water gain from the lower levels, but
this should be avoided by designing the mix, checking with preliminary trials
and accurately controlling the mix proportions throughout the work.
Trial mixes shall be tested in accordance with ASTM C232-90 (bleeding test).
Segregation or bleeding shall not be greater than 1.5% for concrete generally
and 0.5% for concrete with microsilica. Testing shall be carried out on all trial
mixes and on every 500 m3 of concrete produced.
3. Durability Tests
The following tests shall be carried out on all trial mixes and on every
1000 m3 of concrete produced:
Chloride Permeability to AASHTO T-277
Type of Concrete Maximum Charge Pass

(Coulombs)
Age 28 days
Concrete generally 3,000
Microsilica concrete 1,000
Water Permeability to DIN 1048

(Coulombs)
Age 28 days
Concrete generally 15 mm
Microsilica concrete 8 mm
Initial Surface Absorption to BS 1881 Part 5

(Coulombs)
Age 28 days
Concrete generally 0.3 ml/m²/sec
Microsilica concrete 0.15 ml/m²/sec
30 Minute Absorption to BS 1881 Part 122

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(Coulombs)
Age 28 days
Concrete generally 3.0%
Microsilica concrete 1.0%
3.02 STRENGTH TESTS
A. For each mix of concrete the Contractor shall prepare three separate batches of
concrete using the materials which have been approved and the mixing plant which
he proposes to use for the Permanent Works.
B. Six test cubes shall be cast from each batch.
C. The making, curing and testing of all test cubes shall comply with the
requirements of BS 1881. The workability test of the concrete carried out in
accordance with BS 1881 shall be recorded for a range of mixing
temperatures and at various times after mixing. The mixing temperature shall be the
temperature after the water has been added. Slump control graphs shall be
prepared for use on site.
D. Three cubes from each batch shall be tested for compressive strength at 7 days and
the remaining three at 28 days.
E. The density of all the cubes shall be determined before the cubes are
crushed.
F. The strength of the mix shall be approved if the mean strength at 28 days of the set
of nine cubes from the mix (three cubes from each of the three separate batches)
exceeds the Characteristic Strength plus 11.5 N/mm2
3.03 WORKMANSHIP
A. Batching and Mixing
1. The quantity of cement, the quantity of fine aggregate and the quantity of the
various sizes of coarse aggregate shall be measured by weight except that
aggregates may be measured by volume for concrete of Grade C10.
2. A separate weighing device should be provided for weighing the cement.

Alternatively, the cement may be measured by using a whole number of bags in
each batch.
3. The amount of water should be measured, by volume or weight. Any solid

admixtures to be added should be measured by weight but liquid or paste
admixtures may be measured by volume or weight.
4. The batch weights of aggregate shall be adjusted to allow for a moisture

content typical of the aggregate being used.
5. The accuracy of the measuring equipment shall be within 3% of the quantity of

cement, water or total aggregates being measured and within 5% of the
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quantity of any admixture being used. All measuring equipment shall be

maintained in clean, serviceable condition.
6. The mixer should comply with the requirements of BS 1305 where applicable.
The mixing time should not be less than that used by the manufacturer in
assessing the mixer performance.
7. For mixes of low workability or high cement content the Engineer may direct
that the mixing time be determined by tests to ensure that maximum strength is
achieved.
8. Plant used for making concrete shall be free from any concrete or mortar
containing either high alumina or super-sulphated cements.
9. Calibration of the batching and mixing plant shall be carried out at intervals
agreed with the Engineer.
10. The requirements of 3.3.B for Ready Mixed Concrete shall also apply to site
batched concrete.
B. Rea d Mixed Concrete
1. Ready mixed concrete shall comply with the requirements of this Specification
and with BS 5328, except for those clauses which are directly over-ridden by
this Specification and the supplier shall be made aware of the
requirements of these documents.
2. Concrete shall only be mixed at a depot approved by the Engineer which shall
comply with the requirements of the quality system for Ready Mixed Concrete
(QSRMC) Technical Regulations.
3. Unless specially authorised by the Engineer, the concrete shall be mixed and
the water added to the mixer at the depot. No additional water shall be added
at any stage from batching to placing. When the Engineer is asked to authorise
dry batching, he will require to be satisfied that appropriate steps will be taken
to ensure the quality, consistency and strength of the concrete as placed and
that the water will be added to the dry ingredients under properly
controlled conditions (see 3.3.A).
4. Truck mixer's mixing performance when tested in accordance with BS 3963

shall be within the limits of table 5 of BS 1305.
5. The drum of the truck agitator or truck mixer shall be completely clean and
empty before it is filled with concrete. Trucks shall not be loaded in excess of
the manufacturer's rated capacity, which shall be displayed on the vehicle in
terms of the volume of mixed concrete. Concrete shall be discharged from the
trucks within thirty minutes after the introduction of the water to the cement
unless longer time is authorised by the Engineer. This will not normally be
allowed, except in exceptional circumstances.
6. The actual batched weight of cement, water, admixture, additives and coarse
and fine aggregates, the time of introduction of the water and the mixing
temperature after water has been added shall be recorded on each delivery
ticket by the supplier. When concrete is wet batched no water shall be added
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after batching.
7. In addition, where required by the Engineer, the Contractor shall provide

details of the aggregate moisture contents determined at the plant. These shall
be provided on a daily basis both as test results and in the form of a print out of
the data programmed into the batching plant. The delivery ticket shall show
details of any automatic adjustments to the quantity of water added to
the mix, ie. compensating for the actual moisture contents measured during
batching.
8. The supplier's test certificate referred to in Clause 5 or 12 as appropriate

of BS 5328, giving the results of tests on aggregates for workability and
strength, shall be submitted by the Contractor to the Engineer at weekly
intervals.
9. Calibration of the Ready Mix Plant shall be carried out at regular intervals and
calibration certificates of the plant shall be submitted to the Engineer.
C. Transport of concrete
1. The requirements of BS 5328 Part 3 shall be met.
2. In addition to the requirements of BS 5328 Part 3 the concrete shall be

compacted and in its final position within 45 minutes of the introduction of
cement to the aggregate unless a longer time is agreed by the Engineer.
Precautions shall be taken to ensure that the loss of slump due to temperature
rise during transport, pumping and placing does not exceed 25 mm.
3. Containers used for transporting concrete, made from Portland Cements,

shall be free from any concrete or mortar containing either high alumina or
super-sulphated cement.
3.04 CONCRETING
A. Preparation and permission to concrete
1. Prior to the commencement of concrete works, the Contractor shall provide

the Engineer with fully detailed proposals of the method of placing,
compacting, finishing and curing the concrete. The method statements, which
shall be subject to the approval of the Engineer, shall cover all principle types
of concrete elements, e.g. foundations, walls, columns, beams, slabs etc.
2. As a minimum requirement, preparations for concreting shall follow the

guidelines given in ACI 305R-91 Section 4.
3. The concrete-mixing plant, mixers, pipelines, pumps chutes and transport

equipment shall be shaded and/or painted white. Pump lines and other
surfaces shall be kept cool by insulating them or by covering them with
hessian kept damp by spraying with water.
4. Surfaces on which concrete is to be placed shall be moist but free of standing

water at the time of concreting. This shall be achieved by spraying the forms
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and reinforcement prior to placing concrete. Shading shall be provided to

prevent solar heat gain of forms and reinforcement.
5. When daytime temperature and drying conditions are critical the concreting
shall be scheduled to begin during the late afternoon to prevent the
occurrence of severe thermal effects. Consideration should also be given to
nightime concreting.
6. The Contractor shall give the Engineer at least 24 hours written notice before
concreting to allow time for final inspection and approval.
B. Placing and compacting concrete
1. The Contractor shall take measures to ensure under all circumstances that
the temperature of the concrete at the time of placing does not exceed 28 C
in exposed external walls and 32 C elsewhere. In the event that conditions
become such that these requirements cannot be met, concreting shall be
suspended immediately and not resumed until the requirements can be met
again. Under such circumstances, additional precautions may have been
taken to avoid the temperatures being exceeded on future pours.
2. During concreting and throughout the first stage of hardening, the concrete
shall be protected from the harmful effects of sunshine, drying winds, rain or
running water.
3. The requirements of BS 8110 Part 1 clause 6.5.2 shall be met and also:
a) When directed by the Engineer, the Contractor shall demonstrate the

efficiency of the proposed methods of placing and compaction on a trial
section. When a trial section has been approved by the Engineer, this
section shall be maintained as a control for the duration of the contract.
The trial section may become part of the permanent works if
appropriate.
b) Concrete shall not be placed or compacted by any method which

causes segregation, undesirable finish or defective structural quality. It
shall not be moved into position by rakes or vibrators. The thickness of
concrete placed at one time shall not exceed the amount which can
immediately be compacted with the means available. This is unlikely to
be more than 500mm.
c) Adequate measures shall be taken to avoid displacing reinforcement

and other embedded items.
d) Adequate staging or other facilities shall be provided so that

compaction can be carried out without either operatives or plant
adversely affecting the reinforcement or concrete that has already
been placed.
e) Concrete shall not be subjected to disturbance between 4 hours and 24

hours after compaction except with the agreement of the Engineer.
f) The number and size of the vibrators shall be such as to ensure

thorough compaction of the entire volume of concrete being placed.
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They shall be either the immersion type with a frequency of not less
than 100 Hertz when operating submerged in concrete or the exterior
type with a frequency of not less than 50 Hertz. The vibrators shall be
applied systematically at such intervals and for such periods that
dense, compact, homogeneous concrete is produced and
segregation and voids do not occur. Immersion vibrators shall be
withdrawn sufficiently slowly to prevent the formation of voids and shall
not be placed against reinforcement.
Poker vibrators shall not be applied to external face of shuttering to

aid compaction of beams columns etc.
g) All equipment shall be kept free from coatings of hardened concrete

and shall not be wetted during use.
h) Placing Concrete under Water
No concrete shall be placed under flowing water. Underwater concrete

shall be placed by methods in accordance with BS 8004: Foundations.
Full details of the method proposed shall be submitted 14 days in
advance to the Engineer and his approval obtained before placing
begins.
C. Concreting near joints
1. Concrete shall be placed continuously up to all joints. Particular care shall be

taken in the placing of the new concrete close to joints. This concrete shall
be fully compacted with a vibrator where possible. Immediately prior to
recommencement of concreting at a joint, the surface of the existing concrete
shall be free from laitance and shall be roughened so that the tips of the
largest aggregate are exposed but not disturbed. This surface shall be
prepared when the concrete has set but not hardened, by spraying with a fine
spray of water or brushing with a stiff brush, which is sufficient to remove the
outer mortar skin. Where this treatment is impracticable, sand blasting or a
needle gun shall be used to remove the surface skin and laitance; hacking of
hardened surfaces shall be avoided. The joint surface shall be cleaned
immediately before the fresh concrete is placed against it and shall be
thoroughly wetted to reduce absorption of water from the fresh concrete.
Surplus water shall be drained/removed prior to concreting.
D. Height of Concrete Delivery
Concrete shall not be dropped from a height exceeding 1.5m. Any trunking or chutes
used shall be kept clean. Concrete shall not be pumped through aluminium alloy
conduits.
E. Concreting Against Ground
Where it is specified that concrete shall be placed directly in contact with the ground
it shall be done immediately following the final preparation of the formation.
F. Concrete for Walls

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The concrete in each section between joints or corners shall be placed in successive
pours working away in both directions from the centremost panel of that section. The
minimum interval between placing adjacent panels shall be 3 days unless directed
otherwise.
G. Temporary Stopends
If a delay of more than thirty minutes occurs during concreting, the work shall be
completed against a temporary stopend. If the location of the joint is not satisfactory
for a construction joint (see 1.2.A) the concrete shall be cut back to a satisfactory
location.
For deep lifts a temporary stop end may be formed in 'steps' subject to the approval
of the Engineer.
H. Deep Lifts
For lifts exceeding 2.5 metres the Contractor shall submit his proposals for the
Engineer's approval. Particular attention shall be paid to the factors mentioned
in BS 8110 Part 1 Clause 6.5.2.
I. Curing of Concrete
1. General Requirements
The method of curing shall provide an effective means of preventing

premature drying of the concrete and the effects of plastic shrinkage and shall
ensure that the concrete has satisfactory durability and strength, the minimum
of distortion, freedom from excessive efflorescence and will not cause by its
shrinkage early age (i.e. during curing) cracking in the structure. Methods of
curing and protection shall comply with the guidelines given in ACI 305R-91,
together with the additional requirements contained within the following
paragraphs:
Concrete shall be cured for a minimum of seven days. For concrete

incorporating cement replacements such as GGBFS, PFA or Microsilica, this
period shall be increased to 10 days minimum. If a change in curing method
is made during this period, it shall only be done after the concrete is 3 days
old.
Unless an alternative method has been approved by the Engineer, moist

curing techniques shall be adopted using wet hessian and reflective
polythene sheeting. Approved white pigmented curing compounds may be
applied to supplement the use of wet hessian and polythene. Use of curing
compounds alone will not generally be approved. Curing compounds will not
be permitted on surfaces to which further concrete or a surface finish is
subsequently to be bonded.
Water used for curing purposes shall comply with 2.1.E and shall be within
5°C of the placed concrete temperature.
The hessian and polythene shall be left in place for at least a further 7 days
following curing to reduce the rate of drying of the concrete surface.

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Where structural members are of considerable depth or bulk, additional

measures may be required. Under such circumstances, the method of curing
requires the approval of the Engineer. It may be necessary to insulate the
concrete so that it is maintained at a suitable temperature, or so that the rates
of evaporation of moisture from the surfaces are kept to appropriate values,
or both.
Where curing compounds are approved for use by the Engineer, the following
criteria shall be satisfied:
The efficiency index E of the membrane shall be at least 90% as calculated

by:
E = W-W1 (100%)
W
W= average percentage loss of moisture by control
specimens.
W1 = average percentage loss of moisture by test.
Curing membranes shall be pigmented.
Curing compound shall not be used on concrete surfaces which are to be

bonded with concrete later (e.g. at construction joints) unless all such
surfaces are broken away to completely remove the membrane prior to
further concreting at the joint. Furthermore, curing compounds shall not be
allowed to contaminate reinforcement.
As membrane curing compounds may affect the subsequent treatment or

finish of the surface of the concrete, their use requires to be approved by the
Engineer before they are adopted. The Contractor is to supply sufficient
technical data regarding his suggested compound to enable the Engineer to
assess its suitability.
2. Un-formed Surfaces
Within ten minutes of placing and compaction, the un-formed surfaces of the
concrete shall be completely covered with reflective polythene sheeting with
substantial close fitting taped laps. The polythene sheeting may be raised a
short distance above the concrete so that it does not mark the surface. At
the edges of the pour, the polythene shall drape over the forms and it shall be
securely fixed to prevent billowing due to the wind.
Within three hours of placing and compaction the polythene shall be quickly
removed and replaced with wet hessian laid onto the concrete surface. The
polythene shall then be replaced and secured as above.
The polythene sheeting and hessian may be temporarily removed for surface
finishing of the concrete.
The hessian shall be kept continuously damp during the curing period.
Inspections shall be carried out at intervals not exceeding 6 hours.
Protective measures shall be maintained throughout the curing period to

shade the concrete from direct sunlight and protect it from the wind by the use
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of wind breaks.
3. Formed Surfaces
Formwork shall be shaded and continuously wetted to prevent high

temperatures accelerating the curing. As soon as possible, forms shall be
loosened to enable curing water to run down inside them. Within half an hour
of stripping, formed surfaces shall be covered by wet hessian and reflective
polythene and then treated in accordance with the requirements above for un-
formed surfaces.
J. Protecting Concrete
1. Concrete shall be protected against damage from thermal shock, physical

shock, overloading, movement and vibration. Particular care shall be taken
during the curing period.
2. Concrete which shall remain exposed after completion of work shall

be protected against damage from dirt, rust marks and other disfiguration.
3. No traffic shall be allowed on any concrete surface until it is hard enough

to resist damage by such traffic.
4. Before making good any damage, the Contractor shall obtain

the Engineer's approval of the methods and materials proposed.
5. Concrete shall not be cut without the prior approval of the

Engineer.

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3.05 DIMENSIONAL TOLERANCES
A. The concrete work shall be constructed to an accuracy which shall permit the proper
assembly of components and installations and shall be compatible with the finish.
The accuracy of the work shall be within the tolerances stated on the Drawings or
specified elsewhere and in the absence of any other requirements, shall comply with
the following:
All setting out dimensions + or - 5mm
Sections of concrete members + or - 5mm
Foundations
Surface against ground (underside) + or - 100mm

Top surfaces of bases and piers + or - 20mm
Piling Refer to piling Specification
Floor slabs
Surface level (5m straight edge) + or - 5mm
Surface level to datum + or - 10mm
Columns and walls
Plumb in storey height + or - 5mm

Cross diagonal distortion in storey height + or - 10mm
between adjacent columns
Plumb in full building height + or - 20mm
Inside faces of lift shafts in storey height + or - 5mm

Inside faces of lift shafts in full basement + or - 10mm
Dimensions and position of openings+ or - 5mm
Holding down bolt assemblies Refer to Specification

15
Position of embedded items + or - 5mm
B. Notes:
1. The thickness of a slab shall not be less than 95% of the nominal thickness
specified.
2. Where stated on the drawings, slabs shall be laid to the specified falls.
3. Gaps and slots for sealants shall satisfy the requirements specified
elsewhere.

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3.06 COMPLIANCE OF CONCRETE WITH SPECIFICATIONS
A. General Requirements
1. Provided that the specified materials have been used and the concrete has
been properly made and handled, concrete will be judged by the strength of
the hardened concrete, in comparison with the specified characteristic
strength together with the cement content.
2. Sampling and testing of concrete shall comply with BS 1881, together with
further specifications referred to herein. The Contractor shall afford access to
the Engineer to witness all tests. The testing laboratory requires the approval
of the Engineer. It shall be capable of carrying out every concrete test
required by this Specification at the frequency specified and all equipment
shall be kept in good working order and calibrated at regular intervals.
3. The Engineer may arrange for independent concrete testing to verify the
results obtained by the Contractor’s laboratory. Such testing shall not relieve
the Contractor of his responsibilities for testing under the Contract.
B. Sampling
1. To test for workability
One sample shall be taken at the point of placing for each 10 cu.m of
concrete batched or for readymix concrete, each truck load delivered. For
each 50 cu.m of concrete produced, an additional sample shall be taken for
comparison purposes at the point of batching.
2. To test for strength
At least one sample shall be taken from each mix (OPC or ASTM or SRC) of
concrete each day and an additional sample for each 20 cu.m. or 20 batches
of structural concrete, whichever is the lesser.
Additional samples will be required of all mixes until concrete production has
been shown to be the Engineer's satisfaction.
C. Testing Workability
1. Each sample required by Clause 3.6.2 shall be tested for workability.
2. For each sample the temperature of the concrete shall be measured and
recorded with the time the test was performed.
3. For each mix of each grade the equivalent slump measured by the cone test
shall be determined by trial mixes. Control shall be maintained by measuring
the slump at the point of placing.
D. Testing the strength
1. Three standard 150mm cubes shall be made from each sample required by
clauses 2.3.6.2 and stored and tested at 28 days in accordance with BS
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1881. An additional cube shall be made, stored and tersted at 7 days in

accordance with BS 1881.
2. The 28-day result shall be the mean of the three cube results.
3. Report the Results of Tests
The report of the tests for strength shall embody the information
required by Part 116 of BS 1881, together with the information about the
workability required by Part 102 of BS 1881, and the information listed below:
i. Name of Contractor
ii. Identification of mixer or ready mix supplier and depot.
iii. Grade of concrete.
iv. Type of concrete.
v. Section of work represented by sample.
vi. Density of cube (kg/cu.m.).
Single copies of the completed report forms shall be given to the Engineer
within 4 days of each test.
A statistical record of the results of the cube testing shall be maintained by

the Contractor for each mix design. This shall include calculation of the
standard deviation and mean strength for the mix and plots of cube test
results against time. Up to date results and graphs shall be forwarded to the
Engineer on a weekly basis.
4. Compliance
Compliance with the strength shall be determined if:-
i. The average strength of each group of 4 consecutive test results for each
mix exceeds the specified characteristic strength by not less than 3.0
N/sq.mm and is not less than 8.5 N/sq.mm below the mean strength
determined for all previous test results for the mix.
ii. Each individual result exceeds 95% of the specified characteristic

strength and is not less than 16.0 N/sq.mm below the mean strength
determined for all previous test results for the mix.
5. Action to be taken in the Event of Non-compliance
The action to be taken in the event of non-compliance shall be determined by

the Engineer, and may range from qualified acceptance to rejection and
removal of all or part of the concrete cast between the previous set of 4 cubes
and the next set of 4 cubes.
The Contractor shall provide at his own expense all records, samples,
including core samples, tests and their results as may be required by the
Engineer, whether the concrete be finally accepted or not.

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3.07 FINISHES
A. Samples
When required by the Engineer full-scale reinforced samples shall be built by the
Contractor to demonstrate finishes for the Engineer's approval. The samples shall
incorporate junctions, joint and applied finishes if required by the Engineer. If
acceptable, the samples may be incorporated in the works. Subsequent finished
work shall not be inferior to the samples, which shall be used as models. The
remainder of the work shall use the same methods as the models.
B. Finishes to formed surfaces
1. General
All forms shall be well made and not liable to move or allow grout-loss. They
shall be true to shape and free from defects likely to detract from the
appearance of the finished concrete.
Whatever method the Contractor uses to obtain each finish, the same method
(including the formwork, the release agent and the curing procedure)
shall be used for the whole of each separate building or item of construction.
In the event of front runs evident upon removal of formwork, these should be
carefully removed without delay with any additional remedial work carried out.
For exposed finishes fins and irregularities projecting more than 3mm shall be
removed; the positions of formwork ties shall be to the Engineer's approval
and the holes left shall be filled with a cement and fine aggregate paste to
match the colour of the original concrete.
Alternatively, more stringent attention shall be given to the sealing of

formwork tie holes when required by the Engineer.
2. Types of finish
Where details of the required finishes are not specified separately the
following shall apply:
Type A Rough finish for buried or rendered work:
This finish is obtained by the use of properly designed formwork or moulds of

closely jointed saw or wrought boards or other suitable material. The
surfaces will be imprinted with the grain of the boards and their joints. In
addition, small blemishes caused by entrapped air or water may be expected,
but the surface should be free from voids, honeycombing or other large
blemishes. The holes left for formwork bolts shall be filled. Fins and
irregularities projecting more than 3mm shall be cleaned off.

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Type B Normal finish for exposed work:
This finish is obtained by the use of properly designed forms of closely jointed
wrought boards, plastic, steel or other suitable material, provided that the
surfaces shall be free from the imprint of the forms. Small blemishes caused
by entrapped air or water may be expected, but the surface should be free
from voids, honey-combing or other large blemishes. The holes left for
formwork bolts shall be filled. Fins and other projections shall be removed
and all blemishes filled with a cement and fine aggregate paste. Care
shall be taken in the choice of any release agent used, to ensure that the
finished concrete surface is not permanently stained or discoloured.
Type C Superior finish for exposed work:
This finish can only be achieved by the use of high quality concrete and by
using properly designed forms having a hard, smooth surface. The concrete
surfaces should be smooth with true, clean arises. Only very minor surfaces
blemishes should occur and there should be no staining or discoloration from
the mould oil or curing agent.
The surface shall be free from the imprint of wood grain. Unfaced wrought
boarding or standard panels shall not be used. The material for the form shall
be provided in large sheets and arranged in an approved uniform pattern:
joints between sheets shall be arranged to coincide with architectural
features, sills or heads of windows or changes in direction of the surface; all
joints between sheets shall be accurately aligned in the plane of the sheets.
Bolt holes are not allowed.
Other types of finish
These shall include any finish different from A, B and C that requires the use
of special forms or linings, the use of a different concrete mix near the
surface, grinding, bush hammering or other treatment. If any of these special
finishes is required it shall be fully specified on the Drawings.
Whichever method the Contractor uses for obtaining each finish, the same
method shall be used for the remainder of the work.
Remedial treatment to the finish of the concrete, additional to that specified

above, requires the approval of the Engineer.
3. Finish of unformed surfaces
The finish of unformed surfaces shall be tamped, floated, trowelled or

brushed as defined below and shown on the Drawings.
TF Tamped surfaces shall be formed by levelling and tamping the

concrete to produce a uniform plain or ridged surface, surplus
concrete being struck off by a straight edge immediately after
compaction. It is also the first stage of the following finishes:
FF Floated shall be a uniform surface which has been worked no more

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than is necessary to remove screed marks by hand with a wood or

steel float of a type approved by the Engineer. The surface shall not
be floated until the concrete has hardened sufficiently.
ST Steel trowelled shall be a hard, smooth finish free from trowel marks
formed with a steel trowel under firm pressure. Trowelling
shall not commence until the moisture film has disappeared and the
concrete has hardened sufficiently to prevent excess laitance from
being worked to the surface. If laitance is brought to the surface it
shall be removed.
BR Brushed shall be formed by first producing a floated finish and then,

before the concrete has hardened, by drawing a wire broom over the
concrete surface at right angles to the traffic flow to give an average
texture depth of 1mm.
PF Power float shall be a uniform surface which has been worked no

more than is necessary to remove screed marks with a power float of
a type approved by the Engineer. The surface shall not be floated
until the concrete has hardened sufficiently.
4. Direct Finishing
Where specified, direct finishing consisting of dry-shake or granolithic

application shall be carried out in accordance with Specification 23.
5. Plastic Cracking
If plastic shrinkage cracking occurs, the construction affected shall be rectified

and the contractor shall take all necessary steps to prevent a recurrence.
Rectification method and results shall be subject to the approval of the
Engineer.
6. Random Drying Shrinkage Cracking and Plastic Settlement Cracking
If any cracking of the concrete occurs in an uncontrolled manner, the

construction affected shall be rectified and the contractor shall take all
necessary steps to prevent a recurrence. Rectification method and results
shall be subject to the approval of the Engineer.
3.08 CONSTRUCTION JOINTS A. Details

Construction joints, including Stopends and crack inducing joints, shall meet the
following requirements:
1. Construction joints shall be at right angles to the member and shall have neat,
clean lines. Formed joints shall be plain unless a key or surface rebate is
specifically detailed on the drawings or called for by the Engineer.
2. Where kickers are required they shall be placed integrally with the floor slab;
this may necessitate a special design for the formwork. Kickers shall have a
height of not less than 70mm and not more than 170mm above the floor slab
or above any splay. Concrete in kickers shall be of the same mix as the main
member. The concrete shall be vibrated into place and prepared as for other
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joints.
3. Joints in columns and walls shall only be formed about 15mm above the
soffits of suspended floors, at floor levels, or at the tops of kickers which shall
not be less than 75mm. There may be a joint between haunches or column
capitals and the column.
4. Joints in other locations may be allowed at the discretion of the Engineer.
In certain circumstances the Engineer may limit the number of joints

allowed in a vertical member in accordance with the requirements of the
design.
B. Location
1. The location of construction joints not shown on the drawings shall be subject
to the Engineer's approval. The Contractor's proposals shall be based on the
following guidelines:
a) The number of construction joints shall be kept to a minimum

consistent with reasonable precautions against the effects of shrinkage;
their location shall take due account of shear and other stresses. Joint
lines shall be arranged so that they coincide with features of the
finished work and meet the requirements of any added finishes,
screeds, etc.
b) Vertical joints in walls generally shall not be spaced at intervals greater

than 6m and in no case shall be more than 10m. Where, however, a
wall changes direction by at least 60 degrees, the overall spacing of
joints may be increased to 10m subject to the length of pour in either
leg of the wall being no more than 5m. Where possible joints shall be
positioned at least 2m away from corners. Refer also to Section
7.3.4.6.
c) Joints in beams and slabs if required shall be between the quarter and
third points of the span unless otherwise directed by the Engineer. It is
preferable that no joints are formed in end bays.
2. Joints in ground slabs should, wherever practicable, coincide with the

locations of joints shown on the drawings. Where additional joints are
required their locations shall be to the approval of the Engineer.
Joints in unreinforced ground slabs (including slabs nominally reinforced with

not more than 0.1% steel in either direction) shall be at centres not greater
than 5m.
C. Workmanship
Work at construction joints shall be in accordance with BS 8110 Part 1 Clause

6.12.The recommendations for joints to transfer tensile or shear stresses shall be
followed. Roughening of the joint surface shall be carried out sufficiently to remove
the outer mortar skin.
D. Crack inducers
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1. Crack inducers in ground slabs shall be fixed where shown on the drawings
and used in accordance with the manufacturer's recommendations.
2. Crack inducers in reinforced concrete walls shall be used only after the
\
3. Engineer's approval has been given.
3.09 MOVEMENT JOINTS
A. Movement joints are designed to permit relative movement of adjacent parts of a

member or structure without impairing its structural integrity. The joints shall be
formed in the locations and to the details shown on the Drawings.
1. The material forming the joint requires the Engineer's approval except where
their use is directed by name. When seeking approval the Contractor shall
provide full technical data and a sample.
3.10 JOINT FILLERS AND SEALANTS
Refer to drawings for specification requirements and relevant specification divisions.
PART 4 FLOOR SCREEDS
4.01 SCOPE
This Appendix covers the use of cement-sand screeds and lightweight screeds for floors.
4.02 GENERAL
A. The requirements of Specification 03310 shall apply except as varied herein.
B. Reference can be made to British Standards Codes of Practice CP204 "Insitu floor
finishes", CP202 "Tile Flooring and slab flooring" and BS 8203 "Sheet and tile
flooring".
4.03 MATERIALS
A. Sand shall be to BS 882 table 2 and graded within the limits of zones 1, 2 or 3.
4.04 SCREEDS LAID DIRECT ON IN SITU CONCRETE
A. Preparation of base concrete
The surface of the base concrete should be brushed with a stiff broom just before it
hardens to remove all laitance and to form a key for the screed which will be laid at a
later date. When it is required to lay the screed, the surface of the base concrete
must be thoroughly cleaned and wetted (preferably overnight) and any surplus water
removed before the laying of the screed commences. Immediately prior to laying the
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screed, a thin brush coat of cement grout should be applied to the damp surface of
the base concrete and well scrubbed in. The grout must not be applied more than
twenty minutes before it is covered with the screed.
B. Mix proportions
The screed should be composed of 1 part Ordinary Portland cement to 3 parts

concreting sand by weight. The cement should be batched by weight, but the
sand may be either weight- or volume-batched. Allowance should be made for
the bulking of damp sand. A free water/cement ratio of 0.45 by weight should not be
exceeded.
C. Laying, bay sizes and joints
The screed should be laid and thoroughly compacted in bays not exceeding 3.0 - 4.0
m wide. The length shall be agreed with the Engineer. Where movement joints
(expansion or contraction joints) occur in the structural slab, these should be carried
through the screed and the bay sizes in the screed adjusted accordingly. If a very
smooth surface is required, the final working up can be done by means of steel float,
but excessive trowelling should be avoided.
In the presence of conduits and ducts within the thickness of the screed, a strip of
expanded metal (BS 405) or wire netting (BS 1485) not less than 450mm wide shall
be laid across. There should be a minimum thickness of screed of 20mm over the
top of the duct.
D. Curing
As soon as each bay is completed, it must be covered with polythene sheets and the
curing should continue for not less than 4 days. The sheets must be adequately
lapped and held down and round so that they are not blown away.
4.05 SCREEDS LAID ON PRECAST CONCRETE UNITS
A. Preparation of structural floor surface
The surface should be thoroughly cleaned and then damped twenty-four hours
before the screed is laid, but any accumulation of water in irregularities in the face
concrete must be removed. A thin brush coat of cement grout should be applied and
well scrubbed in not more than twenty minutes before the screed is laid.
B. Mix proportions
The recommendations given in Clause 7.B.4.2 apply.
C. Laying, bay size and joints
The screed should be laid and thoroughly compacted in bays not exceeding 3.0 -
4.0m wide and about 5.0m long. Apart from these bay sizes, construction joints
should, as far as possible, be formed at the end junctions of all precast units which
are laid end to end, and at all other positions where there is a change in the
rigidity of the supporting structural members.

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D. Curing
The recommendations given in Clause 4.4.4 apply.
4.06 AERATED OR CELLULAR CONCRETE SCREEDS
This type of mortar or concrete is produced by mixing Portland cement and water and a resin
based foaming agent, so as to give a screed with a density of 700 kg/m3 minimum.
A. Preparation of base concrete
Generally no special preparation is required apart from cleaning and brushing.
B. Cement, sharp washed sand, water and foaming agent shall be mechanically mixed
together for approximately 6 to 8 minutes in a mobile mixer consisting of a vertical
whisk rotating in a stationary drum. The recommendation of the manufacturers of the
foaming agent shall be strictly adhered to. The minimum thickness is usually 40mm.
The usual bay widths are 2.0 - 2.5m to allow for levelling off between forms. The
length of casting bays shall be agreed with the Engineer. Movement joints in the
structural slab should be carried through the screed.
PART 5 WATERTIGHT CONCRETE
5.01 SCOPE
This Part deals with the use of watertight concrete.
5.02 General
A. The requirements of Specification 03310 shall apply except as varied herein.
B. Structures for retaining or excluding water or other aqueous liquids shall be

watertight without the use of a separate waterproofing membrane.
C. The watertight structures are to be designed and detailed in accordance with the
requirements of this Specification and with those of BS 8007. "The Structural Use of
Concrete for Retaining Aqueous Liquids".
5.03 MATERIALS
A. Aggregates
The maximum allowable drying shrinkage of aggregates shall be 0.04%.
5.04 WORKMANSHIP
A. General

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The Contractor shall take full responsibility for ensuring that the resulting construction
is completely watertight and free from penetration of moisture. When, in the
opinion of the Engineer, damp patches (and/or leakage of water) in the finished work
are due to failure of the Contractor to comply with this Specification the affected work
shall be made good at the Contractor's expense.
B. Joints
1. The maximum length of wall panels placed in one continuous pour between
vertical construction and/or movement joints shall be 5 metres. Where
intermediate crack inducing joints at 5 metres maximum centres are
incorporated in the work then the only restriction on the length of wall panels
cast in one operation shall be the centres of the construction and movement
joints shown on the Drawings or the Contractor's capacity for making
continuous pours whichever is the lesser.
2. Kickers shall not be less than 150mm high and shall be cast monolithically
with the base.
3. The Contractor shall obtain the approval of the layout and form of all
additional joints other than those shown on the drawings prior to
commencement of the work.
4. Particular care shall be taken to ensure full compaction of the concrete

around all joints and waterstops.
5. The concrete at the joint shall be bonded with that subsequently placed
against it, without provision for relative movement between the two. Concrete
shall not be allowed to run to a feather-edge, and all joints shall be formed
against a stop end. Particular care shall be taken when forming the joints.
6. The surface of the first pour shall be roughened to increase the bond strength
and to provide aggregate interlock. If the joint surface is not roughened until
the concrete has hardened, the larger aggregate particles near the surface
shall be exposed by sandblasting or by applying a scaling hammer or other
mechanical device. Powerful hammers shall not be used as they may
damage or dislodge aggregate particles so reducing, rather than increasing,
the capacity of the joint to transfer stresses.
7. Care shall be taken that the joint surface is clean immediately before the fresh
concrete is placed against it. It shall be dampened prior to the new
concrete being placed, to prevent excessive loss of mix water into it by
absorption.
C. Water bars
1. Samples of the different types of water bars shall be submitted to the

Engineer for approval.
2. Water bars shall be provided in all construction and day work joints, in
addition to any joint which may be detailed on the drawings.
3. Before commencement of work the Contractor shall obtain the Engineer's

approval of the methods to be used to support and maintain the water-bars in
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the correct location while the concrete is placed. Unless indicated otherwise
on the drawings all construction joints in watertight concrete shall be formed
as indicated on the drawings.
4. All water bars will be jointed by welding but all multiple joints and special
intersections shall be as manufactured by the supplier.
5. Care shall be taken at all times to ensure that water bars are not perforated
on damaged in any way and the concrete shall be carefully placed and
compacted around the water bars to ensure dense void free impervious
concrete.
D. Formwork
1. The formwork shall comply with the relevant clauses in this specification.
Any bolt or fastening embedded in or passing through the concrete shall be to
the approval of the Engineer and shall not impair the water tightness of the
structure. The use of through bolts and sleeves is strictly prohibited.
2. All cast-in service holes shall incorporate sleeves with puddle flanges and
temporary openings for services should incorporate water bars.
3. Slotted inserts or sockets cast into the structural concrete shall be provided
for all fixings; including services. The cutting of holes in watertight concrete is
strictly prohibited.
5.05 TESTING FOR WATERTIGHTNESS
A. General
1. The Contractor's programme and method of construction shall allow for the
satisfactory completion of tests for watertightness on each water retaining or
water excluding structure following completion. Completed parts of structures
may be tested subject to prior approval by the Engineer but no part shall be
tested until all the concrete in a structure has reached the specified strength.
2. When filling is complete the structure shall be kept full for an absorption
period of 7 days before the test commences. On satisfactory completion of
the test the water shall be disposed of in a manner approved by the Engineer.
B. Water Excluding Structures
1. The term 'Watertight' as applied to any wall, floor or other member shall mean
that 6 calendar months after the completion of the whole of the Works
including the superstructure (or 6 calendar months after the cessation of all
pumping of ground water on site whichever is the latest) there shall be no
seepage of water through any wall, floor or other member nor any damp
patch in excess of 0.50m² in area visible on its internal face. The number of
damp patches shall not exceed 1 for every 200m² (or part of200m²) of the
total internal surface area of walls, floor and other elements of the structure
the external surfaces of which are in contact with water.
2. These conditions shall be achieved without artificial heating or ventilation.

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Seepage of water shall be deemed to exist when sufficient flow occurs to form
a visible pool or film of water on the concrete surface. A damp patch shall be
deemed to exist when the colour of the concrete is darkened by saturation but
no visible pool or film of water is present.
C. Water Retaining Structures
1. For uncovered structures, where the plan area of the water does not exceed
1000m3 at the end of the absorption period, an open topped steel tank shall
be filled with water to the same depth as the structure and shall be placed in
the structure. This water tank shall have a plan area of at least 1.5m2 and a
capacity of at least 1.8m3 and shall previously have been proved to be
watertight. The levels of the water in the structures and in the tank shall be
equalized and recorded at intervals of 24 hours for 7 days following an
absorption period of 7 days. The structure will be deemed to be watertight if
the difference between the water levels does not exceed 10mm at the end of
the 7 days test period.
2. When the uncovered plan area of the water exceeds 1000m2 the Contractor
shall record the wet and dry bulb temperatures, the humidity, the wind speed
and the rainfall at 24 hour intervals for the test period of 7 days following an
absorption period of 7 days. From the information recorded the Contractor
shall calculate the variation to the depth of water due to rainfall, sunshine, etc.
during these 7 days, making allowance for the degree of exposure of the site.
The resultant loss or gain due to the water level in the structure and the
structure will be deemed to be watertight if the approved calculations show
that the balance of variation due to leakage is equivalent to a depth of less
than 10mm. Should the leakage exceed this amount but is decreasing daily
the structure will be deemed to be watertight if the limit is achieved in the
subsequent 7 days.
3. Covered structures will be deemed watertight if the drop in water level does
not exceed 10mm at the end of 7 days following an absorption period of 7
days.
END OF SECTION

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DIVISION 4 - MASONRY
04200 MASONRY
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to construct all
masonry work as shown and as specified herein.
B. The work under this Section is limited to the Concrete Reinforcement Section and, with
the exception of items embedded in concrete, is to be installed under this section.
C. The work under this section includes, but is not necessarily limited to, the following:
1. Block work
2. Masonry joint reinforcement, ties, and anchors
3. Buildings-in required precast components
1.02 RELATED WORK NOT INCLUDED
A. Other sections directly related to work covered in this section include the following:
1. Section 03300 - cast - in place concrete .
2. Section 05500 - Miscellaneous Metal
3. Section 07005 - Waterproofing and Dampproofing.
4. Section 07900 - Caulking.
1.03 SUBMITTALS
A. Submit to the Engineer, as provided in the Submittals Section, sample of block, joint
reinforcing, dovetail anchors, slots, blocks fixing ties, cavity trays, and proprietary cavity
closures.
B. Resubmit as required until acceptable.
C. Before commencing with the laying of any architectural masonry, construct on the
Site, where directed by the Engineer, one sample exterior wall panel, minimum
dimension, 2 meters by 1.3 meters of block showing type and tooling of mortar and
bond, block fixing ties, and movement joint for the Engineer's review. Reconstruct until
acceptable. Sample panels shall remain in place for the duration of the masonry work.
Remove sample panel at the completion of the work as directed by the Engineer.
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D. Certificates: Before commencing work submit agreement from

manufacturers of blocks that movement joints are located at positions recommended by
them.
1.04 MATERIAL DELIVERY, HANDLING AND STORAGE
1. General: deliver store and handle in accordance with manufacturer’s

recommendations.
2. Transport: Transport materials in cool containers and do not allow to stand in sun:
especially ensure that metal barrows and containers and boards for mortar and mortar
materials are cool.
3. Storage: keep blocks dry at all times; store on prepared areas free from clinker or
ashes or sulphate bearing soils; cover block stacks and sand piles with tarpaulins;
allow air circulation.
4. Storage: Store cement and lime above ground in dry structures and use in order of
delivery.
1.05 PROTECTION OF MATERIALS
A. All masonry materials for the work of this Section shall be delivered stored and
handled so as to preclude damage of any nature. Manufactured materials,
such as cement and lime, shall be delivered and stored in their original containers,
plainly marked with identification of material and maker. Materials in broken containers,
or in packages showing water marks or other evidence of damage, shall not be used
and shall be removed from the Site.
B. All masonry shall be shipped stacked with hay or straw protection or other suitable
protective device and shall be similarly stacked off the ground on the site. Masonry
shall be unloaded with suitable equipment or manually in manner to prevent damage.
Masonry units shall not be dumped from trucks. In addition, all masonry stored on the
site shall be protected from the weather and staining with the use of tarpaulins or other
covering acceptable to the Engineer.
1.06 PROJECT ENVIRONMENTAL CONDITIONS
A. Work in Adverse Weather: Except where precautions are taken to maintain

materials and ambient temperatures above 4°C do not mix mortar or lay blocks or dpc
material when temperature on falling thermometer reaches 4°C or until temperature
on ascending thermometer in shade reaches 4°C .
B. Take all necessary measures to ensure that block laying continues without
interruption during adverse weather.
C. Hot Weather Work: take all necessary steps to keep mortar and blocks and dpc and
other materials cool including :

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1. Do not mix mortar or lay units while shade temperature is above 40°C in a rising
thermometer or above 43°C on a falling thermometer.
2. Do not allow temperature of fresh mixed mortar to exceed 30°C. Take suitable
measures to ensure this.
D. Contractor is deemed to have allowed in his Tender for all steps necessary for
compliance with above.
1.07 ADJUSTMENT AND CLEANING OF COMPLETED WORK
A. Clean off mortar splashes and other stains from wall surfaces by scrubbing and
washing down with clean water. Do not use acids.
1.08 PROTECTION DURING PROGRESS OF WORKS
A. A Protect work from damage by heat, rain and frost. When humidity is less than 50%
and wind speed exceeds 4m/second provide shelter for wet mortar for at least 24 hours
after mixing to avoid dehydration.
B. B In any period of interruption and in hot weather protect from damage; use approved
coverings that extend down both sides of exposed walls to cover work done in
previous 24 hours and permit free air flow and prevent heat build up.
C. Prevent all blocks from becoming wet.
1.09 PROTECTION OF COMPLETED WORK
A. A Keep completed wall clean and protect from staining.
PART 2: MATERIALS
2.01 MATERIALS :
Cement: Cement shall be Sulphate Resisting Portland Cement to BS 4027:Part 2: 1972 for
work upto the top of the structural ground slab and Ordinary Portland Cement to BS 12
for work above this level
Water: Water shall conform to the requirements specified for water in the "Concrete Work"
section.
Aggregate: Aggregate shall conform to the requirements specified for aggregate in

the "Concrete Work" section.
Additives: Additives to mixes for blocks and mortar shall be from approved manufacturers
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and shall be used strictly in accordance with the manufacturer's instructions. Additives shall
only be used with the Engineer's written instruction.
Wall Ties: Wall ties shall be galvanised wire butterfly-type wall ties to BS 1243.
Damp-Proof Course: Damp-proof course, cavity trays and the like shall be of rubber/bitumen
compound coated polythene membrane 1.5 mm thick obtained from an approved
manufacturer. The membrane shall be of a type suitable for hot climates.
Sand: Sand used shall be approved washed clean sand as per Dubai Municipality
requirements.
A. Aggregates for Use in Blocks for Fire Rated Walls: To BSCP 121; Part 1 (Notes to
Table5) using Class 1 aggregate for 90mm and class 1 or 2 for other blocks.
B. Blocks for Fair Face work are to be specifically manufactured for purpose.
C. Do not use tongued and grooved blocks without the Owner’s permission.
D. Surfaces of blocks that are to receive plaster or render to be suitably textured and
capable of receiving plaster or tender without addition of bonding measures.
2.03 MATERIALS - TIES
A. Cavity Walls: Use approved galvanized vertical twist type wall ties complying with
the requirements of BS 1243, or others having at least equivalent strength and stiffness,
all in accordance with the minimum spacing and embodiment requirements of BS 5628
Pt. 1.
B. Double Leaf (Collar Jointed Walls): Use approved galvanized flat metal wall ties in
accordance with the requirements of BS 5628 Pt1 clause 29.5 and the requirements of
BS 1243.
C. Single Skin Walls: Use approval galvanized ties in accordance with the requirements
of BS 1243 & BS 5628.
2.04 MATERIALS - MOVEMENT JOINTS
A. Movement Joint Sealant: Movement joint sealant shall be suitable for the purpose
intended and used in accordance with manufacturers instructions.
B. Movement Joint Sealant: For joints in brickwork, and for joints between door/window
frames and brickwork electrometric sealants where material will be concealed from
weather.
C. Movement Joint Bond Breaker: Polythene tape or other plastic tape as recommended
by sealant manufacturer.
D. Movement Joint Filler: For vertical joints..

E. Movement Joint Filler: for horizontal joints in concrete or steel frame building
between concrete and top of block walls built up to underside of concrete a bitumen
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bound wood fiber or cork granule board.
F. Suitable ties provisions to be made for transfer of lateral shear across all movement
joints.
G. Sleeved sliding ties to be used to laterally support tops of blockwork walls to ensure no
vertical load is transferred from the structural elements on to the blockwork walls.
H. For all movement joint spacing refer to architect drawings and the manufactures
specification.
MANUFACTURE OF CONCRETE BLOCKS
Blockwork shall comply with BS 2028 and all block work shall comply with Dubai Municipality
required and to the local order No. 44 in regard to the construction and thermal insulation.
All block work shall be supplied by approved manufacturer from Dubai Municipality and shall have
Test Certificate from Dubai Municipality central laboratory.
All external block works shall be 250 mm (10” inch) concrete block with Polystyrene insert with
minimum following specifications and shall be approved by Dubai Municipality central laboratory to
comply with local order in regard to the building insulation.
Materials System Specification

K
BTU IN/h.ft2.F 0.791
DENSITY
Lb/ft3 84.375
R
Ft2 h/Btu 9.968
Mass
Lb/ft2 56.250
Aggregate shall be so sized, graded, proportioned and thoroughly mixed in a batch mixer with such
proportions of cement and water as to produce homogeneous concrete.
The recommended mix to obtain the compressive strength and finish required is as follows:
• 50 kg sulphate resisting cement

• 0.15 m3 fine aggregate (graded up to 4.8 mm)
• 0.30 m3 coarse aggregate (graded up to 9.5 mm)
Precast concrete blocks shall be manufactured in approved vibrated machines. If for any reason
the strength requirement is not achieved, the cement shall be increased at the Contractor's own
expense. The water used in the mix shall be clean and of a sufficient quantity to allow complete
hydration of the cement without providing an excess when moulding.
Concrete blocks shall be used hard, sound, durable, sharp rectangular shape, clean with well
defined arises free from cracks, flaws and other defects.
Concrete blocks shall be either obtained from an approved local factory or manufactured on the
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Site. If manufactured on site, the blocks shall be press moulded in approved moulds and vibrating
pressure machines with a minimum of
2800 cycles per minute.
Closures and half blocks shall be purpose made; cut blocks shall not be used.
Block manufactured on the site shall be cured in the shade by being kept thoroughly moist with
water applied by sprinklers or other approved means for a period of at least (7) days. The blocks
shall be stacked on a clean and level platform free from earth or other impurities during process,
and shall be stacked in honeycomb fashion after curing. The blocks shall not be used prior to one
(1) month after the date of manufacture, nor shall any blocks be used that have not been inspected
and approved by the Engineer.
• Concrete blocks (solid or hollow) shall be of the following dimensions:

• Height - 200 mm plus minus 1% Tolerance
• Length - 400 mm plus minus 1% Tolerance
• Width - As required plus minus 1% Tolerance
The nominal width of blocks shall be as indicated on the Drawings and as directed in writing by
Engineer. Concrete blocks shall comply with the following requirements:-
Compressive Strength at Twenty Eight (28) days

Over Net Area: -
Blocks shall be required to withstand a test load of minimum 7 N/mm2 over the net area of the net
area of the blocks, and solid blocks shall be required to withstand a test load of minimum
10.5N/mm2 over the net area of the blocks.
Water Absorption
20% or less or dry weight.
The design of the cavities and webs of the hollow concrete blocks shall be submitted to the
Engineer prior to the manufacture. The thickness of the face shell and of the membrane of solid
portions shall be nowhere less than forty-(40) mm. The combined thickness of the solid portions
shall be not less than one fourth ( 1/4) of the width and length of the block respectively.
2.05 MORTAR MATERIALS
Mortar shall be prepared with the addition of the minimum quantity of clean water for workability.
Cement and sand mortar (1:4) mix, shall be composed of one part cement to four parts of sand by
volume. Mortar for frames and elsewhere as required shall be one part Portland cement one part
sand.
A. Sand shall be washed, non-salted durable particles, free from injurious amounts of organic
matter.
B. Water shall be free from injurious amounts of oils, acids, alkalis or organic matter, and
shall be clean and fresh.
C. White Cement: to BS 12.
D. Colored Mortar: shall obtain its color from pigments complying with BS 1014 and color of
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mortar shall be approved by the Engineer as part of a sample panel.
E. Admixtures: do not use admixtures, other than plasticiesers, without prior approval. Do not
use calcium chloride or any admixtures containing calcium chloride.
PART 3: EXECUTION
3.01 MORTAR
A. Mortar shall be machine mixed in an approved type of mixer in which the quantity of
water can be accurately and uniformly controlled. The mixing time shall not be less
than 5 minutes, approximately 2 minutes of which shall be for mixing the dry materials
and not less than 3 minutes for continuing the mixing after the water has been added.
Where hydrated lime is used for mortar requiring a lime content, the Contractor will have
the option of using the dry-mix method or first converting the hydrated lime into a putty.
Where the dry-mix method is employed, the materials for each batch shall be well
turned over together until the even color of the mixed, dry materials indicates that
the cementitious material has been thoroughly distributed throughout the mass, after
which the water shall be gradually added until a thoroughly mixed mortar of the
required plasticity is obtained.
B. Mortar boxes shall cleaned out at the end of each day's work, and all tools shall be kept
clean. Mortar that has begun to set shall not be used.
3.02 MASONRY - INSTALLATION
A. All block shall be laid in full beds of mortar with shoved joints and with all joints shushed
solidly in each course. Block shall be damp when laid. All block work shall be laid up
from an outside scaffold and shall be carried up simultaneously at an approximate level.
Block receiving minor handling defects, if allowed to be used, shall be used in surfaces
to be plastered.
B. All masonry shall be laid a full bed of mortar, applied to shells only.
Butter the vertical joint of unit already set in the wall and all contact faces of the unit to
be set. Each unit shall be placed and shoved against the unit previously laid so as to
produce a well-compacted vertical mortar joint for the full shell thickness. Units shall
set with all cells in a vertical position. The moisture content of the units when laid shall
not exceed 35 percent of the total absorption as determined by laboratory test.
C. All masonry shall be laid in stretcher (running) bond. Fill all joints with mortar dense
and neat. Joints shall be 10 mm wide with all joints uniform. Course out brick equally
between columns as approved maintaining joint width.
D. Sizes shall be as specified and called for on the drawings, and the space between face
and the backup material shall be shushed full of mortar.
E. Joints of all masonry shall be tooled in accordance whit the following:

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1. Wait until unit mortar is thumbprint hard before tooling joint. This may require as
much as 3 hours in the shade and 1 hour or less in the sun.
2. The required personnel shall be kept on the job after hours, if necessary,
to properly tool joints.
3. Where masonry is to receive plaster finish, rake joints back 10mm.
4. At exposed facing brick, tool joints slightly concave.
F. Coordinate with the work of installing pressed metal frames. Fill frames fully with
mortar.
G. Control joints using compressible fillers shall be installed at the intersection of

masonry walls with structural concrete and elsewhere as detailed on the drawings. The
maximum length, horizontally, between vertical control joints shall be 16 meters but
joints shall be located only as directed or indicated. Joints shall be equal in width to the
standard mortar joint.
H. All masonry slots, chases, or openings required for the proper installation of the work of
other sections shall be constructed as indicated on the drawings or in accordance with
information furnished before the work is started at the points affected. No chase shall
cut into any wall constructed of hollow units after it is built, except as directed and
acceptable to the Engineer.
I. Surfaces shall be brushed as work progresses and maintained as clean as it is

practicable. Unfinished work shall be raked back where possible, and toothed only
where absolutely necessary. Before leaving fresh or unfinished work, walls shall be
fully covered and protected against rain and wind and before continuing work previously
laid shall be swept clean. The tops of walls or other unfinished work shall be protected
against all damage by the elements by means of waterproof paper, tarpaulins, boards or
other means acceptable to the Engineer.
J. Build in all miscellaneous items to be set in masonry for which placement is not
specifically provided under separate Divisions, including reglets, precast concrete and
ties, electrical panel boxes, sleeves vents, grilles, anchors, grounds, and electric
conduits and fixtures. Cooperate with other trades whose work is to be coordinated
with the work under this section.
K. All anchorage, attachment, and bonding devices shall be set so as to prevent slippage
and shall be completely covered with mortar.
L. All ties and reinforcing for masonry shall be furnished and installed under this section.
M. Space ties as follows :
To columns (Abutting or not exceeding 450mm centers vertically, passing walls)

placing on each side of any movement joint.
To Edge Beams not exceeding 450 centers horizontally in one row along face of
edge beam at each floor level.
To Openings and at Vertical provide additional ties within 150 mm of Movement joints
edges at not exceeding 450mm vertical centers.
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N. Install vertical masonry reinforcement where indicated on the drawings or specified

herein.
O. Aluminum: Any aluminum surface that will be in contact with block or mortar is to be
painted with black bitumen coating solution to BS 3416 Type 1. Ensure that protective
coating is adequate and if not arrange of a further coat of bitumen to be applied.
P. Concrete Blocks: Protect and keep dry at all times.
Q. Concrete Blocks: Where items requiring strong solid fixings are to be fixed to blockwork
e.g. radiators hanging cupboards provide solid (100%) blocks of fixing bricks to receive
fixings
R. Block Nibs Against Steel or Concrete: Where nibs less than 200mm in length occur
against steel or concrete surfaces tie nibs to, steel or concrete using dovetail
anchors at not exceeding 230mm vertical centres placed in vertical metal slots cast in
concrete, or shot fired into steel.
S. Reinforcement: Where length of an internal partition wall exceeds 5m in unbroken

length provide continuous horizontal reinforcement in each alternative course of
blockwork: bed on and surround with mortar and keep back 12mm from faces. Provide
for.
Block work shall be built to the following tolerances:
Tolerance on Line:
Length up to and including 5m ±5mm

Length over 5m ±10mm
Tolerance on Height and Level :

Height up to and including 5m ±5mm
Height over 5m ±10mm
Tolerance on Plumb:
Plumb of wall in 5m height ±5mm
STRUCTURAL BRACING
Any block wall covering more than 14 square meter area shall be braced vertically by
dummy columns and horizontally by dummy beams at lintel level. Such columns and
beams shall be of section 200mm x 200mm in 200mm thick wall and shall be 100mm x
200mm in 100mm thick wall and so on. The detailed design of steel reinforcement and
spacing of such columns and beams shall be decided and approved by the Engineer.
The contractor shall be responsible for obtaining such design and approval from the
Engineer, well in advance before starting of super structure works in view of providing
necessary dowel bars for dummy columns and beams. The price of blockwall shall
include all such activities and cost of such dummy structures in the wall.
Horizontal layer of expanded metal to be provided at every 5 layers of the block wall.
All Blocks shall be sprinkled with water before laying and galvanized wall ties
8"X3"X3mm Min. shall be fixed by Gun to concrete columns every 2 layers of block
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work, alternatively.
All cutting for services in the concrete block shall be with mechanical cutter i.e., grinder.
Curing for block works shall be 3 days.
Damp proof coarse layer shall be provided below external walls, bath and kitchen walls.
3.03 CLEANING
All holes in exposed masonry shall be pointed, and defective joints shall be cut out and repointed
with mortar of same color as that of the original and adjoining work.
Exposed masonry shall be protected against staining by wall coverings, and excess mortar shall be
wiped off the surface as the work progresses.
All exposed masonry shall be thoroughly cleaned. Before applying any cleaning agent to the entire
wall, it shall be applied to a sample wall area of approximately 2 square meters in a location
approved by the Engineer. Use only those cleaning agents recommended by the brick
manufacturer. No further cleaning work may proceed until the sample area is acceptable to the
Engineer, after which time the same cleaning materials and method shall be used on the remaining
wall area.
3.04 FIELD QUALTIY CONTROL
A. Tests: take samples of fresh or hardened mortars when directed, and submit to approved
testing laboratory for testing of compressive strength to BS 5628: Part 1 including
preliminary and site tests at 7days and 28days. Arrange for copies of test report to be
sent directly o to the
B. Engineer from laboratory within 7days of completion of test.
C. Testing solid concrete blocks: ten blocks from each batch are to be selected by the
engineer for testing for compressive strength.
D. Testing hollow concrete blocks: ten blocks from each batch are to be selected by the
Engineer for testing for compressive strength.
END OF SECTION

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DIVISION 5 – METALS
05500 MISCELLANEOUS METALS
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor materials, equipment and incidentals required to provide all
miscellaneous metal as indicated and as specified herein.
B. Miscellaneous metal work include items made from iron and steel shapes, plates, bars,
strips, tubes, pipes and castings which are not specified in other sections of these
specification .
C. This Section cover the following miscellaneous metal items :
1. Steel cat-ladder.
2. Steel access door.
3. Floor Channels and gratings.
4. Other miscellaneous metal works
1. Installation of embedded miscellaneous metal items is included in Division 3 and 4.
2. Masonry reinforcement, masonry ties and anchor slots are included in Division 4.
1.03 SUBMITTALS
A. Submit detail drawings, as provided for in Section 01300, showing sizes of members,
method of assembly, anchorage, and connection to other members.
B. Field measurements shall be taken at the site to verify or supplement indicated

dimensions and to insure proper fitting of all items.
C. Samples: Submit 2 sets of representative samples of materials and finished products

as may be requested by Architect.
1.04 COORDINATION
A. The work of this Section shall be completely coordinated with the work of other Sections.
Verify at the site both the dimensions and work of other trades adjoining items of work in
this Section before fabrication and installation of items herein specified.
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B. Furnish to the pertinent trades all items included under this Section that are to be built into
the work of other Sections.
1.05 REFERENCE SPECIFICATIONS
A. Unless otherwise specified, materials shall conform to the following:
Structural Steel ASTM A36

Structural Tubing ASTM A500, Grads B
Welded and Seamless Steel pipe ASTM A53
Gray Iron Castings ASTM A48, Class 30
Galvanizing, general ASTM A123
Galvanizing, hardware ASTM A153
Galvanizing. assemblies ASTM A386
Aluminum (Extruded Shape) 6061 T6
Aluminum (Extruded Pipe) 6063 T6
Aluminum sheet, Plate and Rolled Shapes 6061 T6
Anchor Bolts and Nuts ASTM A320, Grade B8
Stainless Steel Bolts, Bars, & Shapes AISI, Type 304
Stainless Steel Plate and Sheet AISI, Type 302
Welding Rods for Steel AWS Spec. for Arc
Welding (Type E70XX)
High Strength Steel Bolts, Nuts & Washers ASTM A325 mechanically
galvanized per ASTM B454
Screws Stainless Steel, IFI-104,
Grade 303 or 305
PART 2 : PRODUCTS
2.01 MATERIALS
A. Ferrous Metals
1. Metal Surfaces, General : for fabrication of miscellaneous metal work which will be
exposed to view, use only materials which are smooth and free of surface blemishes
and including pitting, seam marks, roller marks, rolled trade names and roughness.
2. Steel Plates, shapes and bars : ASTM A 36 or BS 1449 .
3. Steel bar grating: ASTM A 569 or ASTM A 36
4. Steel tubing: cold formed, ASTM A500; or hot-rolled, ASTM A 501, BS 4848, or BS
2994.
5. Structural steel sheet: hot-rolled, ASTM A 570; or cold-rolled ASTM A611, class 1; of
grade required for design loading.
6. Galvanised structural steel sheet : ASTM A 446, of grade required for design loading.
Coating designation as indicated, or if not indicated, G90.
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7. Steel pipe : ASTM A 53 or BS 4848. Type and grade as selected by fabricator and
as required for design loading; black finish unless galvanizing is indicated; standard
weight (schedule 40), unless otherwise indicated.
8. Grey iron castings : ASTM A 48, Class 30, or BS 1452 .
9. Malleable Iron castings : ASTM A 47, grade as selected by fabricator.
10. Brackets, flanges and anchors : cast or formed metal of the same type material and
finish as supported rails, unless otherwise indicated.
11. Concrete inserts : threaded or wedge type; galvanised ferrous castings, either
malleable iron, ASTM A 47, or cast steel, ASTM A 27. Provide bolts, washers and
shims as required, hot-dip galvanized, ASTM A 153.
B. Grout
1. Non-Shrink Non-Metallic Grout: Pre-mixed, factory-packaged, non- staining, non-

corrosive, non-gaseous grout complying with CE CRD- C621. Provide grout
specifically recommended by manufacturer for interior and exterior applications of
type specified in this section.
C. Fasteners
1. General : Provide zinc-coated fasteners for exterior use or where built into exterior
walls select fasteners for the type, grade and class required.
2. Bolts and Nuts : Regular-hexagon head type, ASTM A 307, Grad A, or BS 1768.
Lag Bolts : square head type, FS FF-B-561 .
Machine Screws : cadmium plated steel, FS FF-S-92, or BS 4183 .
Wood screws : flat head carbon steel, FS FF-S-111, or BS 1210.
Plain washers : round, carbon steel, FS FF-W-92, or BS 3410 .
Masonry anchorage devices: expansion shields, FS FF-S-325, or BS 5050.
Toggle bolts : tube-wing type, FS FF-S-589, type, class and style as required.
Lock washers : helical spring type carbon steel, FS FF-W-84.
D. Paint
1. Shop primer for ferrous metal : manufacturer’s or fabricator’s standard, fast-

curing, lead-free primer; selected for good resistance to normal atmospheric
corrosion, for compatibility with finish paint systems indicated and for capability to
provide a sound foundation for field-applied topcoats despite prolonged exposure;
complying with performance requirements of FS TT-P-645.
2. Shop primer for ferrous metal : fast-curing, lead-free, abrasion- resistant, rust-
inhibitive primer selected for compatibility with substrates and with types of alkyd-
type finish paint systems indicated, and for capability to provide a sound foundation
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for field-applied topcoats despite prolonged exposure; complying with performance

requirements only of FS TT-P-86, Types I, II, and III.
3. Galvanizing repair paint : high zinc dust content paint for regalvanising
welds in galvanized steel.
4. Polyester Powder Coat Finish :
a. Is to be polyester resin powder electrostaticlly applied of high quality metallic

enamel car paint and baked to give minimum thickness of 70 microns, to meet
the requirements of BS 6496. Colour to be select by the Engineer. Manufacturer
is to provide a 10 year warranty, agreeing to repair or replace defective coating,
defined as abnormal deterioration, aging or weathering or loss of adhesion.
2.02 STEEL ITEMS
A. General:
1- Steel Items shall be fabricated of steel bars, shapes, plates and pipe pieces as
shown, with full circumferential and longitudinal welds as required, ground smooth as
approved. Galvanize after fabrication. Bolts, nuts, washers and other required
hardware for hinges and for securing of components shall be stainless steel.
2- Miscellaneous sleeves not specified in other Sections shall be steel or cast iron pipe
in walls and floors with end joints as shown on the Drawing. All pipe sleeves shall
have center anchor around circumference.
3- Miscellaneous steel shall be fabricated and installed as shown and shall include
anchor bolts, lifting hooks, porous checkered plate, miscellaneous steel called for on
the Drawings and not otherwise specified.
B. Cat - ladder : are to be constructed of galvanized steel pipes sections of sizes and
dimensions shown on the drawings. Units are to be complete with bolt fixings.
C. Steel access door: constructed from hollow steel section frames and 1.2 mm thick
galvanized steel sheet and all other steel members as shown on drawings, finished with
high quality paint electrostaticly baked applied and all associated accessories; size and
shapes as shown on drawings.
D. Floor Channels and gratings: Stainless steel floor channels and straight bar gratings, of
medium duty, as shown on the Drawings.
Refer to the Manufacturers list
G Other miscellaneous metal works: Shall be hollow tubes, solid steel bars sections and
plates of sizes and dimensions shown on the drawings, welded and jointed together, of
types, dimensions and patterns shown on the Drawings
1. Painting: shall be Polyester Powder Coat Finish for all steel members

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PART 3: EXECUTION
3.01 FABRICATION
A. All miscellaneous metal work shall be formed true to detail with clean, straight, sharply
defined profiles and smooth surface of uniform color and texture and free from defects
impairing strength or durability.
B. Connections and accessories shall be of sufficient strength to safely withstand

stresses and strains to which they will be subjected. Steel accessories and connections
to steel or cast iron shall be steel, unless otherwise specified. Threaded connections
shall be made so that the threads are concealed by fitting.
C. Welded joints shall be rigid and continuously welded or spot welded as specified or
shown. The face of welds shall be dressed flush and smooth. Exposed joints shall be
close fitting and jointed where least conspicuous.
D. Welding of parts shall be in accordance with the standard AWS practices for arc and gas
welding. All welding shall be done only by welders certified as to their ability to perform
welding in accordance with the requirements of the AWS Code. Component parts of built-
up members to be welded shall be adequately supported and clamped or held by other
adequate means to hold the parts in proper relation for welding.
E. Welding of aluminum work shall be on the unexposed side as much as possible in order
to prevent pitting or discoloration. All welding and other fabrication shall be done before
anodizing.
F. All aluminum finish exposed surfaces, except as specified below, shall have
manufacturer's standard mill finish. Aluminum handrails and sunshade components shall
be given an anodic oxide treatment in accordance with the Aluminum Association
Specification AA-C2-A41. A coating of methacrylate lacquer shall be applied to anodized
aluminum before shipment from the factory.
G. All non-galvanized steel miscellaneous metal work shall be prepared and primed in shop
after fabrication as specified in Section 09901. Abrasions and welding damage of primer
in the field shall be touched up with the primer used immediately after erection.
H. All steel items not specified to be painted shall be galvanized.
3.02 INSTALLATION
A. Install all items furnished except items to be embedded in concrete or other masonry
which shall be installed under Division 3 and Division 4 respectively. Items to be
attached to concrete or masonry after such work is completed shall be installed in
accordance with the details shown or suitable alternate method. Fastening to wool plugs
in masonry will not be permitted. All dimensions shall be verified at the site before
fabrication is started.
B. All steel surfaces to come in contact with exposed concrete or masonry shall receive a
protective coating of an approved heavy bitumastic troweling mastic applied in
accordance with the manufacturer's instructions prior to installation.
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C. Where aluminum contacts a dissimilar metal, apply a heavy brush coat of zinc. chromate
primer followed by two coats of aluminum metal and masonry point to the dissimilar metal.
D. Where items are cast into concrete, backpaint with the above paint the contact areas
before setting.
E. Anchor bolts and expansion bolts shall be set accurately. Where indicated on
Drawings, specified, or required, anchor bolts shall be provided with head or nut
embedded in concrete or suitable pipe sleeves, or both. Where indicated on the
Drawings, specified, or required, anchor bolts shall be provided with square plates or shall
have square heads and washers to be set in the concrete forms with suitable pipe
sleeves, or both. If anchor or expansion bolts are set after the concrete had been placed,
all necessary drilling and grouting or caulking shall be done and care shall be taken not to
damage the structure or finish by cracking, chipping, spalling, or otherwise during the
drilling and caulking. Minimum distance between the center of any expansion anchor
and an edge or exterior corner of concrete shall be not less the 4-1/2 times the diameter
of the hole in which it is installed.
F. Where galvanizing is damaged by field welding or other erection process, an approved

95% zinc dust primer shall be applied to the properly prepared damaged areas.
G. Welding
1. Ferrous Metal Welding. Permissible weld stress for all structural fillet welding provided
under these specifications shall be as tabulated in AWS D1.1 except as specified
herein. The allowable shear stress on the effective throat of a fillet weld shall not
exceed 124 MPa for ASTM A36, ASTM A441, and ASTM A588 steels. "Effective
throat" shall be the shortest distance form the root to the face of the diagrammatic weld
regardless of weld size.
a. Except as otherwise specified, welding shall be performed using only those

joint details which have a prequalified status when performed in accordance with
the AWS code and the AISC specification.
b. Welds that are not dimensioned on the construction drawings shall be sized to
develop the full strength of the least strength component involved in the
connection.
2. Aluminum Welding. Welding and brazing of aluminum shall be in accordance with the
recommendations of the Aluminum Association as contained in its publications,
"Welding Aluminum" and "Aluminum Brazing Handbook". All welding rod, filler wire ,
brazing wire flux, and other materials used in such welding shall be as recommended
by the Aluminum Association for use in conjunction with the alloy to be welded in each
case.
END OF SECTION

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DIVISION 7 – THERMAL AND MOISTURE PROTECTION
07005 WATERPROOFING AND DAMPPROOFING
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all materials, labor, and equipment required to perform all waterproofing of
cast-in-place concrete, waterproofing exterior, dampproofing, protection board and related
work necessary for the proper completion of the project as required by the drawings and
as specified herein.
B. Work required in conjunction with the cement plaster waterproofing shall be conducted by
an organization which specializes in waterproofing and has an established reputation for
having satisfactorily done such work. The work shall not be done by workmen regularly
employed on general contract work. Specifications for this work must be read with care
by bidders before bids are received and by all parties during construction.
1.02 GUARANTY
A. As a condition of this Section furnish the Owner with a written guaranty that the
dampproofing membrane and the liquid waterproofing work upon completion will be
waterproof for a period of five years and that during this time all defects in the
waterproofing or bonding, or leaks which may develop through the surface, shall be
promptly repaired at no expense to the Owner, provided such leaks and defects are
not due to causes beyond control of this section.
1.03 APPLICATION SCHEDULE
A. Dampproof the all surfaces of all cast-in-place concrete walls, foundations,

columns and ground beams in contact with soil from the bottom of the footings up to
floors dampproofing layer, and shall be applied below foundations and footings.
B. Masonry waterproofing material shall be applied to all exterior above grade block
masonry surfaces.
C. Floors dampproofing membrane shall be applied below ground slabs and wet areas and
planters, as shown on drawings.
1.04 SUBMITTALS
A. Submit to the Engineer, as provided in Submittals Section for shop drawings,

detailed information on materials proposed and installation methods.
B. Submit two sets of representative samples of any or all proposed materials required
for the work of this Section as requested by the Engineer.
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D. Submit to the Engineer for review, the manufacturer’s specifications and instructions for
materials and installation. These specifications and instructions shall be as required to
provide the detailed drawings.
1.05 DELIVERY, STORAGE AND HANDLING
A. All perishable materials for the work of this Section shall be delivered, stored and
handled so as to preclude damage of any nature. Manufactured materials shall
be delivered and stored in their original containers, plainly marked with identification of
material and maker. Materials in broken containers, or in packages showing water marks
or other evidence of damage, shall not be used and shall be removed from the site.
1.06 JOB CONDITIONS
A. Hot Weather Requirements
1. Protect fresh membrane from hot sun as approved.
2. Provide artificial shade, wind breaks and use cooled materials, as required.
PART 2: MATERIAL AND LOCATION
2.01 Substructure
Foundation, under slabs on grade and planters etc.
Provide Elastic THIXOTROPIC get type, liquid applied water proofing treatment made by
emulsifying, high quality bitumen blend, modified with SBS elastomers, antioxidants
and stabilizers which on drying shall form continuous layer of impermeable water proofing
lining. Apply by using roller trowel or spatula in two coats each coat average DFT 1.2 – 1.4
mm – overall thickness 2.5 mm to manufacturer’s instructions
Typical Coating Materials Properties shall be as follows: Technical Data:
Specific Gravity 1.5

Ultimate elongation of membrane >1000%
Resistance to heat 100°C no flow for 2 hours
Tensile strength >22 N/cm2
Adhesion to cement/concrete >200 N/5 cm
Drying time 1 Dust free 1 hour
Drying time 2 Touch dry 8 hours

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2.02 Underground Water Tank

4 mm thick modified Bitumen based water proofing membrane with non woven polyester,
torch applied are layer to external surface areas with 3 mm protection board and
internal areas minimum 4mm thick GRP lining complying as per specification and drawings.
2.03 Wet Areas
Kitchen, pantry, bathrooms, toilets, laundry, wash areas, pump rooms, liquid applied
polyurethane membrane “marisel-250” or equivalent minimum 2 mm thick to floor and to walls
near bath tub 90cm high & other side of walls 20cm high.
The substrate must be flat, dry and clean. Provide underlay (Geotextile 300 gr/m2 ). Unroll
and align RESISIT RET with laps of 70 mm. In order to prevent creasing each overlap to be
pre-fixed with Phoenix Paste FP75. Primer overlap area with Phoenix FG35 primer. Apply the
tape in the overlap. Laps to be heat-welded over a width of 40mm.
Provide a protective layer over the RESISTIT RET (Geotextile or protection board).
B Material for internal surfaces of tanks waterproofing shall be proprietary chemical

compound mixed with water and reacting with free lime and water in concrete to
produce an integral crystalline waterproof surface.
Refer to the Manufacturer list
C Primers, bonding compounds, adhesives and the like are to be types recommended for
purpose by sheet manufacturer.
D Protection board for surfaces in contact with soil: shall be one layer performed
bitumen impregnated fiber filler board as recommended by bituminous sheet
manufacturer.

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PART 3: EXECUTION
3.01 GENERAL
A. All installation shall conform to the acceptable shop drawings and the system and
materials manufacturer’s specifications and instructions as submitted and reviewed.
3.02 SUBSTRATE SURFACE
A. Concrete surfaces shall be free of roughness or projections, with a clean surface, finished
as specified under concrete finishes section which will allow an even application of the
membrane and insulation.
B. Surfaces shall not contain any grease, oil or any other contaminants which could affect
the complete bonding of the membrane to the concrete surface.
C. Surfaces shall be visibly dry and thoroughly cleaned, (remove all dust, dirt, and loose
materials) immediately prior to application of membrane. Compressed air, vacuum cleaner
or other suitable means shall be used.
3.03 INSTALLATION
A. Installation of Waterproofing on Exterior Masonry
1. Waterproofing shall be applied only after all joints have been caulked and properly
cured. Surfaces shall be clean and free from excess dust. New masonry surfaces shall
be allowed to cure 30 days prior to application. Surfaces shall receive two complete
coats at rates recommended by the manufacturer and as approved. The complete
installation shall be in strict compliance with the manufacturer's instructions as
approved.
B. Installation of Waterproofing on concrete surfaces
1. Two layer bituminous sheet: lay underlayer and capsheet at right angles to each other
with 75mm side laps and 100mm end laps. Bond underlayer to base, and capsheet to
underlayer by torching lower surface of membranes and seal by firm pressure. Seal
laps by torching and pressing down with rounded tip of scraper or spatula.
2. Single layer bituminous sheet : lay with 75mm side laps and 100mm end laps, torch
lower surface of sheet and seal to base by firm pressure and seal laps by torching in
accordance with manufacturer’s instructions.
3. Pipes Etc. : where pipes etc. pass through sheeting make junctions completely
watertight by forming collars fully bonded or sealed to both pipes and sheeting.
4. Inspection: inform the Engineer a reasonable length of time before covering any part of
membrane with overlying construction to allow inspection.

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5. Protect finished sheeting and prevent puncturing during following work. Cover
sheeting with permanent overlying construction as soon as possible. Immediately prior
to covering check for damage and repair as necessary.
C. Installation of Coatings
1. Dry surfaces : dampen before applying water based bitumen emulsion.
2. Apply coatings generally in accordance with manufacturer’s recommendations

to clean, dry surfaces, in dry atmospheric conditions, after primer has dried and after
previous coats have hardened.
3. Ventilation : spaces in which coatings are to be applied are to be well ventilated.
4. Cold and Hot applied bitumen : apply number of coats to thickness and at rate of
application recommended by coating manufacturer or as stated in bill of quantities.
5. Chemical waterproof coating : mix dry powder with water on site and apply mixture to
pre-wetted surfaces in number of coats and at rate of application recommended by
coating manufacturer.
6. Brushing : work coating into recesses, edges, joints, intersections and over surfaces
generally to obtain uniform and continuous film.
7. Intersections : ensure continuity of coatings including at junctions with other

membranes.
8. Covering : final covering is to be laid/applied as soon as possible after coating has

hardened.
END OF SECTION

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SECTION 07193 VAPOR BARRIER
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to install vapor
barriers under concrete slabs over Class A1a subgrade for external works where
indicated and as specified herein.
PART 2: PRODUCTS
2.01 MATERIALS
A. Vapor barrier shall be 250 micron (10 mil) thick polyethylene sheet with a vapor
transmission rating of 0.20 perms or less. Provide with polyethylene tape recommended
to seal joints in vapor barrier.
PART 3: EXECUTION
3.01 INSTALLATION
A. Vapor barrier shall be installed under slabs-on-grade and at other locations

indicated. Laps between adjacent sheets shall be 250 mm minimum and taped
continuously together with polyethylene tape. Vapor barrier will be carefully inspected
prior to concrete placement by the Engineer. Additional polyethylene sheet required for
repair and replacement of damaged vapor barrier shall be furnished and installed as
directed by the Engineer at no additional cost to the Owner.
END OF SECTION

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SECTION 07200 INSULATION
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all materials, labor, and equipment required to install wall insulation
materials as required by the drawings and as specified herein.
1.02 RELATED WORK
1. Section 03300 - Concrete.
2. Section 04200 - Masonry.
3. Section 04400 Natural Stone Slab Cladding.
1.03 SUBMITTALS
A. Submit to the Engineer, as provided in the Submittals Sections, detailed information on
materials proposed and installation methods.
B. Submit one set of representative samples of any or all proposed materials required for
the work of this section as requested by the Engineer.
C. Submit to the Engineer for review, the manufacturer’s specifications and instructions for
materials and installation.
1.04 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. All materials for the work of this Section shall be delivered, stored and handled so as to
preclude damage of any nature.
B. Protect insulations from physical damage and from becoming wet or soiled.
Comply with manufacturer’s recommendations for handling, storage and protection
during installation.
PART 2: PRODUCTS
2.01 MATERIALS
A. Rigid insulation shall be Extruded Polystyrene Insulation Board; 50mm thickness, to

have the following minimum properties:
density : DIN 53420 : 32-35 kg/m3

thermal conductivity
(5 years age value
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at 24 deg. C) : ASTM C-518 : 0.032 W/m deg K

compressive strength
at 5% compression : ASTM D-1621 : 0.245 N/mm2
water absorption : ASTM D-2842 : 1% by volume
PART 3 : EXECUTION
3.01 CLEANLINESS:
A. Keep cavities and ties free from mortar and debris with laths or other suitable means.
Before mortar sets, clean bottom of cavity through holes as necessary. Make good to
holes on completion.
3.02 INSTALLATION OF EXTRUDED POLYSTYRENE BOARD :
A. Fix securely with tightly butted joints, ensuring that:
1. edges are not damaged
2. top edges are covered with a temporary batten to ensure that they remain completely
free of mortar droppings, grout and other debris
3. all parts of inner leaf cavity face are covered.
B. Place and secure each course of insulation before building up inner leaf above level of
previous course of insulation.
END OF SECTION

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SECTION 07500 ROOFING SYSTEM
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to install membrane
roofing system with insulation and all roofing system accessories and finishing materials
as shown on the drawing and specified herein.
1.02 SUBMITTALS
A. Submit to the Engineer as provided in Section 01300 shop drawings showing details of
construction and erection of roofing system and components and detailed technical data
on membrane and other materials proposed. Include independent laboratory testing
results certifying that submitted components and materials meet this Specification.
B. Provide, with shop drawings, certification that the roofer who will execute the work is an
experienced applicator of the roofing system proposed.
C. Submit to the Engineer for review, two representative samples of all roofing
components and materials. Board and sheet stock samples shall be 300 mm square or
long, minimum.
D. Submit to the Engineer for review, the manufacturer's specifications and instructions for
materials and installation of the insulated roofing system. These specifications and
instructions shall be as required to provide the detailed roofing system.
A. All perishable materials for the work of this Section shall be delivered, stored and
handled so as to preclude damage of any nature. Manufactured materials, such
as base sheets, felts, cement and lime, shall be delivered and stored in their original
containers, plainly marked with identification of material and maker. Materials in broken
containers, or in packages showing water marks or other evidence of damage, shall not
be used and shall be removed from the site.
1.04 PRE-ROOFING CONFERENCE
A. Well in advance of commencement of roofing operations but after roofing substrate has
been constructed and prepared for roofing, a pre-roofing conference shall be held to
inspect the substrate. All parties having an interest in the roofing or work on the roofs
shall be informed of the conference.
B. The conference shall include an inspection by all parties of the substrate and its
conformance with the drawings, the approved shop drawings, and the roofing

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C. System manufacturer's approved specifications, and instructions. All objections to

approval of the substrate shall be submitted in writing to the Engineer. Coordinate efforts
to remedy objections and prepare substrate properly to receive roofing.
1.05 JOB CONDITIONS
A. Hot Weather Requirements
1. Protect fresh membrane from hot sun as approved.

2. Provide artificial shade, wind breaks and use cooled materials, as required.
1.06 GUARANTY
A. As a condition of this Section furnish the Owner with a written guaranty that the roofing
system work upon completion will be waterproof for a period of ten (10) years and that
during this time all defects in the waterproofing or bonding, or leaks which may
develop through the surface, shall be promptly repaired at no expense to the Owner,
provided such leaks and defects are not due to causes beyond control of this section.
PART 2 : PRODUCTS
2.01 INSULATION MATERIALS
A. Rigid insulation shall be extruded polystyrene, 50mm (2-in) thickness complying with
the following particular specification :
Density : DIN 53420 : 32 to 35 kg/m3

Thermal conductivity
5 years age value at 24°C : ASTM C-518 : 0.032 W/m degK
Compressive strength
at 5% compression : ASTM D-1621 : 0.245 N/mm2
Water absorption : ASTM D-2824 : 1% by volume

Refer to the above Manufacturers & Suppliers List
B. Separating sheet: (applied on top of roof insulation) vapor permeable, filtering and
protecting membrane having the following minimum properties:
Thickness : 300 microns
Tensile strength : 16.7 MN/m2
Elongation at break : 800%
Tear strength : 125 g/25 microns
Impact strength : 800 g

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Refer to the Approved Manufacturers & Suppliers list
C. Lightweight concrete roofing insulation screed for roof shall be 50mm minimum thickness
foam concrete, 1% slope to drain complying with the following particular specification:
Wet density: 500 - 550 kg/m3

Dry density: 350 - 400 kg/m3
Compression strength: 8 kg/ cm2
Thermal conductivity: 0.079 kcal m/m2°Chr at 33.9C°, for above density.
Refer to the Approved Manufacturers & Suppliers list
2.02 WATERPROOFING MATERIALS
The water proofing membrane shall be a SBS heavy bituminous felt of a type suitable for hot
climates, reinforced with 180 gm/m of non woven polyester in lay modified bituminous
compound presenting high thermal stability, plasticity and flexibility characteristics as detailed
on drawings. The thickness of the membrane shall be 4 or 5 mm as specified and indicated
on drawings.
The typical characteristic of 5 mm thick membrane shall be as follow:
Test Unit Required Tolerances Test Method

Thickness mm 5 ±5% UEAtc
Aeric Mass Kg/m 5.25 ±10% UEAtc
Tensile Strength at break Lon N/5 cm 900 ±20% UEAtc
Tranv N/5 cm 800 ±20%
Elongation at break; long % 50 ±15% UEAtc
Tranv % 50 ±15%
Tear Strength; Long N 170 ≥170 UEAtc
Tranv N 180 ≥170
Cold Bending °C -250° ≤ - 25 UEtc
Form Stability °C 100 ≥100 UEtc
Water Pressure Resistance KPa 400 ≥400 DIN 16935
Softening point R & B °C 115 ≥115 ASTM D36
Down penetration 25°C (77°C) dmm 32 ±5 ASTM D5
Corners
Internal and external corners must be finished with RESITRIX patches. Diameter of these
fittings has to be approx. 200 mm.
Adhesive, primer and coating to use with the RESISTIT RET
FG 35 Primer
• Phoenix FG 35 Primer is a low viscosity solution of synthetic rubber and resins combined
with organic, halogen, free solvents.
• FG 35 will be used for priming the surfaces for self-adhesion membranes or in use with
Phoenix FP 75.
FP 75 Primer

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• Phoenix FP 75 façade paste is a highly viscous bonding compound consisting of

synthetic rubber and resins combined with small quantities of organic, halogen free
solvents.
Alulon Coating
• a by Phoenix developed color coating based on 2 components

• Color : stone gray.
2.03 ACCESSORIES AND FASTENINGS MATERIALS
A. Accessories : angle fillets, jointing strips, reinforcing tape, movement joint sections and
sealant, pipe flashing etc. are to be types recommended for purpose by roof covering
manufacturer.
B. Aluminium for Flashing and the like : to BS 1470, designation S1B, 0.8 mm thick, temper
grade H2.
C. Channel (Reglet): aluminium alloy to BS 1470, designation S1B-H2, 0.8 mm thick,

dovetailed channel section for casting into concrete or surface fixing, as shown on the
Drawings, to receive top edges of flashing, upstands and sealant.
D. Black Bitumen Coating Solution for painting backs of flashing is to be to BS 3416, Type 1.
E. Pointing Sealant shall be polysulphide rubber based compound, cold applied:
1-Man: SIKA
Ref: IGAS – BLACK
2-Man: Fosroc International Limited

Ref: PLIASTISEAL
3- Man: MASTER BUILDERS TECHNOLOGIES (MBT Middle East) or other equal

and approved.
2.04 PROTECTION MATERIALS
A. Protection and finishing materials shall be as following:
1. Un accessible roof (stairs and cores roof): Shall be 50 mm thick; smooth, rounded
and washed gravel, 15-30 mm diameter, free of dust and fines.
2. Accessible Roof: Shall be precast concrete tile, 30 x 30 x 3cm, constructed of grade

25 Precast concrete, smooth finish, laid on top of roof insulation.

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PART 3: EXECUTION
3.01 GENERAL
A. All installation shall conform to the acceptable shop drawings and the system and
materials manufacturer's specifications and instructions as submitted and reviewed.
3.02 SUBSTRATE SURFACE
A. Concrete surfaces to receive roofing shall be free of roughness or projections, with

a smooth clean surface, finished as specified under concrete finishes section which will
allow an even application of the membrane and insulation. Concrete shall have damp
cured for 28 days minimum before application of roofing.
B. Surfaces shall not contain any grease, oil or any other contaminants which could affect
the complete bonding of the membrane to the concrete surface.
C. Concrete shall be free from surface laitance, loose aggregate, form release agents,
curing compounds or other surface treatments.
D. Surfaces shall be visibly dry and thoroughly cleaned, (remove all dust, dirt, and loose
materials) immediately prior to application of membrane. Compressed air, vacuum
cleaner or other suitable means shall be used.
E. Notify the Engineer at least 48 hours before application of roofing commences. A

representative of the roofing manufacturer shall be present while roofing is being applied
to assure conformance to drawings, specifications, and good workmanship
requirements.
F. Notify the Engineer in writing if, when instructed to proceed with work, the surfaces to be
covered are not satisfactory.
G. Commencement of the installation of any material shall be considered as acceptance of

the conditions of all the surfaces to be covered, and no subsequent claim on account of
previous condition of surface will be entertained.
3.03 SCREEDING
A. Flat roof slabs shall receive Class 16 screeding concrete cast to falls as indicated on the
Drawings. The surfaces of the screeding concrete shall be even and free from any
depressions and other defects with reasonably smooth surface finish and ready to
receive water proofing works.
3.04 ROOFING MEMBRANE INSTALLATION
A. The time of roofing operations with respect to adverse weather conditions,

shall be subject to the approval of the Engineer.
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B. The Manufacturer shall certify that the membrane meets or exceeds the individual
requirements set forth herein.
C. The following tests shall be carried out by an independent laboratory on specimens from
supplied material on site, cost of tests to be included in the Contractor rates :
• Low temperature flexibility.

• Softening point.
• Breaking strength and elongation at break for both directions.
D. Antidust priming asphalt shall comply with ASTM - D41.
E. Application shall be according to manufacturer's printed and approved instructions.
F. Sheets to be arranged to give a minimum of 75 mm overlap with adjacent end sheet.
3.05 EXTERNAL AND INTERNAL CORNERS
Without angle fillet
3.06 LIGHTWEIGHT CONCRETE INSTALLATION
A. Mix and apply in accordance with manufacturer’s instructions
END OF SECTION

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SECTION 07900 CAULKING
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all materials, labor, and equipment required to install caulking materials as
required by the drawings and as specified herein.
B. The terms "caulking" and "sealing" as used on the drawings and in these specifications
are synonymous, and either or both terms shall indicate the materials specified herein.
1.02 RELATED WORK
1. Section 03300 - Concrete.
2. Section 04200 - Masonry.
3. Section 04400 - Natural Stone Slab Cladding.
1.03 SUBMITTALS
A. Submit to the Engineer, as provided in the Submittals Sections, detailed information on

materials proposed and installation methods.
B. Submit two sets of representative samples of any or all proposed materials required
for the work of this section as requested by the Engineer.
1.04 PRODUCT DELIVERY, STORAGE, AND HANDLING
A. Sealants shall be stored in unopened containers, under cover, in a cool dry place.
PART2: PRODUCTS
2.01 MATERIALS
A. Concealed Joint Sealant for movement joints is to be oil based mastic compound unless
B. Exposed Joint Sealant for movement joints is to be approved Two-part polysulphide

rubber based compound unless otherwise specified.

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C. Joint Sealant for movement joints in car park decks and sewage treatment works is
to be two-part, compound of chemically resistant electrometric polymers, cold applied,
resistant to fuel and oil spillage.
D. Joint Sealant for movement joints in retaining walls and basements is to be bitumen
based compound.
E. Joint Sealant for movement joints in drinking water reservoirs and for damp conditions is
to be sulphate resistant polymeric compound for use with cement.
F. Primer shall be as recommended by the sealant manufacturer.
G. Backup Material shall be Polyethylene or polyurethance foam as recommended by

the sealant manufacturer.
H. Bond breaker Tape Adhesive-backed polyethylene tape as recommended by the sealant

manufacturer.
2.02 PERFORMANCE AND DESIGN REQUIREMENTS
A. Colors. Colors of sealants shall be as selected by the Engineer from the manufacturer's
standard line of colors. Different colors may be required for different locations.
B. Backup Material. Backup material shall be provided as necessary to control the depth
of sealant and shall be of suitable size so that, when compressed 25 to 50 percent, the
space will be filled.
PART3: EXECUTION
3.01 JOINT PREPARATION
A. All surface to receive sealant shall be clean, dry, and free from dust, grease, oil, or wax.
Concrete surfaces which have been contaminated by form oil, paint, or other foreign
matter which would impair the bond of the sealant to the substrate shall be cleaned by
sandblasting. All surfaces shall be wiped with a clean cloth saturated with xylol or other
suitable solvent and primed before the sealant is applied.
B. Unless otherwise recommended by the sealant manufacturer and permitted by the

Engineer, the depth of sealant in a joint shall be equal to the width of the joint, but not
more than 20 mm.
C. Backup material shall be rolled or pressed into place in accordance with the
manufacturer's installation instructions, avoiding puncturing and lengthwise stretching. If
depth of the joint does not permit use of backup material, bond breaker tape shall be
placed at the bottom of the joint to prevent three-sided adhesion.

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3.02 SEALING
A. Sealing work shall be done before any field painting work is started. The air temperature
and the temperature of the sealed surfaces shall be above 10 C when sealing work is
performed.
B. Upon completion of the sealing work, each sealed joint shall have a smooth, even, tooled
finish, flush with the edges of the sealing recess, and all adjacent surfaces shall be clean.
Sealant shall not lap onto adjacent surfaces. Any sealant so applied as to prevent the
painting of adjacent surfaces to a clean line, or with an excess of material outside the joint
and feathered onto surfaces, shall be removed and the joint resealed.
END OF SECTION

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DIVISION 8 - DOORS AND WINDOWS
SECTION 08120 ALUMINUM DOORS AND FRAMES
PART 1: GENERAL
1.01 SCOPE OF SECTIONS
A. Furnish all labor, materials, equipment and incidentals required to provide and install the
following work:
1. Exterior and interior Aluminium hinged and sliding doors, Aluminium doorframes, and
Aluminium sidelight and glazed transom panel framing.
2. Glass and glazing to this work.
3. Necessary framing, blocking, shims, anchoring and reinforcing required for securing
of this work to the structure, to maintain the design loads specified.
4. Caulking of joints in this work, including joints where such work abuts adjacent
building components, to maintain a weather seal to the exterior and an air seal to the
interior.
5. Aluminium closures between this work and other building enclosures.
6. Air seal membrane between this work and building air seal membrane system.
1.02 RELATED SECTIONS
A. Aluminium Doors and windows
B. Supply of finishing hardware.
C. Sealing under Joint sealants.
D. Glass and Glazing
1.03 REFERENCES
A. American Society of Testing and Materials (ASTM)

B. ASTM C1036: Standard Specification for Flat Glass
C. ASTM C1048: Standard Specification for Heat Treated Flat Glass Kind HS, kind
Coated and Uncoated Glass
D. ASTM E330: Test Method for Structural Performance Exterior Windows and Curtain
wall by Uniform Static Air Pressure Difference.

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E. ASTM E1300: Standard practice for Determining the Minimum Thickness of

Annealed Glass Required to Resist a Specified Load.
F. Sealed Insulating Glass Manufacturers Association (SIGMA)
G. Glazing Recommendations for Sealed Insulating Glass Units.
A. Qualifications
1. Work for this sections shall be designed, fabricated and installed by a company
who has minimum of 10 years experience in successful completion of projects of
similar size and design. If requested submit evidence of this experience.
2. Employ only qualified installers with proven experience in this type of work.
3. If the Work of this Section is not installed by the manufacturer, the work shall be
executed by an installer acceptable to the Owner and approved by the
manufacturer of the Materials to be used.
1.05 SYSTEM DESCRIPTION
A. Employ a professional structural engineer to design components of the work of this

section requiring structural performance and to be responsible for determining sizes,
spacing and loading of components in accordance with applicable codes and
regulations. This structural engineer shall stamp and sign the shop drawings and ensure
that this work is provided in accordance with this design.
B. Design the work of this section to meet or exceed the following design
requirements:
1. Structural deflection: L/240 max. 19mm, 1.2 kPa static pressure.
2. Air leakage of fixed exterior sidelights and transoms: 0.0003 m3/sec per square
meter of wall area with an air pressure of 0.075 kPa static pressure.
3. Water: no uncontrolled water penetration under uniform static pressure of 0.5kPa.
4. Thermal: interior face temperature of Aluminium shall be greater than lowest glass
temperature.
C. Design the exterior work to accommodate structural framing deflections.
D. Design the exterior work to accommodate thermal movement of Materials.
E. Design the exterior work to allow for sufficient tolerances to accommodate normal
building tolerances.

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1.06 SUBMITTALS
A. Shop Drawings
1. Submit Shop Drawings in accordance with section 01300
2. Submit Shop Drawings prepared by the manufactures showing plans, elevations and
conditions of construction and complete details of Materials, anchoring, fastening,
caulking, thermal break, air seal, pressure equalization, drainage of void between
glass and frame, and Materials and methods to provide collection and drainage
of condensation water.
3. Code Shop Drawings to show the following building enclosure principles:
a. Line of air seal through the assembly and its interface with the building assembly.
b. Drainage and ventilation paths through the assembly and to the exterior.
4. No Work shall be fabricated until the Owner reviews Shop Drawings.
B. Samples
1. Submit Samples in accordance with section 01300
2. Submit 300mm square Samples of each glass type
C. Tests
1. Submit test reports that exterior entrance assemblies equivalent to those to be

installed have been tested by an independent testing authority and meet or exceed
the specified air infiltration, water leakage and uniform load design criteria for the
location of installation.
2. Submit the results of thermal stress analysis for all assemblies.
1.07 MAINTENANCE DATA
A. Provide maintenance date for cleaning and maintenance of glass and metal
finishes.
A. Protect Materials from damage during shipment, storage and installation.
B. Protect finished metal surfaces until the full installation is completed and reviewed by the
Owner.
1.09 WARRANTY
A. Refer to General Conditions and Special Conditions of Contract, and section 01740.

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B. Submit a 5 year warranty for the Work of this Section.
C. Warranty shall provide for the removal of Materials which fail to meet design criteria,
replacement with new Materials conforming to Specifications, and restoration of work
damaged by removal and replacement including labour and installation costs.
D. Similarly, submit a warranty applying to factory sealed double glazed units for ten (10)
years. Warranty shall provide for the removal materials which develop obstruction of
vision resulting from dust or film formation on the internal glass surfaces, replacement
with new Materials conforming to the specifications, and restoration of work damaged by
removal and replacement including labour and installation costs.
PART 2: PRODUCTS
2.01 MATERIAL DESCRIPTION
A. Base Tenders on sections and details shown on the Drawings and specified herein after.
B. Acceptance of alternative sections and details will be subject to review by the Owner.
C. Materials specified by manufacturers establish performance and qualities required and

are not intended to restrict submission by other manufacturers.
2.02 ALUMINIUM
A. Aluminium alloy for windows and screens shall be meet the general requirements of BS
4873 or ASTM B221 for aluminum extrusions, ASTM B 209 for aluminum sheet or plate,
ASTM B211 for aluminum bars, rods and wire, constructed from aluminum alloy
extruded sections, and couplings, with electro statically baked applied polyester
finish.
Supplied complete with frames, sub-frames, mullions, transoms, sills, louvers,

doors, opening portions and insect screens, as shown on the drawings, and with
manufacturer’s matching ironmongery, glazing beads, gaskets, weather-strips,
accessories and fixings. Units may be pre-glazed or glazed on site in accordance with
the requirements of glazing section. Windows and supporting members shall be
designed to withstand a wind load of 24 kg/sqm. (5 PSF) and associated negative
pressures.
EXTERNAL AREAS
B. Aluminium section shall be Thermally-broken and the guardroom and stores area shall
be super durable powder coated. Colour as shown on drawing and approved by the
Owner. Manufacturer is to provide a 10year warranty, agreeing to repair or replace
defective coating, defined as abnormal deterioration, aging or weathering or loss of
adhesion.
INTERNAL AREAS
C. Aluminium Finish for services, maid, kitchens, bathrooms, pantries, laundry,
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guardroom and stores area shall be electro statically backed applied polyester powder
coated finish. Colour as shown on drawing and approved by the Owner.
2.03 ASSEMBLY COMPONENTS
A. Assembly screws, zinc plated steel or stainless steel.
B. Fixing screws, stainless steel or cadmium plated steel.
C. Gaskets, extruded santoprene, EPDM or neoprene.
D. Sealant at aluminium to aluminium joint, butyl tape.
E. Exterior joints seals, silicone.
F. Expansion joints, flexible EPDM minimum thickness 1.5mm
G. Sheet aluminium for metal flashing, 3003 H14 sheet, 1.3mm thick.
H. Sheet aluminium for covers and cap plates, wall panels, sills 3003 H14 sheet 3mm thick.
I. Semi-rigid fiberglass or mineral wool insulation insulated panels.
J. Fiberglass or mineral wool bat insulation for packing voids and cavities.
K. Filler extrusion, rigid PVC extruded.
L. Bituminous paint, best grade acrylic lacquer or utility enamel.
M. Flexible air sealed membrane, EPDM, minimum 1.1mm
N. Metal air seal membrane, minimum 0.76mm galvanized steel.
2.04 ADDITIONAL STEEL REINFORCING
A. It is the responsibility the contractor to provide additional concealed steel reinforcing if

necessary to support entrance assemblies including door frames, if required.
2.05 ADJUSTABLE ANCHORS ANDREINFORCING
A. Anchor bolts, steel zinc plated, high strength minimum grade 5.
2.06 GLASS TYPES
Refer to Section 8800.
2.07 GLAZING MATERIALS
A. Setting blocks
1. Neoprene, EPDM or silicone with a Shore a hardness of 80-90

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+5 durometer and maximum compression set in accordance with ASTN d395- C864.
2. Setting block material must be compatible with sealed unit sealant.
3. Setting block size, 6mm thick, or width slightly wider thanthickness of glazing
unit, and of length of 25mm for every 1sqm. Of glass area with a minimum length of
50mm.
B. Spacer shims
1. Neoprene EPDM or silicone with a Shore A harness of 40-60 durometer.
2. Size, number and location of shims is dependent on the size of the glazing unit and
shall be as recommended by glass manufacture.
2.08 GLAZING SALANTS
A. One- component, neutral cure, low modulus silicone sealant conforming to BS 5889
Type A, DIN 18545 (E) , DIN 18540, UNI 9610 and meets performance
requirements of BS 4254 NFP 85517 and 85519.
B. Sealant, equal to Dow Corning 897.
C. Colour, selected by owner from manufacture’s standard colours.
2.09 ALUMINIUM DOORS, HINGED, EXTERIOR AND INTERIOR
A. Refer to Door and Frame Schedule and to drawings for frame types, profiles and details
of aluminium doorframes.
B. Exterior and interior aluminium doors, fully glazed, 6mm thick.
C. Aluminium as specified in 2.02, fully welded corners.
D. Minimum 3.2mm thickness for extrusions faces, 4.8mm for internal weds.
E. Snap on glazing stops with neoprene or EPDM bulb type glazing. No. exposed screws.
F. Cutout doors for hardware. Provide reinforcing back plates to suit hardware. G Do not
apply manufacturer’s name to doors.
G. If necessary internally reinforce top and bottom rails of doors higher than 2150cm
2.10 ALUMINIUM DOORS, SIDELIGHT AND SCREEN FRAMES, EXTERIOR AND INTERIOR
A. Refer to Door and Frame Schedule and to drawings for frame types, profiles and details
of aluminium doorframes.
B. Aluminium as specified in 2.2, fully welded corners.
C. Minimum 3.2mm thickness for extrusions faces, 4.8mm for internal weds.
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D. Snap on glazing stops with neoprene or EPDM bulb type glazing. No. exposed screws.
E. Cutout doors for hardware. Provide reinforcing back plates to suit hardware.
F. Reinforce, drill and tap frames for mortised, templated special security hardware where
indicated in Door and Frame Schedule.
2.11 HARDWARE
A. Provide the following hardware fabricated for and installed at single or pairs of
doors/frame.
1. Offset pivots of cast aluminium with steel pins, oilite top pivot bearings and ball
bearing bottom pivot bearings, for each leaf.
2. Overhead concealed closers, two speed type for use with pivots, as approved, for
each leaf.
3. Dead latches, less cylinders, with latch holdback and operating tool with lever handle
for inactive leaf.
4. Flush bolts, 300mm length, top and bottom, inactive leaf.
5. S.S. Pull handles 1no. for each leaf
6. S.S. Push bars 1no. for each leaf
7. Floor springs, 1no. each double swing leaf.
8. Fabricate and allow for hardware furnished under the Door hardware section
including, cylinders and thresholds.
B. Provide and install weather stripping, gasketing and door seals on exterior doors and
frames, including weather stripping sweep in underside of doors, ( ensure weather
stripping is in contact with threshold to provide a positive seal), coloured to match colour
of doors.
2.12 SEALANT AND ACCESSORIES
A. Sealant
1. One- component, neutral cure, low modulus silicone sealant, meeting requirements
of DIN 18545, T2 Class E, of DIN 18540, T2, and of NBI
2. Colour, selected by Owner from manufacturer’s standard colours.
B. Joint filler (backer rod)
1. Closed cell plastic foam filler as recommended by sealant manufacture. Joint filler
shall be non-staining, compressible, self restoring filler designed to remain under 25%
compression within the joint and to form convex surface to receive sealant.
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C. Cleaning material
1. Xylem, methyl-ethyl-ketene, Toulon, or as recommended by sealant manufacturer
2.13 FABRICATION
A. Fabricate exterior and interior aluminium hinged doors, aluminium door frames and
aluminium sidelight and transom frames as indicated on the Drawings, with minor
modifications providing for the specified requirements and the manufacture’s standard
section.
B. Fabricate the exterior work of this section of the rain screen, pressure equalization and
air seal principles including rain screening and baffling and air seal of interior building air
from external cavities.
C. Fabricate the work of this section in accordance with the testing requirements specified
D. Conceal fastenings.
E. Fabricate sheet metal panels, fasteners and anchorage system to conform to design
performance and to provide a uniform, flat surface on metal panels, free from distortion
and oil canning, after installation, in service, regardless of temperature.
F. Provide metal panel finishes for uniformity in appearance and texture throughout.
Remove and replace panels which do not match adjacent panel of the same finish.
G. Conform to overall section dimensions and configurations detailed on the drawings.
H. Ensure maximum wind loads for entrances are in accordance with climatic code
conditions for the Site.
I. Ensure extrusions, supports and fastenings support bearing load requirements and
accommodate maximum range of temperature variation without abnormal stress or
distortion.
J. Fabricate and assemble frames at plant ready for installation in prepared openings.
K. Provide weep holes in frame to drain void between glass and frame. Provide weep holes
in metal panels.
L. Provide interior to exterior framing members with thermal break.
M. Carefully fit joints to be inconspicuous.
N. Black paint aluminium in contact with concrete, concrete block, mortar or plaster board
with a full bodies coat of bituminous paint. Use neoprene separator where aluminium is
fastened to steel.

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PART 3: EXECUTION
3.01 EXAMINATION
A. Examine substrate surfaces to receive the work of this section and ensure that work
done as part of the work of other sections is complete and that there are no conditions
which will adversely affect the performance of this work.
B. It is the responsibility the contractor to verify the accuracy and alignment of

structural building framing to which this work is connected.
C. Notify the Owner of any unsatisfactory conditions. Do not proceed with this work until
unsatisfactory conditions have been corrected. Commencement of work implies
acceptance of surfaces and conditions.
3.02 COORDINATION
A. Coordinate installation of work of this section with work of other section and in
accordance with contractor’s schedule.
B. Supply to other subcontractors necessary items to be built into their work.
3.03 ERECTION
A. Erect work of this section in correct locations as shown on drawings, level, plumb,
square and at proper elevations and alignment with other work.
B. Secure individual assembled units to structure with steel anchor brackests, loose bloated
to vertical members over an adjusting plant set in position and securely welded following
final grid adjustment.
C. If required, install concealed steel reinforcing, braces and supports to meet design
requirements.
D. Fit intersecting member to flush hairline joints and mechanically fasten together, except
where indicated otherwise.
E. Field applies isolation coating to metals in contact with dissimilar metals and
cementations materials e.g. concrete, concrete block, mortar and plasterboard. Use
separator sheet where aluminium is fastened to steel.
F. Fill voids and cavities with insulation.
G. Air seal
1. Install metal or membrane to provide a continuous air seal between this work and
adjacent building components.
2. Secure metal air seal with secure fasteners. Form perimeter edge of metal air seal
membrane to permit joint sealing.
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3. Make provision in air sealed membranes to accommodate movement resulting from

thermal change and structural deflection.
4. Cut, fit, and form air seal membranes as required accommodate conflicting framing
and other obstructions.
3.04 ALUMINIUM DOOR FRAMES, AND SIDELIGHT AND TRANSOM FRAMES, EXTERIOR
AND INTERIOR
A. Install door frames, and side light and frames where indicated and as detailed.
B. Set frames plumb, square, level and at correct elevation, maintaining uniform width and
height. Anchor frames to partitions using anchors supplied with frames.
C. Brace frames rigidly in position while being built in.
D. Make allowance for deflection to ensure structural loads are not transmitted to frames.
3.05 ALUMINIUM DOORS, EXTERIOR AND INTERIOR, HINGED
A. Install doors in accordance with manufacture’s instructions.
3.06 ALUMINIUM SPECIFICATION
1) Section to be extruded from aluminum alloy B 6063 TS or equivalent in accordance with

BS 1474.
2) All aluminum surfaces to have super-durable powder coated finish to approval unless
otherwise mentioned.
3.07 GLASS NOTES:
1) All reflective glass to be pyrolitically coated glass.
2) Glass shall conform to the requirements of ASTM C1036, quality Q3 unless otherwise
specified. Heat treated glass shall conform with the requirements of ASTM C1048,
tempered glass shall also conform to ANZI Z97.1-984. All heat treating shall be by the
horizontal process and processed in such a manner as installed in the building.
3) Insulating glass shall comply with the following standards:
1) E773 Test Method for seal durability.
2) E774 Specification for seal insulating glass units.
3) E546 Test Method for frost point of seal insulating glass units.
4) E576 Test Method for dew / frost of seal insulating glass units.
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3.08 GLAZING TYPES
G1 Vision Panel: (Double Glazed) 6mm thick fully tempered bronze tinted glass + 12mm
space + 6mm thick clear annealed glass.
3.09 GLAZING
A. Class locations
1. Refer to Door and Frame Schedule.
2. Refer to elevations and details on Architectural Drawings.
B. Company with the glazing principles in Sealed Insulating Glass Manufacturers

Association (SIGMA) glazing recommendations for sealed insulating glass units, and as
follows:
1. Provide for glass expansion.
2. Ensure compatibility of sealant with glazing accessories.
3. Glaze in a manner to ensure rattle-free cushioning. Set glass properly centered with
uniform bite, face and edge clearance, free from distortion and stress.
4. Remove foreign matter detrimental to adhesion of glazing materials.
5. Securely attach stops in proper alignment.
6. Set glass with equal bearing full width of panel using setting blocks and spacers of
proper size to support and hold glass in position independent of the glazing tape.
7. Apply continuous length of glazing tape to interior leg of glazing rebates making joints
only at corners.
C. Provide anti- walking blocks for dry/dry glazing system.
3.10 HARDWARE
A. Delivery and storage
1. Provide adequate secured area for storage of hardware.
2. Hardware will be delivered to the Site by Hardware supplier. Off- load hardware,
checking and verifying delivered quantities in coordination with hardware
subcontractor.
3. Unpack hardware as required and dispose of waste packing.
B. Installation

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1. Cut, drill and prepare doors template to receive hardware.

2. Install hardware to doors and frames in accordance with manufacturer’s packaged
installation, template, and adjusting instructions, supplied by the Hardware
subcontractor. Adjust all hardware as and when required to provide smooth
operation of doors and ensure clearances are maintained. Adjust weather stripping
and gasketting to provide a positive seal. Repair damage to adjacent surfaces
resulting from failure to conform with this requirement.
3. Allow for cutting and fitting or thresholds around mullions, so that when installed,
outside appearance is continuous across opening.
4. Allow for contact switches in exterior doors and frames for security.
5. Provide lubricants required and use in manner to ensure smooth function of

hardware consistent with manufacturer’s recommendations.
6. Use proper sized drills and taps for screws provided. Do not use self-drilling screws
unless provided for items such as kick plates, push plates and door seals.
7. Ensure fastening component are tightened snugly. Do not burr or otherwise mar the
edges of surfaces of hardware components. Repair defects caused by this work in an
approved manner.
3.11 CAULKING
A. Seal joints between this work and adjacent building component surfaces, and where
required to provide a completely weather-tight enclosure on the exterior and an air seal
enclosure on the interior.
B. Perform work in accordance with section 07900 and as specified herein.
C. Fill spaces deeper than 13mm with joint backing material packed tightly in place to within 10
mm of finished surface. Fill remaining space to within 2mm of surface with sealant.
D. Fill voids and shim spaces between metal frames and abutting construction with insulation
and apply interior seal of sealant and backing from interior frame face.
E. Apply sealant in strict accordance with manufacture’s printed directions.
F. Apply sealant to clean, dry, grease and oil free surfaces. Exposed sealant shall be smooth,
free from ridges, wrinkles, air pockets and embedded foreign materials.
G. Use glazing tape and sealant where gaskets are indicated.
H. Remove excess sealant or drippings which would set up or become difficult to remove form
finished surfaces. Do not use chemicals, scrapers, or other tools which would affect
finished surfaces for sealant removal. Finished surfaces damage due to this work shall
be replaced at this contractor’s expense.

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3.12 CLEANING
A. Thorough clean and polish glass on exterior and interior.
3.13 CLEAN UP
B. Remove excess Materials from the Site.
END OF THE SECTION

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SECTION 08710 HARDWARE
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish and deliver to the project site all finish hardware for doors and additional padlocks
as shown on drawings and hereinafter specified.
B. Furnish all templates required by the manufacturers of the doors and frames to enable the
manufacturers to make proper provision in their work to receive the finish hardware. All
locks, lock strikes, and flush bolts shall be made to ANSI standard dimensions.
C. Types of hardware required include the following :
1. Hinges
2. Pivots and floor springs
3. Lockcases
4. Lock cylinders and keys
5. Bolts
6. Exit devices
7. Push/pull units
8. Overhead door closers
9. Door furniture and special handles
10. Door selectors
11. Door trim units
12. Protection plates
13. Weather stripping for exterior doors
14. Sound stripping for interior doors
1.02 RELATED WORK
A. Other sections directly related to work covered in this section include under the
following:
1. Section 06100 - Rough Carpentry.
2. Section 08114 - Steel Doors and Frames.
3. Section 08120 - Aluminum Doors and Frames.
4. Section 08211 - Wood Doors and Frames
1.03 SUBMITTALS
A. Samples

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1. If required by the Engineer, submit a sample of any or all items of hardware proposed for
review.
B. Hardware Schedules
1. Submit to the Engineer for review a complete hardware schedule as provided in the
Submittals Section for shop drawings.
2. No templates shall be distributed until the hardware schedule has been accepted by the
Engineer.
3. Provide approved physical hardware items to door manufacturers if and as

required for fabrication onto doors.
1.04 PRODUCT HANDLING
A. Packing and Marking
1. All hardware shall have the required screws, bolts and fastenings necessary for
proper installation, wrapped in paper and packed in the same package as the
hardware. Each package shall be legibly labeled, indicating that portion of the work
for which it is intended.
PART 2: PRODUCTS
2.01 MANUFACTURERS
A. All hardware shall be best grade, entirely free from imperfections in manufacture and
finish. Qualities, weights, and sizes specified herein are the minimum that will be
accepted.
B. Hardware Items shall be as shown on drawings and shall be manufactured by

reputed company. Refer list of approved manufacturer or other equal and approved.
2.02 MATERIALS AND FABRICATION
A. Hand of Door: Drawings shown direction of slide, swing or hand of each door leaf.
Furnish each item or hardware for proper installation and operation of door movement as
shown.
B. Manufacturer’s Name Plate: Do not use manufacturer’s products which have

manufacturer’s name or trade name displayed in a visible location (omit removable
nameplates), except in conjunction with required UL labels and as otherwise acceptable to
Architect.
1 - Manufacturer’s identification will be permitted on rim of lock cylinders only.

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C. Fasteners: Provide hardware manufactured to conform to published templates,

generally prepared for machine screw installation. Do not provide hardware which has
been prepared for self-tapping sheet metal screws, except as specifically indicated.
D. Furnish screws for installation, which match each hardware item. Provide Phillips type flat-
head screws and not less than 5 sets of matched screwdrivers for each size of screw.
E. Provide concealed fasteners for hardware units which are exposed when door is closed.
Do not use through bolts for installation where bolt head is exposed in other work. In
such cases, provide sleeves for each through bolt or use sex screw fasteners.
F. Tools and Maintenance Instructions for Maintenance:

Furnish a complete set of specialised tools and maintenance instructions as needed for
Owner’s continued adjustment, maintenance, and removal and replacement of hardware.
2.03. HINGES, BUTTS AND PIVOTS
A. Templates: Except for hinges and pivots to be installed entirely (both leaves) into wood
doors and frames, provide only template- produced units.
B. Screws: Comply with 2.02 section C, D and E.
C. Hinges shall have caged ball bearing races, (washer bearing type and similar will not be
accepted). hinge pins shall be stainless steel.
D. Number of Hinges: Provide a minimum of three hinges per door leaf up to a height of
2300mm and one additional hinge for every 750mm thereafter.
E. Provide intumescent plugs for all hinge screws.
2.04 LUCK CYLINDERS AND KEYING
A. General: Supplier will meet with Architect to finalise keying requirements and obtain
final instructions in writing.
B. Multiple-building System: Except as otherwise indicated, provide new grandmaster key

system for project.
C. Equip locks with cylinders which are construction keyed, only construction keys to be
issued to the contractor and on instruction from the Architect invalidate such construction
keys by operation of the grandmaster key in each keyway.
D. Equip locks with high security cylinders which comply with performance
requirements for Grade 1 cylinders as listed in ANSI A156, which also UL listed and
incorporate the double locking system as utilised in the designated HS74 series cylinders .
E. Lock cases shall be UL listed and comply with ANSI 115, shall be performance tested and
certified to compare with the designated standard lock case HD99 series. All lock cases
shall have intumescent cover protection for the case body and intumescent plugs for the
screw fasteners for the frond plates. Locks shall be provided that allow furniture such as
lever roses to screw directly into the lock case using machine screws, to provide strength
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of fitting and rigidity.
F. Latch Bolt: Shall be a guided, three part, latch bolt with a minimum throw of 19mm, be
fully reversible without removal of case cover, contain an anti thrust bolt for security and
shall be made of high grade stainless steel.
G. Deadbolt: For use on deadlocks shall have a minimum throw of 25mm and contain
hardened steel rollers and incorporate a reinforced strike plate .
H. Strikes : Provide standard wrought box strike for al locks and latches, with curved lip
extending to protect frame. Finish to match hardware set.
I. Metals : Construct cylinders from brass/ bronze, stainless steel or nickel silver.
J. Comply with Owner’s instructions for masterkeying and, except as otherwise noted,
provide individual change key for each lock which is not designated to be keyed alike with
a group of related locks.
1. Permanently inscribe each key with the number or lock differ and the notation “DO
NOT DUPLICATE” .
K. Key Quantity : Furnish 3 change keys for each lock; 5 master keys for each suite of locks
within the project and 5 grandmaster keys for the overall project.
All keys shall be delivered to the owner or Owner’s representative either by security
courier service or by the authorised manufacturer’s representative.
L. Provide a key control system including tags and secure key boxes, to the Architect
requirements and including tags with selflocking clips, receipt forms, 3 way visible card
index, temporary markers, permanent markers, and standard security metal cabinet to
allow for 150 percent capacity of the total locks used in the project.
1. Provide complete cross index system set up by key manufacturer and place
keys on markers and hooks in the cabinet as determined in the final key schedule.
2. Provide hinged-panel type cabinet, for wall mounting.
2.05 BOLTS AND EMERGENCY EXIT DEVICES
1. Provide dust-proof sockets for bolts, except where special threshold detail provides non-
recessed socket for bolt.
2. Provide rebated flush bolts of the lever action type with a minimum size of 300mm to door
leaves of up to 2300mm and longer bolts to suit doors over 2300mm high.
3. Finish of bolts and sockets shall match related hardware.
4. Panic exit devices shall be made from high grade stainless steel, shall comply with BS
5725, provide dogging or holdback functions on doors used as day time entrances and
external access via locks within the master key system to the direction of the Architect.
5. Rabbetted Doors: Provide suitable rebate sets where meeting stiles of doors are indicated
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as being rabbetted. Such fittings shall match the related hardware on such doors.
2.06 PUSH/PULL UNITS
A. Concealed Fasteners : Provide manufacturer’s special concealed fastener system in

particular for “back to back” fixing requirements .
2.07 CLOSERS AND DOOR CONTROL DEVICES
A. Size of Units : except as otherwise specifically indicated, comply with the manufacturers
recommendations for size of door control unit, depending upon size of door, exposure to
weather and anticipated frequency of use.
B. Combination Door Closers and Holders : Provide units designed to hold door in open
position under normal usage. Incorporate an integral electromagnetic holder mechanism
designed for use with UL listed fire detectors, provided with normally closed switching
contacts.
C. Flush Floor Plates : Provide finished metal flush floor plates for flush closers except where
thresholds are indicated and cover plate is specified to be an integral part of threshold.
Finish floor plate to match hardware, unless otherwise indicated.
D. Recessed Floor Plates : Provide recessed floor plates where no thresholds are indicated
and floor closers are located in an area of resilient flooring, stone flooring or terrazzo.
Recess plates at receive an insert of the floor finish materials, of the normal
thickness as indicated. Provide extended spindle on floor springs as may be necessary to
accommodate thick floor finish inserts.
2.08 DOOR TRIM UNITS
A. Fasteners : Provide manufacturer’s standard concealed fasteners for door trim units (edge
trim, viewers, roses, levers, escutcheons and similar) .
2.09 WEATHERSTRIPPING
A. General : Except as otherwise indicated, provide continuous weatherstripping at each

edge of each exterior door leaf. Provide type, sizes and profiles shown or scheduled.
Provide non-corrosive fasteners as recommended by manufacturer for application
indicated.
B. Replaceable Seal Strips: Provide only those units where resilient or flexible seal strip is
easily replaceable and readily available from local stocks maintained by the manufacturer
or distributor.
C. Weatherstripping at Jambs and Heads :
1. Provide bumper-type resilient insert and metal retainer strips, surface-applies unless
shown as mortised or semi-mortised, or following metal, finish or resilient bumper
material.
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2. Provide Brush Pile insert of polypropylene or nylon woven pile and aluminium strip
backing, complying with AAMA 701.2 .
D. Weatherstripping at Door Bottom :
1. Provide threshold consisting of contact type resilient insert and metal housing of design
and size shown, of following metal, finish and resilient seal strip.
2.10 HARDWARE FINISHES
A. Exposed hardware finishes shall be :
1. For Aluminium Doors: anodised finish, colour as aluminium colour.
2. For full flush and solid wood doors: Polished and Bright brass finish.
3. For steel doors: satin stainless steel - finish.

4. For wood windows and costume casework: bright brass finish.
B. Provide fully matching finishes for all items where possible, to ensure uniformity of
finish only one suite of internationally recognised hardware should be used, in accordance
with requirements previously specified.
C. Provide quality of finish, including thickness of material, composition, hardness and other
qualities complying with the designated standard units referenced in the Hardware
Schedule.
PART 3 : EXECUTION
3.01 INSTALLATION
A. Mount hardware in accordance with BS 4787 except as specifically indicated or required to

comply with governing regulations, and except as the Architect may otherwise direct.
B. Install each hardware item according to manufacturer’s instructions and recommendations.

Wherever cutting and fitting is required to install hardware onto or into surfaces which are
later to be painted or finished in another way, coordinate removal, storage and reinstallation
of hardware or provide surface protections with finishing work specified in the Division-9
sections. Do not install surface-mounted items until finished have been completed on the
substrate.
C. Set units level, plumb and true to line and location Adjust and reinforce the attachment
substrate as necessary for proper installation and operation.
D. Set thresholds for exterior doors in full bed of butyl-rubber of polyisobutylene mastic
sealant.

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3.02 ADJUST AND CLEAN
A. Adjust and check each operating item of hardware and each door, to ensure proper
operation or function of every unit. Replace units which cannot be adjusted to operate
freely and smoothly as intended for the application made.
B. Clean adjacent surfaces soiled by hardware installation.
C. Final adjustment : Wherever hardware installation is made more than one month prior to
acceptance or during the week prior to acceptance or occupancy, and make final check
and adjustment to all hardware items in such space or area. Adjust door control devices
to compensate for final operation of heating and ventilating equipment.
D. Instruct Owner’s Personnel in proper adjustment and maintenance of hardware and

hardware finishes, during the final adjustment of hardware.
E. Continue Maintenance Service: Approximately six months after the acceptance of

hardware in each area., the Installer, accompanied by the representative of the hardware
manufacturer shall inspect and rectify any faults found. Faults of a major nature shall be
detailed in a report to the Owner’s representative.
F. The hardware manufacturer must be able to demonstrate to the satisfaction of the Owner
and Architect that they will supply suitably qualified personnel to the project both during
construction and in a advisory capacity to ensure rectification of any maintenance
problems after acceptance.
Hardware Set
Single Door
Description Quantity
Ball bearing hinges, fire rated, size 102 x 76 x 3mm, tested to carry a maximum 3.00
door weight of 120kg. Satin Stainless steel finish.
Mortise lockcase heavily sprung for lever handles. 8mm lever spindle hole, 1.00
72mm centers. 60mm backset with profile cylinder hole, operates an antisaw
brass deadbolt. Conforms to DIN class 3. Stainless steel forend
2 side key profile cylinder, 71mm long. Fitted with anti pick mushrooms pins. 1.00
Supplied with 3 keys. Master keyed. Satin chrome finish.
1 pair satin stainless steel levers, curved levers, with thumb support, 128mm 1.00
length, 66mm projection on 55mm diameter, 10mm thick roses.
55mm diameter 10mm thick profile cylinder rose. Concealed fixing. Satin 2.00
Stainless steel finish.
Floor door stop, oval shape half moon. Satin chrome finish. Supplied with 1.00
screws.
Double Door

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Ball bearing hinges, fire rated, size 100 x 75 x 3mm thick tested to carry a 6.00
maximum door weight of 120kg. Satin Stainless steel finish
Mortise lockcase heavily sprung for lever handles. 8mm lever spindle hole, 1.00
72mm centers. 60mm backset. Supplied with profile cylinder hole, antisaw
deadbolt. Certified to BSEN 5872, category B & EN 1634-1 fire rating. Forend in
a satin stainless steel finish.
2 side key profile cylinder, 71mm long. Fitted with 6 anti pick mushrooms pins. 1.00
Supplied with 3 keys. Master keyed. Satin chrome finish.
1 pair satin stainless steel levers, curved levers, with thumb support, 128mm 1.00
length, 66mm projection on 55mm diameter, 10mm thick roses.
Strasbourg collection, 55mm diameter 10mm thick europrofile cylinder rose. 2.00
Concealed fixing. Satin stainless steel finish.
Flush bolt, size 225 x 19mm. Satin stainless steel. 2.00
Easy clean socket spring type, dust free. Supplied with screws. Satin stainless 1.00
steel.
END OF SECTION

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SECTION 08800 GLAZING
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment, and incidentals required to install all glazing,
Toughened Glass doors and bath mirror as shown and as specified herein.
1.02 RELATED WORK
1. Section 08120 - Aluminum Doors and Frames.
2. Section 08520 - Aluminum Windows.
3. Section 08630 - Metal-Framed Skylights.
1.03 SUBMITTALS
A. Submit to the Engineer, two representative samples of each type glazing material
specified below. Provide samples of glass in 300mm square minimum size. Resubmit
any or all as required until accepted.
B. Submit to the Engineer, as provided in Submittal Section, full size shop drawings showing
step-by-step glass setting and sealing procedures.
A. All materials for the work of this Section shall be delivered, stored and handled so as to
preclude damage of any nature. All glass shall be delivered and stored in it’s
original container, plainly marked with identification of material and maker. Materials
in broken containers or in packages showing water marks or other evidence of damage
shall not be used and shall be removed from the site.
B. Each piece of glass shall bear the manufacturer’s label showing the strength,
grade, thickness, type, and quality of the glass, and all labels shall remain in place until
the glass has been set and inspected by the Engineer. When glass is not cut to size by
the manufacturer and is furnished from local stick, submit an affidavit stating the strength,
grade, thickness , type, quality , and manufacturer of the glass furnished.

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PART 2 : PRODUCTS
2.01 GLASS TYPE
Sealed insulating glass unit to SIGMA Standards 6 mm thick clear float glass in interior and
6mm thick glazed reflective for exterior plane (as approved by the owner) with 12mm thick air
gap in between or other equal and refer to the List of approved manufacturers & Suppliers
2.02 GLASS MATERIALS
A. Glass Generally: to BS 952, free from bubbles, inclusions, cracks, rippling, dimples and
other defects.
1. Tolerance in thickness : ± 0.2 mm
2. Tolerance in length up to 2000 mm : ± 2 mm
3. Tolerance in length above 2000 mm : ± 3 mm
B. Clear Float Glass: float glass has flat, parallel surfaces which provide clear, undistorted
vision and reflection.
Minimum performance to be as follows:
1. Thickness : 6mm unless otherwise specified

2. Day light reflection : 8%
3. Shading coeffeciant : 0.98
4. U. Value : 5.8 W/m2.K (ASHRAE)
C. Toughened Glass: impact performance to BS 6206, Class A, clear float glass. When it
breaks, toughened glass fragments into small, comparatively harmless pieces.
Refer to schedule of Aluminum windows and drawings for particular usage.
D. Tinted Float Glass: body tinted Float glass, with selected and approved color. Refer to
schedule of Aluminum window and drawings for particular usage.
E. Heat Mirror Glass: heat mirror glass shall be HPR 28 with flat, parallel surfaces which
provide clear, undistorted vision and reflection.
Refer to schedule of Aluminum windows, drawings and DM requirements if any for
particular usage.
2.03 ACCESSORIES AND COMPOUNDS
A. Glazing Compounds, Tapes Strips, Gaskets and Sealants are to be types recommended
by glass and surround manufacturers, unless otherwise specified, and are to be obtained
from approved manufacturers.

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B. Rubber Gaskets: to BS 4255, Part 1, unless otherwise specified.
C. Silicone Sealant: to BS 5889, type A, unless otherwise specified, colour to be selected by

the Engineer.
D. One Part Polysulphide Sealant: to BS 5215, unless otherwise specified, colour to be

E. Two Part Polysulphide Sealant: to BS 4254, unless otherwise specified, colour to be

PART 3 : EXECUTION
3.01 QUALITY OF WORK:
A. Glazing must be wind and water tight under all conditions with full allowance made for
deflections and other movements
B. Panes are to be accurately sized with clean, undisfigured and undamaged edges and
surfaces
C. Keep materials dry until fixed
D. Ensure that glass, surround materials, primers, sealers and paints which are to be used
together are compatible
E. Preparation of surrounds, dimensions of edge cover and clearance, positions and

materials of distance pieces, setting and location blocks are to be BS 6262 and to glass
and sealant manufacturers' recommendations.
3.02 FIXING GENERALLY
A. Preparation : all surfaces to receive glazing are to be clean, dry, unobstructed and
free from grease at time of priming, sealing and glazing. Allow primers or sealers to dry
between coats and before glazing. Ensure that priming or sealing by others has been
carried out and, if unsatisfactory, report to the Engineer before glazing commences.
B. Bead Fixing : fix beads at pre-determined centers in accordance with surround

manufacturer's recommendations, unless otherwise specified.
3.03 GLAZING METHODS
A. Generally : comply with the requirements of FGMA - Flat Glass Marketing Association
(Glazing System Manual and Glazing Manual), and shall also conform to the shop
drawings.
B. Non-Setting or Rubberizing Compounds :

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1. Fully bed glass and beads in compound and fix beads securely
2. Trim excess compound to form smooth, neat chamfer.
C. Tapes and Capping Sealant :

1. Apply tape of sufficient thickness to produce minimum 3 mm bed both sides of glass
after compression; butt joint tape at corners, leaving no gaps; use tape of sufficient
width to fill inside joint after compression and to finish approximately 6 mm below
sight line on outside to receive capping sealant
2. Bed beads to frame in bedding sealant, filling all voids, press firmly into position to
compress tape and fix securely
3. Trim excess tape to a smooth chamfer
4. Apply capping sealant to fill outside joint, finishing to a smooth chamfer.
D. Tapes, Sealant And Inside Trim :
1. Apply tape of sufficient size to produce minimum 3mm bed and to fill joint after
compression; butt joint tape at corners, leaving no gaps.
2. Apply sealant, overlapping pane by at least 3mm
3. Fix beads securely, compressing sealant to form a complete seal
4. Insert internal trim between bead and glass in continuous lengths, leaving no gaps
and allowing for shrinkage.
5. Trim excess tape to a smooth, neat chamber
E. Gasket (Channel Type):
1. Ensure that fixing surfaces are smooth, undistorted and free from burrs, weld spatter
and projections; any required painting is to be carried out before glazing.
2. Lay out gaskets in flat, warm are for 24 hours before glazing.
3. Ensure that edges of glass are arrrised or covered with self-adhesive tape.
4. Fit gasket to frame, butt jointing any ends in center of top of opening, leaving no gaps
5. Lubricate gaskets and zipper strips with water or liquid paraffin
6. Insert glass carefully using hardwood or plastic spatulas
7. Equalize edge clearance with setting blocks
8. Insert zipper strips and allow to retract for at least 4 hours before mitring corners and
pushing into position, leaving no gaps.
F. Gaskets (Single Sided)

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1. Ensure that fixing surfaces are smooth, undistorted and free from burrs, weld spatter
and projections; any required painting is to be carried out before glazing
2. Apply load bearing strip to rebate upstand with butt joints at corners, leaving no gaps
3. Support glass on setting blocks
4. Insert gaskets into groove to seal glass, leaving no gaps and allowing for shrinkage.
G. Mirrors :
1. Fix accurately and securely, but do not overtighten fastenings

2. Ensure undistorted reflection both within and between adjoining panes.
3.04 PROTECTION AND CLEANING
A. Indicators : do not use painted or stuck on indicators on solar control or coloured glass.
Whitewash on ordinary glass must be restricted to small central areas of panes.
B. Cleaning : remove cement and plaster based spillage whilst wet. Remove all smears
and excess glazing materials. Leave glazing clean and free from scratches inside and
out.
C. Clean and remove all labels from all glass when directed and clean glazing compound
from frames around glass installed under this Section upon completion of the work. All
defective or broken glass and glass broken because of faulty setting shall be replaced
under this Section
D. All glass shall be protected under this Section from accidental damage with tapes or
streamers attached to the sash or frame. No tape or streamer shall contact the glass.
E. Aluminium panels shall be cleaned as recommended by the panel

manufacturer. All labels shall be removed without damage or staining of exposed
faces.
END OF SECTION

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DIVISION 9 - FINISHES
SECTION 09220 PORTLAND CEMENT PLASTER
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required for Portland cement
plaster system, including metal furring and lathing, as shown on drawings and specified
herein.
1.02 RELATED WORK
A. Section 4200 - Masonry.
B. Section 03300 - Concrete.
1.03 REFERENCES
A. ASTM C91 - Standard Specification for Masonry Cement.
B. ASTM C150 - Standard Specification for Portland Cement.
C. ASTM C206 - Standard Specification for Finishing Hydrated Lime.
D. ASTM C207 - Standard Specification for Hydrated Lime for Masonry Purposes.
E. ASTM C631 - Standard Specification for Bonding Compounds for Interior Plastering.
F. ASTM C897 - Standard Specification for Aggregate for Job-Mixed Portland Cement
Based Plasters.
G. ASTM C926 - Standard Specification for Application of Portland Cement- Based Plaster.
1.04 SUBMITTALS FOR REVIEW
A. Section 01300 - Submittals: Procedures for submittals.
B. Product Data: Provide data on plaster materials, characteristics and limitations of

products specified.
A. Perform Work in accordance with ASTM C926.

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1.06 MOCK-UP
A. Section 01400 - Quality Control: Requirements for mock-up.
B. Provide mock-up of exterior and interior wall and ceiling system.
C. Construct mock-up, 2 m long by 1.5 m wide, illustrating surface finish.
1.07 ENVIRONMENTAL REQUIREMENTS
A. Section 01601 - Control of Material: Environmental conditions affecting products on site.
B. Do not apply plaster when substrate or ambient air temperature is less than 10 degrees C
nor more than 35 degrees C .
C. Maintain minimum ambient temperature of 10 degrees C during installation of

plaster and until cured.
PART 2 : PRODUCTS
2.01 PLASTER BASE MATERIALS
A. Cement: to ASTM C150, Type I Portland .
B. Lime: to ASTM C206, Type S and C207, Type S.
C. Aggregate: In accordance with ASTM C897.
D. Water: Clean, fresh, potable and free of mineral or organic matter which can affect
plaster.
E. Bonding Agent: in accordance with ASTM C631; type recommended for bonding plaster
to concrete and concrete masonry surfaces.
F. Admixtures: use pasticiser and water-retaining Agents with prior approval.
2.02 PLASTER FINISH MATERIALS
A. Cement: As specified for plaster base coat, gray color.
B. Lime: As specified for plaster base coat.
C. Color Pigment: Mineral oxide.
D. Water: Clean, fresh, potable, and free of matter, which can affect plaster.
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2.03 FURRING AND LATHING
A. Metal Lath: to ASTM C847; flat diamond self-furring mesh, of weight to suit application,
backed with treated paper; galvanized.
B. Wire Mesh Reinforcement: 38 x 38 mm galvanized steel 24 gage 0.6 mm wire, woven

mesh.
C. Casing Bead: Formed sheet steel, depth governed by plaster thickness, maximum
possible lengths, expanded metal flanges, with square edges; galvanized.
D. Corner Bead: Formed sheet steel, depth governed by plaster thickness, maximum
possible lengths, expanded metal flanges with radiused edge; galvanized.
E. Base Screed: Formed sheet steel , depth governed by plaster thickness, maximum
possible lengths, expanded metal flanges, with beveled edge; galvanized.
F. Corner Mesh: Formed sheet steel, minimum 0.5 mm thick, expanded flanges shaped to
permit complete embedding in plaster, minimum 50 mm size; galvanized.
G. Strip Mesh: Expanded metal lath, minimum 0.5 mm thick, 100 mm wide galvanized.
H. Control and Expansion Joint Accessories: Formed sheet steel accordion profile, 50 mm
expanded metal flanges each side, galvanized.
I. Anchorage: Tie wire, nails, and other metal supports, of type and size to suit application;
to rigidly secure materials in place, galvanized.
J. Fasteners: ASTM C1002, self-drilling, self-tapping screws.
2.04 CEMENT PLASTER MIXES
A. Mix and proportion cement plaster in accordance with ASTM C926, and as indicated.
B. Base Coat and Brown Coat: One part cement, minimum 3-1/2 and maximum 4
parts aggregate, and minimum 15 percent and maximum 25 percent hydrated lime.
C. Finish Coat: One part cement, minimum 4 and maximum 5 parts aggregate, and
minimum 25 percent and maximum 50 percent lime.
D. Mix only as much plaster as can be used prior to initial set.
E. Add color pigments to finish coat in accordance with manufacturer's instructions.
F. Mix materials dry, to uniform color and consistency, before adding water.
G. Add admixtures to all coats as manufacturer’s instructions.
H. Protect mixtures from freezing, frost, contamination, and excessive evaporation.
I. Do not retemper mixes after initial set has occurred.

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PART 3 : EXECUTION
3.01 EXAMINATION
A. Verification of existing conditions before starting work.
B. Masonry: Verify joints are cut flush and surface is ready to receive work of this section.
Verify no bituminous or water repellent coatings exist on masonry surface.
C. Concrete: Verify surfaces are flat, honeycomb are filled flush, and surfaces are
ready to receive work of this section. Verify no bituminous, water repellent, or form
release agents exist on concrete surface that are detrimental to plaster bond.
D. Metal Lath and Accessories: Verify lath is flat, secured to substrate, and joint and surface
perimeter accessories are in place.
E. Mechanical and Electrical: Verify services within walls have been tested and approved.
3.02 PREPARATION
A. Dampen masonry surfaces to reduce excessive suction.
B. Clean concrete surfaces of foreign matter. Clean surfaces using acid solutions, solvents,
or detergents. Wash surfaces with clean water.
C. Roughen smooth concrete surfaces and apply bonding agent in accordance

with manufacturer's instructions.
3.03 INSTALLATION - LATHING MATERIALS
A. Apply metal lath taut, with long dimension perpendicular to supports.
B. Lap ends minimum 25mm. Secure end laps with tie wire where they occur between
supports.
C. Lap sides of diamond mesh lath minimum 38mm.
D. Attach metal lath to concrete and masonry using wire hair pins, or loops.
E. Ensure that anchors are securely attached to concrete and spaced at maximum 600 mm
on center.
3.04 INSTALLATION - ACCESSORIES

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A. Continuously reinforce internal angles with corner mesh, return metal 75mm from
corner to form the angle reinforcement; fasten at perimeter edges only.
B. Place corner bead at external wall corners; fasten at outer edges of lath only.
C. Place strip mesh diagonally at corners of lathed openings. Secure rigidly in place.
D. Place 100mm wide strips of metal lath centered over junctions of dissimilar backing
materials. Secure rigidly in place.
E. Place casing beads at terminations of plaster finish. Butt and align ends.
F. Secure rigidly in place.
G. Install door and glazed frames plumb and level in opening. Secure rigidly in place.
H. Install metal access panels and rigidly secure in place.
I. Position to provide convenient access to concealed work requiring access.
3.05 CONTROL AND EXPANSION JOINTS
A. Locate interior control and expansion joints every 6 m. or as indicated.
B. After initial set, scribe contraction joints in exterior work every 1 m in each direction by
cutting through 2/3 of the cement plaster depth, neatly, in straight lines.
C. Locate exterior control and expansion joints every 4m in each direction.
D. Establish control and expansion joints with double casing beads butted tight. Set both
beads over 150mm wide strip of polyethylene sheet for air seal continuity.
E. Coordinate joint placement with other related work.
3.06 PLASTERING
A. Apply plaster in accordance with ASTM C926.
B. Apply brown coat to a nominal thickness of 10mm and a finish coat to a nominal thickness
of 3mm over masonry, concrete and clay tile surfaces.
C. Apply base coat to a nominal thickness of 8mm, brown coat to a nominal thickness of
9mm, and a finish coat to a nominal thickness of 3mm over metal lath.
D. Moist cure base and brown coats. Apply brown coat immediately following initial set of
scratch coat.
E. After curing, dampen previous coat prior to applying finish coat.
F. Apply finish coat and wood float or steel trowel as indicated to a consistent and
smooth finish.
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G. Avoid excessive working of surface. Delay trawling as long as possible to avoid drawing
excess fines to surface.
H. Hand or Machine apply aggregate surfacing to full surface coverage.
I. Moist cure finish coat for minimum period of 48 hours.
3.07 ERECTION TOLERANCES
A. Maximum Variation from True Flatness: 3 mm in 3 m.
3.08 SCHEDULES
A. Interior Area : Two coat cement plaster, smooth wood float finish, excluding scratch coat .
B. Exterior Area: Three coat cement plaster, course float finish, excluding scratch coat.
C. Walls to receive ceramic tiles one coat cement plaster, rake float finish, excluding scratch
coat.
D. Water tight and planters surfaces : Two coat cement plaster, smooth steel trowel finish,
excluding scratch coat.
END OF SECTION

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SECTION 09221 COLOURED PREMIX RENDER
PART 1 GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials; equipment and incidentals required for colored premix
render system, including metal furring and lathing, as shown on drawings and specified
herein.
1.02 RELATED WORK
A. Section 4200 - Masonry.
B. Section 03300 - Concrete.
1.03 SUBMITTALS FOR REVIEW
A. Section 01300 - Submittals: Procedures for submittals.
B. Product Data: Provide data on plaster materials, characteristics and limitations of

products specified.
1.04 MOCK-UP
A. Section 01400 - Quality Control: Requirements for mock-up.
B. Provide mock-up of exterior and interior wall and ceiling system.
C. Construct mock-up, 2 m long by 1.5 m wide, illustrating surface finish.
A. Section 01601 - Control of Material: Environmental conditions affecting products on site.
B. Do not apply plaster when substrate or ambient air temperature is less than 10 degrees C
nor more than 35 degrees C .
C. Maintain minimum ambient temperature of 10 degrees C during installation of

plaster and until cured.
PART 2 : PRODUCTS
2.01 COLOURED RENDER MATERIAL

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A. Colored render shall be high quality pre-mixed water resistant cement based double up
plaster intended for block wall, ceilings and other rendering in thick layers.
B. Material shall be suitable for dry and wet areas, interiors as well as exteriors.
C. Material shall be free of salts like sulphides, chlorides … etc.
D. Material technical data
1. Filler : Precisely graded crushed limestone fractions, maximum

grain Φ1.60mm.
2. Type of binder : Portland cement ASTM C 150.
3. Additives : Contains additives to improve consistency, adhesion and

workability
4. Density : About 1.2 kg/liter in dry powder form, about 1.5 kg/liter when
mixed with water
5. Coverage : About 1.30 kg/sq.mtr of dry product per each mm of coat

thickness.
6. Standard : Conforms to and surpass ASTM C 587-681 Clause 5 and

ASTM C 472-73 Clause 10.
7. Color : As selected by Engineer.
2.02 APPROVED MANUFACTURERS
Refer to the Approved Manufacturers List or other equal and approved.
2.03 FURRING AND LATHING
A. Metal Lath: to ASTM C847; flat diamond self furring mesh, of weight to suit application,
backed with treated paper; galvanized.
B. Wire Mesh Reinforcement: 38 x 38 mm galvanized steel 24 gage 0.6 mm wire, woven

mesh.
C. Casing Bead: Formed sheet steel, depth governed by plaster thickness, maximum
possible lengths, expanded metal flanges, with square edges; galvanized.
D. Corner Bead: Formed sheet steel, depth governed by plaster thickness, maximum
possible lengths, expanded metal flanges with radiused edge; galvanized.
E. Base Screed: Formed sheet steel , depth governed by plaster thickness, maximum
possible lengths, expanded metal flanges, with beveled edge; galvanized.
F. Corner Mesh: Formed sheet steel, minimum 0.5 mm thick, expanded flanges shaped to
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permit complete embedding in plaster, minimum 50 mm size; galvanized.
G. Strip Mesh: Expanded metal lath, minimum 0.5 mm thick, 100 mm wide galvanized.
H. Control and Expansion Joint Accessories: Formed sheet steel accordion profile, 50 mm
expanded metal flanges each side, galvanized.
I. Anchorage: Tie wire, nails, and other metal supports, of type and size to suit application;
to rigidly secure materials in place, galvanized.
J. Fasteners: ASTM C1002, self drilling, self tapping screws.
2.04 RENDER MIXES
A. Mix and proportion colored render in accordance with manufacturer recommendation.
PART 3 : EXECUTION
3.01 EXAMINATION
A. Verification of existing conditions before starting work.
B. Masonry: Verify joints are cut flush and surface is ready to receive work of this section.
Verify no bituminous or water repellent coatings exist on masonry surface.
C. Concrete: Verify surfaces are flat, honeycomb are filled flush, and surfaces are
ready to receive work of this section. Verify no bituminous, water repellent, or form
release agents exist on concrete surface that are detrimental to plaster bond.
D. Metal Lath and Accessories: Verify lath is flat, secured to substrate, and joint and surface
perimeter accessories are in place.
E. Mechanical and Electrical: Verify services within walls have been tested and approved.
3.02 PREPARATION
A. Dampen masonry surfaces to reduce excessive suction.
B. Clean concrete surfaces of foreign matter. Clean surfaces using acid solutions,
solvents, or detergents. Wash surfaces with clean water.
C. Roughen smooth concrete surfaces and apply bonding agent in accordance

with manufacturer's instructions.
3.03 INSTALLATION - LATHING MATERIALS

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A. Apply metal lath taut, with long dimension perpendicular to supports.

B. Lap ends minimum 25mm. Secure end laps with tie wire where they occur between
supports.
C. Lap sides of diamond mesh lath minimum 38mm.
D. Attach metal lath to concrete and masonry using wire hair pins, or loops.
Ensure that anchors are securely attached to concrete and spaced at maximum 600 mm
on center.
3.04 INSTALLATION - ACCESSORIES
A. Continuously reinforce internal angles with corner mesh, return metal 75mm from corner
to form the angle reinforcement; fasten at perimeter edges only.
B. Place corner bead at external wall corners; fasten at outer edges of lath only.
C. Place strip mesh diagonally at corners of lathed openings. Secure rigidly in place.
D. Place 100mm wide strips of metal lath centered over junctions of dissimilar backing
materials. Secure rigidly in place.
E. Place casing beads at terminations of plaster finish. Butt and align ends. Secure rigidly in
place.
F. Install door and glazed frames plumb and level in opening. Secure rigidly in place.
G. Install metal access panels and rigidly secure in place.
H. Position to provide convenient access to concealed work requiring access.
3.05 CONTROL AND EXPANSION JOINTS
A. Locate interior control and expansion joints every 6 m. or as indicated.
B. After initial set, scribe contraction joints in exterior work every 1 m in each direction by
cutting through 2/3 of the cement plaster depth, neatly, in straight lines.
C. Locate exterior control and expansion joints every 4m in each direction.
D. Establish control and expansion joints with double casing beads butted tight. Set both
beads over 150mm wide strip of polyethylene sheet for air seal continuity.
E. Coordinate joint placement with other related work.
3.06 RENDERING

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A. Apply plaster in accordance with manufacturer recommendation.
B. Apply render material by machine spaying or by manual trowelling; the first layer should
be pushed hard on the surface. In thick layers use guidance screeds to make surface
straight, and use aluminum linear, wooden straight edge or steel trowel to insure a
level, uniform and flawless finish.
C. Cure by water spray 2 hours after application and once every 12 hours thereafter for at
least the next 3 days.
END OF SECTION

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SECTION 09300 CERAMIC TILE
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to install ceramic tile on
floors, base and walls using thin set applications method, including bath fitting as shown
on the drawings and specified herein.
B. Tile and expansion joint pattern shall be as shown and as accepted.
1.02 RELATED WORK
A. Other sections directly related to work covered in this section includes the following:
1. Section 07005 - Waterproofing and Damp proofing.
3. Plumbing Work Sections.
1.03 REFERENCES
A. ANSI A108.1 - Installation of Ceramic Tile with Portland Cement Mortar.
B. ANSI A108.4 - Installation of Ceramic Tile with Organic Adhesives or Water Cleanable
Tile Setting Epoxy Adhesive.
C. ANSI A108.5 - Installation of Ceramic Tile with Dry-Set Portland Cement

Mortar or Latex Portland Cement Mortar.
D. ANSI A108.10 - Installation of Grout in Tile work.
E. ANSI A118.1 - Dry-Set Portland Cement Mortar.
F. ANSI A118.6 - Ceramic Tile Grouts.
G. ANSI A136.1 - Organic Adhesives for Installation of Ceramic Tile.
H. ANSI A137.1 - Standard Specifications for Ceramic Tile.
I. TCA (Tile Council of America) - Handbook for Ceramic Tile Installation.
J. ASTM C847 - Metal Lath.

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1.04 SUBMITTALS
A. Submit under provisions of Section 01300.
B. Shop Drawings: Indicate tile layout, patterns, color arrangement, perimeter conditions,
junctions with dissimilar materials, control and expansion joints, thresholds, and setting
details.
C. Product Data: Provide instructions for using adhesives and grouts.
D. Samples: Mount tile and apply grout on two plywood panels, (800x600 mm) in size
illustrating pattern, color variations, and grout joint size variations.
E. Manufacturer's Certificate: Certify that Products meet or exceed specified

requirements.
A. Submit Maintenance Data Include recommended cleaning methods, cleaning

materials, stain removal methods, and polishes and waxes.
A. Perform Work in accordance with ANSI A137.1.
B. Conform to TCA Handbook, and ANSI A108.4.
C. Maintain one copy of each document on site.
1.07 QUALIFICATIONS
A. Manufacturer: Company specializing in manufacturing the Products specified in this

section with minimum five years experience.
B. Installer: Company specializing in performing the work of this section with minimum three
years experience and approved by manufacturer.
1.08 DELIVERY, STORAGE, AND HANDLING
A. Protect adhesives from freezing or overheating in accordance with manufacturer's

instructions.
A. Do not install adhesives in an unventilated environment.

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1.10 EXTRA MATERIALS
A. Provide (3 sq m) of each size, color, and surface finish of tile specified, and
representative trim, all properly packed in cartons, and clearly marked on the outside
.
PART 2: PRODUCTS
2.01 CERAMIC MANUFACTURERS
A. Local made of ceramic tile and fittings shall be accepted or other equal and approved
B. Floor and wall ceramic tile shall be dry pressed type with water absorption less than 0.5%
sizes as selected and shown on drawings, minimum thickness 8mm, anti - slip provided
with all fittings and Manufactured by local company.
or other equal and approved
2.02 CERAMIC TILE MATERIALS
A. Ceramic Floor Tile: Internal Corridor, living/bed room to much floor conforming to
the following:
1. Moisture Absorption (0.05 to 0.5) percent.

2. Shape Square.
3. Edge Square.
4. Surface Finish Slip resistant.
5. Color As selected
6. Size Refer to Schedule of Finishes
B. Ceramic Wall Tile: conforming to the following:
1. Moisture Absorption (0.5) percent

2. Shape Square.
3. Edge Square.
4. Surface Finish Matte glazed or semigloss and as indicated.
5. Color As selected.
6. Size Refer to Schedule of Finishes
C. Class Mosaic Tile for fountain floor and walls: To the requirements of DIN-EN176, and
DIN-EN122 supplied glued on paper sheets with adhesive of face, conforming to the
following:
1. Moisture Absorption (0.5 to 3.0) percent

2. Shape Square
3. Edge Square.
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4. Color As selected.
5. Pattern As selected.
6. Size Refer to Schedule of Finishes.
D. Internal corner for first courses of wall tile shall be coved, 100 mm height, match wall tile
for moisture absorption, surface finish, length and colour.
E. Wainscot Cap: Match wall tile for moisture absorption, surface finish, and color, tile length
as manufacture range and approved by the engineer, bull nosed top edge.
2.03 BASE MATERIALS
A. Base: Match floor tile for moisture absorption, surface finish, and color:
1. Length Tile length.
2. Height (150 mm) and as stated on the drawings.
3. Top Edge Bull nosed.
4. Internal Corner Coved.
5. External Corner Bull nosed.
2.04 STAIR MATERIALS
A. Match ceramic tile for moisture absorption, surface finish, and color:
1. Tread Length Tile length.

2. Riser Height As riser height.
3. Nosing Bull nosed.
4. Tread Surface Non-slip.
2.05 ADHESIVE MATERIALS
A. Type recommended by adhesive and tiling manufacturer’s as suitable for type of tile and
location in the works and to be approved.
2.06 GROUT MATERIALS
A. Grout : shall be water-resisting , cement - based material, suitable for grouting ceramic
wall and floor tile joints in interior and exterior installation, as recommended by
manufacturer for use to wall or floor installation conform to BS5750 : Part 2; colours as
selected;
2.07 GROUT MIX
A. Mix and proportion pre-mix grout materials in accordance with

manufacturer's instructions.

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PART 3 EXECUTION
3.01 EXAMINATION
A. Verify that surfaces are ready to receive work.
3.02 PREPARATION
A. Protect surrounding work from damage or disfiguration.
B. Vacuum clean surfaces
C. Seal substrate surface cracks with filler.
D. Apply sealer to substrate surfaces in accordance with adhesive manufacturer's

instructions.
3.03 INSTALLATION - THINSET METHOD
A. Install adhesive tile, thresholds, stair treads, and grout in accordance with manufacturer's
instructions.
B. Lay tile to pattern indicated.
C. Place edge strips at exposed tile edges.
D. Place tile joints uniform in width, subject to variance in tolerance allowed in tile size.
Make joints watertight, without voids, cracks, excess mortar, or excess grout.
E. Sound tile after setting. Replace hollow sounding units.
F. Keep expansion joints free of adhesive or grout.
G. Allow tile to set for a minimum of 48 hours prior to grouting.
H. Grout tile joints.
I. Apply sealant to junction of tile and dissimilar materials and junction of dissimilar planes.
J. Form internal angles coved and external angles bullnosed.
3.04 CLEANING
A. Clean tile and grout surfaces.
3.05 PROTECTION OF FINISHED WORK
A. Do not permit traffic over finished floor surface for 4 days after installation.
END OF SECTION
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SECTION 09410 TERRAZZO TILE
PART1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to install terrazzo floor
and base tiles including stairs and landings tile as shown and as specified herein.
B. Tile and control (expansion) joint pattern shall be as shown and as accepted.
1.02 RELATED WORK
1. Section 07005 - Waterproofing and Dampproofing.
1.03 REFERENCES
A. ASTM A185 - Welded Steel Wire Fabric for Concrete Reinforcement.
B. ASTM C33 - Concrete Aggregates.
C. ASTM C150 - Portland Cement.
D. ASTM C309 - Liquid Membrane-Forming Compounds for Curing Concrete.
E. ASTM D2103 - Polyethylene Film and Sheeting.
F. NTMA (National Terrazzo and Mosaic Association, Inc.) - Terrazzo Ideas and Design
Guide.
1.04 SUBMITTALS
A. Submit two copies of manufacturer's specifications and installation instructions for all
materials required. Include size, thickness, riser, skirting, thread certifications and other
data as may be required to show compliance with these Specifications.
B. Submit one sample panel of each tile type mounted on not less than 600 mm square
plywood or hardboard backing and grouted as required. Engineer's review will be for color,
pattern, and texture only. Resubmit as required until acceptance is obtained.
C. Submit as provided in Section 01300 for shop drawings, layouts of tile jointing for rooms
and areas requiring tile.

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A. Installation Specifications shall conform to NTMA except as provided otherwise herein.
B. Maintain one copy of document on site.
1.06 SAMPLE FLOOR AREA
A. The Engineer will select one room or area which is scheduled to receive floor tile and
designate it as the sample floor area. This area shall be finished and approved before
authorization to proceed with work in other areas.
B. The sample floor area shall, upon approval, be part of the finish work and shall become the
standard of acceptance for floor finish on the remainder of the project.
A. Do not install terrazzo when temperature is below (10 degrees C) or above (40 degrees
C).
B. Maintain this temperature range 24 hours before, during, and 72 hours after installation of
terrazzo.
1.08 COORDINATION
A. Coordinate the work with mechanical and electrical access cover placement in relation
to terrazzo divider strips.
1.09 PRODUCT DELIVERY, STORAGE AND HANDLING
A. Deliver materials and store on the site in original containers with seals unbroken and
labels intact until time of use and handle all in accordance with manufacturer's directions.
No tile shall be dropped during unloading or handling.
PART2: PRODUCTS
2.01 MATERIALS
A. Terrazzo tiles and fittings shall be precast pressed tiles, with the wearing surfaces made
of white Portland cement and local marble chipping of an approved quality and color.
Tiles shall be Grade A, sound, square edged, and of even and uniform texture and color.
Terrazzo tiles shall meet the prescribed laboratory tests.
B. Cement shall conform to ASTM C150, Type I.
C. Color Pigments for Topping: Non-fading mineral type.

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D. Terrazzo Sand shall conform to ASTM C33.
E. Underbed: One part Portland cement to 4 parts sand by volume. Add water to produce
low slump mix.
F. Grout shall be Hydroment tile grout factory mixed with all required aggregate and
pigment. The colors shall be selected by the Engineer.
Man : Building Adhesives limited - BAL England

Tel : 0782659921
Fax : 0782643909
G. Water shall be fresh, clean and potable, free from organic matter, acids and alkalis.
H. Premolded control joint filler shall be approved closed cell, plastic foam filler, 10 mm (3/8-
in) thick.
2.02 MORTAR MIXES
A. Setting bed mortar mixes for floor, base, stair treads, and wall conditions shall conform to
NTMA as approved.
B. Grout shall be mixed with water only in strict accordance with the manufacturer's
instructions. The color of the grout shall be strictly controlled so that all joints will be
uniform throughout, and shall be satisfactory to the Engineer.
PART3: EXECUTION
3.01 GENERAL
A. Coordinate work with the work of other trades affected by tile work. Grounds, door
bucks, electrical boxes, connections for plumbing and heating fixtures, and all fittings
shall be in place and pipe chases and other openings shall be properly closed before any
tile is installed.
B. Inspect all surfaces to receive tile be assured that they are in proper condition for the
work to be performed under this Section. Concrete to receive tile shall cured 28 days,
minimum, before receiving tile. Notify the Engineer in writing of any condition requiring
correction before any tile work is installed. Failure to make such a report shall be
construed as acceptance of the conditions.
C. Coordinate the work of this Section and that of the Section 07005 to insure that the
required joints are caulked before grouting is performed.
3.02 CONTROL JOINTS
A. Install control joints (tile expansion joints) in tile work at locations noted, at the intersection
with walls and vertical obstructions, at other places where construction joints occur in
concrete subfloor.

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3.03 INSTALLATION - FLOOR TILE
A. Set all tile in neat cement paste applied to a plastic setting bed. Thoroughly beat-
in all tile while the mortar bed is still plastic. The beating shall fill the entire space
between ribs of rib-backed tile with mortar. Provide control joints free of mortar where
detailed and required.
B. Tile shall be laid out in grid pattern as shown on Drawings and shop drawings. Unless
shown otherwise, floor tile pattern shall be centered in room with generally no tile cut
smaller than half size and all cuts on the outer edge of the field. Floor tile shall be set with
2 mm joints to receive grout.
C. Extend tile work into recesses and under or behind equipment and fixtures, to form
a complete covering without interruptions, except as otherwise specified or shown.
Terminate work neatly at obstructions, edges and corners without disrupting pattern or
joint alignments.
D. Accurately form intersections and returns. Perform cutting and drilling of tile without
marring visible surfaces. Carefully grind cut edges of tile abutting trim, finish or built-in
items for straight aligned joints. Fit tile closely to electrical outlets, piping, fixtures and
other penetrations so that plates, collars, or covers overlap tile.
E. Provide openings for control joints where and as indicated and as specified above.
If not indicate and detailed, comply with recommendations in TCA "Handbook for
Ceramic Tile Installation" leaving joints ready for sealant specified.
F. Grout tile joints using the approved prepared grout. Force a maximum amount of grout
into the joints. Follow the grout manufacturer's directions explicitly. Tool joints flush for
floor tile and to bottom of cushion edge for wall tile, all as accepted by the Engineer.
Mortar shall not show through grouted joints. The finished grout shall be uniform in color,
smooth and without voids, pinholes or low spots.
3.04 INSTALLATION - BASE
A. Vertical Base Projecting From Wall : 9 mm minimum topping on underbed bonded to wall
substrate, projecting 5mm from finish wall surface, as detailed and shown on drawings .
3.05 APPLICATION - STAIRS
A. Terrazzo Stairs and Landings: Minimum 16mm topping on underbed bonded to treads
and minimum 9mm topping on underbed bonded to risers.
3.06 CURING
A. Use curing method in accordance with NTMA instructions. B Close area to allow
undisturbed curing.
3.07 SURFACE FINISHING
A. Brush apply terrazzo toping mix slurry to topping surface.

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B. Finish terrazzo in accordance with NTMA instructions.
C. Produce terrazzo finish surface to match approved sample, with minimum 70 percent chip
exposed.
D. Grind terrazzo surface with power disc machine; successively sequence using coarse to
fine grit abrasive, using a wet method.
E. Apply grout mix to match matrix over ground surfaces to fill honeycomb exposed during
grinding.
F. After grout has sufficiently cured, grind, using a fine grit abrasive.
3.08 TOLERANCES
A. Maximum Variation from Flat Surface: 2 mm in one m.
B. Maximum variation from Level (Except Surfaces Sloping to Drain): 2mm
3.9 CLEANING AND PROTECTION
A. Upon completion of placement and grouting, clean all tile surfaces so they are free of
foreign matter.
B. Seal and polish surfaces in accordance with NTMA.
C. Tile may be cleaned with acid solutions only when permitted by tile and grout
manufacturer's printed instructions, but not sooner than 14 days after installation.
Protect metal surfaces, cast iron and vitreous plumbing fixtures from effects of acid
cleaning. Flush surface with clean water before and after cleaning.
D. Leave finished installation clean and free of cracked, chipped, broken, unbonded, or
otherwise defective tile work.
E. Prohibit foot and wheel traffic from using tiled floors for at least 3 days after grouting is
completed. Damp cure for 72 hours minimum.
F. Before final inspection, remove protective coverings and rinse neutral cleaner from tile
surfaces.
END OF SECTION

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SECTION 09600 STONE FLOOR AND WALL TILING
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, equipment and incidentals required to install Marble limestone
floor, base, sills and vanity top finish using thinset or mortar bed application as selected
and shown on drawings and as specified herein .
B. Tile and control (expansion) joint pattern shall be as shown and as accepted.
1.02 RELATED WORK
A. Section 07900 - Caulking.
B. Plumbing Work Sections.
1.03 REFERENCES
A. ANSI A118.1 - Dry-Set Portland Cement Mortar.
B. ANSI A118.3 - Chemical Resistant, Water Cleanable Tile-Setting and Grouting Epoxy
and Water Cleanable Tile Setting Epoxy Adhesive.
C. ANSI A136.1 - Organic Adhesives for Installation of Ceramic Tile.
D. ASTM A185 - Welded Steel Wire, Fabric, Plain, for Concrete Reinforcement.
E. ASTM C33 - Concrete Aggregates.
F. FASTM C144 - Aggregate for Masonry Mortar.
G. ASTM C150 - Portland Cement.
H. ASTM C503 - Marble Dimension Stone (Exterior).
I. ASTM C568 - Limestone Dimension Stone.
J. ASTM C615 - Granite Building Stone.
K. ASTM C629 - Slate Dimension Stone.
L. ASTM C1142 - Ready-Mixed Mortar for Unit Masonry.
M. TCA (Tile Council of America) - Handbook for Ceramic Tile Installation.

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1.04 SUBMITTALS
A. Submit under provisions of Section 01300
B. Shop Drawings: Indicate stone layout, patterns, color arrangement, perimeter

conditions, junctions with dissimilar materials, control and expansion joints, thresholds,
and setting details.
C. Submit stone supplier's installation instructions and field erection drawings.
D. Product Data: Provide instructions for using grout.
E. Samples: Mount stone and apply grout on two plywood panels, illustrating pattern, color
variations, and grout joint size variations.
F. Submit sample of colored grout.
G. Submit stone samples for sealant compatibility testing.
A. Submit Maintenance Data: Include recommended cleaning methods, cleaning materials,

stain removal methods, and polishes and waxes.
B. Include list of liquids detrimental to appearance of stone finish.
A. Perform Work in accordance with TCA Handbook for instructions applicable to mortar
setting bed thinset bed and grouting.
B. Maintain one copy of document on site.
1.07 MOCKUP
A. Construct mockup, 2 m long by 1.5 m wide, with finish grout, and specified
accessories.
B. Locate where directed.
PART 2 : PRODUCTS
2.01 NATURAL STONE SLABS AND FITTINGS GENERALLY
A. To be first quality stone, each type obtained from one strata, from one quarry and
delivered in one shipment.
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B. Slabs are to be hard and free from cracks and other defects to surfaces and edges which
may impair structural integrity, function or appearance and are to be cut square and true
with clean edges and uniform in shape and thickness.
C. Length and width dimensions of individual slabs are to be within ± 1mm and thickness
within 3mm from those shown on the Drawings.
D. Submit supplier’s test results for each type of stone for the following tests, which must
meet the following:
Item Stone Marble

Weight per unit of volume ton/m3 2.45 2.7
(ASTM-C97), Min
Absorption coefficient Wt % 4.2 0.11
(ASTM-C97), Max
Compression breaking load Kg/cm2 280 1300
(ASTM-C170), Min
Rupture Modulus (ASTM-C99) Kg/cm2 52 200
Thermal Expansion Mm/m°C 0.005 0.0063
2.02 MARBLE AND STONE MATERIALS
A. Marble: to ASTM C503 ; free of defects detrimental to appearance or durability:
1. Unit Size: as shown on drawings.
2. Thickness: 30mm or as shown on drawings.
3. Surface Finish: Polished as indicated.
4. Colours and types: to be as follows :
Beige color: Gialo Zianna Marble.

Brown color: Gialo Senape Marble.
Dark red color: Rosso Laguna Marble.
Dark Green color: Verdi Glada Marble.
5. The selected marble slabs shall have round edges, correctly cut or rubbed to produce
the required aesthetic finish.
B. Base: Match flooring for surface finish and color; size, Top edge, internal and external
corner as shown on drawing.
C. Stair Treads and Risers: Match flooring for surface finish and color; free of defects
detrimental to appearance or durability, size and Exposed edge as shown on Drawings.
2.03 ADHESIVE MATERIALS
A. Type recommended by adhesive and tiling manufacturer’s

recommendation as suitable for type of tile and location in the works and to be approved
by engineer.
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2.04 MORTAR MATERIALS
A. Portland Cement: ASTM C150, Type I.
B. Sand: ASTM C144, and ASTM C33, Sharp, coarse, clean, screened sand, free from
deleterious materials.
C. Water: Potable.
D. Additives: Plasticizer.
2.05 GROUT MATERIALS
A. Shall be factory mixed with all required aggregate and pigment, the colour shall be
selected and approved by Engineer.
Refer to the Approved Manufacturers list
2.06 ACCESSORIES
A. Sealant: shall be tow part polysulphide as specified in Section 07900.
B. Cleaner: Recommended by stone producer and grout manufacturer which will not
harm stone, joint materials, or adjacent surfaces.
2.07 MORTAR AND GROUT MIX
A. Mix and proportion pre-mix setting bed and grout materials in accordance with
B. Mix and proportion cementitious materials for site made mortarbed.
C. Add mortar color and admixtures in accordance with manufacturer's instructions.

Control uniformity of mix and coloration.
2.08 STONE FABRICATION
A. Form stone into panel sizes and thickness required.
B. Form stair treads and risers to configuration as detailed.
PART 3 : EXECUTION
3.01 EXAMINATION
A. Verify that surfaces are ready to receive work.

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3.02 PREPARATION
A. Vacuum clean substrate surfaces; damp clean stone.
B. Seal substrate surface cracks with filler.
C. Clean stone prior to installation, with edges and surfaces free of dirt or foreign material.
D. Do not use wire brushes or implements which mark or damage exposed surfaces.
3.03 INSTALLATION - THINSET METHOD
A. Install stone in accordance with stone fabricators and manufacturer's instructions.
B. Install stone, thresholds, stair treads, and grout in accordance with manufacturers
instructions .
C. Lay stone units to pattern indicated. Do not interrupt tile pattern through openings.
D. Place thresholds at door frame openings, notching stone for door stop.
E. Cut and fit stone units tight to penetrations through unit. Ensure finish trim will cover cut
edges. Form corners and bases neatly. Align floor and base joints.
F. Maintain uniform joint width subject to variance in tolerance allowed in stone unit size.
Make joints watertight, without voids, cracks, excess mortar or excess grout.
G. Maintain joint width of 6 mm where abutting vertical surfaces or protrusions.
H. Sound test the units and after setting. Replace hollow sounding units.
I. Keep expansion and control joints free of mortar or grout. Apply sealant to joints.
J. Allow thinset materials to cure prior to grouting.
K. To accommodate joint grout, rake out joints 6 to 10 mm. Grout joints. Pack and work into
voids. Neatly tool surface to a flush joint.
L. Apply sealant to junction of stone and dissimilar materials and junction of dissimilar
planes.
M. Set stone in full mortar bed to support stone over full bearing surface. Accurately establish
joint dimensions.
3.04 INSTALLATION - MORTAR BED METHOD
A. Install stone in accordance with stone fabricators and manufacturer's instructions.
B. Install mortar bed, tile, threshold, stair treads, and grout in accordance with

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C. Apply mortar bed over cement screed surfaces to a thickness as shown on drawings.
D. Lay stone units to pattern indicated. Do not interrupt tile pattern through openings.
E. Set stone in full mortar bed to support stone over full bearing surface.
F. Place thresholds at door frame openings, notching stone for door stop.
G. Cut and fit stone units tight to penetrations through unit. Ensure finish trim will cover cut
edges. Form corners and bases neatly. Align floor and base joints.
H. Maintain uniform joint width subject to variance in tolerance allowed in stone unit size.
Make joints watertight, without voids, cracks, excess mortar or excess grout.
I. Maintain joint width of 5 mm where abutting vertical surfaces or protrusions.
J. Sound test the units after setting. Replace hollow sounding units.
K. Keep expansion and control joints free of mortar or grout. Apply sealant to joints.
L. Allow units to set for a minimum of 48 hours prior to grouting.
M. To accommodate joint grout, rake out joints 6 to 10 mm. Grout joints. Pack and work into
voids. Neatly tool surface to a flush joint.
N. Apply sealant to junction of stone and dissimilar materials and junction of dissimilar
planes.
3.05 CLEANING
A. Clean stone and grout surfaces with cleaner; seal with sealer.
END OF SECTION

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SECTION 09901 SURFACE PREPARATION AND SHOP PRIME PAINTING
PART 1: GENERAL
1.01 SCOPE OF WORK
A. Furnish all labor, materials, and equipment required for the surface preparation and
application of shop primers on ferrous metals, excluding stainless steels, as specified
herein.
1. Section 09902 - Painting
1.03 SUBMITTALS
A. Submit to the Engineer as provided in the Submittals section for shop drawings,
manufacturer's specifications and data on the proposed primers and detailed
surface preparation, application procedures and dry mil thicknesses.
B. Submit representative physical samples of the proposed primers, if required by the

Engineer.
PART 2: PRODUCTS
2.01 MATERIALS
A. Welding. All welded joints which will be fully or partially submerged shall be sealed
watertight by continuous welds.
B. Edge Grinding. Sharp corners of cut or sheared edges shall be ground to a radius as
required to ensure satisfactory paint adherence.
C. Surface Preparation. All ferrous metal surfaces, except motors, speed reducers, and
stainless steel, shall be blast cleaned in conformance with the paint manufacturer's
recommendations. All mill scale, rust, and contaminants shall be removed before shop
primer is applied.
D. Shop Painting. Surfaces to be painted after installation shall be prepared for painting as
recommended by the paint manufacturer for the intended service, and then shop painted
with one or more coats of the specified primer.
E. Compatibility of Coating Systems. Shop priming shall be done with primers that are
guaranteed by the manufacturer to be compatible with their corresponding primers and
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finish coats specified in the Painting Section for use in the field and which are
recommended for use together.
PART 3: EXECUTION
3.01 APPLICATION
A. Surface Preparation and Priming
1. Non-submerged components scheduled for priming, as defined above, shall be

sandblasted clean in accordance with SSPC-SP-6, Commercial Grade, immediately
prior to priming. Submerged components scheduled for priming, as defined above,
shall be blast clean in accordance with SSPC-SP-10, near white, immediately
prior to priming.
2. Surfaces shall be dry and free of dust, oil, grease and other foreign material before
priming.
3. Shop prime in accordance with manufacturer's recommendations.
END OF SECTION

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SECTION 09902 PAINTING
PART 1: GENERAL
1.01 SCOPE OF WORK

A. Furnish all materials, labor, equipment and incidentals required to perform all the painting
necessary to complete this contract in its entirety.
B. It is the intent of these Specifications to paint all exposed structural and miscellaneous
steel; steel doors and frames; door closers and surface sand/dust seals at painted doors;
mechanical and electrical equipment, sluice gates, actuators, posts, conveying
systems, pipe, fittings and valves; electrical conduit and appurtenances; exposed
ventilating ducts, equipment and appurtenances; plaster walls and ceilings, concrete walls
and ceilings, architectural wood and plywood components, all as specified in the attached
painting schedules and all other work obviously required to be painted unless otherwise
specified. Minor items not mentioned in the schedule of work shall be included in the
work of this Section where they come within the general intent of the specifications as
stated herein.
C. “Paint” as used herein means all coating systems materials, including primers, emulsion,
enamels, stains, sealers and fillers, and other applied materials whether used as prime,
intermediate or finish coats.
D. The following items will not be painted:
1. Concrete (unless otherwise specified in the painting schedules), cementitious finish,

stone and granite cladding and tile work.
2. Face brick.
3. Finish hardware unless specifically noted otherwise.
4. Non-ferrous metals and stainless steels, unless specifically noted otherwise.
5. Packing glands and other adjustable parts and nameplates of mechanical equipment.
6. Parts of buildings not exposed to sight, unless specifically noted otherwise.
7. Pre-Finished items.
8. Mechanical, electrical and instrumentation equipment which has been finished painted
in the factory as specified.
9. Rubber and plastic materials.
E. Painting Schedule
Descriptions
1. a. Internal wall / ceiling 1 base coat + 2 primer coat +1 finish coat of emulsion
or equivalent
b. External wall 1 base coat + 1 primer coat + 1 finish coat of water
resistant epoxy paint
2. Aluminium Electro Statically backed applied polyester powder
coated finish, color to be approved by the engineer.
3. Steel Shop spray painted finish + 1 base coat of red oxide
with putty + 1 primer coat + 1 finish coat as per
manufacturer’s recommendation.
4. Wooden Shop spray paint finish

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a. Frame, Architrave 1 base coat with putty + primer + 1 finish coat with
Sealer
b. Shutter 1 base coat with putty + primer + 1 finish coat with
Sealer
5. Service Room Floor One base coat oil primer + 2 coat enamel/paint
1.02 RELATED WORK
1. Section 3300 - cast-in place concrete.
2. Section 04200 - Masonry
3. Section 06200 - Finish carpentry
4. Section 09220 - Cement Plaster
5. Section 09901 - Surface Preparation and Shop Painting.
1.03 SUBMITTALS
A. Product Data: Submit manufacturer’s technical information including basic materials

analysis and application instruction for each material proposed for use.
B. Samples: prior to beginning work, Architect will furnish colour chips for surfaces to be
painted. Use representative colors when preparing samples for review. Submit samples
for Architect’s review of colour and texture only. Provide a listing of material and
application for each coat of each finish sample.
1. On 300 x 300mm hardboard, provide 2 samples of each colour and material, with
texture to simulate actual conditions. Resubmit samples as requested until
acceptable sheen, colour and texture is achieved.
2. On actual wood surfaces, provide two 100 x 200mm samples of natural and
stained wood finish. Label and identify each as to location and application.
3. On concrete masonry, provide two 100mm square samples of masonry for each
type of finish and colour; define filler, prime and finish coats.
4. On actual wall surfaces and other interior and exterior building components,
duplicate painted-finishes of prepared samples. Provide full-coat finish samples on
at least 10 sq.m. of surface, as directed, until required sheen, colour and texture
is obtained; simulate finished lighting conditions for review of in-place work.
a. Final acceptance of colors will be from samples applied on the job.
1.04 DELIVERY AND STORAGE
A. Deliver materials to job site in original, new and unopened packages and containers
bearing manufacturer’s name and label, and following information.

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1. Name or title of material.
2. Fed. Spec. or British Standard number, if applicable.
3. Manufacturer’s stock number and date of manufacturer.
4. Manufacturer’s name.
5. Contents by volume, for major pigment and vehicle constituents.
6. Thinning instructions.
7. Application instructions.
8. Colour name and number.
B. Store materials not in actual use in tightly covered containers. Maintain containers used
in storage of paint in clean conditions, free of foreign materials and residue.
1. Protect from freezing where necessary, Keep storage areas heat and orderly.
Remove oily rags and waste daily. Take all precautions to ensure that workmen and
work areas are adequately protected from fire hazards and health hazards resulting
from handling, mixing and application of paints.
1.07 JOB CONDITIONS
A. Apply water-base paints only when temperature of surfaces to be painted and the
surrounding air temperatures are between 10°C and 40°C, unless otherwise permitted by
paint manufacturer’s printed instructions.
B. Apply solvent-thinned paints only when temperature of surfaces to be painted and the
surrounding air temperatures are between 7°C and 40°C, unless otherwise permitted by
paint manufacturer’s printed instruction.
C. Do not apply coatings in snow, rain, fog or mist; or when relative humidity exceeds 85%
or to damp or wet surfaces; unless otherwise permitted by coating manufacturer’s printed
instructions.
1. Painting may be continued during inclement weather only if areas and surfaces to be
painted are enclosed and heated within temperature limits specified by paint
manufacturer during application and drying periods.
PART 2: PRODUCTS
2.01 MATERIALS
A. All painting materials shall be delivered to the mixing room in unbroken packages, bearing
the manufacturer's brand and name. They shall be used without adulteration and mixed,
thinned, and applied in strict accordance with manufacturer's directions for the applicable
materials and surface and with the Engineer's approval before using.
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B. Shop priming shall be done with primers that are guarantee by the manufacturer to
be compatible with the finish paints to be used. Refer to the surface Preparation and
shop Painting Section for special primers.
C. All paint used shall be guaranteed by the paint manufacturer to be fume proof and
suitable for an atmosphere containing hydrogen sulfide.
D. Materials shall be in full compliance with the requirements of pertinent codes and fire
regulations. Proper containers outside of the buildings shall be provided and used for
painting wastes, and no plumbing fixture shall be used for this purpose.
E. Material Quality: Provide best quality grade of various types of coatings as regularly
manufactured by acceptable paint manufacturers. Use only materials displaying
manufacturer’s identification as a standard, best- grade product.
1. Proprietary names used to designate colors or materials are not intended to imply that
products of named manufacturers are required to exclusion of equivalent products of
other manufacturers.
2. Federal Specifications/British Standards establish minimum acceptable

quality for paint materials. Provide a written certification from paint manufacturer that
materials provided meet or exceed these minimums.
3. Manufacturer’s products that comply with coating qualitative requirements of

applicable federal specifications, yet differ in quantitative requirements, may be
considered for use when acceptable to Architect. Furnish material data and
manufacturer’s certificate of performance to Architect for proposed substitutions.
C. Colour Pigments: Pure, non-fading, applicable types to suit substrates and service
indicated.
1. Lead content in pigment, if any, is limited to contain not more than 0.06% lead, as
lead metal based on the total non-volatile (dry-film) of paint by weight.
PART 3: EXECUTION
3.01 INSPECTION
A. Applicator must examine areas and conditions under which painting work is to be applied
and notify Contractor in writing of conditions detrimental to proper and timely completion of
work. Do not proceed with work until unsatisfactory conditions have been corrected in a
manner acceptable to applicator.
B. Starting of painting work will be construed as applicator’s acceptance of surfaces within

any particular area.
C. Do not apply paint over dirt, rust, scale, grease, moisture, scuffed surfaces, or
conditions otherwise detrimental to formation of a durable paint film.

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3.02 SURFACE PREPARATION
A. General : Perform preparation and cleaning procedures in compliance with paint

manufacturer’s instructions and as herein specified, for each particular substrate
condition.
1. Provide barrier coats over incompatible primers or remove and reprime as required.
Notify Architect in writing of any anticipated problems in using the specified coating
systems with substrates primed by others.
2. Remove ironmongery, ironmongery accessories, machined surfaces, plates, lighting

fixtures and similar items in place and not to be finish painted, or provide surface-
applied protection prior to surface preparation and painting operations. Remove, if
necessary, for complete painting of items and adjacent surfaces.
Following completion of painting of each space or area, reinstall removed items.
3. Clean surfaces to be painted before applying paint or surface treatments. Remove oil
and grease prior to mechanical cleaning. Program cleaning and application so that
contaminants from cleaning process will not fall on wet, newly-painted surfaces.
B. Cementitious Materials : Prepare cementitious surfaces of concrete, concrete block,

cement plaster and cement-asbestos board to be painted by removing efflorescence,
chalk, dust, dirt, grease, oils, and by roughening if required to remove glass .
1. Determine alkalinity and moisture content of surfaces to be painted by performing

appropriate tests. If surfaces are found to be sufficiently alkaline to cause blistering
and burning of finish paint, correct this condition before application of paint. Do not
paint over surfaces where moisture content exceeds that permitted in manufacturer’s
printed instruction.
2. Clean concrete floor surfaces scheduled to be painted with a commercial solution of

muriatic acid, or other etching cleaner. Flush floor with clean water to neutralise
acide, and allow to dry before painting.
C. Wood : Clean wood surfaces to be painted of dirt, oil, or other foreign substances with
scrapers, mineral spirits, and sandpaper, as required. Sandpaper smooth those finished
surfaces exposed to view, and dust off. Scrape and clean small, dry, seasoned knots and
apply a thin coat of white shellac or other recommended knot sealer, before application of
priming coat. After priming, fill holes and imperfections in finish surfaces with putty or
plastic wood filler.
1. Prime, stain, or seal wood required to be job-painted immediately upon delivery to job.
Prime edges, ends, faces, undersides, and backsides of such wood, including
cabinets, counters, cases, paneling.
2. When transparent finish is required, use clear varnish for backpriming.
3. Backprime paneling on interior partitions only where masonry, plaster, or other wet
wall construction occurs on backside.
4. Seal tops, bottoms, and cut-outs of unprimed wood doors with a heavy coat of varnish
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or equivalent sealer immediately upon delivery to job.
D. Ferrous Metals : clean ferrous surfaces, which are not galvanised or shop-coated, of oil,
grease, dirt, loose mill scale and other foreign substances by solvent or mechanical
cleaning.
1. Touch-up shop applied prime coats wherever damaged or bare, where required by
other sections of these specifications.
2. Clean and touch-up with same type shop primer.
E. Galvanised Surfaces : Clean free of oil and surface contaminants with non-petroleum
based solvent.
3.03 MATERILAS PREPARATION
A. General : Mix and prepare painting materials in accordance with manufacturer’s

directions.
B. Maintain containers used in mixing and applicaton of paint in a clean condition, free of
foreign materials and residue.
C. Stir materials before application to produce a mixture of uniform dennsity, and as required
during application. Do not stir film into material. Remove film and, if necessary, strain
material before using.
3.04 APPLICATION
A. General : Apply paint in accordance with manufacturer’s directions. Use applicators and
techniques best suited for substrate and type of material being applied.
1. Paint, surface treatments, and finishes, are indicated in “schedules’ of contract

documents.
2. Provide finish coats which are compatible with prime paints used.
3. Apply additional coats when undercoats or other conditions show through final coat of
paint, until paint film is of uniform finish, colour and appearance. Give special
attention to insure that surfaces, including edges, corners, crevices, welds, and
exposed fasteners receive a dry film thickness equivalent to that of flat surfaces.
4. Paint surfaces behind movable equipment and furniture same as similar exposed
surfaces. Paint surfaces behind permanently-fixed equipment or furniture with prime
coat only before final installation of equipment.
5. Paint interior surfaces of ducts, where visible through registers or grilles, with a flat,
non-specular black paint.
6. Paint back sides of access panels, removable or hinged covers to match exposed
surfaces.

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7. Finish exterior doors on tops, bottoms and side edges same as exterior faces,
unless otherwise indicated.
B. Scheduling Painting Apply first-coat material to surfaces that have been cleaned,
pretreated or otherwise prepared for painting as soon as practicable after preparation
and before subsequent surfaces deterioration.
1. Allow sufficient time between successive coatings to permit proper drying Do not
recoat until paint has dried to where it feels firm, does not deform or feel sticky under
moderate thumb pressure, and application of another coat of paint does not cause
lifting or loss of adhesion of the undercoat.
C. Minimum coating thickness : Apply materials at not less than manufacturer’s

recommended rate, to establish a total dry film thickness as indicated or, if not indicated,
as recommended y coating manufacturer.
D. Mechanical and Electrical Work : Painting of mechanical and electrical work is limited to
those items exposed in mechanical equipment rooms and in occupied spaces.
E. Mechanical items to be painted include, but are not limited to, the following :
1. Piping, pipe hangers, and supports.
2. Heat exchangers.
3. Tanks.
4. Ductwork, insulation.
5. Motor, mechanical equipment, and supports.
6. Accessory items.
F. Electrical items to be painted include, but are not limited to the following :
1. Conduit and fittings.
2. Switchgear.
G. Prime Coats:
1. Recoat primed and sealed surfaces where there is evidence of suction spots or
unsealed areas in first coat, to assure a finish coat with no burn-through or other
defects due to insufficient sealing.
H. Stipple Enamel Finish: Roll and redistribute paint to an even and fine texture. Leave no
evidence of rolling such as laps, irregularity in texture, skid marks, or other surface
imperfection.
I. Pigmented (opaque) Finished: completely cover to provide and opaque, smooth surface
of uniform finish, colour, appearance and coverage. Cloudiness, spotting, holidays, laps,
brush marks, runs, sags, ropiness or other surface imperfections will not be acceptable.
J. Transparent (Clear) Finishes: Use multiple coats to produce glass-smooth surface film of
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even luster. Provide a finish free of laps, cloudiness, colour irregularity, runs, brush
marks, orange peel, nail holes, or other surface imperfections.
K. Completed Work: Match approved samples for colour, texture and coverage.
Remove, refinish, or repaint work not in compliance with specific requirements.
3.05 FILED QUALITY CONTROL
A. The right is reserved by the Engineer to invoke following material testing procedure at any
time, and any number of times during period of field painting.
1. Engage services of an independent testing laboratory to sample paint being used.

Samples of materials delivered to project site swill be taken, identified and sealed, and
certified in presence of Contractor.
2. Testing laboratory will perform appropriate tests for any or all of following
characteristics:
Abrasion resistance, apparent reflectivity, flexibility, washability, absorption,

accelerated weathering, dry opacity, accelerated yellowness, recoating, skinning,
colour retention, alkali resistance, and quantitative materials analysis.
B. If test results show that material being used does not comply with specified
requirements, Contractor may be directed to stop painting work, and remove non-
complying paint; pay for testing; repaint surfaces coated with rejected paint; remove
rejected paint form previously painted surfaces if, upon repainting with specified paint,
the two coatings are incompatible.
3.06 CLEAN-UP AND PROTECTION
A. Clean Up: During progress of work, remove from site discarded materials, rubbish, cans
and rags at end of each work day.
1. Upon completion of painting work, clean window glass and other paint-spattered
surfaces. Remove spattered paint by proper methods of washing and scraping,
using care not to scratch or otherwise damage-finished surfaces.
B. Protection: Protect work of other trades, whether to be painted or not, against damage by
painting and finishing work. Correct damage by cleaning, repairing or replacing, and
repainting, as directed by Architect.
1. Provide “Wet Paint” Signs in Arabic/English and labourers native languages as

required to protect newly painted finishes. Remove temporary protective wrappings
provided by others for protection of their work, after completion of painting operations.
2. At completion of work by other trades, touch-up and restore all damaged or

defaced painted surfaces.

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4.0 PAINT FINISH FOR GALVANIZED STEEL
Epoxy polyamide cured primer (solids by volume 50% to 60%) followed by epoxy polyamide
cured high build (solids by volume 50% to 60%) under coat topped with a two component
polyurethane isocyanite cured paint with approved colour and gloss retention
properties and resistant to abrasion, impact, chemical attacks, corrosion, etc., applied
strictly in accordance with the paint manufacturer's recommendations.
END OF SECTION


ROADS AND UTILITIES

VOLUME 2 – PART VIII
BUILDING GENERAL SPECIFICATIONS - MEPF

20010410
JUNE, 2022
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications

Volume 2 – Part VI Particular Specifications for Firefighting Works

Architectural
Volume 2 – Part VIII Building General Specifications – MEPF

AE7 PROJECT NO. 20010410 ii REV 1 – ISSUED FOR CONSTRUCTION
VOLUME 2 – PART VIII DATE OF ISSUE: 16 JUNE, 2022
MEPF
DUBAI – UAE
MEYDAN GROUP LLC

Project: 20010410
Roads and Utilities
Volume 2 – Part VIII
Building General Specifications – MEPF
Table Contents
SECTION 15010 BASIC MECHANICAL REQUIREMENTS ........................................................................... 1
PART I - GENERAL....................................................................................................................................... 1
1.01 SCOPE OF WORK............................................................................................................................ 1
1.02 CALCULATIONS ............................................................................................................................... 1
1.03 WORKING DRAWINGS .................................................................................................................... 1
1.04 CONSTRUCTION DRAWINGS ........................................................................................................ 3
1.05 REGULATIONS ................................................................................................................................. 3
1.06 CLIMATIC AND OPERATING CONDITIONS .................................................................................. 5
1.07 WORKMANSHIP AND MATERIALS ................................................................................................ 5
1.08 INSPECTION AND TESTS AT MANUFACTURER'S WORK ......................................................... 9
1.09 CERTIFIED DRAWINGS ................................................................................................................ 11
1.10 SAMPLES ........................................................................................................................................ 11
1.11 PROTECTION AND CARE OF PLANT AND EQUIPMENT .......................................................... 11
1.12 GUARDS ......................................................................................................................................... 12
1.13 AIR CONDITIONED STORES ........................................................................................................ 12
1.14 PAINTING ........................................................................................................................................ 12
1.15 MANUFACTURER’S NAMEPLATES ............................................................................................. 14
1.16 LABELS ........................................................................................................................................... 15
1.17 LUBRICATION ................................................................................................................................ 15
1.18 SPECIAL TOOLS ............................................................................................................................ 16
1.19 SUNDRY BUILDERS WORK IN CONNECTION WITH SERVICES ............................................. 16
1.20 NOISE .............................................................................................................................................. 16
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1.21 ANTI-VIBRATION MOUNTINGS AND SOUND ABSORPTION ................................................... 16

1.22 AS BUILT DRAWINGS ................................................................................................................... 18
1.23 OPERATING AND MAINTENANCE INSTRUCTIONS .................................................................. 19
1.24 INSTRUCTION AND TRAINING .................................................................................................... 20
1.25 SPARES AND CONSUMABLES .................................................................................................... 20
1.26 MOCK-UPS ..................................................................................................................................... 22
SECTION 15171 ELECTRICAL REQUIREMENTS FOR MECHANICAL EQUIPMENT .............................. 23
PART I – GENERAL .................................................................................................................................... 23
1.01 SCOPE OF SECTION ..................................................................................................................... 23
1.02 WORK INCLUDED .......................................................................................................................... 23
1.03 QUALITY ASSURANCE ................................................................................................................. 23
1.04 APPLICABLE CODES AND STANDARDS .................................................................................... 23
1.05 SUBMITTALS .................................................................................................................................. 24
1.06 OPERATION AND MAINTENANCE DATA .................................................................................... 24
1.07 WARRANTY .................................................................................................................................... 24
1.08 EXTRA MATERIALS ....................................................................................................................... 24
PART 2: PRODUCTS ............................................................................................................................. 24
2.01 CONTROL PANEL ENCLOSURES ............................................................................................... 24
2.02 CONTROL PANEL METERS ......................................................................................................... 25
2.03 CONTROL SWITCHES AND ELECTRICAL ISOLATION ............................................................. 27
2.04 INDICATING LAMPS INSTRUMENTS AND FITTINGS ................................................................ 27
2.05 SMALL WIRING .............................................................................................................................. 28
2.06 LINKS AND FUSES ........................................................................................................................ 30
2.07 TERMINAL BOARDS ...................................................................................................................... 31
2.08 NUMBER PLATES AND LABELS .................................................................................................. 32
2.09 EARTHING ...................................................................................................................................... 32
2.10 LECTRIC MOTORS .................................................................................................................... 32
PART 3: EXECUTION ............................................................................................................................ 34
3.01 INSTALLATION ............................................................................................................................... 34
SECTION 15190 MECHANICAL IDENTIFICATION ...................................................................................... 35
PART 1: GENERAL ................................................................................................................................ 35
1.01 SCOPE OF WORK ...................................................................................................................... 35
1.02 WORK INCLUDED ...................................................................................................................... 35
1.03 QUALITY ASSURANCE .............................................................................................................. 35
1.04 APPLICABLE CODES AND STANDARDS ................................................................................ 35
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1.05 SUBMITTALS .............................................................................................................................. 36

1.06 OPERATION AND MAINTENANCE DATA ................................................................................ 36
1.07 WARRANTY ................................................................................................................................ 36
PART 2: PRODUCTS ............................................................................................................................. 36
2.01 PLANT AND PIPEWORK IDENTIFICATION ............................................................................. 36
2.02 DUCTWORK IDENTIFICATION ................................................................................................. 37
PART 3: EXECUTION ............................................................................................................................ 38
3.01 STORAGE ................................................................................................................................... 38
3.02 GENERAL .................................................................................................................................... 38
3.03 PLANT AND PIPEWORK IDENTIFICATION ................................................................................. 39
3.04 DUCTWORK IDENTIFICATION ..................................................................................................... 39
SECTION 15325 FIRE PROTECTION SYSTEM AND EQUIPMENT ........................................................... 40
PART 1: GENERAL ................................................................................................................................ 40
1.01 SCOPE OF WORK ...................................................................................................................... 40
PART 2: PRODUCTS ............................................................................................................................. 40
2. 01 PIPE WORK ................................................................................................................................. 40
2.02 VALVES ....................................................................................................................................... 45
2.03 FIRE HOSE CABINET (FHC) ..................................................................................................... 46
2.04 FIRE HYDRANT .......................................................................................................................... 47
2.05 AUTOMATIC SPRINKLER SYSTEM ......................................................................................... 47
2.06 PORTABLE FIRE EXTINGUISHERS ......................................................................................... 52
2.07 FIELD ACCEPTANCE TESTS AND MAINTENANCE ............................................................... 53
SECTION 15410 PLUMBING PIPING ............................................................................................................ 57
PART 1: GENERAL ................................................................................................................................ 57
1.01 SCOPE OF SECTION ..................................................................................................................... 57
1.02 WORK INCLUDED .......................................................................................................................... 57
1.05 SUBMITTALS .................................................................................................................................. 60
1.06 OPERATION AND MAINTENANCE DATA .................................................................................... 60
1.08 WARRANTY ................................................................................................................................ 60
PART 2: PRODUCTS ............................................................................................................................. 61
2.01 SOIL WASTE AND RAINWATER PIPEWORK ............................................................................. 61
2.02. POTABLE HOT AND COLD WATER SERVICES ........................................................................ 62
PART 3: EXECUTION ............................................................................................................................ 63
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3.01 SOIL WASTE AND RAINWATER PIPEWORK.............................................................................. 63

3.02. POTABLE HOT AND COLD WATER SERVICES PIPEWORK ................................................... 67
SECTION 15450 PLUMBING PIPING INSULATION ................................................................................... 73
PART 1: GENERAL ................................................................................................................................ 73
1.01 SCOPE OF SECTION ..................................................................................................................... 73
1.02 WORK INCLUDED .......................................................................................................................... 73
PART 2: PRODUCTS ............................................................................................................................. 74
2.01 GENERAL........................................................................................................................................ 74
2.02 PLANT AND PIPEWORK INSULATION ........................................................................................ 74
PART 3: EXECUTION ............................................................................................................................ 76
3.01 STORAGE ....................................................................................................................................... 76
3.02 FIXINGS .......................................................................................................................................... 76
3.03 PLANT AND PIPEWORK INSULATION ........................................................................................ 76
3.04 PROTECTION ................................................................................................................................. 79
SECTION 16010 BASIC ELECTRICAL REQUIREMENTS ........................................................................... 67
PART 1: GENERAL ................................................................................................................................ 67
1.01 GENERAL ....................................................................................................................................... 67
1.02 SCOPE OF WORK ......................................................................................................................... 67
1.03 ELECTRICAL SUPPLY ................................................................................................................... 68
1.04 EARTHING REQUIREMENTS ....................................................................................................... 68
1.05 CO-ORDINATION ........................................................................................................................... 69
1.06 CLIMATE CONDITIONS ................................................................................................................. 69
1.07 ACCESSIBILITY .............................................................................................................................. 70
1.08 STORAGE OF MATERIALS AND EQUIPMENT ........................................................................... 70
1.09 PREVENTION OF NOISE AND VIBRATION ................................................................................. 70
1.10 GUARDS ......................................................................................................................................... 71
1.11 SIGNS AND NOTICES ................................................................................................................... 71
1.12 GOVERNING CONDITIONS .......................................................................................................... 71
1.13 MOUNTING HEIGHTS .................................................................................................................... 72
1.14 LABEL AND IDENTIFICATION....................................................................................................... 72
1.15 VERMIN PROOFING ...................................................................................................................... 74
1.16 FIRE AND SAFETY PRECAUTIONS ............................................................................................. 74
1.17 CLEANING DOWN .......................................................................................................................... 74
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1.18 MATERIAL SUBMITTALS............................................................................................................... 74

1.19 SHOP DRAWINGS ......................................................................................................................... 75
1.20 AS BUILT DRAWINGS ................................................................................................................... 75
1.21 DOCUMENTS ................................................................................................................................. 77
1.22 SPECIAL TOOLS ............................................................................................................................ 77
1.23 SPECIAL REQUIREMENT ............................................................................................................. 77
PART 2: PRODUCTS ............................................................................................................................. 77
PART 3: EXECUTION ............................................................................................................................ 77
SECTION 16110 ELECTRICAL RACEWAYS ................................................................................................ 78
PART 1: GENERAL ................................................................................................................................ 78
1.01 GENERAL REQUIREMENTS ......................................................................................................... 78
1.02 SCOPE AND DESCRIPTION OF WORK ...................................................................................... 78
1.03 QUALITY STANDARDS .................................................................................................................. 78
1.04 SUBMITTAL .................................................................................................................................... 79
1.05 DELIVERY, STORAGE AND HANDLING OF MATERIALS .......................................................... 79
PART 2: PRODUCTS ............................................................................................................................. 79
2.01 METAL CONDUIT ........................................................................................................................... 79
2.02 FLEXIBLE CONDUIT ...................................................................................................................... 79
2.03 PVC CONDUIT ................................................................................................................................ 81
2.04 CABLE TRAY .................................................................................................................................. 80
2.05 CABLE TRUNKING (METAL) ......................................................................................................... 80
2.06 CABLE TRUNKING (PVC) .............................................................................................................. 81
2.07 CABLE LADDERS ........................................................................................................................... 81
2.08 UNDERGROUND DUCTS .............................................................................................................. 81
PART 3: EXECUTION ............................................................................................................................ 82
3.01 METAL CONDUIT INSTALLATION ................................................................................................ 82
3.02 FLEXIBLE CONDUIT INSTALLATION ........................................................................................... 83
3.03 VC CONDUIT INSTALLATION ....................................................................................................... 83
3.04 CABLE TRAY INSTALLATION ....................................................................................................... 85
3.05 CABLE TRUNKING INSTALLATION ............................................................................................. 87
3.06 CABLE LADDER INSTALLATION .................................................................................................. 87
3.07 UNDERGROUND DUCT AND MANHOLES .................................................................................. 88
SECTION 16120 WIRES AND CABLES ........................................................................................................ 89
PART 1: GENERAL ................................................................................................................................ 89
1.01 GENERAL REQUIREMENTS ......................................................................................................... 89
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1.02 SCOPE AND DESCRIPTION OF WORK ...................................................................................... 89

1.04 SUBMITTAL ................................................................................................................................. 90
1.05 DELIVERY AND HANDLING OF CABLES ................................................................................ 90
PART 2: PRODUCT ............................................................................................................................... 91
2.01 SINGLE CORE PVC INSULATED CABLES .............................................................................. 91
2.02 FLEXIBLE CABLES ..................................................................................................................... 91
2.03 MULTI-CORE POLYVINYL CHLORIDE (PVC) INSULATED NON ARMOURED CABLES .... 91
2.04 MULTI-CORE POLYVINYL CHLORIDE (PVC) INSULATED STEEL WIRE ARMOURED AND
PVC SHEATHED CABLES ..................................................................................................................... 90
2.05 CROSS-LINKED POLYETHYLENE (XLPE) INSULATED STEEL WIRE ARMORED AND PVC
SHEATHED CABLES .............................................................................................................................. 90
2.06 TV AND COMMUNICATION CABLES ....................................................................................... 91
PART 3: EXECUTION ............................................................................................................................ 91
3.01 INSPECTION ............................................................................................................................... 91
3.02 SUB-CIRCUIT WIRING - LIGHTING .......................................................................................... 91
3.03 SUB-CIRCUIT WIRING -SMALL POWER.................................................................................. 93
3.04 SUB-CIRCUIT WIRING - POWER (SINGLE AND 3 PHASE) ................................................... 94
3.05 CIRCUIT WIRING - FIRE ALARM .............................................................................................. 94
3.06 CIRCUIT WIRING - COMMUNICATIONS .................................................................................. 94
3.07 FLEXIBLE CABLE INSTALLATION ............................................................................................ 95
3.08 CATV AND COMMUNICATION CABLES INSTALLATION ....................................................... 95
3.09 INTERNAL CABLE INSTALLATION ........................................................................................... 95
3.10 EXTERNAL CABLE INSTALLATION .......................................................................................... 97
3.11 MARKING OF CABLE ............................................................................................................... 100
3.12 JOINTING AND TERMINATING CABLES ............................................................................... 101
3.13 SLEEVES, TAPES AND SEALING COMPOUND...................................................................... 99
SECTION 16135 ELECTRICAL BOXES AND FITTINGS ........................................................................... 101
PART 1: GENERAL .............................................................................................................................. 101
1.01 GENERAL REQUIREMENTS ................................................................................................... 101
1.02 SCOPE AND DESCRIPTION OF WORK ................................................................................. 101
1.04 SUBMITTALS ............................................................................................................................ 102
PART 2: PRODUCTS ........................................................................................................................... 102
2.01 FABRICATED MATERIALS ...................................................................................................... 102

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PART 3: EXECUTION .......................................................................................................................... 103

3.01 INSTALLATION ......................................................................................................................... 103
SECTION 16142 ELECTRICAL CONNECTION FOR EQUIPMENT .......................................................... 104
PART 1: GENERAL .............................................................................................................................. 104
1.03 GUARANTEES .......................................................................................................................... 105
1.05 SUBMITTALS ............................................................................................................................ 105
PART 2: PRODUCTS ........................................................................................................................... 106
2.01 MATERIALS AND COMPONENTS .......................................................................................... 106
PART 3: EXECUTION .......................................................................................................................... 107
3.01 INSTALLATION OF ELECTRICAL CONNECTIONS ............................................................... 107
SECTION 16143 WIRING DEVICES ............................................................................................................ 109
PART 1: GENERAL .............................................................................................................................. 109
1.02 SCOPE AND DESCRIPTION OF WORKS .............................................................................. 109
1.04 SUBMITTAL ............................................................................................................................... 109
1.05 DELIVERY, STORAGE AND HANDLING ................................................................................ 110
PART 2: PRODUCTS ........................................................................................................................... 110
2.01 GENERAL .................................................................................................................................. 110
2.02 LIGHTING SWITCHES (GRID ASSEMBLIES) ........................................................................ 111
2.03 EXTERNAL LIGHTING SWITCHES ......................................................................................... 111
2.04 13 AMPERES SWITCH SOCKET OUTLETS .......................................................................... 111
2.05 15 AMPERES SOCKET OUTLETS .......................................................................................... 112
2.06 FUSED CONNECTION UNITS ................................................................................................. 112
2.07 SINGLE PHASE ISOLATORS AND SWITCH FUSES ............................................................ 112
2.08 MULTI-PHASE ISOLATORS AND SWITCH FUSES ............................................................... 114
2.09 COOKER CONTROL UNITS .................................................................................................... 114
2.10 TIME SWITCHES ...................................................................................................................... 114
2.11 CONNECTIONS TO FIXED APPLIANCES .............................................................................. 115
2.12 INDUSTRIAL SOCKET OUTLETS ........................................................................................... 115
2.13 TELEPHONE OUTLET AND RADIO/TV OUTLET PLATES ................................................... 116
PART 3: EXECUTION .......................................................................................................................... 116
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3.01 INSPECTION ............................................................................................................................. 116

3.02 INSTALLATION OF WIRING DEVICES ................................................................................... 116
SECTION 16190 SUPPORTING DEVICES ................................................................................................. 118
PART 1: GENERAL .............................................................................................................................. 118
1.01 SECTION INCLUDES ............................................................................................................... 118
1.03 SUBMITTALS ............................................................................................................................ 118
PART 2 PRODUCTS ................................................................................................................................ 118
2.01 PRODUCT REQUIREMENTS .................................................................................................. 118
PART 3: EXECUTION .......................................................................................................................... 120
3.01 INSTALLATION ......................................................................................................................... 120
SECTION 16195 ELECTRICAL IDENTIFICATION ..................................................................................... 119
PART 1: GENERAL .............................................................................................................................. 119
1.01 SECTION INCLUDES ............................................................................................................... 119
1.03 SUBMITTALS ............................................................................................................................ 119
PART 2: PRODUCTS ........................................................................................................................... 119
2.01 NAMEPLATES AND LABELS ................................................................................................... 119
2.02 WIRE MARKERS ....................................................................................................................... 120
2.03 COLOUR CODING .................................................................................................................... 120
2.04 CIRCUIT IDENTIFICATION CHARTS ...................................................................................... 121
2.05 CABLE IDENTIFICATION TAGS .............................................................................................. 121
2.06 EQUIPMENT DANGER SIGNS ................................................................................................ 121
2.07 LANGUAGE ............................................................................................................................... 122
PART 3: EXECUTION .......................................................................................................................... 122
3.01 PREPARATION ......................................................................................................................... 122
3.02 INSCRIPTIONS ......................................................................................................................... 122
3.03 INSTALLATION ......................................................................................................................... 123
SECTION 16425 POWER DISTRIBUTION BOARDS ................................................................................. 124
PART 1: GENERAL .............................................................................................................................. 124
1.01 GENERAL REQUIREMENTS AND RELATED DOCUMENTS ............................................... 124
1.03 GUARANTEES .......................................................................................................................... 124
1.05 SUBMITTALS ............................................................................................................................ 125
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1.06 DELIVERY, STORAGE AND HANDLING OF MATERIALS .................................................... 125

PART 2: PRODUCT ............................................................................................................................. 125
2.01 CUBICLE CONSTRUCTION ..................................................................................................... 125
2.02 MAIN CIRCUIT BREAKER........................................................................................................ 127
2.03 FEEDER BRANCH CIRCUIT BREAKERS ............................................................................... 127
2.04 METERING AND INSTRUMENTATION ................................................................................... 127
2.05 1600 A LOW TENSION DISTRIBUTION BOARD (Single busbar) ......................................... 128
2.06 1600 A LOW TENSION DISTRIBUTION BOARD (Double busbar) ....................................... 129
PART 3: EXECUTION .......................................................................................................................... 130
3.01 INSTALLATION ......................................................................................................................... 130
3.02 FIELD QUALITY CONTROL ..................................................................................................... 130
SECTION 16426 LOW VOLTAGE PROTECTIVE DEVICES ...................................................................... 131
PART 1: GENERAL .............................................................................................................................. 131
1.03 GUARANTEES .......................................................................................................................... 131
1.05 SUBMITTALS ............................................................................................................................ 132
PART 2: PRODUCTS ........................................................................................................................... 132
2.01 MAIN CIRCUIT BREAKER........................................................................................................ 132
2.02 MOULDED CASE CIRCUIT BREAKERS ................................................................................. 133
2.03 MINIATURE CIRCUIT BREAKERS (MCB) .............................................................................. 133
2.04 RESIDUAL CURRENT CIRCUIT BREAKER ........................................................................... 134
2.05 CARTRIDGE FUSE ................................................................................................................... 134
PART 3: EXECUTION .......................................................................................................................... 134
3.01 INSTALLATION ......................................................................................................................... 134
SECTION 16452 EARTHING SYSTEM ...................................................................................................... 137
PART 1: GENERAL .............................................................................................................................. 137
1.03 GUARANTEES .......................................................................................................................... 137
1.05 SUBMITTALS ............................................................................................................................ 137
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PART 2: PRODUCTS ........................................................................................................................... 138

2.01 MATERIALS............................................................................................................................... 138
PART 3: EXECUTION .......................................................................................................................... 139
3.01 INSPECTION ............................................................................................................................. 139
3.02 INSTALLATION ......................................................................................................................... 139
3.03 EARTH LOOP IMPEDANCE ..................................................................................................... 141
3.04 EARTH RESISTANCE .............................................................................................................. 141
3.05 COMMUNICATION EARTHING ............................................................................................... 141
3.06 SUPPLEMENTARY AND EQUI-POTENTIAL BONDING ........................................................ 142
3.07 LIGHTNING PROTECTION ...................................................................................................... 142
SECTION 16470 PANEL BOARDS .............................................................................................................. 143
PART 1: GENERAL .............................................................................................................................. 143
1.03 GUARANTEES .......................................................................................................................... 143
1.05 SUBMITTALS ............................................................................................................................ 144
1.06 DELIVERY, STORAGE AND HANDLE OF MATERIALS ........................................................ 144
PART 2: PRODUCT ............................................................................................................................. 144
2.01 GENERAL .................................................................................................................................. 144
2.02 LIGHTING AND POWER PANELBOARDS ............................................................................. 146
2.03 DISTRIBUTION PANELBOARDS ............................................................................................. 146
2.04 NAMEPLATES ........................................................................................................................... 147
PART 3: EXECUTION ...................................................................................................................... 147
3.01 INSTALLATION ......................................................................................................................... 147
SECTION 16510 INTERIOR AND EXTERIOR LIGHTING .......................................................................... 149
PART 1: GENERAL .............................................................................................................................. 149
1.03 GUARANTEES .......................................................................................................................... 149
1.05 SUBMITTALS ............................................................................................................................ 148
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PART 2: PRODUCTS ........................................................................................................................... 148

2.01 INCANDESCENT AND SPOTLIGHT........................................................................................ 148
2.02 FLUORESCENT LUMINAIRES ................................................................................................ 150
2.03 DISCHARGE LAMP LUMINAIRE ............................................................................................. 150
2.04 PROTECTION OF ELECTRICAL EQUIPMENT ...................................................................... 151
2.05 LAMPS ....................................................................................................................................... 151
2.06 LAMPHOLDERS AND STARTERS .......................................................................................... 153
2.07 BALLASTS ................................................................................................................................. 153
2.08 COLUMNS ................................................................................................................................. 154
2.09 CONTROLS ............................................................................................................................... 154
2.10 WIRING AND CABLING ............................................................................................................ 156
2.11 HANDHOLES............................................................................................................................. 156
2.12 JUNCTION BOXES ................................................................................................................... 156
PART 3: EXECUTION .......................................................................................................................... 156
3.01 INSPECTION ............................................................................................................................. 156
3.02 GENERAL .................................................................................................................................. 156
3.03 INTERNAL LUMINAIRES INSTALLATION .............................................................................. 157
3.04 SURFACE MOUNTED LUMINAIRES INSTALLATION ........................................................... 157
3.05 RECESS MOUNTED LUMINAIRES INSTALLATION .............................................................. 157
3.06 PENDANT MOUNTED INSTALLATION ................................................................................... 159
3.07 ADJUST AND CLEAN ............................................................................................................... 159
3.09 EARTHING ................................................................................................................................ 161
SECTION 16720 FIRE DETECTION AND ALARM SYSTEM ..................................................................... 162
PART 1: GENERAL .............................................................................................................................. 162
1.11 APPLICABLE STANDARDS AND SPECIFICATIONS ............................................................. 163
1.12 OUTPUT SIGNALS UNDER FIRE CONDITIONS ................................................................... 163
1.13 SYSTEM DIFFERENCE ............................................................................................................ 163
1.14 APPROVALS FROM THE CONCERNERD LOCAL AUTHORITIES ( I.E. CIVIL DEFENSE
FIRE DEPARTMENT) ........................................................................................................................... 165
1.15 SCOPE OF WORK .................................................................................................................... 165
1.18 RELATED WORKS A. A. Section 16120 Conduits ................................................................ 167
1.19 SUBMITTALS ............................................................................................................................ 167
PART 2: PRODUCTS ........................................................................................................................... 167
2.01 CONTROL AND INDICATING EQUIPMENT ........................................................................... 167
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2.02 SYSTEM DESCRIPTION .............................................................................................................. 168

2.03 MONITORING AND CHECKING CIRCUITS AND FAULT CONDITIONS ................................. 162
2.04 BASIC SYSTEM FUNCTIONS ................................................................................................. 162
2.05 MAIN FIRE ALARM CONTROL PANEL (ADDRESSABLE TYPE) ............................................. 163
2.06 SMOKE SENSORS ....................................................................................................................... 164
2.07 HEAT SENSORS .......................................................................................................................... 165
2.08 BEAM SENSORS ....................................................................................................................... 165
2.09 DUCT SENSORS .......................................................................................................................... 165
2.10 PULL STATION CALL POINT ...................................................................................................... 165
2.11 ALARM INDICATING DEVICES ................................................................................................... 166
2.12 INTERFACE UNITS ...................................................................................................................... 167
2.13 REPEAT PANEL ........................................................................................................................... 167
PART 3: EXECUTIONS ............................................................................................................................ 167
3.01 INSTALLATION ............................................................................................................................. 167
3.02 TESTING AND COMMISSIONING............................................................................................... 167
3.08 SPARES & TOOLS ....................................................................................................................... 168
SECTION 16950 TESTING AND COMMISSIONING ................................................................................. 170
PART 1: GENERAL .............................................................................................................................. 170
1.01 GENERAL REQUIREMENTS ....................................................................................................... 170
PART 2: TESTING................................................................................................................................ 171
2.01 TESTING REQUIREMENTS ........................................................................................................ 171
2.02 ELECTRICAL TESTING ............................................................................................................... 172
2.03 TELECOMMUNICATION AND CONTROL .................................................................................. 172
PART 3: COMMISSIONING ................................................................................................................. 174
3.01 GENERAL...................................................................................................................................... 174
3.02 SWITCHBOARDS ......................................................................................................................... 174
3.05 FIRE ALARM SYSTEM ................................................................................................................. 174
PART 4: INSTRUCTION AND TRAINING ........................................................................................... 177
4.01 INSTRUCTION AND TRAINING OF CLIENTS STAFF: .............................................................. 177

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SECTION 15010
BASIC MECHANICAL REQUIREMENTS
PART I - GENERAL
1.01 SCOPE OF WORK
A. This Section covers the basic general requirements applicable to all

Division 15 works that shall be provided for by the Contractor.
1.02 CALCULATIONS
A. The Contractor shall acquaint himself with the constructional details of the
buildings and exterior works both before and during the course of erection
and shall take his own particulars with regard to the installation of
mechanical equipment. The Contractor shall check the sizes of all
mechanical equipment taking into account any additions or deletions
required to ensure the installations fit into the room or other spaces
allocated and in relation to other plant and equipment being provided.
B. The Contractor shall undertake and prepare all necessary calculations and
drawings relating to the mechanical equipment and for all associated
foundation, structural and builder's and services work, except where
specifically defined otherwise in the Specification and/or on the Drawing.
C. The Contractor shall provide and submit to the Engineer all calculations,
drawings and supporting data for the mechanical equipment.
D. The Contractor shall provide calculations, details, drawings and technical

data to enable the Engineer to ascertain the correctness of the specialist
designs of the associated foundations, supports, bases and fixings.
1.03 WORKING DRAWINGS
A. The Contractor shall provide for approval working drawings of the whole
mechanical works. The drawings shall include, but not necessarily be
limited to the followings: -
1. Co-ordinated general arrangements of all services to a scale of not

less than 1:100
2. Co-ordinated detailed layouts of plant rooms and similar spaces to a

scale of not less than 1:50.
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3. Schedules of all equipment’s to be installed, together with start

and running power consumption.
4. Indicate with accurate dimensions sizes and positions of all plant,

equipment, pipes, conduits, trunking, under floor ducting, cable tray,
cables together with all inspection points and cable joints.
5. Fully indicate all ductwork, pipe work, sizes and positions of all plant
equipment’s and valves together will all inspection points and test
positions.
6. Fully indicate all builders’ work requirements inclusive of all

foundations, bases, plinths, sumps and holes together with the overall
sizes and masses of the plant concerned.
7. Show the disposition and depth of all cables, pipes, ducts, buried direct
in the ground and taken at intervals where change of direction occur
and where cables increase or decrease in number/size and at every
point where the services enter into or depart form ducts or buildings.
8. Indicate the number, size and services for every cable, ducts, and
pipes for every service within the building. Circuit lists for every
distribution board shall be entered onto the relevant drawings and such
lists shall agree with the lists fixed within the distribution board door.
9. Indicate all equipment and control wiring diagrams together with all
specialist systems. Generators, Public Address, Fire Alarm, etc.
Diagrams must be coordinated and show all required interlocks etc.
between systems or components.
10. Show all cables in pits and ducts on drawings to a scale of 1:50 or
larger.
11. Show clearly on site drawing all the new buildings together with all
other existing buildings and other permanent features and dimensions
between such buildings and cables, pipes, ducts, etc. clearly marked.
12. Show clearly all plumbing and drainage and setting out dimensions for
all drainage pipe work and manholes, both within the building and
throughout.
13. The s i t e , t o g e t h e r w i t h i n t e n d e d d r a i n a g e p i p e w o r k
b a c k f i l l , o r surround in each location, schedule to be included to
indicate manhole, and cover size, etc.
B. The symbols used for each service for all working drawings shall be
shown on separate drawings.
C. In addition to the working drawings, the Contractor shall obtain and

provide at the request of the Engineer, two sets of all manufacturers’
detailed drawings for all items of plant, equipment, apparatus and
materials. These drawings shall be suitably titled and have drawings
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references number added. Specific requirements are given in the

individual specification Sections.
D. All drawings, diagrams and schedules called for in this clause shall be
submitted to the Engineer for examination and approval.
E. The Contractor shall make due allowance for an approval/comment

period and it must be clearly understood that the correctness of the
submitted information will directly affect this comment/approval period.
F. The Contractor shall be responsible for coordinating all mechanical,

electrical, lift, fire protection plumbing, drainage and irrigation works, and
engineering systems such that each may be installed in a proper manner,
ensuring correct performance and allowing adequate maintenance
access. All services shall be installed such that the positioning of ducts,
pipes, cables, and all items of equipment avoid conflict. The Contractor's
working drawings shall indicate any services co-ordination needs
prior to submission to the Engineer for approval; tender drawing shall
not be reissued as working drawings.
1.04 CONSTRUCTION DRAWINGS
A. Following approval of the Contractor's drawings by the Engineer, they

shall constitute "Construction Drawings" and the E and M equipment shall
be manufactured and installed in accordance with those approved
drawings. The acceptance by the Engineer of any such drawing shall not
relieve the Contractor of his responsibility under the Contract and shall
not commit the Engineer or make the Engineer liable for any mistake of
the manufacturer's deficiencies in strength or efficiency in operation of
any part of any item for its specified purpose.
B. The Engineer reserves the right subsequently to amend or add to the

Construction Drawings as may be necessary or expedient.
C. The Contractor shall provide to the Engineer, immediately after approval

of each detailed drawing, one copy on transparent plastic film and two
prints.
1.05 REGULATIONS
A. The installation materials and components shall comply with all relevant
statutory instructions and regulations current at the date of tender,
whether so detailed or not. In particular, the following departments must
be consulted.
1. Local standards
2. British Standard Specifications
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3. British Standard Code of Practice

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4. UK IEE Regulations for Electrical Installation

5. US National Electrical Code
6. US National Electrical Safety Code
7. UK Chartered Institution of Building Services Engineers (CIBSE)
8. The American Society of Heating, Refrigerating and Air Conditioning
Engineers (ASHRAE)
9. Electrical Regulations issued by Local Authority.
10. US Sheet Metal and Air Conditioning Contractors National Association
(SMACNA)
11. UK HVCA DW142 Ductwork specification.
12. US National Fire Protection Association Standards
13. IEE Regulations for Electrical Equipment of Buildings
14. Local Laws, Rules and Regulations
15. U.K BSRIA code for pipe work flushing.
1.06 CLIMATIC AND OPERATING CONDITIONS
A. City : Dubai, UAE

Temperature : See specification clauses
1.07 WORKMANSHIP AND MATERIALS
A. The Contractor shall be responsible for ensuring that the components of

each system are mutually compatible and integrated to form fully efficient
systems complying with the Drawings and Specification. Corresponding
parts throughout the Works shall be made to gauge and be
interchangeable wherever possible. The Contractor shall, when required
by the Engineer, prove interchangeability by the actual interchange of the
various parts.
B. All articles and materials specified to conform to British and other

standards shall be clearly and indelibly marked with the appropriate
standard number specified except where marking is impracticable when
relevant documents shall include this information.
C. All materials and workmanship shall be to the satisfaction of the Engineer.

The Contractor shall maintain a competent supervising engineer and
supervisors for each specialization and for each section of the work on
Site throughout the whole of the time to the completion of the works. The
Engineer shall give prior approval to the appointment of this supervising
engineer and shall have the authority to withdraw this approval at any
time. No person shall be allowed to execute any type of work, which is
normally carried out by a skilled tradesman unless he is thoroughly
experienced and proficient in the trade concerned. The Engineer shall
have the authority to require any tradesman to demonstrate his
proficiency to the satisfaction of the Engineer.
D. Where "stainless steel" is specified or used it shall have resistance to

atmospheric corrosion and be of a grade to suit its particular use.
Particular attention shall be made to the prevention of seizure by fretting
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where two corrosion resistant metals are in contact, by the selection of

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materials of suitable relative hardness and surface finish and the

applications of lubricants. Where bronze is specified or used it shall be
zinc free.
E. All cast iron shall be of standard grey close-grained quality to BS 1452

Grade 14 or better. The structure of the casting shall be homogenous
and free from non-metallic inclusions and other injurious defects. All
surfaces of casting which are not machined shall be smooth and shall be
carefully fettled to remove all foundry irregularities.
F. Minor defects not exceeding 12.5% of total metal thickness and which will
not ultimately affect the strength and serviceability of the casting may be
repaired by approved welding techniques. The Engineer shall be notified
of larger defects and no repair welding of such defects shall be carried
out without prior approval.
G. If the removal of metal for repair will reduce the stress-resisting cross-
section of the casting by more than 25%, or to such an extent that the
computed stress in the remaining metal exceeds the allowable stress by
more than 25%, then that casting may be rejected.
H. Castings repaired by welding for major defects shall be stressed-relieved

after such welding.
I. Non-destructive tests will be required for any casting containing defects

whose extent cannot otherwise be judge, or to determine that repair
welds have been properly made.
J. All major stress-bearing forgings shall be made to a standard

specification, which shall be submitted to the Engineer for approval before
work is commenced. They shall be subject to internal examination and
non- destructive tests for the detection of flaws and shall be heat-treated
for the relief of residual stresses. The name of the maker and particulars
of the heat treatment proposed for each such forging shall be submitted
to the Engineer. The Engineer may arrange for such forgings to be
inspected at the place of manufacture with a representative of the
Contractor.
K. Particular attention shall be paid to the prevention of corrosion due to the

close proximity of dissimilar metals. Where it is necessary to use
dissimilar metals in contact, they shall be selected so that the bimetallic
corrosion is as low as possible. The publication by the UK H.M.
Stationary Office entitled "Corrosion and its Prevention at Bimetallic
Contacts" shall be used as a guide.
L. The use of iron and steel shall be avoided in instruments and electrical
relays wherever possible. Steel screws, when used, shall be zinc,
cadmium or chromium plated or, when plating is not possible owing to
tolerance limitations, shall be of corrosion resisting steel. All woodscrews
shall be of dull nickel-plated brass or of other approved finish. Instrument
screws (except those forming part of a magnetic circuit) shall be of brass
or bronze. Spring shall be of non-rusting material, e.g., phosphor bronze

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or nickel silver, as far as possible. Pivots and other parts which are non-

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ferrous material and unsuitable shall be of an approved rustproof steel

where possible.
1.08 INSPECTION AND TESTS AT MANUFACTURER'S WORK
A. The Engineer and his duly authorized representative shall have at

all reasonable times access to the Contractor's premises to inspect and
examine the materials and workmanship of mechanical equipment being
manufactured there, and if part of such equipment is being manufactured
on other premises, the Contractors shall obtain for the Engineer and for
his duly authorized representative permission to inspect as if that
equipment was manufactured on the Contractor's own premises. Such
inspection, examination or testing, if made, shall not relieve the
Contractor from any obligation under the Contract.
B. All works, materials and the like rejected shall be corrected or replaced as
necessary at the Contractor's own expense to the satisfaction of the
Engineer.
C. Where the mechanical equipment is composite unit of several individual
pieces manufactured in different places, it shall be assembled and tested
as one complete working unit, at the manufacturer's works, to the relevant
test or tests required.
D. The Contractor shall submit his proposed programme of tests for

the Engineer' approval six weeks before the commencement of testing.
E. The aforementioned works tests carried out before delivery to the Site
shall not in any way relieve the Contractor of completing satisfactory Site
tests after erection as specified.
F. The Contractor shall give the Engineer reasonable notice, at least ten
clear days in writing, of the date and the place at which any mechanical
Equipment will be ready for testing as provided in the Contract and the
Engineer shall thereupon at his discretion notify the Contractor of his
intention either to release such part upon receipt of works tests
certificates or of his intention to inspect such part. The Contractor shall
forward to the Engineer six duly certified copies of all relevant test
readings.
G. The Contractor shall provide, free of charge, such labor, materials,

electricity, fuel, water, stores, apparatus, instruments and other things as
may be reasonably demanded to carry out efficiently such tests of the
mechanical equipment in accordance with the Contract, and shall provide
facilities to the Engineer or to his authorized representative to accomplish
such testing. Where inspection or testing is to be carried out at a Sub-
contractor's works, a representative of the Contractor shall be present.
H. Works tests shall also be carried out such that due consideration is given
to the Site conditions under which the mechanical equipment is required
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to function. The tests certificates shall give all details of such tests.

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I. Specific performance works tests are described in the relevant Sections

of Division 15, and include:
a) Sample performance testing of air handling units for airflow,

heating and cooling & and noise emission.
b) Sample type - performance testing of fan assisted and non-f an

assisted Variable Air Volume boxes coupled to proposed diffusers, in a
test room at the manufacturers works for heating and cooling
airflow, air distribution and noise emission.
1.09 CERTIFIED DRAWINGS
A. The Contractor shall be responsible for providing all "Certified" drawings

from manufacturers of mechanical equipment, prior to their manufacture
and installation. A "Certified' manufacturer's drawing shall mean a
drawing which is prepared by a manufacturer as showing the exact
dimensions and details of items of the mechanical equipment, as they will
be supplied and installed in the Works.
1.10 SAMPLES
A. The Contractors shall provide a sample properly labeled of all fittings,

valves, insulation, cocks, unions, grilles, dampers, switchgear, cables and
other like accessories described in the Specification or as required by the
Engineer.
1.11 PROTECTION AND CARE OF PLANT AND EQUIPMENT
A. All mechanical equipment shall be packed in robust containers to prevent

damage and mishandling during transport to Site. Before dispatch from
works all mechanical equipment shall be thoroughly cleaned, protected
against damage, deterioration, corrosion and ingress of dirt and packed
and protected suitable for prolonged storage in a humid and saline
atmosphere.
During storage and erection at the Site, the mechanical equipment shall be
kept clean and free from dirt and debris, and water shall not be allowed to
remain in any pockets of the equipment. All items of mechanical
equipment shall be stored clear to the ground on suitable timbers to the
All mechanical equipment, particularly electrical and other sensitive

instrumentation shall at all times be protected so that it is not subject to
damage by rainwater, moisture, dust, etc., from any source. Mechanical
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equipment which may be damaged by heat or sun shall be protected

accordingly. All open piped ends and duct ends whether installed or in
store shall be fitted with plastic caps or suitable protective covering.
1.12 GUARDS
A. A guard shall be provided for all open unprotected intakes to axial fans,
centrifugal flow fans, for V-belt drives or in any position required by the UK
Factories Act.
Fan guards shall be manufactured by the fan maker, have galvanized steel
wire mesh, not greater than 25mm attached to a rigid galvanized steel rod
framework.
Guards to V-belt drives shall be made of galvanized steel wire at least 12

gauge with a mesh not greater than 12.5mm attached to a rigid galvanized
framework of rods not less than 10mm. The guard shall be readily
removable to permit the belts to be changed. Adequate access panels
shall be provided in the side of the guard to allow tachometer readings of
the two shafts to be taken and belt tension tested. Allowances shall be
made for the adjustment of the motor on its slide rails.
Cleaning: The Contractor shall be responsible for cleaning all mechanical

equipment at all times to the satisfaction of the Engineer. The cleaning
shall be carried out notwithstanding the fact that the installation or any part
thereof may be in use of partial use within the premises in occupation by
others. A Certificate of Completion will not be issued until the Engineer is
satisfied that all dirt, jointing materials and other extraneous and injurious
materials have been removed.
1.13 AIR CONDITIONED STORES
A. The Contractor shall provide air-conditioned site stores for all goods,
which deteriorate when subjected to the site climatic conditions detailed.
The contractor will adhere strictly to the Manufacturer's instructions with
regard to storage temperatures for all materials being used for the
construction of this project.
1.14 PAINTING
A. The preparation, painting and treatment of mechanical equipment surfaces

shall be in accordance with relevant items in Division 15 and Division 9.
B. Full details of the manufacturer's standard finishes shall be given to the

Engineer for his approval prior to manufacturer. Special care shall be
taken to ensure standard finishes are suitable for the particular conditions
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applicable to the individual items of plant.

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C. Any damage to paintwork, which occurs, shall be made good by the

Contractor at his own cost to the satisfaction of the Engineer.
D. The interiors of control panels shall be finished white enamel paint (two
coats) and shall comply with the appropriate BS for enamel finish and the
exteriors of such panels shall be of BS Specification colour as specified by
the Engineer to give a minimum reflection value of 42%. Instruments shall
be finished dull black and control handles, push button and similar fittings
shall be chromium plated or otherwise durably finished to the approval of the
Engineer.
E. All bright metal parts shall be covered before dispatch with an approved
protective compound and protected adequately during delivery to Site. After
erection these parts shall be cleaned with a correct solvent and polished
bright where required.
F. Machined mating surfaces such as gear teeth, etc., shall be coated with a
thick layer of grease. Other machined surfaces shall be given a coat of rust-
preventing paint, which shall be readily removable when required.
G. Where it is the usual practice of the manufacturer of special items such as
pumps, compressors, electric motors, gearboxes, switch gear, etc., to apply
a high standard of protective enamel paintwork in the shops before
dispatch. This will be acceptable provided any subsequent damage to the
paintwork is made good by the Contractor, at his own cost. The preferred
finish is light grey and red for Fire related equipment.
H. The inside of outdoor control cubicles, cabinets, etc., where condensation is

liable to occur, shall be coated with an approved anti-condensation
composition.
I. The Contractor shall obtain the paint manufacturer's guarantee that each
coat of paint is compatible with the previous and subsequent coats so that
peeling, flaking and other faults do not occur.
J. The Contractor shall include for painting all pipes, ducts, flange edges, etc.,
prior to their being insulated.
K. Final decoration of exposed pipe work, brackets and ductwork shall be

carried out in accordance with Division 9.
1.15 MANUFACTURER’S NAMEPLATES
A. Nameplates: Each item of mechanical equipment and plant shall have the
manufacturer's name or trademark on a corrosion-resistant nameplate
securely affixed in a conspicuous place. The manufacturer's name or
trademark may be cast integrally with stamped or otherwise permanently
marked upon the item of the equipment. The nameplate shall show the
equipment reference number, date of manufacture and the capacity. Such
other information as the manufacturer may consider necessary to complete
identification shall be shown on the nameplates.

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1.16 LABELS
A. Identification labels of plastic laminate or similar approved materials

engraved black on white unless otherwise agreed, with not less than 5mm
"line" style letters shall be fixed on or adjacent to all controls, switches and
distribution gear, by means of at least two brass screws. Socket outlets of all
voltages shall be similarly identified or engraved.
B. The labels shall bear the identification shown on the Drawings, such as
indication, designation, and function and, where necessary, phase, voltage,
current, frequency, pressure and temperature. All labels shall be in Arabic
and English.
1.17 LUBRICATION
A. A complete schedule of recommended oils and other lubricants shall be

furnished by the Contractor. The number of different types of lubricants
shall be kept to a minimum. The schedule and the name of the supplier of
the lubricants shall be submitted to the Engineer for approval before
incorporation in the instruction manuals. In the case of grease lubricated
roller type bearings for electric motors, lithium base grease is preferred.
B. Where lubrication is affected by means of grease, preference shall be given

to a pressure system, which does not require frequent adjustment or
recharging. Frequent for this purpose, means more than once weekly and
grease systems having shorter periods between greasing should be avoided.
Where necessary for accessibility, grease nipples shall be placed at the end
of extension piping and, when a number of such points can be grouped
conveniently, the nipples shall be brought to a battery plate mounted in a
convenient position. Button head type nipples shall be of the same size and
type for every part of the plant. Arrangements shall be provided to prevent
bearings being overfilled with either grease or oil
C. Where more than one special grease is required a grease gun for each
special type shall be supplied and permanently labeled.
D. Oil sumps shall be fitted with oil level indicators of the sight glass type, or
where this is not practical, with dipsticks. The indicators shall show the level
of all temperatures likely to be experienced in service. The normal,
maximum and minimum levels at 30oC shall be clearly visible in the sight
glass type from the normal access floor to the particular item of plant, and
they shall be easily dismantled.
E. All sight glasses shall be firmly held and enclosed in metal protection in such
a manner that they cannot be accidentally damaged.
F. All lubrication systems shall be designed so as not to present a fire hazard

and particular care shall be taken to prevent leakage of lubricants and to
avoid leaking lubricants coming into current contact with any electrical
equipment, heated surfaces or any other potential source of fire.
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G. The Contractor shall supply flushing oil for each lubrication system when an
item of plant is ready for preliminary running and a sufficient quantity of the
approved lubricants for setting to work and for the commercial operation for
one year after the relevant Certification of Completion has been issued.
1.18 SPECIAL TOOLS
A. The Contractor shall supply two complete sets of any special tools
necessary for the operation, maintenance and dismantling of the
mechanical equipment. The Contractor shall supply wall-mounted
strongboxes, each fitted with a suitable lock and two keys, and located near
the item of mechanical equipment for which they will be used. The
Contractor shall not use such tools during the erection of the mechanical
equipment.
1.19 SUNDRY BUILDERS WORK IN CONNECTION WITH SERVICES
A. The Contractor shall include in his prices for drilling, raw bolting, plugging,
screwing and nailing of all brackets, hangers, for all pipe work, ductwork
conduit, cable tray, cable trucking and cable supports. The Contractor shall
also include for supplying all brackets, hangers and supports as necessary.
1.20 NOISE
A. The Contractor shall provide a quiet installation. All items of mechanical

equipment shown on the Drawings shall be carefully chosen with a view to
silent operation. The recommendations in BS 5720 and BSCP 3 Chapter III
shall be followed wherever necessary. The Contractor shall prepare detailed
noise level calculations to indicate the anticipated noise levels in all critical
areas.
B. All possible steps shall be taken, (e.g. by the use of sound insulation, sound
attenuators, anti-vibration mountings, and careful design of pumps, motors,
fans, ducts, bends, dampers, grilles and other equipment) to reduce the
noise produced by the mechanical equipment.
C. The Contractor shall determine the noise levels of all primary mechanical
equipment’s before proceeding with manufacture and submit sound power
levels of such Equipment to the Engineer for approval before manufacture is
commenced.
1.21 ANTI-VIBRATION MOUNTINGS AND SOUND ABSORPTION
A. The Contractor shall provide and fix all mechanical equipment to prevent
noise and the transmission of vibration through the structures.
B. All fans, motors, pumps and other items, as appropriate, shall be mounted
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on resilient mountings in such a manner that the plant foundations are

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isolated from the floor or structure. In addition, all rotating plant shall be
statically and dynamically balanced.
C. Mechanical vibration shall be eliminated by the use of anti-vibration

mountings and flexible connections to ensure an isolation efficiency of 95%
from the building structure except where defined otherwise on the Drawings
or in the Specification.
D. Spring type anti-vibration mountings shall be the captive partially encased

and restrained type to prevent lateral movement.
1.22 AS BUILT DRAWINGS
A. Thirty days prior to the date of the handing over certificate, the Contractor
shall provide for approval "as built" record drawings of the whole works.
B. The Drawings shall include the following: -
1. General arrangements of all services to a scale of not less than 1:50.

2. Detailed layouts of plant rooms and similar spaces to a scale of not
less than 1:20.
3. Schedules o f a l l p l a n t a n d c r o s s e d r e f e r e n c e d e q u i p m e n t t o
t h e maintenance manual.
4. All equipment and control wiring d iag ra ms together w ith specialist
system i.e. public address, fire alarms, etc.
5. These m a y b e p r o d u c e d s e p a r a t e l y o r i n c l u d e d w i t h t h e
g e n e r a l distribution diagrams.
6. Indicate with accurate dimensions, sizes and positions of all plant,
equipment and valves together with all inspection points and test
positions. All plants to have indicated manufacturer's name, model
and type number also cross-referenced to maintenance manual.
7. Fully indicate all ductwork, pipe work, sizes and positions of all plant
equipment and valves together with all inspection points and test
positions. All plant to have indicated manufacturer's name model and
type number also cross-referenced to maintenance manual.
8. Show the disposition and depth of all cables, pipes, ducts, buried direct
in the ground and taken at intervals where cable increase or decrease
in number/size and at every point where the services enter into or
depart from ducts or buildings.
9. Indicate the number, sizes and services for every cable, duct, and
pipe, for every service within each building. Circuit lists for every
distribution board shall be entered on to the relevant drawings and
such lists shall agree with the list fixed within the distribution board
door.
10. Show clearly on site drawings all the new buildings together with all
other existing buildings and other permanent features with dimensions
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between such buildings and cables, pipes, ducts, etc. clearly marked,
together with installed backfill and surround to each services.
11. Indicate all equipment and control wiring diagrams together with all
specialist systems i.e. public address, fire alarm, etc. Diagrams must
be coordinated and show all required interlocks etc. between systems
or components.
12. Show clearly all plumbing and drainage and setting out dimensions for
all drainage pipe work and manholes both within the building
throughout the site, together with drainage pipe work backfill, or
surround in each location. A schedule shall be included to indicate
each manhole size, cover size, and invert level and ground level.
C. The symbol used for each service for all, as built drawings shall be shown on
separate drawings.
D. In order to achieve accurate as-built drawings, all relevant information

relating to the mechanical works shall be entered onto prints supplied
immediately after the work has been carried out. The marked up prints shall
be available for inspection at the Contractor's site office at any reasonable
time during the progress of the works.
E. All service routes, intersections and joints shown on the prints and finally
recorded shall be actually physically measured from permanent features and
accurate distances shall be shown on the Drawings.
F. In addition to the as built drawings, the Contractor shall obtain and provide
two sets of all manufacturers’ detailed drawings for all items of plant,
equipment, apparatus and materials. These drawings shall be suitably titled
and have drawing reference numbers added.
G. The Contractor shall provide two copies of all as built drawings for review
comments and approval. Upon receiving approval in writing from the
Engineer, or his representative, the Contractor shall provide one negative
copy of each approved as built drawing and bind one set of prints into each
of 6 no. Copies of the operating instructions specified in clause 1.23.
1.23 OPERATING AND MAINTENANCE INSTRUCTIONS
A. The working, operating and maintenance instruction shall be prepared in

draft as soon as the working drawings are in hand and shall take the form
of a manual in which fully detailed information relating to the maintenance
and operation of the complete installation and its component parts is
presented.
a. Overall gene ral description of the com plete

e q u i p m e n t i n s t a l l e d together with the method of functioning.
b. Full technical descriptions of each and every item of equipment,
including the electrical circuit details as applicable.
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c. Operating procedures for each section of the works and each

individual item of equipment or plant.
d. Planned maintenance schedules for the installation and its component

parts to include commissioning performance details and
measurements.
e. Schedule of components comprising each and every item of equipment

including manufacturer's name, description and part number of each
component.
f. A copy of the manufacturer's literature, describing each item of

equipment, plant fittings and accessory type used throughout the
installation. This l i t e r a t u r e s h a l l l i s t t h e t e c h n i c a l d a t a
a v a i l a b l e , together with catalogue list numbers for replacement
purposes.
g. Generally all drawings must be arranged to flood out from their position
and be entirely visible when any part of the manual is being read.
They shall be printed on linen backed paper.
h. Each section shall be encased in a loose-leaf ring binder covered in

plastic material of an approved colour and of a type, which shall be flat
when open.
i. The Contractor shall include for the preparation and supply of six
copies of the above operating and maintenance instructions for each
section after all details have been approved by the Engineer.
j. Electric transfer of "As Built" drawings shall be provided as required by

the Engineer.
1.24 INSTRUCTION AND TRAINING
A. The Contractor shall be responsible for the provision of suitably qualified

personnel for the instruction and supervision of the Employer's staff at Site
in the operation and routine maintenance of all mechanical equipment and
associate works. Unless specified to the contrary in the specific technical
clauses in Division 15 and Division 13, instruction and training shall be for
periods of six hours daily for twenty days after the satisfactory
commissioning of the installation and as necessary, after each subsequent
commissioning of a system or part thereof.
1.25 SPARES AND CONSUMABLES
A. A list of spares and consumables for 1 year’s operation for every item of
plant and system shall be furnished by the Contractor at the time of

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tendering.

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1.26 MOCK-UPS
A. The Contractor shall provide mechanical equipment to allow full

Architectural Mock-ups to be built as described elsewhere in the
specification.
END OF SECTION

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SECTION 15171
ELECTRICAL REQUIREMENTS FOR MECHANICAL EQUIPMENT

PART I – GENERAL
1.01 SCOPE OF SECTION
A. This Technical Specification details the electrical requirements of the

mechanical equipment and plant.
B. All electrical materials, equipment, plant and installation procedures shall

be in accordance with Division 16 of this Specification.
1.02 WORK INCLUDED
A. The work includes the provision of all labour materials and the
performance of all operations in connection with the electrical
requirements for mechanical equipment.
B. Co-ordination: The Contractor shall be responsible for the full co-

ordination of the work of all trades.
A. The Contractor shall employ specialist electrical equipment installers and

manufacturers that can demonstrate at least 5 years successful
experience in the supply and installation of the type of equipment and
systems specified.
1.04 APPLICABLE CODES AND STANDARDS
A. The Electrical Requirements shall comply with the latest relevant British
Standards in all respects.
B. The following are some of the most commonly used British and other
Standards associated with Electrical works. However, the Contractor shall
ensure all applicable Standards are complied with, whether listed here or
not.
BS 1376 - Specification for colours of light signals.

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BS 2757 - Method f o r d e t e r m i n i n g t h e t h e r m a l c l a s s i f i c a t i o n o f
electrical insulation.
BS 4099 - Colours of indicator lights, push buttons, annunciators and

digital readouts.
BS 4794 - Special requirements for specific types of control Part 2

switches.
BS 6231 - Specification for PVC insulated cable for switchgear and

control gear wiring.
IEC 144 - Degrees o f p r o t e c t i o n o f e n c l o s u r e s f o r l o w vo l t a g e

switchgear & control gear.
1.05 SUBMITTALS
A. Drawings refer to Section 15010
B. Product data - relating to each and every component and assembly.
C. Systems information - full schematic and wiring diagrams including panel

fascia layouts.
1.06 OPERATION AND MAINTENANCE DATA
A. Comply with Section 15010
1.07 WARRANTY
A. Provide 12 months warranty in accordance with contract conditions
1.08 EXTRA MATERIALS
A. Comply with Section 15010.
PART 2: PRODUCTS
2.01 CONTROL PANEL ENCLOSURES
A. Panels shall be constructed from 2 mm thick galvanized steel plate to

IP54.
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B. Each composite panel shall include a main isolator interlocked with the
door which shall be lockable. All panels shall be finished with stove
enamel internally and externally. All panels shall be sealed against
ingress of moisture, dust and vermin. All starters and controls shall be
located in panels unless agreed otherwise by the Engineer. Anti-
condensation heaters and ventilation fans shall be provided in each panel.
C. An earthing bar shall be provided throughout the entire length of the

control panel.
D. Ventilation fans and filters should be provided in control panels to limit

interior temperatures. Plant room ambient air must be assumed to be at
45°C.
E. A minimum of 2 doors shall be provided on any panels wider than 800 mm

which shall be fabricated to form rigid trays with dust excluding gaskets
around their perimeter.
Doors shall be fitted with hinges to facilitate the removal of the door panels
if required.
All doors shall be interlocked or arranged such that the door that provides
access to the main isolator must be opened first. All door locks shall be
provided with common keys.
Panels shall be designed with the following limitations:-
Height = 2200 mm max.
Length of single section = 2400 mm max.
2.02 CONTROL PANEL METERS
A. Ammeters and voltmeters shall be provided for each motor either of the
moving coil or moving iron self-contained type to BS 89 (Industrial
Grade).
B. All instruments shall be flush mounted and those with moving coil or
moving iron movements shall be centre pivot type with circular scales
unless otherwise specified or approved. They shall be of the dead-beat
type and shall be capable of carrying their full scale currents continuously
without undue heating or impairing their accuracy. The indicated reading
shall be clearly defined and shown against indelibly marked scales
engraved on enameled metal. The pointers shall be of clean outline. The
pointers and scales shall be such that the scale is marked on a stepped
section to avoid the casting of shadows on the scale, and parallax errors.
The markings on the dials shall be restricted to the scale markings.
Instrument transformer ratios and maker's name shall not appear
prominently on the dials but may be marked in an unobtrusive position.
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The glass covers to dials shall be of non-reflecting glass.

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C. Means shall be provided for zero adjustment without dismantling the

instrument or removing the instrument from the panel.
D. Busbar voltmeters shall be calibrated while hot. All voltage circuits to
instruments shall be protected by a fuse on each pole of the circuit placed
as close as possible to the instrument transformer terminal or, where
instruments are direct connected, as close as possible to the mains
connection in any one of three phases. All instruments and apparatus shall
be back connected and all instruments shall be properly earthed.
2.03 CONTROL SWITCHES AND ELECTRICAL ISOLATION
A. Control switches shall comply with BS 4794.
B. Switches shall be of the rotary type.
C. All control switches shall be capable of being locked in the "off" position,
unless stated otherwise.
D. The contacts of all switches shall be strong and have a positive wiping
action when operated.
E. All control switches shall be provided with labels.
F. All control panels shall be provided with a defeat proof door interlock
isolator controlling the main incoming supply. The isolator shall be
capable of making and breaking on full load without damage. Additionally
the isolator shall have:-
a. Auxiliary contacts to isolate any secondary supplies to the
control panel.
b. Manual override switch to enable the control system only to
be energized whilst the incoming supplies are isolated.
G. The panel shall be constructed such that power (3 phase and single
phase) equipment is located behind the interlocked isolator door.
Control (extra low voltage) equipment shall be located behind the second or
subsequent doors to ensure segregation and shielding from power
equipment.
All internal wiring shall be enclosed within wire ways. Inter wiring that is
required to pass between the power and control sections of the panel
shall be enclosed within separate or segregated wire ways to ensure
electrical separation of the power and control systems.
2.04 INDICATING LAMPS INSTRUMENTS AND FITTINGS
A. Indicating lamps fitted into the facias of switch and instrument cubicles or
panels shall be adequately ventilated.
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B. A red warning light shall be provided to indicate "Main Supply On".
C. The following must be included on all local HVAC control panels.
a. Run/trip lamps for all equipment

b. Panel live lamp
c. Rotary selector switches for duty/standby plant
d. Rotary switches for all single plant items
e. Ammeters for all motors
f. Warning lamps
g. Gauge
h. Hours run meters
D. Lamps shall be easily replaceable from the front of the panel by manual
means without the use of extractors.
E. The bezel of metal or other approved material holding the lamp glass
shall be of an approved finish and easily removable from the body of the
fitting so as to permit access to the lamp and lamp glass.
F. The lamps shall be clear and shall fit into a standard form of lamp holder.
The rated lamp voltage should be 10 percent in excess of the auxiliary
supply voltage, whether ac or dc. For ac circuits, lamp units shall have an
integral transformer providing a 6V supply to the lamp.
G. The lamp glasses shall comply with BS 1376 and BS 4099 and shall be in
standard colours, red, green, blue, white and amber. The colour shall be
in the glasses and not an applied coating and the different coloured
glasses shall not be interchangeable. Transparent synthetic materials
may be used instead of glass, provided such materials have fast colours
and are completely suitable for use in tropical climates.
H. All indicating 1 amp circuits shall have a "Test Lamp" switch.
2.05 SMALL WIRING

A. All control panel wiring shall be carried out in a neat and systematic
manner with cable supported clear of the panels and other surfaces at all
points to obtain free circulation of air.
B. In all cases, the sequences of the wiring terminals shall be such that the
junction between multi-core cables and the terminals is affected without
crossover. Except where terminals are approved by the Engineer for use
with bare conductors, crimped connectors of approved type shall be used
to terminate all small wiring. Insulating bushes shall be provided where
necessary to prevent chafing of wiring.
C. All panel wiring shall comply with the requirements of BS 6231 Type A or
B, as appropriate. Conductors shall be copper and have a minimum cross
section equivalent to 50/0.25 mm (2.5 mm²), 7/0.67 mm (2.5 mm²) or
1/1.78 mm (2.5 mm²). 7/0.67 mm shall only be employed for rigid
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connections which are not subject to movement or vibration during

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shipment, operation or maintenance. Flexible conductor’s equivalent to

30/0.25 mm (1.5 mm²) or smaller sizes generally shall only be employed
with written approval.
D. All wires shall be colour coded and fitted with numbered ferrules of
approved type at each termination. At points of inter-connection between
wiring, where a change of numbering cannot be avoided, double ferrules
shall be provided. Such points shall be clearly indicated on the wiring
diagram.
E. No wires shall be teed or jointed between terminal points.
F. Electrical wiring and instruments shall be located so that leakage of oil or

water cannot affect them.
G. All metallic cases of instruments, control switches, relays etc., mounted

on control panels or in cubicles, steel, or otherwise, shall be connected
by means of copper conductors of not less than 2.5 sq.mm section to the
nearest earth bar. These conductors may be bare or have insulation
coloured green/yellow stripes.
2.06 LINKS AND FUSES
A. Provision shall be made for isolating links to enable circuits to be isolated

for maintenance and testing items of plant on the panels without affecting
other circuits. These links shall be clearly labelled.
B. All incoming supply terminals above 110V shall be shrouded.
C. Fuses of the appropriate rating shall be fitted to each outgoing circuit to

provide both overload and short-circuit protection.
D. All fuses shall be of the HRC cartridge type and comply with BS 88.
E. Carriers and bases for fuses and links shall be coloured in accordance
with local practice. The labelling of links and fuses shall be in accordance
with the schematic diagrams. A complete set of spare fuses shall be
provided in each panel.
F. If miniature circuit breakers and/or moulded case circuit breakers are

utilised in any circuit, and "back-up protection is required to afford
adequate discrimination between these circuit breakers and any other
protective device in the circuit, HRC fuses shall be used as `fault current
limiters".
G. The rating and characteristics of fault current limiters shall be such as to

limit the fault current of the ultimate circuit breaker in the circuit to the
fault current capacity of the circuit breaker. Fault current limiters shall be
such that they will not operate under overload as distinct from short circuit
conditions. Fault current limiters shall be labelled as such.
H. Equipment fixed inside cubicles shall be required to give easy access to

wiring and terminals. Resistance boxes shall be located so that the
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adjustment screws are on a vertical accessible face. Stud terminals shall

be provided for all resistances.
2.07 TERMINAL BOARDS
A. Grouped terminal boards of adequate capacity and fully numbered, with

permanent labels, shall be provided for all wires leading to equipment
outside a panel. Terminal numbers or markings shall correspond with those
used on related apparatus and wiring diagrams. Removable plates or other
facility shall be provided for the entry of incoming cables, conduits,
trunking, etc. with means for effective earthing to the cubicle chassis.
Provision shall be made for the earthing of all non-current- carrying
metalwork. For main power terminals incorporated within a panel, soldered
socket type terminals shall be provided.
B. All terminal boards shall be mounted in accessible positions and when in

enclosed cubicles, are preferably to be inclined towards the doors. Spacing
of adjacent terminal boards shall be not less than 100 mm and the bottom
of each board shall be not less than 200 mm above the incoming cable
gland plate. Separate terminations shall be provided on each terminal strip
for the cores of incoming and outgoing cables including all spare cores.
Barriers shall be provided between wires of different voltages on the same
or adjacent terminals.
C. Terminals that are "live" from other power sources when the cubicle
isolator is open shall be shrouded and fitted with a danger label.
D. Screw or stud type terminals shall only be used with crimped ring type
wiring terminations. Plain steel screws and studs shall be not less than size
M6 but stainless steel and bronze down to size M5 may be used provided
that the current carrying capacity is adequate. All studs shall be provided
with nuts, washers and lock washers.
E. Insertion type terminals shall generally be employed for small circuit

wiring whereby the stranded conductor or crimped termination is clamped
between plates by a screw having a suitable locking device. Terminal
entries shall be shrouded such that no current carrying metal is exposed.
Tapped holes shall have not less than three full threads.
F. Terminal assemblies are preferably to be of the unit form suitable for

mounting collectively on a standard assembly rail, secured from the front
and giving the required number of ways plus 10% spare.
G. All connections shall be made at the front of the terminal boards and no
live metal is to be exposed at the back.
H. No more than two leads shall be taken to any common pair of terminals,
unless specially approved by the Engineer.

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2.08 NUMBER PLATES AND LABELS
A. Number plates and labels shall be provided and fixed to all items,
including push buttons, operating levers, indicating lamps, etc. to show the
purpose and function of each item and to ensure its safe and satisfactory
operation. The type, size, inscription and position of labels shall be to the
Engineer's approval.
B. Adhesive die stamped or printed tapes shall not be permitted for labelling
equipment.
2.09 EARTHING
A. All control panels shall be provided with a continuous copper earth bar
having a sectional area of not less than 75 mm² placed at a convenient
position near the bottom of the panel. The area of the earth bar shall not be
less than half the cross-sectional area of the phase busbars and not less
than the area of the incoming neutral conductor.
B. All metal cases or earth terminals of the various instruments, relays, etc. on
the panels shall be connected to this earth bar by copper connections of not
less than 2.5 mm2.
C. All metal parts other than those forming part of any electrical circuit shall be
earthed in an approved manner and all earthing terminals shall be of
adequate dimensions.
2.10 LECTRIC MOTORS
A. Motors shall be of the totally enclosed fan cooled (TEFC) design to BS

5000 and shall be fitted with axially locating type bearings and/or heavy
duty thrust bearings at the non-driving end and roller type bearings at the
drive end. All bearings shall be of adequate proportions and design suitable
for the particular application.
B. Motors shall be of the squirrel cage induction type. Motors shall be

suitably finished to accord protection against any corrosive liquid or
fumes.
C. All motors shall be built of high grade components and materials and shall
operate without undue vibration and with the minimum of noise.
D. The insulation shall be Class `F' to BS 2757 but the temperature rise shall
be limited to 80 oC measured by the resistance method, at an ambient
temperature of 50 oC. The motors shall be suitable in all respects for their
operational duties taking into account such an ambient temperature within
the building.
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E. All motors rated at 11 KW and above shall be fitted with thermostatic

control elements actuating directly on the control circuit of the motor and
disconnecting it from the supply in the event of a temperature rise
exceeding the acceptable limits for its insulation class.
F. The motors shall be fully tropicalized, and shall be fitted with anti-
condensation heaters.
G. The motors shall be capable of providing 10% in excess of the specified

volume flow of their respective fans under all operating conditions.
Selections must assume that resistance increases by the square law and
absorbed power by the cube law.
H. Motors are required to operate from 220 V / 1 Ph / 50 Hz or 380 V / 3 Ph

/50 Hz supply as applicable, and shall be continuously rated.
I. The motors shall be capable of satisfactory operation with a voltage

variation of 10% above or below the supply voltage. They shall also be
capable of operating satisfactorily with a frequency variation of 2.5%
above or below the normal frequency of 50 or 60 Hz, as applicable.
1. No motor shall run faster than 1500 rpm. unless otherwise approved
by the Engineer.
2. Motors shall be designed to operate at a power factor not less than

0.85.
3. Motors shall be suitable for the starting methods specified.
4. Motor starting currents shall not exceed the following values:
Auto-transformer starting - 1.5 times the full load current.
Star/Delta starting - 3.5 times the full load current.
Direct-on-line starting - 6 times the full load current.
J.The connections of the motors shall be brought out to easily accessible

terminals of the stud type, totally enclosed. They shall be substantially
designed and thoroughly insulated from the frame. Cambric or equal
insulation shall be used for the connections from the windings to the
terminals. Terminal boxes shall be fitted with glands to accept the
specified type of cable.
K. The cable glands shall be downwards pointing at such an angle as is

necessary to clear the motor base plate and plinth.
L. Motors shall have visible nameplates indicating:-
Motor power --- KW

Voltage

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Phase
Cycles
RPM
Full load amps, Locked Rotar amps Frame size
Manufacturers name and model
Power Factor
PART 3: EXECUTION
3.01 INSTALLATION
A. Installation of all the equipment, plant and material included in this

Section of the Specification shall additionally be in accordance with the
requirements of Division 16.
END OF SECTION

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SECTION 15190
MECHANICAL IDENTIFICATION
PART 1: GENERAL
1.01 SCOPE OF WORK
A. This Section covers the basic general requirements applicable to all

Division 15 works that shall be provided for by the Contractor.
1.02 WORK INCLUDED
A. The work includes the provision of all labour, materials and the
performance of all operations in connection with the supply and
installation of Mechanical Identification systems as specified herein and
where referred to on the Drawings.
B. Coordination: The Contractor shall be responsible for the full coordination

of the work of all trades.
A. Manufacturers: Firms regularly engaged in the manufacture of

Mechanical Identification systems whose products have been in
satisfactory use for a similar application and not less than 10 years.
B. Installer: Firms regularly engaged and qualified in the installation of

Mechanical Identification systems with at least 5 years successful
installation experiences on projects of a similar nature.
A. Mechanical Identification systems and all associated materials and

workmanship shall comply fully with the latest relevant British Standards
in all respects.
The following are the most commonly used and relevant British
Standards associated with pipework products and associated materials.
However, the Contractor shall ensure that all applicable British Standards
are complied with whether listed here or not.
BS 1710 - Specification for Identification of Pipelines and Services.
BS 4800 - Specification for Paint Colours for Building Purposes.

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1.05 SUBMITTALS
A. Drawings refer to and Section 15010
B. Products: Full manufacturers colour data for each product.
C. Samples-Full-size colour sample of pipework and ductwork identification.

A. Comply with Section 15010
B. Mechanical identification system shall correspond totally to “As Built"
data.
1.07 WARRANTY
A. Provide 12 months warranty in accordance with contract conditions.
PART 2: PRODUCTS
2.01 PLANT AND PIPEWORK IDENTIFICATION

A. All pipework shall be colour coded in accordance with BS 1710 as
detailed in Table 1.
TABLE I
IDENTIFICATION OF PIPELINES
Pipe contents Colour code Basic colour

Indication (approx. 150mm)
(approx. 100mm)
Drinking Water To BS 1710 Blue

Cold Water down Service To BS 1710 Green
Hot Water Supply To BS 1710 Green
Drainage To BS 1710 Black
B. Identification to pipework shall consist of 100mm PVC adhesive bands over

the basic colour and shall include flow direction arrows together with the
abbreviation of the service name. All coding requirements are to be agreed
with the Engineer.
C. Code indication for safety conditions shall be as follows:-
Safety Colour BS colour reference

BS 4800
Red 04 E 53
Yellow 08 E 51
Auxiliary Blue 18 E 53

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Safety colour references are as follows:-
1. Red for firefighting equipment.

2. Yellow with black diagonal stripes for warning of danger.
3. Yellow with trefoil symbol for ironizing radiation (as defined in BS
3510).
4. Auxiliary blue in connection with green basic colours, to denote
pipes carrying fresh water, either potable or non-potable.
Safety colour references shall be applied using 100mm wide sections of

PVC adhesive band in all permanent locations, to be agreed with the
Engineer.
Colour references shall include notation as follows:-
1. FIRE
2. DANGER
3. RADIATION
4. POTABLE OR NON-POTABLE
In the case of fire service, all equipment, i.e. valves, suction tanks, etc.,
shall also be painted red.
D. Uninsulated pipework shall be painted with one coat of undercoat and one
coat of gloss finish to the relevant BS colour.
E. Valve identification shall be by means of 40mm diameter traffolyte discs of

white/black/white composition. Letters and figures of 8mm minimum height,
identifying the service and valve number shall be engraved into the
material. A 3mm diameter hole shall be drilled through the disc for the
purpose of securing the disc to the valve.
F. Plant identification shall be by means of traffolyte labels of

white/black/white composition. Letters and figures of 8mm minimum
height identifying the plant shall be of a size to be agreed with the Engineer.
A minimum of two 3mm diameter holes shall be drilled through the label to
the plant.
G. All plants shall carry the manufacturer's identification plate which shall
incorporate all details of electrical and mechanical duties.
2.02 DUCTWORK IDENTIFICATION
A. Ductwork shall be colour coded in accordance with HVAC Specification

DW142 to the colours indicated in Table 2. For conditioned air, identification
shall comprise either of two symbols (one red, one blue) or a single symbol
coloured, part red, part blue.

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TABLE 2
DUCT IDENTIFICATION COLOURS
Type Colour BS 4800
Conditioned Air Red and Blue 04353 / 18E53
Warm Air Yellow 10E53
Fresh Air Green 14E53
Exhaust / extract recirculated air Grey AA009
Foul Air Brown 06C39
B. Direction of flow shall be by PVC self-adhesive equilateral triangles with

one apex pointing in the direction of flow. The minimum length of side of
the triangle shall be 150mm.
PART 3: EXECUTION
3.01 STORAGE
A. All identification materials shall be stored within a well lit container or

purpose made compartmented racks or shelving. The material shall be
adequately covered to prevent damage and ingress of dirt.
B. Refer to Section 01600
3.02 GENERAL
A. Identification shall be placed where it can be easily seen and at positions

where identification will be required. To ensure that the symbols are seen,
the following points shall be considered:-
1. The symbols shall be on the surface which faces the positions of normal
access to the completed installation.
2. The symbols shall not be hidden from view by structural members, other
ducts, plant or other services distribution systems.
3. The symbols shall be placed where there is adequate natural or artificial

light.

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B. Symbols shall occur frequently enough to avoid the need for ducts and
pipes to be traced back. Symbols should be placed at any service and
access points to the distribution system.
C. Identification shall be applied to pipework and ductwork at every entry and

exit point to a room but in no case of intervals of less than 12m.
3.03 PLANT AND PIPEWORK IDENTIFICATION
A. In addition to the colour bands, all pipework in plant rooms and service
areas, whether insulated or not, shall be legibly marked with black or white
letters to indicate the type of service and the direction of flow. Services shall
be identified as follows:-
Chilled Water: CHW

Refrigerant: RFG
Cold Water: Raw RW
Soft SW
Domestic Hot Water: Raw RW
Soft SW
Fire Main: FM Gas:
Gas: GAS
B. The basic identification colour shall be applied using a PVC adhesive band
either applied to pipework insulation or pipe when uninsulated. Identification
shall be placed at all junctions, at both sides of valves, services appliances,
bulkheads, wall penetrations and at any other places where identification is
necessary or advantageous.
C. Where pipes are run in pairs, the letters F and R shall be added to indicate
flow and return respectively.
3.04 DUCTWORK IDENTIFICATION

A. All ductwork in plant rooms and services areas, whether insulated or not,
shall be legibly marked with black or white letters to indicated the type of
service and the direction of flow. Services shall be identified as follows:-
Supply Air - S
Return Air - R
Fresh Air - F
Exhaust - E
B. Ductwork identification shall be applied to ductwork whether insulated or
not, at all branches, plant connections, wall penetrations and at any other
place where identification is necessary or advantageous.
END OF SECTION

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SECTION 15325
FIRE PROTECTION SYSTEM AND EQUIPMENT

PART 1: GENERAL
1.01 SCOPE OF WORK
A. The firefighting services shall be executed as shown on the drawings. All

firefighting system layout drawings and components shall be approved by
the Local Civil Defense Department.
PART 2: PRODUCTS
2. 01 PIPE WORK
A. General Requirements:-
- All pipes shall be of sizes and general routing as shown

on the contract drawings.
- Valves shall be of the same size as the pipe run in which it is

installed.
- Piping material shall be as specified hereafter.
- Pipes shall be installed in a neat manner to present a

neat and pleasing appearance.
- Pipes shall be installed in a manner to permit free expansion

and contraction without causing damages to piping or
construction. Adequate off-sets and change of direction in
the piping shall be provided to accomplish this. On long
pipe runs expansions loops or expansion joints shall be
provided. Where expansion joints are used careful
consideration shall be given to anchoring and guiding the
pipes for controlled expansion and contraction.
- Adequate clearance shall be left between pipes and adjacent

surfaces or existing installations for the easy installation of
valves and accessories.
- Drain valves shall be provided at all low points and as required

to permit draining any part of the system for maintenance
and repair irrespective whether they are shown on the
Contract drawings or not. Drain valves shall also be
provided for alarm valves as shown on the Contract
drawings for the purpose of testing the system.

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- When water filled supply pipes pass through open areas or

other areas exposed to freezing, the pipe shall be protected
against freezing by insulating coverings, frostproof casings,
or other reliable means capable of maintaining a minimum
temperature of 4c.
- The Contractor shall inspect the site conditions for verifying the
required clearance and space necessary for the installation
of all pipe work.
B. Pipes and Fittings
- All firefighting and drain piping shall be standard weight

galvanized steel pipe to ASA schedule 40 or equal
approved.
- Galvanized steel pipes shall be joined by threading for up to

and 50mm diameter and grooved for coupling system for 65
mm diameter and above. Welding of galvanized pipes will
not be permitted.
- All fittings for galvanized steel pipes shall be screwed

malleable iron fittings for all pipe size to ANSI B16.3.
- All threaded and welded fittings shall be of 16 bar working

pressure rating.
- All threaded fittings and pipe shall have threads cut to

ANSI/ASTME Standard B1.20.1.
- All fittings shall have the same thickness and be the same
schedule and rating as the pipe of the corresponding size.
- All changes in direction, change in pipe size, branching and

jointing of pipes shall be made with regular pipe fittings
such as elbows, reducers, tees, coupling, unions, flanges,
etc. Bending of pipes for elbows and field fabricated fittings
will not be permitted.
- Elbows shall be of the long radius type.
- Branch connection on black steel pipes may be made with

forged steel weldolets or threadolets where the branch pipe
is not larger than one half the size of main pipe.
- Pipes shall be cut square and to the exact length with a

hacksaw or pipe cutting device and the cut end of the pipe
shall be reamed with a special tool to the full inside
diameter and all chips shall be removed.
- Threads shall be cut with new dies and all burrs and chips
formed in the threading operating shall be removed with
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wire mesh. Grooves for coupling shall be carried out by

purpose built grooving machine.
- Threaded joints shall be made up tight with approved Teflon

tape thread sealant. Lampwick, cord, wool, or any other
similar materials will not be permitted in making up
threaded joints.
- Care shall be taken that the pipe does not intended into the
fittings sufficiently to reduce the water flow.
C. Unions, Couplings and Flanges
- Pipe unions, couplings or flanges, depending on size and

material of piping, shall be provided at piping connections to
equipment and valves, control valves, and other
accessories that need to be taken out for replacement,
cleaning or repair.
- Unions, couplings or flanges shall be provided at adequate
intervals, in the piping to permit easy disassembly for
alteration and repair.
- Disconnecting unions or flanges shall be

i n s t a l l e d b e t w e e n t h e equipment and the isolating
valves.
- Unions used on threaded pipe size 50mm and smaller shall

have female threaded ends and ground metal to metal
seats.
- Flanges shall always match the flanges provided on valves

and equipment as far as pressure rating, facing, drilling and
thickness.
- Flanges on black steel piping shall be black, forget steel of the

slip-on or welding neck type. Flanges on galvanized steel
piping shall be galvanized steel of the threaded types.
- Flanges joints shall be made perfectly square with the pipes

and shall be fitted with proper thick rubber ring gaskets and
assembled with steel; square head machine bolts and
hexagonal nuts. Gaskets for flat face flanges shall be of the
full face ring with pushed bolt holes.
D. Pipe Hangers and Supports
- All piping shall be supported on steel hangers and

supports of adequate strength and design to carry the
weight of piping and contents without sagging, swaying,
vibrating, failing or deforming. Hangers and supports shall
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allow free movement of pipes due to expansion and

contraction without causing noise or damage to piping or
construction. Hanging pipes from other pipes will not
permitted.
- Hangers and supports shall be of a design that permits

removal without dismantling the pipes and shall be supplied
complete with all required rods, bolts, nuts, turnbuckles,
swivels, coupling brackets and all other components and
accessories.
- Hangers and supports shall be securely fastened to the

building construction by means of expansion bolts without
causing overstress to any part of the construction.
- Hangers and supports shall be designed and the tested to

sustain a load 7 times the actual support load.
- Vertical pipes shall be supported by steel pipe clamp

comprising two flat bar yokes formed to fit the pipe and
drilled and fastened to the pipe with bolts and nuts. The
extended ends of the clamp shall be hung from the
underside of the floor slab by two rods fastened to the
concrete.
- Vertical pipes shall be supported at their base and at a

minimum of every storey height.
- Horizontal pipes shall be hung from the ceiling by

individual steel hangers of the adjustable clevis type with
rod, nuts and turnbuckle.
- All rods shall be threaded for a sufficient length to allow

for vertical adjustment of pipes. Each rod shall be provided
with two nuts: one for positioning and one for locking.
- The minimum size of hanger rod for individually supported

horizontal pipes shall be: 10mm for pipe size up to
50mm, 13mm for pipe size 65mm to 80mm, 16mm for
pipe size 100mm to 125mm, 20mm for pipe size 150mm
and 22mm for pipe size 200mm and larger.
- The maximum support spacing for horizontal drainage

pipework shall be: 1.5m, 1.8m, 2.0m, 2.5m, 2.7m, 3.0m,
3.3m, 3.6m, 4.2m, 4.8m, 5.2m, for pipe sizes 15mm,
20mm, 25mm, 32mm, 40mm, 50mm, 65mm, 80mm,
100mm, 125mm, 150mm, respectively.
- The maximum support spacing for horizontal sprinkler

pipework shall be 4.5m for pipe size 40mm and larger and
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3.6m for pipe size less than 40mm.

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- At least one hanger shall be provided for each section of

branch line and between each two branch lines of
sprinkler piping.
- The distance between a hanger and the centerline of

an upright sprinkler shall not be less than 0.60m.
- The unsupported length between the end sprinkler and the

last hanger on the line shall not be greater than 0.60m
when this limit is exceeded additional hanger shall be
provided.
- The length of an unsupported armover to a sprinkler shall

not exceed 0.60m. The hanger closest to sprinkler shall
be of type that prevents upward movement of the piping
- Wall mounted sidewall sprinklers shall be restrained to

prevent movement.
- Types of hangers to be used for pipe support shall be in

accordance with NEPA 13.
- The contractor shall submit show drawings of pipe hangers

and supports to be used showing the fixation details and
location of hangers, for the Engineer approval.
2.02 VALVES
A. General
- All valves used shall be of 250 psi or 16 bar cold water

pressure rating.
- All valves connected to water supply and sprinkler piping

shall be of indicating type.
- Gate valves used for drain and shutoff purposes shall be

solid wedge disk, non-rising stem and bronze trim, and
shall be screwed, bronze body with screwed bonnet for
valves size 50mm and smaller, and flanged, cast iron
body with bolted bonnet for valves size 65mm and larger.
- Globe valves where required, shall be screwed, bronze body

and trim, integral seat, revolving disk, and screwed
bonnet for valves size 50mm and smaller, and flanged,
cast iron body, bronze trim, renewable seat and disk and
bolted bonnet for valves size 65mm and larger.
- Check valves shall be bronze trim, swing pattern, renewable

disk, and shall be screwed, bronze body and screwed cap
for valves size 50mm and smaller, and flanged, cast iron
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body and bolted cap for valves size 65mm and larger.
- All check valves shall be suitable for horizontal or vertical
installations.
B. Indicating Valves
- All indicating valves shall be outside screw and yoke “O.S &
Y” gate valves with rising stem that indicates if the valves
is open or closed.
- Indicating valves shall not close in less than 5 seconds when

operated at maximum possible speed from the fully open
position to avoid damage to piping by water hammer.
- Indicating valves shall be flanged, bronze trim, solid wedge

disk.
- Indicating valves shall be bronze body with screwed bonnet

for valves size 50mm and smaller, and cast iron body with
bolted bonnets for valves size 65mm and larger.
2.03 FIRE HOSE CABINET (FHC)
A. The fire hose reel cabinet shall be automatic swinging recessed type.
B. Hose reels shall be in accordance with BS 5274. The hose reel shall have a
30 meters long of 25mm internal diameter reinforced rubber hose capable
of withstanding a working pressure of 16bar. The hose shall be wound on a
fabricated steel drum with circular side plates.
C. The hose reel shall turn ‘ON’ automatically when 1.5 - 1.8 meters of
hose is withdrawn from the reel.
D. The hose reel shall be equipped with shut-off valve for connecting
with pipework.
E. The hose nozzle shall be of high impact plastic, JET/SPRAY/SHUT/OFF

nozzle.
F. The cabinet shall be heavy steel construction finished with red colour
plain labelled “FIRE HOSE REEL” and in Local language. The construction
material shall be as detailed on drawings or Particular specifications.
G. The fire hose cabinet shall include a dry chemical fire extinguisher of the
ABC type as specified hereafter.
H. The fire hose cabinet shall be of dimensions sufficient to include the hose
reel, the shut-off valve, Landing Valve and the fire extinguisher and to fit
with the available space as shown on the Drawings.
1. Pressure Reducing System

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Pressure reducing system shall be complete with
• Gate valve
• Pressure reducing valve-type PRV
Valve shall be such that complete replacement of inspection of

any part can be made without removal of the valve body from
the pipe. Valve shall be provided with a by-pass arrangement
complete with all valves and pressure gauges, as detailed on
the drawings.
2.04 FIRE HYDRANT
A. Pedestal fire hydrant shall be constructed of cast iron castings to BS. 1452
complete with 100mm dia flange inlet and two 65mm dia valves with
instantaneous outlets to BS.336 and with brass male couplings protected
with cap secured by a suitable length of chain.
B. The fire hydrant shall be sound construction and hydraulically tested to a

pressure of 20.7 bar before being connected to the firefighting network.
C. The fire hydrant shall be installed about 760mm above ground level and
finished with red color paint.
D. The fire hydrant shall be provided with an isolating installed underground

complete with extension tube, operating key and over.
E. A fire hose unit shall be installed to serve each fire hydrant, it shall
comprise 65mm dia textile fire hose 30m long with male and female
couplings, nozzle jet and spray with male coupling, and cabinet.
2.05 AUTOMATIC SPRINKLER SYSTEM
Sprinklers shall be installed as shown on the drawings and in accordance

with the requirements of NEPA 13-1991
Shop drawings prepared by the Contractor and approved by Civil Defense

Department shall show the exact location, spacing and types of sprinklers.
All sprinklers shall be manufactured, tested and approved in accordance

with the applicable standards of Underwriters laboratories and Factory
Manual.
The following limitations and requirements shall be strictly followed:-
- Orifice size of the sprinkler shall be 15mm with 15mm NPT

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thread type.

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- The pipe size supplying one sprinkler shall be 25mm.
- Return bends shall be used for pendant type sprinklers

to avoid accumulation of sediment in sprinklers except for
dry pendant type sprinklers.
- Type, spacing, and position of sprinklers shall be as

specified here under.
- Sprinklers located in skylight area shall be protected with

approved sprinkler shield.
- Sprinklers so located as to be subject to mechanical injury

shall be protected with approved sprinkler guard.
- All sidewalk sprinklers and ceiling mounted pendant

sprinklers shall be provided with escutcheons plates of
the same colour as of the walls or ceiling on which the
sprinklers are mounted.
- Sprinklers shall not be altered in any respect or have any

type of ornamentation or coating applied after shipment
from the place of sprinklers manufacturer.
- When painting the sprinkler piping or painting in areas near

sprinklers, care shall be taken to avoid any coating
applied to sprinklers.
- Any sprinklers that have been painted or coated except

by the sprinklers manufacturer, or damaged shall be
replaced with new approved sprinklers of the same
characteristics. Cleaning of painted sprinklers, or repairing
damaged sprinklers will not be permitted.
- The protection area per sprinkler shall not exceed 18m2

for light hazard occupancy.
- The protection area per sprinkler shall not exceed 12m2

ordinary hazard occupancy.
- The protection area per sprinkler shall not exceed 9m² extra
hazard occupancy.
B. Spacing, Location, and Position of sprinklers
All sprinklers shall be located and spaced as shown on the Contract

drawings and in compliance with the following limitations.
a. Upright and Pendant Sprinklers

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- The distance between branch lines and between sprinklers

on the branch lines shall not exceed 4.6m.
- The distance from the walls to the end sprinklers on the

branch lines shall not exceed one-half of the allowable
distance between sprinklers on the branch lines.
- The distance from the walls to the end branch lines

shall not exceed one-half of the allowable distance
between the branch lines.
- Sprinklers shall be located a minimum of 100mm from a wall.
- A minimum clearance of 450mm shall be maintained

between top of storage and sprinkler deflector.
- Deflectors of sprinklers shall be parallel to ceilings and

located 25mm to 300mm below ceilings.
- Deflectors of sprinklers under beams shall be located 25mm

to 100mm below beams and not more than 500mm below
roof or floor deck.
- Deflectors of sprinklers in bays shall be at sufficient distance

from the beams as shown on Table 4.4.1.3.1.2 and Figure
4.4.1.3.1.2 of NFPA 13-1991 to avoid obstruction to the
sprinkler discharge pattern, otherwise the spacing of
sprinklers on opposite sides of the beams shall be
measured from the centerline of the beam and the
distance shall not exceed one-half of the allowable
distance between sprinklers.
- The operating elements of all sprinklers shall be located

below the ceilings.
- Where sprinklers are located in area containing piping, light

fixtures, ducts etc. which are likely to interfere with the
proper distribution of water from sprinklers, the sprinklers
should be so located or spaced that any interference is
held to a minimum.
Sprinklers shall be installed beneath duct over 1.2m wide unless sprinklers
can be spaced in accordance with Table 4.4.1.3.1.2 of NFPA 13-1991.
b. Sidewall Sprinklers
- The distance between sprinklers on the branch lines

shall not exceed 4.0m
- Deflectors of sprinklers shall be at a distance from walls and

ceiling not more than 150mm or less than 100mm unless
special construction arrangements make a different

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position advisable for prompt operation and effective

distribution.
C. Sprinklers Specification
- All sprinklers shall be of k-factor 5.3-5.8 unless otherwise

specified, and manufactured of brass finish pattern, frame,
and deflector, except for dry pendant type which shall
have chrome plated components.
- Sprinkler shall be integrated with sensitive glass bulb

operated at the required temperature rating. Fusible
element will not be accepted.
- Unless otherwise indicated on the drawings, all sprinklers

shall have a temperature rating 68C (155 F) with bulb
color Red.
- Sprinklers having a temperature rating 93 C (200F) shall

have bulb color Green and white frame color.
- Corrosion – resistant coated sprinklers shall be installed

where required.
- Sprinklers equipped with protection guards or shields shall

be installed where required.
D. Sprinklers Types
a. Standard Pendant Sprinklers:
Sprinklers designed to be installed in such a way that the water stream is

directed downwards against the deflector.
Pendant sprinklers shall be installed for all ceiling mounted sprinklers.
Standard Pendant sprinklers shall be marked SSP and shall be

Installed in Pendant position only.
b. Standard Upright Sprinklers:
Sprinklers designed to be installed in such a way that the water spray is

directed upwards against the deflector.
Upright sprinklers shall be installed in all areas containing exposed

sprinklers piping.
Standard Upright sprinklers shall be marked SSU and shall installed in

Upright position only.
c. Sidewall sprinklers:

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Sprinklers having special deflectors that are designed to discharge most of

the water away from the nearby wall in a pattern resembling one quarter of
a sphere with a small portion of the discharge directed at the wall behind the
sprinklers.
All sidewall sprinklers shall be of quick-response extended coverage type

with special extended directional and discharge patterns.
Sidewall sprinklers shall be installed horizontally and marked with

SIDEWALL-TOP
E. Alarm Valves Assemblies
Each alarm valve assembly shall comprise:-
- Control check valve with motor gong

- Indicating gate valve equipped with tamper switch
- Water flow switch
- Test Connection
- Pressure gauge
Water flow switch shall be so constructed and installed that any flow of
water from a sprinkler system equal or greater than from a single automatic
sprinkler will actuate the alarm system.
Water flow switch including alarm circuits shall be tested by an actual water
flow through use of the test connection.
Tamper switch provided for the indicating gate valve shall initiate an alarm
when the indicating valve is moved from the normal position. A test
connection not less than 50mm in diameter, terminating in a smooth bore
corrosion – resistant orifice to provide a flow equivalent to one sprinkler,
shall be installed and be equipped with sight glass, drain valve and shut off
valve.
Test connections may be used for draining the system sections.
All alarm valve assemblies shall be provided with identification signs.
2.06 PORTABLE FIRE EXTINGUISHERS
A. General
The fire extinguishers shall be of the rechargeable type and shall be

supplied complete with the operating charge from the factory.
All portable fire extinguishers shall be mounted on special wall brackets that
shall be supplied with the extinguishers from the factory. The brackets shall
be specifically supplied for the extinguisher type and size concerned. All fire
extinguishers shall have capacities as detailed elsewhere.
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B. Types
1 Type FE-1
10kg NAF-S-III Fire extinguisher shall be supplied with operating valve

suitable for the gas agent, with large size operating lever, full vision
pressure gauge, discharge hose with steel cylinder approved by D.O.T.
and civil defense.
2 Type FE-2
6Kg Carbon dioxide fire extinguishers shall be of the pull-pin, squeeze-

handle type with double braided hose, non-conducting discharge horn
and heavy duty drawn steel cylinder with hard, scratch resistant finish.
3 Type FE-3
6kg NAF-S-III gas agent ceiling mounted including manual release unit,
Actuator, sprinkler head, pressure gauge, safely value (68°C).
4 Type FE-4
6kg dry chemical fire extinguishers shall be of the ABC type with a rugged
all-brass operating valve, large size operating lever, full vision pressure
gauge, discharge hose and heavy duty drawn steel cylinder with lard,
scratch resistant finish.
2.07 FIELD ACCEPTANCE TESTS AND MAINTENANCE
The Contractor shall perform all tests including but not necessary limited to
the followings:-
- Flushing Test
- Hydrostatic testing of pipe network
- Testing of alarm valves
- Testing of sprinklers
- Testing of hose reels, fire hydrants and Siamese connection
- Maintenance inspection test
No part of any piping system shall be painted, covered or enclosed until it

has been tested, inspected and accepted.
All tests shall be conducted in the presence of the Engineer, as directed by

him and to his entire satisfaction.
The Contractor shall provide all labor, equipment, material, instruments,
power and connections required to execute all testing, balancing and
adjusting as directed.
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All expense incurred by the testing shall be borne by the contractor

including the cost of repair or replacement of defective work, cost of
restoring, repairing or replacing damaged work resulting from the tests and
the cost of replacing defective or inadequate equipment and material all as
B. Hydrostatic Testing of Pipe network
All piping systems including drainage piping shall be hydrostatically tested

for ensuring complete tightness at not less than 16 bar pressure for 2 hours.
Systems can be tested as a whole or in sections to facilitate the progress of

the work.
No part of any piping system shall be tested to a pressure less than the
specified test pressure measured at the lowest point of the system.
Care shall be taken not to subject any equipment, apparatus or device to a

pressure exceeding its prescribed test pressure as obtained from its name
plate data or from manufacturer’s published data. Pressure tests shall be
applied before connecting piping to equipment. Relief valves, instruments,
automatic air vents, and all devices that might be damaged by the test
pressure shall be removed, disconnected or blanked off.
No pressure shall be applied against the closed gate of gate valves. All
valves shall be in the open position but not completely back seated during
testing. End valves shall be capped.
In testing flanged piping, temporary blank flanges shall be installed and
firmly anchored to accommodate all developed end thrust.
All piping that can be damaged by end thrust developing from hydrostatic
testing shall be properly clamped during testing especially at changes of
direction.
The piping system to be tested shall be closed plugging and blanking all
opening in the system and filled slowly with water making sure to vent all
entrapped air. Plugs shall be released temporarily to ensure that water has
reached all parts of the system.
Pressure shall be applied to the system by means of a hand pump drawing

form a water container.
The pump discharge shall be connected to the system through a globe

valve, check valve and recently calibrated pressure gauge of suitable range
to have the test pressure read in the middle of the range.
After the test pressure is reached, the pump shall be blocked off by closing
the globe valve and the variations of pressure in the system monitored on
the pressure gauge.

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While the system is under pressure a careful inspection shall be made of all
pipes and joints and if any leaks in joints or evidence of defective pipe or
fitting is disclosed the defective work shall be corrected immediately by
replacing defective parts with new joints and materials. No make shift
repairs or application of any repair compound will be permitted.
After the correction is made the pressure test shall be repeated until a
completely tight system is ensured.
The test pressure shall be released slowly so as not to produce shocks

and sudden contraction that might damage the piping.
C. Flushing Test
- All provisions shall be made to properly drain all parts of the

system. Flushing test shall be performed for the
firefighting system.
- Flushing of each main pipe supplying branch lines of

sprinkler system shall be made through the test
connection installed at each alarm valve assembly and
other test connections installed.
- Flushing of the risers shall be made through the hose reels.
- Additional drain connections shall be provided, where

needed to perform the flushing test for all parts of the
firefighting system.
In any case if lines become plugged during the flushing test or flow test,
piping must be dismantled and cleaned.
D. Test of Alarm Valves
- Flow switches shall be tested by opening the test

connections installed at the alarm valve assemblies and
the other test connections installed. The water flow shall
be observed through use of the installed sight glass and
the pressure shall be read form the installed pressure
gauges.
Water flow detecting devices including the associated alarm circuits

and alarm signals located in the central control panel shall be tested
by an actual water flow through use of the test connection.
- Tamper switches mounted on the indicating valves including

the associated alarm circuits and alarm signal located in
the central control panel shall be tested by playing with
the indicating valve.
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E. Test of sprinklers
Operating test of automatic sprinklers shall be performed in accordance

with Civil Defense Department instructions and requirements.
All automatic sprinklers shall be replaced when the representative

samples fail to meet test requirements.
F. Maintenance
The Contractor shall perform during maintenance period all weekly,

monthly quarterly and annual inspections test and maintenance for the
sprinkler system, in accordance with the requirements of NFPA 13 A-
1987. Records shall be maintained on all work performed.
The Contractor shall submit to the Owner a copy of NFPA 13 A

standards.
END OF SECTION

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SECTION 15410
PLUMBING PIPING
PART 1: GENERAL
A. This technical Specification establishes the minimum requirements for the

equipment to be incorporated into the above ground Soil, Waste and
Rainwater and Hot and Cold Water Services plumbing pipework.
It also establishes the quality of materials and workmanship to be used in

the supply and installation of the systems.
1.02 WORK INCLUDED
A. Provision of all labour, materials and the performance of all operations

necessary for the supply and installation of pipework and fittings of the soil
and waste systems as specified herein and as detailed on the Drawings.
B. Coordination: The Contractor shall ensure that the soil and waste systems
are fully compatible with all trades, particularly those of the Civil,
Mechanical and Electrical services, for successful installation and
operation.
C. Submittals: The Contractor shall submit to the Engineer for review and
approval, all calculations and drawings for the equipment proposed and
associated builder’s works to show that the plant as installed will meet all
the specified criteria.
No works shall commence on the site until the design has received the
A. Manufacturers: The contractor shall only propose the use of materials

produced by firms who have been regularly engaged in the manufacture of
plumbing pipework systems and whose products have proved satisfactory
in similar service for not less than 10 years.
B. Installer: Firms proposed for the installation of the plumbing pipework

systems shall have been regularly engaged for at least 5 years in the
installation of plants of a similar type, quality and scope as is required for
this project.
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A. The plumbing pipework shall comply fully with the latest relevant British in
all respects.
B. The following are the most commonly used and relevant British associated
with Soil and Waste Systems. However the Contractor shall ensure that all
applicable British Standards are complied with, whether listed here or not.
BS: 416 - Cast iron spigot and socket soil, waste and ventilating
pipes. In conjunction with BS 460 and mechanical
jointing pipework.
BS: 1184 - Copper and copper alloy traps.
BS: 1740 - Wrought steel pipe fittings. In conjunction with BS 21,

1387 and 2279.
BS: 3380 - Wastes (excluding skeleton sink wastes) and bath

overflows. In conjunction with BS 2779, 3643 and 5572.
BS: 3505 - Specification for uPVC pressure pipes.
BS: 3868 - Prefabricated drainage stack units: galvanized steel. In

conjunction with BS 729, 1387, 2971 and 4504.
BS: 3943 - Plastic waste traps. In conjunction with BS 2779 and 3380.
BS: 3974 - Pipe supports. (Part 1 & 2)
BS: 4118 - Glossary of sanitation terms.
BS: 4514 - Unplasticized PVC soil and ventilating pipes, fittings and
accessories.
BS: 4576 - Unplasticized PVC rain water goods. In conjunction with BS

2494 Part 2, 4514.
BS: 4660 - Unplasticized PVC underground drain pipe and fittings. In

conjunction with BS 2494, 5955 and CP312.
BS: 4772 - Ductile iron pipes and fittings. In conjunctions with BS

1211.
BS: 5254 - Polypropylene waste pipe and fittings. In conjunction with

BS 21, 2494 and 2779.
BS: 5255 - Plastic waste pipe and fittings. In conjunction with BS 21,
2494, 2779 and 4515.

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BS 843 - Thermal-storage electric water heaters. In conjunction

with BS 34 56, S e c t i o n s 2. 21, 2 . 7 and 3.9 and 399 9 Part
2.
BS 864 - Parts Capillary a n d c o m p r e s s i o n t u b e f i t t i n g s
o f copper and copper alloy. In 1 & 2 conjunction with BS
219, 864, 1010, and 1973, 2871, 2872, 2874, 2879 and 3284.
BS 1010 - Specification for drains of taps and stop valves for water
services.
BS 2494 - Elastomeric joint rings for pipework and pipelines. In

conjunction with BS 1179, 3502, 3574, 4250, and 4947.
BS 2779 - Pipe threads for tubes and fittings where pressure-tight

joints are not made on the threads
BS 2871 - Copper and copper alloys: Tubes.
BS 3284 - Polyethylene pipe (type 50) for cold water services. In

conjunction with BS 21 and 5556.
BS 3505 - uPVC pressure pipes for cold potable water. In

conjunction with BS 21 and CP 312.
BS 3605 - Seamless and welded austenitic stainless steel pipes and

tubes for pressure purposes. In conjunction with BS 3600.
BS 3955 - Electrical c o n t r o l s f o r h o u s e h o l d a n d s i m i l a r g e n e r a l
purposes
BS 3974 - Pipe supports.

Part 1 & 2
BS 4346 - Joints and fittings for use with uPVC pressure pipes. In
conjunction with BS 3505, 3506, 4576, 4660, 5481 and
6209.
BS 4368 - Compression coupling for tubes. In conjunction with BS

1706, 2051, 2779, 2871, 3601, 3602, 3605, 3643, 4368 and
Din 2353.
BS 5114 - Performance requirements for joints and compression

fittings for use with polyethylene pipes. In conjunction with BS
1972, 1973, 2494 and 3284.
BS 5433 - Underground stop valves for water services. In

conjunction with BS21, 61,864, 1972, 3284, 3885 and 5728
Part 1 and 2.
BS 6281 - Devices w i t h o u t m o v i n g p a r t s f o r t h e p r e v e n t i o n o f
contamination of water by backflow. In conjunction with BS
864, 2779, 2872, 4504, 5412 and 5413.

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BS 7291/4 - CPVC pipe & fittings for hot and cold water distribution.
BS 1387 - Galvanized steel medium and heavy duty.

BS 6675 - Servicing valves (copper alloy) for water services. In
conjunction with BS 864, 1400, 2871, 2872 and 2874.
BS 6700 - Design, installation, testing and maintenance of services

supplying water for domestic use within buildings and their
curtilages.
BS: 5481 - Unplasticized PVC pipes and fittings for gravity sewers. In
conjunction with BS 2494, 4660 and CP 312.
BS: 5572 - Sanitary pipework. In conjunction BS 416, 437, 1188, 1387,

1710, 1973, 2871, 3506, 3868, 4118, 4514, 5254, 5255, CP3.
BS: 6283 - Safety devices for use in hot water systems. In conjunction
with BS 864, 2056, 2779, 2872, 2874, 3075, 3457, 4504, 5412
and 5413.
BS: 8000 - Part B Section 3 - Above ground drainage.
BS: 6367 - Drainage of roofs and paved areas.
In addition to the above standards the works shall be in accordance with all
local bye-laws, local municipality requirements and the manufacturer’s
recommendations.
1.05 SUBMITTALS
A. Drawings - refer to Section 15010
B. Products - submit full manufacturer’s data for every item.
A. Comply with Section 15010.
1.08 WARRANTY
A. Provide 12 month warranty in accordance with contract conditions.

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PART 2: PRODUCTS
2.01 SOIL WASTE AND RAINWATER PIPEWORK

A. Pipework and fittings
1. All main soil, waste and vent pipework pipes shall be installed in
UPVC and MUPVC pipework and fittings to BS4516 and BS5255.
2. The jointing of the pipework and fittings shall be by the use of solvent
weld sockets and shall be carried out in full compliance with the
manufacturer's recommendations.
3. Expansion joints and pipe support brackets shall be installed in

accordance with the manufacturer's recommendations and
BSCP312.
4. Sleeves shall be provided where pipes pass through walls or floors to

allow free axial movement of the pipes. Sleeves shall be of a
material compatible with the pipes they protect, noncombustible and
two pipe sizes larger than the pipe being protected and packed with
mineral fiber material.
5. Where such pipes pass through fire compartment walls, floors or

ceiling cavity barriers the pipes shall be installed with fire sleeves.
B. PVC branch soil waste and vent pipework
1. The soil, waste and vent pipework shall be UPVC OR MUPVC TO

BS4514 OR BS4576.
2. The soil waste and vent pipework shall have solvent joints in general,
with expansion joints where specified.
3. All pipework shall be adequately supported at the centers indicated in

Table 13 of BS5572. All PVC pipework shall be supported by two
piece ring clips with extension studding to expanding ragbolt fixings in
the brickwork. Where the brackets are to be used as anchor points
they will be made to grip the pipe by means of a rubber sleeve, and
must support the pipe with additional studding and back plates to the
duct wall. All horizontal waste pipework shall be supported on the
manufacturer's screw-to-wall brackets.
4. All waste pipes shall fall from fittings to their respective main soil pipe
so as to be self draining. Branch vent pipes shall rise towards their
respective main vent pipe so as to be self venting.
5. All branch waste pipes to a range of fittings shall have an access

provided on the pipe in an accessible position at the end of the run. All
traps shall be adequately ventilated in order that the seal may be
maintained.

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6. Water closets shall be connected by flexible self sealing w.c.

"Multikwik" connector, and shall be discharged into adjacent soil pipe.
C. PVC traps
1. All basins shall be provided with an appropriately sized PVC bottle trap
to BS3934.
2. All sinks, etc, and other mechanical and specialist items of

equipment, shall be provided with an appropriately sized white PVC "P"
or "S" trap to BS3943 (unless such specialist item of equipment is
supplied with its own integral trap).
3. Traps to be chrome plated where exposed to view, and in these

situations a chrome plated cover plate shall be provided to mask the
penetration of the waste pipe through the duct wall or structure.
Approval shall be obtained from the local Public Health Authority of
all types of traps that are intended for installation. All traps shall have a
75 mm water seal.
D. Waste bosses
1. Waste Boss connections when fitted to pipes shall consist of two parts
with inner and outer flanges, solvent welded as a complete unit with in-
built gradients for the waste pipes of 1 1/4o. Where it is not possible
to gain access to the bore of the soil pipe, purpose made bosses with
integral clamping action may be used provided the mating surfaces are
suitable for and used with solvent weld cement.
2. Waste Boss connections to branch fittings shall be solvent welded to

set positions of its branch fittings.
2.02. POTABLE HOT AND COLD WATER SERVICES
A. PIPEWORK AND FITTINGS
1. All internal potable cold / hot water service pipework shall be CPVC
pipes according to DIN 8079 pressure pipe fittings shall be PN16.
B. SYSTEM DESCRIPTION
1. This section relates to the installation of potable water systems, both hot
and cold at all facilities.
2. The potable water shall be supplied from the local water main
network valve connection to the individual water supply.
3. Internal Potable Water Installation:

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i. All cold water supply piping inside the building shall be

made of CPVC pipes. The piping layouts are as
indicated on the drawings
ii. The water supply network shall enter the buildings via an
underground sleeve.
iii. The vertical riser and distribution pipework shall run inside
pipe chases, inside false ceilings and in walls as indicated
on the drawings.
iv. Potable water supply is provided for the following.
Lavatory basins.
Shower/baths and bidets
Kitchen sinks
Water Closets
Washing Machine
Dishwasher
Water Heater
4. Hot water shall be provided for all sanitary and ancillary equipment
etc., from localized or central electric hot water storage heaters as
indicated on the drawings and designed by contractor, through
insulated pipework.
C. Thermal insulation shall comply with Section 15450.
PART 3: EXECUTION
3.01 SOIL WASTE AND RAINWATER PIPEWORK
A. Workmanship
1. Materials and workmanship to be of best quality and executed in

accordance with the Specification, drawings and manufacturers
recommendations.
2. Where any pipe is required to be shortened it shall be cut off square

and cleanly with an approved pipe-cutting machine.
3. Where special joints or jointing materials are shown for pipes of any
materials, they shall be of an approved type and manufacture, and the
joint shall be made in accordance with the manufacturer's instructions,
or as directed.
4. Responsibility shall be assumed to identify and install all necessary

expansion couplings and fire sleeves throughout the installations.
5. All plant, pipes and fittings etc. shall be thoroughly cleaned of all
foreign matter before installation. Each section of the installation shall

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be clean and free from any obstructions whatsoever before proceeding

with the next section of the installation.
6. All vertical soil, waste and vent pipes are to have access doors
provided on each floor, above flood level of fittings served. Access to
be provided in ducts to sanitary services. All vent pipes are to
terminate 300 mm above roof level, with suitable weathering slate
apron and vent cowl or copper wire balloon.
7. Flexible joints are to be provided wherever pipes cross expansion

joints.
8. All soil, waste, vent and rainwater pipes shall be to the sizes and
positions indicated on the drawings to take the discharge from the
branch w a s t e a n d v e n t p i p e s , s a n i t a r y f i t t i n g s a n d
e q u i p m e n t adjacent thereto.
9. On completion the whole of the work is to be handed over in a sound

and clean condition. In the event of any pipe being fractured from
any c a u s e w h a t s o e v e r a f t e r h a v i n g b e e n ( to a l l
a p p e a r a n c e s ) properly installed, responsibility shall be assumed
in every instance and any such defective pipes shall be replaced for
approval.
10. All pipework shall be erected to present a neat and orderly

appearance, arranged parallel to or at right-angles to the structural
members of the buildings, giving maximum headroom and shall not
obstruct windows or doorways. Pipes shall bend around piers,
projections and into recesses forming part of the structural works
whether so indicated on the drawings or not. Pipework shall be erected
such that there is a minimum clearance of 75 mm to finished floor level
and a minimum clearance of 25 mm to finished wall faces.
11. Slopes of drainage system (gravity) shall be a minimum of:

Foul water - 1%
Drain and rainwater pipes - 0.5%
B. The discharge pipework shall be so installed as to minimize the risk of

blockage. Access covers and/or rodding eyes are to be positioned such as
to enable maintenance equipment to be inserted into the system(s) to
permit cleaning or clearing of all sections of the system(s).
The pipework system and fittings are to be installed so that broken or

defective parts can be easily removed and replaced.
The discharge pipework shall ensure that there is no leakage of

contaminated water or foul air into any building.
C. The work shall be set out and responsibility assumed for the accuracy of
the same, and the position of all fittings shall be approved by the Owner's
representative. When first setting to any work, consideration must be given
to the work of other trades.

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D. Responsibility shall be assumed for leaving all unfinished works in a safe

conditions during the progress of the works.
All materials & equipment are to be installed and protected in such

manner as to be adequately covered against damage and deterioration,
and during the execution of the work the open ends of all pipework shall
be temporarily plugged off by means of blank ends and compression caps
respectively.
E. Vent pipe roof termination
1. Discharge stacks complete with domical cages shall terminate not less
than 300 mm above the roof, and not less than 900mm above the head
of any window or air conditioning unit within 3000mm horizontally from
the pipe.
F. Connection to sanitary fittings
All outlets shall be trapped and provided with accessible and adequate
means of removal and cleaning. The traps shall be designed to be
self- cleaning all surfaces and joints are to be smooth.
1. All traps with outlets for pipes up to and including 50 mm shall have a
minimum water seal of 50 mm.
2. Traps with outlets for pipes of over 50 mm shall have a minimum

water seal of 75 mm.
The waste pipes to the various sanitary fittings shall be of the following
sizes unless otherwise indicated on the drawings:
Wash basins 32 mm diameter

W.C's 100 mm diameter
Shower bath tray 40 mm diameter
Floor gullies 50 mm diameter
Cabinet sinks 40 mm diameter
G. Self siphonage tests
The contractor shall undertake tests for self-siphonage and induced

siphonage in branch discharge pipes by fitting each appliance to over
flowing and then discharging by removing the plugs and discharging the
W.C(s) at the upstream end of the discharge pipe. All seals are to remain
in the traps.

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The numbers of sanitary appliances to be discharged for this

performance test are enumerated below:
Type of Use Number of Number of appliances to be discharged

appliances simultaneously
of each kind
on the stack
9 liters WC Wash Kitchen
Domestic 1 to 9 1 1 1
10 to 24 1 1 2
Congested 1 to 24 1 1
5 to 9 1 2
10 to 13 2 2
14 to 26 2 3
27 to 39 3 4
40 to 50 3 5
H. Testing and commissioning
1. All tests requested by Local Municipality on the entire installation shall

be carried out, and all necessary appliance and equipment for this
purpose shall be supplied.
2. Provision shall be made to carry out any test requested at any time
during the progress of the works or after their completion.
3. Whilst phased testing may be carried out (which may or may not have
been witnessed) it will be required to demonstrate the water tightness,
alignment, and level and cleanliness of the whole installation seven
days prior to the handover inspection.
4. This requirement will be discharged by applying a full running water

test to the whole installation as described below and by the drawing
through of a drain profile which will be provided to the required detail.
5. All tests shall be carried out in the presence of the Owner's

representative, and seven days’ notice shall be given for readiness to
test any section of the installation. Test Certificates shall be
submitted to the person witnessing the test, for their signature of

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approval, to the effect that the system satisfies the requirements of this
Specification.
6. All sections of works must be pre-tested to satisfy that the system will
pass the required test, prior to carrying out the main test to be
7. The Test Certificate shall be required to be completed for all sections of

the installation.
8. After erection and immediately prior to sealing in, all rainwater, main
soil, waste, vent and branch soil, waste pipes, shall be checked
throughout for obstructions and finally tested for soundness.
9. The above ground sanitation and rainwater pipe installation shall be

subjected to two air tests, one of 75 mm water gauge for a minimum
period of 15 minutes prior to connection of sanitary fittings and
building in of pipework, and a second air test on completion of the
system with all traps and WC's connected when the test pressure
shall be 45 mm water gauge for a minimum period of 15 minutes.
10. At s t a r t o f t e s t i n g s a n i t a t i o n a n d R a i n w a t e r P i p e w o r k
s h a l l b e checked for alignment and stability; mechanical joints shall
be re- torqued where necessary.
11. Access d o o r s s h a l l b e r e m o v e d , w a s h e r s g r e a s e d
a n d d o o r s replaced.
12. The whole system shall be ridded through with an appropriately sized
disc type plus the allowance shall also be made for testing to the
Local Authority requirements and for carrying out separate and
independent tests if required.
13. The provision shall also be made for obtaining an acceptance test
certificate form the Local Authority on completion of the works. The
test for the Local Authority shall be allowed for as an addition to the
tests required under this specification.
3.02. POTABLE HOT AND COLD WATER SERVICES PIPEWORK
A. Product handling
1. All products shall be delivered in manufacturer's original protective

packaging. All products shall be inspected at time of delivery for
damage and for compliance with Specifications. Any products that are
found to be damaged or not in accordance with the Specifications shall
immediately be repaired or removed from the site and replaced.
Repairs shall not be undertaken before the Engineer's review of
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Contractor's proposed action.

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2. All products shall be handled and stored as recommended by the

manufacturer to prevent damage and deterioration. The Contractor
shall supply handling equipment such as lifting beams, reinforced
canvas slings, protective padding, struts, cradles, etc., required to
handle the products without damaging hardware or linings and
coatings.
3. Products shall be protected against damage and the ambient

conditions both during transport, site storage and immediately up to
the time products are installed. Precautions shall be taken to protect
the product from mechanical damage and the effects of sunlight and
heat, until the backfilling operations have been completed. All site
storage areas shall be shaded.
B. Installation of pipework
1. Pipework from the water meter to the inside of the buildings where
running below ground level shall be galvanized or uPVC as detailed.
Joints in buried pipework shall be kept to the absolute minimum.

Marker tapes shall be laid 150 mm above the pipework. If valves are
required, they are to be in a valve chamber with the surface box
lettered to indicate what service is below them.
2. The underground pipework shall be laid in 200 mm of sand or stone

free bedding material and wherever possible in straight lines to uniform
gradients. The clearance between the pipework and footings of the
buildings is not to be less than 200 mm. If less, the pipes shall be
installed in a flexible sleeve.
3. All pipework shall run vertically or at an inclination of 1° to the

horizontal to enable the whole system to be drained off either through
the system or through a valve discharging externally with an air gap to
prevent contamination by backflow. When the pipework is drained
down, air is to be allowed into the system to prevent failure or
damage to the hot water cylinder. A manual air inlet value shall be
fitted to the high point in the system to achieve this.
4. Where pipes are run in walls, floors, etc., all hot pipework shall be
insulated.
5. All pipework shall be erected to present a neat and orderly

appearance, arranged parallel to or at right-angles to the structural
members of the buildings, giving maximum headroom and shall not
obstruct windows or doorways. Pipes shall bend around piers,
projections and into recesses forming part of the structural works
whether so indicated on the drawings or not. Pipework shall be
erected such that there is a minimum clearance of 75 mm to the
finished floor level and at least 25 mm to the finished wall faces.
6. All fittings shall, as far as practicable, be the same size as the tubes
and pipes connected to them. Bushed outlets will only be accepted if
the required outlet size of a fitting is not of standard manufacturer.

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Eccentric bushings and square tees shall be used where concentric

bushing and pitcher tees might cause air to be trapped in the system.
Elsewhere square tees shall be confined to dead-leg branches of
domestic hot water supply systems and on cold-water branches to
fitting or ranges of fittings.
7. Elbows shall be used, where practicable, in preference to bends

Square elbows will not be permitted.
8. Pipework shall follow the contours of walls and shall be graded to

ensure venting and draining. The clearance between pipework (or the
insulation) and the wall and any other fixtures shall be not less than 20
mm.
9. Purpose-made sets or springs may be used where it is necessary to

deviate from a straight run.
10. Sets or springs in tubes of 50 mm size and above shall be fire-made

and tubes shall remain circular after setting.
11. Eccentric reducing sockets shall be used where changes of bore are
made in runs of nominally horizontal pipework to facilitate air venting
and draining.
12. Tubes shall be reamed after cutting and shall be free from burrs, rust
scale and other defects and shall be thoroughly cleaned before
erection. Open ends left during the progress of work shall be
temporarily closed with purpose-made metal or plastic plugs or caps,
or blank metal flanges.
13. Where pipework passes through walls, floors or ceilings, sleeves shall
be provided. Pipework passing through flooring shall be provided with
approved type floor and ceiling plates fastened securely to the pipe.
The sleeves to be of the same metal as the pipe.
14. All entry and exit holes to or from a building for pipework services shall
be sealed and plugged. For service conditions below 60°C the sealant
shall be mastic compound, above this temperature it shall be silicon
rubber. Where the pipework enters the building through a large hole
or duct, a mild steel blanking plate not less than 6 mm thick shall be
built into the walls of the hole or duct. The service pipes shall pass
through clearance sockets welded to the plate and the space between
pipe exterior and socket interior shall be sealed and plugged.
15. Pipework of 75 mm size and larger subject to expansion and

contraction and hung from supports shall be suspended on swivel
hangers unless otherwise agreed.
16. Hangers for horizontal pipework shall be supported in accordance with

the manufacturers’ requirements of support, Hangers and Brackets.

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17. Piping that is insulated shall be secured by clips that allow sufficient
space behind the back of the pipe for the pipe insulation to be
properly installed.
18. All pipework shall be installed so that the vertical distance between the
discharge point and overflow level of the receiving appliance shall not
be less than 25 mm for taps and/or fittings up to and including 20 mm
and 70 mm for those over 20 mm to prevent contamination as result of
backflow of water.
19. A 15 mm diameter washout pipe, discharging outside the building will

be provided at ground floor level to drain the system. The top of the
outlet is to be in excess of 70 mm from the ground or receiver.
20. Where drinking water and non-potable water supply points are
installed, they shall be clearly marked to provide ready identification.
Every drinking water point shall be segregated from firefighting water
supply points. Every drinking water pipe shall be readily
distinguishable from other pipes. Drinking water hoses and flexible
pipes shall be marked to prevent them being used for cleaning
purposes.
C. System testing
1. The Contractor shall ensure that all pipework is watertight to the

satisfaction of the Engineer and shall supply all pressure gauges,
meters, hoses, pumps and other temporary supports, equipment and
manpower necessary for carrying out pressure tests.
2. The Contractor shall, during testing, check the satisfactory operation of

each valve installed under the Contract.
3. Before filling or pressure testing is started the Contractor shall re-

check pipes and valves for cleanliness and shall re-check the
operation of valves. The open ends of the pipes shall normally be
stopped off by blank flanges or capped ends additionally secured
where necessary by temporary struts and wedges.
4. Potable water system shall be tested with water to 1.5 times the
normal system working pressure or 6 bar whichever is greater while
uncovered but adequately anchored. The testing shall be carried out in
sections if necessary. If a section should fail the test, the
Contractor shall trace and repair all leaks and defects and retest the
section before any further pipes or section of adjacent pipework are
laid.
5. The system shall be filled with potable water and all air expelled. After
the system has been completely filled, the pressure shall be steadily
and gradually increased until the test pressure has been reached. if
any loss is recorded, repairs shall be made and the test re-run.
6. Written records of every test clearly identifying the tested system

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together with time of test and name of testing Engineer in tabulated

format shall be submitted for review by the Engineer upon completion
of the test.
D. Flushing and disinfection
1. Potable water pipelines shall be flushed with potable water after

completion of pressure testing and before introducing disinfection.
2. Liquid chlorine, calcium hypochlorite shall be used for disinfection.

Where chlorine is used, it shall be introduced only in conjunction with
proper equipment and under the supervision of qualified personnel
familiar with the physiological, chemical and physical properties of
liquid chlorine and who are suitably trained and equipped for dealing
with any emergency which may arise from its use.
3. Potable water from a suitable source shall be injected with flow

control at a constant and measured rate. The water shall receive a
dosage of chlorine fed at a measured rate to ensure chlorine
concentration in the water entering the pipe is maintained at a
minimum of 50 mg/Lit. The chlorine residual shall be measured at
regular intervals to ensure that the required chlorine concentration is
maintained.
4. During the application of chlorine, valves shall be manipulated to

prevent the treatment dosage from flowing back into the line
supplying the water. Chlorine application shall continue until the
entire pipeline is filled with chlorine solution.
5. After 24 hours retention, the chlorinated water shall be flushed out with
potable water, until the chlorine concentration in the water leaving the
pipeline does not exceed 21 mg/Lit. Chlorine residual determination
shall be made to ascertain that the heavily chlorinated water has been
removed from the pipeline.
6. Flushing water shall be discharged only to sites or into conduits.

Discharges which cause damage, create nuisance or health hazard, or
interfere with the work of others will not be permitted.
END OF SECTION

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SECTION 15450
PLUMBING PIPING INSULATION
PART 1: GENERAL
A. This technical specification establishes the type and quality of materials and
the standard of workmanship to be used in the supply and application of
thermal insulation to plumbing piping.
1.02 WORK INCLUDED
A. The work includes the provision of all labour, materials and the
performance of all operations in connection with the supply and
application of thermal insulation as specified herein and where referred to on
the Drawings.
B. Coordination: The Contractor shall be responsible for the full coordination of

the work of all trades.
A. Manufacturers: Firms regularly engaged in the manufacture of thermal

insulation materials whose products have been in satisfactory use for a
similar application for not less than 10 years.
B. Installer: Firms regularly engaged and qualified in the application of thermal

insulation materials with at least 5 years successful installation experience
on projects of a similar nature.
A. The thermal insulation products and all associated materials shall comply
with the latest relevant British Standards in all respects.
B. The following are the most commonly used and relevant British Standards
associated with thermal insulation products and associated material.
However, the Contractor shall ensure that all applicable British Standards
are complied with whether listed here or not.
BS 476 Part 4 : Non-combustibility Test for Materials.
BS 476 Part 7 : Method for Classification of the Surface Spread of

Flame of Products
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BS 476 Part 20 : Method for Determination of the Fire Resistance of

Elements of Construction.
BS 1485 : Specification f o r Z i n c C o a t e d H e x a g o n a l S t e e l
Wire Netting.
BS 3958 Part 3 : Metal Mesh Faced Man-made Mineral Fibre

Mattresses.
BS 3958 Part 4 : Bonded Preformed Man-made Mineral Fibre Pipe

Sections.
BS 3958 Part 5 : Specification for Bonded Man-made Mineral Fibre

Slabs.
BS 5422 : Specification f o r t h e u s e o f T h e r m a l I n s u l a t i o n
Materials.
BS 5970 : Code of Practice for Thermal Insulation of

Pipework and Equipment.
PART 2: PRODUCTS
2.01 GENERAL
A. For general applications the thermal insulation materials shall be made from
materials which will not burn, but materials which are not entirely non-
combustible may be accepted if they have self-extinguishing characteristics,
the total mass of combustible materials is small and combustion does not
produce dense smoke or toxic fumes. All material finishes shall conform to
spread of flame classification class O. Such materials shall only be used with
the prior permission of the Engineer.
B. Insulation shall be rotproof, odorless, non-hygroscopic, shall not sustain

vermin and shall not contribute to metal corrosion. Any finishes (or
coverings) used shall not deteriorate with age or the effects of solar heat.
C. Thermal insulation materials and their finishes shall be asbestos free and be
suitable for continuous use throughout the range of operating temperatures
and within the environment indicated.
D. All insulating materials and associated products, sealants, tapes,

adhesives, securing bands and protective cladding shall be as specified or
equal and approved.
2.02 PLANT AND PIPEWORK INSULATION
A. Thermal insulation shall be pre-formed rigid sections or slabs, the basic

material consisting of one of the following:
❖ Rockwool mineral fibre (density 110-160 Kg/m³).

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❖ Pre-formed glass fibre sections (density 80-110 Kg/m³).
The insulation shall be manufactured from long stranded mineral fibres, resin
bonded to form sections having uniform density and high compressibility.
The preformed rigid insulation outside surface shall be smooth, unbroken,
uniform, concentric and firm.
B. Pipework insulation shall be high-density rigid resin bonded preformed rock

wool mineral fibre sections of the thickness specified. The insulation shall
comprise of two half sections with a factory applied reinforced aluminum foil
covering hinging the two half mating sections for ease of installation. The
covering shall have a 50mm side overlap of reinforced aluminum foil to
enable the outside surface to be completely sealed.
C. Where thermal insulation of plant is required the insulation shall be

performed rigid sections or slab. The material shall consist of long fine fibres
(free from shot and coarse fibres) bonded with a temperature resistant resin.
The density shall be a minimum of 48 Kg/m³ and the surface shall have a
factory applied reinforced aluminum foil finish.
D. Thickness of insulation shall be determined in accordance with the following

tables for the appropriate medium and the declared value of thermal
conductivity of the insulation material at the relevant temperature.
When selecting the insulation thermal conductivity, the space available for
the installation shall be thoroughly examined to ensure that the resultant
thickness can be accommodated.
TABLE 1
THICKNESS OF INSULATION FOR HOT WATER SERVICES
DECLARED THERMAL CONDUCTIVITY (W/moC)
Size of Tube Up to 0.040 0.041-0.055 0.056-0.070
Mm Minimum thickness of insulation (mm)
15 to 32 25 25 25
40 to 50 25 32 32
65 to 80 32 32 32
100 32 32 38
125 32 38 44
150 38 44 44
Flat Surface 44 44 44

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PART 3: EXECUTION
3.01 STORAGE
A. All thermal insulation materials shall be stored in their original packaging in
such a manner as to prevent the ingress of dust or moisture. The height of
the packages shall be restricted to prevent any deformation of preformed
rigid sections.
B. Flat sheet and rolled metal materials used for protective claddings shall be
stored away from the ground surface, adequately covered and protected in a
manner to prevent damage to the materials.
C. All storage areas shall have adequate lighting to allow for the inspection of all
materials.
3.02 FIXINGS
A. All mechanical fixings (rivets, screws) shall be as recommended by the

manufacturer of the material being fixed. All mechanical fixings, sealants,
tapes and adhesives shall be entirely suitable for the medium that they are
being applied to and the application shall be fully in accordance with the
manufacturer’s recommendations.
3.03 PLANT AND PIPEWORK INSULATION
A. Thermal insulation to pipework shall be carried out by specialists and strictly

in accordance with this Specification. No thermal insulation shall be applied
to pipework prior to witnessing of the pipework pressure test and only then
after a full inspection and approval by the Engineer.
B. Thermal insulation shall be applied to the following:-
i. All pipework carrying hot fluids in circulation including flanges and bodies
of valves on all sizes of pipework.
ii. External distributing mains and fittings above ground and in ducts, on
roof chases and trenches including all valve bodies and flanges.
Insulation shall fit closely on pipework and other surfaces without gaps
between.
C. The following lines shall not be insulated:
1. Pipe used solely for fire protection.
2. Chromium-plated pipe to plumbing fixtures.
D. All sections of the insulation shall be of the correct size and made for the
type and grade of piping to which it is fitted and shall form a tight fit on the
pipework after application of adhesive and lapping. Bends shall be formed
by cutting a series of gussets in the pre-formed sections to form a
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continuous finish with the pipework. The valve bodies and flanges in plant

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rooms and those components within the entire pipework system 65mm dia
and above shall be insulated with the same insulation as the accompanying
pipework but contained within a removable aluminium box. Where a vapour
seal is incorporated into the insulation, all joints shall be effectively sealed
with approved sealing material and securely fixed.
E. Load bearing inserts of hardwood or phenolic foam complete with a

factory applied vapour seal shall be used at support positions on chilled
water pipework. The insert shall be of the same thickness as the insulating
material and cut such that 50 mm protrudes either side of the support. The
pre-formed insulation section shall be butt jointed to the insert and the joint
fully sealed with 75mm wide aluminium tape to maintain the vapour seal.
At flanges, expansion joints and anchor points, particular attention shall be
paid to sealing the insulation against water vapour ingress.
F. Each pre-formed rigid insulation section shall be butt jointed to the next, the
point being fully sealed with 75mm wide aluminium tape. The preformed
sections on domestic hot and cold water services shall be secured hard to
the bracket where inserts are not used. The reinforced aluminium side
overlap shall be sealed with a suitable adhesive or 75mm wide aluminium
tape. Outer coverings shall not come into contact with pipework and
attachments.
G. Each section of pre-formed insulation shall be screwed to the pipe by one of

the following means:
❖ Circumferential tie wires each formed from three turns of wire not less
than 1mm thick, spaced not more than 450mm apart.
❖ Circumferential bands of non-ferrous metal, plastic fibre or adhesive

sheet.
❖ Rigid insulation applied to cylinders and flat surfaces shall be secured

with non-ferrous metal or plastic fixings.
H. The insulation on pipework concealed from view within buildings will not
require further protective cladding.
I. Insulation on pipework exposed to view and within plant rooms shall be clad
fully in a pre-formed aluminium stucco finish cladding 0.8mm thick held in
place by means of rivets or self-tapping screws. All joints shall be sealed
with a non-setting sealing compound.
J. Insulation on pipework exposed to the outside atmosphere shall be clad with

a covering of polyisobutylene sheet fixed with adhesive, lapped and solvent
welded to form an impervious seal. At entries into buildings, the
weatherproof insulation shall extend not less than 100mm beyond the inner
face of the wall and be sealed to the satisfaction of the Engineer.
K. Thermal insulation on pipework in concrete trenches shall be as that for

insulation on pipework exposed to the outside atmosphere.

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3.04 PROTECTION
A. The Contractor shall take all necessary measures to protect the works during
construction. Any damaged sections of insulation shall be completely cut out
and replaced with a new section. The vapour seal shall be repaired to
ensure continuity.
All damaged sections shall be replaced at the Contractor's expense until the
system is accepted and finally handed over.
END OF SECTION

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SECTION 16010
BASIC ELECTRICAL REQUIREMENTS

PART 1: GENERAL
1.01 GENERAL
A. All general Provisions contained within this, or any other, section of the
specification shall be fully applicable to each and every other section.
B. All work carried out on the installation shall be carried out in a neat,
efficient and workmanlike manner, to provide for proper operation,
maintenance and repair. The work shall be in accordance with the
requirements of these Specifications, and shall fulfill their true intent
and meaning. No deviations from these Specifications and/or Drawings
shall be made without written approval of the Engineer.
C. These Specifications and associated drawings form a composite set of

documents, intended for the selection and installation of equipment
having the general and specific characteristics as detailed.
D. Unless otherwise specifically stated, the installation shall be left

complete, tested and ready for operation in all respects and fully
integrated and coordinated with all other construction.
E. The Contractor shall submit proof, if requested by the Engineer that the
materials, appliances, equipments or devices that he furnishes
and installs under this contract, meet the requirements of local
authority, BS, NFPA as regards fire and casualty hazards.
1.02 SCOPE OF WORK
A. The work under this division of the specifications shall include

furnishing all labour, materials, equipment and services to furnish and
install the complete electrical system, putting into operation, tested and
commissioned as shown on the accompanied drawings and specified
herein. The work includes, but is not limited to, the following principal
systems and equipments:
− Co-ordination of incoming electricity and telephone supplies as

detailed on the drawings including the external substation,
associated switchgear and incoming mains with local authorities.
− LV switchgear and cables for lighting power and plant systems.
− General lighting and small power to the entrances, circulation and

plant areas.
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− Low brightness recessed fluorescent lighting and aesthetic lighting.
− External lighting and electrics in the external areas and car parks.
− Emergency lighting arrangements.
− Distribution of voice cabling systems to designated areas spaces.
− Small power systems in all areas.
− Addressable fire alarm system including smoke detectors, manual

actuators, fire alarm facilities and sounder systems to all areas of
the development including all interface with plant and other
systems.
− Primary electric supply for mechanical motor control centres and

isolated plant items.
− Lightning protection system for the building and all earthing of the
electrical systems.
− Labelling, testing, commissioning and provision of full operating

instruction manuals and record drawings for all electrical systems
incorporated in this contract.
1.03 ELECTRICAL SUPPLY
A. The electrical supply from local authority shall be:
3 phase, 4 wire, 380/220 volts, 50 Hertz earthed neutral system.
1.04 EARTHING REQUIREMENTS
A. The earthing system shall in all respects comply with the following:
1. The National Electric Code (NFPA 70).
2. Any special requirements of the Statutory Electricity Supply

Authority.
3. Any requirements stated within this Specification.
4. The International Electro technical Standardisation (CENELEC).
B. The earthing system will take the form of TN-C system for the
distribution system and a TN-S system in all buildings.
The contractor is to ensure that the installation earthing complies with

the requirements as laid down in section 16452 of this Specification.

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C. The earthing conductor (the final conductor by which the connection to

the selected means of earthing is made) is to be of copper construction
and comply with NFPA 70 requirements.
D. All extraneous conductive parts are to be protected by equipotential

bonding in accordance with NFPA 70.
1.05 CO-ORDINATION
A. The Contractor shall be held solely responsible for the proper co-
ordination of all phases of the Work and timely delivery to the site of all
equipment and materials for proper execution of the Work.
It is the sole responsibility of the Contractor to fully co-ordinate the

Work with all or any other disciplines and to ensure proper phasing of
the Work to ensure continuity of all works under this Contract. If it
becomes necessary to remake any part of these Works or that
of any other discipline or trade as a result of poor or badly timed co-
ordination, then all costs associated with remaking those Works will
be borne by the Contractor.
B. The contractor shall co-ordinate with all Authorities and shall include for
attendance along will all costs involved in re-directing existing services.
C. The Contractor shall take into consideration all statutory and local
requirements issued by the, Local Authority, Central Government,
Broadcasting Authority, Telephone and Telecommunications Authorities
along with any other requirements to be considered for the correct and
legal operation of the electrical and telecommunication installation or
equipment connected to the installation as part of this Contract.
1.06 CLIMATE CONDITIONS
A. External to building and in non-air conditioned spaces, all apparatus

shall be rated for an ambient temperature maximum of 55oC, minimum
of 5oC and a maximum humidity of 100% rh.
B. In air conditioned buildings, all apparatus shall be rated for

ambient temperature of 45°C maximum; minimum of 0° C and a
maximum humidity of 85% rh
C. When equipment is installed in direct sunlight, it shall either be shielded

from direct radiation or suitably rated for additional solar gains.
D. All apparatus shall be rated for continuous services twenty four hours a
day, seven days a week throughout its normal rated life, except for
necessary routine maintenance.

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1.07 ACCESSIBILITY
A. All work shall be so installed as to be accessible for operation,

maintenance and repair. Deviations from the drawings may be made to
accomplish this, but no change shall be made without written approval
from the Engineer. Access door locations shall be approved by the
Engineer before installation work is commenced.
1.08 STORAGE OF MATERIALS AND EQUIPMENT
A. All material and equipment, fixed or unfixed, shall be protected against

corrosion, deterioration and ingress of foreign matter. All equipment
shall be kept clear of the floor or ground by means of wooden bearers
or other means, and shall be protected against the weather.
1.09 PREVENTION OF NOISE AND VIBRATION
A. Provision shall be made to minimise noise and vibration. However,

different manufacturer's equipment will have varying sound and
vibration characteristics. The Contractor shall be entirely responsible for
ensuring that equipment installed does not transmit unnecessary noise
or vibration.
B. All equipment installed in plantrooms and outside areas shall not

be audible in the occupied areas.
C. Any vibration isolators, isolating bases, flexible connections, silencers,

other acoustic treatment or anti-vibration precautions necessary shall
be included in the rates for the equipment.
D. In individual cases, the suspension shall ensure that the natural

frequency of the vibratory system in the vertical direction is not more
than 1/3 of the exciter frequency and never exceeds 25Hz.
E. The Contractor shall submit proof of the selected noise proofing

measures to the Engineer before commencement of work.
F. The Contractor shall submit to the Engineer for approval the

noise generation by the plant selected so that structural
soundproofing measures can be evaluated. This means either data on
the acoustic capacity level in relation to frequency, or the sound
pressure level measured at 1 metre from the plant at octave median
frequencies from 63 Hz to 4000Hz. Details of the spatial and
operational conditions shall also be given.
G. All costs of noise sound level measurements and any repeat

measurements, necessary if acoustic requirements are not met, shall
be allowed for by the Contractor.

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1.10 GUARDS
A. All moving parts of machinery shall be protected by strong guards to

adequately protect all personnel working on or in the vicinity of
equipment. The guards shall be constructed in such a manner that the
movement of drive belts and rotation of shafts may be readily observed
without removal of the guard.
B. All 'live' parts of electrical equipment shall be protected in such a way to

adequately protect all personnel working on or in the vicinity of
equipment from injury.
C. Wherever possible, al protective guards shall be supplied by the

equipment manufacturer. All guards shall be strongly attached to
equipment and shall be designed to be easily removed for access,
servicing, adjustment and maintenance.
1.11 SIGNS AND NOTICES
A. All signs and notices shall be in Arabic and English with the Arabic
version being above or to the right of the English version.
B. A schedule of all signs and notices with proposed Arabic translations

shall be approved by the Engineer prior to manufacture.
1.12 GOVERNING CONDITIONS
A. The entire electrical installation shall in all respects comply with

the requirements of the following in the ruling sequence listed.
1. Local authorities for Power, Electricity and telephones.
2. International Electrotechnical Commission (IEC).
3. ANSI/NEMA Standards.
4. British Standards (BS).
5. International Organization of Standardization (ISO).
6. European Committee for Electrical Standardization (CENELEC).
7. International Telegraph and Telephone Consultive

committee (CCITT).
8. National Fire Protection Association (NFPA).
9. Any special requirements stated elsewhere within this

Specification.

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1.13 MOUNTING HEIGHTS
A. Unless otherwise stated on the drawings, the following shall be

mounting heights of equipment centre lines above finished floor level;
Panel Board 1900mm (Top of Panel above FFL)

Isolating Switch 1350mm
Light Switch 1350mm (100 from door frame)
Push Button Station 1350mm
Wall Mounted Telephone 1350mm
Fire Alarm Manual Call Point 1350mm
Fire Alarm Sounder 2100mm
Fire Alarm Panels 1800mm (top of Panel above FFL)
Socket Outlet 400mm
Telephone Socket 400mm
TV/Radio antenna socket 400mm
Note: Where accessories with varying mounting heights (e.g. light switch
and socket outlet) are shown in approximately the same
location, their centre lines shall aligned vertically.
1.14 LABEL AND IDENTIFICATION
A. Each item of the electrical installation including electrical

switchgear, control gear etc. shall be fitted with a non-corrodible
label clearly indicating its function, circuit number and phase.
B. Each label shall be made of white plastic not less than 50mm x 12mm
high suitably engraved with black 5mm high letters and fixed by means
of two brass set screws, nuts, and shakeproof washers.
C. Warning labels made of red plastic with white letters at least 25mm high
reading "DANGER High Voltage" shall be fixed to the entrance doors of
all 13.8 kV switch, transformer.
D. Warning labels made of red plastic with white letters at least 12mm high
reading "DANGER 400V" as appropriate shall be fixed to the lids,
covers or doors of any equipment which contains terminals or
conductors connected to more than one phase of a low voltage supply.
The method of fixing shall be as detailed above.
E. Prior to final testing the Contractor shall confirm that all labelling is
intact over the whole site and that all cables have been fitted
with circuit markers.
F. All conductors shall have their outer covering coloured to suit the phase
to which they are connected.
G. An instruction notice giving details of first aid treatment for electric

shock shall be positioned in an approved position in each switchroom.
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Manufacturer's or Contractor's names or trademarks shall not be

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exhibited anywhere through the installation without the prior

approval and permission of the Engineer with exception that the
Contractor's name and address may be fixed in an approved position
on the main intake switchboard.
H. All labels shall be in English and Arabic.
1.15 VERMIN PROOFING
A. All items of electrical equipment shall be adequately vermin proofed.
B. Where cables enter or leave the bottoms of switchboards, or pass

through pipe ducts, they shall be sealed by the use of hard wood plugs
treated with vermin repellant and surrounded by mastic sealant.
C. All spare pipe ducts shall be similarly sealed by the use of solid hard
wood plugs.
D. Alternative methods of vermin sealing will be accepted, but the written

comments of the Engineer must be obtained prior to installation.
1.16 FIRE AND SAFETY PRECAUTIONS
A. The whole of the works shall be carried out with care and so arranged
as to minimise the risk of fire and the extent of damage resulting from
any outbreak of fire.
1.17 CLEANING DOWN
A. The Contractor shall allow in his tender for the final cleaning down and
painting of all scratched or damaged electrical apparatus, panelboards,
cubicle panels, distribution boards and transformers.
1.18 MATERIAL SUBMITTALS
A. The Contractor shall submit samples and full relevant manufactures

literature for all material proposed for the project, in accordance with the
requirements of the relevant sections of this specification.
B. No order shall be placed until the Contractor has obtained full written
approval of the relevant material submittal from the Engineer.
C. The Contractor shall submit a sample of the exact make, model and
finish proposed for each material required.
D. Manufacturer's performance data and certified factory drawings

giving full information pertinent to the adequacy of the relevant
equipment shall be submitted for approval.

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E. Submittal shall be made in a manner to ensure complete

information regarding what is being offered and in a manner that
facilitates easy filing and ready access to all data.
F. Where data certified drawings or other required information is not

available until after orders have been placed, the Engineer may give
provisional approval until all requested drawings and information
have been supplied to the Engineer and approved by him. It is the
Contractor's responsibility to ensure that all necessary information is
supplied to the Engineer in accordance with the progress of work.
G. Should the Engineer give provision approval due to lack of

complete information, and should the missing information not
eventually meet with approval, the Engineer shall not be held
responsible for any delay of additional expense incurred. For
equipment where delivery from the manufacturer is likely to be
prolonged, it is essential that the Contractor provided the material
submittal at the earliest possible date, so as to ensure approval and
orders in complete conformity with the progress of the works.
1.19 SHOP DRAWINGS
A. The Contractor shall submit for approval by the Engineer detailed

construction drawings before starting work. These drawings shall
comply with and complement the Tender Documents in showing
physical layout of all equipment, exact location of all
equipment, lighting, columns, luminaires and cables including
dimensioned locations of underground cables, construction and
installation details, wiring diagrams, etc. No work shall be started on
site until approval of the Drawings has been given in writing by the
Engineer.
1.20 AS BUILT DRAWINGS

A. At the completion of the works the Contractor shall have consolidated
all information developed during the progress of the works onto
the drawings.
The Record Drawing shall consist of the following categories:
i. All formal drawings submitted by the architect for construction

purposes fully updated in terms of details, identification, notes,
quantities, sizes.
ii. All drawings developed by the Contractor in pursuance of the

works, updated in all respects.
iii. All drawings submitted by manufacturers, fully updated to

represent the as fitted details.
B. The drawings shall be submitted in a full set of two prints for checking
by approving authority, and the items marks shall be attended to by
the Contractor within a 10 days maximum. The set supplied to the
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Client at handover shall consist of the first submission by the

Contractor and shall be overstamped "PRELIMINARY".
C. The title block shall contain all the following information:
Contract: Employer
Projet Title
Consultant - Consultant's job reference
Management/Main Tenderer - job reference
Contractor - job reference
Date
Drawing: Drawing title etc.
Drawing Identification No:

Drawing derived from:
Record drawing No:
The Contractor shall submit a sample title block to the design team for
approval at an early stage and shall confirm the final
numbering sequences against the schedule of drawing tittles to
confirm titles to conform with the Employer's requirements.
D. The drawings will have been originally developed and drawn

using an industry standard system, probably Intergraph DOC.DGN
files or DXF files.
The Contractor is to ensure that any work he carries out is compatible

with the files he receives, so that the record drawings files are
readable and can be manipulated by the same system.
If the Contractor does not have a compatible system he shall obtain

the services of a suitable CADD bureau.
E. The final submission of drawings will be made only of drawings

carrying the stamp of the Approving Authority and signature of the
checking engineer.
The Contractor shall deliver one full set of drawings as

follows:
1. Groups i) and ii) (Clause 1.20A)
1 copy negative on plastic, 2 prints, 1-35mm transparency for the

Client
1-35mm transparency and a full set of Intergraph DOC.DGN files

for the Design Authority (DWG Files) with the File Structure and
Keywords scheduled out for reference.
F. Full indexes of drawings shall appear in the O&M handbooks and in

addition there shall be additional drawings produced being drawings
indexes only.
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G. The 35mm transparency set shall be issued individually mounted in

standard cards 82mm x 187mm with the full title and drawing
number types onto the face of the card.
1.21 DOCUMENTS
A. Maintenance Literature: Prior to the final acceptance of the

installation the Contractor shall submit to the Engineer manuals
for all equipment supplied under the Contract. The manuals shall
be A4 size bound in loose leaf binders or booklets suitably enclosed
and including the following:
1. Single line diagram of the complete network,

2. Control, protection and circuit diagrams for all equipment,
3. Setting up, commissioning and operating instructions,
4. Trouble shooting procedures,
5. Maintenance instructions including schedules for preventative
maintenance,
6. Complete recommended spares list including manufacturers
name and catalogue number.
7. Name of manufacturers' local authorised representatives and
service agent.
1.22 SPECIAL TOOLS
A. The Contractor shall supply as part of this contract all special

tools required for equipment maintenance.
1.23 SPECIAL REQUIREMENT
A. All electrical material imported and proposed for the project by

the Contractor shall be in accordance with the electrical local
authority requirements.
PART 2: PRODUCTS
Not used.
PART 3: EXECUTION
Not used.
END OF SECTION

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SECTION 16110
ELECTRICAL RACEWAYS
PART 1: GENERAL
A. Examine all other sections of the Specification for requirements

which affect work of this Section. Cooperate with such trades to
assure the steady progress of all work under the Contract.
1.02 SCOPE AND DESCRIPTION OF WORK
A. The requirements of this section shall apply to all electrical raceways

referred to on the drawings and elsewhere within this Specification.
B. The types of electrical raceways required shall comprise the

following:-
1. Metal Conduit
2. Flexible Conduit
3. PVC Conduit
4. Cable Tray
5. Cable Trunking (Metal)
6. Cable Trunking (PVC)
7. Cable Ladder
8. Underground Duct
C. All installation works required by this specification and the

accompanying drawings shall employee fully segregated
conduits/ducts/trunking/tray system compartments; applicable for:
1. General lighting circuits

2. Emergency lighting circuits
3. General small power
4. Fire Alarm System
5. Telecommunications system
6. Sub-main cables
7. Control function cables
8. Final plant electrical supplies (mechanical plant, lifts etc.)
1.03 QUALITY STANDARDS
A. The manufacturer shall be regularly engaged in the manufacture

of electrical raceways of the type and capacities required, whose
products have been in satisfactory use in similar service for not less
than 5 years. Preference shall be given to “Local" manufacturers.

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B. The raceways furnished under these specifications shall conform to

all applicable by standards.
1.04 SUBMITTAL
A. The Contractor shall submit samples and manufacturer's data

on all electrical raceway system materials, together with
samples of the proposed materials.
1.05 DELIVERY, STORAGE AND HANDLING OF MATERIALS
A. The Contractor shall provide colour-coded thread protectors on

the exposed threads of metal conduit, handle raceways carefully to
prevent end-damage and avoid scoring the finishes. Where possible
the raceways shall be stored indoors. If necessary to store outdoors,
the raceways shall be elevated well above ground and enclosed with
durable waterproof wrapping.
PART 2: PRODUCTS
2.01 METAL CONDUIT
A. All metal conduit shall be heavy gauge welded steel complying with
BS 4568,not less than 20mm diameter and finished with hot dipped
galvanising providing heavy protection (Class 4) both inside and
outside. All conduit and fittings shall be free from rust or other
defects.
B. All conduit fittings shall be malleable iron manufacture complying

with BS4568.
C. All fittings shall have a hot dipped galvanised finish.
D. All bushes shall be hexagonal headed, heavy duty, long threaded

brass bushes complete with serrated tempered shakeproof washers.
All bends shall be cold set. All tees shall be made using circular tee
conduit boxes.
E. All saddles shall be of the spacer bar type and of the same finish as
that of the conduit which they are being used to secure.
F. A tapped earth connection facility shall be provided in every box.
G. All accessory boxes shall have one adjustable fixing lug to facilitate
final levelling of accessory.
2.02 FLEXIBLE CONDUIT
A. Flexible conduit shall only to be used for final connection to items of

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fixed equipment subject to vibration.

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B. Flexible conduit and adaptors shall be manufactured in accordance

with BS 731 Part 1.
C. Brass adaptors shall be provided for connection at either end of the

flexible conduit and should be of the compression type.
D. Flexible conduit shall be of the weather proof type having an overall

PVC sheath. No length shorter than 500mm of flexible conduit shall
be used unless specified elsewhere in this specification.
2.03 PVC CONDUIT
A. All PVC conduits shall be U.P.V.C. Rigid Conduits complying with

BS
6099-2.2 / IEC 614-2-2 heavy gauge in all respects, and may be
used where ambient temperatures do not exceed 75oC.
B. All conduit fittings shall confirm to BS 6099-2-2/IEC 614-2-2

standards and BS 4607 Part 5.
C. No conduit shall be less than 20mm diameter.
D. Conduit boxes shall be of the B.E.E.S.A. circular pattern with

appropriate spout entries and 50.8mm accessory fixing centres.
E. All connections and terminations shall be by means of a

manufacturer's standard adaptor.
F. All boxes shall have brass thread inserts for the fixing of accessories
or covers.
However care must be taken in the support of totally enclosed

lighting fittings. Where excessive temperatures are likely to occur
special insulated boxes shall be used, i.e. of a pattern specifically
designed by the manufacturer to improve weight-loading
characteristics at high temperatures.
G. All tees shall be made using conduit tee boxes. Tangential entry
boxes shall be used where appropriate. Multiple conduits may
necessitate the use of large U.P.V.C. adaptable boxes for junctions.
H. All saddles shall be of the spacer bar type and from the
same manufacturer as that of the conduit which they are being used
to secure.
I. A tapped earth terminal shall be provided in every conduit box.
J.All wall mounted accessory boxes shall have one adjustable fixing lug
to facilitate final levelling of accessories.
K. In order to facilitates interchangeability and to eliminate

problems of differential manufacturing tolerances, it is essential that
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all PVC conduit and appropriate accessories covered by this

specification shall be obtained from the same manufacturer.
2.04 CABLE TRAY

A. All cable trays shall be of heavy duty perforated type with return
flange.
B. All cable trays shall be manufactured from hot-dip zinc coated steel
to BS 2989 with a standard heavy duty galvanising coating.
C. All bends, tees, cross units and angles shall be of the same
specification as that of the cable tray finish and shall be standard
products from the same manufacturer as the cable tray. Site
fabrication shall not be permitted.
D. Cable trays and accessories shall be of a thickness of not less than:
1.5mm up to 305mm width.
2.0mm above 305mm width.
E. All fixing brackets, nuts and bolts shall be finished by hot dip
galvanising.
F. Tinned copper earth continuity straps shall be provided at every joint.
G. Where cable tray crosses building expansion joints, the tray shall
be installed as shown in the typical drawing details.
2.05 CABLE TRUNKING (METAL)
A. Metal cable trunking shall comply with BS 4678 Part 1:Class 3

and shall be manufactured from galvanised steel sheet.
B. Only purposed made bends, tees, risers, end stops, fittings,

connectors, covers and accessories by the same manufacturer
as the trunking shall be used and finished in hot dipped
galvanised steel to BS 2989. Site fabrication shall not be
permitted.
C. Tinned copper earth straps shall be provided at every joint.
D. Covers shall be of the overlapping type and secured to the

trunking by either an approved clip or screws.
E. In areas subject to corrosive atmospheres, eg. chlorine, all

trunking shall be painted with chlorinated rubber paint.
F. Cable trunking shall be used wherever possible to replace

multiple conduit runs.

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G. Cable trunking shall be single or multi-compartment.

Where multi- compartment is used vertical dividers shall be
provided between the compartments which shall be welded to
the trunking prior to galvanising.
2.06 CABLE TRUNKING (PVC)
A. Heavy Duty uPVC trunking with clip on lid (all insulated) shall
be used wherever possible to replace multiple conduit runs.
Where applicable, trunking shall comply with the requirements
contained in BS 4678 Part 4. Any non-standard trunking
accessories shall be fabricated by the manufacturer, no site
fabrication shall be allowed.
B. In order to facilitate interchangeability and to eliminate

problems of differential manufacturing tolerances, it is essential
that all PVC cable trunking and appropriate accessories
covered by this specification shall be obtained from the same
manufacturer.
2.07 CABLE LADDERS
A. All cable ladders shall be heavy (2mm) gauge, manufactured

from hot-dip galvanised sheet steel to BS 2989.
B. All couplers, bends, tees etc shall be by the same manufacturer

as the ladder.
C. Ladder system supports shall be determined in accordance

with the manufacturer's structural information to ensure undue
stress or bending does not occur.
D. In areas subject to corrosive atmosphere, eg. Chlorine, the

ladders shall have a PVC finish.
E. Tinned copper earth straps shall be provided at every joint.
2.08 UNDERGROUND DUCTS
A. Underground duct banks shall be of individual uPVC rigid

conduits complying with BS 6099-2-2 / IEC 614-2-2 heavy
gauge.

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PART 3: EXECUTION
3.01 METAL CONDUIT INSTALLATION
A. Where conduits are to be cast in concrete, they shall be

secured using crumpets, clips or saddles as approved by the
Engineer.
B. All ends of conduits shall be reamed to remove all traces of

burrs.
C. Conduit threads shall be of sufficient length to allow conduits

to butt together within couplers.
D. Oil and grease shall be removed from all threads.
E. Conduits shall be supported at intervals of 1.5 m in isolated

positions or 1 m in accessible situations.
F. Conduit shall not be permitted to be installed closer than 75
mm to pipes of other services.
G. All conduit boxes not to be fitted with accessories shall have

metal cover plates which shall be overlapping where flush
boxes are used.
H. 'Draw in' boxes shall be provided in conduit runs exceeding 3 m

in length. Draw in' boxes shall be at a maximum 12 m
spacing and readily accessible at all times. Adaptable junction
boxes shall also be accessible at all times for inspection and
maintenance.
I. Inspection elbows, bends or tees shall not be permitted

for flush installation.
J. Care shall be taken to prevent water, dirt and debris from

entering the conduit system.
K. Extension rings shall be used where boxes are found not to be

flush with the finished surface.
L. Conduits and conduit accessories shall be protected from rust

and mechanical damage. Exposed conduit threads and
damaged or rusty areas shall be painted, using an oxide
undercoat and aluminium paint, after being cleaned to bare
metal.
M. Conduits installed in areas subject to corrosive atmospheres

shall be painted with chlorinated rubber paint after the
installation is complete.

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N. Under no circumstances shall metal conduit be used as a

circuit protective conductor (CPC). Every final sub-circuit shall
incorporate its own separate Cu/PVC CPC.
O. Spacing factors shall be applied to all conduits in accordance with

522-08 of the IEE Wiring Regulations, 16th Edition (BS7671).
3.02 FLEXIBLE CONDUIT INSTALLATION
A. Flexible conduits shall only be used in short lengths, of less than 1m, in
cases where a final connection is required to be made to a fixed item of
equipment which is subject to vibration or thermal expansion.
B. Flexible conduits shall be 1.25 x L, L being the direct distance between

connection unit and fixed appliance, up to maximum length of 1m.
C. Purpose made glands shall be used on the ends of all lengths of flexible
conduit.
D. A separate Cu/PVC circuit protective conductor shall be included in all

lengths of flexible conduits.
E. Conduits shall be installed so as not to incur undue mechanical strain,

damage or excessive temperatures.
3.03 VC CONDUIT INSTALLATION
A. Where conduit boxes are not to be fitted with accessories, they shall be
fitted with cover plates which shall be overlapping where flush boxes are
used.
B. Conduits shall be jointed and terminated utilizing the following appropriate

components as supplied by the conduit manufacturer:
1. Purposed made adaptors and accessories.

2. Permanent adhesive - Solvent cement to produce a rigid watertight
joint when used with standard couplers and accessories.
3. Flexible adhesive - A non-hardening adhesive to be used where
expansion facilities are required i n l o n g c o n d u i t r u n s , i n
conjunction with expansion coupler.
C. Conduits up to 25 mm diameter may be bent cold with the use of the

appropriate bending spring obtained from the conduit manufacturer. For
larger size conduits, it is necessary to use heat or appropriate
manufacturer's standard ready made bends.
D. Adequate allowance shall be made for linear expansion and contraction of

the conduits under normal working temperature variations, as follow:-
1. Expansion couplers shall be used on all straight runs of conduit

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exceeding 6 metres in length.

2. Conduit shall be free to slide within saddles.

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3. Allowance for expansion in cast in-situ installation is normally only

required to effect structural movement at building expansion joints.
E. Conduit shall be supported at intervals of 1.5 metres in isolated positions or

1 metre in accessible situations. Where working temperatures tend to be
high, this spacing shall be reduced accordingly.
F. Multiple conduits may necessitate the use of large PVC adaptable boxes for
junctions, which shall be readily accessible at all times.
G. Care shall be taken in the support of totally enclosed lighting fittings.

Where excessive temperature are likely to occur special heat resistant
boxes shall be used, i.e. of a pattern specifically designed to improve weight
loading characteristics.
H. Spacing factors shall be applied to all conduit in accordance with 522-08 of

the IEE Wiring Regulations, 16th Edition (BS7671).
I. Conduits shall not be installed closer than 75 mm to pipes of other

services.
J. "Draw-in" boxes shall be installed in all conduit runs exceeding 3 m in

length at a maximum 12 m spacing and shall be readily accessible at all
times.
K. Inspection elbows, bend or tees shall not be permitted for flush

installation.
L. Extension rings shall be used where boxes are found to be not flush with
the finished surface. Care shall be taken to prevent water, dirt, dust or
debris from entering the conduit system.
3.04 CABLE TRAY INSTALLATION
A. Where practical cable tray shall be run horizontally and flat or vertically and
shall be supported at distances not exceeding 1.5 m to the building
structure using mild steel brackets. These brackets shall be secured to the
building structure using expanded bolts and washers or built into the
building structure during construction.
B. Where cable tray is suspended, 2 No. drop rods shall be used at each
suspension point to an angle iron or channel support to which the cable tray
is bolted. The spacing of suspension points shall be determined in
accordance with the manufacturer's structural information such that
undue stress or deflection does not occur.
C. Where cable tray is cut, the open ends shall be painted using an oxide
undercoat and an aluminum top coat. Where the finish is PVC a top coat of
liquid PVC solution shall be applied after the completion of the cable tray
installation.
D. Cable trays run parallel with walls shall not be mounted closer than 75mm
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to the wall.

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E. All cables shall be secured to the cable tray at distances in accordance with
F. Bare copper or aluminum cables shall not be run on cable tray.
G. Earth continuity shall be ensured by means of tinned copper earth straps

bolted across each joint. Flexible braided straps shall be used for
expansion joints.
3.05 CABLE TRUNKING INSTALLATION
A. Cable trunking shall be fixed securely to the building structure at intervals

not exceeding 1.5 m.
B. Where vertical runs of trunking exceed 3 m in length, pin racks shall be

fitted by the Contractor.
C. Spacing factors shall be applied to all cable trunking in accordance with

D. For metal trunking installations, earth continuity shall be ensured by

means of tinned copper earth straps bolted across each joint. Flexible
braided straps shall be used for expansion joints.
E. Metal trunking cut during installation shall have the cut ends painted with an
oxide undercoat and an aluminum top coat.
F. Where metal trunking is installed in areas subject to corrosive

atmospheres, the complete trunking installation shall be painted with a
chlorinated rubber paint after the installation is complete.
G. Expansion joints with gaps shall be incorporated in all PVC trunking runs in
excess of 6 metres in length. External couplings shall have elongated slots
and fixing holes shall be drilled oversize to give freedom of linear
movement. Internal couplings shall be securely fixed at one end by use of
thiscotrophic adhesive leaving the other end free for linear movement.
H. Bare copper or aluminum cables shall not be run in metal trunking.
3.06 CABLE LADDER INSTALLATION
A. Where practical, cable ladders shall be run horizontally and flat or

vertically and shall be supported at distances not exceeding 1.5 m to the
building structure using mild steel brackets. These brackets shall be
secured to the building structure using expanded bolts and washers or built
into the building structures during construction.
B. Where cable ladder is suspended, 2 No. drop rods shall be used at each
suspension point to an angle iron or channel support to which the cable
ladder is bolted. The spacing of suspension points shall be determined in
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accordance with the manufacturer's structural information such that

undue stress of defection does not occur.
C. Where cable ladder is cut, the open ends shall be painted using an oxide
undercoat and an aluminum top coat. Where the finish is PVC, a top coat of
liquid PVC solution shall be applied after the completion of the cable ladder
installation.
D. Cable ladders run parallel with walls shall not be mounted closer than 75
mm to the wall.
E. All cables shall be secured to the cable ladder at distances in accordance

with 522-08 of the IEE Wiring Regulations, 16th Edition (BS7671), a
maximum number of 4 cables may be secured by one clip.
F. Bare copper or aluminum cables shall not be run on cable ladder.
G. Earth continuity shall be ensured by means of tinned copper earth straps

bolted across each joint. Flexible braided straps shall be used for
expansion joints.
3.07 UNDERGROUND DUCT AND MANHOLES
A. Multiple conduit runs or banks shall be supported on preformed non-

metallic separators. Spacing between separators shall be close enough to
prevent sagging of conduits and breaking of couplings and water tight seals.
Separators shall be secured with cords where necessary and not tie wires.
B. Duct lines shall have a continuous slope downwards away from building.
Trenches shall be excavated along straight lines so the elevation can be
adjusted if necessary to avoid unseen obstructions.
C. During construction, partially completed duct lines shall be protected from

the entrance of debris such as mud, sand, and dirt by means of suitable
conduit plugs. As each section of duct line is completed a test mandrel not
less than 300 mm long with a diameter 6 mm less than the size of the
conduit shall be drawn through each conduit, after which a brush with stiff
bristles shall be drawn through until the conduit is clear or all particles of
earth, sand or gravel; conduit plugs shall then be immediately installed.
END OF SECTION

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SECTION 16120
WIRES AND CABLES
PART 1: GENERAL
A. Examine all other sections of the Specification for requirements, which

affect work of this Section whether or not such work is specifically
mentioned in this Section.
A. The requirements of this section shall apply to all multicore and single core
cables, referred to on the drawings and elsewhere within this Specification.
B. The types of cables shall have copper conductors and comprise the
following:-
1. Single core PVC insulated cables.
2. Flexible mutli-core cables.
3. PVC/PVC cables.
4. PVC/SWA/PVC cables.
5. XLPE/SWA/PVC cables.
6. TV and Communication cables.
A. Cables shall only be purchased from manufactures specialising in the

manufacture or the type of cable mentioned.
B. Cables shall generally be manufacturer's standard construction and

materials. Where this contradicts any part of this Specification, the
Contractor shall state so at the time of tender.
C. Manufacturer's shall provide proof of supply of similar types of cables to

known users for a period not less than 5 years.
D. All equipment furnished under this specification shall conform to

applicable local standards and BS.
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1.04 SUBMITTAL
A. The Contractor shall submit samples of each type of cable they are offering.
B. For all cables the Contractor shall submit the following manufacturers
details:
Dimensions
Weights
Construction
Current rating
Manner of installation
Maximum conductor operating temperature
Volt drop/amp/metre
Impedance: Separate resistance and reactance values o f s i n g l e and
multicore cables
Resistance of armouring in ohms/1000 metres length of cable
Characteristic curves for short circuit rating
Minimum bending radius
1.05 DELIVERY AND HANDLING OF CABLES
A. End of cables shall be sealed to prevent ingress of moisture.
B. Where cables are transported on drums these shall be adequate

circumstances for the cables.
C. After winding on drums, the cables shall be protected by being completely

enclosed.
D. Care shall be taken during transit to avoid damage to cable and drums.
Before acceptance on site, cable drums and cables shall be inspected for:
1. Damage
2. Compliance with specification
3. Quantity
E. Cable, wire and accessories shall be stored in factory installed coverings in

a clean, dry indoor space, which provides protection against the weather.
F. Each distribution cable shall be supplied in one continuous length, no joints

shall be permitted.
G. Cables shall be handled with care and every effort made to avoid damage
to the cable, to other services and to building fabric. Recommendations or
instructions available from the cable manufacturers concerning the
installation of cables shall be taken into account; in particular co-axial
cables shall not be bent in radius less than six times the overall diameter.
Any damage shall be reported immediately to the Engineer.

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H. Cable drums shall be unloaded carefully by means of either a crane or

ramp and impact with the ground shall be avoided. They shall be supported
on axles and axle stands while the cable is being pulled; twisting and
abrasion of the cable serving or over sheath shall be avoided.
I. Cables shall be pulled over cable rollers adequately spaced to prevent the
cable being dragged over ground or other surfaces. For cables pulled into
thrust boring or cables ducts and for all cables exceeding 10 m length,
cable stockings shall be such for hauling. Precautions shall be taken to
ensure that strain is taken on the cable cores as well as the sheath and
excessive stain shall be avoided.
PART 2: PRODUCT
2.01 SINGLE CORE PVC INSULATED CABLES
A. A. Single core cables shall be of high conductivity copper stranded wire

insulated with PVC.
B. Cables shall comply with BS 6004 Table 5, and shall be of 600/1000V

grade.
C. Cables shall be coloured in accordance with section 524 of the IEE Wiring
Regulations, 16th Edition (BS7671) and BS 3858.
2.02 FLEXIBLE CABLES
A. All flexible cables used for pendant lighting fittings or for final connections to
fixed or portable equipment shall be of 300/500 grade and comply with BS
6500 Table 12.
B. Flexible cables shall be of annealed copper conductors insulated with heat

resisting PVC, sheathed with heat resisting PVC and shall be of circular
construction.
C. Cable cores shall be coloured, and conform to 2.01C above.
2.03 MULTI-CORE POLYVINYL CHLORIDE (PVC) INSULATED NON ARMOURED

CABLES
A. All low voltage multi-core distribution cables shall be 600/1000v polyvinyl

chloride (PVC) insulated copper conductor, none armored complying with
BS6346.
B. Cable conductors shall be of high conductivity copper wire insulated with

polyvinyl chloride (PVC).
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C. Cable cores shall be coloured in accordance with section 524 of the IEE
Wiring Regulations, 16th Edition (BS7671) and BS 3858.
D. Joints shall not be allowed in any cable.
2.04 MULTI-CORE POLYVINYL CHLORIDE (PVC) INSULATED STEEL WIRE ARMOURED

AND PVC SHEATHED CABLES
A. All low voltage multi-core distribution cables shall be 600/1000v polyvinyl

chloride (PVC) insulated copper conductor, steel wire armoured and PVC
sheathed cable complying with BS 6346.

polyvinyl chloride (PVC). The armouring shall consist of a single layer of
galvanised steel wire and the cable be sheathed overall with PVC.
C. Steel wire armouring shall be securely bonded to earth at each

termination by means of an adequately sized metallic bond which shall be
as short and straight as it is practicable.
D. Cable core shall be coloured in accordance with section 524 of the IEE
E. Joints shall not be allowed in any cable.
2.05 CROSS-LINKED POLYETHYLENE (XLPE) INSULATED STEEL WIRE

ARMORED AND PVC SHEATHED CABLES
A. All low voltage multi-core distribution cables shall be 600/1000v grade

cross-linked polyethylene (XLPE) insulated copper conductor, steel wire
armoured and PVC sheathed cables complying with BS 5467.

cross-linked polyethylene. The armouring shall consist of a single layer of
galvanised steel wire and the cable shall be sheathed overall with PVC.
C. Steel wire cable armouring shall be securely bonded to earth at each

termination by means of an adequately sized metallic bond which shall be
as short and straight as it is practicable.
D. Cable cores shall be coloured in accordance with section 524 of the IEE
E. Joints shall not be allowed in any cable.

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2.06 TV AND COMMUNICATION CABLES
A. Co-axial cables shall be 75 ohm to be used for audio/video signal

transmission and shall comply with IEC 78, IEC 96 and BS 5425, BS 2314.
The size and type shall be sized to meet the signal requirements at the
outlet points. Refer to Section 16781-4, 3.02C for the correct acceptable
limit.
B. Wires for communication shall be single-core or multicore insulated and

sheathed conductors which are used only for high duty indoor application.
The conductor insulation and the sheath shall be polyvinyl chloride (PVC),
and shall be rated for minimum of 300/500v, and shall comply with IEC 189.
The insulation resistance shall be a minimum of 100 mega ohm x kms The
copper conductor diameter shall be indicated on the drawings. In multicore
wires each group of 4 conductors shall be star-twisted. Shielding shall be
provided if required as shown on the drawings.
C. Communication cables shall be multicore, shielded. The conductor

insulation shall be polyethylene (PE) and shall be rated for an operation
voltage of approximately 150v and test voltage of 500/200v core- core/core-
sheath. The insulation resistance shall be a minimum of 10000 mega ohms
x kms. Each group of 4 conductors shall be-twisted. The conductors
diameter shall be as indicated on drawings. The cable shall be provided
with an aluminium shielding underneath the outer sheath.
PART 3: EXECUTION
3.01 INSPECTION
A. The Contractor shall examine the areas and conditions under which the
cables are to be installed and correct any unsatisfactory conditions
detrimental to the proper and timely completion of the work. The
Contractor shall not proceed with the work until all unsatisfactory conditions
have been corrected in a manner acceptable to the Engineer.
3.02 SUB-CIRCUIT WIRING - LIGHTING
A. Lighting installation wiring will take the following forms:
1) Single core PVC insulated cables in trunking/conduit for i n te rn a l

wiring.
2) Multi-core PUC/PVC, PVC/SWA/PVC or XLPE/SWA/PVC in conduit,
duct banks or direct buried for external wiring.
B. The types of lighting luminaires required are detailed on the drawings, and
the types of lighting installations and accessories are detailed elsewhere in
this specification and on the drawings.

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C. No conductor smaller than 2.5 sq mm shall be used.

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D. All lighting circuit wiring shall be carried out using the "loop-in" system.
E. Each lighting circuit shall be wired as shown on the drawings and in

accordance with this Specification.
F. Each lighting circuit shall have a separate circuit protective conductor

throughout to each light and switch point.
G. Where a lighting circuit is to be installed in trunking or conduit together any

with other circuit(s) deviating from drawings, the circuit conductor must be
derated for grouping in accordance with table 4B1 of the IEE Wiring
Regulations, 16th Edition. This will normally result in the need to increase
the conductor sizes as shown in the schedule.
3.03 SUB-CIRCUIT WIRING -SMALL POWER
A. Small power installation wiring will take the following forms:
1) Single core PVC insulated cables in trunking/conduit for internal

wiring.
2) Multi-core PUC/PVC, PVC/SWA/PVC or XLPE/SWA/PVC in conduit,

duct banks or direct buried for external wiring.
B. The types of lighting luminaires required are detailed on the drawings, and
the types of lighting installations and accessories are detailed elsewhere in
this specification and on the drawings.
C. No conductor smaller than 2.5 sq mm shall be used.
D. All lighting circuit wiring shall be carried out using the "loop-in" system.
E. Each lighting circuit shall be wired as shown on the drawings and in

accordance with this Specification.
F. Each lighting circuit shall have a separate circuit protective conductor

throughout to each light and switch point.
G. Where a lighting circuit is to be installed in trunking or conduit together any

with other circuit(s) deviating from drawings, the circuit conductor must be
the conductor sizes as shown in the schedule.

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3.04 SUB-CIRCUIT WIRING - POWER (SINGLE AND 3 PHASE)
A. Power installation wiring will take the form of one of the following:
1. Single core PVC insulated cables in trunking/conduit.
2. Multi-core PVC or PVC/PVC cables in cable tray, ladder or

conduit for internal wiring.
3. Multi-core PVC/SWA/PVC or XLPE/SWA/PVC in conduit, duct

bank or direct buried for external wiring.
B. The types of power installations required for this project are detailed
elsewhere in this Specification and on the drawings.
C. Power installations will generally be wired on a single circuit basis as

described on the drawings and will serve fixed items of equipment.
D. No conductor small than 4.0 sq. mm shall be used.
E. Each power circuit shall have a separate circuit protective conductor.
F. When a power circuit is to be installed in trunking or conduit together with

any other circuit(s) deviating from drawings, the circuit conductors must be
the conductor sizes as shown on the drawings.
3.05 CIRCUIT WIRING - FIRE ALARM
A. Fire alarm installation wiring will take the form of either of the following:
1. Single c o r e P V C i n s u l a t e d c a b l e s i n d e d i c a t e d galvanised
steel conduits.
B. No conductor smaller than 2.5 sq. mm shall be used.
C. The types of communication installations required for this project are

detailed elsewhere in this specification and on the drawings.
3.06 CIRCUIT WIRING - COMMUNICATIONS
A. Communications installation wiring will take the form of multi-core cables in

trunking/conduit.
B. The types of communication installations required for this project are

detailed elsewhere in this specification and on the drawings.

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3.07 FLEXIBLE CABLE INSTALLATION
A. Flexible cables shall not be concealed in any part of the installation.
B. Where flexible cables are subject to heat they shall be constructed

containing a minimum of three cores.
C. All flexible cables are to be of circular construction containing a minimum of

three cores.
D. Where portable appliances exceed 200 watt rating, the flexible cable shall
not be smaller than 32/0.20 sq. mm.
E. Flexible cables exceeding 1 m in length shall not be allowed, hard wiring

shall be taken to within 1 m of all equipment or apparatus to be supplied.
3.08 CATV AND COMMUNICATION CABLES INSTALLATION
A. Cables shall be installed in a neat and tidy manner, being concealed where
possible and run through conduits or trunking solely dedicated to the CATV
or communication cables.
B. Manufacturers of CATV or communication systems may have their own

individual requirements. Where this is so, the Contractor shall obtain such
information and make due allowances in the tender.
C. TV and Communication cables shall not be run parallel with or adjacent to

electrical power cables at any time.
D. Full guidance on installation of specialist cables shall be obtained from the

manufacturers.
3.09 INTERNAL CABLE INSTALLATION
A. Where cables enclosed in conduits are run vertically in excess of 5 m the

cables shall be clamped, so as to relieve strain on the cables, using suitable
approved clamps.
B. Where cables are run in trunking the cables of each circuit or groups of
circuits shall be clipped together using nylon straps or other suitable
straps or clips. Vertical runs of trunking exceeding 5 m shall be supplied
with pin racks to relieve the strain on cables.
C. Suitable precautions shall be taken during multiple circuit wiring follows a

common route then the wiring shall be installed in trunking rather than
multiple conduits.
D. To ease future maintenance and modifications, where multiple circuit

wiring follows a common route then the wiring shall be installed in
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trunking rather than multiple conduits.

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E. All cable runs shall be continuous, where multiple circuit wiring follows a
common route then the wiring shall be installed in trunking rather than
multiple conduits.
F. All cable runs shall be continuous, no joints will be permitted.
G. Saddle and clips used for fixing cables shall be from the same
manufacturer as the cable which they are being used to fix and shall be
constructed of the same material as that of the cable sheath with an
overall covering of PVC to the same colour as that of the PVC covering of
the cable. All saddles and clips shall be secured using brass round head
screws. Where cables are supported on cable tray they shall be fixed to
the cable tray using suitable approved straps of clips. Ties shall be
spaced at not grater than 600 mm intervals along each cable, and within
100 mm of end bend or set.
H. Cables shall not be run inside cable trunking.
I. Bends in cables shall not be of a smaller radius than twice the overall
diameter of the cable.
J. Each gland shall be from the same manufacturer as the cable on which it
is used and shall be stamped describing the size and number of
conductors. PVC shrouds shall be used to protect every gland.
K. Where cables are laid on cable trays or ladder in mechanical or electrical

technical rooms, they shall be mechanically protected by a cover to a
height not less than 2 m from ground level.
L. When installing cables, core shall be taken to ensure that electrolytic

action does not take place between the cable and any other material.
M. Power and lighting cables shall be installed in one cable tray, TV and
Communications cables shall be installed in another cable tray with fire
alarm cables separated by mechanical separators.
3.10 EXTERNAL CABLE INSTALLATION
A. A. No work shall commence until the contractor has investigated the site
satisfactorily, and ascertained that the area is free from drains or other
underground services.
B. Unless otherwise indicated, excavations within 600 mm of existing

services shall be by hand digging. All services uncovered, whether
expected or not, shall be reported immediately to the Engineer; they shall
be supported by slings or other suitable means and protected. Any damage
to services, however minor, shall be reported immediately to the Engineer;
no repairs or replacement shall be done unless the Engineer gives his
approval.
C. When cable trenches are opened all cables shall be laid as quickly as
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possible. The Engineer approval shall be obtained before a trench is

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backfill, generally backfilling shall be commenced within 24 hours of cable

laying and the work completed speedily.
D. Excavations shall be kept free of water and protected against damage or

collapse. The safety of persons and the protection of structures,
buildings, roads and services from damage shall be ensured.
E. Before cables are laid the bottom of the trench shall be graded evenly,
cleaned of loose stones and then covered for the full width of the trench
with a 150 mm layer of earth which has passed through a sieve with a
maximum mesh of 12 mm or with sieved sand. Where the level of the
trench bottom has to change the slope shall not be greater than 1 in 12.
F. After cables have been laid a further layer of earth or sieved sand shall be
added over the full width of the trench and tamped to provide finally not
less than 50 mm cover over the cables. The earth shall have passed
through a sieve with a maximum mesh of 12 mm.
G. Trenches shall be backfilled in layers and each layer shall be rammed.

The first two layers shall be 100 mm deep and rammed by hand; then
ramming may be used. Warning tapes and covers shall be provided.
H. Warning tapes shall be of polythene not less than 150 mm wide and 0.1
mm thick. They shall be yellow in colour and bear the continuously
repeated legend "-CAUTION ELECTRIC CABLE BELOW-" or similar in
English and Arabic, in black letters not less than 30 mm high.
I. Warning covers shall be provided, and comply with regulation and codes
of practice, for M.V. cables. Covers shall be laid directly on tamped sieved
earth or sand that covers the cables.
J. Cables laid in trenches shall cross other cables only at junctions;

clearances between the cables shall be maintained at cross overs.
Cables shall not be laid one above the other except where indicated.
K. If more than one cable is to be drawn in a duct, the cables shall be

bunched together and pulled in one operation, wherever possible.
L. Where cables run under roadways, they shall be installed in PVC ducts,
encased in concrete. The ducts shall extend for a minimum distance of 1
m on each side of each roadway.
M. Where cables enter ducts beneath ground to buildings, these ducts shall
be sealed to prevent the ingress of water by means of sealing fittings
which will be filled with sealing compound. At least one spare duct shall
be installed at each building entry point.
N. Details and routes of external cables are shown on the drawings.

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O. Cables shall be installed to the requirements of the IEE Wiring

Regulations, 16th Edition and all current amendments. Section 522-08 of
these regulations states requirements for support of cables.
P. Cables shall only be terminated using the correct size and type of gland
with earth tag and shroud from the same manufacturer as the cable. All
gland shall be dustproof and for external applications the glands shall be
fully weatherproof.
Q. Cable armouring shall be bonded to earth at each termination by means

of a green/yellow Cu/PVC earth conductor, sized in accordance with
Section 543 of the IEE Wiring Regulations, 16th Edition, connecting the
cable gland earth tag to the local earth terminal. The apparatus gland
plate shall be cleaned to bare metal around the cable gland earth tag
bolted connection to ensure a sound electrical connection.
R. Where cables pass through walls or floors, they shall be protected by

PVC or mild steel sleeves cast in to the building fabric. If the walls or
floors are fire divisions, then the sleeves shall be fire stopped after
installation of the cables(s) to the same rating as the walls or floors
through which they pass.
S. Before any tradesman is allowed to terminate an armoured cable on the

permanent works, he shall make a demonstration termination in the
presence of the Engineer and obtain the approval of the Engineer.
T. Where cables pass through ducts or sleeves entering buildings , the

Contractor shall seal the ends of the ducts or sleeves using a suitable
approved stopper after installation of cable.
3.11 MARKING OF CABLE
A. Buried cables shall be permanently identified by concrete slab and

marker. The markers shall be 600 mm square by 100 mm thick with
impressed character; they shall be made of grade 20 concrete, as defined
in BS8110, with 10 mm aggregate. The impressed characters shall be in
English and Arabic and worded "M.V. CABLE" or "L.V.CABLE" as
appropriate together with circuit details as indicated; in addition the work
"JOINT" shall be added where appropriate.
B. Cables markers shall be located at every point where cable enters a

building, sub-station, or distribution pillars, at each joint, change of direction,
road and pathway crossing, and along the route of the cable at the interval
not exceeding 45 m.
C. Except where cables are buried, located in switchrooms, in ducts and

spaces designated solely for electrical services, or have orange

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oversheaths, they shall be identified by adhesive bands coloured orange,

complying with standards and codes of practice mentioned elsewhere in
this specification. The bands shall be not less than 100 mm long, located at
least once within each separate compartment through which cables pass
and at intervals not exceeding 12 m.
D. Except where cables are buried, or enclosed in conduit, trunking or

ducting they shall be permanently identified by discs. The discs shall be of
laminated plastic materials with black character on white; character shall be
not less than 3 mm high. The inscription shall indicate the nominal voltage,
the designation of the load, the number and cross sectional area of cores
and the rated voltage of the cable.
E. Cables identification discs shall be attached to the cables with ties. Disc
shall be located within 500 mm of terminations and joints, at least once
within each separate compartment through which the cable pass, and at
intervals not exceeding 24 m, they shall coincide with the colour bands.
3.12 JOINTING AND TERMINATING CABLES
A. The Engineer shall be informed whenever cables are to be jointed.
B. The Engineer shall be given evidence that the joint or termination

manufacturer has stated that materials to be employed are suitable for the
type of cable to be jointed or terminated.
C. A cable shall not be cut until the jointing or terminating commences and the
work shall proceed continuously until it is completed. All necessary
precautions shall be taken to prevent damage and ingress of moisture and
impurities, cables ends shall be free from moisture before jointing
commences. Where circumstances prevent completion the cable ends shall
be sealed.
D. The Contractor shall employ for this work staff who are fully qualified and
competent for the types of joints and terminations to be made.
E. For joints is armoured cables, bonding conductors shall be connected

across the armouring. A split ferrule shall be place under the armouring to
prevent deformation of the cable by the clamp.
F. At terminations, armouring and metal sheaths shall be connected directly to

the external earthing terminal of the equipment by a bonding
conductor. For L.V. cables the bonding conductor shall have cross sectional
area in accordance with regulations mentioned elsewhere in this
specification and for M.V. cables it shall be as indicated.

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G. At terminations, cable tails shall be formed by separating and bringing out

the cores. Each tail shall be long enough to connected to the terminals of
the equipment.
H. Core identification at terminations shall be by coloured or numbered plastic

stretch or shrink ferrules.
I. Continuity of spare cores shall be maintained at joints, and at

terminations the cores shall be connected to spare terminals.
J. Compression connectors and associated dies for the compression tool

shall be the correct type and size. The tool shall be so designed that the
correct compression must be applied before it can be released.
K. Tools for manipulation and termination of cables shall be of a design

approved by the cable manufacturer. Corrugation of the metal sheath or
damage to outer coverings will not be accepted. A wood block or wooden
faced tool shall be used to finally dress the cable into position.
L. Repairs to a cable sheath, regardless of the extent of the damage, will not
be accepted, straight through joints only are permitted.
M. Terminations and joints shall be made in accordance with the

manufacturer's instructions. Only clean, dry plastic filling compound shall be
used.
N. Masking of cables shall comply with relevant regulation and codes of

practice mentioned elsewhere in this specification and requirements of the
Section.
O. All pre-moulded rubber parts shall be 100% production tested at the

factory with industry standard applied potential and corona extinction
tests. The factory shall certify in writing that these tests have been
performed. No soldering shall be permitted on drain wires or shielding tapes
except with written approval of the Engineer.
P. All electrical cables entering the high voltage compartments of electrical

equipment shall be terminated by means of "deadfront" equipment
wherever possible.
3.13 SLEEVES, TAPES AND SEALING COMPOUND
A. Sleeves shall be of the shrink type, applied col d by a mechanical device or

by the use of heat. They shall provide a sufficient thickness of
insulation to suit the particular application.
B. Insulation type used in joints and terminations shall be compatible with, and
have a temperature rating and insulating property not less than the cable
insulation. They shall comply in general with the regulations and codes of
practice mentioned elsewhere.

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END OF SECTION

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SECTION 16135
ELECTRICAL BOXES AND FITTINGS
PART 1: GENERAL
A. Examine all other sections of the Specification for requirements which affect
work of this Section whether or not such work is specifically mentioned in
this Section.
B. Coordinate work with that of all other trades affecting, or affected by work of
this Section. Cooperate with such trades to assure the steady progress of
all work under the Contract.
A. Extent of electrical box and electrical fitting work is indicated by drawings

and schedules.
B. Types of electrical boxes and fittings in this section include the following:
Outlet boxes
Junction boxes
Pull boxes
Floor boxes (underfloor and flashflood)
Conduit bodies
Bushings
Locknuts
Knockout closures.
A. Manufacturers: Firms regularly engaged in manufacture of electrical

boxes and fittings, of types and sizes required, whose products have been
in satisfactory use in similar service for not less than 10 years.
B. Installer: Qualification with at least 5 years of successful installation

experience on projects with electrical installation work similar to that
required for project.
C. I.E.E. Compliance: Comply with I.E.E. as applicable to construction and

installation of electrical wiring boxes and fittings.

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D. British Standards Compliance: Comply with British Standards as

applicable to sheet-steel outlet boxes, device boxes, and cover and box
supports.
1.04 SUBMITTALS
A. Product data: Submit manufacturer's data on electrical boxes and fittings.
B. Samples: The Contractor shall submit sample of each type of box and
fitting they are offering.
PART 2: PRODUCTS
2.01 FABRICATED MATERIALS
A. Interior Outlet Boxes: Provide galvanised flat, rolled sheet steel interior
outlet wiring boxes, of types, shapes and sizes including box depths, to suit
each respective location and installation, construct threaded screw holes
with corrosion-resistant screws for securing box covers and wiring devices.
B. Interior Outlet Box Accessories: Provide outlet box accessories as

required for each installation, including mounted brackets, wallboard
hangers, extension rings, fixtures studs, cable clamps and metal straps for
supporting outlet boxes, which are compatible with outlet boxes being used
and fulfilling requirements of individual wiring situations.
C. Weatherproof Outlet Boxes: Provide corrosion-resistant cast metal

weatherproof outlet wiring boxes, of types shapes and sizes, including
depth of boxes, with threaded conduit ends, cast metal face plates with
spring-hinged waterproof caps suitable configures for each application,
including face plate gaskets and corrosion resistant fasteners.
D. Junction and Pull Boxes: Provided galvanised code gauge sheet steel
junction and pull boxes or with screw on covers, of types, shapes and sizes,
to suit each respective location and installation with welded seams and
equipped with stainless steel nuts, bolts, screws and washers.
E. Conduit Bodies: Provide galvanised cast-metal conduit bodies, or types,

shapes and sizes to suit respective locations and installation, construct with
threaded, corrosion-resistant screws.
F. Bushings, knockout Closures and Locknuts: Provide corrosion-resistant

punched-steel box knockout closures, conduit locknuts and malleable iron
conduit bushings, offset connectors, of types and sizes to suit respective
uses and installation.

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PART 3: EXECUTION
3.01 INSTALLATION
A. General: Install electrical boxes and fittings where indicated, complying with
manufacturer's written instructions, applicable requirement of I.E.E. and
BS's "Standard of Installation", and in compliance with recognised industry
practices to ensure that products fulfill requirements.
B. Coordinate installation of electrical boxes and fitting with wire/cable and

raceway installation work.
C. Provide weatherproof outlets for interior and exterior locations exposed to

weather or moisture.
D. Provide knockout closures to cap unused knockout holes where blanks

have been removed.
E. Install boxes and conduit bodies locations to ensure ready accessibility of

electrical wiring.
F. Avoid using round boxes where conduit must enter box through side of box,
which would result in difficult and insecure connections when fastened
with locknut or bushing on rounded surface.
G. Fasten boxes rigidly to substrate or structural surfaces to which attached, or

solidly embedded electrical boxes in concrete or masonry.
H. Provide electrical connections for installed boxes.
END OF SECTION

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SECTION 16142
ELECTRICAL CONNECTION FOR EQUIPMENT

PART 1: GENERAL
A. Examine all other sections of the Specification for requirements which

affect work of this section whether or not such work is specifically
mentioned in this section.
B. Coordinate work with that of all other trades affecting or affected by work of
the Section. Cooperate with such trades to assure the steady progress of
A. Extent of electrical connections for equipment is as indicated by drawings

and schedules. Electric connections are hereby defined to include, but not
limited to, connections for providing electrical power without exception to all
equipment which needs electrical power.
B. Types of electrical power connections specific in this section include the

following:
- To all A.H.U's control panels and equipment.
- To all motor control centres. (MCC)
- To all socket outlets
- To all isolators
- To motors. (if covered by electrical contract)
- To motor starters. (if covered by electrical contract)
- To all heaters and A/C equipment (if covered by electrical contract)
- From motor starters to motors. (if covered by electrical contract)
- To all lighting fixtures and switches.
- To master units of communication, signal, alarm, etc. and to all

secondary units where required.
- To earth all equipment.

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C. See Sections 16481 and 16482 for Motors Control Centres and Motor
Starters furnished integrally with equipment; not work of this section.
D. See Division - 15 sections for control systems wiring is not work covered by
this section.
E. See all the notes on electrical drawings for detail of scope of work
included under this section.
1.03 GUARANTEES
A. Attention is directed to provisions of the GENERAL TERMS AND

CONDITIONS AND SPECIAL CONDITIONS regarding guarantees and
warranties for work under this Contract.
B. Manufacturers shall provide their standard guarantees for work under this
section. However, such guarantees shall be in addition to and not in lieu of
all other liabilities which manufacturers and Contractors may have by law or
by other provisions of the Contract Documents.
A. Manufacturers: Firms regularly engaged in manufacture of connectors and

terminals, or types, and ratings required, and ancillary connection materials,
including electrical insulating tape, electrical flux, and cable ties, whose
products have been in satisfactory use in similar service for not less than 5
years.
B. Installer: Qualified with at least 5 years of successful installation

required for the project.
C. BS Compliance: Comply with applicable portions of BS as to type

products used and installation of electrical power connections (terminals
and splices), for junction boxes, motor starters, and disconnect switches.
1.05 SUBMITTALS
A. Product Data: Submit manufacturer’s data on electrical connectors,

terminals and materials.

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PART 2: PRODUCTS
2.01 MATERIALS AND COMPONENTS
A. General: For each electrical connection indicated, provide complete

assembly of materials, including but not necessary limited to, pressure
connectors, terminals (lugs), electrical insulating tape, electrical solder,
electrical soldering flux, heat-shrinkable insulating tubing, cable ties,
solderless wire nuts, and other items and accessories as needed to
complete splices and terminations of types indicated.
B. Metal and Heavy Gauge PVC Conduit, Tubing and Fitting: Provide heavy
gauge PVC and metal conduit, tubing and fittings of types, grades, sizes
and fittings of types, sizes and weights (wall thickness), indicated for each
type service. Where types and grades are not indicated, provide proper
selection as determined by Installer to fulfill wiring raceways. Provide
products complying with Section - 16110 raceways", and in accordance
with the following listing of metal conduit, tubing and fittings.
- Heavy gauge PVC conduit (for indoor except plant
rooms).
- PVC external coated rigid steel conduit (external area and

plant rooms).
- Rigid metal conduit fittings
- Electrical metallic tubing
- PVC externally coated electrical metallic tubing
- Flexible metal conduit
- Flexible metal conduit fittings
- Liquid-tight flexible metal conduit
- Liquid-tight flexible conduit fittings
C. Wire, Cable and Connectors: Provide electrical connectors and terminals

as recommended by connector and terminal manufacturer for intended
applications.
D. Electrical Connection Accessories: Provide electrical insulating tape,

heat-shrinkable insulating tubing and boots, solder, electrical soldering flux,
wire nuts and cable ties as recommended for use by the accessories
manufacturers for type services indicated.

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PART 3: EXECUTION
3.01 INSTALLATION OF ELECTRICAL CONNECTIONS
A. Install electrical connection as indicated; in accordance with connector

manufacturer's written instructions and with recognised industry practices,
and complying with requirement of the I.E.E. Wiring Regulations, 16th
Edition, "Standard of Installation" to ensure that products fulfill
requirements.
B. Connect electrical power supply conductors to equipment conductors in

accordance with equipment manufacturer's written instructions and wiring
diagrams. Wherever possible, mate and match conductors of electrical
connections for proper interface between electrical power supplies and
installed equipment.
C. Coordinate installation of electrical connections for equipment with

installation work.
D. Splices insulated by wound tape shall not be acceptable. Protective

earthing conductors must be free of splices.
E. Prepare cables and wires, by cutting stripping covering armour, jacket, and
insulation properly to ensure uniform and neat appearance where cables
and wires are terminated.
F. Trim cables and wires as short as practicable and arrange routing to

facilitate inspection testing and maintenance.
G. Tighten wire-binding connector screws firmly.
H. Provide PVC-coated conduit and fittings where indicated for highly-

corrosive atmosphere and outdoor installation.
I. Provide flexible conduit for all motor connections, and for other electrical
equipment connections where subject to one or more of the following:
- Exterior location
- Moist or humid atmosphere where condensate can be

expected to accumulate (showers, baths, toilet, etc.)
- Corrosive atmosphere
- Subjected to water spray

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- Subjected to dripping oil, grease or water.
J. Provide heat - shrinkable termination for all cables having the size of 500
mm2 and above.
K. Refer to basic electrical requirements section for identification of electrical

power supply conductor terminations with markers approved as to types,
colours. letters and markers sizes, by Architect/Engineer. Affix markers to
each point of termination as close as possible to each point of connection.
L. Where a conduit enters a box or other fitting a bushing or grommet shall be

provided to protect the wire from abrasion unless the design of the box or
fitting is such as to afford equivalent protection.
END OF SECTION

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SECTION 16143
WIRING DEVICES
PART 1: GENERAL

affect work of this Section whether or not such work is specifically
mentioned in this Section.
B. Coordinate work with that of all other trades affecting, or affected by work
of this Section. Cooperate with such trades to assure the steady progress
of all work under the Contract.
1.02 SCOPE AND DESCRIPTION OF WORKS
A. This Specification applies to wiring devices used as accessories for the

electrical installations as indicated on the drawings or schedule and
elsewhere within this specification.
B. Types of electrical wiring devices required for the installation in this

project include:
1. Lighting switches (grid assembly).
2. Lighting switches (plate switches).
3. Ceiling switches.
4. External lighting switches.
5. 13A switch socket outlets.
6. 15A socket outlets.
7. Fused connection units.
8. Single phase isolators and switch fuses.
9. Multi phase isolators and switch fuses
10. Cooker control units
11. Connections to fixed appliances.

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12. Shaver socket outlet

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13. Industrial socket outlet
14. Telephone and TV/radio outlets.
A. Standards
The equipment and installation shall comply with the standards and codes
of practice listed in Section 16010 Part 1 or their approved equivalents. In
the event of the discrepancy between this specification and any relevant
standard or code of practice, the specification shall be followed and the
Engineer informed.
B. Manufacturers
Firms regularly engaged in manufacture of wiring devices, of types and

ratings required, and whose products have been in satisfactory use in
similar service for not less than 5 years.
C. Source Quality Control
Before installation, wiring devices shall be tested in accordance with

standards mentioned elsewhere and have relevant listing or certificates of
approval.
D. Workmanship
All work undertaken in part or whole shall be carried out and completed to
the standards mentioned elsewhere and to the satisfaction of the
Engineer.
Any defects or damage caused partly or wholly in the installation of wiring

devices to the building or building fabric shall be made good to the
1.04 SUBMITTAL
A. The Contractor shall submit to the Engineer complete and detailed

manufacturer's data relating to the wiring devices offered. Refer Section
16010 Part 2.
For approval submissions shall include the following:

1. Name of the
manufacturer.
2. Country or
origin.
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3. Name and address of agents in the country stating whether

any manufacturing or fabrication is carried out in the country.
4. Method of obtaining spare parts for maintenance and list of

spare parts sufficient for a 2 years period.
5. Technical performance of the equipment

selected.
6. Dimensional details needed for installation and

maintenance.
7. Delivery time from the date of

orders.
8. Submit copies of test reports or

certificates.
9. Control schematic and

wiring.
B. The Contractor shall provide samples of proposed wiring devices together

with the above submittal.
A. Box crate or otherwise completely enclose and protect all equipment from
dirt, construction debris, traffic and operation.
PART 2: PRODUCTS
2.01 GENERAL
A. Switch plates, socket-outlet plates and similar items shall be of metal or

plastic material as indicated on the drawings or as directed by the Engineer.
B. Decorative finishes of metal plates shall comply with appropriate

standards, as mentioned elsewhere. The finish and/or colour shall be
standard throughout the installation unless otherwise indicated or as
C. Switches shall comply with standards mentioned elsewhere in this

specification and be suitable for use on inductive and resistive loads. They
shall be single pole, unless otherwise indicated or directed by the Engineer,
and where mounted adjacent one to another they shall be grouped in a
single enclosure and share a common switchplate.

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D. Where indicated, switches with pilot lamps shall be provided. This lamp
shall be a neon lamp with resistor and red coloured lens unless otherwise
indicated.
2.02 LIGHTING SWITCHES (GRID ASSEMBLIES)
A. Lighting switches for interior use, grid type, shall be of 220 volts A.C., single
pole, minimum 15A and mounted on adjustable grid enclosed in metal box.
The switches shall be of the quick make, slow break type and shall comply
with standards mentioned elsewhere in this specification.
B. Where switches are to be flush type they shall be supplied with
overlapping cover plates finished flush with the sides of the metal box.
2.03 EXTERNAL LIGHTING SWITCHES
A. All external lighting switches shall be one way, two way or multigang
arrangements and be complete with a gasket forming splash proof and
dustproof enclosures. The switches shall also comply with standards and
regulations mentioned elsewhere.
B. A suitable drain hole must be provided.
2.04 13 AMPERES SWITCH SOCKET OUTLETS
A. 13 amperes, 220 volts, switch socket outlets shall be provided as

indicated on drawings, and shall have two-pole and earthing pin.
B. B. Switch socket outlets shall comply with IEE Wiring Regulation

(16th Edition) and other codes of practice mentioned elsewhere in this
specification and shall be double pole switched.
C. Weatherproof socket outlets shall be provided with push-on cap retaining

ring without switch.
D. All wall mounted switch socket outlets with the exception of those
mounted in services or plant rooms shall be of the rectangular 3-pin
shuttered pattern, flush mounting type with front plates as indicated
elsewhere. Socket outlets shall be mounted in flush metal box. Where
surface mounted socket outlets are required, They shall be of the flush
pattern, mounted on suitable adaptor boxes.
E. All surface sockets shall be provided with a 13A unbreakable plug top
complete with fuse. Each twin socket shall be counted as two sockets.

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F. Plugs shall be provided with all socket-outlets, and handed over the
Engineer.
G. Socket outlets provided in services plant rooms shall be metal clad type,
surface or flush mounted as indicated elsewhere.
2.05 15 AMPERES SOCKET OUTLETS
A. 15 amperes, 220 volts, socket outlets shall be provided as indicated on

drawings and shall have two poles and earthing pin.
B. Socket outlets must comply with Local standards and other Codes of
Practice and regulations mentioned elsewhere in this specification.
C. All wall mounted socket outlets with exception of those mounted in

services or plantrooms shall be 3 pin, flush mounting type with front plates
as indicated elsewhere. Socket outlets shall be mounted in flush metal
boxes complete with an earthing terminal and earth tag to connect the
socket outlets are required, they shall be of the flush pattern, mounted on
suitable adaptor boxes.
D. Socket outlets provided in services or plant rooms shall be metal clad type,
surface or flush mounted as indicated elsewhere.
2.06 FUSED CONNECTION UNITS
A. Spur units are to be of the 13 amperes, 220 volts rating combining a double
pole switch, a single pole fuse in the live line and a pilot light for
confirmation that the unit it turned on.
B. All wall mounted spur units, with the exception of those to be installed in
services and plant rooms. They shall mounted on either metal or plastic
purpose-made mounting boxes to be of the same material as that of the
front plates.
C. In plant rooms and services rooms, spur points shall be of the surface
mounted type and shall be metal clad.
2.07 SINGLE PHASE ISOLATORS AND SWITCH FUSES
A. These shall be of the double pole single throw type, complying with
regulations and standards mentioned elsewhere in this specification.
B. Finishes shall be either of white plastic for flush isolators or rust proof metal
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for surface isolators and switch fuses.

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C. All fuses shall be of HRC type as described elsewhere in this

specification. These items of switchgear are to be used for the isolation of
single phase items of fixed equipment fed by an individual circuit.
D. Type of equipment required is described elsewhere in this specification and

on drawings.
2.08 MULTI-PHASE ISOLATORS AND SWITCH FUSES
A. Multiphase isolators and switchgear shall be used for the isolation of

multiphase items of fixed equipment fed by an individual circuit.
B. Switches shall be of multipole, single throw operation and must comply with
standards mentioned elsewhere in this specification.
C. Types of equipment are described elsewhere in this specification.
D. These items are to be manufactured from rust proofed, metal-clad

material.
E. All fuses shall be of HRC type, as described elsewhere in this

specification.
2.09 COOKER CONTROL UNITS
A. Cooker control units shall be of 45A double pole type complying with
standards and codes mentioned elsewhere.
B. All units shall be fitted with pilot light and switch socket outlet 13 amperes.
C. Finishes shall be as described elsewhere in this specification and as

D. All units shall be of flush type with an overlapping from cover.
E. For surface installations a suitable adaptor box shall be provided.
2.10 TIME SWITCHES
A. Time switches shall be of the self-starting, selfwinding, synchronous-

motor driven type.

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B. The rated voltages and rated current shall be as indicated on the

drawings.
C. Time switches shall, unless otherwise indicated or as directed by the

Engineer, incorporate the following:
A 150 hours spring reserve to drive the mechanism during electricity supply
interruptions;
An easily replaceable cartridge fuse-link, complying with codes mentioned
elsewhere, inserted in the motor circuit.
An ON-OFF manual switch to enable the circuit to be controlled at will

without affecting normal dial operation.
2.11 CONNECTIONS TO FIXED APPLIANCES
A. Final connections to this type of equipment shall be carried out by using

either an insulated copper sheathed cable or a flexible metallic conduit with
heat resisting cables run through the conduit.
Supply and install a double pole isolator adjacent to each fixed appliance.
Conduit for kitchen equipment shall not be run in the floor screed.
B. Flexible Conduit
Final connections made using flexible conduit are to comprise a metallic

flexible conduit covered with continuous PVC sheath and shall comply with
Section 16110 'Flexible Conduit and Fittings of this specification.
Sufficient length shall be allowed for vibration and movement of the

equipment. A separate circuit protective conductor wire must be run
inside the conduit.
2.12 INDUSTRIAL SOCKET OUTLETS
A. Industrial socket outlets shall be single or multiple types and rating as

B. Socket outlets shall have an enclosure of IP44 or IP67 integrated with

switch or without it as shown on drawings.
C. Socket outlets shall be single phase with two poles and earthing pin or
three phase with three poles, earthing pin with or without neutral pin as
shown on drawings.

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D. Socket outlet shall be integrated with 30 mA (RCD) residual current

device as earth leakage protection.
2.13 TELEPHONE OUTLET AND RADIO/TV OUTLET PLATES
A. All outlet plates where specified shall be of similar style and finished to that
specified for the associated lighting switches and socket outlets and shall
be suitable for mounting recessed or flush.
B. Unless otherwise specified telephone outlet plates shall be complete with a

terminal box suitable for termination of a 2 pair cable as minimum and a
cable clamp to secure the outgoing telephone handset connecting cable.
C. Unless otherwise specified, TV outlet plates shall be complete with one co-
axial socket outlet. Where twin outlets are required to provide booth FM and
Radio and TV signals, they shall be complete with duplexing network as
necessary.
PART 3: EXECUTION
3.01 INSPECTION
A. The Contractor must examine areas and conditions under which wiring
devices are to be installed and correct any unsatisfactory conditions
detrimental to proper and timely completion of the work. He shall not
proceed with the work until unsatisfactory conditions have been corrected in
a manner acceptable to the Engineer.
3.02 INSTALLATION OF WIRING DEVICES
A. Install wiring devices where indicated, in accordance with manufacturer's

written instructions, applicable requirement of BS, IEE, and in accordance
with recognised industry practices to ensure that products serve their
intended function.
B. Programme installation of devices for after wiring is completed.
C. Install devices only in electrical boxes, which are, clean and free from
excess building materials, debris, etc.
D. In walls or ceilings of concrete, tile or other noncombustible material, boxes

and fittings shall be so installed that the front edge of the box or fitting will
not be set back from the finished surface more than 5 mm. In walls and
ceilings constructed of wood or other combustible material, outlet boxes
and fittings shall be flush with the finished surface or project therefrom.
E. Plaster surfaces that are broken or incomplete shall be repaired so that

there will be no gaps or open spaces at the edge of the box or fittings.
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F. In making an exposed surface extension from an existing outlet of

concealed wiring, a box or an extension ring shall be mounted over the
original box and electrically and mechanically secured to it.
G. All wiring devices shall be fixed independently of the system of wiring. All
fixing screws or bolts shall be of steel and where the appropriate
apparatus has a protective coating of zinc or is mounted outside, an
electro-galvanized finish shall be used complying with relevant standards
and codes of practice.
END OF SECTION

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SECTION 16190
SUPPORTING DEVICES
PART 1: GENERAL
1.01 SECTION INCLUDES
A. Examine all other Sections and the Specifications for requirements which
affect work of this section or not such work specifically mentioned in this
section.
A. This specification is for extent of supporting devices.
B. Types of supporting devices in this section include the following:
- Conduit and Equipment Supports

- Anchors and Fasteners
1.03 SUBMITTALS
A. Product Data: Provide manufacturer's catalogue data for fastening

systems.
B. Manufacturer's Instructions: Indicate application conditions and limitations

of use stipulated by Product testing agency specified under Regulatory
Requirements. Include instructions for storage, handling, protection,
examination, preparation, installation, and starting of Product.
PART 2 PRODUCTS
2.01 PRODUCT REQUIREMENTS
A. Materials and Finishes: Provide adequate corrosion resistance.
B. Provide materials, sizes, and types of anchors, fasteners and supports to

carry the loads of equipment and conduit. Consider weight of wire in
conduit when selecting products.

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C. Anchors and Fasteners:

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1. Concrete Structural Elements: Use precast insert system,

expansion anchors and preset inserts.
2. Steel Structural Elements: Use beam clamps.
3. Concrete Surfaces: Use expansion anchors.
4. Hollow Masonry, Plaster, and Gypsum Board Partitions: Use

toggle bolts and hollow wall fasteners.
5. Solid Masonry Walls: Use expansion anchors and preset inserts.
6. Sheet Metal: Use sheet metal screws.
7. Wood Elements: Use wood screws.
PART 3: EXECUTION
3.01 INSTALLATION
A. Install products in accordance with manufacturer's instructions.
B. Provide anchors, fasteners, and supports in accordance with BS

"Standard of Installation".
C. Do not fasten supports to pipes, ducts, mechanical equipment, and

conduit.
D. Do not use spring steel clips and clamps.
E. Do not use powder-actuated anchors.
F. Do not drill or cut structural members.
G. Fabricate supports from structural steel or steel channel. Rigidly weld

members or use hexagon head bolts to present neat appearance with
adequate strength and rigidity. Use spring lock washers under all nuts.
H. Install surface-mounted cabinets and panel boards with minimum of four

anchors.
I. In wet and damp locations use steel channel supports to stand cabinets
and panel boards 25 mm off wall.
J. Use sheet metal channel to bridge studs above and below cabinets and
panel boards recessed in hollow partitions.

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END OF SECTION

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DUBAI – UAE
SECTION 16195
ELECTRICAL IDENTIFICATION
PART 1: GENERAL
1.01 SECTION INCLUDES
A. Examine all other Sections and the Specifications for requirements which
A. This specification is for extent of electrical identification as indicated by

drawings and schedules.
B. Types of electrical identification in this section include the following:
- Nameplates and labels
- Wire and Cable markers
- Colour coded markers
- Circuit identification charts
- Cable identification tags
- Equipment warning signs
1.03 SUBMITTALS
A. Provide catalogue data and samples for nameplates, labels, charts, tags,
signs and markers prior to commencing works.
PART 2: PRODUCTS
2.01 NAMEPLATES AND LABELS
A. Nameplates and Labels shall be engraved three-layer 2mm traffolyte,

securely screwed to the housing and have black letters on white
background in Arabic and English.

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B. The locations are for each electrical distribution board, control equipment
enclosures and communication cabinets.
C. Lettering shall be block capitals standing:
1. 3mm high for identifying individual equipment and loads.
2. 6mm high for identifying grouped equipment and loads.
D. Labels using embossed adhesive tape, with 5mm white letters on black
background for identification of individual wall switches, receptacles, and
control device stations shall be used.
2.02 WIRE MARKERS
A. Wire and cable markers shall be split sleeve or tubing type.
B. The locations shall be for each conductor at panel board gutters, pull
boxes, outlet and junction boxes, and each load connection.
C. Power and lighting circuits on branch or feeder circuits and control circuits
shall require a number.
2.03 COLOUR CODING
A. Provide colour bands 75 mm wide for all trunking runs, applied at panel
and junction box locations and at 15 m centres within an area.
B. Provide colour bands 25 mm wide for conduits upto 50 mm in diameter and

one-half the conduit diameter for larger conduits, applied at panel and
pullbox locations, within each room, and at 6 m centers within an area.
C. Colour banding :
- 127/220 Volt : grey.
- 220/380 Volt : brown.
- Fire alarm : red.
- Telephone : blue.
- Intercommunication and sound : yellow.
- Low voltage switching : black.
- Television : rust.
- Earthing system : green.

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2.04 CIRCUIT IDENTIFICATION CHARTS
A. Individual circuit identification charts shall be provided for all panel boards
and distribution boards.
B. Charts shall be typed on A4 size sheets. They shall be enclosed in a clear

plastic envelope and shall be securely fixed to the inside cover of the unit.
Additional copies of the charts shall be included in the Operation and
Maintenance Manuals.
2.05 CABLE IDENTIFICATION TAGS
A. All cables which exit from manholes, vaults, handholds, and transformer or
switch enclosures shall be properly tagged or labeled. Tags shall be
permanent, no corrodible and clearly readable. Tags should include the
information listed below for the various circuit categories:
Feeder Name
Voltage
Phase (single conductor cables)
For buried cables (LV+MV) use warning tapes as shown on drawings.
B. Cable identification for wire and cable circuits shall be of an opaque nylon
material arranged to include a marker plate, non-releasing nylon ties, and
cable fastening tail. One side shall be roughened to hold black nylon
permanent ink. Identification shall be permanent and waterproof. The
holding device shall be designed to allow the fastening tail to pass around
the cable through the holding device, and prevent removal of the tail without
cutting it loose from the marker. Cable identification shall be inscribed in
Arabic and English.
2.06 EQUIPMENT DANGER SIGNS
A. For external use, pressure sensitive danger signs shall be used.

Dimensions shall be 510 mm by 710 mm. The signs shall be heavy-duty
vinyl with a self-adhesive backing which can be applied to curved or
irregular surfaces. Danger signs shall be weather-resistant and shall not
discolour or deteriorate with age.
B. Danger signs shall be inscribed with the equipment voltage level along with
an internationally recognised danger sign.
C. All signs shall be in English and Arabic.

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2.07 LANGUAGE
A. The Arabic and English languages shall be used for all labelling and charts.
PART 3: EXECUTION
3.01 PREPARATION
A. Degrease and clean surfaces to receive nameplates and labels.
3.02 INSCRIPTIONS
A. All items of switchgear and control gear including all electrical

components shall be provided with labels giving the following information:
1. Manufacturer name.
2. Country of origin.
3. Type number or code.
4. Rated voltage or frequency.
5. Rated current if applicable.
6. The short circuit breaking capacity and the appropriate time.
7. Name o f the international standard with which the

equipment complies.
B. Circuit identification charts in panelboards and distribution boards shall give

the following information :
1. Circuit number.
2. Phase.
3. Load name.
4. Connected load.
5. Outgoing terminal numbers.
6. Size and type of protective device.

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3.03 INSTALLATION
A. Install warning and descriptive labels as follows :
1. Metallic surfaces using stainless steel or chromium plated

bolts and/or self tapping screws.
2. Concrete surfaces or masonry walls using raw plugs and brass

wood screws.
3. Timber surfaces using minimum 6 mm countersunk brass screws.
4. All insulated enclosures using an approved plastic welding adhesive.
5. For all buried cables and conduits.
END OF SECTION

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SECTION 16425
POWER DISTRIBUTION BOARDS

PART 1: GENERAL
1.01 GENERAL REQUIREMENTS AND RELATED DOCUMENTS

the Section. Cooperate with such trades to assure the steady progress of
A. This Specification is for extent of power distribution boards including all

types of main or sub-main distribution boards and load centers referred to
the drawings, schedules and elsewhere within this Specification.
1.03 GUARANTEES
A. Attention is directed to provisions of the General Terms and Conditions and

Special Conditions regarding guarantees and warranties for work under this
Contract.
A. Manufacturers: Firms regularly engaged in manufacture of distribution

boards and enclosure, of types and sizes and rating required, whose
products have been in satisfactory use in similar service for not less than10
years.

required for the project.
C. Special Use-Markings: Provide distribution boards constructed for special

use, with British Standards marks indicating that special type usage.

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D. Comply with applicable BS safety standards pertaining to distribution board

and accessories, and enclosures.
E. IEE Compliance: Comply with IEE as applicable to installation of

distribution board, cabinets, and cutout boxes. Comply with IEE articles
pertaining to installation of wiring and equipment in hazardous locations.
F. BS Compliance: Comply with BS Standards Publications for Electrical

Equipment.
1.05 SUBMITTALS
A. Product Data: Submit manufacturer's data including schematic drawings,

layout of enclosure and distribution of protective devices, technical
specification, installation instructions and general recommendations for
each type of distribution board required. Include data and sizes
substantiating that units comply with requirements.
A. Handle distribution boards carefully to prevent breakage denting or

scoring the finish. Store distribution boards inside and protect from weather.
When necessary to store outdoors, elevate well above ground and enclose
durable, waterproof wrapping.
PART 2: PRODUCT
2.01 CUBICLE CONSTRUCTION
A. Cubicle pattern main or sub-main distribution boards shall be supplied by

the manufacture of the component protective devices and shall comply with
BS 5486: Part 1 (IEC 60439-1 Form 4).
B. The distribution board enclosures shall be either pressed or fabricated from

sheet steel having a minimum thickness of 1.5 mm. The steel shall be
electro zinc plated, (Zintec) and shall have a minimum of priming coat,
undercoat and finishing coat of paint. The undercoat and finished coat shall
be stove enamelled.
C. The distribution board shall house the main circuit breaker, feeder circuit
breakers, instrumentation service entrance of incoming cables or bus- duct
and manual transfer switch.
D. The distribution board shall be dead front type, completely enclosed, self
supporting structure approximately 2.0m high, independent of wall
supports.

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E. The distribution board construction shall be of the universal frame type

using die-formed members bolted and braced. The sides, top and rear shall
be covered with removable screw-on plates having formed edges all
around.
F. The distribution board shall consist of the required number of vertical

sections bolted together to form one rigid distribution board incorporating
switching and protective devices of the number, ratings and type noted here
in or shown on the drawings with all necessary interconnections,
instrumentation and control wiring.
G. The distribution board shall incorporate bus-bars which shall be of hard

drawn high conductivity copper. These bars shall be TPN + E of the size
required. In all cases the bus-bars shall be noted at not more than 1
ampere per square mm of a minimum 50% of the full rated estimate total of
MCCBs connected to them. All bus-bar shall be supported on porcelain
insulators, or on laminated bakelite carriers to withstand mechanical
forces exerted during short circuit conditions when directly connected to a
power source having the indicated available short circuit current.
H. Small w i r i n g , necessary fuse blocks and terminal blocks within

the distribution board shall be furnished when required. All groups of
control wires leaving the distribution board shall be provided with terminal
blocks with suitable numbering strips.
I. An earthing bus and lugs shall be furnished firmly screwed to each

vertical section structure and shall extend the entire length of the
distribution board.
J. The distribution board shall be provided with adequate lifting means and
shall be capable of being rolled or moved into installation position and
bolted directly to the floor without the use of floor sills.
K. The distribution board shall contain a glanding plate at top and/or bottom
of the board to allow easy terminating of cable glands with room to install
and connect cable trays etc.
L. Complete block, power and control and wiring diagrams shall be included.
All wiring shall be numbered. Full details technical data shall be supplied
about all parts inside the MDB (main breakers, sub-main breakers, over
loads, contractors … etc.).
All C.BS and instrumentation’s inside and outside the MDB shall be
labeled both in English and Arabic. The writing shall be white on plastic
plates with black background. Labels shall be fixed by small screws on
the devices or the base that house the device. Labels also shall be put
on the outside door (indicating lamps, gauges, breaker’s hand, keys …
etc.).

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M. The MDB shall have covered empty spaces for future use at the button of
the panel. None electric field’s metal cover shall be used to prevent cable
heating.
2.02 MAIN CIRCUIT BREAKER
A. The main circuit breaker shall be a be fixed mounted front removable or

withdrawable type of moulded case or air type as indicated on the
drawings or specified on section 16426 Protective Devices. The Breaker
shall be in accordance with Local Electricity Board specification if inter-
faced with Their supply.
2.03 FEEDER BRANCH CIRCUIT BREAKERS
A. The feeder protective devices shall be moulded case circuit breakers

MCCB as described in Section 16426 Protective Devices and as shown
on drawings.
B. Circuit breakers shall be equipped with individually insulated, braced and

protected connectors. The front faces of all circuit breakers shall be flush
with each other. Large, permanent, individual circuit numbers shall be
affixed to each breaker in a uniform position and equip each breaker with
a circuit card holder and neatly printed card identifying the circuit. Tripped
indication shall be clearly shown by the breaker handle taking a position
between ON and OFF. Provisions for additional breakers shall be such
that no additional connectors will be required to add breakers.
C. The feeder or branch devices shall be removable from the front and shall
be individually mounted with the necessary device line and load
connections front accessible.
2.04 METERING AND INSTRUMENTATION
A. The MDB shall have the following as a minimum:
1 Indicating lamps for the incoming 3 main phases (Red, Yellow,

Blue).
2 The MDB shall have the following breakers with the capacities
shown on the Drawings:
a. Electromagnetic main moulded circuit breaker (MCCB). It

shall be thermally and magnetically protected. Both
protections shall be adjustable. The CB shall be 3 pole or 4
pole as in the DRG.
b. Electromagnetic (MCCB), 3P, for every sub-circuit in the

MDB as per the Drawings.
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3 The MDB shall have 3 (A-meter) suitable for the panels load
supplied with 3 CTS. It shall also have a volt-meter with a
selector switch for the three phase and the neutral. A
frequently (HZ) gauge shall also be supplied. All gauges are
for the incoming supply.
4 The MDB shall be working at 3 phase, 400 volts,

50HZ.
5 The main MDB’s door shall normally be un-openable without

putting the external’s main breaker handle off. In addition to
this the external (On, Off) handle shall have an obvious screw
to open the panels door without turning the breaker off.
2.05 1600 A LOW TENSION DISTRIBUTION BOARD (Single busbar)
A. General
The low tension distribution board has to be used for 11/0.4 kv

distributions substation indoor type supplied with 220/380/415 volt as
main supply twin section busbars have rate of 1600 A. The frame of
switch board should be made from steel sheet not less than 1.5mm in
thickness and the treatment should be with not even process and antirust
process before enameling anti condensation heater is requested.
All the incoming and outgoing cable feeder should be connected through
the bottom of the switch board the cable size for the incoming feeder are
seven single core with 630 sq mm.
The cable holes should be with cable gland.
The switch board should be factory assembled with all equipment

according to the specifications mentioned below and satisfy IEC standard
(60439-1 Form4).
B. Low tension distribution board (1600A):
1A- Rated insulation voltage 1000 volt

1B- Rated operation voltage 690 volt
2- Insulation test voltage 2500 volt
3- Operating voltage 220/380/415 volt
4- Frequency 50 Hz
5- Ambient temperature - 5/50 c
6- Protection degree of enclosure JP4X
7- Dynamic strength 1 sec. 35 KA
8- Rated current of busbar system 2000A

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9- Size of main cable supply with gland 1 *630sq mm

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10- Number of supplying cables 7 cable (single core)

11- Rated current of supplying feeder 1600A
12- Rated current of busbar section MCCB 1600A
13- Dimension of distribution board:
A- Height 2m
B- Width 2.70 m
C- Depth 0.80 m
2.06 1600 A LOW TENSION DISTRIBUTION BOARD (Double busbar)
A. General
The low tension distribution board has to be used for 11/0.4 kv

distributions substation indoor type supplied with 220/380/415 volt as
main supply twin section busbars connected together with 1600A MCCB
have rate of 1600A. The frame of switch board should be made from
steel sheet not less than 1.5mm in thickness and the treatment should be
with not oven process and antirust process before enameling anti
condensation heater is requested.
All the incoming and outgoing cable feeder should be connected through
the bottom of the switch board. The cable size for the incoming feeder
are 14 single core with 630sq mm.
The cable holes should be with cable gland.
The switch board should be factory assembled with all equipment

according to the specifications mentioned below and satisfy IEC standard
60439-1 Form 4.
B. Low tension distribution board (1600 A)
1A- Rated insulation voltage 1000 volt

1B- Rated operation voltage 690 volt
2- Insulation test voltage 2500 volt
3- Operating voltage 220/380/415 volt
4- Frequency 50 Hz
5- Ambient temperature - 5/50 c
6- Protection degree of enclosure JP4X
7- Dynamic strength 1 sec. 35 KA

8- Rated current of busbar system 2000A
9- Size of main cable supply with gland 1 *400sq mm
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10- Number of supplying cables 12 cable

11- Rated current of supplying feeder 1600A
12- Rated current of busbar section MCCB 1600A
13- Dimension of distribution board:
A- Height 2m
B- Width 3m
C- Depth 0.80 m
PART 3: EXECUTION
3.01 INSTALLATION
A. Install power distribution boards, including electrical connections, in

accordance with the Manufacturer's written instruction, applicable with
recognized industry practices to ensure that products serve the intended
function.
B. Co-ordinate installation of power distribution boards with cable and

C. Install only in permanently dry locations away from all mechanical and
public health services.
D. Anchor enclosures firmly to structural surfaces, ensuring that they are

permanently mechanically secured.
E. Check ratings of all circuit protection devices.
F. Provide electrical connection within enclosures.
G. Fill out power distribution boards directory card upon completion of

installation work.
3.02 FIELD QUALITY CONTROL
A. Prior to energisation of circuitry, check all accessible connections to

manufacturer's torque specifications.
B. Prior to energisation of distribution boards, check with earth resistance

tester phase-to-phase and phase-to-earth insulation resistance levels to
ensure requirements are fulfilled.
C. Prior to energiesation, check distribution boards for electrical continuity of

circuits, and for short circuits.
D. Subsequent to wire and cable hook-ups, energies distribution boards and

demonstrate functioning in accordance with requirements.
END OF SECTION
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SECTION 16426
LOW VOLTAGE PROTECTIVE DEVICES

PART 1: GENERAL

B. Coordinate work with that of all other trades affecting or affected by work
of the Section. Cooperate with such trades to assure the steady progress
of all work under the Contract.
C. All MCCB and MCB's shall be of the same manufacturer.
A. Extent of protective device work is indicated by drawings and schedules.
B. Types of protective devices in this section include the following:-

- Main circuit breakers
- Moulded case circuit breakers
- Miniature circuit breakers
- Residual current circuit breaker
- Cartridge fuses
1.03 GUARANTEES

CONDITIONS AND SPECIAL CONDITIONS regarding guarantees and
warranties for work under this Contractor.
B. Manufactures shall provide their standard guarantees for work under this
section. However, such guarantees shall be in addition to and not in lieu
of all other liabilities which manufacturers and Contractors may have by
law or by other provisions of the Contract Documents.
A. Manufacturers: Firms regularly engaged in manufacture of protective

devices of types, sizes and ratings required, whose products have been in
satisfactory use in similar service for not less than 10 years.

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B. Installer: Qualified w i t h a t l e a s t 5 y e a r s o f s u c c e s s f u l
i n s t a l l a t i o n experience on projects with electrical installation work
similar to that required for the project.
C. IEE Compliance: Comply IEE requirements as applicable to construction

and installation of protective devices.
D. BS Compliance: Comply with applicable requirements of the BS

Standards publications for moulded case miniature and power type circuit
breakers.
1.05 SUBMITTALS
A. Product Data: Submit manufacturer's data on protective devices,

including catalogue cuts, time current trip characteristic curves, and
mounting requirements.
B. Maintenance Stock, Fuses: For types and ratings required, furnish

additional fuses, amounting to one unit for every 5 installed units, but not
less than one unit of each.
PART 2: PRODUCTS
2.01 MAIN CIRCUIT BREAKER
A. The main circuit breakers shall be of air or moulded case type and shall
comply with BS 4752 (IEC 157.1).
B. The main circuit breaker shall be fixed mounted front removable or

withdrawable type with current monitor and solid state sensor for phase
and earth sensing protection. The static sensor shall have adjustable
settings for each of the following tripping characteristics:-
- Long - delay pick up point

- Long - delay tripping time
- Short - delay pick up point
(Instantaneous protection)
- Earth point pick up
- Earth tripping time
C. Extra facilities may be required such shunt trips, undervoltage release,

auxiliary switches, self and remote indications monitor, motorized for
remote control, load monitoring, measurement of phase currents,
maximum current and fault currents.

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2.02 MOULDED CASE CIRCUIT BREAKERS
A. Moulded case circuit breakers (MCCB's) shall comply with BS 3871: Part
2 for ratings up to 100A and BS 4752 (IEC 157.1) for ratings above 100A.
They shall be of the quick-make, quick-break, trip-free, thermal magnetic
adjustable releases or with solid state trip units complete with De-ion arc
grids, alloys contacts and inter-pole contacts. All units shall incorporate a
visual indication of open or closed contacts.
B. Extra facilities may be required, such as shunt trips, under-voltage

release, auxiliary switches, remote indications or tripping, residual current
protection or special calibrations. Such extra facilities shall be specified
elsewhere in this specification or on the drawings.
C. The Contractor shall supply 1 no. spare MCCB of every current rating and
type used on the Project. These spare MCCB's shall be handed to the
Engineer, and signed for upon practical completion of the works.
2.03 MINIATURE CIRCUIT BREAKERS (MCB)
A. Miniature circuit breakers (MCBs) shall be plastic moulded units

incorporating thermal magnetic protection against overloads and short
circuits, and shall comply with BS 3871 Part 1. The tripping mechanism
shall be designed to provide delays operation on overload and
instantaneous operation under fault condition. Breakers shall have
positive ON/OFF indication, be "trip free" and shall trip to the full off position
under overload and/or short circuits. Triple pole units shall be used for three
phase circuits. All multiple breakers shall have an integral common trip bar
as standard.
B. The circuit breakers shall be grouped and mounted on removable cradles.

Each group shall be connected to a common bus bar of the appropriate
phase.
C. Where the fault level of the system is such that the use of MCBs is not
acceptable, then moulded case circuit breakers (MCCBs) as specified
elsewhere shall be utilised.

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2.04 RESIDUAL CURRENT CIRCUIT BREAKER

A. Residual current circuit breaker (RCCB) shall comply with BS 4293 and BS
3871 - Part 1 and shall generally comprise a solid state sensing device, trip
coil/mechanism, contact system/switching mechanism.
B. The sensitivity of the breaker shall be 300, 30, 10 or 5 mA maximum

tripping time of 30 ms.
C. Each breaker shall incorporate a test circuit with a test button to simulate
fault conditions.
D. The combined units shall be compatible with other MCBs installed within
distribution boards.
E. The Contractor shall supply 1 no. spare RCCB of every current rating,
sensitivity and type used on the project. These spare RCCB shall be
handed to the Engineer, and signed for upon practical completion of the
works.
2.05 CARTRIDGE FUSE
A. Cartridge fuse links shall be of the high rupturing capacity (HRC) type and
shall comply with BS 88 Part 2 (IEC 269 - 2).
B. Each HRC fuse link shall be ASTA certified for its claimed breaking
capacity and shall be so mounted that the current rating on each fuse link is
clearly visible.
C. The Contractor shall supply 5 No. spare HRC cartridge fuse links of every
current rating and type used on the project. These spare fuses shall be
handed to the Engineer, and signed for, upon practical completion of the
works.
PART 3: EXECUTION
3.01 INSTALLATION
A. Install protective devices as indicated, in accordance with manufacturer's

written instructions and with recognised industry practices to ensure that
with IEE and BS Standards for installation or protective devices.
B. Coordinate with other work, including electrical wiring work as necessary to

interface installation of protective devices with other work.
C. Fasten circuit breakers without mechanical stresses, twisting or

misalignment being exerted by clamps, supports or cable.
D. Set field-adjustable circuit breakers for trip settings as indicated,

subsequent to installation of devices.

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E. Install fuses, if any, in fused circuit breakers.

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F. Inspect circuit-breaker operating mechanisms for malfunctioning and,

where necessary, adjust units for free mechanical movement.
A. Prior to energisation of overcurrent protective devices, test devices for

continuity of circuitry and for short-circuits. Correct malfunctioning units, and
then demonstrate compliance with requirements.
END OF SECTION

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SECTION 16452
EARTHING SYSTEM
PART 1: GENERAL
work of this section whether or not such work is specifically mentioned in
this section.
B. Coordinate work with that of all other trades affecting, or affected by work of
this section. Cooperate with such trades to assure the steady progress of all
work under the Contract.
A. The extent of the earthing system is indicated on the Drawings and by the
requirements of this section.
1.03 GUARANTEES

CONDITIONS and SPECIAL CONDITIONS regarding guarantees and
warranties for work under this Contract.
section. However guarantees shall be in addition to and not in lieu of all
other liabilities which manufacturers and Contractors may have by law or by
other provisions of the Contract documents.
A. Manufacturers: Firms regularly engaged in the manufacture of earthing

equipments, whose products have been in satisfactory use in similar service
for not less than 15 years.
B. Standards: All equipment furnished under these specifications shall

conform to application standard of IEE and BS 7430.
1.05 SUBMITTALS
A. Manufacturers data, illustrated leaflets or products, dimensions, fixing

details, description of products.
B. Submit Master Equipment List in compliance with General Terms and

Conditions and Special Conditions.
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A. All products shall be carefully packed to avoid damage during transit.
PART 2: PRODUCTS
2.01 MATERIALS
A. All earthing materials required shall be furnished new and undamaged in

accordance with the following requirements.
B. Earth rods shall be of a diameter as shown on drawings and to BS

standard.
C. Earth rods of copper alloy or the 'copperweld' (copperclad rods

constructed with a thick copper exterior sleeve inseparably and permanently
molten-welded to a central high tensile steel core for rigidity) type shall be
used to provide a reliable earthing system with good corrosion resistance
and high electrical conductivity with soft drawn bare stranded copper wire
earth cable used to form the earth grids or mats. PVC insulated copper
conductors shall be used for final connections from earth grids/mats to
structures, equipment etc. All copper to copper underground connections,
splices, taps etc. should be made by the exothermic weld process and the
joint epoxy resin encapsulated before burial.
D. Cable shall be as follows:
1. Bare: Soft drawn copper, Class B

stranding.
2. Insulated: Soft drawn copper, Class B
stranding with green/yellow coloured
polyvinyl chloride insulation.
E. Connections shall be made by exothermic welding process or equivalent.

The earth conductor in the conduit run shall be continued through the
conduit run and bushing earth connection and terminated on the panel
board earthing.
F. An earth electrode shall have an interconnected resistance to earth of not

more than 5 ohms. Where this value is exceeded it shall be augmented by
additional electrodes connected in parallel spaced at approximately 4
metres apart until this value is reached.
G. 1. Execution: Generator and generator equipment and boards shall

have separate earthing electrodes.
2. The Neutral of the Low Voltage winding of the transformer shall be

connected to earth bar in sub-station.
3. Earthing bar of the distribution board and L.V. cable sheaths or

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armour shall be connected to the sub-station earth bar.

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4. The Low Voltage neutral shall be earthed at the source substation.
H. 1. The steel conduit systems, metallic equipment enclosures, metallic

lighting fixtures, cable trays, all non-current carrying metal parts of
electrical systems, and any other equipment or system components
required by the latest BS code and IEE regulations shall be earthed
and the connection shall be made at the panel boards bus and shall
be extended to earth electrodes as hereinafter specified.
2. The c o n d u i t s y s t e m shall not be considered as continuous

for earthing purposes. A separate earth conductor shall be
installed in the same conduit with the phase and neutral
conductors. The separate earth conductors shall be sized
according to the BS Code and IEE requirements. No earthing
conductors shall be smaller than 2.5 mm2 unless this is part of
a multicore cable. Where flexible connections are made to
equipment, earthing jumpers shall be provided. All connections
of heavy gauge steel conduit system shall be checked for good
electrical continuity.
1. All electrical equipment shall be connected to the earth grid with
copper earth conductor. The term "electrical equipment" shall include
all metal enclosures containing electrical connections or bare
conductors excepts that individual devices such as solenoids,
pressure switches, and limit switches shall be exempt from this
requirement unless the device requires earthing for proper operation.
Large equipment such as power distribution board or motor control
centers shall be furnished with an earthing bus which the Contractor
shall connect to the earth grid. All earth connection surfaces shall be
cleaned immediately prior to connection. The Contractor shall provide
all earthing material required but not furnished with the equipment.
2. Where earth grid extension conductors are indicated on the Drawings

to be provided for connection to electrical equipment, the Contractor
shall connect the bare earthing conductor to the equipment, earth
bus, pad or lug. In addition to the earth grid extension conductors, an
earth cable to each end of the earth bus in each assembly of power
distribution board or panel boards. Where an earth conductor is
included with the phase conductors of power circuits, the earth
conductor shall be connected to the equipment earthing facilities and
to the source earth bus. Where an earth conductor is not included
with the phase conductors, the equipment shall be earthed by
connecting a separate earth cable to the equipment earthing facilities
and to the tray earthing cable or source earth bus. Except where
otherwise indicated on the Drawings, integral parts of a cable
assembly shall be sized in accordance with the requirements of the
IEE. All earth conductors installed in conduit shall be insulated.
J. Earthing bars shall be high conductivity, soft copper, cross section not
less than 3 mm thick by 25 mm wide.

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K. Exothermic welds shall comprise moulds, cartridges, materials, and

accessories as recommended by the manufacturer of the moulds for the
items to be welded.
L. Clamps, connectors, bolts, washers, nuts and other hardware used with
the earthing system shall be of copper.
PART 3: EXECUTION
3.01 INSPECTION
A. The Contractor shall examine the area and conditions under which the
earthing systems is to be installed and correct any unsatisfactory conditions
detrimental to the timely and proper completion of the work. Do not proceed
with the work until the conditions are satisfactory in a manner acceptable to
the Engineer.
3.02 INSTALLATION
A. Earth Rods: Where the ground conditions make it possible, earth rods shall
be the preferred earth. All earth rods shall be located in suitable locations
and installed to the depth requires to achieve stated resistance. Where the
required earth rod length exceeds 2.5 metres, standard sections shall be
welded together to provide an extended rod with open true center line and a
minimum of joint resistance. During welding, the earth rod sections that
have been welded shall be supported by a guide.
B. CONDUCTORS:
1. Exposed conductors shall be installed inconspicuously in vertical

or horizontal positions on supporting structures. When located on
irregular supporting surfaces or equipment, the conductors shall
run parallel to or normal to the dominant surface.
2. Conductors routed over concrete, steel or equipment surfaces

shall be kept in close contact with those surfaces by using
fasteners located at intervals not exceeding 1 metre.
3. Standard sizes of stranded copper conductor used for

earth continuity shall be according to IEE regulations.
4. Suitable earthing facilities, acceptable to the Engineer, shall

be furnished on electrical equipment consist of compression
type terminal connectors bolted to the equipment frame or
enclosure and providing a minimum of joint resistance.
C. All earth rods shall have inspection pits as shown on drawings. The pit shall
be constructed from precast concrete. All connections to the earth rod shall
exposed when the cover is raised. Attach a "DANGER - ELECTRICITY"
sign to the wall of the inspection pit. Use English and Arabic white letters on
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red background. Inspection pit cover shall be constructed from cast iron.

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D. Earthing conductors shall be installed in 50 mm PVC duct at entry points

into building. Duct route shall be from 1 m outside the building to concrete
cable trench within building. Conductors shall be clipped to side or base of
trench.
E. All connections between rods and earthing tape or cables shall be made by
the exothermic process which produces a fused joint. Bolted connections
may be used for connection to removable items of equipment only.
Joints in copper tape shall be made by either welding or brazing.
Earth rods shall be driven with a cap driving stud. Earth conductors shall be
buried to a minimum depth of 600mm below finished grade.
Exposed earthing tape and conductors shall be securely fastened to the

mounting surface using copper or brass straps.
3.03 EARTH LOOP IMPEDANCE
A. The completed earthing system shall have sufficiently low impedance to

limit the voltage to earth and to facilitate the operation of the current
protective devices in the circuit.
3.04 EARTH RESISTANCE
A. Prior to connection of earth rods to the earthing system the Contractor shall
obtain individual measured earth resistance data from selected earth rods,
recorded under his supervision, and the results sent to the Engineer within
5 days.
B. After connection of earth rods to the earthing mat, the Contractor shall
obtain an earthing resistance measurement from the earthing test point.
The data shall be obtained, identified and recorded, and the results sent to
the Engineer within 5 days.
C. Final resistance measurement form the earthing system electrodes shall be

done in the hot season (end of August).
3.05 COMMUNICATION EARTHING
A. 1. All PABXs shall have an independent earthing system used on a

functional earth to BS 6701: Pt1. The earthing cable inside the
building shall be 50 sq mm wire moisture and heat resistance PVC
insulation to earth bus in telephone equipment room.
2. Provide one 35 sq mm wire with moisture and heat resistant PVC

insulation to telephone service conduit.

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3. Provide one 4 sq mm wire with moisture and heat resistant PVC

insulation to conduits termination at backboard.
B. Fire Alarm and Detection: Provide one 10 sq mm wire with moisture and
heat resistant PVC insulation in 20 mm in conduit to nearest earth bus.
C. Public Address Sound System: Provide one 10 sq mm with moisture and

heat resistant PVC insulation in 20 mm conduit to nearest earth lug in
equipment rack.
3.06 SUPPLEMENTARY AND EQUI-POTENTIAL BONDING
A. In accordance with Section 547 of the IEE Wiring Regulations 16th

Edition (BS 7671) bonding conductors shall be installed in appropriate
locations to ensure all simultaneously accessible exposed or extraneous
conductive parts are at equal potential. The Contractor shall undertake such
tests and install such supplementary bonding conductors that are necessary
to ensure compliance with these requirements.
B. Supplementary bonding conductors shall conform to the requirements of

Section 547-03 of the IEE Wiring Regulations 16th Edition (BS 7671) and
shall have a minimum cross-sectional area of 2.5 sq.m where
mechanically protected and 4.0 sq.m where not so protected.
C. Main equi-potential bonding conductors shall conform to the requirements

of Section 547-2 of the IEE Wiring Regulations and shall have a minimum
cross-sectional area of 6.0 sq.mm.
3.07 LIGHTNING PROTECTION
A. For lightning protection system and earthing requirements see section

16670.
A. Earth resistance tests shall be carried out after installation of the

individual earthing systems in accordance with the specification. The
earth resistance tests shall be carried out in accordance with Section 713-
11 of the IEE Wiring Regulations 16th Edition and readings obtained
officially recorded by all witnessing parties.
END OF SECTION

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SECTION 16470
PANEL BOARDS
PART 1: GENERAL
this section.
the Section. Cooperate with such trades to assure the steady progress of all
A. This Specification is for extent of all types of lighting and power panel
boards including cabinets cut out boxes, as indicated by drawings,
schedules and elsewhere within the Specifications.
1.03 GUARANTEES
A. Attention is directed to provisions contained elsewhere regarding

guarantees and warranties for work under this Contract.
B. Manufacturers shall be provide their guarantees for work under this

A. Manufacturers: Firms regularly engaged in manufacture of panel boards

and enclosure, of types and sizes and ratings required, whose products
have been in satisfactory use in similar service for not less than 10 years.

requirement for the project.
C. Special Use-Markings: Provide panel boards, constructed for special use,

with British Standards marks indicating that special type usage.

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D. Comply with applicable BS safety standards pertaining to panel board and

accessories, and enclosures.
E. IEE Compliance: Comply with IEE requirements as applicable to
installation of panel boards, cabinets, and cutout boxes. Comply with IEE
articles pertaining to installation of wiring and equipment in hazardous
locations.
F. BS Compliance: Comply with BS Standards Publications for Electrical

Equipment.
1.05 SUBMITTALS
A. Product Data: Submit manufacturer's data including and schematic

drawings layout enclosure and all accessories inside panelboards
specifications, installation instruction and general recommendations for
each type of panelboard required. Include data substantiating that units
comply with requirements.
1.06 DELIVERY, STORAGE AND HANDLE OF MATERIALS
A. Handle panelboards and enclosure carefully to prevent breakage, denting

or scoring the finish. Store panelboards and enclosure inside and protect
from weather. When necessary to store outdoors, elevate well above
ground enclose with durable, waterproof wrapping.
PART 2: PRODUCT
2.01 GENERAL
A. Lighting, Power Branch Circuit and Distribution panel boards, shall

conform to code. The complete Technical Specification providing bus size,
size and number of branch circuit breakers, branch circuit loads and wiring
is provided for each panel board in the contract electrical schedule volumes.
B. Enclosures: IP55 suitable for recessed or surface monitoring.
C. Interior components shall be mounted on back plate of reinforced steel for

rigid support and accurate alignment.
D. One flat key tumbler cylinder type door look with two keys per lock shall be
provided.
E. Provide for enclosure earthing in accordance with Section 16452.
F. Bus bar: Hard drawn high conductivity copper, with silver plated contact
surface and the following additional requirements.

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G. Finish: Baked grey enamel finish with rust inhibitor.

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H. Provide circuit breakers in accordance with Section 16426. Provide two

adjacent single pole breakers to opposing polarities in such a manner that
two pole breakers can be installed in any location. The same shall be for
three adjacent single pole breakers to opposing polarities.
I. Neutral and Ground buses shall be of the same rating as the phase bus.
J. Nameplate: One 25 mm wide laminated plastic, attached by means of

stainless steel rivets or permanent adhesive, showing panelboard number
in 13 mm white cut-in letters on black background.
K. A directory holder with clear plastic or glass plate and metal frame shall be
mounted on the inside of each door.
L. Protection degree shall be according to IEC.
2.02 LIGHTING AND POWER PANELBOARDS
A. The panelboards shall be of the dead front type with bolt-on circuit
breakers in the mains, if indicated, and branches. The panelboards shall be
designed for 400/220 volts, 3-phase, 4-wire, 50Hz application.
B. The lighting and power panelboards shall be equipped with bolt-on or plug-
in type circuit breakers. Circuit breaker ratings shall be as shown in the
panelboard schedules. Plug on type circuit breakers are not acceptable.
C. Continuous current rating of busbars shall be as shown on panel board

schedules.
D. Where a main protective device is not shown, disconnect switches shall be

provided. Bus bar and branch devices shall be of the sequence-phase type
connections.
E. The neutral and a grounding bar shall be mounted at the opposite end of
the structure from the mains and shall have numbered terminals for
connection of neutral and grounding wires.
2.03 DISTRIBUTION PANELBOARDS
A. Distribution panelboards shall be of the deadfront type and shall be

designed for 400/220 volts, 3-phase, 4-wire, 50Hz applications. Each
distribution panel shall be enclosed in a sheet metal cabinet with front
doors, catches, locks, etc. Locks shall be fitted for the same key as locks
on other lighting and power branch circuit panelboards. All distribution
panelboards shall meet pertinent standards.
B. The distribution panelboards shall be equipped with bolt-on moulded case

circuit breakers. Circuit breaker ratings shall be as shown on the distribution
board schedules.

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C. Where a main protective device is not shown disconnect switches shall be

provided. Current-carrying connections to bus shall be of the bolted type,
factory assembled. Bus bars shall be of the sequence-phase type
connections and arranged for 3-phase, 4-wire mains or lugs.
D. The Neutral Bar shall be mounted at the opposite end of the structure from
the mains and shall have numbered terminals for connection of neutral
wires.
E. Each Distribution Board shall be equipped with three ampere meters, volt
meter and a selector switch.
2.04 NAMEPLATES
A. Each panel board shall have an affixed engraved nameplate. The

nameplate shall be both in English and Arabic.
B. Each distribution panelboard switch shall be equipped with a nameplate

which indicates the name of the equipment (motor, panelboard, etc.,) to
which the feeder conductors are connected. Where more than one piece of
equipment or panelboard is connected to the circuit this fact shall also
appear on the nameplate. Feeder numbers used on the drawings shall be
applied on the switch nameplates.
PART 3: EXECUTION
3.01 INSTALLATION
A. Install panelboards and enclosures, including electrical connections, in

accordance with the manufacturer's written instructions, applicable
requirements of the IEE Wiring Regulations, 16th Edition and in accordance
with recognised industry practices to ensure that products serve the
intended function.
B. Co-ordinate installation of panelboards and enclosure with cable and

C. Install only in permanently dry locations away from all mechanical and
public health services.
D. Anchor enclosure firmly to walls and structural surfaces, ensuring that they
are permanently mechanically secured.
E. Check ratings of all circuit protection devices.
F. Provide electrical connections within enclosures.
G. Fill out panelboard's directory card upon completion installation works.

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A. Prior to energisation of circuiting, check all accessible connections to

manufacturer's torque Specifications.
B. Prior to energisation of panelboard, check with earth resistance tester

phase-to-phase and phase-to earth insulation resistance levels to ensure
requirements are fulfilled.
C. Prior to energisation, check panelboard for electrical continuity of circuits,

and for short circuits.
D. Subsequent to wire and cable hook-ups, energise panelboards and

demonstrate functioning in accordance with requirements.
E. A separate earthing bus, marked with a yellow green strip along its front
and bonded to the steel cabinet, shall be provided for connecting all earth
conductors. Bus bars shall be copper, shall be securely fastened to
bases, and shall not depend upon breakers for support. All main buses and
back pans shall be so designed that branch breakers may be
changed without additional machining, drilling, or tapping.
F. Panelboard assembly shall be so designed that any individual breaker can

be removed without disturbing adjacent units or without loosening or
removing supplemental insulation supplied as a means of obtaining
clearances and other requirements of BS standards.
G. Provide panelboard accessories and devices including, but not

necessarily limited to, cartridge and plug time-delay type fuses, circuit
breaker, earth fault protection units, etc., as recommended by panelboard
manufacturer for ratings and applications indicated.
H. Construction shall allow maintenance of incoming line terminations, main

device connections and all main bus bolted connections to be performed
without rear access.
END OF SECTION

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SECTION 16510
INTERIOR AND EXTERIOR LIGHTING

PART 1: GENERAL
this section.
the Section. Cooperate with such trades to assure the steady progress of all
A. This specification is for extent of interior and exterior lighting fixture work as
indicated by drawings and schedules.
B. Types of interior and exterior lighting fixtures in section include the

following:
Incandescent Spotlight / Downlight Fluorescent

Discharge Lamp Luminaires
C. Applications for interior and exterior lighting fixtures required for project
include the following:
General interior lighting

Exterior lighting
1.03 GUARANTEES
A. Attention is directed to provisions contained elsewhere regarding

guarantees and warranties for work under this Contract.
A. Manufacturers: Firms regularly engaged in manufacture of lighting

fixtures of types and ratings required, whose products have been in
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satisfactory use in similar service for not less than 10 years.

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B. Installer: Qualified with at least 5 years of successful installation and

experience on projects with interior lighting fixtures similar to that required
for this project.
C. IEE Compliance: Comply with requirements as applicable to construction of

interior building for this project.
D. CIBSE Code for Interior Lighting 1994.
E. BS Compliance: Comply with applicable requirements of BS Standard

Publications pertaining to lighting equipment.
F. CBM Labels: Provide fluorescent lamp ballast which comply with Certified
Ballast Manufacturers Association Standards and carry the CBM Label.
1.05 SUBMITTALS
A. Product Data
Submit manufacturer's data on interior and exterior lighting fixtures.
B. Shop Drawings:
Submit dimensioned drawings of lighting fixture installations, including but

not necessary limited to, layout, relation to associated panelboards, and
connections to panelboards. Submit fixture shop drawings in booklet form
with separate sheet for each fixture, assembled in luminaire "type"
alphabetical order, with proposed fixture and accessories clearly indicated
on each sheet.
A. Luminaires, lamps, and accessories shall be delivered to the job site

wrapped in protective covering and stored in a dry location free from dust or
water, and in such a manner to permit easy access for inspection and
handling. Luminaires, lamps, and accessories shall be handled carefully to
prevent damage. Damaged items shall be replaced at no additional cost.
PART 2: PRODUCTS
2.01 INCANDESCENT AND SPOTLIGHT
A. All lighting fittings shall be furnished complete with internal wiring, lamps
and lamp holders, leads, trim, rings, frames, hangers and reflectors.
B. Lighting fittings shall be of sizes, types and ratings as indicated on

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drawings and schedules.

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C. All wiring within the lighting fittings shall be suitable for the voltage,
current and temperature to which insulation will be subjected.
2.02 FLUORESCENT LUMINAIRES
A. All luminaire control gear components and wiring shall be enclosed in a

steel canopy, protected from corrosion.
B. Recessed, surface and suspended mounted luminaires shall be designed

for use with control gear having maximum case temperatures, suitable for
use in ambient temperatures and conditions where they are to be
installed.
C. All luminaires shall be labelled where visible with the voltage, frequency,
current rating to include control gear and lamp(s), manufacturer's name
and fixture type.
D. All ballasts shall be of the quickstart dry type, epoxy resin insulated.
E. Where reflector and white louvre assembly is specified, the reflector shall
be constructed from highly polished aluminum.
F. All wiring within the luminaires shall be suitable for the voltage, current
and temperature to which insulation will be subjected.
G. All luminaires shall be fitted with dry type high power factor correction
capacitors correcting to 0.9 lagging, rapid start and low noise features;
type 1 class P; sound rated A, and with internal thermal protection.
H. The metal canopy shall be finished with a white high gloss stove
enamelled paint.
I. All luminaires shall be fitted with radio interference suppression.
2.03 DISCHARGE LAMP LUMINAIRE
A. Discharge lamp luminaires shall be of a type as specified on the Drawings

and schedule.
B. They shall generally be of a type suitable for use with mercury vapour or
sodium vapour type lamps and shall have integral control gear unless
C. Where control gear is to be separately mounted, it shall be completely

enclosed in a metal clad type enclosure complete with conduit entry facilities
and fixing accessories.
D. Power factor correction capacitors shall be supplied of adequate rating to

provide an overall circuit power factor not less than 0.85 lagging.

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E. Luminaire enclosures for internal use shall be fabricated from sheet

steel,finished in a corrosion and abrasion resistant paint finish or shall be of
cast alloy similarly resistant to corrosion or abrasion. All enclosures shall be
complete with conduit or glanded cable entry and all necessary support and
fixing accessories.
2.04 PROTECTION OF ELECTRICAL EQUIPMENT
A. All electrical equipment enclosures shall be classified in accordance with

BS 5490 using the IP systems and two digit number code.
B. All equipment for outdoor use shall be dustproof and weatherproof as

classification IP 54 minimum.
C. All equipment for use in hazardous areas shall conform to the

requirements of BS 5345 and BS 5501 and be appropriate to the
classification of the hazard.
2.05 LAMPS
A. Every incandescent lighting point shall be complete with the number and
size of lamps required and each lamp shall be suitable for the mains
voltage of 220 volts.
Unless otherwise indicted lamps shall be coiled coil, pearl finish. Up to

and including 150 watts, lamps shall have bayonet caps, larger sizes shall
be fitted with the appropriate ES cap. for general service with an average
life expectancy of 750 hours and light output of 13-15 lumens per watt.
Special purpose high output lamps shall consist of a tungsten filament

housed in a halogen filled quartz tube giving a light output of 17-22
lumens/watt and a life expectancy of 2000 hours.
B. Tubular fluorescent lamps shall conform to the requirements of

ANSI/NEMA or approved equipment and shall be of the bi-pin type. They
shall be of 26mm diameter T8 - tri-phosphor krypton filled type or 38mm
diameter T12 - halo-phosphate type according to the design of luminaire
in which they are to be mounted.
The electrical characteristics shall conform to the following:-
AVE TUBE POWER

LENGTH LIGHT OUTPUT CONSUMPTION
TYPE OF TUBE MM LUMENS WATTS
T8-Tri- 600 1200 18

Phosphor 1200 3000 36
T12-Halo- 600 1200 20

Phosphate 1200 30`0 40
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2400 9400 125

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Average life expectancy 5000 hours.
The standard colour shall be "WHITE" 4000 degree K colour No. 84,
unless otherwise specified.
C. High pressure mercury vapour discharge lamps shall generally conform to

BS 3677 or approved equivalent and shall be MBF style in ratings 50W to
125W to MBFI style in ratings 250W to 1000W.
The lamps shall be suitable for operation in cap position as denoted in the
luminaire in which it is intended they are to be used. The lamps shall be
capable of maintaining an average life of 5000 hours with an average light
output of 40-45 lumens/watt, in the 50-125W sizes and 65-85 lumens/watt
in the 250-1000W sizes.
D. High pressure sodium vapour discharge lamps shall be of high pressure

type (SON).
Lamps shall be suitable for operation in the cap position required in the
luminaire in which it is intended they are to be used. The lamps shall be
capable of maintaining an average life of 8000 hours with an average light
output of approximately 100 lumens/watt.
E. Compact fluorescent lamps shall be of the type as indicated on drawing in

a huge of wattage of 9-35.
Lamps shall be suitable for operation in the cap position as denoted in the
luminaire in which it is intended they are to be used.
F. Metal halide discharge lamps shall be suitable for operation in cap

position as denoted in the luminaire in which it is intended they are to be
used.
The lamps shall be capable of monitoring an average life of 5000 hours

with an average light output of 66-85 lumens.
2.06 LAMPHOLDERS AND STARTERS
A. Lampholders for incandescent and mercury vapour lamps, shall conform to

UL 496.
B. Lampholders, starters and starter holders for fluorescent lamps shall

conform to UL 542.
C. Provide mechanical self retaining neoprene gasket of dust and moisture proof
seal between bulb and lampholder.
2.07 BALLASTS
A. Ballasts for mercury vapour and sodium vapour lamps shall be provided
in accordance with lamps: ANSI C82.4.
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B. Maximum allowable temperature rise at rated input above an average

ambient temperature of 50 degrees C shall be 115 degrees C.
C. Ballasts for fluorescent lamps shall be rapid start type at least provided in
accordance with IEC, thermally protected type, high power factor and low
losses and of the energy saving type.
2.08 COLUMNS
A. Columns shall be fabricated of round, round tapered, or octagonal section

(as shown on drawings) of galvanised steel designed and tested to
withstand wind velocities of 140 km/hour when fully assembled and
erected, and have a minimum yield strength of 3380 kg/cm². Each
column shall have an oval reinforced hand hole frame to accept a flush
access door fixed with tamper proof screws. Height of columns shall be
as shown on the drawings.
B. Columns shall comply with ASTM standards for welded construction.

They shall be extruded in one section with a full length longitudinal weld
ground smooth to the base metal. The columns shall have a top-dip
galvanised finish applied by total immersion. The column shall be
provided with an anchor base plate and high-strength anchor bolts and
nuts. The base shall house a miniature circuit breaker or fuse with cable
glands as needed.
C. Bracket arms, where required, shall match the column and be designed to
accommodate the required lanterns. The column, bracket arm and
column fittings shall provide a smooth raceway for the column wiring.
D. A grounding terminal shall be provided inside the shaft of the column.
2.09 CONTROLS
A. All external lighting shall be controlled via photo electric cells with the
following characteristics:
i) Supply voltage: as shown

ii) Control load rating: as shown
iii) Sensitivity: switch on 50 lux
switch off 100 lux
iv) Power consumption: Max. 3 watts during daylight conditions @
supply voltage.
v) Delay time for
daytime function: 30 seconds
vi) Ambient temp. range: -20°C to + 50 °C
vii) Net weight: 115 g (approximate)
viii) Mounting: 3 pin locking plug to suit cirlock socket.
Gasket fitting to ensure water / dust tight
fitting.
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ix) Housing: Weatherproof and resistant to ultra violet light.

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2.10 WIRING AND CABLING
A. Provide wiring and cabling in accordance with Section 16120.
2.11 HANDHOLES
A. Handholes shall be provided in accordance with the requirements of the

drawings. They shall be fitted with sufficient inlet and outlet openings for
power cabling and ground wires.
2.12 JUNCTION BOXES
A. Junction boxes shall be code gauge galvanised steel and shall comply with
BS for shapes and sizes to suite their respective locations and installations
and shall be provided with covers to suit their function and installation. An
appropriate expansion fitting shall be installed wherever the conduit run
crosses an expansion joint.
PART 3: EXECUTION
3.01 INSPECTION
A. The Contractor must examine the areas and conditions in which the
luminaires will be installed and correct or bring to the attention of the
Engineer any unsatisfactory conditions before installation commences.
3.02 GENERAL
A. Install lighting fixtures at locations as indicated in accordance with fixture

manufacturer's written instructions, applicable requirements of IEE and BS
"Standard of Installation" and with recognised industry practices to ensure
that lighting fixtures fulfill requirements.
B. The attention of the Contractor is directed to the various types of ceiling

finishes e.g., exposed tee, concealed spline, plaster, etc. Perusal of the
ceiling finish schedule is mandatory.
C. All fixtures shall be furnished complete with lamps. Permanent lighting

fixtures shall be installed after completion of all masonry and structural work
and shall not be used for lighting purposes during construction. The
Contractor shall provide temporary lighting as herein before specified.
D. Mounting heights of fixture are, in most cases, indicated on the drawings.

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Where job conditions require mounting heights different from those specified
or shown to avoid equipment or structural features, etc., such changes in
mounting heights shall be as directed by the Engineer.
E. Lighting fixtures shall be set plumb, square, level and in alignment and shall
be secured in accordance with manufacturer's directions and approved shop
drawings.
F. The Contractor executing the work under this section of the Specifications
shall examine the architectural, mechanical and structural drawings to
acquaint himself with the structural features of the building and the
location of pipes, ducts, etc., which would alter the location or spacing of
outlets to the Engineer for a decision as to the proper location. This
Contractor shall be responsible for the proper reinforcement of any ductwork
necessary to carry the added weight of lighting fixtures where same must be
mounted on the bottom of such ductwork.
G. All conductor installation shall be suitable for the maximum temperatures

they will be subjected to, in luminaire canopies and outlet boxes, etc. Cables
shall be kept clear from the surface of the temperature can reach
90°C.
3.03 INTERNAL LUMINAIRES INSTALLATION
A. Luminaires shall be arranged for surface, recess or pendant mounting as

required by the general structure and decor of the building. Where a
suspended ceiling is provided, recess mounted luminaires shall be fitted
unless otherwise specified or noted on the Drawings.
3.04 SURFACE MOUNTED LUMINAIRES INSTALLATION
A. All surface or pendant mounted luminaires shall be fixed to a surface or flush

mounted metal conduit box. Direct surface mounted luminaires shall be
spaced a distance of 12mm from the mounting surface by using extension
rings.
B. The connection between the permanent wiring and the luminaire shall be
made using 150°C rated cable. The cable shall be connected using a
porcelain or heat resistant connector block housed in the conduit box.
3.05 RECESS MOUNTED LUMINAIRES INSTALLATION
A. All recess mounted luminaires shall preferably be suspended

independently of the ceiling in which they are fitted. Where such an
arrangement is not possible or practical, the luminaires shall be fitted in and
supported by the ceiling. The Contractor shall ensure that the suspended
ceiling is suitably strengthened to carry the additional weight.
B. The connection between the permanent wiring and the luminaire shall be
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made using a heat resistant flexible cable connected to a 2A, 3 pin "plug-

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in" type ceiling rose, conduit box mounted adjacent to the luminaire and
accessible on removal of the luminaire.
C. The flexible cable shall be three core type, one core being used as the
circuit protective and earth bonding conductor. Where the cable forms the
connection to a tungsten lamp luminaire it shall be rated for operation at
150°C minimum.
3.06 PENDANT MOUNTED INSTALLATION
A. Tube pendants shall be mounted from a ball and socket type swivel
dome cover plate fitted to a ceiling mounted metal conduit box and
conduit of minimum diameter 20mm. The conduit entry to the luminaire
shall be fitted with a lock nut and a flexible copper bond shall be provided
from the fixed conduit installation to the pendant tube.
B. Proprietary type pendant luminaires, whether single or multi-lamp units

shall be bonded and provided with suitable terminations to ensure reliable
earth continuity throughout all exposed metalwork.
C. Plain pendants shall consist of a multi-terminal ceiling rose conforming to

BS 67, a flexible cord of heat resistant cable and a heat resistant
lampholder.
D. Luminaires shall not be suspended by means of flexible cables with the

exception of certain lightweight domestic and commercial types of
luminaires, which shall be agreed with the Engineer.
E. Suspended luminaires shall be supported by means of purpose

manufactured metal supports.
F. White break joint rings shall be provided between the fittings and conduit
box to mask the joints as deemed necessary by the Engineer.
3.07 ADJUST AND CLEAN
A. Clean interior lighting fixtures of dirt and debris upon completion of

installation.
B. Protect installed fixtures from damage during remainder of construction

period.
A. Upon completion of installation of lighting fixtures, and after building

circuitry has been energised, apply electrical energy to demonstrate
capability and compliance with requirements. Where possible, correct
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malfunctioning units at site, then retest to demonstrate compliance;

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otherwise, remove and replace with new units, and proceed with
retesting.
B. At the time of Substantial Completion, replace lamps in lighting fixtures

which are observed to be noticeably dimmed after contractor's use and
tested.
C. All luminaires shall be functionally tested to prove that they operate
satisfactorily.
D. Check and record illumination levels in accordance with design

requirements.
3.09 EARTHING
A. Provide equipment earthing connections for all lighting fixtures .
B. Separate earthing wire should be used between any fixture and

panelboard. Minimum size 2.5mm2.
END OF SECTION

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SECTION 16720
FIRE DETECTION AND ALARM SYSTEM
PART 1: GENERAL
1.01 The contractor shall be responsible for the supply, installation,

commissioning and servicing of the analogue addressable fire alarm
system
1.02 The contractor must review the consultant’s proposal for suitability to his
system. All deviations should be brought to the notice of the engineer.
1.03 The contractor or his representative must have, at least 10 years’

experience in installing, commissioning and servicing fire detection and
alarm systems, at least 5 of which must be with analogue addressable
systems.
1.04 All equipment central to the operation of the analogue addressable

systems shall be designed and manufactured by the company installing
and commissioning the system. As a minimum requirement, this clause
covers the following:
1. Fire Alarm Control Panel
2. Repeat Panels
3. Addressable ancillary equipment
4. Power supplies and automatic point detection equipment
1.05 The manufacturer shall be approved to BS5750 part 1 Quality System

Standard for the design and manufacture of the equipment referred
to in clause 1.5 (ISO).
1.06 The main equipment proposed for use shall be approved by at least
one of the following:
1. Loss prevention Council (LPC)
2. Underwriters Laboratories (UL)

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1.07 The manufacturer shall have available a complete set of technical

manuals for all equipment installed. This must cover technical
specification, system design recommendations and guidelines for
installation, commissioning, operating and servicing the proposed
equipment.
1.08 The manufacturer, given reasonable notice, shall permit the buyer
or its nominated agent to conduct a quality audit at the premises
where the proposed equipment is manufactured.
1.09 All deviations from this specification that the contractor proposes to
make shall be clearly indicated in writing, referring to the relevant
paragraph(s) of this specification.
1.10 The system offered shall be approved by the concerned local

authorities. Fire department and any changes in equipment,
materials shall be incorporated at no extra cost
1.11 APPLICABLE STANDARDS AND SPECIFICATIONS
Where applicable, the fire detection and alarm system and

installation shall comply fully with the British Standards or NFPA
rules and regulations.
1.12 OUTPUT SIGNALS UNDER FIRE CONDITIONS
A. Provision shall be made in the Fire Alarm Control Panel to provide the
following:
1. Potential free NO/NC contacts or interface as

required for the fire door and elevators
2. Potential free NO/NC contacts or interface as

required for shutting or starting mechanical /HVAC
equipment such as AHU’s, pumps, dampers, fans
etc as may be required.
B. The electrical contractor shall be responsible for providing conduiting and

wiring from the fire alarm control panel up to the required equipment(s) as
mentioned in paragraph ‘A’ above.
1.13 SYSTEM DIFFERENCE
There may be some difference between one manufacturer and another.

The purpose of these specifications is to lay down the requirements in
general for the fire alarm system. The system supplier shall ensure that
all functional aspects of the fire alarm system shall be achieved though
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the equipment specifications one manufacturer may differ from the

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other in some aspects. It is expected that the system supplied shall be a

product of the latest technology only from the specified
brands/manufacturers.
1.14 APPROVALS FROM THE CONCERNERD LOCAL AUTHORITIES ( I.E. CIVIL

DEFENSE FIRE DEPARTMENT)
A. Before commencing any installation works, the contractor shall obtain

engineer’s approval in respect of the system he is going to use. Based on
the contract drawings the contractor shall prepare all necessary drawing
with the help of his system supplier (manufacturer). After coordinating
with other trades, the contractor shall submit his drawings to obtain the
concerned local authorities fire department approval.
B. The contractor shall also be responsible for obtaining all approvals from
the concerned local authorities. Fire department during and after the
installation as deemed necessary and as required.
1.15 SCOPE OF WORK
A. Supply, install, test and commission the fire alarm & detection
system as specified, as indicated on drawings and as required as per the
concerned local authorities Fire Department Regulations.
B. Contractor shall install smoke detectors above false ceiling and also where
false ceiling depth is 80cm and above within contract price.
C. The electronically operated analogue addressable system including but not

limited to the following items:
1. Fire Alarm Control Panel
2. Fire Alarm Repeater panels (when indicated in drawings)
3. Power supply and standby batteries with charger
4. Smoke sensors
5. Sensor sounders
6. Heat sensors
7. Beam sensors
8. Duct sensors
9. Manual call points
10. Audio visual alarms
11. Alarm sounders
12. Interface units
13. System interface with main fire alarm panel (where indicated)
14. System interface with firefighting
system (sprinkler, fire extinguishing system)
15. System interface with air handling units
16. System interface with elevators
17. System interface with smoke and fresh air fans
18. System interface with building management system
19. System interface with ATS
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20. System interface with smoke doors

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21. Printers
22. System interface with other specifies systems like
access control etc.
1.16 Any additional ductwork, encasement works required shall be the

responsibility of the electrical contractor. He shall not be entitled for any
additional claims on these accounts.
1.17 It is assumed that the contractor before signing the contract has
surveyed the site and ascertained the routes and hurdles.
1.18 RELATED WORKS A. A. Section 16120 Conduits

B. Section 16110 Raceways
C. Section 16200 Cables & Wires
D. Section 16300 Supporting Devices
1.19 SUBMITTALS
A. Shop drawings showing complete details
B. Manufacturer’s detailed instructions
C. Submit all shop floor and other relevant drawings to the concerned
local authorities fire department and obtain necessary approvals.
PART 2: PRODUCTS
2.01 CONTROL AND INDICATING EQUIPMENT
A. The Fire Alarm Control Panel (F.A.C.P.) shall be the central processing
unit of the system, receiving and analyzing signals from fire sensors,
providing audible and visual information to the user, initiating automatic
alarm response sequences and providing the means by which the user
interacts with the system.
B. System shall be true analogue with the ability to print the output from a fire
sensor over a period of time
C. The (F.A.C.P) shall be modular in construction allowing for future extension

of the system

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D. The (F.A.C.P) shall be able to be easily configured to meet the exact

detection zone and output mapping requirements of the building
considered.
E. The (F.A.C.P) shall be microprocessor based and operate under a

multitasking software program. Operating programs and configuration data
must be contained in easily up datable and non-volatile memory
(EEPROM).
F. All devices i.e., optical sensors, heat sensors, duct and beam sensors, fire
alarm interface units, electronic sounders, manual call points etc. shall
appear their addresses on visual display unit of the panel.
G. The (F.A.C.P) shall meet the requirements of BS5839 Part 4 or NFPA 72

and shall be approved, together with associated ancillary equipment, by the
Loss Prevention Council (LPC) or (UL)
H. No more than 250 addressable input devices shall be controlled by a single

loop processor card.
2.02 SYSTEM DESCRIPTION
A. The (F.A.C.P) shall be capable of operating with any of the following types
of automatic detection equipment:
1. Conventional detectors
2. Analogue addressable sensors
B. The (F.A.C.P) shall be capable of operating with conventional detectors

and analogue addressable detectors suitable for installation in hazardous
areas.
C. Analogue addressable devices shall be connected to loops capable of

accepting up to 250 devices per loop.
D. The (F.A.C.P) shall have a minimum capacity for operating 4 fully loaded
addressable loops. This shall be extendible up to a maximum capacity of
10 loops class (A/B) per panel.
E. Provision shall be made for each addressable loop to be sub-divided into a

maximum of 8 geographical zones. The section of wiring corresponding to
each zone circuit shall be protected from faults in other sections by
line isolator modules.
F. It shall be possible to allocate all 250 SAFE addressable devices per loop
with maximum loop distance of 672 km.
G. The (F.A.C.P) shall have provision to drive and monitor up to 8

repeater panels providing a repeat of the indications on the (F.A.C.P)
display and up to a further 3 repeater panels also incorporating the full
set of system manual controls.
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H. System shall be of safe addressable type I.e. all the devices on the top of
the FACP shall be:
Safe addressing shall cover the benefits of soft addressing and also
overcome the limitations of hard addressing. This means that,
2.03 MONITORING AND CHECKING CIRCUITS AND FAULT CONDITIONS
facilities shall be provided to constantly monitor and check the following

circuits and fault conditions.
A. The power supply on the loops
B. For open circuit, short-circuit, earth fault and any other fault condition in the
loop wiring
C. For communication failure and errors in all cord and loops
D. For faults in keyboard and printer circuits
E. Monitoring of all devices status every 1 minute
F. Provision shall be done at the fire alarm control panels to silence the
loop powered alarm sounders but the visual indication shall remain until the
system is reset
G. It shall be possible to change the sensitivity of analogue sensors from the fire
alarm control panel only.
2.04 BASIC SYSTEM FUNCTIONS
A. The (F.A.C.P) shall monitor the status of all devices on the addressable loops
for fire, short circuit fault, open-circuit fault, incorrect addressing, unauthorized
device removal or exchange, pre-alarm condition and contaminated sensor
detector condition.
B. In the event of a fire being reported from the smoke/heat detectors, activation
of manual call points or sprinkler operation the sequence of alarm operation
C. If fire condition is reported from a sensor area this should cause a fire signal to
be reported at the control panel. The system should incorporate a delay for up
to 3 minutes maximum and if the alarm is not acknowledged in this period, the
evaluation message should be broadcast through the speakers automatically
to the affected floor plus the floor above and below. The alert signal to other
floors shall be as previously described.
D. If a manual break glass unit is activated or a sprinkler flow switch is operated,

then the evacuation shall be transmitted immediately to the effected floor plus
the floor above and the floor below. The signal to the other floors shall
be as previously described.
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E. In each of the above cases, upon initiation of an evacuation signal all

the electronic sounders in areas such as plant rooms and emergency
staircase shall operate immediately. The signals shall not discriminate with
floors.
F. Activation of the fire alarm system shall directly initiate some or all of the
following to be agreed as part of the overall engineering policy:
1. Signal to all elevator machine rooms indicating fire

status(to control lifts)
2. Release doors normally locked by magnetic devices
3. Release doors normally held open by magnetic devices
4. Shutdown mechanical equipment ventilation plant
5. Shutdown general exhaust fans
6. Startup smoke extract fans
7. Startup exhaust makes up fans
8. Startup stair vestibule pressurization fans
9. Automatically operate fire dampers.
10. Initiate alert signals in all panels.
G. Supervised by the fire alarm system in main building
2.05 MAIN FIRE ALARM CONTROL PANEL (ADDRESSABLE TYPE)
A. The panel shall be computer controlled using analogue technique to detect

smoke/heat/fire conditions. The panel shall be complete with, but not limited
to, the following elements:
B. Visual display unit capable of displaying 2 lines 40 characters backlit display
C. Integral sealed lead acid battery and charger, with 24-hour back up in the
event of supply mains failure.
D. Essential control sound alarms, silence alarms and reset fire. These shall be
enabled by a key switch
E. Cancel fault buzzer
F. Fire, fault, warning and power on lamps.

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G. Simple menu driven function keys with password protection shall allow users
to an extensive range of software-based features such as:
1. Last 150 fire and trouble events
2. Current fault and warnings logs
3. Analysis of analogue sensor information
4. Interrogation of sensor cleanliness
5. Enable/disable sensors, zones, sounders, interface, unit channels
6. Fire plan configuration menus
7. Outstation label changes
8. Address allocation
9. Status of outstation
10. Status of all cards
11. Printer on off, line feed and test facilities
12. Address allocation including SAFE addressing
H. Up to 250-device capacity per 672 km loop.
I. RS 232/RS 485 computer communication option
J. Shall have minimum of 2 master alarm circuits 24V 7AMP
K. In addition to the above, all other necessary control, elements and

accessories shall be included to provide a complete an efficient panel
confirming to the requirements of BS or NFPA.
2.06 SMOKE SENSORS
A. These shall of addressable optical type with inbuilt isolator in a single head.
The optical element shall monitor for visible smoke from slow smoldering fires.
Smoke sensing design shall comply with BS 5445: part 7 and shall be LPCB
approved or comply with NFPA –72 and shall be UL approved.
B. All smoke sensors shall comprise of three components:
1. Termination Plate, electronic module and replaceable sensor

chamber. The termination plate shall incorporate the terminals
for wiring. The electronic module shall plug –on onto the
termination plate as a second fix item all electronic
components and circuitry suitable for an analogue addressable
system.
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2. This design shall allow sensing element alone to be

replaced, should it become dirty almost dirty, excessively dirty,
due to a built up of dust from the surrounding atmosphere.
When removed, the panel shall display a fault condition with a
message “Sensor chamber removed” with a relevant
label/address. The sensor chamber shall also have viewing
LED indicator.
3. Sensors mounted in the false ceilings shall be provided with

semi flush mounting kits.
2.07 HEAT SENSORS
A. These shall comply with the requirements of BS 5445: Part 5: 1977 and shall
be LPCB approved or comply with NFPA-72 and shall be UL listed. They shall
be complete with other elements described for smoke sensors above, for
an analogue safe addressable sensing device.
B. Sensors mounted in the false ceilings shall be provided with a semi

flush mounting kits.
2.08 BEAM SENSORS
A. The beam sensors shall detect fire by obscuration of an optical beam by

smoke. It shall utilize a transmitter and receiver unit. It shall be used in areas
as indicated in the drawings.
B. The beam sensors shall be LPCB or UL approved and to BS 5893 Part 5 or

NFPA-72
2.09 DUCT SENSORS
Duct sensors shall be safe addressed, loop powered, loop signaled. They
shall comprise of a sampling unit with probes extending into a straight
section of the mechanical ventilation ductwork. The duct shall comprise of
Optical Smoke/Sensing devices.
2.10 PULL STATION CALL POINT
These shall comply with the requirements of BS 5839:part 2: 1983 or NFPA-

72 and shall be complete with all electronic components and circuitry for an
addressable device. Polycarbonate cover type option shall also be provided if
required. The unit shall incorporate glass to broken.

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2.11 ALARM INDICATING DEVICES
A. Alarm Bells: Alarm bells shall be of the vibrating type, 10 inches in diameter,
with a sound output of 87 dBA at 3 meters distance, polarized for line
supervision, operable from 18 to 30 volts DC. Mounting shall be surface for
outdoor applications and semi-flush or flush for indoor applications. Finish
shall be red textured enamel.
B. Alarm Strobe Bells: Strobe alarm bells shall be of the vibrating type, 10
inches in diameter, combined with a strobe light. Sound output shall be 87
dBA at 3 meters distance, polarized for line supervision, operable from 18 to
30 volts DC. Integral strobe light lens shall be fabricated of white
polycarbonate with red "FIRE" lettering. Strobe light shall produce 8000
peak candlepower at one flash per second. Mounting shall be surface for
outdoor applications and semi-flush for indoor applications. Finish shall be
red textured enamel. .
C. Alarm horns Alarm horn shall include a die cast metal housing and grille to
protect the horn mechanism, with a sound output of 92 dBA at 10 feet,
polarized for line supervision, operable from 18 to 30 volts DC. Mounting shall
be surface for outdoor applications and (semi-flush) (flush) for indoor
applications. Finish shall be red textured enamel.
D. Alarm Strobe Horns: Strobe alarm horns shall include a die cast metal
housing and grille to protect the horn mechanism combined with a strobe light.
Sound output shall be 92 dBA minimum at 10 feet, polarized for line
supervision, operable from 18 to 30 volts DC. Integral strobe light lens shall
be fabricated of white polycarbonate with red "FIRE" lettering. Strobe light
shall produce 8000 peak candlepower at one flash per second. Mounting
shall be surface for outdoor applications and (semi-flush) (flush) for indoor
applications. Finish shall be red textured enamel.
E. Remote Alarm Lamp: Remote alarm lamp, for indication of ionization smoke
detector actuation, shall be suitable for flush ceiling mounting on a square or
octagonal outlet box.
F. Remote Annunciator: Remote annunciators shall be of the supervised type

with integral power supply, driver module, zone lamp assemblies, supervised
zone trouble lamps and control assemblies. Back lighted zone lamp windows
shall indicate each activated zone. Control assemblies shall include
system alarm, trouble and supervision lamps, annunciator power, lamp test
switches and silencing switches, annunciator shall be flush mounted, finished
in textured red enamel.
G. The sounders shall comply with BS or NFPA requirements.

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2.12 INTERFACE UNITS
A. These shall be used to interface with the fire/fault signals emanating from the
local control conventional (zonal) fore alarm control panels. These units shall
also give/accept contact from other services required to be interfaced with fire
alarm system e.g. Interfacing with AHU’s BMS, elevators, pressurization fans
etc. It shall be installed of addressable type with all inputs and outputs are to
be fully monitored for cable faults . Power supply units if required, with the
interface shall also be monitored for any faults.
2.13 REPEAT PANEL
A. The repeat panel shall be sites at the indicated locations. It shall provide
system repeat facilities to repeat all of the liquid crystal display message as
well as the common indications. It shall have essential alarm controls, menu
facilities and an optional printer allowing it to take the role of the main system
indicator for the day to day running of the system. The repeat panel shall be
complete with built-in battery and charger to comply with BS 5839 shall
require 220V AC supply. The repeat panel shall be located as shown in the
schematics.
PART 3: EXECUTIONS
3.01 INSTALLATION
A. Fire alarm components shall be installed directly to conduit outlet boxes at the
following mounting height above finished floor level, measured to the center of
box unless stated otherwise.
B. Fix manual call station semi-recessed at 1.50m heights above finished floor.
C. Automatic smoke and heat sensors. Ceiling mounted/surface

mounted/above ceiling mounted
D. Alarm Sounders. 2.20m above finished floor
E. Outdoors alarms fix where indicated by the concerned local authorities. Fire
department and approved by the engineer.
3.02 TESTING AND COMMISSIONING
A. After the installation is complete, the contractor shall conduct operating and
commissioning tests. The equipment shall be demonstrated to operate in
accordance with the requirements of the specification. The system installation.
Testing and commissioning shall be as per the concerned local authorities.
Fire department approval and requirements.
B. The Fire Alarm Systems shall be complete programmed in accordance with the
concerned local authorities fire department requirements and as a specialist from
the manufacturer shall attend and demonstrate the complete system.
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C. Fire brigade and testing shall be the contractor’s responsibility and the
contractors shall do any requirements for approval and handing over the fire
alarm installation without extra payment even in time.
D. Drawing and specification are complimentary each to the other.
E. The “CODE FOR THE SYSTEM OPERATION” shall be handed over

to the client at the completion of the maintenance period.
3.03 Shall co-ordinate with other trades for the installation of the system
3.04 The contractor/sub-contractor will be responsible for providing all access equipment
necessary to enable safe installation of the system.
3.05 The contractor shall provide necessary training to client’s personnel to give them on
job training, instructions etc. for proper operating and maintenance of the system.
3.06 The contractor will repair, correct or replace any defect of any nature that may occur
for a period of 2 years from the date of issue of the certification of completion.
3.07 Contractor shall provide a full set of manuals and operating instructions. It shall
include descriptive brochures, technical manuals for all equipments forming part of
the contract.
3.08 SPARES & TOOLS
Contractor shall provide manufacturers recommended spares/tools at the time of completion

of the project for the use of the client. These spares/tools are not to be used by the contractor
during the period of 2 years of maintenance. The scope of supplying spare/tools includes but
not limited to the following:
FIRE ALARM TOOLS
1 OPERATING INSTRUCTION CHART 1 NO
2 O/M MANUALS (ORIGINAL) 1 SET
SPARE PARTS

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1 SENSORS/SMOKE CHAMBERS 9 NO
2 SENSORS / HEAT CHAMBERS 3 NO

3 SENSOR / DUCT TYPE CHAMBER 1 NO
4 INTERNAL ALARM HORN WITH C.M. 2 NO
5 CONTROL MODULE 4 NO
6 MONITOR MODULE 3 NO
7 PULL STATION 2 NO
8 SHORT CIRCUIT ISOLATOR 1 NO
END OF SECTION

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SECTION 16950
TESTING AND COMMISSIONING
PART 1: GENERAL
A. Access shall be afforded at all times to the Engineer to enable him to inspect
the Electrical Equipments.
B. Upon completion of the Electrical Equipments installation or part of the

installation, the Contractor shall carry out and be responsible for testing and
commissioning it, in stages if required, to ensure that it is in proper working
order and capable of performing all of its functions in accordance with the
Specification and to the satisfaction of the Engineer. Any Electrical
Equipments damaged in commissioning shall be replaced and retested by the
Contractor at his own expense to the satisfaction of the Engineer.
C. All testing shall be carried out according to the requirements of the

relevant standards and regulations as may be stated or implied in the
Specification or otherwise agreed by the Engineer in writing.
D. The Contractor shall submit, no later than 6 weeks prior to the

commencement of testing and commissioning, a schedule of all Electrical
Equipment tests and commissioning procedures that he intends to carry out to
prove that the Electrical Equipment complies with the requirements of the
Specification together with his proposed programme for such tests and
commissioning.
E. Tests shall not commence before the schedule of tests has been
approved and such other tests as may be required by the Engineer shall be
included within the schedule of tests.
F. The Contractor shall give to the Engineer in writing at least ten days' notice of
the date by which he will be ready to make the specified tests on completion
of installation. Unless otherwise agreed the tests shall take place within seven
days after the said date on such day or days as the Engineer shall in writing
notify the Contractor.
G. The tests shall as far as possible be carried out under normal working
conditions to the satisfaction of the Engineer and shall extend over such
periods as he may direct.
H. The Contractor shall provide all skilled labour, supervision, apparatus and
instruments required for commissioning and testing and within a reasonable
time thereafter furnish to the Engineer a total of six certificates of all
tests performed and accepted, signed by the Contractor, or an authorised
person acting on his behalf, as prescribed in the appropriate regulations and
specifications.
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I. If any part of the Electrical Equipment fails to pass the specified tests, further
tests shall, if required by the Engineer, be repeated. The Contractor
shall, without delay, put in hand such modifications as are necessary to meet
the requirements as described in the Contract and any expense which the
Owner may have incurred by reason of such further tests may be deducted
from the Contract price.
J. Acceptance shall not in any way absolve the Contractor of his

responsibility for the performance of the Electrical Equipments after erection
as a complete working system in all respects.
K. Each completed system within the installation shall be tested as a whole

under normal site operating conditions to ensure that each component
functions correctly in conjunction with the rest of the system.
L. The Contractor's particular attention is drawn to the requirements of

Section 01650 and 01700 of the Specification in regard to testing,
commissioning and handover of the Works.
PART 2: TESTING
2.01 TESTING REQUIREMENTS
A. The Contractor is to programme, oversee, co-ordinate and record all the

testing and commissioning of the electrical systems. This will be carried out in
co-ordination with those elements undertaken by the mechanical services
Contractor. The electrical Contractor shall allow for liaising and attendance
and providing all necessary test and general data information at the right
times.
B. The systems are to undergo phases of testing, and commissioning, in

accordance with the following:-
Phase 1. Works testing and quality assurance of elements;
Phase 2. Site installation, wiring, checks, performance and operational tests

for all elements;
Phase 3. Sub system group operational tests/performance tests;
Phase 4. Complete system operational and performance tests on dummy

loads;
Phase 5. Complete system operational and performance tests on Client

loads.

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C. In summary the following electrical systems will be subject to testing and

commissioning:
- Switchgear & control

- Standby diesel generator and controls
- Fire detection & alarm
- Domestic power and lighting
- Public address
- Motor control centres and cabling to mechanical and HVAC
systems
- Lightning protection system
- External Lighting (general and flood)
- All feeder cables.
2.02 ELECTRICAL TESTING
A. At the completion of the electrical installation for each facility it shall be tested
to ensure that it is satisfactory and complies with the requirements of the
Specification.
B. Tests of the installation shall be carried out in the following sequence:
1. Protective conductor continuity, including main and supplementary

equipotential bonding
2. Earth electrode resistance
3. Measurement of insulation resistance including site built assemblies

and distribution cables
4. Check of protection by electrical separation, barriers and enclosures
5. Check of phase rotation
6. Verification of polarity
7. Measurement of earth fault loop impedance
8. Test of operation of residual current devices
9. All external distribution cables, in accordance with the relevant BS
2.03 TELECOMMUNICATION AND CONTROL
A. All special systems such as telephone, public address, fire and detection
systems shall be tested as recommended by the suppliers.
B. The Contractor shall submit to the Engineer in writing the procedure to test
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these systems as a whole for the site.

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C. At the completion of these special systems installation for each facility.

These installation shall be tested individually for each facility then it
should be tested with their control system such as fire and detection alarm
and telephone etc... In order to test the performance of these systems as
whole.
PART 3: COMMISSIONING
3.01 GENERAL
A. All Electrical Equipment and integral systems shall be commissioned in

accordance with the relevant standards and regulations given in the
Specification and to the recommendations of specialist suppliers (e.g.
Switchboards, Fire Alarm Systems, and Public Address Systems, Cables,
etc.).
B. Full operational tests shall be carried out on all systems to demonstrate that
they operate in accordance with the requirements of the
Specification.
3.02 SWITCHBOARDS
A. Design tests of: Rated continuous current short circuit current enclosure
dielectric.
B. Production tests of: Dielectric

Mechanical operation
Grounding
Control wiring
Electrical operation.
3.05 FIRE ALARM SYSTEM
A. Wiring runs shall be tested for continuity, short circuits and grounds
before system is energized. Resistance, current and voltage readings shall
be made as work progresses.
i. A s y s t e m a t i c r e c o r d shall be maintained of all readings using

schedules or charts of tests and measurements. Areas shall be provided
on the logging form for readings, dates and witnesses.
ii. The acceptance inspector shall be notified before the start of the
required tests. All items found at variance with the drawings or this
specification during testing or inspection by the acceptance inspector, shall
be corrected.
iii. Test r e p o r t s s h a l l be delivered to the acceptance inspector as
completed.

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B. All test equipment, instruments, tools and labor required to conduct the
system tests shall be made available by the installing contractor. The
following equipment shall be a minimum for conducting the tests:
i. Multimeter for reading voltage, current and resistance.

ii. Two way radios, flashlights, smoke generation devices and
supplies.
iii. A manufacture recommended device for measuring air flow
through air duct smoke detector sampling assemblies.
iv. Decibel meter.
v. Megger ‐ 500V
vi. Earth resistance tester
C. In addition to the testing specified to be performed by the installing

contractor, the installation shall be subject to test by the acceptance inspector.
D. System wiring fire alarm circuits shall be tested for continuity, grounds, and
short circuits.
E. Acceptance testing
i. A written acceptance test procedure (ATP) for testing the fire

alarm system components and installation will be prepared by the
engineer in accordance with NFPA 72, NFPA 72E NFPA 72H and
this specification. The contractor shall be responsible for the
performance of the ATP, demonstrating the function of the
system and verifying the correct operation of all system
components, circuits, and programming.
ii. The acceptance inspector shall use the system record

drawings. During the testing procedure to verify operation as
programmed.
iii. System wiring shall be tested to demonstrate correct system

response and correct subsequent system operation in the event
of:
- Open, shorted and grounded conventional zone circuits.
- Primary power or battery disconnected.
iv. System evacuation alarm indicating appliances shall be

demonstrated as follows:
- All alarm notification appliances actuate as programmed
- Audibility and visibility at required levels.
v. System indications shall be demonstrated as follows:
- Correct message display for each alarm input at the control

panel.

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- Correct annunciator light for each alarm input at each

annunciator as shown on the drawings.
vi. Secondary power capabilities shall be demonstrated as follows:
- Correct zone transmitted for each alarm input
- Trouble signals received for disconnect
vii. Secondary power capabilities shall be demonstrated as follows:
- System primary power shall be disconnected for a period of

time as specified herein. At the end of that period, an alarm
condition shall be created and the system shall perform as
specified for a period as specified.
- System primary power shall be restored for forty eight hours

and system charging current shall be normal trickle charge
for a fully charged battery bank.
- System battery voltages and charging currents shall be

checked at the fire alarm control panel using the test codes
and displayed on the LCD display.
viii. In the event of system failure to perform as specified

and programmed during the ATP procedure, at the discretion of
the acceptance inspector, the test shall be terminated.
a. The installing contractor shall retest the system, correcting

all deficiencies and providing test documentation to the
acceptance inspector.
b. The acceptance inspector may elect to require the complete

ATP to be performed again if, in his opinion, modifications to
the system warrant complete retesting.
c. Changes made to a systems configuration program required

by the acceptance inspector or to comply with the systems
operating parameters shall be validated to insure that in
making the software programming change no other part of the
systems operation was effected. The validation shall utilize
systems software which meets the requirements of NFPA 72
section 7-1.6 "System Reacceptance Testing" as specified in
the NFPA 72 National Fire Alarm Code 1993 edition. Change
validation methods other than that described will not be
considered acceptable and shall allow the acceptance
inspector to require the complete ATP to be performed again.

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PART 4: INSTRUCTION AND TRAINING
4.01 INSTRUCTION AND TRAINING OF CLIENTS STAFF:
A. The Contractor shall be responsible for the provision of suitably qualified

personnel for the instruction and supervision of the staff nominated by the
Client at Site in the operation and routine maintenance of all Electrical
Equipment and associated works. The instruction and training shall be for
periods of six hours daily for six days after the satisfactory commissioning of
the installation and as necessary, after each subsequent
commissioning of a system or part thereof.
B. The Contractor shall accept for training up to four technicians in every system
nominated by the Client who will be assigned to train in all aspects of
the installation on Site during operation of the installation.
C. The cost of the training will be the Contractor's responsibility. During the
training period the salaries of the trainees, their subsistence and all their out-
of-pocket expenses will be the responsibility of the Owner.
D. Before the commencement of such training, the Contractor shall have

available additional copies of sufficient As Built drawings record drawings,
operating and maintenance instructions and spare parts lists referred to
Section 16010 Basic Electrical Requirements, of the Specification so that the
staff nominated can fully understand the operation and maintenance the
equipment. Two months prior to the commencement of
commissioning and training, the Contractor shall submit to the Engineer of the
commissioning, regulation and testing, together with the training programme.
END OF SECTION

MEPF

ROADS AND UTILITIES

VOLUME 2 – PART IX
DEWA – PEW TECHNICAL SPECIFICATIONS

20010410
JUNE, 2022
OHAMMED BIN RASHID AL MAKTOUM CITY
DUBAI – UAE
Project:20010410
Roads and Utilities
GENERAL INDEX

Specifications

drainage Specifications
Volume 2 – Part VI Particular Specifications for FireFighting Works

Architectural
Volume 2 – Part VIII Building General Specifications MEPF

Environmental and Health & Safety
Requirement
AE7 PROJECT NO. 20010410

VOLUME 2 – PART IX REV 1 – ISSUED FOR CONSTRUCTION
DEWA – PEW TECHNICAL DATE ISSUED: 16 JUNE, 2022
SPECIFICATIONS
DUBAI – UAE
MEYDAN GROUP LLC

Project:20010410
District One – Phase 3B - 3B Extension and
3C Roads and Utilities
Volume 2 – Part IX
DEWA – PEWC Technical Specifications
Table of Contents
SECTION 1 ........................................................................................................................................................... 8
GENERAL ........................................................................................................................................................... 8
1.01 CONTRACT DOCUMENTS .............................................................................................................. 8
1.02 CONFIDENTIALITY OF INFORMATION .......................................................................................... 8
1.03 SITE CONDITIONS ........................................................................................................................... 8
1.04 DESCRIPTION OF THE PROJECT .................................................................................................. 8
1.05 SITE OF THE WORK ........................................................................................................................ 8
1.06 ADJOINING LANDS ......................................................................................................................... 9
1.07 CLEANLINESS OF SITE AND WORKS GENERALLY .................................................................... 9
1.08 FOULING AND CONTAMINATION .................................................................................................. 9
1.09 UTILITY MAINS AND SERVICES, LOCATIONS, ETC. .................................................................... 9
1.10 SAFEGUARD OF EXISTING PROPERTY AND UTILITIES ........................................................... 11
1.11 USE OF PUBLIC HIGHWAY ........................................................................................................... 12
1.12 COMPLAINTS AND CLAIMS ......................................................................................................... 12
1.13 SETTING OUT OF THE WORKS .................................................................................................... 12
1.14 PROTECTION FROM WATER........................................................................................................ 13
1.15 POLICE AND HEALTH REGULATIONS ........................................................................................ 13
1.16 WATER SUPPLY ............................................................................................................................ 13
1.17 DISPOSAL OF WASTES ................................................................................................................ 13
1.18 POWER SUPPLY ............................................................................................................................ 13
1.19 OTHER SERVICES ......................................................................................................................... 13
1.20 SAFETY AND MEDICAL FACILITIES ............................................................................................ 13
1.21 ACCESS .......................................................................................................................................... 14
1.22 ORDER OF CARRYING OUT THE WORKS .................................................................................. 14
1.23 PROGRAMME OF WORK .............................................................................................................. 14
1.24 CONTRACTOR'S PROGRESS REPORTS .................................................................................... 15
1.25 PROGRESS MEETINGS ................................................................................................................. 16
1.26 ORDERING MATERIALS ............................................................................................................... 16
1.27 SAMPLES ....................................................................................................................................... 16
1.28 TESTING MATERIALS ................................................................................................................... 17
1.29 MATERIAL TESTING LABORATORY ........................................................................................... 17

DEWA – PEW TECHNICAL 2 DATE OF ISSUE: 16 JUNE, 2022
SPECIFICATIONS
DUBAI – UAE
1.30 INSPECTION OF MANUFACTURING PROCESSES AND FACTORY TESTING OF

MATERIALS .................................................................................................................................... 17
1.31 REMOVAL OF CONDEMNED MATERIALS .................................................................................. 17
1.32 MATERIALS ARISING FROM EXCAVATIONS AND DEMOLITION ............................................. 18
1.33 PROVISION OF FACILITIES FOR ENGINEER'S INSPECTIONS .................................................. 18
1.34 INSPECTIONS BY THE ENGINEER DURING PERIOD OF MAINTENANCE ............................... 18
1.35 LANGUAGE OF CORRESPONDENCE AND RECORDS .............................................................. 18
1.36 RECORD DRAWINGS .................................................................................................................... 18
1.37 PENULTIMATE ACCOUNT ............................................................................................................ 18
1.38 QUALITY CONTROL, TESTS, METHODS AND DEFINITIONS..................................................... 19
1.39 WATER WASTAGE ........................................................................................................................ 19
1.40 REFERENCE SPECIFICATIONS.................................................................................................... 19
1.41 PIPELINE ACROSS PRIVATE PROPERTY. .................................................................................. 19
1.42 DEWA SAFETY AND OCCUPATIONAL HEALTH RULE’S ......................................................... 19
1.43 ISO 9001 AND ISO 14001 COMPLIANCE ...................................................................................... 20
SECTION 2 ......................................................................................................................................................... 21
EXCAVATION AND BACKFILLING ............................................................................................................................ 21
2.01 GENERAL EXCAVATION ............................................................................................................... 21
2.02 PRE-CONSTRUCTION RECORDS ................................................................................................ 22
2.03 TOPSOIL AND SURFACING MATERIAL ...................................................................................... 22
2.05 EXCAVATED MATERIALS ............................................................................................................. 23
2.06 FORMATION ................................................................................................................................... 23
2.07 INSPECTION BY THE ENGINEER ................................................................................................. 23
2.08 ROCK AND HARD MATERIALS .................................................................................................... 24
2.09 USE OF EXPLOSIVES.................................................................................................................... 24
2.10 TRENCH EXCAVATION FOR PIPEWORK .................................................................................... 25
2.11 GEOTEXTILE FABRIC & GRANULAR MATERIALS FOR PIPE BED AND SURROUND FOR
TRANSMISSION MAIN PIPELINES ............................................................................................... 26
2.11.a Granular Material for Pipe Bedding and Surround ..................................................................... 26
2.11.b Pipelines on Granular Beds .......................................................................................................... 27
2.11.c Geotextile Filter Fabric .................................................................................................................. 27
Property ......................................................................................................................................................... 28
Test Method ......................................................................................................................................................... 28
Min. Requirements ..................................................................................................................................................... 28
ASTM D-4533 ......................................................................................................................................................... 28
2.12 WIDTH OF TRENCHES .................................................................................................................. 28
2.13 REMOVAL OF PAVEMENTS ......................................................................................................... 29
2.14 BARRICADES, GUARDS AND SAFETY PROVISIONS ................................................................ 29
2.15 TRENCHES NOT TO BE LEFT OPEN ........................................................................................... 30
2.16 MAINTENANCE OF TRAFFIC AND CLOSING OF STREETS ...................................................... 30
2.17 PROTECTION OF SERVICES AND/OR STRUCTURES ................................................................ 31

SPECIFICATIONS
DUBAI – UAE
2.18 SUPPORT TO EXCAVATIONS....................................................................................................... 31

2.19 CONTROL OF WATER AND FLOATATION .................................................................................. 32
2.20 VENTILATION ................................................................................................................................. 33
2.21 BACKFILLING ................................................................................................................................ 33
2.22 STRUCTURAL AND NON-STRUCTURAL FILLING ...................................................................... 34
2.23 STONE PITCHING .......................................................................................................................... 36
2.24 REINSTATEMENT OF DAMAGED SURFACES AND PROPERTY. .............................................. 36
2.25 REINSTATEMENT OF UNPAVED LAND ....................................................................................... 36
2.26 REINSTATEMENT OF PAVED CARRIAGEWAYS, PARKING AREAS & HARD SHOULDERS .. 37
2.27 REINSTATEMENT OF OTHER SURFACED AREAS .................................................................... 37
2.28 EXCAVATION AND REINSTATEMENT IN DEVELOPED RESERVATIONS ................................ 37
2.29 CLEANING UP OF PIPELINE ALIGNMENTS ................................................................................ 38
2.30 NON-DISRUPTIVE PIPELINE CONSTRUCTION BENEATH ROADS ........................................... 38
SECTION 3 ......................................................................................................................................................... 39
PIPES AND APPURTENANCES ................................................................................................................................. 39
3.03.A GLASS REINFORCED EPOXY (GRE) PIPES FOR POTABLE WATER ...................................... 50
ASTM D 2583 ......................................................................................................................................................... 51
Aluminium parts: electro dip coated ........................................................................................................................ 85
3.4.5.2 TILTING DISC CHECK VALVE....................................................................................................... 89
GENERAL: ......................................................................................................................................................... 90
3.4.6 FLOAT VALVES ............................................................................................................................. 91
3.4.7 AUTOMATIC PRESSURE REDUCING VALVE AND CHECK VALVE ASSEMBLY ..................... 93
APPLICATION: ......................................................................................................................................................... 93
PARTICULAR SPECIFICATIONS: .............................................................................................................................. 93
MAIN VALVE CHARACTERISTICS: ........................................................................................................................... 94
MATERIALS OF CONSTRUCTION: ........................................................................................................................... 94
PILOT SYSTEM : ......................................................................................................................................................... 95
APPLICATION: ......................................................................................................................................................... 96
3.7.1 INTRODUCTION .......................................................................................................................... 119
3.7.1.1 General ........................................................................................................................................ 119
RTU Types ....................................................................................................................................................... 119
3.7.1.2 RTU Functions ............................................................................................................................ 120
3.7.1.3 RTU Address ............................................................................................................................... 120
3.7.1.3.1 Maintenance and Repair ............................................................................................................. 120
3.7.1.3.2 MTBF & MTTR .............................................................................................................................. 120
3.7.2 CONSTRUCTION .......................................................................................................................... 120
3.7.2.1 General ......................................................................................................................................... 120
3.7.2.2 Environment ................................................................................................................................. 121
3.7.2.3 Equipment Housing .................................................................................................................... 121
3.7.3 POWER SUPPLIES ..................................................................................................................... 123
3.7.3.1 General ......................................................................................................................................... 123
SPECIFICATIONS
DUBAI – UAE
3.7.3.2 Voltages........................................................................................................................................ 123

3.7.3.3 Battery Backup ........................................................................................................................... 123
3.7.4 SIGNAL INPUTS AND OUTPUTS ............................................................................................. 124
3.7.4.1 Digital Inputs ............................................................................................................................... 124
3.7.4.2 Digital Outputs ........................................................................................................................... 125
3.7.4.3 Analogue Inputs......................................................................................................................... 125
3.7.4.4 Analogue Outputs...................................................................................................................... 126
3.7.4.5 Pulse Inputs ............................................................................................................................... 127
3.7.4.6 Local Keypad/Display................................................................................................................ 128
3.7.5 SOFTWARE REQUIREMENTS .................................................................................................. 128
3.7.5.1 Mains Failure .............................................................................................................................. 128
3.7.5.2 Alarms and Events ................................................................................................................... 128
3.7.5.3 Alarm Suppression .................................................................................................................... 130
3.7.5.4 Alarm Tagging............................................................................................................................ 131
3.7.5.5 Data and Event Tagging ........................................................................................................... 131
3.7.5.6 Data and Recording and Storage ........................................................................................... 131
3.7.5.7 Programming .............................................................................................................................. 132
3.7.6 COMMUNICATIONS .................................................................................................................... 133
3.7.6.1 General ........................................................................................................................................ 133
3.7.6.2 Local Communications ............................................................................................................. 133
3.7.7 MAINTENANCE, CHECKING AND FAULT FINDING FACILITIES......................................... 133
3.7.7.1 General ......................................................................................................................................... 133
3.7.7.2 Debugging of Programs ............................................................................................................. 134
3.7.8.1 General ......................................................................................................................................... 135
3.7.9 TYPES OF COMMUNICATIONS MEDIA ................................................................................... 135
3.7.10 LINK SPEED ................................................................................................................................ 136
3.7.11 FALLBACK CIRCUITS ................................................................................................................ 137
3.7.12 RTU COMMUNICATIONS PROTOCOL ..................................................................................... 137
3.7.12.1 General ......................................................................................................................................... 137
3.7.12.2 Error Checking (Error Detection/Automatic Repeat Request). ................................................ 137
3.7.12.3 Security and Privacy ................................................................................................................. 137
3.7.12.4 Interference Rejection ................................................................................................................ 137
3.7.12.5 PSTN Communication ................................................................................................................. 137
3.7.12.6 Leased Line/Private Wire Communication ............................................................................... 138
3.7.13 INTERFACES ................................................................................................................................ 138
3.7.13.1 General ......................................................................................................................................... 138
3.7.13.2 Analogue Circuits ....................................................................................................................... 138
3.7.13.3 Digital Circuits ............................................................................................................................ 139
3.7.14. COMMUNICATION EQUIPMENT ................................................................................................ 139
3.7.14.1 General Considerations ............................................................................................................. 139
3.7.14.2 Indication Provided .................................................................................................................... 139
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DUBAI – UAE
3.7.14.3 Diagnostics .................................................................................................................................. 139

3.7.15 CONNECTION APPROVAL TO PUBLIC TELECOMMUNICATION SYSTEMS ...................... 139
3.7.16.1 Intrudction .................................................................................................................................... 140
3.7.16.2 Optical Equipment ....................................................................................................................... 140
3.7.18 POINT TO MULTI POINT RADIO ................................................................................................. 147
3.7.18.1 Network radio ............................................................................................................................... 147
3.7.19 REMOTE STATION RADIO .......................................................................................................... 149
3.16 MARKER PLATES AND POSTS .................................................................................................. 167
3.24 Granular Material for Pipe Bedding and Surround ................................................................... 174
3.25 Geotextile Filter Fabric ................................................................................................................ 175
Property ....................................................................................................................................................... 175
Test Method ....................................................................................................................................................... 175
Min. Requirements ................................................................................................................................................... 175
ASTM D-4533 ....................................................................................................................................................... 175
SECTION 4 ....................................................................................................................................................... 182
CONCRETE AND REINFORCING BARS ................................................................................................................. 182
4.01 SCOPE .......................................................................................................................................... 182
4.02 MATERIALS .................................................................................................................................. 182
4.04 CONCRETE MIX DESIGN ............................................................................................................ 186
4.05 TRIAL MIXES ................................................................................................................................ 186
4.06 LIMITATION OF WATER / CEMENT RATIO ................................................................................ 187
4.07 WORKABILITY ............................................................................................................................. 188
4.08 ADMIXTURES ............................................................................................................................... 188
4.09 STORAGE OF MATERIAL ........................................................................................................... 188
4.10 COMPOSITION OF CONCRETE .................................................................................................. 189
4.11 PROPORTIONING ........................................................................................................................ 190
4.12 GENERAL REQUIREMENTS FOR MIXING ................................................................................. 191
4.13 MACHINE MIXING ........................................................................................................................ 191
4.14 ON SITE MIXED CONCRETE ....................................................................................................... 192
4.15 READY-MIXED CONCRETE ........................................................................................................ 192
4.16 TRANSPORTING MIXED CONCRETE ......................................................................................... 193
4.17 TIME OR AMOUNT OF MIXING ................................................................................................... 194
4.18 AMOUNT OF WATER AND SLUMP TEST .................................................................................. 194
4.19 DELIVERY ..................................................................................................................................... 195
4.20 CONCRETING IN HOT WEATHER .............................................................................................. 195
4.21 QUALITY CONTROL OF CONCRETE ......................................................................................... 196
4.22 FORMWORK ................................................................................................................................. 197
4.23 PLACING CONCRETE ................................................................................................................. 198
4.24 CONSTRUCTION JOINTS ............................................................................................................ 199
4.25 CURING CONCRETE-WATER METHOD ..................................................................................... 200
4.26 CURING CONCRETE-MEMBRANE METHOD ............................................................................. 200
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DUBAI – UAE
4.27 PROTECTION OF CONCRETE .................................................................................................... 201

4.28 CONCRETE BLOCK WORK ........................................................................................................ 201
4.29 REINFORCING.............................................................................................................................. 202
SECTION 5 ....................................................................................................................................................... 206
LININGS AND PROTECTIVE COATINGS FOR CONCRETE ................................................................................... 206
5.01 GENERAL ..................................................................................................................................... 206
5.02 WATERPROOFING TO CAST-IN-SITU CONCRETE, PRECAST CONCRETE AND
BLOCKWORK............................................................................................................................... 206
SECTION 6 ....................................................................................................................................................... 210
TRANSPORTATION, STORAGE, INSTALLATION .................................................................................................. 210
OF PIPES, TESTING & COMMISSIONING ............................................................................................................... 210
6.01 HANDLING AND TRANSPORT OF PIPELINE MATERIALS ....................................................... 210
6.02 STORAGE OF PIPES AND APPURTENANCES.......................................................................... 210
6.03 MATERIALS SUPPLIED BY THE EMPLOYER ............................................................................ 211
6.04 INSTALLATION OF PIPEWORK .................................................................................................. 212
6.05 CONNECTIONS TO EXISTING MAINS ........................................................................................ 214
6.06 JOINTING OF PIPES .................................................................................................................... 215
6.07 FLOTATION OF PIPEWORK ........................................................................................................ 216
6.08 VALVES ........................................................................................................................................ 217
6.09 EXTERNAL PROTECTION OF JOINTS ....................................................................................... 217
6.10 THRUST AND ANCHOR BLOCKS.............................................................................................. 217
6.11 VALVE CHAMBERS AND FLOWMETER CHAMBERS ............................................................... 218
6.12 OTHER WORKS ........................................................................................................................... 218
6.13 CONNECTIONS TO EXISTING MAINS AND SERVICE PIPES ................................................... 218
6.14 TESTING, DISINFECTION AND CLEANING PIPELINES ............................................................ 219
6.15 Disposal of Water Used for Testing, Disinfections and Cleaning ........................................... 223

SPECIFICATIONS
DUBAI – UAE
SECTION 1
GENERAL
1.01 CONTRACT DOCUMENTS
These specifications shall be read in conjunction with the other Tender Documents,
including the Tender Form, Form of Agreement, Schedule of Unit Prices (Bill of
Quantities) and Appendices, General Conditions of Contract, Special Conditions of
Contract, Drawings and Notices and Addenda.
All these documents and drawings are to be regarded as mutually explanatory and
complementing each other, and in the event of discrepancy or assumed
discrepancy being found, the Contractor shall immediately inform the Engineer of
the matter in writing and the Engineer will issue his instructions in the matter in
accordance with Clauses of the General requirements for pipe line installations and
the Engineer's instructions shall be final and binding.
1.02 CONFIDENTIALITY OF INFORMATION
The Contractor shall treat the details of this contract as private and confidential for
his own information only, and shall not publish or disclose the details in any trade
or technical paper or elsewhere (except as necessary for the purpose thereof)
without the previous consent of the Employer.
1.03 SITE CONDITIONS
Before submitting his tender, the Contractor shall be deemed to have satisfied
himself as to the engineering characteristics and qualities of the various soils on
site, the suitability of the materials he proposes for use in the works to meet the
requirements of the specifications, and the locations of quarries and borrow pits.
The Contractor shall make his own site and soils investigations and he shall not be
entitled to additional payments for such investigations. The Contractor must satisfy
himself as to the nature of the soil through which excavations and foundations are
to be made or which are to be used in the construction. No claim from the
Contractor for additional payment will be considered.
1.04 DESCRIPTION OF THE PROJECT
General
1.05 SITE OF THE WORK

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DUBAI – UAE
1.06 ADJOINING LANDS
The Contractor shall conduct his operations in such a manner as to avoid injury or
damage to adjacent property, improvements or facilities. Buildings, trees, ground
cover, and shrubbery that are not designated for removal, pole lines, fences, guard
rails, guide posts, culvert and property markers, signs, structures, conduits, pipelines
and other facilities within or adjacent to the street or right-of-way shall be protected
from injury or damage. The Contractor shall provide and install suitable safeguards to
protect such objects from injury or damage, which objects if injured or damaged, by
reason of the Contractor's operations, shall be replaced or restored by the Contractor
at his own expense to a condition as good as when he entered upon the works, or as
required by the Specifications. The Contractor shall not disturb any monuments,
property corners or survey markers without permission from the Engineer, and he
shall bear the expense of resetting any monuments, property corners or survey
markers which may be disturbed.
The Contractor shall be responsible for all damage to streets, utilities, roads,
highways, ditches, embankments, bridges, culverts or other public or private property,
which may be caused by transporting equipment, materials, or men to or from the
work. The Contractor shall make satisfactory and acceptable arrangements with the
property owner of the damaged property concerning its repair or replacement.
The convenience of owners of property adjoining the site shall be provided for as far
as possible. Convenient access to driveways, and buildings adjoining the work shall
be maintained and temporary approaches to intersecting streets and alleys shall be
provided and kept in good condition.
1.07 CLEANLINESS OF SITE AND WORKS GENERALLY
Throughout the Contract, the Site and all temporary and permanent works shall be
kept in a clean, tidy, and sanitary condition.
1.08 FOULING AND CONTAMINATION
The Contractor shall, at his own expense, take such measures as the Engineer may
require, to prevent contamination of the soil and the entry of spillage from concrete
mixing operations, oils, or other deleterious materials, into any drainage system, or
natural watercourse.
1.09 UTILITY MAINS AND SERVICES, LOCATIONS, ETC.
It shall be the responsibility of the Contractor to obtain all information available from
all various Ministries/ Departments/ Municipalities/ Authorities in UAE, regarding the
positions of mains and services, and he shall make this information available to the
Engineer as soon as he obtains it.

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DUBAI – UAE
Before opening up the ground for any purpose, the Contractor must notify all
concerned parties by issue of a formal "Notice of Intent" and must obtain
information by formal notice regarding the location of all underground services.
The complete responsibility for obtaining this information rests with the Contractor or
party requiring opening up the ground.
"Notices of Intent" are required to be circulated to all concerned parties and "No
Objection Certificates" from all various Ministries/ Departments/
Municipalities/Authorities in UAE.
Drawings and notices shall be sent in duplicate, one of which shall be retained by the
addressee and the other returned to the sender duly marked to show underground
services. "Notice of Intent" will be given 14 (fourteen) days in advance of the proposed
works. In the event that the work is not started within 8 (eight) weeks of the date of the
Notice of Intent, it will be deemed to have elapsed. A further Notice of Intent will then
be submitted.
All locating work shall be carried out in advance of excavation work. The Contractor
shall obtain all information and assistance available from the Service Authorities for
locating the mains and services, and shall take the Engineer's approval for any trial
excavations which may be necessary to confirm or establish these locations. The
absence of such information shall not relieve the Contractor of his liability for the cost
of any repair work necessitated by damage caused by him to such mains and
services in the course of his work and for the cost of all losses arising from their
disruption.
All costs for executing such boreholes and trial holes shall be deemed to be included
in the Contractor's rates for excavation. Only trial holes and boreholes required by the
Engineer for particular purposes, and ordered in writing by him, shall be paid for
under the appropriate item in the Bills of Quantities.
No public or private facility shall be extinguished or interrupted without the written

permission of the Engineer. Such permission will not be given until suitable
permanent or temporary alternatives, approved by the Engineer, have been provided
by the Contractor, or, in the case of accommodation works, by the owner of the facility
or his agents.
The Contractor shall make arrangements with the Service and Public Authorities
concerned, for the phasing into his Programme of Works of all work which needs to be
done by them or their Contractors, or by the Contractor himself, concurrently with the
works.
The Contractor shall take any and all measures reasonably required by any Public or
Service Authority for the support and full protection of all mains, pipes, cables and
other apparatus during the progress of the works, and shall construct and provide to
the satisfaction of the Authority concerned, all works necessary for the prevention of
damage or interruption of services. If in the execution of the works, by reason of any
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DUBAI – UAE
subsidence caused by, or any act of neglect or default of the Contractor, any damage
to any apparatus or any interruption of, or delay to the provision of any service is
caused, the Contractor shall report it to the Engineer immediately and bear and pay
the cost reasonably incurred by the Authority concerned in making good such damage
and shall make full compensation to the Authority for any loss, sustained by reason of
such interruption or delay.
The Contractor shall, at all times during the progress of the works, afford facilities to
properly accredited agents of any Public Service Authority for access to all or to any
of their apparatus situated in or under the site, as may be necessary for inspection,
reporting, maintaining, removing, renewing or altering such apparatus in connection
with the construction of the Works or for any other purpose what so ever.
The absence of information shall not relieve the Contractor of his liability for the cost
of any repair work necessitated by damage caused by him to such mains and
services in the course of his work and for the cost of all losses arising from their
disruption.
Any temporary or permanent diversion of mains and services will only be permitted
after agreement with the appropriate Service Authority and the Engineer.
Permanent diversions will only be considered where the main or service occupies the
line and level of the pipe work or structure to be constructed by the Contractor, or
where the position of the main or service completely prevents this construction. Only
permanent diversions, which the Engineer considers essential for these reasons, will
be measured and paid for under the items in the Bills of Quantities.
Temporary diversion and restoration of mains or services shall be at the Contractor's

expense.
1.10 SAFEGUARD OF EXISTING PROPERTY AND UTILITIES
It shall be the Contractor's responsibility to safeguard by means of temporary or

permanent supports, or otherwise, all pipes, cables, structures or other things which
would be liable to suffer damage if such precautionary measures were not taken.
Temporary safeguards shall be to the approval of the Engineer and of the Authority,
Ministry or Owner concerned.
Permanent safeguards shall be to the approval of the Authorities, or Owner

concerned and the Engineer.
All temporary and permanent safeguards will be at the Contractor's expense.
Any additional costs, due to difficulty of working or to any other reasons arising from
the presence of the aforementioned, shall be borne by the Contractor.

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DUBAI – UAE
1.11 USE OF PUBLIC HIGHWAY
The Contractor shall ensure that all vehicles, which he intends to use on the public
highway, comply with and are used in accordance with all relevant statutory
requirements currently in force in U.A.E.
The Contractor shall take every precaution and shall make adequate provisions to
prevent excavated material or other debris being deposited on the public highway
from his vehicles, and shall promptly comply with any instructions issued by the
Engineer or other Authorities to remove any material so deposited, at his own
expense.
1.12 COMPLAINTS AND CLAIMS
During the course of the work, complaints and claims may arise from the public or from
various Authorities. The Contractor shall satisfy the Engineer that he is dealing with all
such matters without delay, until appropriate clearance certificates from any Authority
concerned are produced by the Contractor. This Clause shall in no way absolve the
Contractor from his obligations under Clause 5.15 of the Conditions of Contract.
1.13 SETTING OUT OF THE WORKS
The Contractor shall prepare detailed setting out drawings based on trial whole
information's and data sheets for the Works, as necessary, and submit them to the
Engineer, in triplicate, for approval. Any modifications to the setting out drawings or
data sheets required by the Engineer shall be made by the Contractor and
resubmitted for final approval. Approval by the Engineer shall be signified by the
return to the Contractor of one copy duly signed by the Engineer.
Should it be necessary during setting out or during construction for agreed setting out
details to be amended, the Contractor shall amend the drawings or data sheets, or
make new ones for approval, as required by the Engineer.
Copies of setting out drawings and data sheets shall be preserved for use by the
Contractor in preparing final records and drawings, in accordance with the requirements
set out elsewhere.
The Contractor to note that it is his responsibility to obtain the NOC and demarcation
from the Dubai Municipality/other concerned, before the start of actual commencement
of works on site. Any fees associated with the above, shall be included in the contract
rates.
The Contractor shall provide onsite for the surveying works and sitting out, at least one
(1) No. Robotic Total Station, which uses a radio to communicate the Total Station and
the prism, to cover both, survey and stake out.

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DUBAI – UAE
1.14 PROTECTION FROM WATER
Except as elsewhere specified, the Contractor shall keep the whole of the works free
from water, and allow in his price for all the measures necessary for the purpose, and
shall clear away and make good, at his own cost, all damage caused thereby.
1.15 POLICE AND HEALTH REGULATIONS
The Contractor shall keep in close contact with the police and other officials of the
areas concerned regarding their requirements in the control of workmen, passage
through adjacent areas, or other matters, and shall provide all assistance or facilities
which may be required by such officials in the execution of their duties. The
Contractor shall obey Municipal, Police and Health Regulations and all other
regulations.
1.16 WATER SUPPLY
The Contractor shall at his expense make adequate arrangements to the satisfaction
of the Engineer for the supply of all potable and other water required for any purpose
connected with the works, and shall provide, operate, and maintain all the necessary
installations.
The Contractor shall pay all charges in respect of the provision of meters and
connections, and water rates for water. The Contractor's notice is particularly drawn
to the importance of checking the availability of water for use in construction work.
1.17 DISPOSAL OF WASTES
The Contractor shall, at his expense, make adequate arrangements to the satisfaction
of the Engineer for the disposal of all debris, rain and subsoil water, sewage, and all
other waste materials arising from or connected with the works.
1.18 POWER SUPPLY
The Contractor shall, at his own expense, arrange for the supply (either from DEWA
or from his own resources) and distribution of all electricity required for or in
connection with the works. The Contractor will not be granted any additional cost or
time incase DEWA will not provide power supply for works during construction, testing
and commissioning etc., during the contract period.
1.19 OTHER SERVICES
The Contractor shall, at his own expense, make his own arrangements for, and shall
provide any services (including telephone and other utilities) which he may require in
addition to the foregoing, including 2 projects sign boards etc.
1.20 SAFETY AND MEDICAL FACILITIES

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DUBAI – UAE
The Contractor shall, at his expense, arrange for medical attention to be available
when necessary, and shall provide dressing stations complete with all adequate first-
aid equipment on the site. The Contractor shall display in suitable places the names
of his employees who are available, from time to time, to render first aid services. The
Contractor shall provide for the transport of serious cases to the nearest hospital.
The Contractor shall, at his own expense arrange for special masks to be worn by all
his labour and staff, and provide the same for the use of the Engineer's site staff,
while working with asbestos cement pipes, i.e., tapping, cutting, etc.
The Contractor shall comply with all requirements of legislation of the UAE and the
Emirate of Dubai concerning the working conditions, safety, health or welfare of any
employee of the Contractor, the Engineer or the Employer.
The Contractor shall comply with best industry practices for the safety of workmen
and the public.
The Contractor shall file with the Engineer, the names, addresses, and telephone
numbers of representatives who can be contacted in Dubai at any time, in case of
emergency. These representatives shall be fully authorized and equipped to correct
unsafe or excessively inconvenient conditions at short notice.
1.21 ACCESS
The Contractor shall, at his own expense, make all arrangements for providing safe
and expeditious access from the public highway to the site and, where necessary,
shall construct, maintain, safeguard and reinstate, to the satisfaction of the Engineer,
all roads and other access works which may be required for that purpose.
The Contractor shall ensure that none of the aforementioned access works (whether
of a permanent or temporary nature) shall obstruct or impede any utilities, drainage or
irrigation systems, or have other adverse effects on surrounding land or property.
Transportation of pipe and other materials to the site for permanent construction shall
start only after construction of access roads to the satisfaction of the Engineer.
1.22 ORDER OF CARRYING OUT THE WORKS
The Contractor shall proceed with the construction of the works, in accordance with a
sequence approved by the Engineer.
1.23 PROGRAMME OF WORK
In the programme and particulars required under the Conditions of Contract, the
Contractor shall:
A. Provide details of the sequence he proposes for carrying out the works and the
time of completion for work areas handed over to him under the provisions of
relevant Clause.
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DUBAI – UAE
B. State and allow a reasonable margin of time for contingencies.
C. State his intentions regarding shift work, if required.
D. The Programme of Work should be submitted to DEWA in a SOFT COPY &

HARD copies done in PRIMAVERA software (version 3 or above). The
Programme of Work (Approved by DEWA) will be considered as a BASELINE
Programme, to compare the actual progress of the project.
E. The Work Programme shall contain mainly 3 layouts:
a. First layout to be Work Breakdown Structure Layout (WBS) to show the

group of activities with all information’s.
b. Second Layout to be Responsibility Layout will show the Responsible
Recourse (contractor-subcontractor-vendors-manager) for each Activity or
group of activity this called (Organization Breakdown Structure Layout
(OBS). Third Layout will be Cost Layout, showing the planned value,
earned value & actual cost. Planned value will be consider as same as the
value mentioned in the BOQ and then actual value will be the payments
done to the contractor while earned value will be calculated by Primavera
with all Diagrams like Bar Charts and S curves
F. The Programme of Work should be updated to show the progress of the work and
shall be submitted to DEWA on weekly basis.
G. DEWA reserve the right to call for any reasonable number of further detailed
programmes during the period of the contract so that DEWA may be able
adequately to follow the progress of the works both on and off the site.
H. The submission whether approved or not by DEWA of such programmes,

particulars or any cash flow estimates shall not relieve the contractor of any of
his duties or responsibilities under the contract.
I. If at any time it should appear to DEWA that the actual progress of the works
does not conform to the BASELINE Programme of Work, the contractor shall
produce at the request of DEWA a revised programme showing the proposed
modifications to such programme necessary to ensure completion for DEWA
review and approval.
J. Provide monthly a proposed CPM chart, showing his plans for materials supply
and implementation, standard listing, period bar chart, a complete resources
report and a cash flow curve.
The Contractor shall provide and maintain the following new Cameras, two (2)
Nos. of Sony Digital Camera. The model of the camera is subject to the engineer’s
approval.
1.24 CONTRACTOR'S PROGRESS REPORTS
The Contractor shall report monthly progress as agreed by the Engineer’s

representative to the Engineer, on charts submitted in quadruplicate, and showing
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DUBAI – UAE
actual work done superimposed upon copies of the programme. He shall furnish an
explanation of any deviation from the programme, and shall state proposals for
improving progress, if lacking in any respect.
Along with the monthly progress report, the Contractor shall submit a monthly “As
Built" drawing showing overall progress and the pipes laid and commissioned during
the month.
1.25 PROGRESS MEETINGS
Progress meetings shall be held on a fortnightly basis in accordance with an agreed

schedule. All matters bearing on the progress and performance of the work since the
preceding progress meeting shall be discussed and resolved, including any previously
unresolved matters, deficiencies in the work or the methods being employed for the
work, and problems, difficulties, or delays which may be encountered.
Unless otherwise specified or required by the Employer or Engineer, the meetings

shall be attended by the Employer, the Engineer and the Contractor. Subcontractors
may attend when involved in the matters to be discussed or resolved but only when
requested by the Employer, Engineer, or Contractor.
1.26 ORDERING MATERIALS
All material for incorporation in the permanent and /or temporary works will be
supplied by the Contractor, except to the extent specified elsewhere or otherwise
instructed by the Engineer. The Contractor shall obtain the Engineer's written
approval for the particular supplier from whom he proposes to obtain materials.
Except where otherwise stated or approved by the Engineer, all materials used in the
works shall be as specified or described in the Specifications, Drawings and Bills of
Quantities and shall comply with the appropriate current standards published by the
British Standards Institution, ASTM or other approved standards.
The Contractor shall be responsible for payment of royalties, if any, arising due to the
obtaining of materials for use in the works. No separate payment will be made by the
Employer as a royalty for materials.
1.27 SAMPLES
In addition to any specific provisions in the Specifications or in the Bills of Quantities

for the sampling and testing of materials, the Contractor shall, at his own expense,
submit, for retention by the Engineer, samples of all materials which he proposes to
employ in the permanent work. No material shall be used in the permanent work
unless and until such samples shall have been approved in writing by the Engineer.
The Engineer may exercise his powers under the relevant Clause of the Conditions of
Contract in respect of any materials which, in his opinion, are inferior to the relevant
sample previously approved.

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DUBAI – UAE
1.28 TESTING MATERIALS
All materials intended for use in the permanent work including necessary soil testing
and for the testing of which no specific provision is included elsewhere in the
Specifications or in the Bills of Quantities, shall be tested at the Contractor's expense,
either at the place of manufacture or fabrication, or on site, or at a laboratory
approved by the Engineer. The testing shall determine, to the satisfaction of the
Engineer whether the materials comply with the requirements of the Specifications. If
such testing is undertaken at the place of manufacture or fabrication, the Contractor
shall submit the supplier's test certificates to the Engineer before the dispatch of the
relevant consignment.
Either in addition to, or as an alternative to, testing at the place of manufacture or

fabrication, or on the site, or at an approved laboratory, the Engineer may direct that
tests be carried out elsewhere by an independent person or laboratory at the
Contractor's expense.
1.29 MATERIAL TESTING LABORATORY
The Contractor shall arrange for sampling, hauling and testing for the required
laboratory testing of soils and materials, all at his own expense, at an independent
laboratory approved by the Engineer and as required by the Engineer.
1.30 INSPECTION OF MANUFACTURING PROCESSES AND FACTORY

TESTING OF MATERIALS
The Contractor shall afford the Engineer full access to inspect the manufacture and
witness factory testing of all materials to be incorporated into the permanent works.
Reasonable notice shall be given by the Engineer of his intention to visit the factory
for such purpose, and the Contractor shall keep the Engineer informed of his
manufacturing and testing programme.
Factory tests required on materials shall be as detailed in these Specifications or in

the relevant British, American, or other national or international standards, as
applicable. Records of all tests carried out shall be kept at the place of manufacture
and shall be open to inspection by the Engineer. Copies of tests shall be sent to the
Engineer, as required.
1.31 REMOVAL OF CONDEMNED MATERIALS
The Engineer may require the Contractor to remove and dispose of any materials
employed in the construction of the permanent works which, in the opinion of the
Engineer are unsuitable, or have been incorrectly deposited, or have suffered
damage by exposure to the weather, or otherwise are not in accordance with the
specified requirements for such materials. The Contractor shall not be entitled to any
payment whatsoever in respect of such materials.

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DUBAI – UAE
1.32 MATERIALS ARISING FROM EXCAVATIONS AND DEMOLITION
The Contractor shall not sell any materials arising from excavation, demolition, and
the like, carried out on the site, unless authorized in writing by the Engineer.
The re-use or disposal of any such materials shall have the prior approval of the
Engineer.
1.33 PROVISION OF FACILITIES FOR ENGINEER'S INSPECTIONS
The Contractor shall provide the necessary equipment, access including inspection
platforms and foot bridges and labour to enable the Engineer and the Engineer's
Representative conveniently to carry out such inspections as they may deem
necessary, at all times during the currency of the Contract.
1.34 INSPECTIONS BY THE ENGINEER DURING PERIOD OF MAINTENANCE
The Engineer will give the Contractor due notice of his intention to carry out any
inspections during the period of maintenance, and the Contractor shall, thereupon,
arrange for a responsible representative to be present at the times and dates named
by the Engineer. The Contractor's Representative shall render all necessary
assistance and take note of all matters and things to which his attention is directed by
the Engineer.
1.35 LANGUAGE OF CORRESPONDENCE AND RECORDS
All written communications from the Contractor to the Employer or the Engineer shall
be in the English language.
All books, time sheets, records, notes, drawings, documents, etc., shall be in the
English language. If the original documents are in another language, a certified
translation in English shall be submitted to the Engineer.
1.36 RECORD DRAWINGS
As the work proceeds, the Contractor shall make Record Drawings based on the
Contract Drawings, as modified, to portray the works as actually constructed.
Drawings shall be supplemented as necessary by schedules, data sheets, etc.
Draft Record Drawings shall be submitted to the Engineer for his approval, and then
finalized in accordance with any amendments required by him.
The originals (reproducible transparencies) and three copies of all Record Drawings
shall be submitted. Along with drawings on formats based on software format on the
latest base maps issued by Dubai Municipality.
1.37 PENULTIMATE ACCOUNT

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Not later than sixty days after the issue of the Certificate of Completion for the whole
of the works, the Contractor shall submit to the Engineer a penultimate account with
detailed final measurements of the whole of the works as constructed, at the date
shown on the Certificate of Completion, together with all further sums which the
Contractor considers to be due to him under the Contract.
1.38 QUALITY CONTROL, TESTS, METHODS AND DEFINITIONS
1.38.1 Construction Control
The Contractor shall maintain close control of materials and quality of the works, and
shall report promptly to the Engineer should any circumstances make him dissatisfied
with the progress and/or quality of the work.
1.38.2 Tests During Construction
Unless otherwise stated, the tests referred to be as called for the relevant AASHTO,
ASTM, BS and DIN Standard Specifications, and other pertinent international
specifications, in accordance with the latest editions current on the effective date of
the Contract.
a. WATER WASTAGE
The Contractor will be charged by DEWA (PEWC) for all losses of water occurred
during the shutdown and execution of work, and that occur as a result of negligence
in the execution of the works.
b. REFERENCE SPECIFICATIONS
The contractor will make available on site during the duration of the works, a copy of
all Standard Specifications referred to in these Specifications, and also any alternative
Standard Specifications he may request approval for.
A copy of these Specifications will be submitted to the Engineer upon his request.
c. PIPELINE ACROSS PRIVATE PROPERTY.
Contractor shall remove and reinstate at his cost the existing fence wherever the
pipes are to be laid across the fenced area.
d. DEWA SAFETY AND OCCUPATIONAL HEALTH RULE’S
Contractor shall adhered to the following:
a) Contractor has to submit a copy of his Safety Policy, prior to starting the work.

SPECIFICATIONS
DUBAI – UAE
b) Contractor shall strictly adhere to DEWA’s Safety Rules, a copy of which be

collected prior to the beginning of his work on site.
c) Contractor shall produce method of statements outlining how he will approach

work activities. The method statements shall include risk assessments.
d) Contractor shall monitor and provide details and near hit performance during
the course of the contract.
e) Contractor shall ensure that visitors to the site are properly made aware of
Safety & Emergency procedures during a check-in procedure.
f) Contractor shall report on their Health & Safety Performance as part of their
project progress reporting.
g) Contractor shall report to Safety Section of DEWA thru the concerned Dept. all
accidents and near Misses (Near Hits) as per procedure and prescribed form. In
continuation of which they shall also fill up the Follow up Report form including
their actions.
h) Contractor shall report quarterly o Safety Section of DEWA thru the concern
department, as per procedure, their Accident Frequency Rates (AFR), Accident
Severity Rates (ASR), other parameters in connection with Safety and
Occupational Health.
i) Contractor shall report quarterly o Safety Section of DEWA thru the concern
department as per procedure, Risk Assessment Report with their part of action.
j) Contractor shall provide the all-necessary information and cooperation to the

Safety Section of DEWA and DEWA’s staff in inspection, investigation and in
other safety and occupational health issues.
k) Contract shall cooperate with Safety Section of DEWA during cross checking
which DEWA reserves the right for.
l) Contractor shall take the specification thru the concerned department before
procuring and after that quality standard clearance of PPE’s from Safety
Section of DEWA.
m) Contractor shall take care and take necessary action of all other additional
items if found hazardous and risky in nature.
n) Apart from those mentioned above, Contractor shall adhere to follow the latest
advice and suggestions on Health & Safety issues, during the Contract.
e. ISO 9001 AND ISO 14001 COMPLIANCE
DEWA is an ISO 9001 and ISO 14001 certified company as well as certified from the
British Safety Council as a safety conscious organization. The Contractor and
Subcontractors working for the Project shall also be covered under these certifications
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DUBAI – UAE
and therefore, they are obliged to follow strict control, regulations and audits, which
are obligatory under these certifications.
Accordingly, all site works on the Project shall be in compliance with ISO 14001. The
Contractor shall ensure that his staff and laborers are trained adequately, so that they
are familiar and can comply with the general requirements. Control, segregation and
disposal of waste shall be according to the requirements of environmental regulations.
SECTION 2
EXCAVATION AND BACKFILLING
2.01 GENERAL EXCAVATION

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General excavation means excavation, whether bulk or incidental required for

structures and exploratory excavations and shall not include Trench Excavation.
The ground shall be excavated by such methods and to such dimensions and depths
shall allow for the proper construction of the Works.
Where nominal "payment" limits of excavation are not shown in the Drawings or
otherwise specified they shall be deemed to be the minimum net limits, which would
allow the outline of the completed structure to be lowered vertically from ground level
into its final position. The Contractor shall make his own allowance for any working
space required, any excavation outside the aforesaid limits which has not been
ordered by the Engineer, whether it be excavated to suit the Contractor's method of
working or unavoidable over break or due to his carelessness or error, shall be held to
be Excess Excavation and shall not be measured for payment.
Generally Bulk excavation in cut or fill and necessary access road work shall be
carried out prior to trench or structure excavation and bulk excavated or filled up level
shall form the commencement level of trench excavation. Payment shall be
computed only for the approved Bulk excavation in cut and imported fill as per the
approved working drawings and not for the quantity of the fill material utilized from the
cut quantity or extra available from trench or structure excavation.
2.02 PRE-CONSTRUCTION RECORDS
Before an excavation is started:
A. Initial ground levels shall be agreed at suitable intervals with the Engineer.
B. Surface materials and conditions will be recorded in presence of the Engineer

and where appropriate the owners or occupiers of the land.
C. The Contractor shall take photographs to illustrate existing damage or

conditions which may prove contentious at the time of reinstatement.
This information shall be neatly presented and submitted to the Engineer. To this
shall be added details of any existing natural or piped subsoil drainage or other
underground features as work proceeds.
Trial excavations to be carried out along the route of pipeline for location of all existing
services and findings to be presented on drawings with location, type and levels. All
services to be included in final drawings. The excavations shall not be backfilled
without approval.
2.03 TOPSOIL AND SURFACING MATERIAL
Before commencing excavations or filling to an area, topsoil and other surfacing

materials shall be stripped and stored separately from the subsoil. Subsequent
spreading of topsoil or removed to spoil shall be as directed on site.
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DUBAI – UAE
2.04 LAND DRAINS
Where pipelines are to be laid in agricultural land the surface and subsoil drainage
shall be maintained whether natural or artificial. Before commencing work the
Contractor shall ascertain from the owner or occupier of the land the location of any
existing land drains or mole drains.
2.05 EXCAVATED MATERIALS
All excavated material will remain the property of the Employer unless designated as
surplus to the Contract requirements in which case it will be removed from site
immediately. The Contractor shall dispose of such surplus or unsuitable material and
his proposed tips shall be subject to the approval of the Dubai Municipality.
inconvenience as possible.
Excavated material for use as backfill shall be as approved. Different classes of

material shall be handled and deposited separately.
Where (natural) subsoil drainage depends on the relative positions of pervious or

impervious strata, special care shall be taken to separate those materials and replace
them in their natural positions.
2.06 FORMATION
Damage to the formation shall be prevented by bottoming-up with hand excavation

immediately before placing concrete or pipe laying. Any damaged formation shall be
excavated and refilled with concrete or selected material as instructed. No permanent
works of any kind shall be constructed on an excavated surface until the formation
has been approved.
2.07 INSPECTION BY THE ENGINEER
When the specified levels or limits of excavation are reached the Engineer will inspect
the ground exposed, and if he considers that any part of the ground is by its nature
unsuitable he may direct the Contractor to excavate further. Excavation as ordered to
remove unsuitable material below the specified limits of excavation shall not be held
to be Excess Excavation.
Should the material forming the bottom of any excavation, while acceptable to the
Engineer at the time of his inspection, subsequently become unacceptable to him due
to exposure to weather conditions or due to flooding or have become puddled, soft or
loose during the progress of the Works, the Contractor shall remove such damaged,
softened or loosened material and excavate further by hand. Such further excavation
shall be held to be Excess Excavation.

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2.08 ROCK AND HARD MATERIALS
For the purpose of this Contract rock and hard material shall mean those natural or
artificial materials which are so hard that they require specialized "rock splitting"
techniques in order to break them down to such a size that they can be removed by
conventional excavating plant. Use of pneumatic tools or rippers will not in itself justify
rock or hard material classification. The Contractor shall notify the Engineer as soon
as he encounters rock or hard material for which he intends to claim payment to
permit an assessment to be made as excavation proceeds. Hard subkha and
cemented sand materials shall not qualify for any extra over payment applicable for
the above mentioned materials such as Hard/rock category
2.09 USE OF EXPLOSIVES
Explosives shall only be used with approval. Explosives shall be acquired, stored and
used in accordance with the laws of the country and any licenses shall be held on site
for examination at any time. The storage and use of explosives shall comply with the
detailed requirements of the Engineer. Detonators shall be conveyed and stored
separately.
The charges shall be limited so that the amplitude of vibration in any direction does
not exceed +0.1mm at 40Hz frequency of vibration or other such amplitude and
frequency so that the maximum particle velocity does not exceed 25mm per second.
It will be measured at the nearest building, water or service main or where the works
are not within 100m of buildings or services it will be measured at this distance. The
Contractor is to provide an approved viborgraph such as 'The Cambridge Universal
Vibrograph' or 'I.C.C. Combigraph' capable of giving a vibrogram of displacement with
an amplitude record all on a time base. Alternatively a Dawes-Elcomatic recorder or
equal approved may be supplied, being capable of producing a vibrogram of
amplitude and/or a record of particle velocity. Concrete plinths or wall brackets shall
be provided to give a firm standing for the vibrograph when recording is taking place.
These are to be removed when no longer required.
Notices setting out the procedure shall be posted round the site, together with any
other safety requirements. Sufficient watchmen at each end of the excavation or
where directed shall be provided, together with fencing and other measures for the
protection of persons, vehicles and property. Adequate screens, shields, matting or
other measures to intercept material liable to be blown outside the excavations shall
also be provided.
Warning of an impending firing of a charge by a siren shall be given.
Blasting operations shall only be carried out under the supervision of a competent
foreman.
The firing of charges must not unreasonably interfere with or be a danger to persons
or property. The Engineer reserves the right to withdraw permission for the use of
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DUBAI – UAE
explosives if his Representative is not satisfied with the precautions taken. If there is
street lighting or plants etc. in or around the area if blasting, care should be taken see
that the operations are of forces not to damage or affect such plant, street-lighting etc.
The Engineer's and DWD's representative must be present during such operations.
Proper records of explosives shall be maintained for inspection of Engineer and
Police authorities.
2.10 TRENCH EXCAVATION FOR PIPEWORK
Trench excavation means excavation of trenches in which pipes are to be laid and the
term pipes shall mean pipes of all kinds and for whatever purpose.
The line and level of trenches shall be as shown in the Drawings or as may be
directed by the Engineer. Before commencing Trench Excavation, the route of the
trench shall be pegged out accurately and the natural ground levels and lengths shall
be measured and agreed with the Engineer.
A. The Contractor shall include for clearing the route of the pipeline of all surface
obstructions, grading the route to provide access for his equipment and
personnel, executing all cutting to remove high points of rises in terrain and in
all respects prepare the route for pipe laying operations, all in accordance with
the requirements of good pipeline construction practice.
B. Unless otherwise shown on the Drawings or instructed by the Engineer, water

pipelines shall be laid in trenches with minimum soil cover as specified in
clause 6.04. L...
C. The bottom of the trenches shall be properly trimmed-off, bottomed and

prepared to provide a firm and uniform bearing throughout the entire length of
the pipe. Care shall be taken to prevent excavation below the level of the
bottom of the pipe, and portions of trenches excavated below the grade shall
be filled with suitable material and thoroughly compacted to specific degree in
layers of 150 mm by the Contractor at his own expense as directed by the
Engineer at the Contractor's own expense.
D. Where rock or hard subkha materials are encountered, the excavation shall be
carried below the bottom of the pipe for a depth of 150 mm which shall be
back-filled with granular fill or soft sand compacted to the proper grade and
density.
E. Where pipe trenches are excavated across or along asphalted roads,

sidewalks, stairs and pavements, the Contractor shall carefully saw cut the
edges of the asphalt, stairs and pavements, remove the hard-core and paving
tiles and store them for reuse, or cart away the spoils to tips as directed and
shall comply with Dubai Municipality Local Orders and as amended related to
this activity.

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F. The sides of trench excavation shall be vertical unless the Engineer otherwise
approved in writing and where this work is in a surface road or adjacent to a
road then the conditions of Dubai Municipality Local Orders and as amended
relating to such activity shall be strictly adhered to.
G. Any widening or deepening of trench excavation necessary to accommodate

curves, joints or bends in the pipe or to provide extra working space for the
construction thereof shall be held to be Excess Excavation and is deemed to
be included in the Contractor's rates.
H. Trial holes shall be excavated well ahead of the trench excavation to such
depths as necessary to determine the alignment for the trench. Trial holes
may also be required by the Contractor to determine the position of
underground services, subsoil drains or for any other reason. Trial holes shall
be excavated and reinstated at the Contractor's expense and the Contract
Rates for pipe installation shall be deemed to include for all trial holes.
All trial holes must be backfilled by same evening, and no trial pit will remain
open overnight. Reinstatement of trial holes also must be carried out as per the
approved procedure, at no extra cost.
I. Hand excavation must be used where existing cables, water mains, sewers,
etc., cross or are in the main roads, where traffic is likely to be unreasonably
dislocated by use of machine, or for reasons of limited access, or where
instructed by the Engineer. In other places, hand or machine excavation may
be employed at the discretion of Contractor.
J. Excavation by machine must not normally be deeper than 150 mm below the
finished grade, unless the Engineer decides otherwise. The Contractor will be
held responsible for making good at his own cost all additional damage to road
surfaces and private lands caused by the use of mechanical excavators.
2.11 GEOTEXTILE FABRIC & GRANULAR MATERIALS FOR PIPE BED

AND SURROUND FOR TRANSMISSION MAIN PIPELINES
2.11.a Granular Material for Pipe Bedding and Surround
stable gravel or crushed stone to BS 882 and shall be graded in accordance with BS
882: Part 2, as shown in the following table:-
Table 2.11.a; Granular Material for Pipe Bedding
TEST SIEVE PERCENTAGE BY WEIGHT PASSING SIEVE

(MM)
63 _
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DUBAI – UAE
37.5 _
20 _
14 100
10 85 – 100
5 0 – 25
2.36 0-5
NOTE:
1. Total Acid soluble content of the material when tested in accordance with
BS1377 shall not exceed 0.3 percent by weight of sulphate expressed as SO 3
(Sulphur Trioxide).
2. The Material shall have a compaction factor value not exceeding 0.15.
2.11.b Pipelines on Granular Beds
Where granular bedding to pipelines are detailed the minimum thickness of bedding
materials beneath the pipe shall be 200 mm (minimum 100 mm under sockets)
commencing pipe laying be as short as practicable.
The bedding material shall be extended to the full width of the trench and shall be
carefully compacted in layers not exceeding 200 mm, to achieve positive deflection
and to the specified accepted limits.
Recesses shall be formed in the bedding to accommodate pipe joints while ensuring
continuous even support along the length. Bedding material shall be prevented from
entering pipe joints. After joints has been made bedding material shall carefully place
and hand compacted beneath the joint barrel to close any void left by the recess.
Where the formation of the trench is of silt or soft clay and is below the natural water
table a 75 mm blinding layer of sand shall be substituted for the specified bedding
materials directly above formation and carefully compacted if directed.
2.11.c Geotextile Filter Fabric
The Geotextile filter fabric shall be laid for pipes above 450mm dia. The granular
bedding and surround to all pipes above 450mm dia. shall be enclosed within a
geotextile filter fabric

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DUBAI – UAE
Filter fabric shall consist of thermal bonded/needle punched synthetic polymer fibres.
composed of at least 85 percent by mass polyolefins, polyesters,
polypropylene,polyethylene or polyamides. They shall be formed into a network such that
the filaments or yarns retain dimensional stability relative to each other, including
selvages.
The geotextile Manufacturer/supplier must be certified according to ISO 9001 for

quality management and ISO 14001 for environmental management system.
The fabric shall be stabilized against ultra violet light, inert to commonly encountered
chemicals in the in-situ soil and saline water and it shall conform to the following
minimum requirements
Grab Strength (N) ASTM D-4632 800

Puncture Strength (N) ASTM D-4833 355
Burst Strength (kPa) ASTM D-3786 2000
Trapezoid Tear (N) ASTM D-4533 220
Permeability (m/sec) ASTM D-4491 0.0001
Apparent Opening Size (mm) ASTM D-4751 0.6
Ultraviolet Degradation ASTM D-4355 70 @ 150 h
Where filter fabric is used to enclose granular pipe surrounds, the fabric will be placed
on the prepared trench formation and carefully supported during pipe laying
operations. When the pipe has been laid complete with surround to the correct level,
the filter fabric shall be closed over the top of the surround by forming a lap of
minimum width 500 mm. All membrane joints shall be overlapped a minimum of 500
mm.
installation or during backfilling of the trench. Any fabric damaged or displaced before
or during installation or during placement of over laying aggregate material shall be
replaced or overlaid to the satisfaction of the Engineer at the Contractor’s expense.
During period of shipment and storage, the fabrics shall be maintained wrapped in a
heavy duty protective covering and protected from direct sunlight, ultra-violet rays
and temperature greater than 70o C.
2.12 WIDTH OF TRENCHES

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The width of the trench shall be sufficient to permit the pipe to be laid and jointed
properly, and the backfill to be placed and compacted as specified.
Unless otherwise shown on the Drawings or instructed by the Engineer, the minimum
width of trenches for the pipes of 150 mm diameter and above shall be equal to the
pipe outside diameter plus 600 mm and for all pipes less than 150 mm in diameter,
width of trench shall be OD plus 500 mm.
Trenches shall be of such extra width, when required, as will permit the convenient
placing of timber supports, sheeting and bracing and handling of specials. Extra
widths and support wherever necessary shall not be paid separately but deemed to
be included in rates elsewhere.
2.13 REMOVAL OF PAVEMENTS
The Contractor shall remove pavement and road surfaces as a part of the trench
excavation, and the amount removed shall depend upon the width of trench specified
for the installation of the pipe and the width and length of the pavement area required
to be removed for the installation of valves, fittings, valve chambers, thrust blocks,
manholes, or other structures.
The width of pavement removed along the normal trench for the installation of the
pipe shall not exceed the width of the trench specified by more than 150 mm on each
side of the trench. The width and lengths of the area of pavement removed for the
installation of valves, meters, fittings, valve chambers, thrust blocks, manholes, or
other structures shall not exceed the maximum linear dimensions of such structures
by more than 500 mm on each side. Wherever, in the opinion of the Engineer,
existing conditions make it necessary or advisable to remove additional pavement,
the Contractor shall remove it as directed by the Engineer but shall receive no extra
compensation therefore. The Contractor shall prior to excavation in roads and paved
areas mark out the limit of excavation and saw cut the pavement to produce a vertical
face through bound materials and suitable for the subsequent tying in of subsequent
reinstatement works. The remaining excavation shall be maintained as a vertical face
and shall be supported where appropriate or as directed by the Engineer to ensure
that no undermining of the remaining road surface takes place. Where in the opinion
of the Engineer or Dubai Municipality representatives undermining has taken place
then a new edge shall be defined and the surface saw cut and excavated back to this
face for reinstatement purposes and shall be done at Contractor's expense. All works
shall be in accordance with Dubai Municipality rules and regulations relating to this
type of work.
2.14 BARRICADES, GUARDS AND SAFETY PROVISIONS
To protect persons from injury and to avoid property damage, adequate barricades,
constructions signs, torches, yellow flashing lights, revolving lights and guards as
required shall be placed and maintained during the progress of the construction work
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and until it is safe for traffic to use the road. All materials, stockpiles, equipment and
pipes that obstruct to traffic shall be enclosed by fences or barricades and shall be
protected by proper lights. The safety rules and regulations of Dubai Municipality,
Dubai Traffic Police and shall be complied within full at Contractor's expense.
The Contractor shall comply with regulations relating to the placing of warning signs,
lights or flares. In the absence of such regulations, the Contractor is to place warning
signs visible during day-light and yellow flashing lights or flares visible during
darkness in accordance with the detail approved by Dubai Municipality Roads
Department and Dubai Traffic Police relating to the particular location for the road
signing.
Where works affect footpaths or access to properties then suitable alternative routes
or provisions shall be made and the public protected, guided and informed by
approved provisions.
Should the Contractor fail to erect any barrier, safety guards, signs, lights or any other
warning signal for protection after being requested to do so by any authorized person
or body, the Employer shall erect such signs and barriers, etc., which he considers
necessary for the safety of the works and the public, at the Contractor's expense.
2.15 TRENCHES NOT TO BE LEFT OPEN
Trench excavation shall be carried out expeditiously and, subject to any specific
requirements of the Contract, the refilling and surface reinstatement of trench
excavations shall be commenced and completed as soon as reasonably practicable
after the pipes have been laid and jointed. Pipe laying shall follow closely upon the
progress of trench excavation and the Contractor shall not permit unreasonably
excessive lengths of trench excavation to remain open while awaiting testing,
commissioning, backfilling, etc. of the pipeline. In any case not more than 500m long
trenches shall be left open in one section. Greater lengths if found required shall have
the prior approval of the Engineer, and no trench, in any case shall be left open for more
than 3 weeks. The Contractor shall be responsible for preventing and taking precautions
against floatation of pipes in locations where open trench excavations may become
flooded, and these precautions may include the partial filling of the trench leaving pipe
joints exposed for water tightness testing of the joints.
If the Engineer considers that the Contractor is not complying with any of the
foregoing requirements he may prohibit further trench excavation until he is satisfied
with the progress of laying and testing of pipes and refilling of trench excavation. The
Contractor will not be permitted to excavate trenches in more than one location in any
one road at a given time without the Engineer's written permission.
2.16 MAINTENANCE OF TRAFFIC AND CLOSING OF STREETS
The Contractor shall carry on the work in a manner that will cause the least
interruption to traffic and he shall not close, or partly close, any road or street without
the written consent of the Dubai Municipality Roads Department, Dubai Traffic Police
and the Engineer.
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After such consent, the Contractor shall, at his own expense, provide means of
access to all buildings, rights of way, etc., warning signs, lights, barricades and
diversion notices.
All road crossings in open cut shall be adequately shored and timbered, with
arrangements to maintain the flow of traffic as directed by the Engineer and subject to
the approval of Dubai Municipality Roads Department, the Services Authorities and the
Dubai Traffic Police.
Special attention shall be given to the backfilling of road crossings and the Contractor
shall repair and replace road surfacing material by like kind and quality, maintain and
make good all such works as directed by the Engineer.
The Contractor, shall, in all respects, comply with the requirements of the Authorities,
the Police and the Engineer and in accordance with Dubai Municipality Local Orders
and as amended and subject to Dubai Municipality Roads Department NOC. Except
as provided above, the Contractor shall at all times maintain free passage over all
roads for all traffic.
2.17 PROTECTION OF SERVICES AND/OR STRUCTURES
The Contractor shall be responsible for the care and protection of all existing
DEWA/ED, ETC cables, sewer pipes, water pipes, culverts, or other facilities and
structures, which may be encountered in or near the area of his work. Temporary
support, adequate protection, and maintenance of all underground and surface
structures, drains, sewers, and other obstructions encountered in the progress of the
work shall be furnished by the Contractor at his expense and under the direction of
the Engineer.
Any services or structures that have been disturbed or damaged due to negligence of
Contractor shall be promptly restored to their original condition, or better, to the
satisfaction of the Engineer and subject to Services Authorities NOC's at contractor's
expense.
In the event of any damage to existing structures, facilities and services during the
progress of the work and of the failure of the Contractor to exercise proper care, the
Contractor will be held liable for the cost of all repairs to said structures, facilities and
services.
2.18 SUPPORT TO EXCAVATIONS
The sides and/or the bottom of excavations shall be adequately supported as per
provisions of Local Order No: 29 and its amendments.
Supports shall be properly maintained until permanent work is sufficiently advanced to

permit their removal and shall be left in if specified or as instructed.

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Trench supports shall be so arranged to permit withdrawal during the placing of the
pipe bedding so as to prevent voids.
Battered sides to trenches or other excavations will only be permitted if they can be
constructed within the limits of the site, without damage or interference to existing
services, properties or structures, without undue interference with pedestrians and
traffic and to slopes, which are sufficiently flat to ensure stability of the ground.
2.19 CONTROL OF WATER AND FLOATATION
All excavations including trenches, headings and tunnels shall be kept free of water.
In addition, precautions shall be taken to prevent floatation of partially built structures,
completed structures to be backfilled on commissioning of the works, and pipelines
not backfilled.
Dewatering methods, proposed break tanks may include temporary drains,

intercepting ditches, cut-off drains, sub-drains, sumps, wells, pumps, well-points or
other dewatering equipment and shall include all other things necessary to keep water
out of the excavations or to lower groundwater around structures liable to floatation.
All necessary precautions shall be taken to prevent any adjacent ground from being
adversely affected by loss of fines through any dewatering process.
The Contractor shall submit methods statements for prior approval of the Engineer.
Method Statements shall include proposals for disposal of the water arising from
dewatering systems.
Under no circumstances will permission be given for the discharge of groundwater

into the existing sewerage system.
If permission is given to use new or existing pipes or culverts which are not part of the
live sewerage system, they shall be thoroughly cleaned of all silt and any resulting
damage made good after use.
All temporary Works for control of water shall be sited clear of the Works, except
where temporary sub-drains under the Works are approved in which case the pipes
shall be laid covered with tarred felt cloth or other approve material.
Unless otherwise directed all temporary drains and sub-drains shall be finally sealed
with concrete at approved intervals and all temporary ditches, sumps, wells, etc., shall
be refilled and reinstated as specified elsewhere.
If lagoons for the storage of groundwater are permitted, they will be suitably protected
with fencing and attended by day and night to prevent access by the general public
and will not be sited adjacent to buildings. Approved means of preventing the
formation of mosquito larvae on the surface of the lagoons will be employed.
All necessary precautions shall be taken to prevent any ground water from entering
mains to be used for the conveyance of potable water.
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2.20 VENTILATION
Adequate ventilation and efficient apparatus shall be provided to keep excavations,

trenches, tunnels and headings free from all gases from whatever source.
2.21 BACKFILLING
Backfilling around structures and in pipe trenches, except where filling is designated
on the drawings or specified as "non-structural fill" or "structural fill" to support
structures shall be carried out as detailed below.
Backfilling shall normally be carried out using selected excavated materials similar to
the in situ materials in which the trench or structure is being constructed. Where the
Engineer's Representative designates the excavated material as unsuitable, suitable
material shall be imported, at no extra cost.
Material for backfilling may be selected from any part of the site and methods of
selection may include sieving to remove large particles or methods of hand or
machine sorting.
Where the excavation is near an existing structure liable to subsidence, where part of
the works may later be constructed over or near it or in emergencies the Contractor
may be instructed to backfill with concrete.
Backfilling shall be carried our as defined below.
A. Cohesive Soils
Cohesive soils shall be placed in layers not greater than 150mm thick
(compacted thickness) and compacted such that throughout each layer placed
the dry density is not less than 95% of the in situ dry density of the soil prior to
excavation when tested in accordance with relevant BS specification.
The placement moisture of the soil shall be within the range 2% below to 1%
above the natural in situ moisture content of the soil before excavation.
It is to be noted that the cohesive ( subkha ) soils or hard materials from

excavations shall be broken down to suitable sizes to be used for, backfilling,
of the top two layers for stability or as per Engineer’s instructions at no extra
cost.
B. Granular Soils
Granular soils shall be placed in layers not greater than 150mm thick
(compacted thickness) and compacted such that throughout each layer placed
the dry density is not less than 95% of that obtained in the vibrating hammer
compaction test when the test is carried out on the same soil at the same
moisture content in accordance with relevant BS specification.

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Unless otherwise directed the moisture content shall be maintained and if

necessary adjusted by approved means to fall within the range plus 1.5% to
minus 3% of optimum moisture content determined in the vibrating hammer
compaction test.
For free draining granular soils that have no clearly defined optimum moisture
content, compaction shall be carried out to achieve a relative density of not
less than 95%. During compaction the soil shall be made as wet as
practicable.
C. Testing of Backfill
The Contractor shall provide at his own cost the services of an approved
independent laboratory as is necessary for the carrying out of all the tests for in
situ and backfilled soil properties and shall maintain with a copy to the
Engineer, a daily log of tests carried out.
All back fills shall be carried out in layers of 150 mm thick. In-situ soil
compaction tests shall be carried out for pipe line trenches at the rate of one
test per 100mtrs of trench length for each layer of 150mm thick, starting from
450 mm above the crown of the pipe. Deep test shall not be carried out as the
test location may not be representative. Also, the Contractor shall continue
backfilling the next upper layer only if the test result for the previous layer is
available and found to have passed as per the requirements. In addition to the
pipeline trench backfilling and testing the chambers pits and pits forming at the
sides of the Thrust blocks shall backfilled in accordance with the relevant
specifications and tested for compaction for every 150 mm thick layers of
backfills. The initial layer to be tested shall be the excavated formation level for
the Thrust Block or chamber pits, which shall be tested prior to placing the
structure. The remaining in-situ soil compaction tests to be carried out as the
backfilling progresses layer by layer.
Where a land drain passes through an excavation the backfill shall first be taken up to
form a bed for replacement pipes. The severed drains shall then be exposed at each
side of the trench excavation. This new drain shall be of similar pipes of the same
diameter as those in the existing drain. Before any further backfilling is done the
Contractor shall notify the owner or occupier to enable him to see the reinstated land
drain. The replacement drain shall be surrounded with pipe bedding material to a
minimum thickness of 150mm before further backfilling.
2.22 STRUCTURAL AND NON-STRUCTURAL FILLING
Structural filling is required in paved carriage ways, hard shoulders, footpaths and
parking areas and wherever a structure is to be supported on the fill and where
settlement is required to be minimized to structural minimal. Non-structural filling will

SPECIFICATIONS
DUBAI – UAE
normally be carried out to embankments and other fill areas. Embankments hall
normally be overfilled and subsequently trimmed to the required profiles.
A. Structural Filling
Structural filling shall be carried out using well graded natural sands and gravel having the
following minimum requirements:
Liquid limit not less than 25%
Plasticity index not less than 6%
The material shall have a smooth grading curve within the sensibly parallel to
the grading envelope below:
Sieve Size % by Mass Passing
75 mm 100
37.5 mm 85 - 100
10 mm 45 - 100
5 mm 25 - 85
600 um 8 - 45
75 um 0 - 10
Above the water table, locally occurring Subkha materials may be used for
structural filling, subject to Engineers approval.
The material shall be laid and compacted to layers not greater than 150 mm
thick (compacted thickness) to achieve a dry density of not less than 95% of
the maximum dry density, determined in the modified vibrating hammer
compaction test. The placement moisture content shall be adjusted to fall
within the range 1% above to 2% below the optimum percentage determined in
the modified vibrating hammer compaction test as per the relevant BS
specification.
B. Non-Structural Fills
Cohesive Soils selected as being suitable shall be placed and compacted in

layers not greater than 150mm thick compacted to 95% as per the relevant BS
specification. The material shall be placed at its natural moisture content
unless this is more than 2% below the optimum moisture content determined in
the Proctor Compaction Test in which case it shall be raised by approved
means to a moisture content in the range of 2% above and below the optimum.
Granular Soils selected as being suitable shall be placed and compacted in

layers not greater than 150 mm thick (compacted thickness) to achieve a dry
SPECIFICATIONS
DUBAI – UAE
density of not less than 90% of the maximum dry density determined in the
vibrating hammer compaction test. The placement moisture content shall be
adjusted by approved means to bring the moisture content within the range 3%
below to 1.5% above the optimum moisture content determined in the vibrating
hammer compaction test.
Disposal on Site of Unsuitable Materials If the Contractor is given permission to

dispose of excavated materials which are designated unsuitable for filling or
backfill on the site they shall be placed in regular layers without compaction as
directed. If the Contractor is not given such permission they shall be classified
as surplus excavated material.
2.23 STONE PITCHING
The sides and bed of the watercourse or embankment shall first be trimmed to the
required profile.
The pitching shall be hand placed, roughly square on all faces, and the upper (water)
face shall be roughly dressed and laid to break joints. Pitching shall be firmly bedded
and jointed in 75 mm thick cement mortar.
2.24 REINSTATEMENT OF DAMAGED SURFACES AND PROPERTY.
If any pavement, fences, poles, Irrigation system or other property and surface
structures have been damaged, removed, or disturbed by the Contractor, whether
deliberately or through failure to carry out the requirements of the contract documents,
state laws, municipal ordinances, or the specific directions of the Engineer or through
failure to employ usual and reasonable safeguards, such property and surface
structures shall be replaced or repaired at the expense of the Contractor. If the
Employer specifies that the replacements or repairs shall be made by the Contractor,
he shall replace or repair and restore the structures to a condition equal to that before
the work began, and to the approval of the Engineer, and shall furnish all required
labor, plant and materials therefore.
2.25 REINSTATEMENT OF UNPAVED LAND
In general the reinstatement of stripped areas of unpaved land shall be restored to a

condition not inferior to that which existed before the site was occupied.
The compacted backfill shall be taken up to a level which allows for settlement. In
arable, grassed and similar areas the surface to be top soiled shall then be loosened
to a depth of 200mm and topsoil replaced on it to the specified depth without
compaction using approved topsoil of comparable quality to make up any deficiency.
Areas where grass is to be sown shall be worked with fine tilth, leveled, graded and
rolled with a light roller. The seed shall be sown evenly at the specified rate of
application in the proper season and in suitable weather conditions, and the areas

SPECIFICATIONS
DUBAI – UAE
again rolled. Restoration and re-seeding of any areas where the new grass is
inadequate.
Reinstatement of the grassed area shall be in accordance with the specification and
the approval of Dubai Municipality Horticulture Department.
As an alternative to seeding the "dibbing in" at 200mm centers of "Bugunda" or similar

tropical grass tufts may be required.
The grass shall be well watered four times a day and the Contractor will be required
to keep the grass cut short until the Maintenance Certificate has been issued.
2.26 REINSTATEMENT OF PAVED CARRIAGEWAYS, PARKING AREAS

& HARD SHOULDERS
There shall be only "one time" reinstatement for asphalted roads and paved areas
and these shall be reinstated strictly in adherence to Local Order No. 29 and its
amendments vide Administrative Order No. 22 and is further clarified as follows:
All affected asphalt surfaces shall be reinstated only 'one time' reinstatement by the
Contractor as per the cross sections pertaining to the relevant road classification
stated in above Administrative Order.
Any settlement in reinstated areas up to a period of one year shall be treated as

defective workmanship and will have to be repaired free of cost to the client.
All reinstatement must be carried out by Dubai Municipality approved road contractors
only.
The testing of materials and in-situ test shall be those commonly employed on Dubai
Municipality Roads Department contracts.
2.27 REINSTATEMENT OF OTHER SURFACED AREAS

Reinstatement of surfaced areas other than roads such as pavements or reservations
shall be reinstated with an acceptable wearing surface as per local Order No. 29 and
its amendments vide Administrative Order No. 22 and maintained up to a period of
one year. Any settlement in the reinstated areas during this period will have to be
done at Contractor's expense.
2.28 EXCAVATION AND REINSTATEMENT IN DEVELOPED RESERVATIONS
The Municipality Horticulture Department will remove any trees, bushes and plants
from developed reservations that they wish to preserve prior to the commencement of
work by the Contractor.
The reinstatement of the developed reservations shall be to backfill and compact the
excavations in accordance with Clause 2.20 and to restore the surface in accordance
with Clause 2.23 and 2.24.

SPECIFICATIONS
DUBAI – UAE
2.29 CLEANING UP OF PIPELINE ALIGNMENTS
After installation and backfilling of the pipeline and also after restoration of surfaces,
the Contractor shall clean the site and the surrounding ground and he shall dispose of
all waste material, debris, and rock resulting from his operations. The Contractor shall
restore the site and the surrounding ground to the satisfaction of the Engineer.
2.30 NON-DISRUPTIVE PIPELINE CONSTRUCTION BENEATH ROADS
Where instructed to do so, the Contractor will be required to construct pipeline

beneath roads, and elsewhere, using non-disruptive methods, such as pipe boring
and jacking, which avoid breaking the ground surface. The Contractor shall submit full
details of his proposals for such non disruptive methods to the Engineer for approval
and subject to Dubai Municipality Roads Department NOC for each such locations.
Work on non-disruptive pipeline construction shall be performed only by contractors,

approved subcontractors, who are experienced in the performance of such work under
similar conditions, with the approved from Dubai Municipality for the methodology of
operation.

SPECIFICATIONS
DUBAI – UAE
SECTION 3
PIPES AND APPURTENANCES
3.1 GENERAL
3.1.1 Scope of Works
The work shall consist of supply of Fibre Cement. Pipes and Joints, G.R.E. Pipes/
Fittings, Valves, flow meters, domestic water meters, Manhole covers with frames,
Detectable warning tapes, A. C. Joint Lubricant (Soft Soap), PVC pipes, House
connection materials etc.
All materials and equipment supplied shall be suitable for use in Dubai and under
conditions prevailing at the site of the works.
All the materials are to be approved by the Dubai Electricity and Water Authority-
water division before ordering. Sample for all items shall be submitted to DEWA
without any cost charged to DEWA, and will remain DEWA’s property. All samples
shall conform to the specification. Any deviation in the samples shall be clearly
mentioned in the submission. If requested by DEWA, the tenderer shall carry out
testing on samples without any extra charges at the evaluation stage and/or after
award of the contract. The sample shall have a sticker showing tender number
and tenderer name.
The items under ‘provisional’ or ‘provisional quantity’ may be ordered either partly
or fully or can be deleted from scope of tender.
Any failure in testing in presence of DEWA’s representative at the time of delivery,

can be considered a cause of rejection for the entire consignment, and DEWA’s
decision shall be final and binding to the tenderer.
If there is contradiction in different clauses of specification for any item/part, the

clause with high in quality or DEWA decision will prevail. If there is any ambiguity/
conflict in interpretation of specification, DEWA decision will be final and binding
on the tenderer.
The following are to be submitted along with the submittal for approval:
Quality system certificate to conform ISO 9000 (or equivalent) series for the
manufacturer.
Original detailed catalogues, product technical data and any other required
documents.
Details of past supply records for the last four years in U.A.E., Gulf countries, and
other countries, separately.

SPECIFICATIONS
DUBAI – UAE
Important:
(I) Where no year is shown following the specification of B.S., I.S.O. etc., and
the latest edition shall be deemed applicable.
(ii) Non ISO 9000 certified manufacturers with previous successful supply
experience for similar items, may be approved at DEWA’s sole discretion.
(iii) If the detail in catalogue and technical data is different from DEWA
specifications, deviation shall be cleared mentioned and clarify whether actual
supply shall be as per DEWA specification or not.
3.1.2 ENVIRONMETAL ASPECTS
DEWA is implementing “ENVIRONMENTEL MANGEMENT SYSTEM –ISO 14001

– 96’’. All finished product to be supplied, shall be environmental friendly and shall
have no impact on environment. The manufacturer / supplier / Tenderer shall
follow Dubai Municipality local order no. 61 of 1991 on the environment protection
regulations in the Emirate of Dubai.
3.2 FIBRE CEMENT (F.C.) i.e. ASBESTOS CEMENT (A.C.)

PRESSURE PIPES FOR POTABLE WATER
3.2.1 General
Fibre cement (FC) pressure pipe shall conform to the requirements of BS-EN
512/1995. F. C. Joints shall be manufactured by the same F. C. pipe
manufacturer. No internal or external coating shall be provided. The pipes shall be
manufactured by an established F.C. pipe manufacturer having successful
experience in the manufacture and supply of large diameters of high pressure F.C.
pipes. Evidence of such experience shall be provided with the tender offer. The
manufacturer shall be certified to ISO 9000 series.
Pipes and Joints shall be made from a close and homogeneous mixture essentially
consisting of Chrysotile Asbestos Fibers (no other fibers allowed to use), Sulphate
Resisting Cement and Potable Water excluding any materials liable to cause
ultimate deterioration in the quality of the pipes.
Full detail of technical collaborator, if any, shall be submitted
3.2.2 References
The following standards are applicable where referenced in the following

specifications:

SPECIFICATIONS
DUBAI – UAE
1 BS - EN 512 1995 Pipes & Joints
2 BS - EN 681 - 1 1996 Elastomeric seals for

joints in pipe work and
pipelines
3 BS 4027 1996 Cement
4 ISO 2785 1986 Pipe design
3.2.3 Class and Type
Hydraulic test pressure at the factory is the basis of pipe classification. F. C. pipes
and joints shall meet the requirements for Class 18, i.e. test pressure in the
factory 18 bars. F. C. pipes and joints class-24 shall meet the requirement 24 bars
of test pressure in the factory. This shall be applied similarly for other class. If
class is not mentioned in Bill of Quantity, pipes shall be supplied with class 18.
Pipe wall thickness shall meet all design requirements. Pipe ends shall be plain
with bevelled edge.
3.2.4 Dimensions
Fibre cement pipe shall be manufactured and supplied in 3-metre nominal lengths for
diameters 300 mm and smaller and in 5-metre nominal lengths for above 300mm.
Allowance for different lengths will be accepted up to 5% against 10% as mentioned in
ISO/BS. For direct supply to DEWA, pipes above 300mm diameter, shall be supplied
only in 5 metre lengths. All joints and pipe ends shall have the following principal
dimensions:
CLASS - 18
Nominal Outside Diameter Calibration Length Length Of F.C.

Diameter At The Machined At The Machined Joint
End End
mm mm
mm mm
75 93 110 104
80 106 110 104
100 126 125 120
150 178 125 120
200 234 155 150
225 255 155 150
250 288 155 150
SPECIFICATIONS
DUBAI – UAE
300 344 155 150

350 402 210 200
450 508 210 200
500 560 210 200
550 616 240 200
600 668 250 240
700 780 250 240
900 1000 280 270
1200 1320 310 300
CLASS - 24
Nominal Outside Diameter Calibration Length Width Of F.C.

Diameter At The Machined At The Machined Joint
mm End End mm
mm mm
225 270 155 150
300 354 155 150
600 688 250 240
900 1026 280 270
1200 1360 310 300
CLASS 40
Nominal Outside Diameter Calibration Length Width Of

Diameter Class At The Machined At The Machined End F.C. Joint
mm End mm mm
mm
600 40 734 260 250
900 40 1110 310 300
Tolerance on external diameter of F. C. pipes at the calibrated (machined)

end:
Nominal diameter Tolerance

mm mm
Upton 300 + 0.6
Over 300 up to 500 + 0.8
Over 500 up to 700 + 1.0
Over 700 up to 1100 + 1.2
Over 1100 up to 1600 + 1.5

SPECIFICATIONS
DUBAI – UAE
3.2.5 Cement
All cement used in the manufacture of fibre cement pipe and joints shall be a high
sulphate resisting cement conforming to BS 4027:1996, type LA with strength
class-42.5 N. Copies of cement mill certificates shall be submitted with each
consignment of pipe delivered upon request.
3.2.6 Joints
Fibre cement pipe shall be provided with spigot ends to be joined with 'Reka' type
couplings using two rubber rings, which compress to form a watertight seal when
the joint is assembled. Each pipe shall be supplied with one joint and two rubber
rings at no extra cost. Rubber rings shall be of EPDM rubber and conform to the
requirements of BS. EN. 681-1:1996. the manufacturer of rubber rings shall have
fitness certificate for use in contact with potable water from the Authority of ‘Water
Regulations Advisory Scheme, U.K.’ or equivalent National Authority acceptable
to DEWA. The joints shall be capable of withstanding an internal pressure equal to
the factory test pressure without any leaks when deflected to the angle specified
below:
Nominal Diameter Max Joint Deflection Angle

mm Degrees
80-250 5
300 - 350 4
400 - 600 3
700 - 1200 2
1300 and above 1
Copies of test reports showing compliance to these requirements shall be

submitted to the Engineer for approval if requested. REKA rubber rings for
couplings shall be supplied in closed bags / containers shielded from sunlight.
Each bag / container shall contain only one size of rubber rings and shall be
marked with a clear print indicating the diameter and the number of rings in the
bag.
3.2.7 Design Calculations
Pipe design calculation as per ISO 2785 shall be submitted to the Engineer for
review, showing maximum safe burial depth for each diameter and class of pipe, if
requested.
3.2.8 Curing

SPECIFICATIONS
DUBAI – UAE
Water curing shall be done on all manufactured pipes and joints for a minimum 14
days. No steam curing shall be accepted. Steam curing is a process whereby all
manufactured items are transferred into enclosed chamber with steam nozzles
spraying steam to accerlate curing. This process does not ensure consistent
curing (slow curing) and subsequently quality is affected. Manufacturer is advised
to give curing methodology.
3.2.8 Testing
Factory Quality Control:
Fibre cement pipes shall be factory tested in accordance with BS-EN 512-1995 by
manufacturer. These tests are to be carried out as their internal routine
acceptance test by manufacturer before inspection and testing carried out by
client/consultant. Copies of test certificate shall be submitted for each
consignment delivered if requested by DEWA / Consultant. The pipes shall pass
the result obtained from formulae mentioned in both standard BS 512 and
ISO160.
Inspection and testing and of a Consignment of Finished Product at factory:
The inspection and testing of a consignment of finished product is to be carried

out in presence of DEWA representative / Consultant. Inspection, sampling, lot
size and testing shall be in accordance with BS - EN 512:1995. The size of
inspection lot will be at client discretion limited within minimum and maximum lot
specified in BS 512, taking into consideration quality of past supplies. Lot size for
diameters larger than 1000 mm shall be 200 pipes. The manufacturer shall carry
out all tests including destructive tests in presence of DEWA’s representative/
consultant before delivery. The tenderer shall give Fourteen days advance notice.
The pressure bursting test for pipes diameter above 1000mm shall be carried out
hydraulically/mechanically. Testing and related activities shall be carried out at no
additional cost. Pipes, which are destroyed in testing, shall be replaced at no
additional cost. In addition to above, if requested by DEWA, the tenderer shall
carry out tests on pipes/joints delivered to site at tenderer’s expense including
transportation.
The pipes shall pass the result obtained from formulae mentioned in both
standard BS 512 and ISO160.
For outside U.A.E. manufacturer:
In addition to above, 1 % of total numbers of pipes of each size and class after
delivery to DEWA stores/sites, the tenderer shall arrange testing at local
laboratory / any other arrangement in DUBAI for all tests including destructive
tests. The pipes shall pass the result obtained from formulae mentioned in both
standard BS 512 and ISO160. Any failure shall lead to for complete rejection of
consignment and DEWA decision shall be final and binding to the tenderer. The
SPECIFICATIONS
DUBAI – UAE
Contractor/Tenderer shall replace pipes, which are destroyed in testing, at no

extra cost. The cost of transport of pipes and joints for testing at local laboratory
and delivery once again, shall be born by the tenderer / contractor.
Failure of Pipes and Joints at the Time of Testing At Sites in Dubai
During hydro pressure testing at site after delivery to Stores/site and, if

pipes/joints failed, shall be replaced at no extra cost including transport expenses.
The reason of the failure shall be investigated by DEWA and DEWA decision shall
be final and binding to the tenderer.
3.2.9 Markings
Each pipe and joint shall be legibly and indelibly marked with the following:
i. Manufacturing standard
ii. Manufacturer's name or trademark.
iii. Manufacturing date
iv. Home line positions at pipe ends [pipe only].
v. Nominal Diameter (ND) in mm
vi. Pressure rating in Bars (Class)
viii. DEWA / Contract no.
The date of manufacture and company trade mark / name shall be engraved
minimum 2mm deep on the pipe and shall be clearly legible and shall be to the
satisfaction of DEWA.
3.2.10 F.C. Pipes -Full Length Calibrated - Class 18
Full length calibrated F.C. pipe shall conform in all respects to F.C. pipe
specifications except that pipe shall be machined for full length and shall have the
following outside diameter along the entire length of the pipe.
Nominal Diameter Outside Diameter mm

mm
500 560
550 616
600 668
700 780
900 1000
1200 1320
All pipes shall be pressure tested only, (No destructive tests) in accordance with
BS - EN - 512-1995 requirements after normal manufacturing. Each pipe shall be
pressure tested for a second time for duration of 5 minutes in presence of
DEWA’s representative after the entire length has been machined, to insure pipes
SPECIFICATIONS
DUBAI – UAE
have not been damaged during the machining works. All pipes above 300 mm dia.
shall be of 5 meters length only. The pipes shall be supplied without joints.
3.2.11 F.C. Special Joints - Class 18
F.C. special joints shall be designed to fit F.C. pressure pipe with the following outside
diameters.
CLASS 18
F.C. Special Joint to fit To Fit To Outer Length Of Joint
on pipes of Nominal Diameter Of F.C. (mm)
Diameter (mm) Pipe
(mm)
75 97 104
80 109 104
100 130 120
150 183 120
200 240 150
225 258 150
300 350 150
500 565 200
550 618 200
550 620 200
550 622 200
550 624 200
600 672 240
600 674 240
600 676 240
700 784 240
700 786 240
900 1004 270
900 1006 270
900 1008 270
1200 1325 300
1200 1327 300
1200 1329 300
F.C. Special Joints: Class 40:
A.C. Special Joint to fit on To Fit To Outer Diameter Of Width Of Joint

pipes of Nominal Diameter Class A.C. Pipe mm
mm mm
600 40 734 250
900 40 1110 300

SPECIFICATIONS
DUBAI – UAE
If the outside diameter at calibrated ends (O.D) is mentioned in the item

description, then special joints shall be fit to the specified O.D. The A.C. special
joints shall be of class 18 and shall conform to BS- EN - 512-1995.
Following shall be marking on special joints by solid marker (metal marker)
1 The nominal diameter and outer diameter shall be written on each special joint
clearly, e.g. 150 / 181 mm for 150mm special joints
2 SP. JT.
3 Manufacturer name
4 Date of manufacturing
5 Contract no.
6 Two circular black lines to differentiate form normal joints.
3.2.12 F. C. Step Joints - Class 18
F.C. step joints shall be designed to fit F.C. pressure pipe having outside
diameters at calibrated ends (O. D.) as specified in the item
The F.C. step joints shall be of class 18 and shall conform to BS- EN - 512-1995.
One circular black line shall be on each joint to differentiate form normal joints.
The nominal diameter and outer diameter (O. D.) shall be written with metal
marker on each side joint clearly, e.g. 75 - 93 mm (on one side) and 80-126mm
(on another side) for 80/75mm F. C. step joint. The joint length shall be same as
of standard F. C. joint - class 18. If requested by DEWA, shop drawing shall be
submitted for approval.
Following shall be marking on step joints by solid marker (metal marker)

1 The nominal diameter and outer diameter shall be written on each step joint
clearly, e.g. 150 / 181 mm on one side of joint and 150/ 178 on another side
of joint
2 ST. JT.
3 Manufacturer name
4 Date of manufacturing
5 Contract no.
6 One circular black lines to differentiate form normal joints.
3.2.13 Samples
The following samples are to be submitted by the F.C. pipe supplier / tenderer, if
requested.
SPECIFICATIONS
DUBAI – UAE
1. 225mm F.C. pipe class 18 - one meter long with both ends calibrated and
beveled - as per specifications.
2. 225mm F.C. joint class 18 with rubber rings as per specifications- 1 no.
If requested by DEWA, sample of other size shall be submitted.
3.2.14 Pipe Data Sheets
Supplier shall fill the Pipe Data Sheets in section of Schedule of this tender for
each pipe size and class in the contract. The data sheets shall be submitted with
the tender.
3.2.15 Storing in Stock Piles at Manufacturer Store/ Contractor Store/ Site/

during transport
Care must be taken that the storage surface is leveled and firm and clear of rocks
or solid objects that might damage the pipes. The pipes shall be stored in
separate stockpiles according to their class and nominal diameter. Any
extraneous materials are to be removed from the area.
Stockpile should not exceed a certain height. This height is limited for safety and
practical reasons as per the table below.
DN 80-400 450-600 700-1000 1100- 1500

1400
Storing  2m  2.4m  3.0m  2.8m  2.0m
height h
Wooden wedges to avoid off sliding of the whole pipe stack should be placed on
both sides of the first layer in the stack. The first layer of pipes shall be placed on
white wood bearers.
3.2.16 Transportation of Pipes

Great care is to be taken while loading the pipes on the trucks at the factory. F.C.
pipes and joints shall be properly and securely transported from the place of
manufacture to stores/sites. Where pipes are transported by truck, the pipes shall
be transported on wooden cradles or skids and shall be properly protected from
contact with metal surfaces by rubber or wooden spacers or wedges. Ensure that
the lower pile is supported by means of timber bearers. Pipe movement should
not occur during transport. If required, pipes shall be tightened by means of pliable
straps /ropes No stacking shall be allowed for pipe larger than 900 mm in
diameter during transport. No nesting (smaller size of pipe inserted in bigger size
of pipe) shall be allowed.

SPECIFICATIONS
DUBAI – UAE
Where any part of the transport is done by ocean freight or barge, or other means
for pipes imported from outside the U.A.E., then the following packing procedures
shall be applicable and followed:
All F.C. pipes and joints shall be transported in full wooden crates. That crates
shall be provided with transverse wooden spacer such that the unsupported span
of FC pipe does not exceed 2 meter, inside the crates. Crates shall be provided
with skids to allow lifting by forklift. Pipes inside the crates shall be provided with
rubber or polystyrene end protectors around the spigot surface of the pipe. Crates
shall be marked with the manufacturer’s name, the contract No. and details of
contains. Pipes shall not touch each other inside the crates. No nesting shall be
allowed inside the crates. Pipe 600mm in diameter and larger, shall be individually
crated. All packing and transportation expenses shall be deemed included in the
supply rates and no extra payment shall be made by DEWA. Packing and crating
details shall be submitted with the tender. Guideline sketch shall be supplied by
DEWA during evaluation of tender, which shall be complied strictly
3.2.17 Unloading
Unloading at stores/sites must be carried out carefully under the control and
responsibility of the tenderer. Care should be taken to avoid severe impact with
any solid object (i.e. other pipes, ground, etc.). Rate shall include unloading and
stacking as directed.
(a) Unloading by hand

Unloading by hand should only be used for smaller diameter pipes not exceeding
35 kg. for one man.
(b) Unloading using skids and ropes

Two wooden skids of suitable size should be placed on the side of the truck at
approximately 1/5 of the length of the pipe from each end and set an angle not
steeper than 45 degree. One end of each of two ropes should fastened to the
truck, on the opposite side of the skids. The other end of ropes should be passed
on the outer side of the skids under each end of the pipe to be unloaded. The pipe
can then be lowered by rolling carefully all way down the skids, controlled by the
ropes. The pipe travel should be under control. In no case, pipes shall be allowed
to roll free on the skids. Do not lower more than one pipe at the time
(c) Mechanical unloading

Mechanical unloading is required for pipes heavier than 200 kg. Flexible slings or
beams should be used combined with a mobile crane. When unloading with
mobile crane, care must be taken that the pipes do not slide off the slings.
Therefore it is recommended to use ropes or wide rubber or canvas bands to hold
the pipes and not the steel cables. For small diameter pipes one must center the
sling in the middle of the pipe and tighten it as much as possible to prevent the
pipe from slinding out of the sling. Avoid the use of steel hooks for lifting the pipes
SPECIFICATIONS
DUBAI – UAE
at its ends because this can damage the machined ends. If the use of canvas or
rubber slings is not possible use hooks with rubber protection.
(d) Unloading couplings

Even very small couplings must be unloaded with great care. They must not be
thrown off the truck on the ground. In general, couplings are bundled and can be
offloaded like the pipes. With a wooden beam going through the strapped
couplings, unloading can be easily performed.
3.2.18 Submission
Following are to be submitted along with tender / for approval of material.

1. Sample as described above
2. ISO 9000 Series certificate of manufacturer
3. Original catalogue and product technical data
4. Compliance/deviation of specifications paragraph by paragraph. Each page
shall be stamped and signed by the manufacturer, supplier and tenderer.
5. Certificate of cement manufacturer showing compliance to the specification
6. Certificate from the Authority of ‘Water Regulations Advisory Scheme, U.K.’ or
equivalent National Authority acceptable to DEWA for rubber used for rubber
ring, showing fitness to use with potable water
7. Certified agreement between technical collaborator and manufacturer, if any.
8. Supply record of last four years
9. Copy of all tests
10. Transportation detail – step by step procedure and sketch
3.03.A GLASS REINFORCED EPOXY (GRE) PIPES FOR POTABLE

WATER
3.03.A.1 General
This specification covers the requirements for the design, material, method of
manufacturing and testing of Glass Reinforced Plastic pressure pipe, fittings
and flanges.
3.03.A.2 Specification references
The material, subject of this specification shall be fabricated and tested in

accordance with the latest edition, revision or addendum of the
referenced codes, specifications or standards.
References
ASTM D 2310 Machine made reinforced thermosetting resin pipe.
ASTM D 570 Standard test method for water absorption of plastics.

SPECIFICATIONS
DUBAI – UAE
ASTM D 1598 Standard test method for time to failure of Plastic pipe under
constant internal pressure.
ASTM D 1599 Standard test method for short-time hydraulic failure

pressure of plastic pipe, tubing and fittings.
ASTM D 2105 Standard test method for longitudinal tensile properties of

reinforced thermosetting resin pipe and tube.
ASTM D 2290 Standard test method for apparent tensile strength of in or

tubular plastics and reinforced plastics by split disk method.
ASTM D 2412 Standard test method for external loading characteristics of

plastic pipe by parallel-plate loading.
ASTM D 2444 Standard test method for impact resistance of thermoplastic

pipe and fittings by means of a top (falling weight).
ASTM D 2563 Standard practice for classifying visual defects in glass-

reinforced plastic laminate parts.
ASTM D 2583 Standard test method for indentation hardness of plastics by

means of a Barcol impressor
ASTM D 2584 Standard test method for ignition loss of cured reinforced
resins.
ASTM D 2925 Standard test method for beam deflection of reinforced

thermosetting plastic under full bore flow.
ASTM D 2992 Standard practice for obtaining hydrostatic or pressure

design basis for “fiberglass” (glass fibre-reinforced
thermosetting-resin) pipe and fittings.
ASTM D 3567 Standard practice for determining dimensions of reinforced

thermosetting resin pipe (RTRP) and fittings.
ASTMD 3418 Standard Test Method for Transition Temperature of

Polymer by Thermal Analysis.
3.03.A.3 Pipeline Design
3.03.A.3.1 Design Conditions
Design Pressure

SPECIFICATIONS
DUBAI – UAE
GRE pipe/fittings shall be designed in accordance of 10 bars maximum

sustained working pressure (PN10), 16 bar maximum sustained working
pressure (PN16) and 25 bar maximum sustained working pressure (PN25) as
per B.O.Q. item to severe internal operating pressure that the system shall be
subjected to under all modes of operation, including starts-up, shut downs,
etc., throughout the entire life time of the system. If PN is not mentioned in
BOQ, It shall be PN10.
For PN16 or higher, the manufacturer shall submit details upon request.
Design Temperature
The design temperature should be the most severe temperature that the
system will be subjected to under all modes of operation, throughout the
entire lifetime of the system. The high design temperature should be the
highest temperature that the piping system will be subjected to i.e. 50
degree C, the cold design temperature should be the lowest temperature
that the piping will be subjected to under all modes of operation i.e. 5
degree C. The installation temperature shall be the expected ambient
temperature at the location during the time of the year in which the piping
shall actually be installed.
3.03.A.3.2 Hydrostatic Design Stress
The hydrostatic design stress (HDS) is the estimated maximum tensile

stress in the pipe wall in circumferential direction due to internal
hydrostatic pressure that can be applied continuously with a high degree
of certainly that failure will not occur.
The hydrostatic design stress shall be obtained by multiplying the
hydrostatic design basis (HDB) by the service (design) factor. The
hydrostatic design basis shall be the extrapolated value of the long term
hydrostatic strength (LTHS) to 50 years and shall be determined in
accordance with ASTM D 2992.
The hydrostatic design stress implies a minimum safety factor of 3, based
on the short-time hydraulic test method as described in ASTM D 1599.
3.03.A.3.3 Mechanical Design
The Contractor shall be responsible for conducting (by a specialized

engineering office), a computer based flexibility and stress analysis of the
piping system based on static (normal) operating conditions in addition to
dynamic (surge / trip) conditions, as per the manufacturer specifications. The
engineering office shall hold a valid certificate to the approval of the Engineer.
A suitable piping support system shall be designed such that all stresses in the
pipe, fittings and flanges are within the allowable limit set by the manufacturer.
The engineering office scope to include generating isometric drawings showing
supports location, loads, types, functions and support detailed design.

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The contractor shall be responsible for fabrication and installation of the

aforementioned piping support system. The contractor shall also be responsible
for supply and installation of any additional auxiliary equipment deemed
necessary in the Design Report.
3.03.A.4 Basic Materials
3.03.A.4.1 General
All structural materials shall be new, fresh and free from all detrimental
defects and imperfections and only be used for production. Testing and
controlling shall be done according to the relevant methods. The basic
materials shall be combined into pipes and fittings meeting the
performance requirements of this specification.
3.03.A.4.2 Resin
The resin to be used shall be epoxy resin. The resin-curing agent mixture
shall have sufficient chemical and mechanical resistance to meet the
imposed requirements. The resin shall be stored in adequate tanks for a
period of maximum 6 months, on suppliers prescribed conditions.
3.03.A.4.3 Curing Agent
The curing agent shall be an aromatic or cyclo-alipthalic amine type. The

choice of the curing agent type depends on the application of the RTRP-
system and/or the fabrication method. The curing agent shall be stored in
adequate tanks for a period of at maximum 6 months, on suppliers
prescribed conditions.
3.03.A.4.4 Reinforcement
As reinforcement of the thermosetting resin, two types of glass with low

alkali content shall be used. The glass reinforcement materials shall be
stored dry and protected against dust or other negative influences.
Liner Reinforcement
C-glass or polyester non-woven shall be used as reinforcing material for

the chemically resistant inner layer (liner).
Structural Reinforcement

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DUBAI – UAE
E-glass shall be used as reinforcing material for the structural wall. This
type of glass appears in the form of continuous roving or woven cloth.
Rovings are used in the filament winding process for the production of
pipes. Woven glass fabrics are used for the production of fittings and as
local reinforcement for all products. The reinforcing material shall be
provided with a special finish to assure a good adhesion with the matrix.
3.03.A.4.5 Adhesive
For all adhesive bonded joints a two component epoxy or other resin
mixture shall be used, depending on the application different types of
adhesive are available. The adhesive should be delivered as a kit,
containing pre-measured quantities of resin and curing agent and written
instructions covering preparation of surfaces, mixing, joining, safety, pot
life and curing. The adhesive has to be used before the latest work up
date, indicated on the packing.
3.03.A.4.6 O-Ring Seal
EPDM may be supplied depending on the type of fluid that shall be

transported.
3.03.A.4.7 Locking Strip
A thermoplastic locking strip may be supplied for the locking joints.
3.03.A.4.8 Potable Water Approval
The GRE piping shall not impart any taste, odor or colour to drinking
water. Pipes and fittings shall be approved and listed for potable water
use to minimum 50 degree C in accordance with Water Regulation
Advisory Scheme (WARS) – UK in accordance with BS 6920 or by the
National Sanitation Foundation (NSF) – USA in accordance with NSF
standard 14. The said certificate shall be submitted along with the
detailed report given by the agency. The test carried out by agency shall
be on a sample cut from a GRE pipe / fitting itself. GRE pipes above
ground to be painted to prevent sunlight from penetrating the pipe wall.
Painting procedure should follow manufacturer’s recommendations and
be approved by the engineer.
3.03.A.5 Fabrication
3.03.A.5.1 Pipes
Pipes are manufactured by the filament winding process, in which glass

reinforcement impregnated with Isophthalic, vinylester or Epoxy resin and
wound onto the outside of a mandrel in predetermined pattern under
SPECIFICATIONS
DUBAI – UAE
controlled tension. The rovings are saturated with the resin/curing agent
mixture and helically wound under a calculated winding angle.
3.03.A.5.2 Fittings
All GRE standard fittings up to 400 mm shall be filament wound on

precision steel moulds. Standard 45 and 90 degrees elbows shall be of
the smooth radius type having a turning radius of 1.5 x DN, and shall be
filament wound on precision steel moulds for dia. 600mm or below. All
GRP flanges shall be filament wound. Hand lay up flanges shall not be
permitted.
3.03.A.5.3 Wall Structure
Liner
GRE pipes and fittings shall have a resin rich liner reinforced with C-glass
with low alkali content or linear non-woven polyester/epoxy. The resin
content shall be at least 70% by weight and the minimum thickness of the
liner shall be 0.5 mm. The resin used for the liner shall be exempted of
pigments.
Reinforced Wall
GRE pipe structural wall shall be filament wound using continuous fibrous
glass strand rovings of E-glass, with a low alkali content impregnated with
Isophalic, vinylester or epoxy resin. For fittings woven glass fabrics made
of E-glass are used. The resin used for the reinforced wall shall be the
same as used for the liner in order to assure an optimal adhesion
between those two layers. The winding angle of the continuous glass
strand rovings of pipes shall be 55-65 degrees. Dark pigments hindering
visual inspection shall not be used.
Topcoat
GRE pipe and fittings (except on joint sealing areas) shall have a resin-
rich exterior surface having a minimum thickness of 0.3 mm.
3.03.A.5.4 Joints
The pipe jointing system shall be a flexible tensile resistant joint with an O-ring
seal and /or a locking device, of the type known as Rubber Seal Lock Joint up
to dia. 600mm as per requirement on site. Special pipe sections, with one end
configured to suit DEWA fiber cement couplers, have to be provided wherever
a GRP line connects to a fiber cement line.

SPECIFICATIONS
DUBAI – UAE
Reinforced Concrete Thrust Blocks shall be used at all changes in direction, size
reduction or expansion, and other thrust locations underground for unrestrained
systems. Thrust Blocks shall encase the entire GRP Fittings at the directional
change and should be constructed to fully absorb all thrust loads.
Thrust Blocks can be avoided by providing restrained fittings (i.e. changes in

direction, size reduction or expansion) and by providing self-restrained pipes and
joints immediately before and after the fittings. This hybrid pipe system shall be
Engineered and designed by the manufacturer.
3.03.A.6 Performance Requirements.
3.03.A.6.1 Impact Resistance
Pipe and fitting shall show no porosity when tested in accordance with ASTM
D 2444 or BS 5480.
3.03.A.6.2 Boil Resistance
Samples made from pipe or fitting laminates shall show no evidence of

delamination or other impairment when tested accordance with ASTM D 570.
3.03.A.6.3 Beam Strength
The axial modulus of elasticity of pipes, when tested in accordance with ASTM
D 2925, shall have a minimum value of 11500 N/mm2.
3.03.A.6.4 Stiffness
GRE pipe shall exhibit without structural damage a minimum stiffness (EI/D3)
at 5% deflection required by AWWA C 950.
3.03.A.6.5 Ultimate Hoop Stress
The short-time hydraulic failure strength of pipe and fittings, when tested in
accordance with ASTM D 1599, shall not be less than three times the rated
pressure.
3.03.A.6.6 Axial Tensile Stress
The axial tensile stress for pipes when tested in accordance with ASTM D
2105, shall not be less than 75 N/mm2.
3.03.A.6.7 Hoop Tensile Strength
The hoop tensile strength of pipes, when tested in accordance with ASTM D
2290, shall not be less than 210 N/mm2.

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DUBAI – UAE
3.03.A.6.8 Hardness
The indentation hardness of pipes and fittings, when tested in accordance with
ASTM D 2583 shall be at least 30 Barcol.
3.03.A.6.9 Glass Content
The glass content of the reinforced wall of pipes and fittings shall be
determined in accordance with ASTM D 2584. The glass content for pipes
shall be at least 65% by weight. The glass content for fittings shall be at least
60% by weight.
3.03.A.6.10 Hydrostatic Design Stress.
The hydrostatic design stress for pipes and fittings shall be obtained from the
extrapolated long term hydrostatic tests in accordance with ASTM D 2992 for a
life-time of 50 years. The minimum service (design) factor for the
determination of the hydrostatic design stress shall be 0.5.
3.03.A.7 Inspection and Testing
The pipe manufacturer must demonstrate the capability to produce pipe meeting
the requirements of these specifications and of consistent properties and quality.
A detailed quality control/quality assurance program must be implemented at the
manufacturing facilities and all necessary test equipment to be operating by skilled
technicians. The manufacturer’s Quality Control scheme shall be certified by a
recognized independent authority to meet the requirements of ISO 9001.
3.03.A.8 Markings and Identification
Each pipe section shall be marked with the following information.
1. Manufacturer’s name.
2. Nominal diameter.
3. Pressure rating
4. Product Classification.
5. Product Unique number.
6. Date of Manufacturing.
3.03.B GLASS REINFORCEMENT EPOXY (GRE) FITTINGS

SPECIFICATIONS FOR POTABLE WATER
All fittings (including bends, tees, reducers and flanges) used with FC water
pipelines shall be GRE fittings complying with the following specifications.
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DUBAI – UAE
The following specifications are referenced as applicable:
Reference Description
AWWA C 950-88 AWWA Standard for Fiberglass Pressure Pipes
ASTM D3517-91 Standard Specification for "Fiberglass

(Glass-Fibber-Reinforced-Resin)Pressure Pipes
BS 5480:1990 Glass Fiber Reinforced Plastics (GRP)

Pipes and Fittings for use for Water
Supply or Sewerage. Parts 1 & 2.
3.03.B.1 General
This specification covers the design, manufacture and testing of glass fibre
reinforced plastic pressure pipes / fittings for use with Fibre Cement pressure Pipe
in nominal sizes 50 mm and larger. GRE fittings and pipe shall be designed and
manufactured in accordance with AWWA C950 and the requirements herein. One
manufacturer shall produce all components of GRE pipes/fittings
The manufacturer must demonstrate the experience and capability to produce

fittings of the same diameter and pressure range as those required. The
manufacturer shall be certified to ISO 9000 series for quality system management.
A detailed check list (for each clause) shall be submitted by the tenderer along
with the tender documents to confirm his compliance to the specifications. Detail
of technical Collaborator Company with the manufacturer, if any, shall be
furnished along with the tender.
3.03.B.2 Construction
GRE fittings shall have the following principal construction:
i. Corrosion resistant, resin rich liner having a minimum thickness of

0.5mm.The liner surface in contact with water shall be reinforced
with "C" glass veil or mat impregnated with Epoxy Resin. The liner
shall be continuous along the circumference of the pipe and shall be
of uniform thickness and composition.
ii. A structural wall consisting of continuous glass filament windings

and/or woven rovings and chopped glass reinforcement, and

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DUBAI – UAE
may include fine fillers, all impregnated with Epoxy resin as

required.
iii. A resin-rich exterior surface having a minimum thickness of 0.25

mm.
No dark pigments shall be allowed in the GRE fittings. Flanged joints, where
specified, shall be GRE filament wound flanges, manufactured from epoxy resin
glass reinforcements.
All G. R. E. products shall be hot cured. Glass transition temperature shall be at

least 125 degree Centigrade for epoxy resin products.
3.03.B.3 Design Requirements
GRE pipe/fittings shall be designed in accordance of 10 bars maximum sustained

working pressure (PN10), 16 bar maximum sustained working pressure (PN16) and
25 bar maximum sustained working pressure (PN25) as per B.O.Q. item to severe
internal operating pressure that the system shall be subjected to under all modes of
operation, including starts-up, shut downs, etc., throughout the entire life time of the
system.
For PN16 or higher, the manufacturer shall submit details and design upon
request.
Hydraulic test pressure at the factory shall be 1.5 x maximum sustained working
pressure (PN). This shall be applied similarly for other pressure. If PN is not
mentioned in Bill of Quantity, pipes/fittings shall be supplied as PN10.
Pipe/fittings wall thickness shall meet all design requirements. Spigot fittings
ends shall be plain with bevelled edge and shall have outer dia. Same as Fibre
Cement Pipe at calibrated ends with tolerance of +0.6 or –0.6.
GRE pipes/fittings and flanges shall be designed in accordance with AWWA C950
for service at the following conditions for PN10:
Maximum operating pressures 10.0 Bars

Maximum test pressure at factory 5.0 Bars
Maximum allowable vacuum 1.0 Bar
Minimum depth of cover 1.0 Metre
Maximum depth of cover 4.0 Metre
Truck loading (Wheel Load) 90.0 KN
Service temperature (Maximum) 50.0 Deg. C.
For PN16 and above, manufacturer shall submit design data as above.
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DUBAI – UAE
Flange / Flange fittings shall be designed for installation above ground (in
Chambers) without thrust blocks. Flanged branches on Spigot Tees shall be
designed to resist end thrust from closed valves.
The pressure rating for GRE pipe and fittings shall be based on the long-term
hydrostatic design pressure established in accordance with AWWA C950 and
design factor of 2.0.
Laminated or adhesive Joints used in the fabrication of fittings shall be equal or
superior in strength to the sections they join. The thickness of laminated joints
shall not be less than the wall thickness of the adjoining pipe section. All hand
laminations or windings shall utilize only one type of resin throughout.
3.03.B.4 Chemical Requirements
GRE pipes/fittings shall not impart any taste, odor or colour to drinking water.
GRP pipe/fittings shall be certified and listed for potable water use by the Water
Regulations Advisory Scheme (WRAS), U.K., in accordance with BS 6920 or by
the National Sanitation Foundation (NSF) - USA in accordance with NSF Standard
14. The certificate shall be submitted for pipes/fittings and fit for cold and hot
water up to 50 degree C. If requested by DEWA, testing to comply with BS
6920 at local laboratory shall be carried on sample submitted to DEWA, at no
extra cost.
3.03.B.5 Dimensions
GRE fittings shall be produced in Metric sizes and shall be classified by their
nominal inside diameter (ND). All standard fittings up to and including diameter
600 mm used in the water system shall be filament wound on precision steel
moulds (except mentioned in the DEWA standard sketches which shall be
provided after award of tender). The fittings manufactured on steel moulds shall
be in one piece. The two pieces joined together, is not acceptable. Standard 90
and 45 degree bends of nominal diameter 600mm and smaller shall be of the
smooth radius type, having a turning radius of 1.5 times nominal diameter. Fittings
diameter larger than 600 mm may be of the moulded or mitered (manufactured
from GRP pipe sections) construction and internal surfaces shall be finished
smooth. Tangential (invert) spigot/spigot/flanged Tee shall be used in washout
chambers and shall have a bottom tangential flanged outlet with main spigot ends.
The overall dimensions and other details of standard fittings shall be as per the
DEWA standard shop drawings, which shall be supplied during evaluation/ after
award of tender and shall be complied strictly
1. The tolerance in length shall be +/– 5 mm for 400 mm dia. and below and +/-
10 mm for dia. 450 – 1200 mm.
2. Spigot Joints, where specified, shall have the same Outside Diameter (O.D.)
as DEWA-WD Fibre cement (FC) pipe class 18 or 24 or 40 to which it is to be
SPECIFICATIONS
DUBAI – UAE
jointed. Tolerances on the O. D. of the spigot of the GRP fittings shall be

same as tolerance to external diameter of F.C. pipes at calibrated ends
mentioned in F.C. pipe specifications such that the joint remains watertight
under all normal operating and surge conditions. The spigot ends shall be
clearly marked with a "home line" indicating the proper insertion limit for the FC
couplings. The spigot width (length) shall not be less than half the FC coupling
joint width except in flange / spigot adaptor. In flange/spigot adaptor, the spigot
width (length) shall be equal to width (length) of Fibre Cement coupler +
20mm. Spigot ends shall be with beveled edges.
3. The actual fitting inside diameter shall not be less than that shown in the
table below:
Nominal Diameter (ND) ( mm ) Minimum Inside Diameter ( mm )

50 48
80 78
100 98
150 148
225 223
300 298
400 398
450 448
500 497
550 547
600 594
700 695
900 890
1200 1190
4. G.R.E. Flanges shall be flat faced and drilled to BS 4504 PN 10 drilling pattern for
PN 10 pipes/fittings and for 225 mm and 550 mm dia for which ISO 2084 - 1974 /
PN 10 for PN10 pipes/fittings shall be applied. Similarly BS 4504 PN16 pattern for
PN16 pipes/fittings and BS4504 PN 25 pattern for PN25 pipes/fittings shall be
applied. GRE Flange gasket (full face) design and thickness shall be as
recommended by the GRE fitting manufacturer. Hand lay-up flanges shall not be
acceptable.
5. The thickness of GRE flanges for PN10 shall not be less than shown in the
table below:
Nominal diameter ( mm ) Minimum GRP flange thickness

(mm )
50 35
80-100 38
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150-200 44
225 45
300 54
400 60
450 64
500 64
550 68
600 72
700 78
900 93
1200 108
For other pressures, detail shall be submitted by the manufacturer to meet the
design requirement
6. The wall thickness of GRE fittings shall be determined by the manufacturer to meet
the design requirements of this specification but shall in no case be less than the
minimum thickness for PN10 as shown in the table below:
Nominal D Minimum GRE Fittings/Pipe

diameter thickness
(mm) (mm)
80 - 300 5.0
350-500 6.5
550 7.5
600 8.0
700 9.5
900 12.0
1200 16.0
3.03.B.6 Mechanical Properties
GRE fittings and pipes for PN10 used for fabrication shall meet the following
minimum strength requirements.
SR NO Property Test Method Minimum Value

ASTM As per table 10 of AWWA
1 Hoop Tensile Stress for GRP pipe
D2290 C950 for class 150 psi
Per table 11 of for
2 Axial Tensile Stress pipe ASTM D 638 GRP AWWAC950 for 150
psi

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DUBAI – UAE
Axial Tensile Stress for

3 ASTM D 638 70 MPa
flange/flange. Fittings
Initial Hoop Stress failure for molded ASTM 3.5 x rated
4
fittings D1599 Working pressure
ASTM Dia. 300mm 10000 pa
5 Initial Pipe Stiffness Dia.> 300mm 5000 pa
D2412
For other pressures, detail shall be submitted by the manufacturer to meet the
design requirement
3.03.B.7 Visual Requirements

GRE fittings shall be free from delamination, crazing, dry areas or cracks. Spigot
ends shall be free from end delamination, torn edges and gouges and shall be
finished smooth to ensure water tightness. All laminates shall be fully cured with a
minimum Barcol hardness of 33 when tested in accordance with ASTM 2583. The
inside liner of the G.R.P. fittings shall be free of cracks, voids and air inclusions.
3.03.B.8 Testing
1) Routine Tests
G.R.E. pipes and fittings shall be factory tested by the manufacturer in
accordance with AWWA C950 or BS 5480 at the frequency specified below. Test
results and certificates shall be submitted to the Engineer for each consignment
delivered if requested by DEWA.
SR
NO. Test Frequency
1 Visual inspection Every Item

2 Dimensions Every Item
One per 10 Flg x Flg
3 Hydraulic pressure
Items
3a Hydraulic pressure up to 600mm dia One per 20 spigot items
4 Pipe Stiffness for dia. > 300mm mitered Items itemsper
One for 100
dia.items
300mm
5 Barcol hardness (resin cured) Every Item
Pipe Axial and Hoop tensile stress for dia. >
6 One per 100 Items
300mm
Initial hoop failure stress for molded fittings Once per order on largest
7
(ASTM D1599) size
GRP pipe used for fitting fabrication shall be Every pipe
8
factory pressure tested at 18 bars
2) Qualification (Type) Tests

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DUBAI – UAE
The following tests shall be carried out on actual pipe/fittings produced by the
manufacturer to establish and accept the design basis for the products. These
tests are not routine quality control tests.
(a) Long term hydrostatic design pressure of the GRE pipes and molded
fittings shall be established on test data extrapolated to 50 years in
accordance with AWWA C950 Section 2.4.2. And ASTM D2992 Procedure
B
The long- term data shall be submitted for:
- Moulded Fittings
- Pipe Designs to resist thrust in flange/flange fittings and branch flanged
Tees. The long term testing of such pipes shall be done Bi-axially.
- Pipe with spigot ends to suit FC couplers may be tested uni-axially.
(b) Short-term hoop tensile strength shall be within the ultimate strength of the
pipe, fittings, laminated joints and flanged joints to withstand a hydrostatic
test pressure of 3.5 times the rated working pressure with no signs of
leakage or weep. For flanged joints, the flanges shall be blinded and the
ends unrestrained during the test.
Testing To Be Witnessed By DEWA / Consultant
(a) The tenderer/contractor shall intimate when pipes to be used in construction

of fittings and full consignment of finished product, is ready for inspection
and testing.
(b) 10% of total quantity shall be inspected and tested in the presence of
DEWA’s representative / consultant for the tests mentioned under serial
no.1, 2 and 5 of routine test. The quantity for testing for serial no. 3,3a,
4,6,7 shall be as mentioned in the column of frequency under routine tests.
10% of total quantity of pipes used for fittings shall be inspected and tested
in the presence of DEWA’s representative/ consultant for the tests
mentioned under serial no.8 of routine test
(c) 10% of total quantity for G.R.P. pipes required in construction for fittings: -
Pressure test shall be witnessed by DEWA’s representative / consultant,
necessary intimation shall be given to DEWA / consultant to witness the
test.
(d) All tests and related matter shall be carried out without extra charges.
3.03.B.9 Samples

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DUBAI – UAE
The following samples are to be submitted by the G.R.E. fittings supplier /

tenderer if requested by DEWA:
1. 225 x 225x 150 mm G.R.P. Tee spigot / spigot / spigot - 1 no.

2. 150 mm G.R.P. bend 90 double flanges - 1 no.
Other sizes, if requested by DEWA, shall be submitted.
3.03.B.10 Submittals/Drawings
Prior to start of production, the fittings manufacturer shall submit to the Engineer
dimensional drawings of each fitting required for approval. The Engineer may also
require design calculations, samples and sample testing for approval at no extra
cost to the client.
For flanged fittings, the manufacturer shall submit before delivery, the
recommended gasket details, the bolt torqueing sequence and maximum
recommended torque for each flange size supplied.
3.03.B.11 Markings
Each fitting shall be indelibly marked with the following:
- Manufacture's Name or Trade mark

- Nominal Diameter (N.D.) in mm
- Pressure Rating in Bars
- Manufacturing Date, Month and Year.
- Inspection Mark.
- DEWA/CW/Contract no.
- Coupling “home line" position on spigot ends.
Note: The marking label shall be prepared on computer sheet and shall be
placed on the fittings/ pipes just before last top layer of glass
reinforcements is applied and shall be readable.
3.03.B.12 Submission:
Following are to be submitted along with tender / for approval of material.

(1) Original catalogue and product technical data
(2) Manufacturer’s quality assurance certificate to ISO 9000 series.
(3) Sample as mentioned above.
(4) Check-list paragraph by paragraph showing compliance and deviation.

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(5) Certificate from Water Regulations Advisory Scheme (WRAS), U.K., /NSF,
USA showing fitness to use with hot and cold potable water in
accordance with BS6920 for pipes/fittings made from epoxy resin
(6) Detail report of testing carried out for fitness to use with potable water
for submission no. (5)
(7) Certified agreement copy between manufacturer and technical
collaborator
(8) Past four years supply record of supplier
(9) Past four years supply record of manufacturer
(10) Past four years supply record of technical collaborator
(11) Result and detail report of long term hydrostatic design pressure
(12) Result and detail report of short term hoop tensile strength
(13) Copy of routine tests
3.4 VALVES AND APPURTENANCE
3.4.1 General
All valves supplied shall be suitable for use with water temperatures up to 50 o C
and in climatic and soil conditions encountered in the Dubai area. The nominal
working pressure shall be 10 bar or as mentioned in the tender. On class 24 pipe
line, all valves shall be PN16 even if it mentioned PN10 in B.O.Q./nothing
mentioned in B.O.Q.
Unless otherwise specified, all valves and appurtenance shall be externally and
internally fusion bonded epoxy coated using electrostatic/fluidized bed process
conforming to DIN 30677 or approved equivalent, with a thickness of 300 micron
(except wherever specified with different coating/lining) holiday free non-toxic and
colour code RAL 5015. Before application of epoxy coating the surface shall be
sand blasted to a minimum SA 2.5 and air blown to ensure good bond. A
certificate verifying the suitability of the epoxy coating for use with drinking water
is required from the manufacturer endorsed by the Water
Regulations Advisory Scheme (WRAS), UK or similar independent national body

acceptable to DEWA.
The flange valves shall be supplied complete with flange gaskets and stainless
steel nuts, bolts and washers of grade 316. Bolts and nuts shall be supplied with
2 washers per bolt. The bolt length shall be such that after the joints are made-

SPECIFICATIONS
DUBAI – UAE
up, the bolt protrudes through the nut, but not more than 12 mm. It shall fit to
G.R.P. flange . Face to face dimensions for flange valves shall be as per BS 5163.
Unless otherwise detail or specified here in, gate and butterfly valves shall be
supplied complete with extension spindles and appurtenances such that the square
nut operation is within 500 mm of the top of the chamber cover slab. Where
required, special couplings shall be incorporated to absorb the weight of the
extension spindle at no extra cost to DEWA.
The dimensions of stem cap of all valves and square nut operator in case of
extension spindles or without extension spindle shall be in accordance with BS
5163. All valves shall be supplied with stem (spindle) cap made from ductile iron.
The spindle cap shall be fixed with spindle by a nut bolt passing through it so that
spindle cap is tied with spindle. The manufacturer shall fix spindle cap to spindle
by a nut bolt before dispatching (not acceptable as loose items).
Unless otherwise specified here in, all attaching hardware of all valves and
appurtenances including the nuts, bolts and washers for flanged valves shall be
stainless steel 1.4404 to DIN 17440 or approved equivalent.
All valves shall be tested to the appropriate test pressure at the manufacturer’s
works and shall be supported by a test certificate from the manufacturer.
Inspection, function test and strength test shall be made in accordance with DIN
3230 or approved equivalent.
The Contractor shall supply the manufacturer’s test certificate. The certificate shall
relate to the individual number cast/written on steel plate on each valve.
Marking of valves shall include the following:
- Manufacturer’s Name or Trademark

- Nominal Diameter(s) (N.D) in mm.
- Pressure Rating in Bars.
- Individual Serial Number which relates directly to the
Manufacturers test certificate on steel plate
- Date of Manufacture mentioned on steel plate fixed on valve
- DEWA Contract no.
- Weight of valve for sizes above 300mm dia.
All gate and butterfly valves shall be clockwise closing. Where specified, position
indicators shall be provided on all gate and butterfly valves and shall have
adjustable end limit stops at both open and closed end positions to prevent
damage by excessive operating force.

SPECIFICATIONS
DUBAI – UAE
The maximum effort required to operate the valve against the maximum
unbalanced head applied at the circumference of the hand wheel or end of tee-
key shall not exceed 15 Kg. where necessary gearing shall be provided as
specified to achieve this.
All gate and butterfly valves shall be designed to provide 100 % water tight shut
off at all specified pressures and suitable for installation of electrical actuators
when required. Line valves of 300-mm dia. and smaller shall be double spigot
gate valves with beveled ends.
The outside dia. of spigot ends after coating shall fit with the AC pipe coupling
supplied to the Contract. While machining spigot ends, the manufacturer shall
take into account thickness of epoxy coating. Outer dia. after coating of spigot
ends shall be as outer dia. of A. C. pipes with a tolerance of + or - 0.3 mm.
Where flanges are required they shall be drilled to PN 10 in accordance with BS

4504 except for 225 mm & 550 mm dia for which ISO 2084 -1974 / PN10 shall be
applied unless specified or directed otherwise.
Hand wheels shall be providing for all valves when installed above ground, when
operation is within reach. Valve installed out of reach above ground shall be
provided with chain drive or remote control drive as the case may be.
All valves shall be preferably manufactured in and supplied from North American/
EEC former Western European countries. Valves manufactured by other
countries, may be approved subject to DEWA approval.
Valve shall be manufactured by an ISO 9000 series certified company who has
had several years of experience in the manufacture of valves and shall have a
fully equipped technical back-up and service facility in the U.A.E.
The manufacturer shall provide a warranty of minimum 5 years to DEWA based

on a repair / replacement basis at no extra cost. The warranty period shall be
counted from the date of issuance of the Takeover Certificate of the project even
though the delivery and installation is made earlier. The warranty shall be valid
whether the warranty certificate is issued or not by the manufacturer/ supplier/
tenderer to DEWA. The tenderer is responsible of any repair/ replacement of the
item during the project defect liability period after which the supplier and
manufacturer is responsible for the same.
The manufacturer of the valve shall provide the certificate for fitness in contact
with potable water (minimum 50oC) from Water Regulations Advisory Scheme
(WRAS), U.K. or equivalent accepted by DEWA.
Before proceeding with any manufacturing, submit shop drawing for Engineer’s
approval. Describe the items being submitted. Show dimension, physical
configurations, components and their composition, coating systems etc... Include
material specification lists which shall summarize the specification features as
called for in these specifications and include such other necessary data as would
SPECIFICATIONS
DUBAI – UAE
provide a complete and adequate specification for re-ordering any spare parts or
an exact duplicate of the original from the manufacturer at future date.
SUBMISSION:
Following are to be submitted along with tender for gate valves, butterfly
valves, air valves and check valves separately.
(1) ISO 9000 series certificate of the manufacturer

(2) Sample
(3) Check list clause by clause
(4) Original catalogue and technical product data
(5) Certificate of Epoxy coating for fitness in contact with potable water
(6) Certificate of EPDM rubber for fitness in contact with potable water
(7) Past Three years supply records separately for U.A.E., Middle East
Countries and Other Countries in the same format as written in schedule
of ‘Details of Past Supply records’
3.4.2 Gate Valves - Resilient Seated
Gate valves shall conform to the provisions of DIN 3352 Part 4 a &B or approved
equivalent and as further specified herein. The valves shall be inside screw, non-
rising stem, and clockwise closing wedge valves suitable for underground use and
flow in both directions. The valves shall be with spigot ends. The spigot ends shall
be suitable to Asbestos Cement Coupling class 18 and outside dia. of spigot ends
shall be exactly the same as outside dia. of Fibre Cement pipes at calibrated ends
as mentioned in the specification of F. C. pipes. If valves are shown as flanged in
the contract drawings/B.O.Q., then flanged valves shall be supplied.
The minimum designed working pressure shall be 10 bars. The valves pressure
rating shall equal the class of pipe and shall be not less than PN 10. Valves
shall be designed for the “Closed End Test”. Gate valves shall be of resilient
seal design with bolted bonnet connection and straight - through port. The
connecting bolts of body and bonnet shall be of countersunk design (exposed
type not acceptable) and top shall be sealed with wax.
The wedge of the gate shall be low clearance - guided in the body and shall have
inner core of ductile iron GGG50 conforming to DIN 1693 or approved equivalent,
fully encapsulated with a synthetic EPDM rubber covering on the inside and
outside by vulcanizing. The rubber covering shall have a minimum thickness of not
less than 2.5 mm on both flow sides, on sealing surfaces minimum thickness shall
be not less than 4 mm with no body metal exposed. The EPDM rubber shall be

SPECIFICATIONS
DUBAI – UAE
approved to be used for potable water and be selected to meet the chemical
properties and temperatures of the fluid being handled by the valves.
Requirement for an EPDM Rubber
Type EPDM
Colour Black
Hardness oSha 70
Tensile Strength Mpa 13
Elongation at break % 300
Density g/cm3 1.12
Range or temperatures in dry atmospheric air oC -4 to 120
Compression set, DIN 53517,24 hours/ 50o C: % 10
The stem shall be manufactured of stainless steel 1.4462/1.4404 to DIN 17440 or

316L or approved equivalent, stem thread shall be of the rolled type. The stem
sealing and bearing shall be maintenance free and shall be designed in the form
of a series of ‘O’ rings of synthetic rubber and stem bearing gap sealed against
entry of dust by a wiper rings. The stem sealing should be replaceable when
required.
Valves above 150mm dia., shall be supplied with two lifting hooks and major
requirement of valve in water network is spigot end valves, however the spigot OD
of the valve shall be same as OD of AC pipe at machined end.
The body and bonnet be ductile iron GGG 50/40 to DIN - EN - 1563 or approved
equivalent. Stem nut shall be dezincification resistant brass, CZ 132 to BS 2872.
Manual operation shall be by hand wheel for valves above ground or by Tee-key
for valves below ground.
The valves body and bonnet shall be internally and externally fusion bonded
epoxy coated as specified. Prior to assembly, the entire valve body and bonnet
shall be holiday tested internally and externally at not less than 3.0 kV to DIN
30677 or approved equivalent.
The end of spigot and flanged valves shall be protected by wrapping bubble
plastic and sealed with mastic tape. It shall cover complete spigot area.
One percent of gate valves supplied size wise of total quantity shall be hydro
tested at local laboratory in presence of DEWA representative at no extra cost for
the manufacturer / supplier who are supplying first time to DEWA and/ or if
required by DEWA..
The spindle cap shall be shall be as per dimension shown in BS 5163 and shall be
made from ductile iron. The spindle cap shall be fixed with spindle by nut bolt of
stainless steel grade 316 and shall pass through spindle and spindle cap.
SPECIFICATIONS
DUBAI – UAE
Gate Valve (resilient seated) with Extension Spindle:
The valves required under this series, are for buried valve design. The valves
shall be supplied with extension spindle, 100 mm dia. PVC pipe piece class
C/D/E, watertight adapter to achieve water tightness between neck of valve body
and PVC pipe. This type of valve shall be used for 1.5m maximum depth. If depth
is more than 1.5m, then standard valve chamber of concrete block work shall be
constructed.
Since valve is to be buried fully below ground, extra protection is required over
epoxy coating. Only epoxy coating is not acceptable.
Following are to be applied/wrapped except spigot portion of valve where F. C.

joint is to be fixed.
(i) Mastic or tape filler or molding putty, if required, shall be applied by hand pressing
to fill the angled / concave section so that exterior surface shall be smooth and free of
projection.
(ii) Immediately after filling with mastic, self-adhesive bituminous wrap or

recommended by manufacturer and approved by DEWA, shall be wrapped as per
manufacturer recommendation.
(iii) Over the wrapping, self-adhesive thin plastic outer wrap shall be applied.
The extension spindle shall be in one piece i. e. the main spindle shall be
extended without connecting coupling. Alternatively, extension spindle with
connecting coupling shall be supplied. The height of extension spindle shall be
such that spindle cap is 300mm from surface box. The size and material of
extension spindle shall be as per manufacturer recommendation and to ensure by
manufacturer / tenderer that it can withstand heavy torque during operation. The
connecting coupling joining to main spindle and extension spindle shall be
attached by nut bolt of stainless steel grade 316 and passing through. The spindle
cap on the extension spindle shall be as per dimension shown in BS 5163. The
spindle cap shall be attached to extension spindle by nut bolt of stainless steel
grade 316 and passing through extensional spindle and cap. Round supporting
plate shall be welded to extension spindle at 100mm below spindle cap and dia. of
round supporting plate shall be 5 mm less than internal dia. of PVC pipe. This is
required to keep extension spindle in the center of PVC pipe. Extension spindle,
connecting coupling and spindle cap shall be epoxy coated in blue colour. The
following marking shall be provided on top of round plate: Name of Manufacturer,
Contract No. and Date of Manufacturing.
The PVC pipe piece shall be 100mm dia and class C/D/E. It shall have length of
1.3m for valve size 150mm dia. and below and 1.0 m for valve size above 150 mm
dia. More length shall be provided if valve is laid deeper than normal depth. PVC

SPECIFICATIONS
DUBAI – UAE
pipe piece shall be fitted over the neck of valve with watertight adaptor. The top of
PVC pipe shall be cut up to bottom of frame of manhole cover, at site.
Watertight adapter or any other suitable arrangement is to be given which shall be

used to connect the neck of valve and PVC pipe. It shall be watertight so that
groundwater cannot enter inside PVC pipe after fixing over the neck of valve.
For every valve with extension spindle installed, Marker plate and post shall be fixed
to indicate the location of valve. The rate for supply and installation of marker plates
and post shall be included in the rate of surface box chamber. For supply, refer
specification mentioned in this section and for installation, refer drawings or as per
manufacturer’s recommendation.
Two separate samples shall be submitted with tender if requested by Engineer.

(1) 100mm Gate valve with spindle cap - 1No. - Without specified wrapping,
extension spindle, PVC protection tube and watertight adaptor
(2) 100mm Gate valve - 1No. - With specified wrapping, extension spindle and
coupling, PVC protection tube, watertight adaptor
Gear Gate Valves
Gear operated valves shall be provided with operating nuts and Tee-keys as
specified. Gear cases shall be totally enclosed and designed for full differential
pressure of 10 bars and shall be with bevel gear except where specified.
3.4.3 BUTTERFLY VALVES
1. Butterfly valves shall conform to one of the following standards: - BS 5155;

DIN 3354; AWWA C504 or ISO 5752.
2. Valves shall be rated for PN 10 (10 Bar) service / as rated in B.O.Q.
3. Valves shall be double flanged with worm type manual operating gear and
with stem cap for valves underground and hand wheel for valves above
ground or with electrical actuator including worm gear as mentioned in
B.O.Q.
4. They shall be manufactured from the following materials.
BODY AND FLANGE DUCTILE IRON OR GREY CAST IRON AND

FACE TO FACE DIMENSION OF VALVE IN
ACCORDANCE WITH B.S. 5155 (SHORT)
DISC ALUMINIUM BRONZE TO B.S. 1400 AB2 OR

EQIVALENT OR NIKEL ALUMINIUM BRONZE
OR DULEX STAINLESS STEEL FOR
PIPELINE AND RESERVOIR PROJECTS AND
IT SHALL BE COATED WITH RYLSON
COATING OR EQUIVALENT AND SHALL BE
SPECIFICATIONS
DUBAI – UAE
FIT IN CONTACT WITH POTABLE WATER

UPTO 50 DEGREE C. (CERTIFICATE TO BE
ATTACHED). FOR PUMPING STATION
PROJECTS, IT SHALL BE OF ONLY DUPLEX
STAINLESS STEEL AND POLISHED
INTERNAL BODY LINING EPDM RUBBER BONDED BY VULCANIZING

PROCESS TO TEMPRATURE RESISTANT
100deg.C AND SUITABLE FOR USE WITH
POTABLE WATER UPTO 50 DEGREE C AND
EXTENDED OVER THE FLANGE. SHORE
HARDNESS OF LINER AFTER VULCANISING
SHALL BE 70-75 o (Sh.A)
CERTIFICATE FOR SUITABILITY FOR USE IN
CONTACT WITH POTABLE WATER AT 50o C
FROM WRAS, UK OR EQUIVALENT, IS TO BE
SUBMITTED.
THICKNESS OF LINING SUBJECT TO

CASTING ALLOWANCE
DN SHAFT DISC NON -

SEALING SEALING
CRITICAL
AREA AREA AREA
500-600 12MM 9MM 6MM

700-900 16 MM 12MM 7MM
1200 22 MM 14MM 9MM
SHAFT ALUMINIUM BRONZE OR
SHAFT PIN DUPLEX STAINLESS STEEL OR AS
SUGGESTED BY MANUFACTURER AND
APPROVED BY DEWA
SELF LUBRICATING TYPE WITH EPDM 'O'

SHAFT BEARING RING SEALS OR DRY DESIGN HAVING NO
WETNESS BY LINE MEDIA FLOWING
THROUGH VALVE OR AS RECOMMENDED
BY THE MANUFACTURER & APPROVED BY
DEWA.
SPINDLE EXTENSION VALVE SHALL BE WITH EXTENSION

SPINDLE UPTO A MINIMUM OF 500 MM
BELOW MANHOLE COVER. IT SHALL BE
SUPPLIED BY MANUFACTURER OF
SPECIFICATIONS
DUBAI – UAE
BUTTERFLY VALVE / LOCAL

MANUFACTURER AND SHALL BE
STAINLESS STEEL OR ALUMINIUM BRONZE.
THE ALTERNATIVE MATERIAL CAN BE
APPROVED AFTER MANUFACTURER
RECOMMENDATION AND DEWA APPROVAL.
THE EXTENTION SPINDLE, IT’S SUPPORT
ARRANGEMENT AND MATERIAL FOR
SUPPORTS SHALL BE AS PER
MANUFACTURER’S RECOMMENDATION
AND DEWA APPROVAL. FOR DIRECT
SUPPLY TO DEWA, EXTENTION SPINDLE
SHALL BE OF LENGTH 100 CM.
STEM CAP STEM CAP AS PER B.S. 5163: 1974 AND 3

NOS. OF EXTRA STEM CAP SHALL BE
PROVIDED FOR EACH SIZE AT NO COST TO
DEWA
EXTERNAL COATING THE PAINT (BLUE COLOR) SHALL BE HIGH

SOLID EPOXY POLYSILOXANE COATING
WITH APPROXIMATELY 10% SOLVENT OR
SOLVENT FREE EPOXY COATING OR
OTHER COATING APPROVED BY DEWA.
PRIOR TO ABOVE, PRIMER SHALL BE
APPLIED. TOTAL AVERAGE THICKNESS
SHALL BE 200 MICRON OR MORE.
GEAR BOX AS DETAILED UNDER SPECIFICATION
“WORM GEAR BOX”
5. All the valves shall be of high reliability, robust design and tropicalized in
accordance to the worst prevailing ambient conditions.
6. All the internal and external fastenings such as nuts, bolts, screws and
fittings shall be of stainless steel grade 316.
7. Flanges shall be drilled to BS 4504 PN10 rating for PN 10 valves and PN16
pattern For PN 16 valves and so on.
8. Butterfly valves shall be used as line valves for sizes larger than 300 mm
nominal diameter and for 300 mm or smaller if mentioned in drawing and/
or B.O.Q.
9. Vales shall have position indicator and shall have adjustable end limit stops
at both open and closed end position to prevent damage by excessive
operating force. They shall close clockwise. Position indicator shall be fixed
in such a way that it can be seen from top for underground valves.
SPECIFICATIONS
DUBAI – UAE
10. Valves shall be supplied with stainless steel nuts, bolts, washers shall be of
standard AISI GRADE 316.
11. The valves shall have the name of the manufacturer, type, number, working
pressure, nominal diameter and month and year of manufacture cast on
valve body in an identifiable top or side position.
12. The supplier shall submit full technical data sheets, catalogues of the valve
in English language.
13. All the valves shall be designed for no leakage under flow from either
direction tested at a differential pressure across the seal of rated working
pressure. Each valve shall be subject to a body pressure/leakage test of
1.5 times the design pressure before leaving the manufacturer's works.
Test certificate by the manufacturer is to be submitted.
14. A certificate showing that any rubber lining used is non-toxic to potable
water in accordance to international standards shall be obtained from an
internationally recognized authority.
15. Nuts and bolts for flange shall be as follows (PN 10 Valves):
Nominal Diameter Of Length Of

Diameter Of Bolts No. Of Bolts Bolts
Valve Per Valve
(mm) (mm) (mm)
550 M27 40 160
600 M27 40 160
700 M27 48 190
900 M30 56 210
1200 M36 64 240
Contractor/supplier shall be responsible to ascertain exact length and dia of bolts

as per requirement.
16. Two lifting hooks to be provided for valves above 300mm dia.
17. Valve supporting foot not to be provided.
18. The manufacturer should be approved for quality assurance scheme under
ISO 9000 Series /BS 5750 or equivalent national standard... Necessary
certificates from the manufacturers are to be submitted to the Engineer for
his approval along with tender/quotation.
19. Following documents are to be submitted to DEWA along with

tender/quotation/approval through consultant.
SPECIFICATIONS
DUBAI – UAE
1. Original Catalogues & full technical data sheet in English.
2 Quality assurances certificate under ISO 9000 Series /BS 5750 or

equivalent issued to manufacturer or certificate of approval of kite
mark of BS or similar mark from respective country to the
manufacturer.
20. Gear Spindle and extension for butterfly valve shall be 50 mm dia. Or
recommended by manufacturer and approved by DEWA.
21. The gear design shall be such that they are suitable for operation with
electrical actuator if desired at later date. The mounting flange for actuator
on manual operated valves shall be available. The design of adapter for
that purpose shall be submitted.
22. The gear arrangement for butterfly valve installed as an isolating valve
before air valve, shall be such that when butterfly valve installed in vertical
pipeline, the spindle position shall be also vertical. These valves shall be
used as isolating valve before air valve.
23 Manufacturer / supplier shall submit pressure testing certificate at the time

of delivery.
24 Inspection/testing at manufacturer place shall be carried out. If

inspection/testing waiver is given by DEWA at manufacturer place, then
inspection shall be carried out locally/ DEWA store.
25 Transport, unpacking and handling can damage the coating. After

installation of butterfly valve, the contractor shall arrange to touch-up the
coating wherever it is damaged or one coat of coating to the full external
surface shall be applied to the satisfaction of the Engineer.
26 Manufacturer to ensure proper packing of the valves. If two or more valves

are shipped in one wooden crate, proper protection shall be ensured with
suitable partition between the valves. Valve flanges shall be protected
suitably to protect the rubber lining extended over the flange.
For 450mm dia. Butterfly Valve:
450 mm dia. Butterfly valve is to be fixed in vertical position i. e. disc shaft in

vertical position. Accordingly valve manufacturer shall design shaft bearings and
other related items. These valves are to be supplied with normal worm gear
coupled with bevelled gear so that gear spindle shall be vertical to operate from
top level of valve chamber by a Tee key. The normal worm gear and bevelled
gear shall be from same manufacturer. The worm gear of manually operated valve
shall have a flange to install actuator at a later date. Normally, it shall be manually
SPECIFICATIONS
DUBAI – UAE
operated valve and PN 10 except if mentioned in BOQ as motor operated valve.

The worm gear and bevel gear shall be installed in such a way that both are
parallel to pipeline. The lifting hook shall be two nos. and fixed in a position so that
valve can be lifted in vertical position.
27 Worm Gearbox
Design
a) The gearbox shall be of worm wheel type consisting of worm wheel and a
full worm shaft including adjustable mechanical end stop.
b) The gearbox shall be self-locking.
c) If required, the gearbox shall be equipped with a preliminary spur gear box
to reduce the required input torque.
d) In case the gearbox shall be used for motor operation, the actuator supplier
shall be consulted regarding torque verification. Preferably the actuator and
the gearbox to be manufactured by the same manufacturer.
e) The gearbox housing shall be made out of GG (grey cast iron) or GGG
(ductile iron). Housing materials such as aluminium shall not be allowed.
f) The gearbox housing shall be completely filled with gear grease to
guarantee proper lubrication in any mounting position.
g) Special dry bearings shall protect the worm shaft from radial forces. An
axial ball bearing shall carry the resoluting thrust.
Design Features
The design of the worm wheel gearbox shall allow the following:
1. To utilise a splinted coupling
2. To operate manually as well as electrically
3. To motorise a manual gearbox at later stage
4. To meet the typical torque / running time requirements for valves and
actuators (type of duty)
5. To withstand max. input torque given according to manufacturer’s technical
data sheet
6. To match with valve mounting flanges and shafts.
7. Flange shall be available on gear box to mount actuator at a later date.
8. The gear box mounting flange and actuator mounting flange shall have
drilling pattern as per ISO 5211.
9. Worm wheel shall be of bronze.

SPECIFICATIONS
DUBAI – UAE
Mechanical Position Indicator
An adjustable mechanical position indicator to show the valve position shall be

available. Gearboxes for buried service shall not be equipped with a mechanical
position indication. In this case a protection lid shall replace the mechanical
position indicator.
Enclosure
Enclosure shall be minimum IP 67, O-Ring sealed to enable easy dismantling for
repair and maintenance.
Coupling/Valve attachment
A separate splinted coupling shall be supplied by the gearbox manufacturer,
which allows efficient machining and easy placement of gearbox on valve
during the mounting, commissioning or maintenance. The gearbox valve
attachment shall be according to ISO 5211.
End Stop Principle
The adjustable mechanical end stop shall be available to protect the valve stem
from excessive force. To guarantee proper seating of the valve after maintenance
works, the mechanical end stop shall be easily adjustable at site.
General
Worm gearbox must be designed for manual operation as well as for operation
with electric actuator. Actuator mounting flanges and valve attachments according
to DIN/ISO and or US-norm must be available.
Within its torque range, a gearbox must be capable to provide the torque required
for opening or closing the driven valve with a considerable safety margin.
Nameplate
Nameplate shall be made of stainless steel showing all relevant gearbox data.
The nameplate shall be securely fixed to the gearbox, so that they cannot be
removed or scratched off during shipment, installation, operation or maintenance.
Painting and corrosion protection
Corrosion protection shall fulfil the requirements of salt spray tests in accordance
with DIN 50021.
Gearbox painting must be performed in such a way, that no corrosion takes place
under the ambient conditions as specified. All outside screws or bolts shall be
made out of stainless steel grade A2 / 304.

SPECIFICATIONS
DUBAI – UAE
Surface preparation and treatment
Surface preparation : Sand blasted, equivalent to SA 2 ½ according to

SIS 0559 000-1967 / DIN 55 928, part 4
Surface treatment :
Aluminium parts : electro dip coated
Cast iron parts : metallic surface protection
Steel parts : metallic surface protection
Structure of the painting
Primer coating : 2-component primer based on epoxy resin with

micaceous iron oxide
Finish coating : 2-component coating based on polyurethane
Colour : Blue colour
Entire film thickness : at least 120 µm
27 Electric Valve Actuators

Design and Construction Requirements
General
The following electric power supply rated values are applied:
Permanent Contingency
Variations Voltage
Electric motors 400 V - A.C. ±5% ± 10 %
50 Hz ± 2 Hz
3 phase 4 wire
Anti-condensation 60V - 250 V - A.C. or D.C. ± 10 %
heaters or
12V - 48V - A.C. or D.C.
Electronic 24 V D.C. ± 10 % + 15 %
equipment - 20 %
(e.g. position
transmitters
)
Actuators shall be designed for valve operation according to VDE 0530/IEC 34 to

ensure a proper function. The valve operation shall be complied with both:
a) Open-close duty (S2-15min) and
b) Modulating / throttling duty (S4-50% ED); up to 1200 starts per
hour; no. of starts depending on actuator size and output speed.
SPECIFICATIONS
DUBAI – UAE
All actuators must be suitable for mounting in any position.

The design must provide simple setting, testing, maintenance and repair. Torque
and limit setting shall be of the mechanical type to allow settings without special
tools or instruments (e.g. battery backed setting tools).
To guarantee proper function under high ambient temperatures, a mechanical
torque and limit sensing shall be used.
The design must allow removing the actuator from the valve without disturbing the
function of the valve. For rising stem applications, the design must allow to
remove the actuator from the output drive with full differential pressure applied.
Electrical connection of actuators shall be made by plug / socket connector, to
allow quick disconnection in case of maintenance or repair.
All materials used shall be suitable to withstand operation under specified
Torque-transmitting housing-parts must be made of cast-iron. Motors shall be of
the non-ventilated totally enclosed type (TENV). Motor housings and covers could
be made of sea water resistant aluminium.
No plastic part of any type shall be used, except for electric/electronic
components, operating knobs/levers and sealing elements.
In order to minimise the amount of spare-parts required, parts like switches,
covers, plug/sockets, limit- and torque-switching gears must be interchangeable
throughout the majority of model numbers installed.
All valve actuators shall be suitable for intermittent operation in the ambient
conditions specified.
Actuators shall be designed in such a way, that exposure to weather will not
interfere with the safe operation. All joints shall be O-Ring sealed.
Interface to the RTU/PLC for remote operation, monitoring and control shall be
through “MODBUS/PROFIBUS/HARD WIRING selectable to DEWA.
In order to prevent loss of screws, all covers which can be opened for setting and
service shall be equipped with captive screws.
Depending on valve application, actuators shall be self-locking. Self-locking shall
remain active even if the actuator is switched into hand-operation-mode.
Electric Motors
General
All motors shall be specifically designed for valve-actuator operation, which is
characterised by high starting torque, low stall torque and low inertia.

SPECIFICATIONS
DUBAI – UAE
Motors must be protected by 3 thermal contacts, which are embedded in the

motor windings. Motor connections shall be internal by the means of plug and
socket (up to 5 kW).
Motors must be totally separated from the lubricant-filled part of the actuator,
allowing replacing a motor without losing any lubricant regardless of mounting
position.
All precautions shall be taken to avoid any type of corrosion and electrochemical
effects, taking place between different kinds of metals.
Motor-insulation must be in accordance with IEC 85 Class F (155° C).
Motors shall be suitable for operation in tropical damp locations, for occasional
contact with corrosive gases and vapours and for the whole range of ambient
conditions specified.
Each motor shall have a rating plate marked in accordance with IEC 34.1.
Sizing Criteria
One actuator size (same outside dimensions) shall be available to cover output
speeds from 4 to 90 rpm for a given torque range, to avoid over sizing and
unnecessary weight load on valve stem, flange and yoke. An increase of actuator
size caused by an increase of actuator output speed is not acceptable to avoid
weight over sizing of actuators.
Actuators must be selected to provide sufficient amount of torque required for safe
valve operation. The actuator output torque must be reached with 90 % of the
nominal voltage.
The actuator supplier has to provide the current at maximum setting torque, in
order to enable proper sizing of applicable electric equipment.
Actuator motors must develop full torque when power is turned on; therefore direct
start-up under full voltage is required.
All motors shall be of the high starting torque type to facilitate 'unseating' of the
valve.
The required valve torque shall be calculated by using the maximum differential
pressure across the valve seat as specified in the data sheet, with sufficient safety
margin.
The actuator shall be capable of opening and closing the valve against this
differential pressure within the time specified on the valve data sheet.
Auxiliary Switches
Unless otherwise specified, electric valve actuators shall be equipped with two
limit switches, one for the end position 'OPEN' and one for the end position
'CLOSE'. For intermediate position switching, two additional limit switches must
be available as an option. One for the opening and one for the closing stroke.

SPECIFICATIONS
DUBAI – UAE
For torque seating or over torque indication, actuators must be equipped with two
torque switches, one for opening and one for closing direction. Optional tandem
switches shall be available, depending on application. Refer to attached wiring
diagram.
All switches (limit and torque) shall be of the snap-action micro switch type, totally
enclosed acc. IP66, each with one set of N/O contacts and one set of N/C
contacts. The connecting wires shall be embedded in the switch-housing.
Switch contacts shall be rated for:
Type of current Switch rating I max

30 V 125 V 250
V
AC (inductive load, cos phi = 5,0 A 5,0 A 5,0 A
0,8)
DC (resistive load) 2,0 A 0,6 A 0,4 A
Torque- and limit switch screws must be easily accessible for adjustment.
Limit- and torque switches must be operated by counter gear-driven cams, which are
mechanically linked to the driving devices, without slip-clutches. No battery backed limit
sensing shall be used to avoid malfunction of the actuator in case of power failure or dead
battery.
Torque switch signalisation must be active in manual operation (by hand wheel) as
well.
The torque switch sensing shall have calibrated dials, directly indicating the torque
setting, independent for 'OPEN' and 'CLOSE' direction. No electronic torque sensing
shall be used.
Position Indication
Actuator shall be equipped with a local indicator, which continuously shows the
valve travel from fully open to fully closed and vice versa.
A 4 - 20 mA transmitter shall be installed in the actuator. High class film-

potentiometers shall be used to sense the valve position. No wire-wound
potentiometers are allowed.
Local Controls
Local controls with 'Open-Stop-Close' push-button-type controls, with motor

controls (reversing contactors) shall be available. A selector switch with 'LOCAL-
OFF-REMOTE', lockable in all three positions, shall be available. A hinged
lockable cover shall protect the push buttons against vandalism, or unintended
operation. The local controls shall be electrically attached to actuator via a plug
and socket connection.
SPECIFICATIONS
DUBAI – UAE
For installations in inside chambers (pits) it shall be possible to separate the

actuator from the local controls and to install the local controls (including motor
controls / electronic components) for mounting at a wall. In this case a wall
bracket shall supplied, including connecting cables (5m), to electrically connect
the local controls and the actuator via a plug and socket connection This solution
shall maintain the IP 67 protection grade.
The following features shall be integral to the motor controls:

a) Reversing contactors (mechanically and electrically interlocked). If
otherwise specified, a semiconductor (thyristor) shall be available as an
option up to 1,5kW.
b) Potential separation (Opto-isolators) for remote signals OPEN-CLOSE
c) Programmable control logic in CMOS SMD-technique
d) Phase sequence and phase failure monitoring
e) Signal from selector switch, position LOCAL/REMOTE, with potential-free

contacts
f) Signals to control room for end positions OPEN/CLOSED with potential-

free contacts
g) Monitor relay for collective fault signal (power failure, phase failure, wrong
phase sequence, thermo switch tripped and torque switch tripped in mid
travel )
h) Control voltage 24V DC for external commands OPEN-STOP-CLOSE resp.

OPEN-CLOSE. Other control voltages should be acceptable as well.
The wiring diagram and customer connection (incoming and outgoing signals)
shall be subject to separate approval.
Wiring and Terminal Boxes
Limit- and torque switches must be wired to actuator plug / socket. The same
applies to additional switches and remote feedback signal transducers.
The terminal compartment shall provide space to accommodate the possible

maximum number of incoming wires. Separate cable entries (2XPG21, 1XPG13, 5)
must be provided for
a) motor power
b) control-wires
c) feedback signal

SPECIFICATIONS
DUBAI – UAE
The cable entries shall be sealed by cable glands, which need to be provided by
the contractor during the commissioning phase.
Each actuator shall provide an adequately sized connection for earthing.
Anti-Condensation Heater
In order to prevent condensation, a heater must be installed inside of the actuator,
suitable for continuous operation.
Enclosures
Protection class of the actuator housing, including the motor and all covers, shall
be IP 67 according to IEC recommendation 34-5 and 529.
Hand Wheel
Actuators must be equipped with a hand wheel for manual operation. Clockwise
operation of the hand wheel shall cause the valve to close. The face of the hand
wheel shall be clearly marked with an arrow and the word 'Close'.
The hand wheel must be sized that one man can generate the rated actuator
output-torque. The torque switches shall be active in manual operation mode as
well, thus allowing providing a signal when the set-torque has been reached.
Operation of the hand wheel shall require manual declutching. Under manual
operation, the hand wheel shall drive the worm shaft to maintain the self-locking.
The motor must be disengaged during hand operation. The hand wheel shall
automatically disengage when the electric motor is energised.
Bearings and Gears
Bearings shall be of the self-lubricated or pre-lubricated type. Bearings shall not

require any maintenance between general overhauls.
Power gears shall be made from heat-treated steel. Worm wheels shall be made
of bronze material.
The actuator gear housing shall be filled with sufficient amount of lubricant. Re-
lubrication between general overhauls shall not be required.
In case quarter-turn-gearboxes are required in combination with multi-turn

actuators to operate the valve, the gear housing shall be made out of cast iron
(GG) or ductile iron (GGG). End stops in both directions shall be available to
protect the valve stem against excessive torque. The gearbox shall be designed
as per valve and actuator requirements. The worm wheel shall be made out of
bronze. Segment type worm wheels shall not be used.
Enclosure for gearbox shall be IP 67.

SPECIFICATIONS
DUBAI – UAE
Noise Level Under all operating conditions the noise level of actuators shall not
exceed 80 dB (A) at 1 m.
Name Plates
Two nameplates made out of stainless steel shall be attached to each actuator;
one on the motor housing, showing all relevant motor data, one on the actuator
gear case showing all relevant actuator data. Special information, like the valve
tag no., shall be possible to be shown if required.
The nameplates shall be securely fixed to the actuator and motor, so that they
cannot be removed or scratched off during shipment, installation, operation or
maintenance.
Painting and Corrosion Protection

Corrosion protection shall fulfil the requirements of salt spray tests in accordance
with DIN 50021. Actuator painting must be performed in such a way, that no
corrosion takes place under the ambient conditions as specified. All outside
screws or bolts shall be made out of stainless steel grade A2 / 304.
Surface Preparation and Treatment
Surface preparation:
Sand blasted, equivalent to SA 2 ½ according to SIS 0559 000-1967 / DIN 55 928,
part 4
Surface treatment:
Aluminium parts: electro dip coated
Cast iron parts: metallic surface protection
Steel parts: metallic surface protection
Structure of the Painting
Primer coating: 2-component primer based on epoxy resin with micaceous iron
oxide
Finish coating:
Structure :2-component coating based on polyurethane

Colour : DB 701 silver grey (similar to RAL 9007)
Entire film thickness:

Aluminium parts :at least 140 µm
Cast iron parts :at least 140 µm
Inspection and Testing at Manufacturer's Work

SPECIFICATIONS
DUBAI – UAE
Each actuator shall be factory tested. Tests shall be performed in accordance with
IEC standards. A final inspection sheet shall be supplied with each actuator which
shall include the following information:
a) General actuator data

b) Nominal current
c) No load current
d) Starting current
e) Power factor at rated torque
f) Output speed
g) Torque and limit switch setting
h) Limit switching (turns/stroke)
i) High voltage test (1,5 kV)
j) Functional test (including all accessories)
k) Visual test
3.4.4 Air Valves
Air valves shall be designed to (a) discharge air during filling of pipelines, (b)
admit air during emptying of pipelines, (c) discharge air accumulated at high
points in pipelines during normal operation.
Air valves of two types are called for: [a] Double Orifice Air valve [b] Single Orifice
Air valve.
3.4.4.1 Double Orifice Air Valve
Double Orifice Air Valves which shall combine both large and small orifices within
one valve. The large orifice shall be sealed by a buoyant rigid ball fully and
automatically. The chamber housing shall be designed to avoid premature closing
of the valve by the air whilst being discharged. The small orifice shall be sealed
by a buoyant ball at all pressures above atmospheric, except when air
accumulates in the valve chamber.
1. The valve will be flanged drilled to BS 4504 PN 10 pattern for PN10 valves,
BS4504 PN16 pattern for PN 16 valves and so on. The valves shall be
supplied with rubber Gasket, stainless steel grade 316 nuts & bolts with
washers at no extra cost.
2. The valve construction shall be without integral isolating valve.

SPECIFICATIONS
DUBAI – UAE
3. The valve rating shall be PN 10 or as mentioned in B.O.Q. with all integral

parts suitable to withstand working temperature of 50oC [max.]
4. The valve shall be dynamic type. The effective sealing pressure required at
valve to give effective sealing shall be 0.2 bar.
3.4.4.2 Single Orifice Air Valve
Single orifice valves shall be of screw down type. Single orifice 25mm valves
should be supplied and fixed with gunmetal/stainless steel ball valve and
gunmetal/s.s. nipple, the cost of which shall be included in that of valve.
3.4.4.3 General Requirements for Both Types of Air Valves
1. MATERIAL OF CONSTRUCTION.
BODY / COVER /DUST COVER : GREY C.I. OR DUCTILE IRON OR

OTHER APPROVED MATERIAL
ALL WORKING PARTS : BRONZE, STAINLESS STEEL GRADE 316

OR
OTHER NON-CORRODING MATERIAL.
COATING : 300 MICRON EPOXY COATING IN

BLUE COLOUR. THE MATERIAL
SHOULD BE CERTIFIED TO BE FIT
FOR USE WITH POTABLE WATER UPTO 50
DEGREE C., BY
AN INTERNATIONAL AGENCY
DRAIN PLUG : ¾’’ STAINLESS STEELGRADE 316
2. Detailed catalogues with drawings and graphs showing air inflow / outflow
curves need to be submitted for approval.
3. The valves shall be supplied with rubber gasket, stainless steel nuts and
bolts grade 316 with washers at no extra cost.
1. Each double orifice air valve shall be fixed with isolating butterfly valve
whether or not indicated in the drawings and the gear orientation of
isolating butterfly valve shall be in such a way that gear spindle of butterfly
valve, is vertical when fixed below air valve.
2. The air valves shall be fixed as per plans or as directed by the Engineer.
SPECIFICATIONS
DUBAI – UAE
3. The valves shall be tested hydraulically after fixing and any leakage shall
be rectified and retested.
3.4.5 Check Valves

3.4.5.1 SWING CHECK VALVE
Check valves shall be with lever and weight operated for sizes above 150mm dia
and UPTO 300mm dia. and without lever and weight up to 150mm to BS 5153 or
other approved standard, and shall be resilient seated and flanged. For sizes
above 300 mm dia., it shall have Tilting Disc with hydraulic damping device. Face
to face dimensions shall be as per BS5153 short series.
Body, bonnet and disc - Ductile iron

Shaft - Stainless steel AISI 316
Hinge, body seat - Gunmetal or Stainless steel grade 316
Shaft Bearing – self lubricating
Hinge pin retainer, Disc guide pin, Hinge to disk connection – stainless steel grade
316
Elastomer – EPDM for parts in contact with water and
NBR/EPDM for parts not in contact with water.
Resilient seat – EPDM rubber bonded by vulcanizing process
for swing check valves
Bolt, hinge, washer, fasteners – Stainless steel AISI 316
Coating –300 micron Electro-statically applied/fusion
bonded epoxy resin or rylsan coating
The alternative materials may be approved at DEWA discretion
It shall have easy change from without too with lever and weight and vice versa.
Check valves shall be flanged in accordance with BS 4504 PN10 pattern/PN16
pattern/PN25 pattern as per pressure rating of valve.
It shall have body tapping and plug of S.S.316.
SUBMISSION:
1. Original Catalogue
2. Technical data sheet
3. Shop drawing
4. Manufacturer compliance to the specification paragraph by
paragraph. Each page shall be stamped and signed by the
manufacturer, supplier and tenderer
SPECIFICATIONS
DUBAI – UAE
5. Head loss graph

6. ISO 9000 series certificate of manufacturer
7. Certificate of epoxy coating for fitness in contact with potable water from
Authority of ‘Water Regulation Advisory Scheme, UK’ or equivalent
National Authority
8. Certificate of EPDM rubber for fitness in contact with potable water from
Authority of ‘Water Regulation Advisory Scheme, UK’ or equivalent National
Authority
9. Past supply record
3.4.5.2 TILTING DISC CHECK VALVE
The Tilting disc valves shall comply in all respect with relevant standards as
detailed below. All check valves above 300mm dia. or all size of check valves in
pumping station projects or as per BOQ shall be tilting disc with external lever and
counterweight and hydraulic damping device. The hydraulic damping device shall
be effective in opening and in closing direction. If recommended by manufacturer
for high pressure valves, damping device shall be provided on both side of tilting
disc.
Body shall be with flanges and drilled as per BS4504 -PN10/PN16/PN25 pattern.
If nothing is mentioned in BOQ, it shall be supplied PN10 pattern.
Disc shall be mounted on stainless steel shafts located in PTFE lined self-
lubricating bearings with synthetic EPDM rubber double shaft seal.
The Tilting disc valve shall be the double offset eccentric type fitted with a non-
ageing sealing element held in place by an adjustable one-piece endless clamping
ring secured with stainless steel grade 316 adjusting set screws mechanically lock
in place - not resin bonded. The profile seal shall provide tight shut off against a
solid rolled in body seat ring of Duplex stainless steel or elastomar. The valve disc
shall be as streamlined as possible to ensure low head losses and secure
movement without disc flutter.
The disc stub shafts shall be manufactured from Duplex stainless steel and
positively keyed to the valve disc and incorporate a key securing device to prevent
shearing. Valve disc pinned to stub shafts are not acceptable. The stub shaft
bearings shall be maintenance-free self-lubricating PTFE lined bushes and shaft
seals of EPDM o-rings.
The check valves shall be equipped with lever and counter weight and hydraulic
damping device for setting the closing time. The Hydraulic damping device shall
be used to damp closing and opening shocks of the valve and shall act in both
limit positions (damped opening range 10 degrees and damped closing range 15
degrees). If recommended by manufacturer, damping device shall be provided on
both side of valve.

SPECIFICATIONS
DUBAI – UAE
The coating and elastomer in contact with potable water shall be WRAS or
equivalent national authority approved for 50 degree C minimum. Relevant
certificate shall be submitted. Manufacturer shall confirm that he will use the same
coating and rubber whose WRAS certificate is attached.
For pumping station projects, limit switches shall be installed to report valve status
to control system
Head loss graph shall be submitted. Also state the corresponding maximum back
pressure during closing for damping device.
Standard : BS 5155/DIN 3354/AWWA/C504-80

Pressure Rating : PN10 or as mentioned in B.O.Q. If nothing is mentioned in
BOQ, it
Shall be PN10
Material:
Body : Ductile Iron.

Valve Disc : Ductile iron epoxy coated with disc facing ring of duplex
stainless
Steel or resilient precision seal of EPDM rubber
Shaft : Duplex stainless steel
Body seat ring : Duplex stainless steel
Elastomer : EPDM for parts in contact with water and NBR/EPDM for
parts not
In contact with water
Bearing material : Self-lubricating PTFE
Coating : Fusion bonded epoxy coating or Rylsan coating – Average
300 micron Thick
All fasteners : Stainless steel AISI 316
Counter Weight : Cast Iron
GENERAL:
1. Manufacturer shall have ISO 9000 series certification.

2. Manufacturer and tenderer shall give Five years warranty against defects of
materials or workmanship.
Face to face dimensions: For PN10 and PN16
DN 200 300 350 400 450 500 600 700 800 900 1200
SPECIFICATIONS
DUBAI – UAE
L 230 270 290 310 330 350 390 430 470 510 630
SUBMISSION:-
(i) Original catalogue
(ii) Drawings
(iii) ISO 9000 certificate
(iv) Epoxy coating and rubber - Fitness certificate in contact with
potable water for minimum 50 degree C
(v) Specification compliance checklist of above specifications
paragraph by paragraph. Each page shall be stamped and
signed by manufacturer and Tenderer.
(vi) Head loss graph
3.4.6 FLOAT VALVES
All valves supplied shall be suitable for use with potable water temperatures up to
50o C and in climatic and soil conditions encountered in the Dubai area. The
nominal working pressure shall be 10 bars.
Float valves and appurtenance shall be externally and internally fusion bonded
epoxy coated using electrostatic/fluidized bed process conforming to DIN 30677
or approved equivalent, with a minimum thickness of 300 micron holiday free non-
toxic and colour code RAL 5015. Before application of epoxy coating the surface
shall be sand blasted to a minimum SA 2.5 and air blown to ensure good bond. A
certificate verifying the suitability of the epoxy coating for use with drinking water
is required from the manufacturer endorsed by the National water Council, UK or
similar independent national body acceptable to DEWA.
Fasteners / nut bolts / studs etc. fixed in the float valve shall be stainless steel
grade 316 or equivalent.
All valves shall be tested to the appropriate test pressure at the manufacturer’s
works and shall be supported by a test certificate from the manufacturer. The
supplier shall supply the manufacturer’s test certificate. The certificate shall relate
to the individual number cast/written on steel plate on each valve.
Float valves shall be designed to provide 100 % watertight shut off after the tank
is full.
Where flanges are required they shall be drilled to PN 10 in accordance with BS

4504.
All valves shall be manufactured in and supplied from North American / EEC
former Western European countries.

SPECIFICATIONS
DUBAI – UAE
Valve shall be manufactured by an ISO 9000 series certified company who has had
several years of experience in the manufacture of valves and shall have a fully equipped
technical back up.
The manufacturer of the valve shall provide a warranty of minimum 5 years based
on a replacement basis including labour and material at no extra cost. The
warranty given by manufacturer shall be endorsed by the supplier/tenderer and
supplier will be responsible for fulfilling the same.
Before proceeding with any manufacturing, submit shop Drawing for Engineer’s
approval. Describe the items being submitted. Show dimension, physical
configurations, components and their composition, coating systems etc. Include
material specification lists which shall summarize the specification features as
called for in these specifications and include such other necessary data as would
provide a complete and adequate specification for re-ordering any spare parts or
an exact duplicate of the original from the manufacturer at some future date.
Float Valves shall be of 10 bar pressure rating, double flanged with face to face
dimension according to DIN 3202 F32. Float valves shall be angle type i.e. inlet
and outlet shall be at 90 degree
Body, bonnet and cone made of cast iron. Float, spindle, seat and cone-pipe -
coupling parts made of rustproof stainless steel containing minimum 13 %
chromium. Sealing elements made of Food Grade EPDM rubber. Corrosion
protection of body components shall be minimum 300 microns Food Grade epoxy.
Float valve shall be single seated suitable for installation in de-pressurized tank
and stress relieved for direct mounting on 200 mm diameter pipeline. Valve should
be suitably sized to have a minimum float stroke of 500 mm and flow rate in
excess of 600 m3/ hr.

- Individual Serial Number which relates directly to the
Manufacturers test certificate on steel plate
- Date of Manufacture mentioned on steel plate fixed on valve
- DEWA Supply order no.
SUBMISSION:
Following are to be submitted along with quotation.
(1) ISO 9000 series certificate of the manufacturer
(2) Check list clause by clause
(3) Original catalogue, technical product data and shop drawing
(4) Certificate of Epoxy coating for fitness in contact with potable water
SPECIFICATIONS
DUBAI – UAE
3.4.7 AUTOMATIC PRESSURE REDUCING

VALVE AND CHECK VALVE ASSEMBLY
APPLICATION:
• Its main application is to reduce a high inlet pressure into a lower and stable
outlet pressure.
• The valve is designed to maintain a stable outlet pressure, regardless of

fluctuations in the inlet pressure or flow and also check reverse flow on
pressure reversal on the line. The valve shall incorporate an instant action
check valve inside the body, which shall prevent any reversal flow from
occurring.
• Valve closes drip tight when the downstream pressure meets the pilot setting or
exceed. The pilot check valves direct downstream pressure above the diaphragm
to close the valve when the system pressure reverse (i.e. downstream pressure is
higher than the upstream pressure).
• During low demand, the valve will operate with a high degree of stability and
accuracy.
• Where cavitations may be present, the valve will be supplied with an Anti
Cavitations trim, made up of two centered cylinders. The cylinders will be
machined out of stainless Steel grade 316 and they will be capable of
withstanding a pressure drop of up to 300 PSI, without causing damage to the
main valve body. At the same time, these Anti Cavitations cages will reduce
the noise associated with cavitations, by 30 to 40%. The anti cavitations
arrangement shall be provided without any extra cost to DEWA
OPERATION:
The valve shall sense the outlet pressure and it shall maintain it below the pilot’s
field adjustable set point. The valve shall also open to allow increased flow when
the outlet pressure drops due to the higher user demand, and to start to close, the
demand decreases and the outlet pressure reaches and surpasses the pilot’s set
point.
PARTICULAR SPECIFICATIONS:
The tenderer has to collect the detail from DEWA for minimum flow, normal
operating flow range, max. Continuous flow, inlet pressure range and outlet
pressure range before submission. After getting data, detail of size
calculation and other design data, ant cavitation graph is to be submitted by
the tenderer.
SPECIFICATIONS
DUBAI – UAE
MAIN VALVE CHARACTERISTICS:
• The main valve is globe type, and it is actuated by a diaphragm or membrane,

and operated by a pilot control system. Its operation is hydraulic and
adjustable with a pilot.
• The main valve diaphragm will never be used as the sealing surface against
the seat. This system will allow the valve to operate with a high degree of
stability, even with extremely low flows.
• The valve sealing will be done with a Buna-N disc against a stainless steel
seat.
• The main valve bonnet shall be manufactured in two parts, in order to allow
easy access to the stem and to facilitate maintenance of the main valve.
• The stem will be guided, from the top and bottom, by easily replaceable
bushings, which shall ensure the stem will remain vertical throughout its travel.
• The seat shall be attached to the valve with normal flat screws and washers,
making it possible to do maintenance without the need for any special tools.
Threaded connection is not acceptable.
• Maintenance of the main valve shall be possible without removing it from the
main line.
MATERIALS OF CONSTRUCTION:
1. Main Valve: Globe Type

a) Body, Cover (Bonnet) Ductile Iron Cylinder, spring casing
b) Stem Stainless Steel AISI 316
c) Stem Nut Stainless Steel AISI 316 / Bronze
d) Seat Ring / Seat Stainless Steel AISI 316
e) Bottom / Top Stem Guide Navy Bronze B-62
f) Disc Retainer / Inner valve Bronze/ductile iron with epoxy coated
g) Rubber Parts EPDM or Buna N fit for drinking water up
to 50 degree C.
h) Diaphragm Reinforced Synthetic Rubber – Fit to drinking
water to minimum 50 degree C
i) Coating for Main body, 300 microns Fusion Bonded Epoxy Coating –
Fit To drinking water to minimum 50 degree
C from WRAS
j) Valve Rating and PN 10 / PN 10 BS 4504 or as mentioned in
SPECIFICATIONS
DUBAI – UAE
flange Drilling BOQ

k) Pressure gauge 100mm dia. Glycerin filled stainless steel
grade 304 – one no. installed at inlet end with
pressure range given by DEWA and one no.
installed at outlet end with pressure range
given by DEWA
l) Upper guide, Bushing retaining ring , Anticavitation inlet cage ,

Anticavitation outlet cage, Resilient disc, Stem nut cotter pin, Locating pins,
Stem cap plug, Body bolts, Stem casing cap screws, Seat ring screws,
clamp plate screws, Piston pin, Bonnet bolts, Clamp plate washers, Inner
valve screws, Stem set screws - Stainless Steel 316
m) Eye bolt (hook), Eyebolt locknut - Steel
2. Pilot Circuit:
a) Tubings, fittings, Strainer, Pilot
Valves, Needle Valve, Filter Body,
Filter Screen, ball valve etc. Stainless Steel AISI 316
i.e. complete pilot system
b) Elastomer EPDM /Buna - N
3. Accessories:
a) Valve Position Indicator Stainless Steel AISI 316
b) Isolation Valve for Pressure Gauge Stainless Steel AISI 316
c) Nuts, bolts, fasteners, pins, etc. Stainless Steel AISI 316
PILOT SYSTEM:
• The valve contains a complete pilot system, and it shall be ready to install in
line and operate without any modifications.
• The pilot system will be isolated by three ball valves, which are closed when
maintenance as to be performed on the pilot system.
• The pilot system shall have a separate stainless steel opening speed control
and closing speed control device, which acts as a low flow stabilizer as well.
• The pressure reducing pilot shall have an adjusting spring with the proper
range for the adequate set point. It shall be possible to change the pilot range,
by simply changing the adjusting spring.

SPECIFICATIONS
DUBAI – UAE
The complete pilot system shall be of stainless steel, AISI 316. Elastomers shall
be of EPDM / Buna. Brass valves, strainer, pipes and fittings are not acceptable
APPLICATION:
• Its main application is to reduce a high inlet pressure into a lower and stable
outlet pressure.
• The valve is designed to maintain a stable outlet pressure, regardless of

fluctuations in the inlet pressure or flow and also check reverse flow on
pressure reversal on the line.
• Valve closes drip tight when the downstream pressure meets the pilot setting. The
pilot check valves direct downstream pressure above the diaphragm to close the
valve when the system pressure reverse (i.e. downstream pressure is higher than
the upstream pressure).
• During low demand, the valve will operate with a high degree of stability and
accuracy.
• Where cavitations may be present, the valve will be supplied with an Anti
Cavitations trim, made up of two centered cylinders. The cylinders will be
machined out of stainless Steel and they will be capable of withstanding a
pressure drop of up to 300 PSI, without causing damage to the main valve
body. At the same time, these Anti Cavitations cages will reduce the noise
associated with cavitations, by 30 to 40%.
FACE TO FACE DIMENSIONS:
PN 10/16
DN 100 150 200 250 300 400 500 600 700 800
L 350 480 600 730 850 1100 1250 1450 1650 1850
MARKING:
- Outlet pressure range

- Outlet pressure set by factory at the time of dispatch
- Date of Manufacture
- DEWA Supply order no.

SPECIFICATIONS
DUBAI – UAE
The above marking shall be with big lettering and in top area of valve so that
it can be read from ground level
3.4.8 NEEDLE VALVE (FLOW CONTROL VALVE)
Needle valve shall be designed for precise and accurate regulating of flow without
causing cavitations damage on valve body/internals or downstream pipes with
minimum noise of less than 70 dBA and minimum vibration. Anti cavitations
arrangement shall be provided without any extra cost to DEWA. Light anti
cavitations arrangement must be provided even there are no cavitations as per
manufacturer design and shall be as per manufacturer recommendation.
Medium of flow is potable water with max. Temperature 50 degree C. It shall be

throttling type and not on-off type. Delta P at full open shall be 0.1bar. It shall be
axial flow type and piston operated.
Epoxy coating and elastomer (that are in touch with potable water) shall be fit in
contact with potable water of minimum 50 degree C. Certificate from WRAS or
equivalent authority shall be submitted.
Pressure Rating : PN10 or as mentioned in B.O.Q.

Material:
Body/Gear box : Ductile iron
Vaned Ring/Slotted cylinder/Piston

/Seat/shaft/slide crank/slide rod/bolts/
Seat ring/collar bush : Stainless steel grade 316
Piston guide on rails : Bronze/stainless steel grade 316
Elastomer : EPDM
Coating : Fusion bonded epoxy coating of average

300 Micron or Rylsan coating in blue
color
Construction Bolts : AISI - 316
Connection : Flange face.
Flange drilling pattern : BS4504 PN10 for PN10 valves and BS

4504 PN16 for PN16 valves.
Closing direction : Clockwise
Closing by : Modulating actuator. Refer actuator and

SPECIFICATIONS
DUBAI – UAE
Gear Specifications
Face to Face dimensions for PN10 and PN16
DN 200 300 350 400 450 500 600 700 800 900 1000 1200
mm
L 400 500 700 800 900 1000 1200 1400 1600 1800 2000 2400
mm
3.5 INSTRUMENTATION, CONTROL AND AUTOMATION

REQUIREMENTS
3.5.1 GENERAL
1. Description
This Section covers the general requirements for furnishing and installation of all
instrumentation, control and automation (ICA) systems complete in every detail for
the purposes specified.
A. Work Included in this Section
Instrumentation work as indicated, specified and required. This intent of

Section is to require that the complete Instrumentation, Control and
Automation System, including all sections, i.e., primary elements (Bulk
Flow meters, Pressure Transmitter & Water Quality Analyzer) etc. shall be
installed and commissioned by a single ICA Sub-Contractor to assure
system uniformity.
Furnish all tools, equipment, materials, and supplies not furnished by the
bulk flowmeter supplier and perform all labour required to complete the
furnishing, installation, including all instrumentation signal and power wiring
and conduits, system validation, start-up and operational testing of a
complete and operable instrumentations and automation system as
specified herein. Provide all the necessary equipment components and
interconnections and the services of the manufacturers' engineering repre-
sentatives for the engineering, implementation, startup, operation, and
instruction to insure that the Employer receives a completely integrated and
operational ICA as herein specified.
It shall be the responsibility of the qualified single firm as described herein

to ensure that the instruments and equipment furnished under this section
are compatible with the equipment furnished under other sections of these
specifications, and that the signal transmission methods are compatible.
2. Reference Standards

SPECIFICATIONS
DUBAI – UAE
The standards referred to for Manufacturers quality procedures and

documentations are:
BS 970 Grades of stainless steel

BS 1646 Symbolic representation of process control functions
and instruments
BS 5308, Instrumentation Cable
BS 5750 Quality procedures
BS EN 60654, Operating conditions for industrial process
measurement and control
BS ISO 5725 Accuracy of measurement methods and results
3.5.2 SYSTEM RESPONSIBILITY
Contractor's attention is directed to the fact that the instrumentation system as

specified in this Section is an integrated system and therefore shall be provided by
a single competent, qualified instrumentation subcontractor (hereinafter in this
Section referred to as the ICA Subcontractor) who shall be subject to approval by
the Engineer and shall have total responsibility for the work of this Section. Entire
system installation including calibration, validation, start-up, operation testing, and
training shall be performed by qualified personnel possessing all the necessary
equipment and who have had experience performing similar installations. System
shall be integrated using the Subcontractor’s latest, most modern proven design
and shall, as far as practical, be of one manufacturer. Overall system performance
shall be guaranteed by the ICA Subcontractor.
The Contractor shall subcontract the work under this Section to a qualified ICA
Subcontractor who shall perform said work but it shall be understood that this
shall not relieve the Contractor from any responsibility under the Contract. Al-
though many references made herein are to work requirements and
responsibilities of the ICA Subcontractor such reference shall only mean that
responsibility shall pass through the ICA Subcontractor but in the final analysis
shall rest with the Contractor.
The ICA Subcontractor shall be responsible for the correct installation of all
hardware and systems specified in this Section.
The ICA Subcontractor shall be responsible to see that all components of the
instrumentation system, including primary measuring, indicating, transmitting,
receiving, recording, totalizing, controlling and alarming devices and all appur-
tenances, are completely compatible and shall function as outlined and he shall
furnish and install such additional equipment, accessories, etc. as necessary to
meet these objectives at no cost to the Employer.
3.5.3 QUALITY ASSURANCE
Qualification and Manufacturers.

SPECIFICATIONS
DUBAI – UAE
The ICA Subcontractor shall be a recognized manufacturer of primary elements,

panel and field instruments, panels, etc., of the general type specified herein and
shall have been regularly engaged in providing this equipment on a single system
responsibility basis for similar works. The personnel employed for system
engineering, supervision, start-up, operational testing and training shall be
regularly employed and factory trained by the ICA Subcontractor. Actual in-
stallation may or may not be performed by the ICA Subcontractor's employees,
but the ICA Subcontractor shall be responsible for the technical supervision of the
installation to insure that it is proper in all respects.
Standard of Quality.
Furnish equipment of the types and sizes specified which has been demonstrated
to operate successfully. Wherever on the Drawings and in these Specifications,
materials or equipment have been specified by using the name of products or
manufacturers, the term "or equal" is always understood to follow immediately.
Material or equipment, so specified, have been selected as being most suitable
and are regarded as standard and are not intended to eliminate others of equal
quality and performance. The order of listed manufacturers shall not be construed
as a preference or order of quality.
The burden of proof of equivalency in quality and performance shall rest with the
ICA Subcontractor and shall require the Engineer's written approval. The
procedure for submission of products for approval as equivalent shall be as
specified under submittals below.
All electrical equipment and materials, including their installation, shall conform to
Section – Electrical requirements unless specified otherwise in this Section.
3.5.4 SUBMITTALS
1. Pre-submittal Conference
Arrange a conference between the ICA Subcontractor and the Engineer or his
representative within sixty (60) days after award of the Contract for the purpose of
informally discussing in detail and verifying the correctness of the ICA
Subcontractor's system engineering methods and equipment and to generally
provide a framework for communication and coordination. This conference shall
be attended by ICA Subcontractor's Engineer, and duly authorized representa-
tives of the Contractor and Engineer.
Prepare a draft of the submittal for review. The draft shall include the following, as
a minimum.
Listing of major items proposed for this Section. Identify item tag number,
description, function, manufacturer, model number, descriptive literature and
statement as to whether item is "as specified or equivalent". Items identified as
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DUBAI – UAE
"equivalent" shall be accompanied by a comparative listing of the published

specifications for the item specified and for the item proposed.
2. Shop Drawings
Before proceeding with any manufacturing, submit Shop Drawings for approval.
Describe the items being submitted. Manufacturer's specification or data sheets
shall be clearly marked to delineate the options or styles to be furnished. Submit
only complete systems, not pieces of equipment from various systems. Show
dimensions, physical configurations, methods of connecting instruments together,
mounting details, and wiring schematics. Schematics shall be complete with tag
and terminal numbers. Submit fabrication, nameplate legends and piping
schematic drawings clearly showing all equipment and tag numbers on all panels.
Include material specifications lists where applicable.
3. Record Drawings
A. Process and Instrumentation Diagrams. Prepare and submit "Record"

process and instrumentation diagrams for all work included.
B. Without limiting the generality of other requirements of these Specifications,

arrange for the submittal, by the ICA Subcontractor, of a reproducible mylar
of complete schematics and wiring diagrams or drawings to include all
installed field and panel conduit and piping/tubing runs and routing, tray
systems, supports,, mounting details, point to point diagrams with a cable,
wire, tube and termination numbers. Drawings shall be a record of work as
actually constructed and shall be labelled as "Record".
4. Factory Inspection.
Engineer or his representative may inspect fabricated equipment at the factory.

The contractor shall give the Engineer 21 days’ notice in writing of the date on and
the place at which any plant will be ready for testing so that factory inspection can
be arranged. Factory inspection shall be made only after the manufacturer has
performed satisfactory checks, adjustments, tests and operations. Tests shall be
made using simulated inputs and output loads. Approval of equipment at the
factory only allows the manufacturer to ship the equipment to the site, and does
not constitute approval by the Engineer.
The Engineer shall indicate on return of the approved submittal each item
requiring factory inspection. Lack of such indication by the Engineer shall
constitute a waiver of factory inspection.
5. Instruction Manuals
Unless otherwise expressly specified furnish ten (10) sets of Instruction Manuals
and Part Lists for instrumentation equipment provided. Obtain data from

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manufacturers, and format and bind as specified. Obtain document distribution

instructions from the Engineer.
A. Schedule.
Deliver 2 copies of manuals not later than the equipment shipment date.
The balance of the copies shall be provided to the Engineer within 2 weeks
of the Final Operational Tests and shall include all revisions necessary to
correct for changes made during installation or checkout.
Submit an "Equipment Specification Data" form for each item of equipment which
shall summarize the specification features as called for in these specifications and
include such other necessary data as would provide a complete and adequate
specification for reordering an exact duplicate of the original item from the
manufacture at some future date. The assigned tag numbers and manufacturer's
part numbers shall be included but will not be considered as a substitute for any of
the required statement of specifications. More than one tag numbered item may
be included on a sheet.
B. Contents.
Include in manuals not less than the following information, as applicable,

for each instrument, equipment:
1. General, introduction and overall description, purpose, functions,

simplified theory of operations, etc.
2. Specifications (include equipment specifications data sheet
described above under Shop Drawings).
3. Installation instructions, procedures, sequences, tolerances and
precautions.
4. Operational procedures.
5. Maintenance, calibration and repair instructions.
6. Parts list and spare parts recommendations.
C. Format.
Use drawings and pictorials to illustrate the test to the extent necessary to
insure a clear, concise presentation. If manuals have been written to cover
a family of similar instruments or equipment’s, strike out inapplicable
information in a neat fashion or emphasize applicable portion by heavily
weighted arrows, circles or boxes; whichever provides the clearest and
neatest presentation. Where identical instruments are used in more than
one control loop or subsystem, include only one instrument manual,
however, an index by tag number for all instruments shall identify its
location in that manual.

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Control loop and/or subsystem operational descriptions shall identify the

function of each instrument and its relation to the other instruments in the
loop.
D. Binding.
Bind each manual in a cover which indicates the panel or process area to
which it applies, manufacturer's name, local address and telephone
number, and year of purchase.
6. Accessory and Maintenance Materials
Furnish the following items as specified herein. Deliver to Engineer as directed,

with itemized list in a letter of transmittal accompanying each shipment.
A. Special Tools and Accessories.
Furnish special tools, instruments and accessories for maintaining

instruments and equipment requiring periodic repair and adjustment as
specified elsewhere herein. Also furnish special lifting and handling
services for equipment requiring such devices.
B. Maintenance Materials and Spare Parts.
Deliver in manufacturer's original containers labeled to completely describe

contents and equipment for which it is furnished.
7. ICA Subcontractor's Certified Reports
The ICA Subcontractor, or his authorized representative, shall submit a written

report for each control panel and associated field instruments certifying that the
equipment (1) has been properly installed under his supervision, (2) is in
accurate calibration (3) was placed in operation in his presence, (4) has been
checked, inspected, calibrated, and adjusted as necessary, (5) has been
operated under maximum power variation conditions and operated satisfactorily,
and (6) is fully covered under the terms of the guarantee.
8. Demonstration and Final Operation Test Plans and Results.
Not later than 30 days prior to the test demonstration a written plan shall be
submitted for approval for demonstrating that each system of equipment
provided meets the specified operational requirements. The plan shall include
procedures to be used in final operation testing of entire systems including a
description for each system of test methods and materials, testing instruments
and recorders, a list of the equipment involved with the functional parameters to
be recorded on each item, and shop drawings of required temporary by-passes
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DUBAI – UAE
and like facilities. Submit three copies of test results and records for all final
operation tests.
3.5.5 PRODUCT DELIVERY, STORAGE AND HANDLING
Box, crate, or otherwise enclose and protect instruments and equipment during
shipment, handling, and storage. Keep all equipment dry and covered from
exposure to weather, moisture, corrosive liquids and gases or any element which
could degrade the equipment.
Protect painted surfaces against impact, abrasion, discoloration and other

damage. Repair any damage as directed and approved.
3.5.6 JOB CONDITIONS
Drawings and diagrammatic and show the intended arrangement for system
operation, piping, and appurtenances. Conform to Drawings as closely as
possible and exercise care (1) to secure neat arrangement of piping, valves,
conduit, and like items, and (2) to overcome structural interferences. Verify
dimensions and conditions at the place of work, and install materials and
equipment in the available spaces.
3.5.7 GUARANTEE AND WARRANTEES
Guarantee all work in accordance with the General Conditions of Contract. With
respect to instruments and equipment, guarantee shall cover (a) faulty or
inadequate design; (b) improper assembly or erection; (c) defective
workmanship or materials; and (d) leakage, breakage, or other failure not caused
by Employer's misuse. For equipment bearing a manufacturer's warranty in
excess of one year, furnish a copy of the warranty to Engineer with Employer
named as beneficiary.
3.5.8 PRODUCTS
1. Materials and Standard Specifications.
Provide instruments, equipment and materials suitable for service conditions and
meeting Standard Specifications such as ANSI, ASTM, ISA and SAMA. The
intent of this specification is to secure instruments and equipment of a uniform
quality and manufacture throughout the plant; i.e., all instruments in the plant,
supplied by the ICA Subcontractor, of the same type shall be by the same
manufacturer. This allows the stocking of the minimum number of spare parts.
2. Mountings

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DUBAI – UAE
Mount and install equipment as indicated. Where not shown, mount field
instruments according to best standard practice on pipe mounts, pedestal
mounts, or other similar means in accordance with supplier’s recommendation.
Where mounted in control panels, mount according to requirements of that Sec-
tion.
Equipment specified for field mounting shall be suitable for direct pipe mounting,
pedestal mounting, or surface mounting and non in-line indicators and
equipment with calibration adjustments or requiring periodic inspection shall be
mounted not lower than 1 m nor higher than 1.5 m above walkways, platforms,
catwalks, etc. All such equipment shall be weather and splash proof, in
accordance with BS EN 60529. If mounted in a designated hazardous area, the
equipment shall be explosion proof or rated intrinsically safe, whether so
specified herein or not.
3. Instrument Identification
All instrumentation and equipment shall be identified by nameplates or tags.

Field equipment shall be tagged with an instrumentation tag number. Tags shall
be black lamacoid with engraved white characters of 5 mm minimum height.
Tags shall be attached to equipment with a commercial tag holder using a
stainless steel band with a worm screw clamping device or by a holder fabricated
with standard hose clamps and meeting the same description. In some cases
where this would be impractical, use 20 gauge stainless steel wire. For field
panels or large equipment cases use stainless steel screws, however, such
permanent attachment shall not be on an ordinarily replaceable part. In all cases
the tag shall be plainly visible to a standing observer. In addition to tags, field
mounted control stations shall have a nameplate indicating their function and the
variable controlled. Nameplate shall be attached by one of the above methods.
4. Electronic Equipment
If the equipment is electronic in nature, provide solid state equipment to the

extent practicable. Select components of construction for their suitability and
reliability. Employ adequate component derating to preclude failures because of
transients and momentary overloads reasonably suspected in normal operation.
Design units for operation without forced cooling, unless such cooling is an
integral part of the service.
5. Equipment Operating Conditions
All equipment shall be noted for normal operating performance with varying
operating conditions over the following minimum ranges:
A. Power
1. Electrical. 220 volts AC + 10%, 50 Hz except where specifically

stated otherwise on the drawings or in the specifications.

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DUBAI – UAE
B. Field Installations
1. Outdoor Areas:
Ambient Temperature : Short term (<2 hours/day)

65ºC max.
Ambient Temperature : 20ºC to 55ºC
Ambient Relative Humidity : 5% to 100%
Weather: Rain, wind and dust
Provide as necessary, enclosures, sunshields, thermostatically

controlled heaters, etc., to assure normal operation under these
conditions.
2. Indoor Areas:
6. Power Supplies
Provide electrical instruments and control devices for operation on 220 volts, 50 Hz
current.
7. Signal Isolators, Converters and Conditioners
Insure that input-output signals of all instruments and control devices are
compatible. Unless otherwise specified signals between field and panels shall
be 4 to 20 mA dc unless specifically approved otherwise. Granting such approval
does not relieve the ICA Subcontractor from the compatibility requirement above.
Provide signal isolators and converters as necessary to obtain the required
system performance. Mount the devices behind control panels or in the field at
point of application.
8. Painting.
Provide factory paint for all instruments and equipment except where in
pipelines. Provide paint as required in Section 8 for structural supports,
brackets, etc.
9. Electrical
a. The construction work shall include all the power supply wiring,
instrumentation wiring, interconnecting wiring and equipment grounding as
indicated, specified and required and not specifically included under Sec-
tion 10.

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DUBAI – UAE
b. Wiring installations shall include cables, conductors, terminals connectors,

wire markers, conduits, conduit fittings, supports, hardware and all other
required materials not specifically included.
c. Provide the materials and complete all the required installations for
equipment grounding as specified of these Specifications.
d. Incidental items, not included in the Contract Documents that can

legitimately and reasonably be inferred to belong in the instrumentation
work shall be provided by the ICA Subcontractor.
e. Field Wiring. Provide 1.0 mm2 or larger stranded cable for multiple
conductors for instrument signal wiring of low voltage service. Provide
shielded conductors if necessary for proper performance and operation of
equipment. Use insulation rated for intended service. Ring out signal wiring
prior to termination. Provide wire number tags marked in in-
delible waterproof form of slip-on type or equal for each termination.
Provide pre-insulated crimp-on connectors for wire termination. Provide
pre-insulated crimp-on connectors for wire terminations and splices. Use
ratchet type crimping tool which does not release until proper crimp
pressure has been applied.
3.5.9 EXECUTION
1. Inspection
Inspect each instrument and piece of equipment for damage, defects,

completeness and correct operation before installing. Inspect previously installed
related work and verify that it is ready for installation of instruments and equip-
ment.
2. Preparation
Ensure that installation areas are clean and that concrete or masonry operations
are completed prior to installing instruments and equipment. Maintain the areas
in a broom-clean condition during installation operations.
3. Manufacturers' Installation and Supervision
Furnish the services of authorized factory personnel especially trained and

experienced in the installation of the equipment to: (1) supervise the installation
in accordance with the approved Instruction Manual; (2) be present when the
instruments and equipment are first put into operation; (3) inspect, check, adjust
as necessary, and approve the installation; and (4) calibrate the instruments, in
accordance with the Specifications herein,, until all trouble or defects are
corrected and the installation and operation are acceptable. Include all costs for
representative's services in the Contract Rates.
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4. Instrument Calibration
Provide the services of factory trained instrumentation technicians, tools and

equipment to field calibrate each instrument to its specified accuracy in
accordance with the manufacturer's specifications and instructions for Calibra-
tion. Each instrument shall be calibrated at 10 percent, 50 percent and 90
percent of span using test instruments to simulate inputs and read outputs that
are rated to an accuracy of at least 5 times greater than the specified accuracy
of the instrument being calibrated. Such test instruments shall have accuracies
traceable to the National Bureau of Standards, as applicable. Provide a written
report to the Engineer on each instrument certifying that it has been calibrated to
its published specified accuracy. This report shall include a listing of a published
specified accuracy, permissible tolerance at each point of calibration, calibration
reading as finally adjusted within tolerances, defects noted, correction action
required, and correction made.
5. System Validation
Provide the services of factory trained and field experienced instrumentation

engineer(s) to validate each system to verify that each system is operational and
performing its intended function within system tolerance. System tolerance is
defined as the root-mean-square sum of the system component published
specified accuracies from input to output. Validate each system by simulating
inputs at the first element in loop (i.e. sensor) of 10 percent, 50 percent and 90
percent of span, or on/off and verifying loop output devices (i.e. recorder, indicator,
alarm, etc. except controllers). During system validation, make provisional settings
on levels, alarms, etc. Verify controllers by observing that the final control element
moves in the proper direction to correct the process variable as compared to the
set point. Verify that all logic sequences operate in accordance with the
specifications.
Cause malfunctions to sound alarms or switch to standby to check system

operation. Check all systems thoroughly for correct operation. Test equipment
for this function shall be as specified under "Instrument Calibration".
Immediately correct all defects and malfunctions disclosed by tests. Use new
parts and materials as required and approved and retest. Provide a report
certifying completion of validation of each instrument system. This report shall
indicate calculated system tolerances, verification that system meets these
tolerances, and any provisional settings made to devices.
6. Commissioning
Upon completion of instrument calibration and system validation, test all systems
under process conditions. The intent of this test is to demonstrate and verify the
operational interrelationship of the instrumentation systems. This testing shall
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DUBAI – UAE
include, but not be limited to, all specified operational modes, taking process
variables to their limits (simulated or process) to verify all alarms, failure
interlocks, and operational interlocks between systems and/or mechanical
equipment.
7. Final Acceptance.
Final acceptance report. Immediately correct defects and malfunctions with

approved methods and materials in each case and repeat the testing. Upon
completion of final operational testing, submit certified report, with substantiating
data sheets, indicating that total ICA System meets all the functional requirements
specified herein. The Engineer will countersign this report and it shall constitute
final acceptance of the ICA System.
Testing shall be witnessed and approved by the Engineer. Notify the Engineer in
writing a minimum of 48 hours prior to the proposed data for commencing the test.
Upon completion of this test the Contractor shall begin or have begun system
start-up. The Employer reserves the right to set the schedule.
8. Start-Up Assistance
When specified elsewhere in this section provide the services of a factory trained
and field experienced instrumentation engineer to assist the Employer personnel
during startup of the system. Purpose of this assistance is to support in making
final adjustments of settings on the instrument systems.
9. Instruction of the Employer’s Personnel
Provide the services of a trained and field experienced instrumentation engineer

to conduct group training of the Employer designated personnel in the operation
of each instrument system. This training shall be for a minimum time period of 3
days, one day of which may be performed during the operational testing period.
Obtain the Engineer's written acceptance that the training has been adequate.
Include instruction covering basic system theory, operating principles and
adjustments, routine maintenance and repair, and "hands on" operation. The text
for this training shall be the process and instrumentation diagrams and operation
and maintenance manuals furnished as per these Specifications.
3.5.10 MEASUREMENT
1. General
Instrumentation, Control and Automation systems and all work in connection

therewith shall be valued by the measurement of only such items as are included
in the Bill of Quantities. The cost of Instrumentation, Control and Automation
systems not itemized in the Bill of Quantities shall be deemed to be included
elsewhere in the Contract Rates to cover all the Contractor's obligations under
the Contract.

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3.5.11 BULK FLOWMETERS
1. Transmission and Distribution Metering
Measurement of flow within the transmission and distribution systems will be

made at selected sites using magnetic flow meters.
2. Magnetic Flow meters
A. General
Magnetic flow meters shall use the principle of electro-magnetic induction

to produce a DC voltage proportional to the rate of liquid flow. Coil
excitation shall be DC. The coils shall generate a magnetic field which in
turn induces a voltage in the flowing liquid which is sensed by a pair of
electrodes in contact with the fluid.
The magnetic flow meter shall utilize DC bi-polar pulsed coil excitation,
automatically re-zeroing after every cycle. The coils shall be protected from
contact with the liquid and the electrodes shall be made of AISI type 316
stainless steel and shall be provided with a minimum preamplifier input
impedance of 1 x 106 mega ohms to reduce errors due to electrode coating
to almost zero. Any form of electrode cleaning is not acceptable.
Replaceable electrodes are also not acceptable.
The electronics shall be remote mounted and the flow meter transmitter
shall retain IP 67 rating. The transmitter shall be furnished with integral
universal wall/pipe stand mounting bracket and 30 meters of cable
minimum. Additional lengths of cable shall be provided as required for a
complete and operable installation at no extra cost.
The Flow Meter sensor shall retain IP 68 rating at 10 meters depth

indefinitely. The metering tube shall be suitably lined to withstand
abrasion of the fluid and suitable for use in potable water.
The flow meter shall have a switching power supply of 24 VDC + 33% to -
25% w/ Backup battery & charger taking power from 220vAC 1 50/60 Hz.
Power consumption shall not exceed 11 VA. All printed circuit boards shall
be contained in a single easy plug-in, easy plug-out type module and be
interchangeable for any size without requiring testing. In addition to the
internal EEPROM or RAM built-in with the flow transmitters, the magnetic
flow meters shall have a dedicated sensor memory which will contain all
the characteristics of the sensor (i.e., calibration factor, correction factor,
excitation frequency, etc.) as well as the user-configured parameters on
site. It shall be an electrically programmable/erasable memory specifically
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DUBAI – UAE
configured for each sensor. This memory shall facilitate automatic transfer
of pre-programmed data to the new electronics in an event of transmitter
fault, without requiring renewed calibration or commissioning. A 2 x 16-
character alphanumeric display shall indicate user-defined flow units and
total flow. All menu advice and commands shall be viewed on this display.
Each magnetic flow meter system shall have an accuracy within + 0.3
percent of the flow rate over the application operating range when the
velocity is within 0.3 m/s to 10 m/s. Meters shall have a repeatability of 0.1
percent of full scale. Accuracy shall be maintained for an ambient
temperature range of 0 degree to 50 degrees C and liquid temperature of
60 degrees C. Accuracy shall be verified by calibration in a flow laboratory
Outputs shall be isolated 4-20mA dc into 800 ohms plus frequency output
selectable from:
(a) 25/50 ms, 24 Vdc pulse, o-10 Hz max. 150 ohm min., or
(b) 50-50 duty cycle 15V peak to peak, 0-1000 Hz max. or
(c) Either (a) or (b) above with open collector.
(d) Two flow alarms
(e) RS232 Communication
(f) Positive Zero Return for external relay contacts.
The flow meter shall be inherently bi-directional, and should total forward
and reverse flow separately.
Inter-connection between meters and signal converters shall be by cable

furnished by the manufacturer at no extra cost.
The electronics shall be the same type for remote or compact, mounting.
Flow meter with pre-potted cables of hard epoxy or cement-like type sealant
is not acceptable.
Magnetic flow meter shall incorporate a detector to constantly monitor

whether the pipe is full and all electronics, electrodes, sensors and cable
connections are operating correctly. Any fault shall be indicated
immediately via a relay to any remote device, such as alarm, or signal or to
the motor actuator of a valve or pump to open or close as directed by the
Engineer.
The flow meter shall incorporate a feature allowing a menu selection and
program changes to be made from outside the housing via hall-effect
sensors. It shall not be necessary to remove covers, panels or fasteners to
accomplish calibration or program changes. The meter software shall
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DUBAI – UAE
incorporate a password, preventing inadvertent program changes. A hand-

held programmer is not acceptable.
Field selectable and adjustable circuitry is to be provided as follows:
a) Low flow cut-off, field adjustable from 0-9% of the full scale.
b) Current damping to modulate peaks and troughs for the 4-

20mA output signal in the event the output signals are
spasmodically received.
c) Noise suppression to cut-off the inaccuracy in magnetic field

and current due to noise created by the liquid flow.
d) Display damping to steady the reading of the flowrate and

total.
Totalized flow and programmed configuration shall be maintained in

memory for up to 10 years.
B. Construction
The magnetic flow meters shall be of short-form type. Meters shall be

designed with end connections of NP 10 flanges. Field coils shall be either
completely encapsulated in the meter lining material or the meter tube shall
be 304 stainless steel with a suitable liner. A suitable protective shield shall
be provided at each end of the liner to withstand the scouring velocities of
the process fluid at the maximum flow rates. The flow meter shall be robust
& fully welded type to prevent entry of moisture to the coils. Sensor of shell-
type enclosure with gaskets in between the shells is not acceptable.
C. Grounding
The flowmeter shall be equipped with built-in grounding electrodes of the

same materials as the sensing electrode. In addition, each magnetic
flowmeter shall be provided with two (2) numbers full-bore stainless steel
grounding rings installed at both ends of the sensor thus providing a
grounding circuit for each magnetic meter...
D. Manufacturer
Flowmeter shall be manufactured by a company who has had several

years of experience in the manufacture of flowmeters of the DC pulse type
suitable for potable water and shall have a fully equipped technical,
marketing and service facility in the U.A.E. The manufacturer of the
flowmeters shall confirm the particular application of the flowmeters for the
intended use and shall provide a warranty of minimum 5 years based on a
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DUBAI – UAE
replacement basis including labour and material at no extra cost. The

warranty shall be issued directly to DEWA.
E. Installation
The Contractor/Supplier shall provide technical services during the

installation and commissioning of the flowmeters and demonstrate that the
flowmeters are functioning satisfactory as per the requirements of this
specifications...
The bulk flowmeter sensor shall be installed on the existing asbestos
cement pipeline and directly buried in the ground without the need of a
chamber while the transmitter will be installed inside GRP Kiosk above
ground level.
F. Power Supply Required
The permanent A. C. power supply shall be provided by DEWA.
G. Battery Back-up
Flow meter specified for operation from dc power supplies shall be

provided with a battery back-up unit to provide uninterrupted power for a
maximum period of 8 hours following main supply failure. The unit shall be
installed in the GRP enclosure housing the flow meter converter. The unit
shall comply with the following requirements:-
a) Combination charger and supply circuits.

b) Load shed circuit to protect battery from deep discharge.
c) Rapid charge facility, re-charge 12Ah battery in less than 8
hours whilst simultaneously the primary load.
d) Input voltage 230ac  10%, 50Hz.
e) Output voltage, nominal 24V dc, and maximum 28Vdc.
f) Low battery alarm at 22Vdc  3%, open collector or volt free
contacts.
g) Low voltage cutout at 21Vdc  3%.
h) Restore from low voltage cutout at 24Vdc  3%.
i) Battery pack rated at 12 Ah minimum, maintenance free.
j) Temperature and humidity, operational,
0 C to + 65 C
5 to 90% RH none condensing.
H. Installation
The Contractor shall survey the flow meter installation sites and after familiarizing
himself with the site conditions, submit working drawings for the installation,
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instrumentation and electrical works involved for every one of these flow meters, to the
Engineer for checking and approval.
The bulk flow meters shall be installed to the existing asbestos cement mains,
direct buried in the manner shown on the Drawings. The Contractor shall submit
working drawings, showing his proposed method of installation.
The Contractor shall coordinate the flow meter installation works, in accordance with
Technical Specification; the Dubai Municipality and other Service Authorities; property
owners; and shall also obtain "No Objection Certificates" (NOC) from all involved
parties. He shall submit a copy of the NOC to the Engineer for checking and approval
prior to starting the construction works, failing which the Contractor shall be held
responsible for the consequences and will be charged for amounts that may be
claimed by any of the mentioned parties.
I. Permanent Power Supply
The permanent power supply shall be provided by DEWA free of charge. The
Contractor shall make the necessary application for the provision of permanent
power supply to DEWA/ED as soon as the actual locations are finalized at no
extra cost.
3.5.12 PRESSURE TRANSMITTERS
Gauge or differential pressure transmitters shall be 24 Vdc loop powered with 4-20
mA output. Capacitance type pressure sensor shall have over pressure limits at
least 100% above the specified process pressure. Transmitter accuracy shall be ±
0.1% of range. Enclosure shall be waterproof to IP 67 for 72 hours at 2 m.
Transmitter shall be provided with in-built zero and span adjustments. Process
connection shall be ½ inch NPT. Wetted parts shall be stainless steel Type 316.
Transmitters shall be provided with a stainless steel Type 316 tag plate, identifying
the manufacturer, model number, span and calibrated range. A calibration report
from the manufacturer shall be furnished for each transmitter. Differential pressure
transmitters used for flow measurement shall be provided with in-built square root
extraction. A stainless steel type 316L three valve manifold and an isolation ball
valve shall be provided for differential and gauge pressure transmitters
respectively.
3.5.13 ANALYZER STATION
A. General
Each analyzer station shall comprise of the transmitters and sensor

assemblies for measuring pH, residual chlorine and conductivity.
The analyzer transmitters and associated pipework shall be assembled

into a GRP enclosure generally as shown on the Drawings. The selected
SPECIFICATIONS
DUBAI – UAE
enclosure shall be of identical type, height and color to the RTU

enclosure.
The pH, chlorine and conductivity sensors shall be part of a pre-fabricated

continuous flow through sensor assembly, provided with an isolation/flow
control valve and a flow rate indicator. The analyzer station shall have a
2” NPT process connection. Analyzer drain shall be piped to an external
drainage system. Each sensor shall be clearly identified and labeled in
the analyzer assembly.
B. Transmitters.
Each station shall be provided with two transmitters. The first one shall
monitor residual chlorine and ph. Residual chlorine measurement shall be
compensated for pH and temperature. There shall be separate current
outputs for residual chlorine and ph. The second transmitter shall measure
conductivity in micro mhos per centimeter. Conductivity measurement
shall also be temperature compensated. A separate current output shall be
provided for conductivity and temperature.
Transmitter shall be microprocessor based with programmable range and

alarm functions. In-built self-diagnostics shall provide sensor failure
alarms. Transmitters shall be suitable for surface mounting. Enclosure
protection shall be to IP 65. Power supply shall be 220 Vac, 50 Hz.
Transmitter output shall be isolated 4-20 mAdc. Transmitter shall have a
digital display for process variable, temperature, and alarm status and
fault conditions. Programming shall be through an in-built membrane
keypad with tactile feedback. Programming shall be password protected.
Transmitter shall be suitable for continuous operation in ambient
temperature of up to 65ºC and relative humidity of up to 95%. Overall
transmitter accuracy shall be ± 1% of the range.
C. Residual Chlorine Sensor.
The analyzer shall measure free residual chlorine without using buffers or
reagents. Three electrode potentiastatic system with platinium counter
and working electrodes silver/silver chloride reference electrode and
constant abrasive grit electrode cleaning. The sensor shall have an in-
built RTD Pt 100 temperature sensor for temperature compensations.
Chlorine measurement shall also be pH compensated. Flow through type
sensor shall be provided with a “T” fitting. The analyzer shall normally
measure free residual Chlorine without using buffers or reagents. A buffer
housing assembly and solid buffer cartridge shall be used in applications
where the process exceeds 8.5 pH.
D. pH Sensor.

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DUBAI – UAE
PH sensor shall measure the hydrogen ion activity. The electrode

assembly shall comprise of a glass measuring electrode, reference
electrode, and solution ground and temperature sensor. Electrode
assembly shall be provided with an integral preamplifier.
E. Conductivity Sensor.
Conductivity Sensor shall be suitable for flow through installation.

electrodes shall be stainless steel Type 316, in Tefzel housing. In-built
temperature compensation shall be provided.
3.6 POWER DISTRIBUTION ENCLOSURE (GRP ENCLOSURE)

WITH ELECTRICAL REQUIREMENT
1. Materials
Enclosures shall be manufactured from polyester resin and "E" type glass
reinforcement. The polyester resins used shall be in accordance with BS 3532
and shall include an Ultra Violet stabilizer.
2. Products
Glass reinforced plastic enclosures shall be supplied in accordance with the

drawings, the specifications and approved shop drawings. The enclosure shall be
identical at each location and sized to accommodate future telemetry equipment,
minimum useable space shall be 900(W) x 470 (D) x 1480 (H) mm. A general
arrangement drawing showing the position of internally mounted equipment shall
be submitted to the Engineer for approval prior to manufacture of the enclosures.
3. Construction.
The enclosure shall be suitable for outdoor installation with an ambient

temperature from 10‫؛‬C up to 55‫؛‬C, solar radiation 1200 w/m2., maximum
humidity: 99% and shall provide protection against impact energy of 20 joules
(hammer of 5 kg falling from a height of 400 mm) and with excellent resistance to
corrosion and ultra violet rays complying to IEC 68.2.4 and IEC 68.2.5.
Enclosures shall be constructed to the dimensions and general layout shown on

the Drawings. The enclosures shall be formed of resin bonded glass fiber inner
and outer skins totally encapsulating a rigid core. The core shall be 12 mm thick
weather proof plywood or 12 mm thick exterior grade resin bonded compressed
pine-strand board. Large panel areas shall be stiffened by encapsulated ribs.

SPECIFICATIONS
DUBAI – UAE
The enclosure shall be constructed to offer fire resistance (retention of stability,

integrity and insulation) as required by BS 476: Part 7 Clause 2 and tested to Parts
20 and 23, in excess of 30 minutes. The contractor shall supply 3 copies of the
necessary test certificates.
The degree of protection of the enclosure against ingress of foreign matter shall
be to BS EN 60947-1, IP55. All doors and covers shall be fitted with sealing
strips of rubber or other material to exclude dust and moisture.
Doors shall be formed of a GRP/Plywood sandwich with box section steel

encapsulated into the edges and frames. Doors shall be hung with hinges of
substantial single knuckle non-rusting type and fitted with self-locking stays
arranged to hold them open at 90. Door catches shall operate at a sufficient
number of points to hold doors firmly closed and secured by externally fitted
locking handles together with a securely fitted lock. A micro switch shall be fitted
on each door arranged to provide a closed contact when the door is securely
closed and an open contact when the door is opened.
Three master keys shall be provided for all cubicles and each enclosure shall be
protected with guard rail safety fencing at no extra cost.
Space for DEWA Electrical Division metering equipment, associated protection,

power distribution board and battery back-up equipment shall be provided in a
separate full height section within the main frame of the enclosure complete with
fire resistant mounting panel. Access to this compartment shall be from a
separate door to the metering equipment and telemetry compartment. A suitably
sized viewing window shall be fitted in the door to permit reading of the electricity
meter without the need to open the door. The meter shall be positioned a
minimum of 1.2 m from finished ground level.
Plain internal holding down flanges at the base of the walls shall be provided for
site drilling upon installation.
Anti-condensation heaters shall be installed in both compartments, wall mounted

and of robust construction. Mechanical guards shall be fitted to protect the
heaters from accidental damage. The heaters shall be 220 volt and controlled by
internally mounted humidistat and overriding on / Auto switch.
4. Finish.
Enclosures shall be self-finished in a semi-gloss titanium oxide white finish

providing a high level of resistance to ultra-violet light. The right-hand door of the
enclosure shall have the DEWA monogram embossed in its bottom right-hand
corner.
All external labels shall be in English and Arabic. Internal labels shall be in
English only. A schedule of labels shall be submitted to the Engineer for
approval prior to manufacture.
SPECIFICATIONS
DUBAI – UAE
Internal labels shall be rear engraved perspex, backwashed to match the internal
colour finish and fixed with countersunk screws. Every internal component shall
be identified, the function of each circuit breaker shall be clearly identified. The
use of stick on labels will not be allowed.
Warning and danger notices shall be engraved labels with red letters on a white
background. Compartments with doors or covers, not interlocked with an isolator
shall have an external label stating “DANGER LIVE TERMINALS” with flash sign
and voltage underneath.
5. Internal Equipment Supports.
Internal equipment supports will be required for control, electrical and telemetry
equipment. Such supports shall be designed and provided in consultation with
the equipment suppliers and will be subject to approval by the Engineer.
6. Distribution Boards
The distribution board for small power, heating and lighting shall be mounted in
the electrical compartment of the enclosure and be fed from a DEWA Electricity
Division 380V, 3 phase supply. MCB’s and residual current devices shall be
fitted as shown on the Drawings and shall comply with clause3.6.10 and its sub
clause under this section.
7. Lightning and Surge Protection.
A lightning and surge protection unit shall be installed at the supply termination
point to protect the electronic equipment from mains borne surges. The unit shall
be of modular construction and designed to meet IEC 801-5 levels 1 - 4 and IEC
364-4-443 AQ2.
8. Installation.
The enclosure shall be installed on a concrete plinth which shall incorporate

ducts for incoming and outgoing cables. Separate ducts shall be provided for
each service and for incoming and outgoing service. Ducts shall be sized to a
maximum fill size of 40% of cross sectional area, minimum size 100 mm
diameter, maximum size 200mm diameter.
Install GRP enclosures at such time as approved when construction and finish of
adjoining work will permit and in sufficient time to avoid delays to construction
progress.
Enclosures shall be mounted on a prepared surface in an approved position and

in full compliance with the manufacturer’s recommendations.
Holding down bolts shall be of appropriate size and not less than 6 no. The
Contractor shall exercise care to avoid damage to reinforcing steel work and any
SPECIFICATIONS
DUBAI – UAE
abortive holes shall be grouted with a 3:1 sand cement mixture. Holes shall be
drilled to the minimum depth required by the bolt and shall not penetrate a
structural slab or cause any undesirable cracking or other damage.
The base of the enclosure shall be sealed to the bearing surface in a manner
recommended by the kiosk manufacturer to ensure the designated IP rating is
maintained. Existing concrete surfaces shall be carefully cleaned and prepared to ensure
a proper bond with the sealing material.
9. Cabling
Cables shall comply with clause 3.6.10 and its sub clause under this section.
Cabling shall include installation ducts as specified, laying, glanding, terminating

at both ends and testing. Cable routes shall be subject to the Engineer’s approval.
A 316 L Type stainless steel plate engraved in English and Arabic with the words
“DANGER CABLE ENTRY BELOW” shall be permanently fixed to the outer side
of the enclosure plinths above the cable entry location. Segregate power and
signal cables.
Cables shall enter the enclosure below ground via pre-cast ducts within the plinth.
As a minimum the following ducts shall be provided.
• Incoming power supply
• Telephone line
• Outgoing local power distribution
• Analog signals
• Digital signals
All ducts shall be sealed using an approved sealing compound and to the
approval of the Engineer. All ground areas shall be reinstated.
3.7 RTU EQUIPMENT
3.7.1 INTRODUCTION
3.7.1.1 General
A. RTUs shall be of a proven design.
RTU Types
The Tenderer shall offer RTUs to 20% fully installed spare capacity for each type of
I/O ‘s.

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DUBAI – UAE
Serial communications links shall be supported so that a minimum of 8 RTUs can

be networked. It shall be possible to configure one of the main RTUs as the
‘Master’ which will communicate with the Master station and to have RTUs act as
‘Slaves’ reporting to the ‘Master’ by low powered radio.
It shall be possible for each ‘Slave’ RTU to perform its own control and monitoring
functions and for Slaves to pass parameters between each other.
3.7.1.2 RTU Functions
RTUs shall be capable of the following functions as a minimum:
A. Data Acquisition
B. Data Recording and Tagging
C. Alarm Management
D. Data Handling
E. Sequence Control
F. Data Processing (Including Math’s Functions)
G. Self-Diagnostics
H. Communications Control
I. Local data entry via integral keypad or similar
J. Local LCD display for the display of plant signals and RTU status.
Each RTU shall have a battery backed real time clock capable of maintaining an
accuracy of ± 1 second per day.
3.7.1.3 RTU Address
Each RTU shall have a unique identification address selected by a portable

programmer or integral keypad and stored in nonvolatile memory within the RTU.
3.7.1.3.1 Maintenance and Repair
A. The RTUs shall be constructed for ease of Maintenance & Repair.
3.7.1.3.2 MTBF & MTTR
A. The tenderer is to supply details on MTBF and MTTR figures for the RTU
equipment.
3.7.2 CONSTRUCTION
3.7.2.1 General

SPECIFICATIONS
DUBAI – UAE
A. The RTUs shall be of a robust modular construction suitable for use in an

industrial environment.
3.7.2.2 Environment
Temperature & Humidity
Equipment Operating Conditions
All equipment shall be noted for normal operating performance with varying
operating conditions over the following minimum ranges:
A. Power
2. Electrical. 220 volts AC + 10%, 50 Hz except where

specifically stated otherwise on the drawings or in the
specifications.
B. Field Installations
1. Outdoor Areas:
Ambient Temperature : Short term (<2 hours/day)

65ºC max.
Weather: Rain, wind and dust
Provide as necessary, enclosures, sunshields, thermostatically

controlled heaters, etc., to assure normal operation under these
conditions.
2. Indoor Areas:

Shock & Vibration
Shock to meet EES 1980
Vibration to meet BS2011 Part 2.1 FC & IEC 68.2.6 Test FC
All RTU and ancillary equipment shall be protected from corrosion.
3.7.2.3 Equipment Housing
Where it is required that the RTU equipment is to be provided in additional

enclosure/panels/kiosks the tender shall provide details of how this is to be
achieved and any areas of the specification that may be compromised.
SPECIFICATIONS
DUBAI – UAE
Where applicable the following details for enclosures shall apply to all RTU types.
A. Protection
Enclosures shall be provided in accordance with IEC 144 (BS 5420) and to
IEC 159 and to IP55 as a minimum.
B. Materials
High impact resistance polycarbonate or rolled sheet steel, minimum

1.5mm thick on all panels except back plates, gland plates and doors which
shall be minimum 1.6mm thick.
C. Space Envelope Availability

When mounted in a GRP enclosure the space envelopes within which the
RTU (including its back up battery whether integral with RTU or in a
separate enclosure) is preferred to fit are as follows:
320 (H) x 400 (W) x 400 (D)
D. Doors and Covers
Enclosures shall have a substantial door with smooth folded edges and
suitably stiffened to prevent flexing under normal use. Tumbler locks shall
be provided with a universal key for each enclosure supplied to the
Purchaser. Sufficient locks shall be provided on each enclosure to ensure
the rating of the enclosure is maintained when shut.
E. Mounting
Enclosures shall be suitable for wall mounting or mounting on a back plate

within a further enclosure.
F. Labels
A single scheme identification label shall be securely fastened to the RTU

of the RTU enclosure.
The label shall show:
• An appropriate address & phone number to be stipulated by the

Engineer.
• RTU type, serial number and any other references necessary to

uniquely identify the RTU.

SPECIFICATIONS
DUBAI – UAE
• Operating voltage/frequency/current.
• “Authorized Access Only”
G. Temperature Sensors
All outdoor RTUs shall have temperature sensors installed for reporting
temperature high alarm if the temperature in the RTU cubicle exceeds a preset
temperature.
3.7.3 POWER SUPPLIES
3.7.3.1 General
Power supplies for RTUs shall be fully protected against reverse polarity,
overvoltage, under voltage and other faults.
Conditioning shall be inherent in the power supply design to protect against
voltage transients and mains-borne radio-frequency interference typically found in
an industrial environment from entering the processing logic circuits.
RTUs shall be capable of monitoring their power supply as part of the watchdog
function, and reporting an incoming power supply failure as an RTU alarm. This
shall not utilize any of the signal inputs/outputs.
3.7.3.2 Voltages
• All mains powered RTUs shall operate on 220 volts ± 5%, 45 to 65Hz a.c.
Any additional enclosures, transformers or circuit-breakers required to meet
the relevant standards shall be included in the tender.
• In the event of any supply voltages a.c. or D.C. being outside the allowable
range the RTU shall not operate in a non-deterministic manner.
• All mains powered RTUs digital inputs shall be sourced from the RTU at
not greater than 28 volts dc. And not less than 15 volts dc. The source
supply shall be isolated from all other RTU circuits
• At solar sites the tenderer shall specify the mechanism for optimizing power
usage.
3.7.3.3 Battery Backup
All RTU types shall be provided with an integral battery separate from all other
batteries to protect the RTU from loss of data and to maintain the real time clock.
In addition RTUs shall be supplied complete with a battery sized to provide the
following minimum functionality for 8 hours following a mains failure.
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DUBAI – UAE
• Monitoring of all digital inputs, and pulse inputs.

• Scanning all analogue inputs.
• Holding all digital outputs in the same position immediately prior to mains
failure.
• Holding all analogue outputs at their values immediately prior to mains
failure.
• Receive or initiate 12 calls a day with the master station.
The RTU shall transmit a battery low alarm to the master station if the battery falls
within 10% of its minimum operating voltage. This shall not utilize any of the
signal inputs/outputs.
It shall also be possible to automatically load test the battery while under mains
supply and report the condition of the battery to the Master station.
The battery shall be automatically recharged by the RTU on restoration of the

mains supply within 12 hours.
It shall not be possible for this battery backup to be inadvertently switched off.
This battery can either be mounted inside the RTU enclosure or in a separate
enclosure. If supplied in a separate enclosure, it shall be supplied complete with 5
meters of cable to connect the battery to the RTU. In all cases the Contractor
shall be responsible for the design of the system including venting. The battery
enclosure shall be of identical IP rating to the RTU enclosure.
3.7.4 SIGNAL INPUTS AND OUTPUTS
The details in the following sections apply to all RTU types.
All signal inputs and outputs shall be protected to meet as a minimum the
requirements of IEC 801. The tenderer shall state the performance criteria which
the RTU complies with respect to the above standard.
Local information shall be available to show what I/O modules are fitted and their
status. This information shall also be made available to the Master station.
3.7.4.1 Digital Inputs
A digital input shall mean the detection of the closure or opening of a remote volt-
free and earth-free contact for a software configurable period of at least 250
milliseconds.
If possible any of the digital inputs shall be able to be used as pulse inputs.

SPECIFICATIONS
DUBAI – UAE
Maximum contact resistance (closed contacts) should be better than 180 ohms.
Minimum contact resistance (open contacts) should be better than 50K ohms.
Isolation between inputs and incoming 220V supply shall be > 1000V ac peak and
> 1000V dc.
Isolation between inputs and all other RTU interfaces shall be > 500V ac peak and
> 500V dc.
3.7.4.2 Digital Outputs
This shall be a volt free relay contact configurable for either normally open or
closed in the de-energized state, which when driven shall either go to the opposite
state continuously or for a software configurable period of time (minimum
2 seconds).
The rating of the contacts shall be 100mA 24 volts D.C. inductive load, or 500mA
55 volts 50Hz a.c. resistive load.
The relay shall be rated for 106 operations.
Isolation to be as for Digital Inputs above.
The relay driver circuit shall be capable of monitoring by the RTU for correct
operation.
3.7.4.3 Analogue Inputs
A. General
On all mains powered RTUs the analogue input loop supplies shall be provided
externally.
Zero and scaling facilities shall be software definable by the user.
B. Noise Rejection
1. Common mode noise rejection shall be greater than 80 dB,

measured at 50 Hz ± 1%.
2. Series mode noise rejection shall be greater than 40 dB, measured
at 50 Hz ± 1%.
C. Accuracy
A minimum of 14-bit analogue to digital conversion shall be used providing

resolution of at least 1 in 16,384. Overall conversion accuracy measured

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DUBAI – UAE
from the RTU terminals shall be linear and better than 0.15% of full scale
under operating conditions specified elsewhere in this specification.
D. Input Impedance
Minimum of 200k ohm on any voltage channel. Maximum of 250 ohm on

any current channel.
E. Cross-talk
Better than 50dB at 50 Hz ± 1% between any channel, no electrical

connection between current loops.
F. Ranges
As a minimum the following input ranges shall be provided:
• 0-5 volts and 1-5 volts D.C. on voltage channels for mains RTUs.
• 0-20mA and 4-20mA D.C. on current channels for mains RTUs.
G. Isolation
To be as for digital inputs above and to include channel to channel isolation

of > 500V ac PK > 500V dc.
3.7.4.4 Analogue Outputs
A. Ranges
As a minimum the following output ranges shall be provided:
• 0-20mA
• 4-20mA
B. Loop Compliance
The integrity of loop signal shall be continuously monitored and if the loop
impedance exceeds the drive capability the fault shall be reported to the
master station. Such faults shall also be displayed locally.
C. Load Impedance
The output shall be capable of driving into 0 to 1200 ohms independently

on each channel.
D. Resolution
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DUBAI – UAE
D to A converter 12 bits.
E. Protection
Each A.O. shall be capable of withstanding indefinitely short circuiting or open

circuiting.
F. Accuracy
Overall conversion accuracy of 0.2% of full scale over the operating

temperature range stated elsewhere in this specification.
G. Settling time shall be better than 40mS.
H. Isolation
To be as for analogue inputs above.
I. Latching. In the event the analogue signal is lost, the plant (e.g. valve
actuator) shall hold the position (fail safe). Each analogue output latching
requirements shall be reviewed against actual site operational requirements prior
to implementation.
3.7.4.5 Pulse Inputs
Each of the digital inputs will be able to be utilized as pulse inputs i.e. being able
to count the number of contact closures or openings.
All pulse inputs should have the following characteristics:
A. Count Rate
Maximum 20Hz.
B. Count Capacity
Up to 9,999,999 plus a roll over count.
C. Reset
Each counter shall be able to be reset to zero or preset to a user selected

value from the Master station by a suitably privileged user at a workstation
or as part of a user program running within the RTU.

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D. Filtering
The pulse input shall include the necessary circuits to prevent spurious
counts from poor waveforms and spurious line interference likely to be
found within an industrial environment.
E. Wetting Voltage
As for digital inputs.
3.7.4.6 Local Keypad/Display
The RTU shall include a keypad/display to provide the following as a minimum:
• Display of RTU I/O in the form of meaningful descriptions with status or

units.
E.g. Upstream Pressure 30 bar
• Display of the RTU communications status
• Resetting of RTU
• Diagnostics data (tenderer to specify)
• RTU time
3.7.5 SOFTWARE REQUIREMENTS

A. RTU Software shall conform to the requirements of IEC 1131-3.
3.7.5.1 Mains Failure
A. In the event of a mains failure and after expiry of the battery back-up, the
manufacturer’s operating software shall be arranged to provide an orderly
shutdown.
B. Upon restoration of the supply, the RTU shall restart in an orderly,

operationally safe manner by performing self-check routines in readiness to
continue as required by the user’s programmed instructions without
intervention.
C. Upon the detection of failure and restoration of mains power, the RTU shall
send an appropriate message to the Master station.
3.7.5.2 Alarms and Events
The system shall be able to detect/generate the following types of alarms at the
RTUs.
A. Status Alarms
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DUBAI – UAE
Each change to status or derived status shall generate an event which, if

so configured, shall be reported as an alarm. It shall be possible to assign
a separate time delay to each status point for which an event has to persist
before being reported as an alarm. This delay shall be configurable from 0
to 900 seconds.
B. Analogue Value Alarms
Each analogue shall have a minimum of four thresholds or limits. If an

analogue or derived value transgresses any one of these limits, an event
shall be generated which shall be able to be reported as an alarm. Each
threshold transgress shall be a separate alarm e.g. high high, high, low, low
low. However, whether the alarm state is higher or lower than the threshold
shall be configurable such that any threshold could be a high or low alarm as
required. It shall be possible to assign a separate deadband to each
analogue point which shall apply to all four associated thresholds. It is
desirable that separate dead bands should be assigned to each threshold for
each analogue point. These limits are in addition to those in (D) below.
C. Derived Alarms
The system shall have the ability to test against a combination of values
and/or states and detect an alarm, it shall provide detection, for example, of
valid pump running combinations.
RTU alarm processing shall enable combined events or alarms to be

derived which shall be reported with a different priority than the constituent
alarm or events.
D. Profile Alarms
Profile alarms shall be provided to test analogue values against diurnal
profiles i.e. a series of thresholds variable with time.
The facility shall test analogue values (e.g. a level) against a profile of
thresholds and shall report alarms when the value transgresses the
threshold after a value and time dead band period.
Profile alarms shall take the form of up to four discrete threshold points
(high high, high, low and low low) the values of which shall be determined
at a configurable interval, typically every 15 minutes, over a 24 hour period.
This shall constitute a single daily profiles.
The RTU alarm management process shall compare downloaded profiles

with the measured plant parameter and produce an alarm if a violation
exists. Normal dead band facilities shall be applied in this case.
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DUBAI – UAE
Profiles shall be downloaded manually or automatically. There shall be the

option to download the previous week’s validated data, for each day of the
week, with assigned values for each (e.g. 15 minute) increment. Seven
days profile data shall be stored at the Master station and the system shall
maintain between 24 and 48 hours of profile data in the RTU. As a default,
on failure to receive an updated profile the RTU shall revert to the start of
the existing profile.
Users shall be able to create profiles by copying logged or archived

validated operational data to form a single ‘baseline’ for the set of profile
thresholds i.e. one value for each 15 minute interval. The system shall
generate the thresholds above and below the baseline profile over the
profile duration from either a global difference or a fixed percentage
deviation of the full scale, e.g. high high shall be ± 5% high +3% etc.
The user shall be able to edit the baseline profile and the threshold levels
for each interval in order to fine tune the profile. It shall not be acceptable
to require users to enter every individual threshold point at each interval.
E. Rate of Change Alarms
There shall also be the facility to generate alarms on the exceeding of a

preset change of value with time. It shall be possible to define alarms on any
of: rate of rise; rate of fall; minimum rate of change required, i.e. alarm on no
change when an instrument has failed. Rate of change alarms shall also be
definable for pulse count values.
F. Receipt of data from a RTU after restoring a communications failure
All active mimics (graphic displays) shall show only the last recorded status and
values following a restoration of a communications failure. All active trends shall
show current and previous values. Alarm lists shall show present and past alarms
that were not recorded during a failure. A facility shall be provided to select past
data for display after a restoration.
3.7.5.3 Alarm Suppression
The supplied system shall include facilities within the RTU to prevent the
occurrence and subsequent reporting of “nuisance” and spurious alarms. A
privileged user shall be able to suppress alarms for a single point and for a whole
RTU. Facilities shall also provide such that a primary alarm which is followed by
consequential secondary ones can be flagged with an identifier to suppress the
secondary alarms when the primary occurs.
RTUs are to record failed attempts at communications with a Master station. This
data shall be part of the RTU data polled by the Master station and used to report
and record communications failures to the System Managers.
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DUBAI – UAE
3.7.5.4 Alarm Tagging
Each alarm shall be tagged in its originating RTU with a source identifier and the
time and date of occurrence. Likewise the time and data of the alarm returning to
normal shall also be recorded in the RTU for use in the Master station.
3.7.5.5 Data and Event Tagging
Data and events for local storage and subsequent transmission from the RTU
shall be tagged with the time and date at the RTU.
3.7.5.6 Data and Recording and Storage
A. Analogue Variables
Sufficient capacity shall be provided to store in a fully tagged form the

instantaneous, maximum, minimum and averaged value of each analogue,
as well as pulse inputs at each type of RTU.
The period between samples shall be configurable, typically 15 minutes for

which storage shall be available for at least 7 days. It shall be possible to
increase the sample rate to a maximum of every minute. The RTU shall
contact the Master station to initiate the transfer of the stored data when
the memory allocated to analogues has been 80% utilized since last read
by the Master station.
B. Events
Sufficient memory capacity shall be provided to store in fully tagged form all
events (including alarms). The memory shall be sized to allow a minimum of
20 events per input and output from the RTU or a 1000 events total,
whichever is greater, per 24 hours. 7 days storage shall be available. When
the event storage is 80% full the RTU shall contact the Master station to
initiate the transfer of the stored data.
C. Profiles
It shall be possible to store daily analogue profiles for alarm purposes for
25% (with a minimum of two) of the analogue inputs at the RTU types:
Profiles shall be structured and utilized. Profiles shall be downloaded from

the Master station and will normally be downloaded daily or on request.
D. Tables

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RTUs shall be capable of receiving and storing for operational control,

through user sequence programs, tabular data such as look up tables for
pumping regimes.
It shall be possible to download the tables from the Master station.
E. Memory Expansion and Allocation
Memory allocations for data storage shall be dynamic and not tied to a
particular input or output. Memory allocated to user functions shall be user
configurable.
Memory allocated to data storage should be used in the form of a circular

buffer such that the oldest data is overwritten by the newest data once the
buffer is complete. All data shall remain available to the Master station or
portable terminal users until it is overwritten in this way, irrespective of the
number of times it has been read by any device.
3.7.5.7 Programming
A. General
The user shall have the capability within the software to monitor inputs,
control outputs using logical sequences, derive data from monitored analogue
and status data, manipulate data (real or derived) such that the Purchaser
can operate and monitor his plant in accordance with the requirements and
intent of this Specification.
The RTU shall be capable of executing a program created by the user in a

high-level language at a portable terminal locally or at any workstation and
downloaded remotely by means described elsewhere in this specification.
For ease of commissioning and maintenance it shall be possible to store

RTU programmes within E2PROM memory such that the programmes are
loaded on power up of an uninitialized RTU. However, application program
changes shall be changeable without the need to change RTU hardware
(EPROMS etc.).
B. Language Structure
The high level language shall be structured and shall have as a minimum
the following attributes:
1. Single statements
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2. Combined statements
3. IF..., THEN..., ELSE... type statements
4. Do...WHILE looping constructs
5. Do...UNTIL looping constructs
6. Full arithmetic capability (+, -, x, E, root extraction, logical
comparisons, boolean, integration, integer and floating point
operations)
7. Scaling functions
8. 30 characters of explanation text for each program line
9. 30 characters of explanation text for each Procedure
10. Timers
11. Remarks
12. Labels
13. Variables, typed according to data types available, including tables
as 1 and 2 dimensional arrays. Conditional looping or branching
constructs shall be nestable up to at least 3 levels.
3.7.6 COMMUNICATIONS
3.7.6.1 General
It is intended that RTUs shall have flexible communications facilities using industry
standards to enable simple future expansion and modifications to networks of
RTUs, other terminals and automated plant. Section describes the scheme
communications in detail.
3.7.6.2 Local Communications
RTUs shall be fitted with a V24/RS232 port for use with a portable terminal, in
addition to ports required for networking with other RTUs and communications
with a Master station.
3.7.7 MAINTENANCE, CHECKING AND FAULT FINDING

FACILITIES
3.7.7.1 General
The Contractor shall offer a portable terminal which can be used for programming,
maintenance and test of the RTUs.
Self-Diagnostics
A. Startup Self Check

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Each RTU shall have self-check features that shall be performed on start-
up of the RTU. These self-checks shall include RAM verification and sub-
system addressing checks.
B. Interval Self Check
The RTU shall perform self-checks whilst operational. Each check during
operation shall be repeated at a minimum rate of once every thirty (30
seconds).
The self-check shall include ADC over-range checks and overflows or

negative totalizer within the applications software.
C. Self-Check Alarm Generation
Failed checks which occur during start-up or at intervals shall be passed to

the Master station as a system alarm.
D. Input Check
The RTU shall perform continuous monitoring of inputs during I/O scans to
establish that the incoming signals are not out of range. The alarm dead
bands shall be user configurable. A failed check shall be passed to the
Master station as an alarm. Provision shall be made to confirm alarms by
repeat input monitoring prior to alarm generation. This facility shall operate
on all digital input and individual analogue inputs if so configured.
E. Maintenance Mode of RTU
Facilities shall be provided which will inhibit alarm dial outs when either the
RTU itself or instruments connected to it are undergoing maintenance or
repair.
This mode shall be initiated by an integral switch, and may be arranged to

expire on a timeout if the switch is not reset.
3.7.7.2 Debugging of Programs
The following facilities shall be the minimum:
B. General. A debugging facility shall be provided from a local terminal. The

facility shall be able to monitor, interrupt and override the programs flow or
control.
C. Monitor/Trace. It shall be possible for the user to monitor which statements

are executed.

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D. Program Halt. It shall be possible to halt a program at predefined

statements whilst under the control of the debugging facility. A message
stating clearly the current position in the program, shall be displayed
whenever a program is halted.
E. Skip/Jump. Once the program has been halted, as in (C) above, it shall be
possible to jump to any point in the program and commence execution from
that point.
F. Single Step. A single step function shall be provided.
G. Variables. The debug facility shall allow monitoring of variables as an

online facility. The Contractor shall provide a facility which notifies the user
whenever selected variables change their value. The facility shall also
specify at what point in the program the change occurred. The user shall
be able to select which variables are to be monitored. The debug utility
shall also include the facility which allows the user to interrogate any
variable. The user shall also be able to alter the value of any variable.
3.7.8 RTU COMMUNICATION
3.7.8.1 General
A. Communication links between RTUs and control centers or other RTUs

shall either be permanent e.g. leased line, cable, radio channel and fiber
optic or shall be made only for the duration of the data flow, e.g. a dial-up
telephone line or scanning radio channel.
B. The RTU protocol shall be open and shall not be proprietary.
C. Full details of the proposed protocols shall be submitted with the Tender for
following applications:
1. Not used.
2. Not used.
3. RTU to/from master station communications.
4. Master RTU to/from slave RTU communications.
D. Not used.
3.7.9 TYPES OF COMMUNICATIONS MEDIA
A. The actual type of communication medium for each RTU site will be
determined by the Employer and specified for individual RTUs. This sub-
section outlines the different communications media that will be used.
B. Public Switched Telephone Network (PSTN).

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1. It is anticipated that PSTN will be used on large majority of RTUs to

control center link.
2. The exchange lines to control centers shall be provided with 3 dB
guaranteed loss. The Contractor shall use the number of lines
required to achieve this for the capacity stated. Lines shall be
grouped as incoming traffic only (i.e. alarms), outgoing traffic only,
and common. All the incoming and common lines will constitute a
joint hunt group. It shall therefore be possible for alarm traffic to be
received by the control center on all the incoming and common lines
when the later are not in use for polling or other outgoing traffic.
3. The facility shall be available within RTU software for RTUs to be
programmed to call the control centers automatically, at periodic
user configurable intervals, in order to provide user confidence in the
RTU and PSTN availability.
4. The control centers shall be able to accommodate a 50% increase in
the number of PSTN lines if required.
C. Leased Lines or Private Wires. Leased line circuits to the following

specification shall be provided:
1. ETISALAT standard analog or digital data circuits capable of

supporting a data transmission rate of 9.6 kbps shall be provided for
RTU communications.
2. ETISALAT approved Digital Terminal Units (DTU) shall be provided
for all digital circuits.
D. Low Power Radio Telemetry to the MPT1309, 1328/29 Standard. Radio

equipment manufactured to these standards shall be used for
communications between RTUs over distances up to 5 kms and more i.e.
point-to-point.
E. Fiber Optic Network. The fiber optic network will be utilized for
communication with the RTUs to MCC. The data interface and terminal
equipment specifications are covered in Section 17.6 - Interfaces &
Network Communication chapter as part of the general data
communication requirements.
F. Network radio links with MCC shall be established for RTU sites where
PSTN, leased lines and Fiber Optic networks are not available.
G. The Contractor is responsible to conduct the survey for the RTU location
and suitable communication media required as mentioned in the Volume 3
of the tender.
3.7.10 LINK SPEED

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A. Normal link speed shall be 9600 bps and the link shall conform to ITU
standard.
3.7.11 FALLBACK CIRCUITS
A. Not used.
3.7.12 RTU COMMUNICATIONS PROTOCOL

3.7.12.1 General
A. The Tenderer shall describe the proposed RTU communications protocol in

the Tender with particular reference to the following:
3.7.12.2 Error Checking (Error Detection/Automatic Repeat Request).
A. Error detection, using a Cyclic Redundancy Check (CRC) polynominal will

be preferred. The CRC shall be of not less than 8 bits and contain an ‘x+1’
term. In the case of detection of error in a packet, it shall be possible to
request transmission of the faulty packet only, and not retransmission of the
whole message.
3.7.12.3 Security and Privacy
A. The protocol shall be devised such as to avoid unauthorized interference to

the RTU or control center by a person with a modem set to correct speed,
parity and stop bits. The protocol shall use a password key protection
system, and data link frame format techniques.
3.7.12.4 Interference Rejection
A. The communications system shall be designed to cope with temporary

interruptions on a line caused by interference.
3.7.12.5 PSTN Communication
A. Call Set-up. Initiation of routine PSTN calls is to be from the MCC.

However the RTU shall also dial the MCC to transfer data on alarms, or
perform an RTU on-line functional test.
B. Signaling. Signaling shall normally be loop disconnected at 10 impulses per

second with a 1:2 make/break ratio.
C. DTMF Signaling. For all types of RTUs, it shall be possible to change the
RTU signaling to DTMF signaling.

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D. Auto Dialing and Answering. Auto-answering and auto-dialing shall be

provided as standard. The auto-answering sequence shall be to ITU
recommendation V.25. The V.25 sequences to be used for PSTN only.
E. Number Storage. The RTU modem shall be capable of storage of not less
than 6 pre-coded 16 digit numbers. These numbers shall be remotely
configurable, although fall back numbers shall be held in non-volatile
memory to be loaded on power-up after sustained power failure.
F. Disconnection of Line. Automatic disconnection of the line shall take place

following loss of Data Terminal Ready (DTR) loss of carrier or loss of data
activity, if not initiated by the RTU. In addition, the RTUs shall disconnect
the line after an EPROM programmable time regardless of other
configuration parameters to prevent holding lines that are noisy.
3.7.12.6 Leased Line/Private Wire Communication
A. The protocol shall permit the operation of RTUs in single site configuration
in private wires and polled for data via a single port on the MCC.
3.7.13 INTERFACES
3.7.13.1 General
A. RTUs connected to the MCC via analogue circuits shall employ integral
modems. For certain media a digital interface may be available on the
communications circuit equipment e.g. low power radio. For such
equipment a digital interface between telemetry RTUs and the
communications circuit shall be provided.
B. Impedance matching and amplifications shall be incorporated in modems

connected for multipoint operations. This is to avoid degradations of signal
level.
3.7.13.2 Analogue Circuits
A. PSTN. The termination for the PSTN circuit shall be via an approved
standard ETISALAT line connector.
B. Leased Line and Radio Circuits. Two-or four-wire operation shall be

selectable. Termination for circuits shall consist of an approved line
termination unit with on board surge protection.
C. Termination Impedance. Termination impedance to line shall be 600 ohms

± 10% balanced.
D. Lightning Protection. PSTN, leased line/private wire communications

circuits at MCC, and RTU sites shall be fitted by the Contractor with a self-
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resetting lightning arrestor, approved and in accordance with Clause 18.06

and barrier transformers wherever necessary.
3.7.13.3 Digital Circuits
A. The interface presented to the RTU shall be based on the RS232C/ITU

V.24/V.28 standards.
3.7.14. COMMUNICATION EQUIPMENT
3.7.14.1 General Considerations
A. Rack Mounting. Where multiple items exist, the use of standard rack
mounting shall be assumed.
B. Enclosures. All communications equipment shall be installed in suitable

equipment enclosures.
C. Safety. All items of equipment shall confirm to the relevant safety detailed
elsewhere in this specification.
3.7.14.2 Indication Provided
A. Illuminated indications shall be provided to confirm the presence of the

following conditions:
1. Carrier detect
2. Data transmit/receive
3. Diagnostics
B. These indications shall be mounted on the front panel if the modem is rack-
mounted, on the PCB if the modem is incorporated with the RTU, or on the
radio front panel if the modem is integral to the radio equipment.
C. For standalone modems a ‘power on’ indication shall be provided in

addition to those indications referred to above.
D. Equipment alarms shall be wired and appeared on the cubicle alarms and
reported to MCC.
3.7.14.3 Diagnostics
A. Diagnostic facilities shall be provided on all communications equipment to

meet the availability requirements.
3.7.15 CONNECTION APPROVAL TO PUBLIC

TELECOMMUNICATION SYSTEMS
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3.7.15.1 Approval
A. All modems, DTUs and other line termination equipment shall be approved
for use on the ETISALAT network, requests for approval shall be submitted
to ETISALAT within 4 weeks of the Contract Start Date, and no installation
shall commence until said approval is granted.
3.7.15.2 Training
A. Training shall be given to DEWA staff for the operations and maintenance
of data flow through PSTN and dedicated lines.
3.7.16 NETWORK COMMUNICATIONS
3.7.16.1 Introduction
The purpose of the communications network is to transport data between

the various components of the overall system. The requirements imposed
on the communications network are based on the functional requirements.
In order to provide reliable, flexible and cost-effective data transport
solution to meet the specified diverse requirements, the communications
network architecture has been split into the following categories:
1. Remote Terminal Unit (RTU) Communication Network. This is between RTUs

and control centers. It is to be based largely on the Public Switched
Telephone Network (PSTN), leased lines, radio links and fiber optic.
The Contractor shall be responsible for making applications and arranging
with Local PSTN Provider for provision of the necessary communications
links and licenses to operate the equipment.
The Contractor shall make applications as necessary to the Ministry of

Communications (MOC) for allocation of frequencies for all radio
communications links, as specified. Operating licenses shall also be
obtained for all radio equipment to be installed under this Contract.
3.7.16.2 Optical Equipment
A. Optical Cables. Each optical fiber underground cable shall comprise of

twelve (12) number of fibers. Optical fibers shall be of Single Mode (SM)
type. Each fiber shall be designed for operation for dual window at nominal
wavelengths of both 1300 nm and 1550 nm. However, the fibers shall be
optimized for operation within 1300 nm single window. Scope of Supply for
the optical links shall include, as a minimum, but not be limited to:
1. Armored underground optical fiber cable, suitable for direct burial.

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2. Buried splice boxes with water, heat proof and environmental

protection enclosures for straight jointing the fiber underground
cable.
3. FDP within each building, to accommodate fiber splices between
underground fiber cable and flexible termination cable.
4. Flexible termination cables with appropriate optical compatible
demountable connectors terminated in optical distribution frames
which shall be housed in a cubicle. This shall form the final
connection between the splice box and optical terminal equipment.
B. Optical Fibers. All fibers shall be of the SM type and shall comply with
International Telecommunications Union (ITU) Recommendation G.652
and the requirements detailed below (the fibers shall be entirely suitable for
jointing by means of automatic fusion splicing technique):
1. Fiber Material. The fiber shall be manufactured from high grade

Silica and doped as necessary to provide the required transmission
performance. The chemical composition of the fiber shall be
specifically designed to minimize the effect of Hydrogen on the
transmission properties.
2. Fiber Coating. The primary coating shall consist of an inert material
which can be readily removed for jointing purposes without damage
to the fiber and without necessitating the use of hazardous
chemicals. A secondary coating may be applied directly over the
primary coating or alternatively a loose jacket may be provided.
Where a tight fitting secondary coating is provided it shall consist of
an inert material. The secondary coating of loose tube shall be
color coded throughout the length of the cable. The secondary
coating shall be capable of withstanding normal handling during
termination. The fiber coating shall be translucent such that fiber
splicing techniques, using optical alignment of cores by means of
injection and detection of light through the cladding, shall be
supported. In addition, the fiber coating shall be optically matched to
the cladding to promote cladding mode stripping. The composition of
the cable shall be specifically designed to reduce the production of
Hydrogen gas and to prevent the migration of Hydrogen and water
into the fiber.
3. Fiber Geometry. The mode field diameter shall be 10 µm with a
tolerance of ±1 µm. The mode field non-circularity shall be less than
6%. The mode field concentricity error shall be stated by the
Tenderer and shall fail within the limits of 0.5 µm to 5µm. The fiber
cladding diameter shall be 125µm ±2.4%. The cladding non-
circularity shall be maximum 2%.
4. Fiber Attenuation. Those optical fibers to be provided within the
scope of the Contract shall have an average attenuation co-efficient
(per optical path) not exceeding 0.4 dB/km at 1300 nm and
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0.3 dB/km at 1550 nm. Variation of fiber attenuation at different

temperature profile shall be according to relevant ITU
Recommendations.
5. Cut-off Wavelength. The cut-off wavelength of fibers shall lie in the
range 1100 to 1280 nm, as measured by the Reference Test Method
detailed in ITU G.652.
6. Dispersion Co-efficient. The fibers shall be optimized for operation
at 1300 nm such that the total dispersion co-efficient is nominally
zero. The dispersion co-efficient at 1300 nm shall not exceed
6 pc/km.nm. The Tenderer shall state the dispersion co-efficient at
wavelengths of both 1300 nm and 1500 nm for dual window working.
C. Fiber Joints
1. Fusion Splices
a. All fiber joints shall be of the fusion type, except where

demountable connectors are specified.
b. Fusion splicing shall be carried out by trained
personnel using automatic fusion splicing equipment
designed for the fiber type. Fiber ends shall be prepared for
splicing using methods and tool recommended by the fiber
and splicing equipment manufacturers. The cleanliness and
accurate cleaving of fiber ends shall be ensured prior to
splicing.
c. The accurate alignment of fiber cores, prior to splicing,
shall be verified using a technique that monitors the optical
power transmitted across the splice interface. Fusion splicing
shall be commenced only after manipulations of fiber
alignment have maximized the transmitted power.
d. Fusion splice optical losses shall average at no more
than 0.05 dB per splice.
e. Splices shall be mechanically strengthened and
protected from the environment by means of purpose
designed splice sleeves or enclosures. The finished splice
shall be supported within the buried splice box by means of
suitable clips or restraints. It shall be possible to remove and
replace the splice in the support device without risk of
damage to the splice or fiber. The cable splice box shall be
buried and contained in water and heatproof enclosures.
f. Each fusion splice shall have spare length of fiber on
either side of approximately 1 m associated with it. This
excess fiber shall be coiled neatly and clipped (or otherwise
retained) within the splice box.

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2. Demounted Connectors
a. Demounted connectors of compatible optical

connectors shall be fitted to each fiber at the termination of
each optical link.
b. The connectors shall be factory assembled in strict
accordance with the manufacturer’s instructions. The
completed terminations shall be examined and tested at the
factory to verify compliance with the manufacturer’s published
performance data. Substandard and defective terminations
shall be rejected and the fiber reterminated.
c. Demountable connectors shall be protected against
contamination and mechanical damage during shipment and
site installation of the associated cable. Fibers terminated in
optical fiber distribution cubicle at each site shall be ferruled,
named for identification.
3. FDP within Buildings
a. FDP shall be wall mounted within the building,

adjacent to the terminal equipment with which the optical link
is associated; the precise location shall be agreed with the
Engineer at site.
b. FDP shall be provided for each optical link and shall
accommodate the fiber splices between the fiber cable and
the flexible termination cable. It shall be fitted with suitable
cable clamping glands at its base for the purpose of cable
entry.
c. The box shall be suitably dimensioned to accommodate the
excess loops of optical fiber associated with each splice.
Splice cassettes or other approved methods shall be used to
provide mechanical support for the splices and to afford a
means of neatly retailing the excess fiber.
d. FDP box shall be of welded sheet steel construction, finished
internally and externally using a durable paint system.
Access to the box shall be by means of a hinged door or a
bolted front panel. Where a hinged door is fitted, access shall
be impended by use of bolted closures. The FDP shall be
fitted with an approved identity label (e.g. engraved laminate).
e. Ends of the armored cable shall be straight jointed in
enclosure and buried. The enclosure should be water and
heat proof. Ingress of water into the joint box due to
breakage by heat expansion is not permissible. It shall be
with self-bonding and waterproof tapes, heat shrinkable
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sleeves, clamps, fiber guides and with all necessary

accessories. On either side of the splice joint box, sufficient
length of optical cable shall be coiled with proper precaution
not to damage the cable.
f. Fiber Distribution Panels
Fibers in each fiber cable provided with demountable
connectors shall be terminated in FDPs at both ends. They
shall be patched at intermediate points with optical patch
cords to fibers coming from different directions as specified.
D. Installation in Ducts and on Cable Trays
1. The optical cables installed under this Contract shall be run in

cable ducts. Within the building, the Contractor shall neatly install
the major runs of cable upon cable trays or racks. The cables shall
be affixed to cable supports using approved ties, clips on cleats at
regular intervals. The Contractor shall supply and install all
necessary cable ducts and construct joint chambers and hand holes
where necessary.
2. Paying out of optical cable shall be by standard means e.g.
roller. Maximum pulling force and bending radius employed during
paying out and commissioning shall be according to cable
specifications.
3. On short runs of cable, for which cable supports are not
provided, the Contractor shall fix the cable to the structure of the
building using approved fixings and cable cleats. Alternatively, the
Contractor may supply and install cable supports for his own
purpose.
4. The Contractor shall be responsible for forming holes through
walls and floors for the installation for his cables. Any making good
and sealing of such cable transits shall also be the responsibility of
the Contractor.
5. Cables existing at the ground or passing through floors shall
be protected against mechanical damage for a distance of 450 mm
above finished ground or floor level.
E. Termination Cables
1. A termination cable is defined as that cable installed between

the splice box at the end of the armored fiber cable and the optical
termination equipment.
2. The termination cable shall be of flexible and rugged
construction, suitable for installation within floor voids at the
buildings. The cable construction shall incorporate strength
member(s), fiber buffering (bedding) and a tough jacket. The fibers
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shall be entirely compatible with those of the approach cable to

ensure good optical and physical fusion splicing properties.
3. Each termination cable shall be supplied in a performed
length with demounted connector. A minimum allowance of 10 m
shall be made for the length of each termination cable.
F. Not used.
G. Cable Construction. The cable core shall be covered with a layer of tape
and shielded with Aluminum foil laminated on both sides with PE.
Intermediate sheath shall be black PE and armored with a layer of
galvanized round steel wires. Outer sheath shall be black PE. The cable
shall be suitable for use in the prevailing climate in UAE and for an induced
voltage up to 15 kV. The thickness and chemical properties of PE sheath
and armor shall be according to relevant IEC standards. Fiber cable
construction shall be agreed by DEWA during engineering.
G. Fiber Insulation Colors. DEWA Standard Color coding system shall be used
to mark the fibers. The thickness and chemical properties and color coding
of the fiber insulation shall be according to relevant standards and shall be
furnished to the Engineer for approval.
Colour Scheme of Loose Tubes:-
Colour Coding
1- Red
2- Blue For 12 Fibers Cable for 24 fibers cable
3- Green
4- White
5- Yellow
6- Grey
Colour Scheme of 4 Fibres:-
1- Blue
2- Green
3- Red
4- Yellow
I. Mechanical Properties. Such as crush strength, maximum pulling force

during installation, minimum bending radius in pulling, final installation and
method of paying out the optical underground cable shall be finished by the
Contractor.
J. Identification

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1. The PE over sheath shall be embossed in English along two lines equally
spaced around the circumference of the cable with the name of the
manufacturer and year of the manufacture followed by:
“DEWA (WD) OPTICAL FIBER CABLE”
2. The PE over sheath shall also be embossed on the circumference of the cable
indicating cumulative marking length of the cable wound on the drum. The
marking starting with “0000” on the inner end of the cable shall indicate actual
length of the cable in drum.
3. The Contractor shall supply information of drum lengths of the cable supplied
unless shorter lengths are specified or are required to complete specific order.
K. Testing. All testing shall be subject to witnessing by the Engineer. Test

results shall be formally documented and submitted for approval.
1. Factory Testing. Factory testing shall be carried out in accordance

with procedures defined in ITU G.652 and IEC 793-1. The test shall
verify the parameters of dimensions, attenuation co-efficient, mode
field diameter, cut-off wavelength and dispersion coefficients. A test
shall be carried out to verify the temperature withstand capability of
the optical fiber.
2. Site Testing. Site testing shall comprise the following tests, to be

carried out for each individual fiber link:
a. Link attenuation at 1300 nm and 1500 nm wavelengths.

b. Fiber attenuation profile measurement using and optical time
domain reflectometer. This test shall be carried out end to
end of each fiber link. Test results shall be presented in
graphical form with graduated axes.
L. Not used.
3.7.17 RADIO COMMUNICATIONS EQUIPMENT
3.7.17.1 Introduction
A. Radio communications equipment shall be provided at the locations as

specified in the Schedule of Communications links. Each installation shall
be complete in every respect and include all antennae, mountings, towers,
cabling and fixtures.
B. The Contractor shall carry out a detailed survey and establish radio
communication with MCC from RTU locations where PSTN, leased lines
and fiber optic networks are not available.

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C. The Contractor shall ensure that all radio equipment is fully compatible with
the SCADA System and adequately rated to achieve the specified
performance requirements of the system as a whole, including data
transmission and bit error rates, transmitter power level and receiver
sensitivity.
D. Power supply for base station units in a point to multi-point system shall be
220 V AC UPS supply and for all point to point installations shall be
220 V a.c. Remote stations in a multi-point system shall be housed in an
IP65 enclosure with an integral mains/d.c. battery charger and battery pack
rated for 4 hours continuous operation in the event of mains power failure.
E. All radio equipment shall meet the following environmental specifications:
Temperature : Full performance at 0 to 55ºC

Operational performance at 0 to 65ºC
Humidity : 0 to 95% RH non condensing
F. The Contractor shall prepare and submit application for allocation of radio
frequencies to the Ministry of Communications (MOC) and obtain all
necessary operating licenses on the Employers behalf.
G. The Contractor shall supply and install all antennae and support structure
and shall provide drawings to show how each type of antenna will be
mounted.
H. Antenna installation shall include all necessary low loss coaxial down
leads, lightning protection of the antenna system and aircraft warning lights
where applicable. Transmission cable shall be suitable for direct exposure
to the environment. All connections shall be provided with “O” ring seals.
The installation shall include all necessary cable hangers, ground kits and
surge suppressers. Externally run cables at remote stations shall be
enclosed in metal conduit.
I. The radio equipment shall form an integral part of the factory and site
acceptance tests of the SCADA system
3.7.18 POINT TO MULTI POINT RADIO
3.7.18.1 Network radio
A. All radios shall be capable of accepting a 4-wire audio input or RS-232 with
an internal switchable modem operating at 1200 bps, 4800 bps or 9600
bps. The radio shall support these data rates within a 12.5 kHz channel
bandwidth using frequency modulator. It shall be possible to upgrade from
4-wire audio or 1200 bps analog input to 9600 bps digital operation.
Upgrade to 9600 bps digital operation shall be performed by configuring
only the modem module.
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B. The radio shall operate in the 360-512 MHz or 1.5 GHz frequency bands.
The radio shall be able to operate in full-duplex, half-duplex or simplex
mode. Radios shall be synthesized and programmable to all frequencies
within the band. The above bands are provisional and are subject to UAE
M.O.C. approval.
C. Each station and its assigned remote units shall operate on a unique
transmit/receive frequency pair and on a non-interfering basis with the
other master/remote systems.
D. The radio shall have redundant transmitters (Tx), receivers (Rx), power
supplies, and batteries operating in hot-standby mode. It shall
automatically switch-over to the standby equipment upon the detection of
an alarm in the on-line system. The radio shall be capable of switching to
operate on any receiver/transmitter combination; switch-over shall occur in
less than 50 ms. it shall be possible to replace a Tx, Rx or power supply
module without interrupting radio communications. Warm Standby
operation is not acceptable.
E. The Network radio shall be mounted in a standard 19” (482.6 mm) rack
space. Rack mount hardware shall permit flush front mounting for cabinets
or center mounting for Telco style racks.
F. The Network radio shall have modular construction. All modules and fuses
and all adjustments to these modules shall be accessible from the front of
the radio by way of a fold down front panel. The need to remove top or
rear covers or remove the radio from a rack to replace the modules or
fuses is unacceptable.
G. All radios shall use N-type connectors for interface to the antenna and
external duplexers.
H. The radio shall operate continuously with both transmitters and receivers
operating simultaneously (full duplex).
I. The Network radio shall include, as a standard feature, an order wire jack
to accept a telephone handset to permit voice communications between the
master and remote radios.
J. The Network radio shall provide the following alarms and indicators, as a
minimum, but not be limited to:
1. Alarms contact outputs:
a. Tx A/Rx A
b. Tx B/Rx B

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DUBAI – UAE
c. a.c. power Fail alarms with relay outputs to drive external

annunciators.
2. Indicators:
a. LED indicators for power on.

b. Tx and Rx active.
c. Alarms for Tx, Rx and power supply failures.
K. Location of radio repeater for radio links between network radios and base
radio at MCC shall be decided on the basis of radio propagation test and in
agreement with DEWA.
3.7.19 REMOTE STATION RADIO
A. The radio shall operate in the 360 - 512 MHz or 1.5 GHz frequency bands.
The radio shall be able to operate in full-duplex, half-duplex or simplex
mode. Each group of remote station radios and their associated master
station radio shall operate on unique transmit/receive frequency pairs, on a
non-interfering basis with the other master/remote systems.
B. The radio shall be synthesized and programmable to all frequencies in the

preceding frequency bands.
C. The radio shall operate in the half-duplex mode with transmitter keying
provided by the associated Remote Terminal Unit (RTU).
D. The radio shall have an external order wire adapter module to accept a
telephone hand set. The order wire handset will be used for voice
communication to the master station / Network radio for service functions.
E. The radio shall provide a “sleep mode” capability. This feature shall enable
a command from the RTU to switch the radio between a low power
consumption mode and normal operation. When in “sleep mode”, the
current draw shall not exceed 7 mA.
F. The radio shall provide the following indications:
1. Analog radios - Keyline active, Tx ON, squelch open, power ON,

out-of-lock, and radio disabled.
2. Digital Radios - RTS, CTS, and carrier detect, transmit data, and
receive data.
G. All radio Personal Computer (PC) boards including RF, modem and
diagnostic PC boards shall be enclosed in a single cast aluminum housing
to eliminate interference with data/computer equipment. A plastic housing
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DUBAI – UAE
or a housing with vents which can allow dust into the radio is not
acceptable.
H. The radio shall be fully synthesized and programmable to all band limited
frequencies and 12.5 KHz, 25 KHz channel spacing via a personal
computer or hand held terminal without changing internal components.
Opening the radio to change modules, frequency crystals, or DIP switches
is unacceptable.
I. Antenna connectors shall be Type N. Lower quality UHF type connectors

are not acceptable.
J. The remote radio shall have the ability to monitor its internal operation and
diagnostic parameters via a hand held terminal or personal computer
plugged into the remote radio. Frequency, transmit power, and deviation
shall be remotely adjustable from the master station, repeater, and polling
remote. The terminal of PC shall be able to monitor the following functions
(functions identified by an “*” shall be user adjustable by connecting a PC
or terminal to the radio):
1. Radio Parameters
a. *transmit and receive frequencies

b. *time-out timer setting
c. *soft carrier dekey setting
d. *loopback code
e. *squelch tail eliminator
f. *PTT delay
g. *CTS delay
h. *hardware/software rev level
i. *date of manufacturer
j. *serial no. /model no.
2. Radio Diagnostics
a. *transmit power
b. *deviation
c. *frequency
d. regulator voltage
e. power supply voltage
f. phase lock loop voltage
g. internal temperature
h. reflected power
i. voltage standing wave ratio
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DUBAI – UAE
j. received signal strength
3.7.20 RADIO COMMUNICATIONS LINKS
Master to Slave shall be P-M, minimum number of channel shall be 2 and

minimum number of transmission rate shall be 9.6 kps.
3.7.20.1 RADIO NETWORK MANAGEMENT SYSTEM.
3.7.20.1.1 TRAINING:
Site training for radio system shall be provided for DEWA staff.
3.7.20.1.2 Radio test equipment and accessories shall be supplied for

regular testing of the radio system commissioned under this
contract.
3.7.20.1.3 Reliable Radio communication:
During the radio propagation tests, any radio repeater required to achieve
reliable radio communication between the RTU’s and base radio stations /
Network radio shall be supplied, installed and commissioned under this
contract.
3.7.20.2 General
3.7.20.2.1 Interfacing the RTU to Existing Main Control Center,

Water Network SCADA (DEWA H.O)
The Contractor shall also to carry out the interfacing RTU to Main Control
Center Water Network SCADA, which shall comply with IEC 870-5-101
standards. The Suitable gateway – RCI (Remote control Interface) modules
with accessories, shall be provide to interface with the Main Control
Center, Water Network SCADA located in DEWA Head Office, supplied
under Water SCADA project by M/s.CEGELEC, Germany.
The Contractor shall carryout all necessary Modifications / Development /

Configurations but not limited to the following to make a complete
operational System.
a. MIMICS
b. DATA MODEL
c. FEP
d. TAG DATABASE.

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DUBAI – UAE
3.8 ELECTRICAL REQUIREMENTS

1. GENERAL
Description
Requirements specified in other Sections of the Specification shall apply to the

electrical requirements as far as applicable.
A. Work Included in this clause
• Power supplies and electrical wiring for bulk meters.
2. QUALITY ASSURANCE
A. Qualification of Manufacturers.
Furnish manufacturer's electrical equipment of the types and sizes

specified which has successfully operated for not less than the past two
years except where specific types are named in this Specification by
manufacturer and catalog number.
B. Factory Tests.
Factory tests are required for all electrical equipment and assemblies.
Perform factory tests in accordance with the codes and standards
specified as applicable to the equipment.
C. Factory Inspection
The Engineer or his representative may inspect fabricated electrical

equipment at the factory. Notify Engineer in sufficient time so that factory
inspection can be arranged. Factory inspection will be made after
manufacturer has performed satisfactory checks, adjustments, tests, and
operation. Approval of equipment at the factory only allows the
manufacturer to ship the equipment to the site, and does not constitute final
acceptance.
3. SUBMITTALS
A. Shop Drawings
Submit, for Employer's approval, shop drawings for electrical work to the
extent required under this Section. Drawings shall be accompanied with
complete equipment descriptive operation and installation data.
B. Record As-Built Drawings.

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DUBAI – UAE
Prepare and submit for all work include in this section. Refer to General
Conditions for uncovering of uninspected and unrecorded work.
C. Materials Lists.
Submit materials lists to extent required under this Section for the
Engineer's review prior to purchase. Within 30 days after receiving the
submittal approval, provide the Engineer with evidence that all equipment
and materials required to complete the installation have been purchased.
D. Technical Data.
Submit descriptive and instruction manuals to the extent required in this

Section.
E. Factory Test Reports.
Submit copies of factory test results, certified by manufacturer. Submit 3

copies unless otherwise specified.
F. Manufacturer's Certified Reports.
To the extent required under this Section, the equipment manufacturer, or

his authorized representative, shall submit a notarized written report with
respect to his equipment certifying that (1) the equipment has been properly
installed, wired, and connected under his supervision, (2) he was present
when the equipment was placed in operation, and (3) the equipment is fully
covered under the terms of the guarantee.
G. Demonstration and Final Operation Test Plans and Results.
Submit a written plan for demonstration that each item of equipment

provided under this Section meets the specified operational requirements.
Submit a written plan for procedures to be used in final operational testing
of entire systems including a description of each system, test methods and
materials, testing instruments and recorders, and a list of the equipment
involved with the functional parameters to be recorded on each item.
Submit three copies of test results and records for all final operation tests.
H. Accessory and Maintenance Materials.
Furnish items as specified herein. Deliver to Engineer as directed with an

itemized list in a letter of transmittal accompanying each shipment.

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1. Not used
2. Maintenance Materials and Spare Parts
Deliver in manufacturer's original containers labeled to completely

describe contents and equipment for which it is furnished.
4. PRODUCT DELIVERY, STORAGE AND HANDLING
A. Delivery.
Deliver electrical materials and equipment in manufacturers' original cartons or

containers with seals intact as applicable. Unless otherwise specified, deliver
conductors in sealed cartons or on sealed reels, ends of reeled conductors
factory sealed.
B. Storage.
Unless designed for outdoor exposure, store electrical material off the
ground and under cover. Prevent corrosion, contamination, or
deterioration.
C. Handling.
Handle materials and equipment in accordance with manufacturer's

recommendations. Lift large or heavy items only at the points designated by the
manufacturer, Use padded slings and hooks for lifting as necessary to prevent
damage.
5. JOB CONDITIONS
Locations of equipment, inserts, anchors, panels, pull boxes, manholes,

conduits, stub-ups, fittings, exterior lighting units and ground wells are
approximate, conform to the Drawings as closely as possible. Exercise care to
secure approved headroom and clearances, and to overcome structural
interference. Verify scaled dimensions, field dimensions and conditions at the
place of work.
A. Changes
Submit written details and reasons for proposed deviations from the
Drawings and Specification, and do not deviate therefrom unless
authorized by Engineer. If approved changes requested by Contractor
require alteration of structures or related work, make the alterations at no
additional cost to Employer.
B. Protection

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Protect electrical material and equipment until final acceptance. Protect

factory painted surfaces from impact, abrasion, discolouration and other
damage. Keep electrical equipment, materials and insulation dry at all
times. Maintain heaters in equipment connected and operating until
equipment is placed in operation. If partial dismantling of equipment is
required for installation, box or wrap the removed parts until reinstalled.
Repair or replace damaged work as directed, at no additional cost to
Employer.
C. Coordinate
Coordinate electrical work with all trades, public utilities and Employer.
Where two or more trades interface in an area, verify that no electrical work
is omitted.
6. RELATED ELECTRICAL WORK
Review entire Contract Documents and provide electrical work required for all
trades unless excluded from the section or specified elsewhere.
7. PRODUCTS AND EXECUTION
A Power Supply
The power supply to site will be undertaken by the Dubai Electricity and Water
Authority/Electricity Division (DEWA/ED).
B Power Supply Termination.
The DEWA/ED will be responsible for the supply and termination of the supply, and
installation of all the LT cables between the service transformers and the LT
switchboards.
C Meters Installation
All kWh meters shall be supplied and installed by the Contractor. Prior to
the purchase and subsequent installation of all the kWh meters, approval
from DEWA/ED shall be obtained for the type being installed. Cutout
fuses, and neutral links may be obtained from DEWA/ED, if available,
otherwise the Contractor shall be responsible for their provision. Cutouts
and neutral links provided by the Contractor must be of the types
approved by DEWA/ED.
8. DISTRIBUTION BOARDS
A. Distribution Board
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DUBAI – UAE
All distribution boards shall be metal clad complete with isolators or MCCB
and contactors or changeover contacts wherever applicable. Bracing shall
be provided on top, bottom, and back. All distribution boards shall be
painted admiralty grey. Where necessary the DBS shall be enclosed in
metal enclosure with lockable doors.
B. Earthing of the Switchboards
A continuous bare copper strip shall be supplied and installed within the
switchboard to run the full length of the structure. Terminals shall be
provided for the connection to the metal cladding or armouring of all
incoming and outgoing cables and to the main earth.
9. DISTRIBUTION SYSTEM
A. General
The distribution system consists of PVC/SWA/PVC cable, PVC/PVC and PVC

insulated cables and all installation materials to form a completed installation,
shall be supplied, installed, connected and tested in accordance with the
Drawings and Specification.
B. Cable Routes
The general cable routes will be proposed by the Contractor for the Engineer's
approval.
C. PVC Armoured PVC Insulated Cables
PVC armoured PVC insulated cables (PVC/SWA/PVC) shall be

manufactured and tested in accordance with BS 3346.
D. PVC Cables
PVC Cables shall comprise high conductivity stranded copper conductor of

the sizes as shown in the drawing and manufactured to BS 3360 and PVC
insulation to BS 2004 and 2746 as applicable. Only PVC cables bearing the
manufacturers name shall be used.
E. Insulation Colour Codes
Insulation colours shall be in accordance with Table 51(B) of the 16th

Edition of the IEE Regulations for the electrical equipment of Buildings.
F. Installation of Cables

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DUBAI – UAE
For the purpose of this paragraph of the Specification, installation of cables

shall include the following:-
1. Measuring, marking off and cutting of all cables to lengths before

installation or laying.
2. Temporary sealing, protection and support of cables being installed
or laid, and testing of cables for insulation before jointing or termina-
tion.
3. Preparation of all necessary materials for the placement, support or
carriage or all cable runs. These shall include earth trenches,
sleeves, ducts, cable trays, trunking, racks, clamps saddles, etc.
4. Sealing of cables in ducts, sleeves or trenches to prevent ingress of
water to GRP cubicle, manholes or flowmeter chamber.
5. Testing of cable insulation and continuity.
G. Jointing of Cables
The Contractor shall be responsible for the sealing and jointing of all cables
within the LT network in this work.
Cable sealing and jointing shall be in accordance with the best current
practice. Cables with metal sheaths or armouring shall be terminated or
jointed with metal sheaths or armouring solidly bonded to the metal joints or
terminal boxes to provide a low resistance path under fault conditions. The
cost of all jointing materials, labour, etc. shall be included in this work.
H. Cable Pulling.
For armoured PVC cables, mechanized devices may be employed for

pulling over trenches and through sleeves or ducts. Cable guides shall be
used for pulling cables round a bend.
I. Installation of PVC SWA PVC Cables.
Jointing and terminating of PVC steel wire armoured cable shall be done by
experienced jointers who shall provide evidence to the Engineer that he
possess the relevant experience for the work. At terminal sealing boxes,
cable cores shall be brought through unbroken terminals and the cores
shall be sealed rigidly within the cast resin.
No straight joints are encouraged in this work but when proved to be

inevitable due to changes or other unforeseen circumstances, this may be
allowed following written approval by the Engineer. Straight joints buried
underground shall be compound filled and totally watertight. The steel
armouring shall be made electrically continuous in such joint and the

SPECIFICATIONS
DUBAI – UAE
effective resistance shall be as low as possible. Where necessary, external

earthing bond may be added.
Termination shall be by means of glands of the compression type complete

with terminating boxes. The glands shall provide a perfect grip on the steel
armouring on termination.
J. Cable Trenching.
Where shown, the cable routes shall be as shown on the Drawings. The
exact location may be adjusted following the approval of the Engineer. The
cable route shall be as straight as possible.
Excavation of trenches for the cables shall be at least 600 mm deep

measured from the finished ground level of the site. The Contractor shall
be responsible for the establishment of this level at site and arrange to
excavate and lay the distribution cables at the appropriate time such that
his cables will not be disturbed when installed. Any subsequent damage to
the cables after installation, shall be the sole responsibility of the Contractor
and he shall make good the damage at his own cost. Trench width shall be
adequate for cable spacing for medium volt, i.e., cable spacing of 75 mm
min.
K. Cable Protection.
Before the cables are laid, the trench shall be partly filled with sand to a
depth of 75 mm. Another 75 mm deep layer of sand shall be filled after
laying the cables.
L. Cable Covers.
Cable covers shall be concrete slabs of appropriate size and 50 mm thick

and laid above the top layer of sand so as to give direct protection to the
buried cable against damage from earth pressure. For identification of the
cable route, cable markers shall be installed over the route particularly at
the points of change of direction or at the joints where these exist. For long
straight runs markers may be installed at appropriate intervals.
M. Backfilling and Reinstatement.
After laying the cable covers, the trench shall be backfilled with loose soil
free from stones or other hard particles. The layer of refill shall be firmly
compacted to the same finished level as the prevailing ground level.
N. Cable Tray and Supporters.

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Cable trays shall be made of perforated hot dipped galvanized steel of not
less than 16 swg with upturned flanges on both sides. Tray width shall be
as appropriate to accommodate all the cables in the same run. Cable
supports shall be steel brackets fixed to ceiling, wall or slab in the manner
as approved by the Engineer. Cable support spacing shall be 1 m to 1.5 m.
O. Installation Materials
All wiring, conduits, conduit boxes, drawing-in boxes, junction boxes,

saddles, brackets, etc., required for the completion of the sub-circuit
installation and wiring shall be included in this work.
Generally, PVC insulated copper conductors shall be used for the wiring of
general purpose outlets.
P. Conduits
All conduits, fittings and accessories for use in concealed conduit

installation shall be PVC. All conduits and fittings, etc., in any other areas
as directed by the Engineer shall be in galvanized steel.
Conduits cast in slab, or floor shall be fixed securely to prevent movement

and the joints shall be securely wrapped with tape where necessary to
prevent them from coming loose or allowing ingress of concrete during
casting. Any defects in the conduit installation shall be made good by the
Contractor at his own cost.
Surface conduit in other areas where exposure is permitted shall be

galvanized steel with fittings and accessories of similar materials. Conduit
saddles shall be spaced at 1 m apart for sizes below 25 mm dia. For bigger
sizes, saddles may be 1500 mm apart. Saddles shall be fixed with rawlplugs
and screwed in drilled holes.
Conduit run shall be straight as practicable and shall either be vertical or

horizontal. Diagonal runs are not permitted. Draw-in boxes shall be added
for runs of more than 2 bends or for straight runs of more than 900 mm
span. Conduit sizes shall be adequate for the number and sizes of the
cables being installed in the conduit. Minimum conduit size to be used shall
be 15 mm dia. Number of cables in each conduit shall comply with Table
B5 of the 14th edition of the I.E.E. Regulation for the Electrical Equipment
of the Buildings.
Termination of PVC conduits in PVC boxes shall be made with the conduit
poking deep through the knockouts and securely fastened to prevent the
misalignment of the conduits during casting. Conduit ends shall be
carefully plugged to prevent ingress of concrete during concreting.
Termination of steel conduit in steel boxes shall by means of threaded
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DUBAI – UAE
conduit joint and brass-made bush. Conduit ends shall be filed free of
burrs before termination. Conduit ends shall be carefully plugged to
prevent ingress of foreign particles, all metal conduits shall be made
electrically continuous. Metal flexible conduits shall not be used as earth
continuity lead.
Q. Wiring System
The wiring of all final sub-circuits from distribution boards to their respective
fittings of lighting and power points shall be in 250/440 volt grade PVC
insulated copper conductor.
All cable sizes shall be capable of carrying the full load current of all their
respective circuits continuously without overheating or undue voltage drop
which shall not exceed 2.5 percent of the nominal supply voltage at the
supply terminal. Minimum cable size for low volt wiring shall be 1.5 sq. mm
copper and for 13 Amp power outlets, the cable size shall be 2.5 sq. mm
minimum.
Wiring code shall be in accordance with the 16th edition of I.E.E. Regulations
for Electrical Equipment for Buildings. The switched wire shall in all cases be
red cored.
Incorrect wiring code will be rejected and the Contractor shall be

responsible for replacement of any part of the wiring rejected by the
Engineer for non-compliance with the Specification.
10. EARTHING SYSTEM
A. Scope
The earthing system shall cover each and every unit facility, consisting of a
main earth at the main DB and localized earths where necessary at any
other unit facility. All these earths shall be bonded together where
possible. The metal sheaths or armouring shall not be used as earth
continuity or earthing lead.
B. Earth Electrodes
Electrodes shall be steel cord copper rods driven into the open ground at
spacing not less than 3 m apart. The electrodes shall be bonded together
and the aggregate earth resistance so formed shall be less than one (1)
ohm.
B. Copper Earthing Lead and Bonding

C.
The bonding of the electrodes and the copper earthing leads shall be bare
copper conductor with nominal cross-section area of not less than 70

SPECIFICATIONS
DUBAI – UAE
sq.mm. The bonding shall be by means of non-corrosive metal clamps or

by brazing.
D. Earth Electrode Inspection and Test Point
All inspections and test points of the earth electrodes shall be boxed up
with brick and cement mortar with a removable slab cover. The position of
these earth electrodes shall be permanently labelled with the word.
"Safety Electrical Earth. DO NOT Remove".
11. TESTING
A. Test Manufacturer's Work
All tests or inspection shall be in accordance with the relevant British

Standards or such other standards as approved by the Engineer.
All tests or inspection at the Manufacturer's works shall be accompanied

with test or inspection certificates showing all the relevant information and
details relating to the test or inspection. Four (4) copies of Test certificates
signed by the Manufacturer's representative shall be submitted to the
Engineer on or prior to the dispatch of equipment to site.
B. Installation Inspection
During installation, or when the Contractor is satisfied that the work is in

satisfactory working order, he shall arrange with the Engineer to carry out
tests for, or inspection of, the installation or completed work. If any part or
equipment is found to be not in accordance with the Specification or
relevant Standards, such variance shall be put right by the Contractor to
the satisfaction of the Engineer and at no extra cost to the Employer.
C. Test, Inspection by Power Supply Authority.
Prior to the completion of the work, the Contractor shall arrange with the
DEWA/ED for the inspection, testing, reading of meters, etc., to obtain
clearance for the connection of power to the plant or equipment.
D. Attendance during Testing.

For all the tests and inspection as aforementioned, the Contractor shall
provide the necessary tools, labour and skilled technicians as and when
required during the period of test and inspection.
All tests and inspections shall be conducted in the presence of the

Engineer. Test results shall be obtained and recorded and produced in
quadruplicate to the Engineer. Any results showing variation from the
efficient performance or manufacturer's test results shall be rectified to the
satisfaction of the Engineer and at no extra cost to the Employer.
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DUBAI – UAE
E. Standard Tests at Site.
The following are the tests required to be carried out and recorded.
1. Earth electrodes impedance and earthing system

2. Insulation resistance test
3. Continuity tests
4. Operation and system tests such as sequence, interlock, etc.
5. Operation of protective gear circuit test by assimulation to check
sensitivity and stability
6. Phase rotation list
7. Polarity test to ensure that single switches are installed in the live
conductor and not in the neutral conductor
8. Test for ring main circuits
9. Insulation resistance test to earth and between conductors before
and after connection of fittings
10. Insulation resistance test on all equipment and apparatus installed,
before and after connecting such equipment to the supply circuit
11. Earth continuity test for each final sub-circuit and the completed
installation to ensure that earth fault loop impedance is such as to
satisfy the requirements of the 16th Edition of the I.E.E. Regulations
for the electrical equipment of buildings.
On the satisfactory completion of the tests mentioned above and on presentation

of the record of such tests to the Engineer the electrical equipment shall be
deemed complete.
12. MEASUREMENT
General
The electrical installation and all work in connection therewith shall be valued by
the measurement of only such items as are included in the Bill of Quantities. The
cost of any electrical installation not itemized in the Bill of Quantities shall be
deemed to be included elsewhere in the Contract Rates to cover all the
Contractor's obligations under the Contract.
3.9 MANHOLE COVERS WITH FRAMES AND SURFACE BOX

Manhole covers with frames and surface box shall be manufactured from ductile
iron materials (Spheroidal Graphite Iron) and complying with BS EN 124: 1994.
Casting shall be smooth, true to pattern and free from projections, sand holes,
blowholes or other distortions. Manhole covers and frames shall meet or exceed
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DUBAI – UAE
minimum wheel loading requirements as defined for CLASS D 400. Engineer may
request third party certification, if consider it necessary.
The frame with a circular clear opening of 600mm diameter or as sized on the
drawings/in the description of item, and shall be single sealed. The keyhole shall
be of the closed type. The cover shall be in one piece (solid top) and circular. The
frame shall be square/circular. Two no. of prising slot shall be provided diagonally
to lift the cover if jammed. Four holes of 5 mm shall be provided in cover for
ventilation. One no. of 5mm hole shall be provided in each keyhole to avoid sand
accumulation. One no. of unidirectional notch shall be provided.
The cover shall be badged DUBAI ELECTRICITY & WATER AUTHORITY -

WATER in English and Arabic and shall also bear the DEWA logo.
The covers are to clearly have the BS no. / Class / manufacturer’s name and
DEWA logo cast thereon.
Covers and frames shall be grit blasted and coated with a suitable heavy duty
abrasion resistant solvent free epoxy paint to a minimum Dry Film Thickness
(DFT) of 300 microns in black colour.
One set of each size from total quantity to be used in the project shall be load
tested locally at no extra cost or as directed by the Engineer.
After installation, the covers and frames shall be greased internally particularly in
the contact area of frame and cover and contact area between GRP sealing plate
and frame in case of surface box
150 mm DIA. SURFACE BOX:
It shall be watertight. The manufacturer/supplier shall forward his proposal to

achieve water - tightness. The surface box shall be double seal and with GRP
sealing plate. The frame shall be square and cover shall be round with 150mm
dia. opening. The cover shall be in one piece (solid top) and one keyhole
(standard) for lifting. The marking on cover shall be (i) manufacturer name (ii)
‘DEWA’ and (iii) ‘WATER’ (iv)  (arrow mark). The surface box shall be installed
in such a way that arrow direction marked on cover, is parallel to the pipeline. The
specifications for manhole covers and frames are also applicable to the surface
box.
SUBMISSION FOR MANHOLE COVER AND SURFACE BOX

(1) Original catalogue and technical product data
(2) Sample of each size
(3) Load test certificate for each size
3.10 FABRICATED STEEL COVER WITH FRAME FOR WATERMETER

CHAMBER - 1100 x 600 MM , 900 x 600MM and 600 x 450 MM
SPECIFICATIONS
DUBAI – UAE
Supply of cover with frame including fabrication, galvanizing, epoxy painting:
The clear opening shall be as per size mentioned and depth shall be 75mm. The
cover shall be twin hinged and made from slip resistant plate (chequered plate)
hinged into a steel frame. The cover shall be in two portions with opening from the
center for size 1100 x 600 and 900 x 600. The cover shall be in one portion for the
size 600 x 450mm. Safety arrangement shall be provided to prevent accidental
closure. The lifting handle shall be provided.
The chequered plate shall be 6mm thick and shall be reinforced underneath with
support channel/other suitable measures. The angle shall be 75 X 75 X 6 mm.
The hinge rod/screw/fasteners/nutbolts shall be stainless steel Grade AISI 316.
The complete set will be sandblasted to S.A. 2.5 after fabrication. It shall be
galvanized and then primer and two coats of powder epoxy coating in blue colour
shall be applied. The powder epoxy coating shall be applied from reputed
company.
Suitable thickness of 300 x 300mm size brass plate with backing steel plate, shall
be fixed inside the cover and with following marking in Arabic and English. The
marking and logo shall be embossed and shall be coloured in blue.
(i) DEWA LOGO

(ii) DUBAI ELECTRICITY AND WATER AUTHORITY
(iii) WATERMETER
The item shall be similar as per DEWA existing sample with minor modification if
suggested by the Engineer. The sample can be viewed at DEWA Central Store –
Aweer Road.
The sample submitted to DEWA, shall at free of cost and shall remain DEWA’s
property.
3.11 DETECTABLE WARNING TAPE
Detectable Warning Tape shall be of high quality, strong, non-corroding, acid and
alkali resistant, tear resistant and resistant to other destructive elements found in
the sand / soil. Detectable warning tape shall have long durability to maintain its
installed width and message. It shall be free of surface area distortion normally.
The width of tape shall be 300mm. Aluminium foil shall be minimum 12 micron
thick and 300mm width and laid between the layers of polythene sheets and
polyester. The total thickness shall be minimum 250 microns.

SPECIFICATIONS
DUBAI – UAE
The tape shall be Blue in colour and printed with minimum 50mm high black lettering
alternatively in Arabic and English. The tape shall be imprinted with “DUBAI
ELECTRICITY AND WATER AUTHORITY WITH LOGO - CAUTION - WATER
MAINS BELOW” in Arabic and English. The tape shall have printed message in
reverse type printing (i.e. on back side of transparent polyester sheet). The
manufacturer name shall be printed at every 1m or less distance. The complete
wording shall be accommodated in 1m or lesser length of tape in English and Arabic.
This will continue for the complete length. The colours shall be vivid, glossy and
permanent. The aluminium foil shall be incorporated so that it can be detected from
ground surface using a buried cable locator such as RD 400 locator manufactured
by Radio Detection Corporation. If requested by Engineer, the demonstration shall
be given for delectability of tape by cable locator at site.
The tape shall be supplied in rolls of 250 metres each. The tape shall be supplied
on stout reels suitably crated.
Notes:
* 2 meter long sample piece of detectable tape shall be submitted with the Tender.
3.12 NUTS AND BOLTS WITH WASHERS
Nuts & bolts with washers shall be of AISI type 316 Stainless Steel complying with
ASTM A276 or equivalent. The grade shall be embossed on bolts. They shall be
supplied with two stainless steel grade 316 standard washers. Unless otherwise
indicated on the drawings, all stainless steel (whether nut bolts or any other items)
shall be Type 316 with a mill finish.
3.13 DISMANTLING JOINTS
The dismantling joint shall have flexibility required for flanged pipe work system
and allows longitudinal adjustment in length for installation & maintenance. The
dismantling joint shall be flange/flange i.e. double flanged and restrained type.
The flange of both faces shall be provided with full face flange sealing area i.e. the
flanges shall not have raised face. The coating and EPDM rubber shall have
fitness certificate in contact with potable water minimum 50 degree C from Water
Regulation Advisory Scheme (WRAS) or equivalent Authority.
Materials of Construction
(i) Spigot Piece : Steel BS EN 10025

Flange Adaptor (up to 300 mm) : Ductile Iron
(Over 300mm) : Steel BS EN 10025
Bolts/Studs/Nuts/Washers : Stainless Steel Grade 316
Tie Bars : Stainless Steel Grade 316
Rubber gasket : EPDM Rubber – Fit for potable Water
to 50degree C. (Certificate to be
attached)
SPECIFICATIONS
DUBAI – UAE
(ii) Nominal pressure (PN) : PN10/PN16/PN25 as per item

Description/drawing
(iii) Surface Protection : Rilsan Nylon or Fusion Bonded Epoxy

Coating minimum thickness - 250
Microns and average 300 microns
(iv) Flange Drilling : (i.) BS 4504 PN10 pattern for PN 10

item.
(ii) BS4504 PN16 pattern for PN16
item.
(iii)BS4504 PN25 pattern for PN
25 item
(v) Adjustment Length and Other Details :
NOMINAL PRESSURE NOMINAL MINIMUM MAXIMUM

BORE RATING LENGTH LENGTH LENGTH
mm mm mm mm
50 to 300 PN 10 / 16 190 170 210
350 to 900 ,, 300 275 325
1000 to1200 ,, 320 290 350
The other material of construction can be approved subject to DEWA approval.
3.14 FLEXIBLE - COUPLING AND FLANGE ADAPTORS
Where flexible couplings are required, they shall be of the tied or restrained type,
Viking-Johnson flexible couplings or equal. The supplier shall follow the
manufacturer’s recommendations as to the methods and equipment to be used in
assembling the joints. In particular, the supplier shall ensure that rubber rings are
correctly positioned and free of twists. The rubber rings and any recommended
lubricants should be obtained only from the coupling manufacturer.
Flexible couplings and flange adaptors shall be capable of withstanding the test
pressure appropriate to the pipes for which they are supplied.
Nominal pressure (PN) PN16/PN10 as per item description
Surface Protection Rilsan Nylon coating to full unit including

Internal & external protection studs, nuts, bolts and suitable to for fit in contact
With potable water (certificate to be attached)
{End ring / flange adaptor body / minimum thickness - 250 microns
Center sleeves / spigot}
Studs / Nuts / Bolts / Tie Bolts minimum thickness 50 microns
SPECIFICATIONS
DUBAI – UAE
Drilling of hole (i.) BS 4504 PN10 pattern for PN 10 item.

(ii) BS4504 PN16 pattern for PN16 item.
Details of couplings for incorporation in the works shall be submitted to the Engineer for
approval.
3.15 A.C. JOINT LUBRICANT - SOFT SOAP
Soft Soap shall be supplied as a lubricant for Asbestos Cement Pipe Joints, which
shall be odorless and washable with water and shall have a paste like
consistency. The soap shall be vegetable based (petroleum based not
acceptable) and free from fish, whale or other animal oils and fats; free from
resins and any poisonous materials. Certificate to that effect shall be submitted by
the manufacturer at the time of delivery. It shall be supplied in packing of 25 kg
net. The packing shall be of good quality (plastic packing is not accepted). The
soap shall be certified and listed for potable use by Water Research Center
(Water Byelaws Scheme), U. K. or equitable in accordance with BS 6920
Catalogue and technical data, net quantity in each drum, and WRC certificate
shall be submitted along with the quotation/tender.
3.16 MARKER PLATES AND POSTS
The marker plate and post shall be provided as shown on the Drawings and
where directed by the Engineer. The sign plates shall be 140 mm by 200 mm and
mounted on a 48 mm diameter ribbed aluminium post finished with an aluminium
cap. The sign plat shall have a plastic face with “slot-in” interchangeable plastic
numerals and letters, a plastic backing plate and an aluminium mounting plate.
The corners of the mounting plate shall be rounded to the same dimensions as
that of the plastic plate. The plate colour shall be blue and the figures shall be
white.
The material used for the plastic plate, numerals and letters shall be resistant to
ultraviolet radiation and suitable for the exposure conditions encountered in Dubai.
The numerals and letters shall be as per manufacturer recommendation and
DEWA approval.
The design of the marker plate and post shall be subject to the approval of the
Engineer.
For every valve with extension spindle installed, Marker plate and post shall be
fixed to indicate the location of valve. The rate for supply and installation of marker
plates and post shall be included in the rate of surface box chamber. For
installation, refer drawings or as per manufacturer’s recommendation.

SPECIFICATIONS
DUBAI – UAE
3.17 FLEXIBLE INDICATOR POSTS
The flexible indicator post shall be fiberglass reinforced composite, which shall be
resistant to impact, ultraviolet light, vandalism and hydrocarbons and temperature
resistance from zero degree C to sixty degree C. It shall be flexible and can
withstand direct vehicle impact and return to its original upright position. Post
width shall be 9 to 10cm, length 150cm or more and colour blue.
It shall allow the placement of decals on both side of post to identify buried water
services. Warning/Message decals shall be UV resistant and also printing with UV
resistant inks. Decals shall be provided on both sides of post. The decals shall be
of high quality and reflective at night. The background colour of decals shall be
blue and message/warning letter shall be white. The blue colour should not fade in
local harsh condition of 50 degree C. The message/warning script shall be as
directed by DEWA which will be different for valves, fittings and along the route of
pipeline. The samples with different script on decals shall be submitted.
Flexible indicator post shall be installed with every valve, every fitting on pipeline
above 450mm dia. and exactly over the pipeline of sizes above 450mm dia. at
every 100m. The base shall be concreted with size 300x300x300mm. Its length
shall be 1.5m where 1m shall be projected above ground.
The other type, design and material can be submitted and installed subject to
DEWA approval
3.18 NEOPRENE RUBBER WRAP FOR G.R.P. FITTINGS
Neoprene synthetic rubber shall have shore hardness ‘A’ of 35 - 55. The neoprene
wrap shall be supplied in 10 meters long rolls, 10 mm thick, and 100 mm wide.
The rolls shall be supplied in closed plastic bags or other packing approved by
DEWA.
3.19 INSERTION RUBBER (RUBBER GASKET) FOR FLANGED

CONNECTIONS
Insertion rubber shall be made from EPDM rubber with hardness 70 - 90 for rubber
lined butterfly valves and EPDM rubber of food grade with hardness 35 - 55 for gate
valves. Insertion rubber shall be fixed for flanged connection as an insertion between
flanges. The outside and inside diameters of rubber insertion for rubber lined
butterfly valves shall be as tabulated below but exact dimension and thickness shall
be checked by contractor. The flange hole drilling shall be done as per BS 4504 (PN
10) pattern. For 225 mm and 550 dia. insertion rubbers, ISO 2084 - 1974 (PN 10)
drilling pattern shall be followed. The table below is only for rubber lined butterfly
valve and indicative. It shall be noted that insertion rubber is not required on the
raised face of butterfly flange as rubber lining is extended on raised face.
Nominal Inner Diameter Outer Diameter Of Thickness Of

Diameter Of Of Insertion Insertion Rubber Insertion
Butterfly Valve Rubber ( mm ) Rubber
( mm ) ( mm ) ( mm )
SPECIFICATIONS
DUBAI – UAE
1200 1333 1455 5

900 1007 1115 5
600 685 780 5
500 584 670 4
225 225 420 3
200 200 340 3
150 150 285 3
100 100 220 3
The technical data of rubber and dimensional drawing shall be submitted along
with tender / approval.
3.20 G. R. P. LADDER (FIBRE GLASS LADDER)
The ladder shall be of glass reinforced plastic. GRP ladder shall be made by high
quality resin, chopped strand mat and C glass veil. The stringers (i.e. handling
arrangement) shall be designed with facility for holding hand while going down /
up on the ladder. The inner width of ladder be 400mm. The width of steps shall
be 80mm and roughened with nonslip surface. The step distance shall be 250mm.
The ladder shall be provided with moulded GRP bracket at every 750mm. The
ladder shall be fixed on concrete wall by 12mm dia. stainless steel grade 316
rawal bolt with washers and nut . The ladder shall be installed at the slope as
mentioned in the drawing or as directed by the Engineer.
3.21 U.P.V.C. PIPES
A. Standards
All materials supplied and all works carried out, shall comply in all respects with
the requirements of this specification and such regulations which may be in force.
Except where modified by this specification, materials shall be in accordance with
BS (British Standard) 3506 (1969): Unplasticized PVC pipe.
As an alternative to BS Standard indicated above, the Tenderer may quote for

materials in accordance with his National or International Standards covering
UPVC pipes. In such case difference between BS Standard and that of the
National or International Standard shall be clearly indicated by the Tenderer in his
offer and one copy of the National standard in English language shall be attached
with the offer.
When BS or National /International Standard are refer to, the edition shall be that
of current at the date of Tender, together with any amendment issued to that date.
The Tender shall specify when tendering, the standards with which his offer
complies. UPVC pipes shall be of class ‘C’ and the manufacturer shall be certified
to ISO 9000 series. Non ISO 9000 certified manufacturers with previous
successful direct supply experience to DEWA may be approved at DEWA’s sole
discretion for similar sizes supplied earlier.
SPECIFICATIONS
DUBAI – UAE
B. Constructions
All details, dimensions and instructions shown on any drawings, diagrams and
specifications quoted herein shall be taken as forming part of this specification.
The PVC pipes shall be made from Unplasticised polyvinyl chloride (UPVC)
generally to the requirements of nominal size 100 mm & 150 mm dia. of BS 3506.
The extruded pipe shall be capable of being flattened completely between the
plates of a hydraulic press without cracking or splitting. The pipes shall be
corrosion resistant and tough. The wall thickness of the pipes shall not be less than
3.4 mm for class ‘B´ but not less than 6.6 mm for Class ’C’.
The external and internal surface of pipes shall be clean, smooth and virtually free
from grooves or other indentations or projections. The smoothness of the internal
surface of the pipe shall be such that the pulling through of the cables in long
lengths shall be facilitated without risk of damage to the exterior surface of the
cable.
Each pipe shall have a tapered socket formed at one end. The socket shall be
reasonable concentric with the axis of the pipe. The spigot end of the pipe and the
socket shall be sufficiently tight interference fit.
Set of end caps and end plugs if included in the scope of supply shall be made of the
same material as shown above for UPVC pipes. The caps are to be used at the spigot
end and plugs are to be used at socket end for sealing of respective UPVC pipes when
the pipes are not in use.
Note: - Tenderer shall submit representative samples for the UPVC pipes.
C. Markings
All pipes shall be indelibly marked. The marking shall show the following legend:
1. Manufacturer’s Name
2. Year of Manufacture
3. DEWA/ WD / Contract no.
Height of the marking shall not be less than 6.5 mm.
Marking along the length of the pipes shall be provided at least at two different
locations spaced equally around the periphery of the pipe.
D. Drawings & Samples

The Tender shall provide drawings, samples and catalogues for the UPVC pipes
and accessories offered.
E. Testing
SPECIFICATIONS
DUBAI – UAE
All tests as per BS 3506, as applicable to UPVC pipe shall be carried out. The
Test certificates for such tests carried out shall be submitted with each
consignment. Tenderer will be required to submit 2 sets of test certificates with
each consignment.
The Tenderer shall submit along with his offer one copy of test certificate for
similar pipes manufactured by the UPVC pipe manufacturer in the past.
3.22 SPECIFICATION OF CARBON STEEL PIPE FOR SLEEVE PURPOSE

The pipe to be used for sleeve purpose shall be of carbon steel pipe to the
specification API 5L grade B or X-52. It shall have following dimensions:
ID of ID of Steel Pipe Wall Thickness Wall Thickness

Asbestos required for sleeve (mm) (mm)
Pipe (mm) (mm) NDRC Open Cut
1200 1630 14 10.5
900 1400 12 10.5
600 1100 10.5 10.5
300 600 7 7
The external surface to be coated with primer and epoxy coated with a total
thickness minimum 250 micron. The detail is to be provided at the submission.
3.23 RUBBER EXPANSION JOINTS (RUBBER BELLOWS)
1. The rubber expansion joints shall be used for absorption of vibration in

pipes, absorption of all type of movements such as axial compression, axial
elongation, lateral and angular deviation, connection of pipes which are not
properly lined up, water hammer reduction etc.
2. It shall be PN10/PN16/PN25 as per piping design. Generally it shall be

PN10 but tenderer/supplier to verify.
3. TECHNICAL DETAILS:
TYPE: SINGLE ARC WITH VACUUM RING

WITH TIE RODS
FLANGE DRILLING PN10/PN16 PATTERN TO BS4504
WORKING PRESSURE. 1OBAR/16BAR
AXIAL COMPRESSION AS WRITTEN IN TABLE
AXIAL ELONGATION AS WRITTEN IN TABLE
LATERAL DEFLECTION AS WRITTEN IN TABLE
SPECIFICATIONS
DUBAI – UAE
ANGULAR MOVEMENT AS WRITTEN IN TABLE

TORSION MOVEMENT 1-5˚
TIE RODS 8NOS or AS PER REQUIREMENT with
LOCKNUT, SPHERICAL WASHERS
AND
SEATS
VACUUM RING ONE IN THE ARC and TWO
RINGS AT THE CORNER
ORIGIN: WESTERN EUROPE/ USA
4. Materials of construction:
Bellow : EPDM rubber combining different layers of fabrics to get the

desired flexibility as well as a long resistance to aging. It
shall be on full face of flange. Part face on flange is not
acceptable
Backing Flange: Carbon steel – with rust preventive treatment of zinc

plated.
Tie Rods: Carbon Steel – with rust preventive treatment of zinc plated
5. Flange drilling pattern shall be as per BS 4504 PN10/16/25
6. Nuts, bolts and washers and all fasteners shall be AISI type 316.
7. It shall be single arc designed type double flanged (flange/flange) rubber

expansion joint and suitable for flanged pipe work of water pumping
stations.
8. The fluid is potable water of maximum temperature of 50˚C. The fitness

certificate in contact with potable water up to minimum 50 degree C shall
be submitted from Water Regulation Advisory Scheme (WRAS), U.K. or
equivalent authority.
9. The material shall be high quality Rubber with necessary reinforcement to

withstand abnormal sudden pressure change inside the pipeline and
vibration.
10. The rubber material shall be suitable for use under direct sunlight
associated with ultra-violet radiation and protection against ozone evolved
from electrical motors or other sources and special coating for U.V. and
ozone protection shall be provided
11. The rubber flange shall be supported from the back by a zinc electroplated/
stainless steel flange. The joints have to be provided with galvanized/
stainless steel Tie rods against the back of the flanges and through to the
mating flanges of the pipe. One metal reinforcing ring of stainless steel has
SPECIFICATIONS
DUBAI – UAE
to be provided at the base of the arch to add strength between the

convolutions and two rings at the corner. All rings shall be embedded inside
rubber.
12. The supplier have to provide Hydraulic test certificates during delivery of
material.
13. Marking:The following marking shall be provided on the body of the

Expansion Joint.
• Manufacturer name/ origin / Trade mark.
• Nominal Diameter in mm.
• Pressure rating in Bars.
• Date of manufacture.
• DEWA contract no.
14. Submission:
• The supplier have to provide full technical details of the Expansion joints
including original catalogues and production shop drawing from the
manufacturer along with their offer.
• Details of Tie rods brackets for Tie rods.
• Service, Installation & Maintenance Manual during the delivery of the
material.
15. WARRANTY:
The supplier and manufacturer have to provide at least 24 months of service

warranty of rubber joints along with their offer. During this period if any failure
occurs the supplier /manufacturer/contractor have to replace the same at free of
cost to DEWA.
16. It shall have following dimensions and movements
Dia. - face to Working Movements

DN face pressure
dimension - PN
-L
Axial Axial Lateral Angular
compression Tension deflection deflection
mm mm bar mm (-) mm(+) Mm(±) degree(±)
300 250 10/16 40 20 20 10
450 300 10/16 40 15 30 6
500 300 10/16 40 15 30 6
600 300 10/16 40 15 30 6
700 300 10/16 40 15 30 6
800 310 10/16 40 15 30 6
SPECIFICATIONS
DUBAI – UAE
900 310 10/16 40 15 30 6

1000 310 10/16 40 15 30 6
1100 350 10/16 40 15 30 5
1200 350 10/16 40 15 30 5
This can be revised with DEWA approval.

3.24 Granular Material for Pipe Bedding and Surround
stable gravel or crushed stone to BS 882 and shall be graded in accordance with
BS 882: Part 2, as shown in the following table:-
Granular Material for Pipe Bedding
TEST SIEVE PERCENTAGE BY WEIGHT PASSING SIEVE

(MM)
63 _
37.5 _
20 _
14 100
10 85 – 100
5 0 – 25
2.36 0–5
NOTE:
3. Total Acid soluble content of the material when tested in accordance with
BS1377 shall not exceed 0.3 percent by weight of sulphate expressed as
SO3 (Sulphur Trioxide).
4. The Material shall have a compaction factor value not exceeding 0.15.
Pipelines on Granular Beds
Where granular bedding to pipelines are detailed the minimum thickness of

bedding materials beneath the pipe shall be 200 mm (minimum 100 mm under
sockets)

SPECIFICATIONS
DUBAI – UAE
commencing pipe laying be as short as practicable.
The bedding material shall be extended to the full width of the trench and shall be
carefully compacted in layers not exceeding 200 mm, to achieve positive
deflection and to the specified accepted limits.
Recesses shall be formed in the bedding to accommodate pipe joints while
ensuring continuous even support along the length. Bedding material shall be
prevented from entering pipe joints. After joints has been made bedding material
shall carefully place and hand compacted beneath the joint barrel to close any
void left by the recess.
Where the formation of the trench is of silt or soft clay and is below the natural
bedding materials directly above formation and carefully compacted if directed.
3.25 Geotextile Filter Fabric
The Geotextile filter fabric shall be laid for pipes above 450mm dia. The granular
bedding and surround to all pipes above 450mm dia. shall be enclosed within a
geotextile filter fabric
Filter fabric shall consist of thermal bonded/needle punched synthetic polymer fibers.
Composed of at least 85 percent by mass polyolefins, polyesters, polypropylene,
polyethylene or polyamides. They shall be formed into a network such that the
filaments or yarns retain dimensional stability relative to each other, including
selvages.
The geotextile Manufacturer/supplier must be certified according to ISO 9001 for

quality management and ISO 14001 for environmental management system.
The fabric shall be stabilized against ultra violet light, inert to commonly
encountered chemicals in the in-situ soil and saline water and it shall conform to
the following minimum requirements
Grab Strength (N) ASTM D-4632 800

Puncture Strength (N) ASTM D-4833 355
Burst Strength (kPa) ASTM D-3786 2000
Trapezoid Tear (N) ASTM D-4533 220
Permeability (m/sec) ASTM D-4491 0.0001
Apparent Opening Size (mm) ASTM D-4751 0.6

SPECIFICATIONS
DUBAI – UAE
Ultraviolet Degradation ASTM D-4355 70 @ 150 h

Where filter fabric is used to enclose granular pipe surrounds, the fabric will be
placed on the prepared trench formation and carefully supported during pipe
laying operations. When the pipe has been laid complete with surround to the
correct level, the filter fabric shall be closed over the top of the surround by
forming a lap of minimum width 500 mm. All membrane joints shall be overlapped
a minimum of 500 mm.
installation or during backfilling of the trench. Any fabric damaged or displaced
before or during installation or during placement of over laying aggregate material
shall be replaced or overlaid to the satisfaction of the Engineer at the Contractor’s
expense.
During period of shipment and storage, the fabrics shall be maintained wrapped in
a heavy duty protective covering and protected from direct sunlight, ultra-violet
rays and temperature greater than 70o C.
3.26 LOW DENSITY POLYETHYLENE PIPES FOR

HOUSE SERVICE CONNECTIONS
A. General
This specification covers Low Density Polyethylene (LDPE) pipes for normal water
service. The outside diameters and pressure class are in accordance with ISO
161/1 - 1978 (E). The minimum wall thickness (e) are calculated using the ISO
formula with a working stress (p) of 32 Kgf/cm2.
e = P.d
2p + P
B. Classification of Pipes
Pipes are classified by maximum sustained working pressure in bars. Pipe supplied
shall be Class 10. The maximum sustained working pressure is based on water at
a service temperature of 200 C.
C. Dimensions
Pipes shall conform to the outside diameters and wall thickness given here below:
Table 1
Nominal Outside Wall Thickness Coil Minimum

Diameter Diameter Class 10 Length Coil
SPECIFICATIONS
DUBAI – UAE
Weight
ND Min. Max. Min. Max.
( mm ) ( mm ) ( mm ) ( mm ( mm ) (m) kg / coil
)
32 32.0 32.3 4.4 4.8 150 53
63 63.0 63.5 8.6 9.4 100 137
D. Visual Requirements
LDPE pipe shall be free from gouges, voids and other defects that would, in the
judgment of the Engineer, impair the serviceability of the pipe.
E. Material Composition
Material composition and pipe material shall be in accordance with BS 1972:1967.
F. Mechanical Properties
Physical characteristics and Mechanical properties of LDPE pipe shall be in

accordance with BS 1972:1967.
G. Sampling and Testing
Sampling and testing of LDPE pipe shall be in accordance with BS 1972:1967.

Copies of factory test reports shall be made available to the DEWA upon request.
Witnessing by the DEWA Engineer of factory testing may be required prior to
delivery of any consignment. In case, factory test is waved, the supplier shall carry
out testing locally without extra charges to DEWA.
H. Marking
All pipe coils shall be indelibly marked in blue colour at intervals of not more than
1 meters with the following:
- Manufacturer’s name
- DEWA/WD/Contract no.
- The nominal size and class as shown in Table 1.
I. Lengths and Weights
The pipes shall be supplied in coils. The coil lengths and minimum weight per coil
shall be in accordance with Table 1.
SPECIFICATIONS
DUBAI – UAE
J. Acceptance
Each delivery of polyethylene pipe to the site shall be accompanied by a

certificate from the manufacturer certifying compliance with these specifications.
Any deviations found on random checks by the Engineer on coil lengths, coil
weights, pipe dimensions and any failure in hydrostatic pressure tests shall be
considered a cause for rejection of the entire consignment. A sample of 2m length
shall be the provided with tender.
3.27 FITTINGS FOR LOW-DENSITY POLYETHYLENE PIPES
Fittings for Low-Density Polyethylene Pipe
Manufactured from Acetal or Gunmetal. Body with internal taper, grip ring for end
loading resistance. “O” ring for watertight seal. All components to be
manufactured from UK WFBS listed materials. The seal of the push fit joint is
obtained using water pressure as a thrust medium and hence, no tool is used to
obtain a watertight joint. Supplier to be approved to ISO 9000 series for quality
management systems. Fittings to be compatible with DEWA, metric 32mm dia
polythene pipe and normal 1” gauge.
Materials Specifications
Bodies
Gunmetal fittings - BS 1400:LG2 cast gunmetal
Plastic fittings - Threaded: generally Dupont Derlin 107 black

601. Acetal Homopolymer; all other fittings;
Hoechst T 1020 black R2 Acetal Terpolymer.
Components - Grip ring Acetal polymer or EPDM “O” ring;

EDPM elastomer to BS 2492 type W, or
Wooduolle Polymer 09-333.
The fittings shall be designed for use underground and to handle potable water at
temperatures up to 500C. They shall be capable of test operation at a pressure of
18 bars without leaking. All fittings shall be manufactured in Western Europe or
North America. The other countries can be approved if it meets specification and
quality.
Adapters for connecting polyethylene and G.I. pipe shall be designed with an inlet
for metric size PE pipe and a female threaded outlet to BS 21:1975 or ISO 7/1.
3.28 FERRULES
SPECIFICATIONS
DUBAI – UAE
Ferrules shall be supplied with a push fit outlet for polythene pipe. It shall be fully
of Gunmetal material. The combined construction of PVC and Gunmetal material
is not acceptable. All ferrules shall be designed as a main stem with a 360 swivel
outlet at 90, with control of water flow via a threaded inner plug. The inlet shall
be a male taper threaded to BS 21:1975. The ferrules shall be designed for use
underground and to handle potable water at temperatures of up to 50C. The
ferrule shall be capable of working at a pressure of 18 bars without leaking. The
ferrule shall be easily “shut off” by means of spindle extending from the top cap.
The design of the ferrule shall further permit use with conventional drilling
machines, which mount on to the ferrule/saddle assembly and drill the pipe via the
ferrule stem waterway, dry or under pressure.
The ferrule stem, inner plug and top cap shall be manufactured of
Gunmetal/Bronze to BS 1400:1986 LG2. The ferrule banjo may be manufactured
of gunmetal only. Any part/parts of ferrule banjo and ferrule shall not be of acetyl
plastic or any plastic material except internal plastic grip ring at outlet end for
fixing polythene pipe. The gunmetal banjo shall be in one piece. Two piece banjos
joined to each other by threading, is not acceptable.
The banjo washer and the top cap washer shall be manufactured in EPDM rubber
to BS 2494 and shall provide the sealing between the outer body and ferrule stem.
A sample shall be submitted with tender.
Gunmetal push fit ferrule shall have inlet 25mm (1”) dia. male threaded type and
outlet shall be 32mm dia. Push fit type.
3.29 SADDLE CLIP
Saddles for installation on asbestos cement pipes shall be of cast gunmetal to BS

1400 LG2 supplied with aluminium bronze or stainless steel grade 316 bolts, nuts
and washer and EPDM rubber gaskets. It shall have an untapped boss on the top
surface suitable for installation of the approved ferrule. All saddles shall accept
ferrules up to 50mm diameter and bolts shall be full length threaded. The O-ring /
washer shall be fixed with glue (adhesive) in their groove / required location and
not as a loose item. A sample shall be submitted with tender.
3.30 STOPCOCKS
Stopcocks shall be gunmetal BS1010 stop valves supplied with double female
threaded ends. The valves shall be provided with a detachable key operator, with
the spindle shielded so as to prevent unauthorized operation with a wrench. The
shield will be of sufficient depth so that when the valve is fully open the spindle
remains recessed in the shield to a depth of 5 mm. The shield shall have two
holes drilled opposite to each other at its open end to allow insertion of a sealing

SPECIFICATIONS
DUBAI – UAE
wire. The spindle dimention shall be as per DEWA requirement. A sample shall be
submitted with tender.
3.31 PUSHFIT CONNECTOR

Connectors shall be of the mechanical “Push-Fit” type with the body manufactured
from Hoechst Hostaform T1020 black acetal terpolymer/polypropylene. The grip
ring will be manufactured from Hoechst Hostaform C13031 acetal copolymer and
the sealing ring from EPDM rubber. The connectors will be designed to work to a
pressure of 18 bar without leaking and at temperatures up to 50 C. A sample
shall be submitted with tender.
3.32 GUNMETAL PUSHFIT ADAPTOR

Gunmetal adaptors for polyethylene pipe shall be of the mechanical “Push-Fit” type
having a gunmetal body to BS 1400: LG2, EPDM rubber ring, ‘O’ ring and a grip ring
of Hoechst Hostaform C13031 acetal copolymer or equivalent. The adaptor will be
designed to work to a pressure of 18 bar without leaking and at temperatures up to
50 C. It shall be in single piece and two parts construction is not acceptable. A
sample shall be submitted with tender.
3.33 WARNING TAPE

Warning tape for house connection shall be manufactured from high grade
polythene pigmented in bright blue, having a thickness not less than 0.1 mm
gauge and a width not less than 150 mm in 250 meter long rolls. The following
warning massage in Arabic and English shall be printed continuously and
longitudinally in a contrasting black colour in characters not less than 20 mm high
specially protected against deterioration and fading:
DUBAI ELECTRICITY AND WATER AUTHORITY

CAUTION
WATER PIPELINE BELOW
* The tape shall be supplied on stout reels suitably crated

* Sample piece of warning tape shall be submitted with the Tender for approval
3.34 BRASS NOZZLE WITH NUT AND WASHER
The brass nozzle with nut and washer shall be suitable for 1/2” (15 mm) dia Kent
meter model no. PSM 15-134 with BSP threaded. The item shall be as per sample
which can be collected from DEWA. The proposed sample by tenderer shall be
submitted along with the tender.
3.35 HANDLING AND TRANSPORT OF PIPELINE MATERIALS
The supplier’s arrangement for handling, lifting, transporting and stacking pipes,
fittings and valves etc. shall ensure that these articles are delivered at store in
undamaged and good condition.

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DUBAI – UAE
Crane and other appliances approved for use by DEWA shall be provided wherever it
is necessary to lift or lower pipes, fittings and valves. Such articles shall not be
dropped and the suppliers shall provide the facilities and supervision necessary to
ensure that the ends of pipes prepared for jointing and coating of valves are not
damaged or distorted in transit or storage.
For transport A.C. pipes and joints, refer A.C. pipes specification. Pipe fittings and
specials shall be supported by sandbags or other padding and lashed down as
described above so that they are not damaged during transport.
3.36 STORAGE OF PIPES AND APPURTENANCES
The suppliers shall properly unload and stack the pipes in the storage area and
stacks shall be laid out a regular pattern as described by DEWA at no extra cost.
3.37 INSPECTION AND TESTING DURING MANUFACTURING/ ON

FINISHED PRODUCT
The Engineer shall be entitled during manufacturing to inspect, examine and test
on the factory the materials and workmanship of all materials to be supplied under
the contract, and if part of the materials are being manufactured on the other
factory, the Tenderer shall obtain permission for the Engineer to inspect, examine
and test. Such inspection, examination or testing does not release the
tenderer/supplier from any obligation under the contract. Facilities shall also be
provided to the Engineer to carry out inspection of materials and equipment’s prior
to dispatch and the suitability of packing methods and packing materials.
The Tenderer shall give the notice for inspection in writing 21 days in advance for
overseas manufacturers and 14 days for local manufacturers and information for
the date and the place at which any material / equipment will be ready for testing.
The tenderer shall collect ‘Inspection Application Form’ from concerned DEWA
Engineer. The form duly filled shall be submitted to DEWA with covering letter
addressed to Manager, Inspection and Expediting Department. The Engineer shall
attend at the place so named. The Engineer shall give the tenderer/supplier 48
hours’ notice in writing of his intention to attend the tests.
Where the Tenderer provides witnessing of tests at the factory / laboratory, he will
provide assistance, labour, materials, electricity, fuel, stores, apparatus and
instruments etc. as may be requisite and as may be demanded to carry out such
tests efficiently.
As and when any material / equipment shall have passed the tests referred to in
this clause, the Tenderer shall furnish to the Engineer a certificate in writing to that
effect. The Tenderer shall furnish to the Engineer for his approval two copies of
the relevant test data in respect of the tests carried out.

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All above said work shall be carried out at no extra cost.
SECTION 4
CONCRETE AND REINFORCING BARS
4.01 SCOPE
Concrete below the ground level shall be composed of sulphate resisting cement,
fine aggregate, coarse aggregate and water, proportioned and mixed as described
in these specifications. Concrete works in the road corridor shall be executed
strictly in accordance to the following specifications.
4.02 MATERIALS
4.02.1 General
Aggregates for concrete shall consist of naturally occurring materials, from sources
approved by the Engineer, complying with the requirements for fine and coarse
aggregates of BS 882 and as specified herein. Approval of aggregates will not
preclude subsequent rejection if results of subsequent tests indicate non-compliance
with the specified requirements.
4.02.2 Fine Aggregate
The grading of fine aggregate shall be within the limits of Table (5) BS 882.
The amount of deleterious material shall not exceed the following limits when
determined by the ASTM Standard tests stated below:
Clay lumps 1% by weight ASTM C142

Coal, lignite & shell 0.5% by weight ASTM C123
Effect of organic impurities shall be less than 10 percent when tested in
accordance with ASTM C40 and C87.
The maximum quantity of acid soluble chlorides (Cl) shall not exceed 0.06 percent
by weight of fine aggregate when tested in accordance with BS 812 and the
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maximum quantity of acid soluble sulphates (SO3) shall not exceed 0.3 percent by
weight of fine aggregate when tested in accordance with BS 1881.
When fine aggregate is subjected to five cycles of the Sodium or Magnesium
Sulphate Soundness Test, ASTM C88, the loss shall not exceed 10 percent by
weight.
Fine aggregate shall be of such uniformity that the fineness modulus as defined in
AASHTO M6 or (ASTM C125) shall not vary more than 0.20 either way from the
fineness modulus of the representative samples used in the mix design.
The sand equivalent for fine aggregate (AASHTO T176) shall be a minimum of 70.
The water absorption of fine aggregates (ASTM C128) or (AASHTO T84) shall not
exceed 2 percent.
4.02.3 Coarse Aggregate
Coarse aggregate shall be prepared as single size aggregates and blended to

produce normal size grading. The combined grading of coarse aggregate shall be
within the limits given in Table (4) of BS 882 for nominal size of graded aggregate
20 mm to 5 mm.
The proportion of soft and friable particles in coarse aggregate shall not exceed 3
percent when tested in accordance with ASTM C 142. The maximum quantity of acid
soluble chlorides (Cl) shall not exceed 0.02 percent by weight of coarse aggregate.
The maximum quantity of acid soluble sulphates (SO3) shall not exceed 0.3 percent
by weight of coarse aggregate.
When coarse aggregate is subjected to five cycles of the Sodium or Magnesium

Sulphate Soundness Test, ASTM C88, the average weight loss shall not exceed
12 percent when Magnesium Sulphate is used and 10 percent when Sodium
Sulphate is used.
The 10 percent fineness values of coarse aggregate determined in accordance

with BS 812 shall not be less than 75 KN. The flakiness index and elongation
indices of coarse aggregate determined by the sieve method described in BS 812
shall not exceed 30, except that for aggregates used in Class E concrete no limit
shall apply. The abrasion loss when tested in accordance with ASTM C131 shall
not exceed 25 percent.
The water absorption of coarse aggregate (ASTM C127) shall not exceed 2
percent.
4.02.4 Combined Aggregate
For the combined fine and coarse aggregates, the quantities of acid soluble salts
shall not exceed the following:
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Chlorides (Cl) - Max. 0.3% by weight of cement.
Sulphates (SO3) - Max. 4% by weight of cement

(Including the sulphate ion
In the cement).
4.02.5 Cement
Ordinary Portland cement and rapid-hardening Portland cement shall comply with
the requirements of BS 12 or ASTM C150 Type II.
Sulphate Resisting Portland Cement shall comply with the requirements of BS

4027 or ASTM C 150 type V.
Super sulphated Cement shall comply with the requirements of BS 4248 or ASTM C
150 type V.
White or coloured Portland cement shall comply with the physical requirements of
BS 12 and pigments shall be inorganic oxide pigments, either natural or synthetic
in origin, complying with the requirements of BS 1012 and BS 1014. Pigments
whether added just before mixing or by the cement manufacturer shall be
incorporated in the proportions agreed by the Engineer.
Each consignment of cement shall be kept separate, identified and used in order of
delivery.
Any consignment not used within six months from the date of manufacture will not
The source of supply of cement shall be subject to the Engineer's approval and
the Contractor shall at all times furnish the manufacturer's certificates and proof
that the required specification has been compiled with, together with a note of the
date of manufacture, certified by an independent agency in the country of origin.
The Engineer shall have the power to reject a part or the whole of any
consignment of cement if he considers it to be unsuitable for use in the works.
The chemical composition of the cement shall comply with the standards as
stipulated above and in addition with the following requirements:
1. Tricalcium aluminate (C3A) content shall be within the range 4 to 12
percent.
2. The total lime (CaO) content shall not exceed 70 percent unless agreed
otherwise by the Engineer.
One brand as approved by the Engineer shall be used throughout the works
unless otherwise authorized by the Engineer in writing.

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4.02.6 Water
Water for concrete, mortar and curing shall comply with BS 3148.
All water used in concrete & mortar shall be clear, fresh water free from oil, acids,
alkali, sugar, vegetable substances, or any other contaminating agent.
If required by the Engineer, Contractor shall provide water quality test results.
Comparison shall be made by means of standard cement test for soundness, time
of setting and mortar strength. Any indication of unsoundness, change in time of
setting of plus or minus 30 minutes or more, a decrease of more than 10 percent
in strength from results obtained with mixtures containing potable water shall be
sufficient cause for rejection of the water being tested.
Non-potable water shall not be used in concrete unless written approval to do so

is granted by the Engineer. In general, the following provisions shall have to be
satisfied.
A. Selection of concrete proportions shall be based on concrete trial mixes

using water from the same source.
B. Mortar test cubes made with the non-potable mixing water shall have 7
days and 28 days strength equal to at least ninety percent (90%) of
strength of similar specimens made with potable water. Strength test
comparison shall be made on mortars, identical except for the mixing
water, prepared and tested in accordance with "Test Method for
Compressive Strength of Hydraulic Cement Mortars (Using 2-inch or 50mm
Cube Specimens)" (ASTM C109).
4.03 CONCRETE GROUT MIX

The concrete grout mix design is to be applied in steel sleeve installed to protect
pipe. Mix design shall be C 400 SRC.
Mix Design for volume of 1 cum of concrete:
Water / cement ratio - 0.60 to 0.70
Cement / Sand / Aggregate ratio in Kg / cum – 1 / 1 / 3
Estimated Density of Concrete – 2270 kg/cum
Yield – 1 cum
Slump – Collapse
Cement – Sulphate Resisting
Water – Drinking
Max. Aggregate size – 5mm
The above data can be modified as per recommendation of manufacturer and
DEWA approval
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Moisture content of aggregate is to be monitored and necessary correction is to

be applied whenever required. Admixture and additives dosage shall be as per
manufacturer’s specification.
4.04 CONCRETE MIX DESIGN
1. Mixes for the classes of concrete shown in Table 4.1 shall be designed by
the Contractor. The class of concrete is denoted by the minimum 28-day works
cube strength and the maximum size of aggregate. For buried concrete the
minimum cement content shall be as described in the Contract.
2. The content of sulphate resisting cement in any mix shall not exceed 540
kg. Per cubic metre for concrete used in ordinary structures and not to exceed 400
kg per cubic metre for water retaining structures and prestressed concrete. The
quantity of water used shall not exceed that require to produce a concrete with
sufficient workability to be placed and compacted in the required location.
TABLE 4.1 - DESIGNED MIXES
Minimum Minimum 28-day Strength

Sulphate Trial Mix Works
Class Resisting Test Test
N/sq mm/mm Cement Content N/sq mm. N/sq mm.
30/20 .....315 40.0 30.0

25/20 .....310 35.0 25.0
20/20 .....305 30.0 20.0
Nominal maximum size of coarse aggregate shall be not larger than:
a. 1/5 (one fifth) the narrowest dimensions between sides of forms, nor
b. 1/3 (one third) the depth of slabs, nor
c. 3/4 (three quarters) the minimum clear spacing between individual
reinforcing bars or wires, bundles of bars.
These limitations may be waived if, in the judgement of the Engineer workability and
method of consolidation are such that concrete can be placed without honeycombing
or voids.
4.05 TRIAL MIXES
1. No structural concrete shall be placed in the works until the relevant mix
has been approved by the Engineer.

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2. The Contractor shall, at least 35 days before the commencement of

concreting, have trial mixes prepared and tested in a laboratory to be
3. When the mix has been approved, no variations shall be made in the
proportions, the original source of the cement and aggregates, or in the
type, size and grading zone of the latter without the consent of the
Engineer who may require further tests to be made.
4. The Engineer may also require field trials to be made on the site by filling
trial moulds to confirm the suitability of the mix for the works. In these
tests, the type of plant used for mixing, the method of compaction used,
and the formwork face to the mould shall be similar in all respects to those
intended for use in the works.
5. When the Contractor intends to purchase factory made precast concrete

units, the Engineer may dispense with trial mixes and laboratory tests,
provided that evidence is given which satisfies him that the factory regularly
produces concrete, which complies with the Specification. The evidence
shall include details of mix proportions, water cement ratio, workability and
strengths obtained at 7 and 28 days.
4.06 LIMITATION OF WATER / CEMENT RATIO
Except for Class E concrete, no concrete which is required to be in contact with

the ground or which is to be surrounded by earth or fill material or which is to be
continually submerged in water shall have a water/cement ratio by weight in
excess of 0.45. The quantity of water used in mixing shall be the least amount
that will produce a workable homogeneous plastic mixture, which can be worked
into the forms and around the reinforcement. In no circumstances shall the
consistency of the concrete be such as to permit a separation of the aggregate
from the mortar during handling. Excess water shall not be permitted and any
batch containing such excess will be rejected.
In measuring water for each batch of concrete, allowance shall be made for the
water contained in the aggregates. The total water in the batch shall be deemed
to consist of the water carried by the aggregates plus the water added.
Frequent tests including the slump and compaction factor tests shall be carried
out to ensure that a consistent water/cement ratio is maintained.
In designing and establishing approved mixes of concrete for any part of the
works the contractor shall take account of the foregoing requirement and he shall
also take account of any other limitations on water/cement ratios which may be
shown in the drawings or expressly stated elsewhere as applying to concrete for
particular parts of the works.

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4.07 WORKABILITY
The workability of each grade of concrete shall be such that satisfactory

compaction can be obtained when the concrete is placed and vibrated in the
works and that it does not segregate when it is handled, transported and
compacted by the methods which the Contractor proposes to use when handling,
transporting and compacting that class of concrete in the works.
For reinforced concrete, the compaction, determined by the method described in

BS 1881 shall not be less than 0.85 nor greater than 0.92.
4.08 ADMIXTURES
Neither admixtures nor cements containing additives shall be used in the works
unless approved in writing by the Engineer.
Chemical admixtures for water reduction and retarding purposes, where their use
is approved by the Engineer shall be of a type approved by the Engineer and shall
conform to the requirements of Type A, Type D, Type F or Type G as specified in
ASTM 494. They shall be used in strict accordance with the manufacturer's
instructions. In order to obtain the Engineer's approval, cube strength and other
tests shall be carried out on trial mixes using the combination of aggregates,
cements and admixtures proposed for use. Further tests shall be carried out if the
brand or type of cement is changed.
The Contractor shall be entirely responsible for the use of any approved
admixtures.
Waterproofing concrete admixture for water retaining structures shall comply with
ASTM C494-81 Type A.
4.09 STORAGE OF MATERIAL
Cement shall be stored in suitable weather-proof buildings in locations approved

by the Engineer. Storage buildings shall have capacity for storage of a sufficient
quantity of cement to allow sampling at least 14 days before the cement is used.
Aggregates shall be stored or stockpiled in such manner that segregation of coarse

and fine particles of each nominal size aggregate will be avoided and also that the
various sizes will not become intermixed before proportioning. Aggregates shall be
stored on hard clean surfaces with not more than 5 percent slope. Each nominal size
of aggregate shall be kept separate at all time. Each heap of aggregate shall be
capable of draining freely. Contamination of the aggregates by the ground and foreign
matter shall be prevented at all times.

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In placing aggregates in storage or in moving them from storage to the weigh

hopper of the batching plant, any method which may cause the segregation,
degradation, or the combining of materials of different gradings which will result in
any size of aggregate at the weigh hopper failing to meet the grading
requirements shall be discontinued. The use of suitable devices to reduce impact
of falling aggregates may be required by the Engineer.
4.10 COMPOSITION OF CONCRETE
4.10.1 Determining the Proportions and Batch Weights

The proportions and batch weights for concrete shall be determined as prescribed
below. The determination shall be made after the materials furnished by the
Contractor have been approved.
The Contractor shall determine the proportions on the basis of trial mixes
conducted with the materials to be used in the work and shall submit these
proportions together with all test results for approval by the Engineer.
The proportions shall be such as to produce concrete of the cement content

specified for each class of mix, within a tolerance of plus or minus 2 percent.
If the materials furnished by the Contractor are of such a nature that a workable
mix cannot be obtained without exceeding the permissible water content, thereby
requiring additional cement above that specified, then the Contractor will bear the
cost of such additional cement without being entitled to any compensation.
If the materials furnished by the Contractor are of such a nature that the specified
strength cannot be obtained without increasing the cement content above the
minimum specified, then the Contractor will bear the cost of such additional
cement without being entitled to any compensation.
Once the mix is determined and approved, the Engineer shall designate the
weights in kilograms of the different components of concrete and these
proportions shall not be changed without his approval.
4.10.2 Adjustment to Proportions
a. Adjustment for Variation in Workability
If it is found impossible to obtain concrete of the desired placeability and

workability with the proportions originally designated by the Engineer, he shall
make such changes in aggregate weights as are necessary, provided that in no
case shall the cement content originally designated be changed except as
provided in subsections c and d, which follow.
b. Adjustment for Variation in Yield

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If the cement content of the concrete, determined by means of the yield test,
AASHTO T121 (ASTM C138) varies more than plus or minus 2 percent from the
designated value in the table in Clause 1403, the proportions shall be adjusted as
may be permitted by the Engineer to maintain a cement content within these
limits. The water content shall in no case exceed the specified amount.
c. Adjustment for Excess Net Water Content
If, when using the designated cement content, it is impossible to produce concrete
having the required consistency without exceeding the maximum allowable net
water content specified in the table, the cement shall be increased as may be
permitted by the Engineer so that neither the maximum water content per bag nor
the limitations of Clause 4.03 on cement content per cubic metre of concrete will
be exceeded.
d. Adjustment for New Materials
No change in the source or character of the materials shall be made without due
notice to the Engineer and no new materials shall be used until the Engineer has
accepted such materials and has approved new mix proportions based on tests
on trial mixes.
4.11 PROPORTIONING
Proportioning shall consist of dividing the aggregates into the specified sizes,
each stored in a separate bin, and combining them with the cement and water as
provided in these Specifications.
At the time of batching, all aggregates shall have been dried or drained sufficiently
to result in a stable moisture content such that no visible separation of water from
aggregate will take place during transportation from the proportioning plant to the
point of mixing. In no event shall the free moisture content of the fine aggregate
at the time of batching exceed 8 percent of its saturated, surface dry weight
(SSD).
Should separate supplies, of aggregate material of the same size group, but of
different moisture content or specific gravity or surface characteristics affecting
workability, be available at the proportioning plant, withdrawals shall be made
from one supply exclusively and the materials therein completely exhausted
before starting upon another.
Bulk cement shall be weighed in an individual hopper and shall be kept separate
from the aggregates until the ingredients are released for discharge. The cement
hopper shall be attached to a separate scale for individual weighing.
When the source of any aggregate is changed, the Contractor shall re-design the
concrete mix and perform trial mixes as required by Clause 4.03 and 4.04 for the
Engineer's approval. The Engineer shall be allowed sufficient time to approve the
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mix and such aggregates shall not be used until the necessary approvals are
given.
For all batches with a volume of one cubic metre or more, the batching equipment
shall conform to one of the following combinations:
A. Separate boxes and separate dial or beam scales for weighing each size of
aggregate.
B. Single box and dial or multiple beam type scales for all aggregates.
C. Single box of separate boxes and automatic weighing mechanism of all

aggregates.
4.12 GENERAL REQUIREMENTS FOR MIXING
All concrete shall be mixed in mechanically operated mixers. All concrete shall be
homogeneous and thoroughly mixed, and there shall be no lumps or evidence of
undispersed cement. Uniformity of concrete mixtures will be determined by
differences in slumps or by variations in the proportions of coarse aggregate.
The difference in slump, determined by comparing slump tests on 2 samples of

mixed concrete from the same batch or truck load, shall not exceed 20 mm.
Variation in the proportion of coarse aggregate will be determined from the results
of tests of 2 samples of mixed concrete from the same batch or truck load and the
difference between the 2 results shall not exceed 3 percent.
The Contractor, at his expense, shall furnish samples of the freshly mixed
concrete and provide satisfactory facilities for obtaining the samples.
4.13 MACHINE MIXING
Concrete mixers may be either of the revolving drum or the revolving blade type.
The mixing drum or blades shall be operated uniformly at the mixing speed
recommended by the manufacturer. The pick-up and throw-over blades of mixers
shall be restored or replaced when any part of section is worn 30 mm or more
below the original height of the manufacturer's design. Mixers and agitators which
have an accumulation of hard concrete or mortar shall not be used.
The temperature of materials as charged into the mixer shall be such that the
temperature of the mixed concrete at the time it is placed in final position does not
exceed 32oC.
The batch shall be so charged into the mixer that some water will enter in advance
of cement and aggregates. All water shall be in the drum by the end of the first
quarter of the specified mixing time.

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Cement shall be batched and charged into the mixer by means that will not result
either in loss of cement due to the effect of wind, or in accumulation of cement on
surfaces of conveyers or hoppers, or in other conditions which reduce or vary the
required quantity of cement in the concrete mixture.
The total elapsed time between the intermingling of damp aggregates and cement
and the start of mixing shall not exceed 30 minutes.
Mixing may be performed at the site of the work but only with the approval of the
Engineer or by ready-mixed methods. When mixed at the site of the work mixing
shall be performed completely at a point not more distant than 350 metres by haul
route from the position of final placement of the concrete. All concrete that is
mixed wholly or partially at a point more distant than 350 metres by haul route
from the position of final placement shall conform to the requirements provided in
Clause 4.14 "Ready-Mixed Concrete".
4.14 ON SITE MIXED CONCRETE
When mixed at the site of the work the mixers used shall be of the paving or
stationary type. The size of batch shall not exceed the rated capacity as
determined by the manufacturer.
4.15 READY-MIXED CONCRETE
Ready mixed concrete shall be mixed and delivered to the site of the work by
means of one of the following combinations of operations:
A. Mixed completely in a stationary mixer and the mixed concrete transported

to the point of delivery in truck agitators or in non-agitating hauling equipment
(known as central-mixed concrete).
B. Mixed partially in a stationary mixer, and the mixing completed in a truck

mixer (known as shrink-mixed concrete).
C. Mixed completely in a truck mixer (known as transit-mixed concrete).

Mixers may be stationary mixers or truck mixers. Agitators may be truck mixers
operating at agitating speed or truck agitators. Each mixer and agitator shall have
attached thereto in a prominent place a metal plate or plates on which is plainly
marked the various uses for which the equipment is designed, the manufacturer's
guaranteed capacity of the drum or container in terms of the volume of mixed
concrete and the speed of rotation of the mixing drum or blades.
Truck mixers shall be equipped with electrically or mechanically actuated

revolution counters by which the number of revolutions of the drum or blades may
readily be verified. The counters shall be of the continuous registering, non-
resettable type, which accurately register the number of revolutions, and shall be

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mounted on the truck mixer so that the Engineer may safely and conveniently
inspect them from alongside the truck.
Truck mixers shall be loaded not to exceed the manufacturer's guaranteed

capacity. They shall combine the ingredients of the concrete into a thoroughly
mixed and uniform mass and discharge the concrete with a satisfactory degree of
uniformity conforming to the requirements in Clause 4.11 "General Requirements
for Mixing".
When shrink-mixed concrete is furnished, concrete that has been partially mixed
at a central plant shall be transferred to a truck mixer and all requirements for
transit-mixed concrete shall apply. No credit in the number of revolutions at
mixing shall be allowed for partial mixing in a central plant.
4.16 TRANSPORTING MIXED CONCRETE
Mixed concrete may be transported to the delivery point in truck gitators or truck
mixers operating at the speed designated by the manufacturer of the equipment
as agitating speed, or in non-agitating hauling equipment, provided the
consistency and workability of the mixed concrete upon discharge at the delivery
point is suitable for adequate placement and consolidation in place, and provided
the mixed concrete after hauling to the delivery point conforms to the
requirements in Clause 4.11 "General Requirements for Mixing".
Truck agitators shall be loaded not to exceed the manufacturer's guaranteed

capacity. They shall maintain the mixed concrete in a thoroughly mixed and
uniform mass during hauling.
Bodies of non-agitating hauling equipment shall be so constructed that leakage of

the concrete mix, or any part thereof, will not occur at any time, and they shall be
self-cleaning during discharge.
No additional mixing water shall be incorporated into the concrete during hauling
or after arrival at the delivery point, unless ordered by the Engineer. If the
Engineer orders additional water to be incorporated into the concrete, the drum
shall be revolved not less than 30 revolutions at mixing speed after the water is
added and before discharge is commenced.
The rate of discharge of mixed concrete from truck mixer agitators shall be
controlled by the speed of rotation of the drum in the discharge direction with the
discharge gate fully open.
When a truck mixer or agitator is used for transporting concrete to the delivery
point, discharge shall be completed within 1-1 1/2 hours, or before 250 revolutions
of the drum or blades, whichever comes first, after the introduction of the cement
to the aggregates. Under conditions contributing to rapid setting of the concrete,

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or when the temperature of the concrete is 30oC or above, a time less than one
hour will be required for the delivery.
When non-agitating hauling equipment is used for transporting concrete to the

delivery point, discharge shall be completed within one hour after the addition of
the cement to the aggregates. Under conditions contributing to rapid setting of the
concrete, or when the temperature of the concrete is 30 oC. Or above, the time
between the introduction of cement to the aggregates and discharge shall not
exceed 45 minutes.
Each batch of ready-mixed concrete delivered at the job site shall be

accompanied by a ticket showing volume of concrete, the weight of cement in kgs
and the total weight of all ingredients in kgs, unless otherwise ordered by the
Engineer. The ticket shall also show the time of day at which the materials were
batched and for transit-mixed concrete, the reading of the revolution counter at the
time the truck mixer is charged.
4.17 TIME OR AMOUNT OF MIXING
Mixing of concrete in stationary mixers shall continue for the required mixing time
after all ingredients, except water and admixture if added with the water, are in the
mixing compartment of the mixer before any part of the batch is released. Transfer
time in multiple drum mixers shall be counted as part of the required mixing time.
The required mixing time in stationary mixers for concrete used for concrete
structures, shall be not less than 90 seconds nor more than 5 minutes.
When transit-mixed concrete is furnished, each batch of concrete shall be mixed

for not less than 70, nor more than 100, revolutions of the drum or blades at the
rate of rotation designated by the manufacturer of the equipment on the metal
plate on the truck mixer as mixing speed. Additional mixing, if any, shall be at the
speed designated by the manufacturer of the equipment as agitating speed. All
materials, including mixing water, shall be in the mixer drum before starting the
count of the number of revolutions of mixing.
4.18 AMOUNT OF WATER AND SLUMP TEST
The amount of water used in concrete mixtures shall not exceed the minimum
amount necessary to produce suitable concrete according to the approved mix
design and within the limitations stipulated in Clause 4.05.
The amount of water added at the mixer shall be regulated in accordance with the
free water in the aggregates. Free water is defined as the total water surface-dry
conditions.
The amount of water used in the mixture shall be the amount required to produce
concrete with a slump within the range shown as nominal slump in the following
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table. When the slump of the concrete is found to exceed the nominal slump, the
mixture shall be adjusted as directed by the Engineer to reduce the slump to a
value within the nominal range shown.
Nominal Slump Maximum Slump

Type of Work (mm) (mm)
Non-reinforced concrete 60-75 80
Reinforced concrete struc-

Tures, foundations, footings 60-75 90
Reinforced concrete walls,

Slabs, columns 65-80 100
Precast concrete elements 40-60 75
The equipment for supplying water to the mixer shall be so constructed and
arranged that the amount of water added can be accurately measured. Any
method of discharging water into the mixer for any batch shall be accurate within
one percent of the required quantity of water to be added to the mix for any
position of the mixer. All equipment shall be arranged so as to permit checking
the amount of water delivered by discharging into measured containers.
Water tanks used to supply water to the mixer shall receive water by gravity from
intermediate tanks having vents open to the air. Tanks shall be designed so that
water cannot enter the tank while water is being discharged into the mixer and
discharge shall be made rapidly in one operation without dribbling.
4.19 DELIVERY
The organization or facility supplying concrete shall have sufficient plant capacity
and transporting apparatus to ensure continuous delivery at the rate required. The
rate of delivery of concrete during concreting operations shall be such as to
provide for the proper handling, placing and finishing of the concrete. The rate
shall be such that the interval between batches shall not exceed 15 minutes. The
methods of delivering and handling the concrete shall be such as will facilitate
placing with the minimum of rehandling and without damage to the structure or the
concrete.
4.20 CONCRETING IN HOT WEATHER
When the ambient temperature reaches 35 oC, the concreting operation shall be
discontinued unless the Contractor has the adequate means of cooling the
ingredients and keeping the temperature of mixed concrete below 30 oC. However

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the concreting shall be discontinued if the atmospheric temperature is more than

44o C
In any event, the surface of freshly placed concrete shall be shaded from the
direct rays of the sun and protected against drying by covering it with wet hessian
cloth or burlaps and where practical, continuous water curing shall be applied
during the first few hours after placement.
4.21 QUALITY CONTROL OF CONCRETE
4.21.1 Sampling and Testing
The Contractor shall sample and carry out a mechanical analysis of the fine
aggregate and each nominal size of coarse aggregate in use employing methods
described in BS 1881 at least once in each week when concreting is in progress
and at such more frequent intervals as the Engineer may require. The grading of
all aggregates shall be within the respective limits specified in Clause 4.02 and
should the fraction of aggregate retained on any sieve differ from the
corresponding fraction of aggregate the Engineer may instruct the Contractor to
alter the relative proportions of the aggregates in the mix to allow for such
difference.
The Contractor shall provide the equipment necessary to determine the

compacting factor of freshly-mixed concrete at each place where concrete is being
made and shall determine the compacting factor of the freshly mixed concrete by
the method described in BS 1881 on each occasion that a set of test cubes is
made and not less than once a day or as the Engineer may direct.
For each grade of concrete a set of nine works test cubes shall be made or
additional as the Engineer may require and not less frequently than as follows:
For concrete grade 30,25 one set of cubes per 20

Or 20 cubic metres or part
thereof, concreted per day.
The cubes shall be numbered consecutively and marked with the date, section of
work from which they are taken and any other relevant information and dispatched
to the approved laboratory for testing. Three cubes shall be tested after seven
days.
If the average of the three, seven day test cubes is below the minimum
requirement, the Contractor must immediately stop all concreting until checks are
made on the material and equipment and immediately rectify any defect which has
become apparent as the result of such checking. If the Contractor elects to
remove and replace the defective concrete without waiting for the results of the
twenty-eight day test, concreting can then continue entirely at the responsibility of
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the Contractor. The six remaining cubes will be considered as three individual
sets and after twenty eight days of curing shall be tested as specified above. If
either of the cubes in any set shows definite evidence, other than low strength, of
improper sampling, molding, handling, curing or testing. It shall be discarded and
the strength of the remaining cube shall then be considered the test result for that
set.
Final acceptance of the concrete works is based on twenty-eight day testing on

the three sets of two cubes each. The work is considered in compliance if the
average of the three sets of cubes equals or exceeds the minimum specified for
the class of concrete being placed, and if the average of the two cubes in any one
set does not fall below 85 percent of the specified works test characteristic
strengths. If the results of the twenty-eight day testing is unsatisfactory, the
Contractor, in accordance with the instructions of the Engineer, shall conduct tests
in the suspect parts of the structure.
As and where directed by the Engineer cylindrical core specimens of 150 mm

nominal diameter shall be cut perpendicular to the face of the hardened concrete
in the works for the purpose of examination and testing. The procedure for
drilling, examination, measurement and testing for compressive strength shall be
in accordance with BS 1881. Prior to preparation for testing, specimen shall be
made available for examination by the Engineer. If the crushing strength of the
specimen in accordance with paragraph 114 of BS 1881 is less than the minimum
crushing strength given in Table 5.1 or if, in the opinion of the Engineer, the
concrete fails to meet the specified requirements in other respects, the concrete in
that part of the work of which it is a sample will be considered not to comply with
the specified requirements.
4.21.2 Failure to Pass Tests
If the specified values are not obtained for cube tests on any concrete mix, no
further concrete of that mix shall be placed in the works and the Contractor shall
establish the cause of the failure and apply such remedies as are necessary. The
Contractor shall demonstrate by trial mixes and the results of cube tests that the
revised mix is in accordance with the Specification.
4.22 FORMWORK
The forms shall be smooth, mortartight, true to the required lines and grade and of
sufficient strength to resist springing out of shape during the placing of the
concrete.
Dimensional tolerances shall be according to the ACI 347-78 “Recommended

Practice for Concrete Formwork".

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All dirt, chips, sawdust, nails, and other foreign materials shall be completely
removed from forms before any concrete deposited therein. Forms previously
used shall be thoroughly cleaned of all dirt, mortar and foreign material before
being reused. Before concrete is placed in forms, all inside surfaces of the forms
shall be thoroughly coated with commercial quality form oil or other equivalent
coating which will permit the ready release of the forms and will not discolour the
concrete. Forms may be removed at the convenience of the Contractor and with
the prior approval of the Engineer after the concrete has hardened. The concrete
surfaces exposed by removing forms shall be protected from damage.
Forms for all surfaces which will not be completely enclosed or hidden below the
permanent surface of the ground, or for surfaced where plywood forms are not
specified, shall be made of surfaced lumber or material which will provide a
surface at least equally satisfactory. Any lumber or material which becomes
warped or cracked prior to placing of the concrete will be rejected.
All exposed sharp edges shall be chamfered with triangular fillets not less than 50
mm by 50 mm, to prevent mortar runs and to preserve smooth, straight lines,
unless otherwise directed by the Engineer, the triangular fillets or chamfer strips
shall be milled from clear, straight grain lumber and shall be surfaced on all sides.
Forms shall be of sufficient strength to support the weight of the fresh concrete,
based on a weight of 2400 kg/cu.m. With a maximum deflection of 5 mm.
Form clamps or bolts shall be used to fasten forms. The use of ties consisting of
twisted wire loops to hold forms in position during the placing of concrete will not
be permitted.
Bolts or form clamps shall be positive in action and shall be of sufficient strength
and number to prevent spreading of the forms. They shall be of such type that
they can be entirely removed or cutback 25 mm or more below the finished
surface of the concrete leaving no metal within 25 mm of the concrete surface and
without the need to cut or chase the finished surface of the concrete to remove
them. All necessary foot bridges at least 3 ft. wide and inspection platforms
around.
Forms shall be complete and inspected by the Engineer before the placing of
concrete therein will be permitted. The area to be concreted shall be separately
prepared and supported.
4.23 PLACING CONCRETE
All concrete shall be used while fresh and before it has taken an initial set. Re-
tampering of partially hardened concrete with additional water will not be
permitted. A surface on which concrete is to be placed shall be thoroughly
moistened with water immediately before placing concrete.
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Mixed concrete, after being deposited, shall be consolidated until all voids are
filled and free mortar just appears on the surface. The concrete shall be placed
as nearly as possible in its final position and the use of vibrators for shifting of the
mass of fresh concrete will not be permitted. Fresh concrete shall not be
permitted to fall from a height greater than 2 metres without the use of adjustable
length pipes of "elephant trunks", double belting may be used in lieu of adjustable
pipes or "elephant trunks".
All concrete shall be compacted by means of high frequency internal vibrators

within 15 minutes after it is deposited in the forms. The vibrators shall not be
attached to or held against the forms or the reinforcing steel. The location,
manner and duration of the application of the vibrators shall be such as to secure
maximum consolidation of the concrete without causing segregation of the mortar
and coarse aggregate, and without causing water to flush to the surface. Fresh
concrete shall be spread in horizontal layers in so far as practicable and the
thickness of the layers shall not be greater than can be satisfactorily consolidated
with the vibrators. If additional concrete is to be placed, care shall be taken to
remove all laitance and to roughen the surfaces of the concrete to ensure that
fresh concrete is deposited upon sound concrete surfaces. Layers of concrete
shall not be tapered off in wedge-shaped slopes, but shall be placed with square
ends and level tops.
The use of chutes in conveying or depositing concrete will be allowed only with
the discretion of the Engineer and wherever they are used they shall be laid at
such inclination as will permit the flow of concrete of such consistency as is
required. The use of additional water in mixing the concrete to promote free flow
in chutes of low inclination will not be allowed. Chutes shall be provided with baffle
boards or a reversed section at the outlet to prevent segregation.
Joints in the concrete due to stopping work shall be avoided as far as possible.
Such joints, when necessary, shall be constructed as directed by the Engineer.
4.24 CONSTRUCTION JOINTS
Construction joints shall be made only where located on the plans, shown in the
placing schedule and/or as approved by the Engineer.
Construction joints shall be made without keys, except when keys are shown on
the plans.
After placing of concrete has been completed to the construction joint and before
placing fresh concrete, the entire surface of horizontal construction joints shall be
thoroughly cleaned of surface laitance, curing compound and other materials
foreign to the concrete, and clean coarse aggregate exposed. Hardened concrete
surfaces shall be cleaned by abrasive blast methods after the curing period or
immediately before placing concrete at the joint. Surfaces of fresh concrete
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(concrete that has been in place not more than 8 hours) may be cleaned with air
and water jets provided surface laitance is removed and clean coarse aggregate
exposed.
Surfaces of horizontal construction joints, where expansion joint filler or bond

breaking compound is to be placed, shall be cleaned of dirt, sawdust, and other
loose materials.
A surface on which concrete is to be placed shall be thoroughly moistened with

water immediately before placing concrete. Moistening with cement grout will not
be permitted.
4.25 CURING CONCRETE-WATER METHOD
All newly placed concrete shall be cured in accordance with the following
provisions.
The concrete shall be kept continuously wet by the application of water for a
minimum period of 7 days after the concrete has been placed. Cotton mats, rugs,
carpets or sand blankets may be used as a curing medium to retain the moisture,
during the curing period. The cotton mats, rugs or carpets shall be of such
character that they will retain water but not prevent evaporation. When cotton
mats, rugs, carpets or sand blankets are to be used to retain the moisture, the
entire surface of the concrete shall be kept damp by applying water with a nozzle
that so atomizes the flow that a mist and not a spray is formed, until the surface
of the concrete is covered with the curing medium.
The moisture from the nozzle shall not be applied under pressure directly upon
the concrete and shall not be allowed to accumulate on the concrete in a quantity
sufficient to cause a flow or ash the surface. At the expiration of the curing period,
the concrete surfaces shall be cleared of all curing mediums.
When concrete flat slabs are to be cured without the use of a Moisture retaining
medium, the entire surface of the slab shall be kept damp by the application of
water with an atomizing nozzle as specified in the preceding paragraph, until the
concrete has set, after which the entire surface of the concrete shall be sprinkled
continuously with water for a period of not less than 7 days.
Timber formwork covering the concrete shall be moistened with water at frequent
intervals to keep it from drying during the curing period. Metal formwork exposed
to the sun must be shaded from its direct rays, painted white or otherwise
protected during the curing period. When forms are removed before the end of the
seven day curing period, specified curing procedures shall be implemented by the
Contractor and continued until the end of the seven day period specified.
4.26 CURING CONCRETE-MEMBRANE METHOD

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The entire surface of the concrete shall be sprayed uniformly with a non-staining
pigmented curing compound immediately after stripping the formwork. Should the
film of compound be damaged from any cause before the expiration of 7 days
after the concrete is placed, the damaged portions shall be repaired immediately
with additional compound.
Surface of newly placed concrete to be cured by the pigmented curing compound

method shall be kept moist or wet until the curing compound is applied, and the
curing compound shall not be applied until all patching or surface finishing have
been completed.
Pigmented curing compound shall conform to the specifications of AASHTO

designation M148, type II, white pigmented or ASTM C309 of the U.S. Federal
Specifications TT-C-800. The curing compound shall be delivered to the work in
ready-mixed form. At the time of use, the compound shall be in a thoroughly
mixed condition with the pigment uniformly dispersed throughout the vehicle. The
compound shall not be diluted or altered in any manner. Curing compound that
has become chilled to such an extent that it is too viscous for satisfactory
application shall be warmed to a temperature not exceeding 30 oC. The curing
compound shall be applied to the exposed surface at a uniform rate of one litter
per 3 square metre area. In the event that the application of curing compound is
delayed, the application of water as provided in Clause 5.24, "Curing Concrete-
Water Method", shall be started immediately and shall be continued until
application of the compound is resumed or started.
4.27 PROTECTION OF CONCRETE
Concrete placed below the ground shall be protected from falling earth during and
after placing. Concrete placed in ground containing deleterious substances shall
be kept free from contact with such ground and with water draining therefrom
during placing and for a period of three days or as otherwise instructed thereafter.
The groundwater around a structure below the ground shall be kept to an
approved level by pumping, or the works shall be flooded, or other approved
means taken to prevent damage. Approved means shall be taken to protect
immature concrete from damage by debris, excessive loading, vibration, abrasion
deleterious ground-water mixing with earth or other materials, floatation and other.
4.28 CONCRETE BLOCK WORK
4.28.1 Concrete Blocks
Concrete blocks shall be hard, durable, sound, clean, well defined edges and free
from cracks, flaws or other defects. They shall comply with the requirements listed
herein.
Table of requirements for concrete blocks

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Requirements Values
1. Dimensions
A. Height, cm. 20 cm. + 1%

B. Length, cm. 40 cm. + 1%
C. Width, cm. 20 cm. + 1%
2. Compressive Strength at 28 days:
For load-bearing walls:
I Average of 12 blocks, N/sq.mm > 12.5 N/sq.mm

II. Minimum for any one block N/sq.mm > 10.0 N/sq.mm
3. Water Absorption
Maximum % of dry weight 14%
Sampling and testing of concrete blocks shall be in accordance with ASTM C140.
4.28.2 Mortar
All mortar shall consist of one part masonry cement to three parts loose sand
complying with the following requirements.
A. Sand complying with ASTM C144, grading and colouring suitable for type
of masonry and as approved by the Engineer.
B. Sulphate Resisting Portland cement shall comply with the requirements of

BS 4027 or ASTM C150 type V.
C. Water Complying with water for Concrete Mixes and curing, of the
Specifications Clause 4.02.6.
4.29 REINFORCING
4.29.1 General
Reinforcing shall include plain the deformed bars, welded mesh and tie wire for
precast and cast-in-situ concrete and masonry.
4.29.2 Submittals

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The Contractor shall submit the following at least two weeks in advance of
fabrication:
A. Shop Drawings. Before ordering reinforcing steel, the Contractor shall

submit bar bending schedules for reinforcing steel prepared in accordance with
BS 4466 showing layouts, bending diagrams, assembly diagrams, dimensioned
types and locations of all bar laps and splice and shapes, dimensions, and details
of bar reinforcing and accessories. Layout plans for bar supports and chairs, with
typical details shall be included. Engineer's review and approval of shop drawings
will apply to the sizes, locations and types of bars, and dimensions of bar splices
only. Dimensions shown on the shop drawings are the responsibility of the
Contractor and Engineer's approval of shop drawings shall not constitute approval
of dimensions thereon.
B. Samples. Representative samples of all reinforcing steel that the

Contractor proposes to use in the works must be submitted, before work is
commenced, to the Engineer for his written approval, together with manufacturer's
certificates stating clearly for each sample the place of manufacture, expected
date and size of deliveries to site, and all relevant details composition,
manufacture, strengths and other qualities of the steel. In the event a reinforcing
steel sample under test fails to meet the specification requirements at any time, or
the Engineer considers that samples which were presented to him for test were
not truly representative, or if it becomes apparent that reinforcing steel which has
not been approved has been used on the works, then the Engineer may instruct
the Contractor to break out and remove completely all such sections of the work
already constructed using such suspect reinforcing steel.
All testing of reinforcing steel bars shall be carried out in accordance with BS 4449
and BS 4482.
4.29.3 Reinforcing Material
A. Reinforcing Bars. Plain and deformed bars shall conform to BS 4449. The
following bar classification and types shall be used unless shown otherwise on the
drawings:
For Use:
GRADE of CONCRETE CLASS of Bar TYPE of Bar
20 U 24 Plain
25 and 30 U 32 Deformed
B. Plain and deformed bars shall conform generally to BS 4449. Plain round
mild steel bars shall be graded 250 and is denoted generally by symbol - R on the
drawing. Deformed high yield bars shall be grade 425 and is denoted by symble -
Y on the drawing.
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The Contractor shall note the necessity of protecting the rebar from contamination
from time of manufacture to placing in the structure. Under no circumstances shall
reinforcing steel be placed directly on the ground. Steel shall be stored on suitable
structures min. of 450 mm above the ground surface. Storage facilities shall be
such as to permit easy access for inspection and identification. Each consignment
of steel reinforcement shall be kept separately and the contractor shall procure
reinforcement in such a way as to minimize storage times on site or in other
locations.
All reinforcing steel will be sand blasted to remove all deleterious materials as
soon as possible before being placed in concrete. If the sand blasting is done in -
situ within 24 hours of placing in -situ of the concrete then the following
requirement for high pressure washing does not apply.
After fabrication and erection and immediately prior to placing of concrete the
reinforcement shall be washed with high pressure potable water jets to thoroughly
clean the rebar of all deleterious material and salts.
All floors, tops of walls etc. and other surfaces which are not to be covered with a
further finish shall be U3 finish. All surfaces on which further finishing screeds or
treatment are to be applied will be U2 finish.
4.29.4 Mesh Reinforcement
Mesh reinforcement shall conform to the specifications of ASTM designation A

185. The gauge of the wire and the dimensions of the mesh will be as shown on
the plans or specified herein.
4.29.5 Black Annealed Reinforcing Wire
Black annealed wire used as reinforcing steel, but not including tie wire, in
structures as shown on the plans, shall be commercial quality black annealed wire
of the gauge designated; the gauge shall be American steel and wire gauge.
Each bundle of steel shall be tagged at the mill with an identifying mill tag,
showing the name of the mill and the melt or heat number. This tag shall be a
metal tag attached with a lead seal and placed in an exposed position for easy
identification by each heat showing physical and chemical analyses, shall be
available to the Engineer at the time of sampling. Two or more samples, each 75
cms long, will be taken at random from each size in each melt or heat. The
Contractor at his expense shall furnish all test samples.
4.29.6 Storage

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The Contractor shall stack separately and label different types of reinforcement for
positive identification.
Steel reinforcing bars shall be kept clean and shall be free from pitting, loose rust
mill scale, oil, grease, earth, paint, or any other material which may impair the
bond between the concrete and the reinforcement.
4.29.7 Bending and Fixing
Bars shall be bent in accordance with the provision of BS 4466. All bending shall
be done cold with the use of an approved bending machine. Re-bending of
incorrectly bent bars shall not be permitted. Bars partially embedded in concrete
shall not be bent.
Reinforcement steel bars shall be handled and stored in a manner to prevent

damage to bars or the epoxy coating. Bars or epoxy coating damaged in handling
or other operations shall be satisfactorily repaired at no additional cost to the
Department. All systems for handling the epoxy-coated bars shall have padded
contact areas wherever possible. All bundling bands shall be padded and all
bundles shall be lifted with a strongback, multiple supports or a platform bridge so
as to prevent bar to bar abrasion from sags in the bar bundle. The bars or bundle
shall not be dropped or dragged. Extra care in handling of these bars shall be
beneficial to the Contractor reducing or eliminating in-place coating repairs.
Before the reinforcement steel bars are lowered into place and prior to placement
of the concrete, the coated bars will be inspected by the Engineer for damage to
the epoxy coating. Sheared ends of bars and other areas requiring limited repair
due to scars and minor defects shall be repaired, using the specified patching or
repair materials.
All reinforcement shall be securely and accurately fixed in positions shown in the
Drawings to ensure that the reinforcement steel framework as a whole shall retain
its shape, and the framework shall be so temporarily supported as to retain its
correct position in the forms during the process of depositing and consolidating
the concrete. The ends of all tying wires shall be turned into the main body of the
concrete and not allowed to project towards the surface.
Splicing, except where indicated on the Drawings or approved shop drawings, will
not be permitted without the approval of the Engineer. Lap lengths shall be as
indicated on the Drawings. Correct concrete cover to reinforcement shall be
maintained with the aid of approved spacer pieces. Spacing blocks shall be used
to ensure accurate cover to the reinforcement steel where necessary, and these
blocks shall be of precast concrete of strength at least equal to that of the
concrete being placed. They shall be as small as practicable and shall be securely
fixed in position by means of wires cast into them. They shall be soaked with
water immediately prior to concreting in. Top reinforcement in slabs shall be
maintained in position by means of chairs made out mild steel, the diameter and
SPECIFICATIONS
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quantity being sufficient to ensure security of the reinforcement in shape and

position. Concrete cover to reinforcement shall be in accordance with Clause
3.11.2 of BS CP8110: Part 1:1985 except for (1) water bearing structures which
shall have a concrete cover of not less than 50 mm on the water-bearing face, (2)
for concrete against the ground or upon blinding concrete which shall have a
minimum cover of 80 mm excluding the thickness of the blinding.
No part of the reinforcement shall be used to support access ways, working

platform, or the placing of equipment or for the conducting of an electric current.
At the time of concreting, all reinforcement steel shall have been thoroughly
cleaned and freed from all loose rust, scale, mud, oil or any other coatings that
might destroy or reduce the bond and it shall also have been cleaned of all set or
partially set concrete which may have been deposited thereon during the placing
of a previous lift of concrete.
Immediately prior to concrete placing the reinforcing steel shall be washed

thoroughly with potable water to remove any deposited salts.
The placing of all reinforcement steel bars will be checked by the Engineer and in
no case is concrete to be placed around any reinforcement steel that has not been
approved by the Engineer. The Engineer will not permit the insertion of bars into
or the removal of bars from concrete already placed. Reinforcement steel
temporarily left projecting from the concrete at the joints shall not be bent without
the prior approval of the Engineer.
All the reinforcements shall be placed straight at the approved spacings. All the
joints of reinforcements shall be tied in accordance with the relevant BS.
4.29.8 Welding of Reinforcing
No welding of reinforcing shall be permitted where it is not specified in the

Drawings.
Reinforcing which is specified to be welded shall be welded by any process, which
the Contractor can demonstrate by bend and tensile tests will ensure that the
strength of the parent metal is not reduced and that the weld possesses strength
not less than that of the parent metal. The welding procedure established by
successful test welds shall be maintained and no departure from this procedure
shall be permitted.
Following the establishment of a satisfactory welding procedure, each welder to

be employed on the works shall carry out welder performance qualification tests
on reinforcing bars of the same metal and size as those on the works. The
requirements of ASME Code Section IX of 1959 shall be observed.
4.29.9 Binding wire for tying of reinforcement.

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Binding wire to be used for tying of reinforcement shall be approved by the

Engineer and shall be complying with the relevant B.S.

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SECTION 5
LININGS AND PROTECTIVE COATINGS FOR CONCRETE
5.01 GENERAL
5.01.1 Scope
This Section deals with waterproofing protective membranes for cast-in-situ

concrete. Other relevant Sections of the Specifications shall form part of this
Section where the context so requires.
5.01.2 Work Included
The work of this Section shall include the supply and installation of protective
coatings on specified surfaces of concrete and concrete block structures to
effectively protect the concrete surface from corrosion resulting from contact with
aggressive groundwater.
5.01.3 Requirements
The Contractor shall furnish all tools, construction equipment, materials, labour
and supervision to provide an effective lining or coating as specified herein.
5.01.4 Product Delivery, Storage and Handling
The Contractor shall deliver products to the job site in their original unopened
containers clearly labeled with the manufacturer's name, brand designation, type
and class as applicable.
The Contractor shall store products in an approved dry area with roll goods laid
flat, one pallet high, and shall protect them from contact with soil and from
exposure to the elements. Products shall be kept dry at all times.
Products shall be handled in a manner that will prevent breakage of containers

and damage to products.
5.02 WATERPROOFING TO CAST-IN-SITU CONCRETE,

PRECAST CONCRETE AND BLOCKWORK
5.02.1 Materials
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a. Waterproof Membrane. Waterproof membrane shall be self-adhering sheet

membrane consisting of a rubber modified asphalt compound, such as Bituthene
1000 manufactured by Servicised Corporation or equal coated to one side of a
polyethylene film. The membrane shall have a minimum overall thickness of 1.5
millimeters and a tensile strength of 140 kilograms per square centimeter and
shall in all respects comply with the requirements of British Standard Code of
Practice 102.
b. Rubberised Mastic Special compound provided by the self-adhering

membrane manufacturer formulated for its intended use.
c. Primer Special compound provided by the self-adhering membrane

manufacturer, formulated for its intended use.
d. Protection Board shall be applied in single or two layers with a total

installation thickness of 12 mm; it shall be bitumen impregnated fiberboard with
treatment to resist fungi and insects, bitumen coated both sides; or alternatively
prefabricated composite board consisting of felt and woven glass fabric saturated
with bitumen coating both sides for a thickness not less than 3.5 mm, and
approved by the membrane manufacturer, subject to approval of the Engineer.
e. Samples. The Contractor shall submit to the Engineer three samples of

each type of the following materials in accordance with the special conditions of
the contract.
- Self-adhering waterproofing membrane sheet:

- 300 mm square.
- Bituminous mastic: half-liter container.
- Primer: half-liter container.
The Contractor shall submit to the Engineer certificates that the materials to be
furnished comply with specification requirements.
5.02.2 Installation
The Contractor shall coordinate the self-adhering waterproofing membrane work

so that the placement of the concrete protection board will follow the
waterproofing membrane application by not more than five days.
All faces of concrete or concrete blockwork below and in contact with, ground
shall be protected with the waterproofing specified herein.
Surfaces to which the waterproofing materials will be applied shall be surface dry,
smooth and free of dirt, grease or oil and shall be free from holes, honeycombing,
loose aggregate which prevent satisfactory application of waterproofing materials.
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All surfaces to be waterproofed shall meet the approval of the Engineer before
application of waterproofing materials.
The Contractor shall apply the membrane sheet with 120-mm overlaps at edges
and ends, rolled down firmly and completely.
The Contractor shall follow the self-adhering membrane manufacturer's approved

written recommendations for specific procedures, details and materials not
specified herein.
If the work must be left partially complete, the exposed edges of outside strips of
membrane shall be finished with a trowelled bead of mastic.
The waterproofing membrane system shall not be applied to vertical surfaces

when the outdoor temperature is less than 10 degrees C or more than 35 degrees
C. If a system has been approved and if the outdoor temperature at the proposed
time of application is not within these limits, application must be delayed until the
permissible temperature range prevails or another system must be submitted for
approval complying with these Specifications.
a. Application of Membrane: When the concrete curing is completed to

Concrete, over the cleaned concrete surface the Contractor shall apply primer in
manner and using quantities in accordance with the membrane manufacturer's
printed instructions. It shall be allowed to dry before proceeding, but re-primed if
not covered with membrane within 36 hours.
After the primer has dried, the Contractor shall apply the self-adhering membrane
to the concrete without stretching, with the polyethylene face out. It shall be
smoothed down with heavy hand pressure or a small roller. Edges and ends shall
be lapped as specified.
The Contractor shall double inside and outside corners by using an initial strip of
300 mm width membrane, centered along the axis of the corner.
This strip shall be covered by the regular application of self-adhering membrane

and the exposed edges of the membrane shall have a trowelled bead of mastic
over these edges.
The membrane shall be applied in two layers over blinding concrete beneath
structures and laps shall be staggered from one layer to the next. Prior to
reinforcement being placed, the membrane shall be covered with two layers of
protection board on vertical faces and with 50 mm thick cement sand screed
supplied by an approved concrete supplier to protect the membrane from damage
during construction. Protection board shall terminate flush with the edges of the
concrete base slab and overlapping with membrane material shall cover edges.
Side wall membrane shall extend down and out to the edge of the previously
applied horizontal slab membrane. Where top of membrane terminates at a reglet,
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DUBAI – UAE
the membrane shall be extended therein and the reglet filled with rubberised
mastic.
Areas around piping and protrusions shall be double covered with an additional
layer of self-adhering membrane for a minimum of 300 mm in each direction. The
membrane edges shall be coated and the gap between the membrane and
protrusions filled with mastic.
b. Installation of Asphalt Protection Board Courses. Within five days after

membrane application, the Contractor shall install asphalt protection board to
vertical and horizontal membrane-on-concrete surfaces. The Contractor shall
install board with polyethylene face out, in two layers and with butted edges and
ends, adhered to the membrane by means of mastic or other approved
compound. Joints in second layer shall be staggered in relation to the joints in the
first layer. Point up with mastic the exposed edges and gaps between
penetrations and edges of the protection board. Protection board on horizontal
slabs shall terminate at the outer corner of the concrete structure above. Sidewall
protection board shall extend down and out to cover the horizontal slab
membrane. Use of tie wires or holing the board shall not be approved for securing
the board. The board has to be glued using approved materials only.

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DUBAI – UAE
SECTION 6
TRANSPORTATION, STORAGE, INSTALLATION
OF PIPES, TESTING & COMMISSIONING
6.01 HANDLING AND TRANSPORT OF PIPELINE MATERIALS
A. The Contractor's arrangements for handling, lifting, transporting and

stacking pipes, valves, meters and fittings, shall ensure that these articles are
installed in the works undamaged and in good order.
Cranes and other appliances approved for use by the Engineer shall be provided
wherever it is necessary to lift or lower pipes, valves, meters and fittings. Such
articles shall not be dropped and the Contractor shall provide the facilities and
supervision necessary to ensure that the ends of pipes prepared for jointing and
coating of fittings are not damaged or distorted in transit or in storage.
B. F.C pipes and joints shall be properly and securely transported from the
place of manufacture to the job site, in accordance with section 3.02.15.
C. Pipe fittings and specials shall be supported by sandbags or other padding

and lashed down as described above so that they are not damaged during
storage.
However Contractor has to note that the use of long boom cranes shall not be
permitted near the Electricity overhead Transmission lines for safety reasons
unless approved by the Engineer.
6.02 STORAGE OF PIPES AND APPURTENANCES
A. The Contractor shall properly stack the pipes in his storage area and the
stacks shall be laid out in a regular pattern and the limits of each stack marked so
that the movement of cranes and vehicles is restricted to access tracks between
stacks and the control of delivery and removal of pipes is facilitated.
B. The number of tiers of asbestos cement pipe stacks shall be as per the
Manufacturer's instructions and approval of the Engineer. Each pipe, including
those in the bottom course, shall bear evenly upon not less than three timbers
with an aggregate width not less than 300 mm. The pipes shall be stacked
parallel to each other. Pipes less than 1000 mm dia. may be stacked on site such
that stacking heights do not exceed the manufacturer's recommendations.

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The timbers supporting each course of pipes in a stack shall be of uniform

thickness and stiff enough for the pipes to be rolled across the stack and shall be
supplied by the Contractor at his own expense.
The outermost pipes in each course shall be secured against rolling by sandbags
or by wedges.
C. Where the pipes are to be delivered and stacked by the Contractor on

designated sites lying on the pipeline route, unless it is otherwise specified
elsewhere, the areas where the pipes are to be stacked shall, if required, be
graded flat by the Contractor at his own expense to provide a firm even surface,
and kept free from loose stones, rubble or waste liable to damage the pipes.
D. Jointing materials, valves, glass reinforced plastic fitting and specials,

meters, gauges and polyethylene pipe shall be stored in purpose built covered
storage areas until required for installation.
E. Joint rubber rings and lubricants shall be stored in a closed and cool
storage area shielded from direct sunlight and heat.
6.03 MATERIALS SUPPLIED BY THE EMPLOYER
A. In the event that pipes and ancillary fittings, specials, valves and meters
shall be supplied by the Employer, these shall be supplied to the Contractor at
DEWA's storage yard. The Contractor shall load, transport and unload the
materials so supplied at his own storage area and/or the site of works and shall be
responsible for proper unloading, stacking and storing.
B. The pipes shall be unloaded from the trucks in an approved manner and
the Contractor shall take utmost care not to damage pipes or any of the materials
so supplied. Any materials damaged in loading, transport and unloading at the site
of works shall be repaired or replaced by the Contractor at his own expense in
accordance with the Engineer's instructions and to his satisfaction.
C. The Contractor will be required to sign vouchers for any materials supplied
to him, and shall keep a proper stores record book to show at any time the
quantity of materials received and those which have taken from the stores for use
in the works. The Engineer shall have the right to inspect at any time the store
record books, and to check the materials in the stores and on the site of the works
to satisfy himself that everything is in order. The Contractor will be required to
account for any discrepancy found.
D. The Contractor shall at his own expense provide and constantly maintain
day and night watching and shall be responsible for the theft or loss of any
materials supplied to him by the Employer whether theft occurred from the stores

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or from the site of works. The Contractor at his owns expense shall immediately
replace any missing materials.
E. On completion of works, the materials used in the works shall be counted

and/or measured and the balance shall be handed over by the Contractor to the
Employer at his indicated storage yard. The loading, transport, unloading and
proper stacking of materials shall be carried out in accordance with the relative
clauses of the Specifications and shall be at the Contractor's expense.
Any materials not accounted for shall be replaced by the Contractor at his own
expense or alternatively, at the Employer's discretion, shall be charged to the
Contractor's account on the basis of current C.I.F. price for delivery to the
Employer's storage yard, plus 20% handling fee.
6.04 INSTALLATION OF PIPEWORK
A. The pipe work route shall be determined by the Engineer. The Engineer
reserves the right to vary or abandon any part or parts of the routes of pipe work
indicated on Drawings and the Contractor shall lay the pipe work in accordance
with any such variations which the Engineer may direct, without any extra cost. .
B. The Contract Drawings show the approximate lines and levels to which the
pipe work is to be built and are subject to amendment by the Engineer. Before
setting out any section of the works, the Contractor or his representative shall
make an inspection of the site together with the Engineer and obtain from him his
instructions in this respect.
All pipes, bends, fittings, specials, valves and meters shall be installed accurately
in accordance with the alignment, levels and gradients so determined, so that the
top of the pipe is not less than the minimum specified depth below the finished
ground level.
C. The Contractor shall provide the surveying instruments, surveyors, skilled

staff and everything necessary for setting out the works to line and level and for
checking the accuracy of pipe laying and jointing, and of the installation of valves
and meters. He shall provide attendance upon the Engineer and provide him with
such assistance as may be necessary to enable him to check the setting out of
the works.
D. The finished pipeline shall run straight between bends or fittings and a
uniform gradient shall be accurately maintained between changes of gradient
shown on the drawings or directed by the Engineer.
E. The bottom of the trenches shall be graded and prepared to provide a firm
and uniform bearing throughout the entire length of the pipe. A compacted soft

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sand bedding of 15 cm. depth is to be provided from selected excavated material

or brought from outside. “Bell” holes shall be excavated under the F.C. collars
location such that the pipe is not supported by the F.C. joints.
The Contractor shall inform the Engineer sufficiently in advance when the
formation levels of the trenches are ready for inspection. No installation work will
be allowed until the bottom of trenches have been inspected and approved by the
Engineer and the depths of the trenches and the kind of excavation have been
recorded and agreed upon by both the Contractor and the Engineer. While
excavating, soft sand / subkha / rock shall be placed separately on the side of
trench.
F. In addition to any inspection and test made when delivery is taken, pipes
and valves shall be inspected by the Contractor immediately before and after
installation and any damage shall be repaired by the Contractor as directed by the
Engineer before the pipe or valve is installed or jointed as the case may be.
The Engineer may, and without thereby relieving the Contractor of any of his
obligations, inspect and test the pipes and valves by any means he considers
appropriate and the Contractor as aforesaid shall repair any damage discovered
by such inspection.
G. The pipe shall be positioned and bedded in the trenches in an approved

manner and properly aligned. Before being positioned, each pipe shall be
thoroughly examined to ensure that it is free from defects and shall have all dirt
removed from the inside thereof. The Contractor shall cut the pipes if and where
needed to the required length and shall thread, chamfer or bevel. The cut ends of
pipes as the case may be, all at the place of manufacturer, shall install all fittings,
specials and adapters as may be necessary for the proper execution of the works
and shall joint the pipes in accordance with the Specifications, the manufacturer's
recommendations and to the Engineer's satisfaction.
H. The Contractor shall keep the interior of pipes clean and free from water,
dirt, stones or other foreign matter as installation proceeds, and at the end of the
day's work or at other times when installation work is not proceeding the open
ends of pipes shall be sealed-off by a wooden plug or other approved stopper in
order to exclude all foreign materials.
I. Pipes which are required to be cut to form closing pieces in any portion of
the pipeline or to terminate in valve chambers or other parts of the works shall not
be cut until after all adjacent pipes have been installed and jointed.
The Contractor shall determine the length of each closing piece and the required
angle and shape of the cut. The cut shall be neatly performed and the end of the
pipe shaped up and trimmed so as to ensure an accurate joint or termination as
the case may be.

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All cutting and machining of F.C pipes shall be done at the place of manufacturer
only. Pipes terminating in headwalls and the like shall, except where otherwise
specified, be cut so that the end of the pipe is flush with the face of the structure
into which it is built.
The unused part of any cut pipe shall become the property of DEWA and shall be
returned to DEWA stores unless, subject to the Engineer's approval, it can be
used elsewhere in the works.
J. Where flexible couplings for asbestos cement pipes are required to be

other than the standard Reka joint, they shall be Viking-Johnson flexible couplings
or equal. The Contractor shall follow the manufacturer's recommendations as to
the methods and equipment to be used in assembling the joints. In particular, the
Contractor shall ensure that rubber rings are correctly positioned and free of
twists. The rubber rings and any recommended lubricants shall be obtained only
from the coupling manufacturer.
Viking-Johnson couplings shall be capable of withstanding the test pressure
appropriate to the pipes for which they are supplied. Details of such flexible
couplings for incorporation in the works shall be submitted to the Engineer for
approval before ordering. Rubber rings incorporated in flexible coupling shall
comply with BS 2494.
K. The Contractor shall provide and install detectable warning tape above all
pipelines laid 600 mm below ground level / finished level.
L. The minimum cover to pipe from the finished level / ground level shall be as
follows:
1. 1.00 M for 300 mm dia. or smaller pipes.
2. 1.2 M for pipes above 300 mm and up to and including 700 mm dia.
pipes.
3. 1.5 M for pipes above 700 mm dia.
The pipes shall generally be laid with min. cover except in areas of crossings
6.05 CONNECTIONS TO EXISTING MAINS
Where connections are to be made to existing mains, the Contractor must make
all necessary arrangements with the Engineer and the Employer and have all
necessary material, plant and labour in readiness on the site and shall complete
the work as rapidly as possible with the minimum of inconvenience to consumers.
The actual connection to an existing main will be made by the Contractor under
the close supervision of the Employer and the Engineer.

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6.06 JOINTING OF PIPES
6.06.1 General
The requirements of this clause shall be read in conjunction with the particular
requirements specified elsewhere for joints of particular kinds.
Before making any joint the Contractor shall ensure that the interior of each pipe
or valve is clean and that it remains clean. Immediately before starting a joint the
Contractor shall clean the end of each pipe to be jointed and shall otherwise
specially prepare the ends for jointing as may be necessary for the particular kind
of joint. All mechanical joints shall be cleaned and have their paint work or
coatings made good before assembly.
The Contractor shall use only the proper jointing parts as specified and obtained
through the suppliers of pipes, couplings or valves. All joints shall be accurately
made and shall be capable of passing tests for individual joints and for the
completed pipeline as may be specified.
After completing a joint any protective paint or coating shall be made good, and
any metal joint, which is not already coated, shall be cleaned and painted with two
coats of bituminous paint. The additional external protection of joints where
ordered by the Engineer shall be carried out as specified.
6.06.2 Deflection at Certain Joints
Where the Engineer orders, or allows, a change of direction to be achieved by the

deflection of a flexible joint of any kind the deflection shall not exceed the
maximum value for the size and type of joint as specified in this Section or in the
relevant schedules or by the manufacturer.
6.06.3 Fibre Cement Collars
Joints between fibre cement pipes shall be made with flexible joints comprising an
asbestos cement collar and rubber sealing rings. Only vegetable based joints
lubricants approved by the pipe manufactures shall be used as per section 3.07
In making these joints the Contractor shall take account of the manufacturer's
recommendations as to the methods and equipment to be used in assembling the
joints. In particular the Contractor shall ensure that rubber rings are correctly
positioned and free from twists. The rubber rings and any recommended
lubricants shall be obtained only through the pipe supplier. The bucket or any
other part of a mechanical excavator shall not be used to apply thrust directly to
pipes or collars in order to make joints. The excavator bucket may, however, be
used in a stationary position as a backstop for a manually operated hydraulic jack

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DUBAI – UAE
(to be approved by the Engineer) which is used to apply a thrust to pipes or

collars.
The pipe shall be marked before pushing into the collar so that a 15 mm gap is left
between it and the preceding pipe. The rubber ring location shall be checked to
ensure they are correct relative to the pipe ends. The contractor for joining the
pipes shall not use Wood or similar spacers to maintain the specified gap.
The contractor shall follow the methods given in catalogues of Fibre Cement
Pipes or as recommended by the manufacturer.
6.06.4 Flexible Couplings and Flange Adapters
In jointing fibre cement pipes with flexible couplings and flanged adapters of the
Viking Johnson type, the Contractor shall take account of the manufacturer's
recommendations as to the methods and equipment to be used in assembling the
joint. In particular, the Contractor shall render the end of each pipe perfectly
smooth so as to allow the joint sleeve to slide freely and where necessary shall
recoat the pipe ends with two coats of quick-drying bituminous solution.
6.06.5 Flanged Joints
Flanged joints shall be made with rubber joint gaskets and steel bolts and nuts
which shall include two washers per bolts. Joint gaskets shall be provided by the
pipe or valve supplier and shall be of such physical properties as to be capable of
forming permanent watertight joints against pressures up to the maximum test
pressure. The use of jointing paste or grease will not be permitted. The gasket
may be fastened to the bolts with cotton thread. The bores of abutting pipes or
fittings shall be concentric and no jointing material is to be left protruding into the
bore. All nuts shall first be tightened by hand and nuts on opposite sides of the
joint circumference shall then be alternately and progressively tightened with a
spanner so as to ensure even pressure all around the joint. BS 4504, BS 3063
and BS 1787 shall apply to flanged joints and flanges shall be PN 10 unless
otherwise noted.
6.06.6 Screwed Joints
Screwed joints on galvanized steel piping and elsewhere shall be made using
PTFE tape.
6.07 FLOTATION OF PIPEWORK
The Contractor shall be solely responsible for ensuring that flotation of the pipe
work does not occur during construction. The extent of the backfill placed over
each pipe after laying and before testing shall be such as will prevent flotation.

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Should any section of the pipe work float out of line or level, the section of pipe
work so affected shall be removed and re-laid by replacing all the rubber rings,
damaged pipes and all sockets in accordance with the Specification and to the
satisfaction of the Engineer at the Contractor's own expense.
6.08 VALVES
6.08.1 General
Gate valves, check valves, air valves, washout valves, fire hydrants etc. shall be
in accordance with the Specifications and shall be installed on the pipelines in the
positions and in accordance with the details shown on the Drawings or as directed
by the Engineer.
6.08.2 Installation
The Contractor shall obtain the necessary installation drawings from the
manufacturer and shall store, transport, handle and install the valves in strict
accord with the manufacturer’s drawings and recommendations.
6.08.3 In-place Testing
Valves and all pipeline appurtenances shall be hydraulically tested on site as

specified in Clause 6.14 for the pipeline in which they are installed.
Valves shall be tested for operation and adjusted so that they operate smoothly,
seat properly, and are installed to the tolerances recommended by the
manufacturer.
6.09 EXTERNAL PROTECTION OF JOINTS
Metallic mechanical joints, flanged joints and ferrule straps shall be protected by a
surround of bitumen compound poured hot into a special mould temporarily fixed
round the joint. The Contractor shall take account of the pipe supplier's
recommendations as to the procedure for forming the moulded surround. The
Contractor shall provide sufficient mould boxes and bitumen compound.
6.10 THRUST AND ANCHOR BLOCKS
Thrust and anchor blocks in accordance with the typical details shown on the
Drawings shall be constructed at stop-ends, bends, tees, pipelines laid to slopes
greater than 1 in 6, and reducers, where directed by the Engineer.
Concrete used in thrust and anchor blocks shall be Class 30/20 and shall comply
with the requirements of Section 4 of the Specification.
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DUBAI – UAE
The workmanship shall be in accordance with the specifications and good practice
and to the satisfaction of the Engineer, the dimensions and steel reinforcement
shall be in accordance with the typical details shown on the Drawings or as
The blocks shall, unless otherwise shown or directed by the Engineer, be so

placed that the pipe and fitting joints will be accessible for repair.
Before internal pressure is applied to a pipeline, all concrete thrust blocks shall
have been constructed and cured for a minimum of 7 days.
Thrust blocks for GRP fittings shall completely encase the fittings except for the
joint area. For fittings up to 300mm diameter an 10mm thick and 100mm wide,
150mm wide for larger than 300 mm diameter, rubber wrap shall be provided on
the ends of the GRP fitting, such that the rubber protrudes slightly from the
encasing concrete. The total wrapped width for sizes above 600 mm shall be 300
mm wide, double thickness wrap shall be provided at section near to the concrete
edge.
6.11 VALVE CHAMBERS AND FLOWMETER CHAMBERS
A. Where shown on Drawings, valves and flowmeters shall be located in

chambers. The particular types of chambers are indicated on the Drawings which
also show the construction details of each type of chamber. GRP flanges shall be
provided with washers under all bolts and nuts heads. GRP flange bolts shall be
tightened using torque wrenches only, in accordance with the GRP flange
manufacturer written instructions. An approved gaskets to be used only.
B. Valve chambers and chambers for flowmeters shall be constructed of Class

30/20/s concrete with the dimensions shown on the Drawings or as instructed by
the Engineer to suit the valves, flowmeters and relevant pipe connections on site.
6.12 OTHER WORKS
Works included in the Contract and which do not have specifications herein shall
be carried out in accordance with the Engineer's written instructions and
Specifications or as specified in the Schedule of Rates (Bill of Quantities).
6.13 CONNECTIONS TO EXISTING MAINS AND SERVICE PIPES
The Engineer will issue to the Contractor detailed instructions regarding each
interconnection that has to be made to the existing mains and service pipes.
Cutting into an existing main or service pipe and effecting the interconnection shall

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DUBAI – UAE
only be made in the presence of a representative from the Employer's

Maintenance Section at the time specified by the Employer. (See also Clause
6.15)
Cutting into the existing main or service pipe and installation of the interconnecting
pipe work shall be carried out efficiently and rapidly so as to reduce to a minimum
the interruption of the public water supply. It may be necessary to undertake such
work at night, when water demands are reduced and/or to schedule such work to
be performed during the winter.
Existing mains and service pipes shall only be cut using special equipment
approved by the Engineer. The cut shall be perpendicular to the centerline of the
pipe and special care shall be taken with respect to the location of the cut to
ensure that the new pipe work shown on the Drawings may be installed. The
Contractor shall agree with the Engineer the length of existing pipe work to be
removed.
The Contractor shall take every care to avoid any dirt or extraneous material
entering the existing main or service pipe.
The Contractor shall submit detailed method statement with a program of

connection work for Engineers approval prior to any connection/cutting of any
existing water main. The Contractor shall have available at the site of the
connection sufficient dewatering pumps and equipments before commencing any
cut into the existing main or service pipe in order that the excavation remains dry
at all times and to reduce the risk of dirty or contaminated water entering the
existing distribution system. The work shall be carried out in a clean and efficient
manner. The Contractor shall provide at the site of the connection sufficient
quantities of clean water containing 10 ppm chlorine in solution. Every item of
new pipe work to be installed shall be submerged in the chlorine solution for at
least 15 minutes immediately before being installed in the permanent works.
The Employer may put the interconnection into use as soon as possible after its
installation and will carry out an inspection to detect any evidence of leakage; any
remedial work necessary to eliminate leakage shall be carried out by the
Contractor. No pipe work shall be covered or backfilled until the Engineer is
totally satisfied that the interconnection is free of all leakage.
6.14 TESTING, DISINFECTION AND CLEANING PIPELINES
6.14.1 General
It shall be a condition precedent to the issue of a Certificate of Completion

according to the Conditions of Contract that all parts of the pipe work shall be

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subjected to a successful hydraulic pressure test and finally disinfected and

cleaned out as specified hereafter.
The Contractor shall submit for the Engineer's approval details of his proposed
methods and programme for testing (including details of test equipment) and shall
arrange for all tests to be witnessed by the Engineer.
The Contractor shall provide all things necessary for carrying out testing,
disinfection and cleaning including pumps, gauges, pipes, connections, stop-ends,
and all other temporary works.
The Contractor shall remain responsible for the care of the works during testing of
the pipe work. The contractor shall replace at his cost any ruptured pipe in the
event of test failure if it is proved as improper handling/poor work manship.
All the existing pipelines/existing crossings forming part of the pipelines laid under
this contract shall be pressure tested, disinfected and commissioned by the
contractor at his cost, including removal and replacing of any damaged pipes,
reinstating the surface etc. Length of pipeline laid for such rectification will only be
measured for payment under the relevant items in schedule of prices.
6.14.2 Testing of Pipelines
After completing the installation of a section of the line, as directed by the

Engineer and before the joints are covered for buried pipes, a hydrostatic test of
the line shall be made by the Contractor.
Concrete for thrust blocks shall be allowed to reach design strength before testing.
Backfilling and compaction shall be completed to the pipe centerline and around
all thrust blocks as required to assure restraint to the pipeline.
The Contractor shall submit to the Engineer detailed procedures for performing
hydrostatic pressure tests of installed piping, fittings, valves, meters and
appurtenances for approval. Procedures for performing hydrostatic pressure tests
shall indicate the location and capacity of the test pump for each test section, test
pressure at the pump and procedure for venting the air from the pipeline.
Before applying the test pressure, all air shall be expelled from the pipe. If
permanent air vents are not located at all high points, the Contractor shall install
suitable cocks at such points so the air can be expelled as the line is filled with
water. After all the air has been expelled, all cocks shall be closed and the test
pressure applied. The line shall be filled slowly to prevent possible water
hammer.
For hydrostatic testing of pipelines, potable water shall be introduced to the

pipeline and the pressure slowly raised to the pressure of 3 bar. This pressure

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shall be applied for a period of 24 hours before the test begins, to allow for a
soaking period. After the soaking period, all joints shall be carefully inspected for
evidence of leakage.
Pumping shall then be resumed to the specified test pressure of 10 bars.
The pipeline shall be deemed to have passed the pressure test if no appreciable
drop in pressure is noted over a period of 30 minutes.
After performing the specified pressure test, the pipeline shall be subjected to a
leakage test. The pressure shall be reduced to the normal working pressure of 9
bars in the pipeline and maintained for a period of 2 hours. Make-up water shall
be added by pumping to maintain the working pressure. The pipeline shall be
deemed to have passed the test if:
(a) No water is visible coming out of the pipe or joints at any point;
(b) the amount of make-up water required during the last one hour of the test
period does not exceed the rate of 0.1 liter per millimeter of pipe diameter
per kilometer of pipeline per 24 hours for each 30 metres head of pressure
applied at the lowest point;
(c) The maximum drop in pressure (during the last half hour of the test period,
when no further make-up water may be pumped in) shall not exceed 10%
of the maximum test pressure.
During all testing, the trench generally and the joint pockets in particular shall be
kept clear of water and should the trench become unstable due to work or leaking
on testing or re-testing it shall be excavated to solid ground and made up with
lean mix concrete or such other material as the Engineer may direct, all at the
Contractor's expense. Should a test fail, the Contractor shall at his own expense
replace defective pipes or fittings or make good leaking joints or otherwise rectify
defective work; cleaning, inspection and testing shall then be repeated, until the
work is to the Engineer's satisfaction.
The length of the section of pipeline to be tested shall not exceed 500 m. If a line
is tested in sections and valves do not close the ends, the line must be provided
with secured blind flanges or stop ends. Testing longer lengths not exceeding
1000 m may be considered, at the Engineer’s discretion taking into account the
prevailing situation at site, without any contradict with any standard.
A simple stop end consists of a section of steel pipe about 0.5-1.0 m long onto
which a closing plate has been welded, containing the necessary opening for
accommodating in going water and out coming air. The stop end may also include
an opening through which the test water may be pumped from the line, if
necessary. The stop end may be jointed to the pipe to be tested by means of a
standard coupling or other method approved by the Engineer. Thrust blocks or

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temporary anchorages must be provided to hold the stop end in place against the
test pressure.
6.14.3 Disinfection of Pipelines
All potable water pipe, fittings, valves, meters and appurtenances shall be
disinfected by the Contractor as specified herein, unless otherwise directed by the
Engineer.
All water and chlorine required for disinfection of pipelines shall be provided by the
Contractor at his own expense. Bacteriological testing will be performed by the
Employer.
The attention of the Contractor is directed to the requirements of these

specifications whereby he is responsible for preventing the entry of foreign
material of any kind into the pipe work. The Contractor shall take extreme care to
keep the interior of the pipe work free of direct and other foreign material. If in the
opinion of the Engineer, dirt or other foreign material enters the pipe work, which
will not be removed by flushing, then the Contractor shall clean and swab the
interior of the pipe work with a five percent hypochlorite disinfecting solution to the
After testing and immediately before commissioning, all pipelines shall be washed
out and disinfected as follows:
(i) All mains shall be flushed out with clean water until there is no
evidence of foreign matter or color in the waste flushing water.
(ii) A stock disinfecting solution shall be prepared by mixing for not less
than 5 minutes, in a clean container, Sodium Hypochlorite (12
percent available free chlorine) and distilled water in the proportion
of 0.80 litter per cubic meter of water by volume. After mixing, the
solution shall stand for a further 5 minutes after which the clear
supernatant liquid shall be decanted into another clean container.
Stock solutions shall be made up fresh daily.
(iii) The main to be disinfected shall be filled with potable water at the
same time as the stock solution is added through a convenient air
valve in such quantities (to be determined by the Contractor and
approved by the Engineer) as will result in a final solution containing
50 ppm free chlorine. Care shall be taken to ensure that the stock
solution is added at a constant rate, commencing when water is fed
into the main and ending as soon as the main is full. Flow meters
required for this operation shall be arranged by the contractor.
(iv) Every main charged with disinfecting solution shall stand for 24
hours, after which a sample shall be taken at a washout valve by the
Contractor in the presence of the Engineer, from whom the sampling
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bottle shall be obtained. If the sample does not show at least 2 ppm
free chlorine, disinfection shall be repeated. If the sample is
satisfactory the main shall be emptied, flushed out and filled with
treated water and allowed to stand for 1 hour.
(v) Two further samples shall then be taken as before, one for a further
determination of free chlorine and the other, in a sterilized bottle, for
bacteriological analysis. If the free chlorine determination shows
more than 0.4 ppm free chlorine the main shall be flushed out again.
If the bacteriological analysis is unsatisfactory disinfection and
sampling shall be repeated until satisfactory results are obtained
before the main is commissioned.
(vi) The Contractor shall provide all equipment, materials and testing
apparatus, etc., as may be necessary for the effective disinfection of
all pipelines.
6.14.4 Cleaning of Pipe work
All pipework shall be cleaned by the Contractor after all pressure tests and
disinfection operations have been performed and accepted by the Engineer.
However, it is the responsibility of the Contractor to prevent all dirt and foreign
matter from entering the paperwork and for cleaning each length of pipe and all
fittings, valves, meters and appurtenances, of sand, dirt and foreign matter during
the installation. Cleaning of chlorinated lines shall conform to the
recommendations of the Chlorine Institute. Flushing shall be carried out in parts
and as per the site conditions and as directed by Engineer.
The Contractor will make his own arrangements for water required for testing,
disinfection, cleaning and flushing.
Arrangements for disposing of water into lagoon or approved location including

providing of required plant, equipment and material shall be at contractor's own
expense.
6.15 Disposal of Water Used for Testing, Disinfections and Cleaning
The Contractor shall provide suitable means for disposal of water used for testing,
disinfection and flushing such that no damage results to facilities; structures or
property. These means shall be subject to the approval of the Engineer and local
Authorities. Details shall be submitted to the Engineer upon request. The
Contractor shall be responsible for any damage caused by his filling, testing,
disinfecting, flushing and wastewater disposal operations.

SPECIFICATIONS
DUBAI – UAE
SECTION 7
MICRO TUNNELING
PIPE SLEEVE FOR 1200 MM DIA. A.C. PIPE INSTALLATION
7.01 DEFINITIONS
For the purpose of this specification the following definition shall apply:
‘Micro tunneling’ : is defined as a miniaturized tunneling technique

Employing sophisticated mechanical excavation
Methods within a non-man – entry guided tunnel
Boring machine.
‘Pipe’ : is defined as the pipe which is jacked in behind the

Micro tunneling machine
‘Shaft’ : is defined as the excavated thrust and reception pits

Used for the micro tunneling operation.
‘Auger system’ : micro tunneling where excavated spoil is transported

From the cutting face back along the installed pipeline
Via a flight of helical augers.
‘Slurry system’ : micro tunneling where excavated spoil is converted to

Slurry and removed by the use of a small diameter
Discharge pipe.
‘Earth pressure’ : Support of the soil at the cutting face by controlled

Balance pressure of the cutting head against the soil
face.

SPECIFICATIONS
DUBAI – UAE
PIPELINE BY NON-DISRUPTIVE METHODE AND PIPELINE REHABILITATION
7.02 APPROVED SUB-CONTRACTOR
Where micro tunneling is to be carried out by a specialist Sub-Contractor they

shall be approved by the Engineer in accordance with the Conditions of Contract.
1. The micro tunneling systems shall be capable of remotely installing pipes in

varying ground conditions with the presence of ground water and
accommodating different joint configurations.
2. Disposal of excavated materials shall be by enclosed remote means using

together screw auger, or slurry system.
3. If necessary, facilities for lubricating the external surface of the pipeline

being installed shall be provided in order to minimize jacking forces. If
required, facilities for grouting any over break are to be incorporated.
4. Pipes shall be capable of sustaining all jacking loads and surcharge loads
arising from overburden and traffic loading.
5. Shafts shall be sufficiently compact to minimize disruption, be capable of

sustaining reactions to jacking loads and be water tight.
7.04 SPECIFIC REQUIREMENTS
1. The normal external cross sectional plan profile of shafts shall not
enclose and area greater than 20 m2 with no dimension of cross section
exceeding 5.0 m.
2. The proximity of buildings is such that the driving of steel sheets piles to
shafts is not permissible, nor is any construction noise greater than 70
db. All constructional plant forming part of the micro tunneling system is
to be electrically driven, either by mains supply or on site generation.
3. Micro tunneling shall not normally be considered where there is a

minimum clearance to services of less than 1 meter unless specifically
4. The Micro tunneling system shall conform to the following criteria:

SPECIFICATIONS
DUBAI – UAE
a) Face support shall be provided by full earth pressure balance

cutting head, or by a pressurized slurry system, as appropriate.
b) The equipment must be capable of operating under the prevailing

ground conditions including hydrostatic pressure from natural
ground level.
c) The micro tunneling system shall be manufactured and operated

having regard to the provisions of the health and safety at works
etc. Act. 1974, including the provisions of the British standard BS
5228: Parts 1 and 2. This requirement shall include fill
environmental monitoring facilities.
d) The system shall have automatic steering control by means of a

microprocessor system with line / level / gradient prediction
capability incorporated.
e) The micro tunneling system shall be capable of installing a pipeline

up to 130 meters in length in one operation to an accuracy in line
of + or – 50 mm and in level of + or – 25 mm. All joint deflections
shall be within 75% of manufactures specified tolerance.
f) Individual pipe length shall normally be in the range 1.5 m - 2.5m.
7.05 SITE INVESTIGATION
The Contractor shall avail himself of all available information’s concerning

ground conditions to determine the appropriate cutting head compatible with
the expected conditions.
The proposed position of drive and reception shafts shall be checked onsite by
the Contractor to ensure that the design has provided sufficient working space
which will cause the least disruption to the flow traffic.
Any alteration to the designed position of shafts must be approved by the

Engineer.
7.06 SURVEY AND SETTING OUT.
7.06.1 Preliminary Survey.
Before commencing the excavation of any shaft or pit from which micro
tunneling is to be commence, the Contractor shall without prejudice to

SPECIFICATIONS
DUBAI – UAE
any other requirement of the contract and to the satisfaction of the

Engineer: -
 Establish at least four reliable temporary survey stations adjacent to

the shaft or pit to facilitate the setting our of the underground works
and checking of the setting out.
 Accurately record initial surface levels for pipelines beneath or

across carriage ways. Such records are to be submitted to Dubai
Municipality Roads Department, as a record for reference in
checking for subsequent settlement.
 Record and report with supporting photographs the condition of all

properties road and footpaths over and alongside each
microtunnleing route.
7.06.2 Surveys during construction.
During construction of micro tunneling drive between any two working

shafts the Contractor shall observe levels on the predetermined cross
section points every fourth day to determine subsidence ( if any).
Upon completion of a micro tunneling drive between any two working

shafts the Contractor shall, without prejudice to any other requirement
of the Contract and to the satisfaction of the Engineer : -
 Repeat the level survey of the ground surface above the centerline
of the pipe jack or heading as described above.
 Record and report with supporting any changes in the conditions of

the properties, roads and footpaths over and alongside the
microtunnleing route.
7.06.3 Survey Prior to Completion.
Shortly prior to the substantial completion of the whole of the works and
again prior to the end of the Defects Liability Period, the Contractor shall
repair the levels surveys and inspection as described above for all the
micro tunneling.
7.06.4 Setting Out of the Works.
The Contractor shall provide the Engineer with details of his proposed
method of setting out the shafts.

SPECIFICATIONS
DUBAI – UAE
7.07 SAFETY
7.07.1 General
Where work is carried out in microtunnleing shafts, the Contractor shall

comply with the recommendations of a recognized Code of Practice to
be approved by the Engineer.
7.07.2 Lightning and Other Electrical Equipment
Lightning and other electrical equipment for use within or adjacent to

shafts shall be either intrinsically safe or flameproof have any
approved type.
7.07.3 Ventilation
All ventilation plant and equipment shall be operated and maintained by

competent persons who shall keep a day log of operations in a form
Each shaft shall be ventilated by a fan which shall be suitably situated and
connected by ventilation ducting to within 5 meters of the working face.
The fan shall be capable of delivering or exchanging at the end of the

ducting atleast 15 cubic meters of air per minute per square meter of area
of the face to be ventilated.
7.07.4 Presence of Toxic and Inflammable Gases
Where ground conditions indicate that the workings may pass through or
are close to materials which could lead to the presence or accumulation of
inflammable gases in or adjacent to underground working or where in the
opinion of the Engineer there is a risk of this the Contractor shall comply
what the following requirements of this Clause.
Each shaft sinking shall be provide with at least one approved automatic
gas detector. Continuos monitoring for toxic and inflammable gases and
oxygen content shall be instituted with monitors set as near as possible to
the most hazardous areas. Regular test shall also be taken for carbon
dioxide content.
All gas detector shall be expertly and regularly maintained.
If gas detection equipment indicated the presence of toxic or inflammable

gases approving hazardous concentrations, all work in the danger area

SPECIFICATIONS
DUBAI – UAE
shall cease and all personnel shall immediately vacate the workings, care
being taken to avoid sparks from metal tools and studs on boots etc., and
the conditions of the workings shall be reported to the Engineer
immediately. The contract shall summit to the Engineer for approval his
proposals for sealing the exposed surfaces of the strata from which gas is
escaping, for providing additional ventilation and flame proof illumination or
such other precautions as may be considered necessary.
If the amount of inflammable gas in any shaft sinking exceeds 1.25 percent
by volume, the electrical supply shall be cut off at the surface to all
apparatus other than telephones and electric safety lamps.
If the amount of inflammable gas in the main body of the air exceeds 2
percent by volume, all persons in the affected area shall be withdrawn.
The nominated competent person shall ascertain the conditions of the area
affected and the measures to be taken to render safe the affected area
shall be approved by the Engineer, such approval not relieving the
Contractor of his obligations under the contract. Personnel will only be
allowed to re-enter the area after safe conditions have been restored.
If the Engineer considers that the conditions within the shaft sinking require
further restrictions, he will inform the Contractor and then Contractor shall
implement such additional restrictions as may be required without delay
and, if so required by the Engineer shall cease any works that the Engineer
considers may constitute a hazard to the works or to personnel until the
additional restrictions have been implemented.
Nothing in this clause shall be deemed to limit the Contractor’s more

general obligations under the contract.
7.08 WORKING SHAFTS OR PITS
The Contractor shall construct working shafts or pits at locations to be agreed

and approved be the Engineer. Full details shall be submitted to the Engineer
for approval before excavation works commences including a plan of the
proposed working area at the head of each shaft to scale not less than 1:50.
This shall show local topography, the working shaft and arrangement of plant,
materials, etc.
The Contractor shall ensure that the area required to set up machinery and
equipment together with an allowance for truck access for spoil removal is kept
to a minimum and does not cause road closures.
Each working shaft shall have a separate ladder bay for access which shall be
isolated from the part of the shaft used for hoisting materials. The ladder will

SPECIFICATIONS
DUBAI – UAE
be vertical, rising through staginess not greater that 6 meters apart and offset
at each staging level. The ladder at shaft entrance shall have up and over
hand rails to assist manual access. All shafts and staginess shall be fully
protected by handrails 1 meter high.
The Contractor may apply at any time for approval to changes of design to
enlarge or modify any of the chambers or access points that are to be
incorporated into the permanent works so at to facilitate their use as working
shafts or pits. However, rejection of any such application or delay in issuing
approval shall not constitute grounds for any additional payment or extension
of time for completion. Any such modifications that is approved shall be
carried out to the Contractor’s design.
Except as otherwise provided in the contract design changes to enlarge or

modify chambers or access points shall not constitute grounds for additional
payment.
7.09 EXCAVATION IN SHAFTS
The Contractor shall plan, program and execute the excavation of shafts, in
accordance with the specifications and drawings.
Before commencing works the Contractor shall submit such details of his
excavation proposals as may be required by the Engineer. No departure from
the approved method of working will be allowed without the approval of the
Engineer.
Excavation in shafts shall be carried out in material encountered, true to line

and level, any miss alignment shall be made good to the satisfaction of the
Engineer at the Contractor’s expense.
The manner in which the excavation is carried out shall be such as to minimize
the extent of any loosening of the ground beyond the limits of the excavations
and to ensure that the ground is fully supported at all times.
Any subsidence of the soil or road structure, if noticed shall be immediately

brought to the notice of Dubai Municipality Roads Department and all
excavation operations shall be completed as soon as possible.
The Contractor shall be at liberty to construct shafts/ pits by any of the

established methods of sinking including the use of concrete caissons.
Where the excavation is in water bearing ground the Contractor shall provide
means of checking whether any solids are being removed with the water from
the excavation. Regular checks shall be made in conjunction with the
Engineer to compare the volume of material removed with the calculated

SPECIFICATIONS
DUBAI – UAE
volume as a safeguard against excessive loosening or loss of material beyond

the shaft dimensions.
7.10 PIPES FOR MICRO TUNNELING
Pipe units to be installed by microtunnleing must be structurally suitable for

both permanent loading when in service, and for the temporary loading during
construction.
The strengths required for the permanent loading are given in the following
table.
Minimum Crushing strength (ken/m)

Type of Rigid Nominal
Pipe Diameter (mm)
Class 90 Class 130 Class 170
200 - 26 34
Rigid
300 27 39 51
400 36 52 68
500 45 65 85
600 54 78 102
700 63 91 119
800 72 104 136
900 81 117 153
1000 90 130 170
1200 108 156 203
1400 126 182 238
Full details of the proposed design, manufacturing and testing of the pipes will
be required for approval by the Engineer, prior to manufacture. The tests
including crushing strength assessment may be required to confirm the validity
of pipe design and to demonstrate its suitability for intended use and shall be
provided for in the Contractor’s rates for the supply of such pipes.
The strengths specified above relate only to the suitability of the pipes for the
permanent loading and do not imply any suitability for the loadings which may
develop during installation. It is the responsibility of the Contractor to ensure
that the pipes have adequate strength in the longitudinal direction to withstand
the longitudinal forces which will develop during jacking without any form of

SPECIFICATIONS
DUBAI – UAE
damage, and that they will be in every way compatible with the installation
equipment and procedures employed.
Subject to availability in the in the required sizes and strength classes, pipes of
the following materials may be proposed for the construction of pipelines by
micro tunneling.
7.11 RIGID MATERIALS
The following particular requirements will apply to pipes of the respective

materials: -
Asbestos cement : expect in respect of requirements otherwise specified,

the pipes shall comply with Clause 3.01. Jointing shall
be by means or rubber ring sealed rebates in the pipe
ends, or by means of any external sleeve as detailed
below: Asbestos cement pipe without internal liner
may be used for drainage only.
Concrete with : The GRP liner pipe shall comply generally with
clause integral GRP 3.01 with minimum stiffness 5000 N/m2.
Pipe line
Jointing of the GRP liner pipes shall be means of

rubber ring sealed couplings on the GRP liner pipes.
Normally a coupling shall be attached to one end of
each GRP liner pipe, and surrounded by concrete
integral with the encasement of the liner pipe barrel, so
as to effectively to form a socket into which the spigot
end of the next GRP liner pipe can be entered.
The concrete encasement shall be reinforced and

designed as the structural element to provide the
required crushing strength and sustain loads
generated during installation i.e. as a concrete pipe in
compliance. And shall completely surround the GPR
pipe couplings. It shall extend sufficiently close to the
spigot end of the GRP pipes to ensure that a
satisfactory gap is maintained between the ends of the
two GRP pipe barrels during jacking. The GRP liner
pipe shall be regarded as providing corrosion
protection only and to be non-structural.
External sleeve The sleeve shall be made from GRP, or from stainless
steel (Avesta Sheffield 254 SMO or similar approved)

SPECIFICATIONS
DUBAI – UAE
and shall have an external diameter of 1800 mm and

minimum thickness of stainless steel sleeves shall be 3
mm .
Rebates shall be provided at the ends of the pipes to accommodate the

sleeves and shall extend for a sufficient distance from the pipe ends to
ensure that the sleeve end cannot transmit the axial jacking loads.
Sealing of the sleeve against the outside of the pipes shall be achieved
either by the provision of rubber ring seals on both pipe ends, or by
attaching one end of the sleeve to a pipe end by means of an appropriate
adhesive and providing a rubber ring seal at the other end (thereby
effectively providing a socket a spigot arrangement).
The integrity of joints against leakage or infiltration and in particular the

resistance of stainless steel sleeves to corrosion under the local climatic
conditions, ground and groundwater conditions external to the pipeline and
the internal environmental conditions of the pipeline in service shall be
guaranteed in writing by the Contractor for a minimum period of 20 years
for the date of the Maintenance Certificate (Defects Liability Certificate).
Such a guarantee shall be provided at the time of submitting the detailed
construction method statement and materials approval request to the
Engineer for approval. No approval will be issued unless this condition is
satisfied.
All types of joint shall have thrust transmitting surfaces which are square to
the pipe axis, flat smooth and free from defects or repairs the distance
between the thrust transmitting surface of adjacent pipe ends, when the
pipes are correctly jointed together, shall be consistent with the dimension
and type of packing ring material to be used. Thrust transmitting surfaces
must have packing rings in order to separate the pipe end surfaces to
maintain the flexibility of the joint and to efficiently transmit the jacking (
axial ) forces from one pipe section to another.
Packing rings must be totally square to the pipe axis, flat smooth and free
from defects or repairs. Packing rings shall be attached to the pipe ends at
the place of manufacture of pipes to ensure that packing rings of incorrect
material are not used at site. Packing rings shall be reasonably
compressible by having Poisson’s ratio equal to zero to eliminate lateral
expansion and subsequent end effects. The compressibility of the packing
material must be such that damage to the pipe ends will not occur during
jacking, and that the subsequent watertightness of the joint will not be
impaired. Packing rings shall be made up of high grade wood chipboard or
other approved material.

SPECIFICATIONS
DUBAI – UAE
Recommend thickness of packing rings are as follows:
Jacking Pipe Nominal Size Recommend Packing Thickness

(mm) (mm)
100<DN< 300 15
301<DN <600 18
601<DN<800 24

SPECIFICATIONS

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EMPLOYER ARCHITECT / ENGINEER

design at world scale

Mohammed Bin Rashid Al Maktoum City

ISSUED FOR CONSTRUCTION

20 June 2022 AE7 Project No.20010400

OT: Outline Specs based on 100% SD Drawings

SPECIFICATION REGISTER AND TABLE OF CONTENTS (TOC) REVISION DATE

BOOK - INFRASTRUCTURE OT B C 0 0.1 1 1.1 Remarks

DIVISIONS SECTION TITLE ISSUED SECTIONS

SPECIFICATION REGISTER & TOC Δ □ ■ • •• Ψ ΨΨ

PART II PARTICULAR SPECIFICATIONS • Ψ

PART III DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE SPECIFICATIONS • Ψ

PART IV APPENDIX TO DUBAI MUNICIPALITY SEWERAGE AND DRAINAGE SPECIFICATIONS • Ψ

PART V PARTICULAR SPECIFICATIONS FOR IRRIGATION WORKS • Ψ

PART VI PARTICULAR SPECIFICATIONS FOR FIREFIGHTING WORKS • Ψ

PART VII BUILDING GENERAL SPECIFICATIONS – CIVIL & ARCHITECTURAL • Ψ

PART VIII BUILDING GENERAL SPECIFICATIONS MEPF • Ψ

PART IX DEWA – PEW TECHNICAL SPECIFICATIONS

AE7 PROJECT NO. 20010410 REV 1 – ISSUED FOR CONSTRUCTION

MOHAMMED BIN RASHID AL MAKTOUM CITY

ISSUED FOR CONSTRUCTION DOCUMENTS

CONSULTANT PROJECT NO.

Volume 1 Construction & Contract Conditions

Volume 2 – Part I General Specifications

Volume 2 – Part II Particular Specifications

Volume 2 – Part III Dubai Municipality Sewerage and Drainage

Volume 2 – Part IV Appendix to Dubai Municipality Sewerage and

Volume 2 – Part V Particular Specifications for Irrigation Works

Volume 2 – Part VI Particular Specifications for Fire Fighting Works

Volume 2 – Part VII Building General Specifications – Civil &

Volume 2 – Part VIII Building General Specifications - MEPF

Volume 2 – Part IX DEWA – PEW Technical Specifications

Volume 3 Bill of Quantities

Volume 4 Tender Drawings

Volume 5 Soil Investigation Report and Project Environmental and

AE7 PROJECT NO. 20010410 iii REV 1 – ISSUED FOR CONSTRUCTION

MEYDAN GROUP LLC

Mohammed Bin Rashid Al Maktoum City

District One – Phase 3B - 3B Extension and 3C

Roads and Utilities

Issued For Construction Documents

SECTION 1 - GENERAL ...........................................................................................................1

AE7 PROJECT NO. 20010410 iv REV 1 – ISSUED FOR CONSTRUCTION

1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND

AE7 PROJECT NO. 20010410 v REV 1 – ISSUED FOR CONSTRUCTION

2/12 BORROW PIT SITE................................................................................................................ 38

AE7 PROJECT NO. 20010410 vi REV 1 – ISSUED FOR CONSTRUCTION

3/17 COMPACTION TRIALS OF WET-MIX MACADAM ROADBASE ............................... 60

AE7 PROJECT NO. 20010410 vii REV 1 – ISSUED FOR CONSTRUCTION

3/48 BITUMINOUS PRIME COAT ................................................................................................ 84

AE7 PROJECT NO. 20010410 viii REV 1 – ISSUED FOR CONSTRUCTION

4/20 TOLERANCES IN PROPORTIONING THE MATERIALS ........................................... 114

AE7 PROJECT NO. 20010410 ix REV 1 – ISSUED FOR CONSTRUCTION

5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS ...................................................... 136

AE7 PROJECT NO. 20010410 x REV 1 – ISSUED FOR CONSTRUCTION

5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED

AE7 PROJECT NO. 20010410 xi REV 1 – ISSUED FOR CONSTRUCTION

6/25 WATER WORKS - FINAL CLEANING AND STERILISATION .................................. 175

AE7 PROJECT NO. 20010410 xii REV 1 – ISSUED FOR CONSTRUCTION

6/54 PIPEWORK WITHIN STRUCTURES ............................................................................... 198

AE7 PROJECT NO. 20010410 xiii REV 1 – ISSUED FOR CONSTRUCTION

7/2.4 Termination of Cables ................................................................................................... 228

AE7 PROJECT NO. 20010410 xiv REV 1 – ISSUED FOR CONSTRUCTION

7/9.3 Insulation ........................................................................................................................... 241

Book VI - Infrastructure & Networks

Book VI - Infrastructure & Networks