Volume II - Specifications Offgrid Ilala

THE UNITED REPUBLIC OF TANZANIA
MINISTRY OF WATER
DAR ES SALAAM WATER SUPPLY AND SANITATION AUTHORITY
OFF-GRID WATER SUPPLY SCHEME IN DAR ES SALAAM
TENDERING DOCUMENT
TENDER NO. TZ-DAWASA-221519-CW-RFB
FOR
Construction of off-grid Water Supply Distribution Networks in ILALA and

Part of KIGAMBONI Municipalities
DAR ES SALAAM WATER SUPPLY AND SANITATION

AUTHORITY
(The Employer)
Tanzania
APRIL 2021
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Section VI : SPECIFICATIONS
This Section contains all the Employer’s Requirements as regards the proposed works and defines the design, construction
and operation/commissioning responsibilities of the Contractor.
Section VI comprises the following:
A. Scope of Works Outlining the objectives and scope of the project;
B. Particular Specification Describing the configuration and physical characteristics

of the proposed works;
C. General Specification Defining the standards and codes of practice for design
and construction;
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SECTION A : SCOPE OF WORKS ....................................................................................... 8
A.1 OBJECTIVES ........................................................................................................................... 8
A.2 SUMMARY OF PROPOSED WORKS ........................................................................................ 8
SECTION B: PARTICULAR SPECIFICATION ................................................................. 11

B.1 BACKGROUND ...........................................................................................................................................11
B.1.1 Location of Site ...................................................................................................................... 11
B.1.2 Prevailing Conditions ............................................................................................................. 11
B.1.3 Registration in Tanzania ......................................................................................................... 12
B.1.4 Other Relevant Contracts ........................................................................................................ 12
B.2 DOCUMENTATION .....................................................................................................................................12
B.2.1 Contract Drawings ................................................................................................................. 12
B.2.2 Programme of Works .............................................................................................................. 13
B.2.4 Environmental and Social Management Plan ............................................................................ 14
B.2.5 Health and Safety Management Plan ........................................................................................ 14
B.2.6 Progress Reports .................................................................................................................... 14
B.2.7 Daily Record .......................................................................................................................... 14
B.2.8 Test Forms ............................................................................................................................. 14
B.2.9 Miscellaneous Forms .............................................................................................................. 14
B.2.10 Documents on Completion ....................................................................................................... 14
B.3 DESIGN OF WORKS...................................................................................................................................15
B.3.1 General ................................................................................................................................. 15
B.3.2 Drawings .............................................................................................................................. 15
B.3.3 Verification by Contractor....................................................................................................... 15
B.4.1 General ................................................................................................................................. 19
B.4.2 Water Quality Standards ......................................................................................................... 19
B.4.3 Design Criteria ...................................................................................................................... 19
B.4.4 Codes and Standards .............................................................................................................. 19
B.4.5 Specific Design Requirements .................................................................................................. 20
B.4.6 Reviews and Approvals ........................................................................................................... 22
B.5 PUMPS .........................................................................................................................................................22
B.5.1 General ................................................................................................................................. 22
B.5.2 Performance Tests .................................................................................................................. 22
B.5.3 Vibration Tests ....................................................................................................................... 23
B.5.4 Sound Pressure Tests .............................................................................................................. 23
B.5.5 Tests on Completion ............................................................................................................... 23
B.5.6 Commissioning Plan ............................................................................................................... 24
B.5.7 Off-Line/“Dry” Tests .............................................................................................................. 24
B.5.8 Pre-Commissioning Tests ........................................................................................................ 24
B.6 PUMPING EQUIPMENT .............................................................................................................................25
B.6.1 Air General ............................................................................................................................ 25
B.6.2 Air Scour Blowers, Vacuum Pumps and Air Compressors .......................................................... 25
B.6.3 Electrical Equipment .............................................................................................................. 25
B.7 PERFORMANCE TESTS .............................................................................................................................29
B.7.1 First Proof-of-Performance Test .............................................................................................. 29
B.8 RESULTS, REPORTS AND TAKING OVER .............................................................................................30
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B.8.1 Taking Over Certificate........................................................................................................... 30
B.9 SECOND AND THIRD PROOF-OF-PERFORMANCE TESTS ..................................................................30
B.10 PERFORMANCE CERTIFICATE ...............................................................................................................30
B.11 OPERATIONAL START-UP PERIOD........................................................................................................31
B.12 SPARE PARTS .............................................................................................................................................31
B.13 SPECIALIST TOOLS ...................................................................................................................................31
B.14 OPERATOR TRAINING..............................................................................................................................31
B.15 FINAL REPORTS ........................................................................................................................................33
B.15.1 As-Built Drawings .................................................................................................................. 33
B.15.3 Operation and Maintenance Manuals ....................................................................................... 33
B.15.4 Inspections during Defects Liability Period ............................................................................... 34
B.16 TRANSMISSION PIPE MATERIAL .....................................................................................................34
B.17. DRILLING AND INSTALLATION OF BORE WELL .............................................................................34
B.18 INSTRUMENTATION AND FLOW METERS ............................................................................................40
B.19 FACILITIES FOR THE ENGINEER’S ........................................................................................................46
SECTION C: GENERAL SPECIFICATION ....................................................................... 49
C.1 GENERAL REQUIREMENTS ...................................................................................... 49

C.1.1 General ................................................................................................................................. 49
C.1.2 Health and Safety ................................................................................................................... 50
C.1.3 Minimisation of the Spread of HIV / AIDS and Child Abuse ........................................................ 53
C.1.4 Environmental Requirements ................................................................................................... 54
C.1.6 Contractor's Yards, Stores and Accommodation for Workmen .................................................... 56
C.1.7 Precautions against Contamination of the Works and Environment ............................................. 56
C.1.8 Restrictions On Use of Roads .................................................................................................. 57
C.1.9 Temporary Water and Electricity Supplies ................................................................................ 57
C.1.10 Existing Services .................................................................................................................... 57
C.1.11 Care of Boundary Walls and Fences ........................................................................................ 58
C.1.12 Demolition of Contractor's Temporary Works ........................................................................... 58
C.1.13 Demolition of Buildings and Structures .................................................................................... 58
C.1.14 Component Life ...................................................................................................................... 59
C.1.15 Painting and Labelling............................................................................................................ 59
C.1.16 Access for Inspection .............................................................................................................. 59
C.1.17 Washdown Facilities ............................................................................................................... 59
C.1.18 Lifting Equipment ................................................................................................................... 59
C.1.19 Provisions for Dismantling ...................................................................................................... 59
C.1.20 Drains ................................................................................................................................... 60
C.2 MATERIALS AND WORKMANSHIP .........................................................................................................60
C.2.1 Standards and Regulations ...................................................................................................... 60
C.2.2 Samples ................................................................................................................................. 61
C.2.3 Quality of Materials and Workmanship .................................................................................... 61
C.2.4 Materials Testing Laboratory .................................................................................................. 61
C.2.5 Inspection and Testing During Manufacture ............................................................................. 62
C.2.6 Connections to Existing Pipes, Cables, Structures, etc ............................................................... 62
C.2.7 Interchangeability .................................................................................................................. 62
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C.2.8 Balancing and Noise Control ................................................................................................... 62
C.2.9 Erection of Plant .................................................................................................................... 63
C.2.10 Guarding of Moving Machinery ............................................................................................... 63
C.2.11 Rating Plates, Name Plates and Labels ..................................................................................... 63
C.2.12 Packing for Export ................................................................................................................. 63
C.2.13 Storage on Site ....................................................................................................................... 64
C.2.14 Manufacturers' Instructions and Recommendations ................................................................... 64
C.2.15 Contractor to be Responsible for Adequacy of Design of Plant ................................................... 64
C.3 GENERAL CIVIL ENGINEERING CLAUSES ............................................................. 64

C.3.1 EARTHWORKS AND DEMOLITION......................................................................................................64
C.3.1.1 Location of Existing Services ....................................................................................................... 64
C.3.1.2 Site Clearance and Topsoil Removal ............................................................................................ 65
C.3.1.3 Erosion ..................................................................................................................................... 65
C.3.1.4 Ground Levels ........................................................................................................................... 65
C.3.1.5 Demolition ................................................................................................................................ 65
C.3.1.6 General Excavation .................................................................................................................... 65
C.3.1.7 Over- Excavation ....................................................................................................................... 66
C.3.1.8 Mechanical Excavation............................................................................................................... 66
C.3.1.9 Classification of Rock Excavation ................................................................................................ 66
C.3.1.10 Explosives ............................................................................................................................... 66
C.3.1.11 Excavated Materials Suitable For Re Use ................................................................................... 67
C.3.1.12 Disposal of Surplus, Demolition or Excavated Materials.............................................................. 67
C.3.1.13 Backfilling of Excavations ......................................................................................................... 67
C.3.1.14 Making good Subsidence after Refilling ...................................................................................... 67
C.3.1.15 Removal of Timbering from Excavations .................................................................................... 68
C.3.1.16 Reinstatement of Surfaces ......................................................................................................... 68
C.3.1.17 Forming Banks and Filled Areas ............................................................................................... 69
C.3.1.18 Restoration of Borrow Areas, Spoil Tips and Quarries ................................................................. 69
C.3.1.19 Top Soiling and Grassing .......................................................................................................... 69
C.3.1.20 Free Draining Fill .................................................................................................................... 69
C.3.1.21 Hardcore ................................................................................................................................. 69
C.3.1.22 Rock Pitching........................................................................................................................... 69
C.3.1.23 Rock Lining ............................................................................................................................. 69
C.3.1.24 Gabions................................................................................................................................... 70
C.3.2 STRUCTURES (GENERAL REQUIREMENTS) .....................................................................................70
C.3.2.1 Excavation for Foundations of Structures ..................................................................................... 70
C.3.2.2 Rock Surfaces under Concrete Structures ..................................................................................... 71
C.3.2.3 Keeping Rock Faces Dry............................................................................................................. 71
C.3.2.4 Structures Liable To Flotation ..................................................................................................... 71
C.3.2.5 Backfilling Around Structures ..................................................................................................... 71
C.3.2.6 Acceptance Tests ........................................................................................................................ 71
C.3.2.7 Testing of Water Retaining Structures .......................................................................................... 71
C.3.2.8 Cleansing and Sterilizing Water Retaining Structures .................................................................... 72
C.3.3 CONCRETE ..............................................................................................................................................72
C.3.3.1 General ..................................................................................................................................... 72
C.3.3.2 Mix designs ............................................................................................................................... 73
C.3.3.3 Reinforcement ............................................................................................................................ 80
C.3.3.4 Formwork ................................................................................................................................. 81
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C.3.3.5 Concreting ................................................................................................................................ 83
C.3.3.6 Testing ...................................................................................................................................... 92
C.3.3.7 Special Concrete ........................................................................................................................ 94
C.3.3.8 Precast Concrete Units ............................................................................................................... 96
C.3.3.9 Site Books and Standards ............................................................................................................ 98
C.3.3.10 Construction Joints in Water Retaining Structures ....................................................................... 98
C.3.4 SITE WORKS...........................................................................................................................................99
C.3.4.1 Underdrains .............................................................................................................................. 99
C.3.4.2 Access Roads ............................................................................................................................. 99
C.3.4.3 Access Tracks .......................................................................................................................... 102
C.3.4.4 Paths and Paved Areas ............................................................................................................. 102
C.3.4.5 Fencing ................................................................................................................................... 102
C.3.4.6 Gates ...................................................................................................................................... 103
C.3.4.7 Catch Drains ........................................................................................................................... 104
C.3.5 BUILDING WORKS...............................................................................................................................104
C.3.5.1 Cement Mortar ........................................................................................................................ 104
C.3.5.2 Blockwork ............................................................................................................................... 104
C.3.5.3 Rendering................................................................................................................................ 105
C.3.5.4 Plastering ................................................................................................................................ 105
C.3.5.5 Timber .................................................................................................................................... 105
C.3.5.6 Door and Window Frames ........................................................................................................ 105
C.3.5.7 Louvre Windows ...................................................................................................................... 106
C.3.5.8 Insect Screening ....................................................................................................................... 106
C.3.5.9 Ironmongery ............................................................................................................................ 106
C.3.5.10 Glazing ................................................................................................................................. 106
C.3.5.11 Terrazzo ................................................................................................................................ 106
C.3.5.12 Painting (Building Works) ....................................................................................................... 106
C.3.5.13 Roof Waterproofing ................................................................................................................ 107
C.3.5.14 Waterproof Membrane ............................................................................................................ 107
C.3.5.15 Fixings to Concrete Structures................................................................................................. 107
C.3.5.16 Grouting in Ironwork .............................................................................................................. 107
C.3.5.17 Building Work and installation of Plant .................................................................................... 108
C.3.5.18 Bonding New Concrete to Old ................................................................................................. 108
C.3.5.19 Isolation of Aluminium ............................................................................................................ 108
C.3.6 METALWORK AND OTHER FITTINGS...............................................................................................108
C.3.6.1 General ................................................................................................................................... 108
C.3.6.2 Structural Steelwork ................................................................................................................. 108
C.3.6.3 Open Mesh Walkways and Covers ............................................................................................. 109
C.3.6.4 Staircases ................................................................................................................................ 109
C.3.6.5 Ladders ................................................................................................................................... 109
C.3.6.6 Handrailing ............................................................................................................................. 109
C.3.6.7 Guardrail ................................................................................................................................ 110
C.3.6.8 Safety Chains ........................................................................................................................... 110
C.3.6.9 Steel Access Covers .................................................................................................................. 110
C.3.6.10 Floor Duct Covers .................................................................................................................. 110
C.3.6.11 Galvanising ........................................................................................................................... 110
C.3.7 WATER PIPELINES ..............................................................................................................................111
C.3.7.1 General ................................................................................................................................... 111
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C.3.7.2 Ferrous Pipes .......................................................................................................................... 115
C.3.7.2.10 Galvanised Steel Pipes and Fittings....................................................................................... 120
C.3.7.3 Unplasticised PVC (uPVC) Pipes and Fittings ............................................................................ 120
C.3.7.4 High Density Polyethylene Pipes and Fittings ............................................................................. 122
C.3.7.5 Transportation, Handling and Storage ....................................................................................... 124
C.3.7.6 Excavation of Pipe Trenches ..................................................................................................... 126
C.3.7.8 Pipe Installation....................................................................................................................... 128
C.3.7.9 Steel Pipelines ......................................................................................................................... 129
C.3.7.9 Additional Protection of Joints on Ferrous Pipelines ................................................................... 131
C.3.7.10 Backfilling of Pipe Trenches .................................................................................................... 131
C.3.7.11 Making Good Subsidence after Refilling ................................................................................... 135
C.3.7.12 Miscellaneous Clauses ............................................................................................................ 135
C.3.7.13 Hydrostatic Testing of Pressure Pipelines ................................................................................. 136
C.3.7.14 Flushing and Sterilisation ....................................................................................................... 136
C.3.7.15 Tie-In Works .......................................................................................................................... 137
C.3.8 DRAINS, MANHOLES AND CHAMBERS ............................................................................................139
C.3.8.1 General ................................................................................................................................... 139
C.3.8.2 uPVC Pipes and Fittings ........................................................................................................... 139
C.3.8.3 Ductile Iron Pipes and Fittings for Gravity Drains ...................................................................... 140
C.3.8.4 Vitrified Clay Pipes and Fittings ................................................................................................ 140
C.3.8.5 Concrete Pipes and Fittings ...................................................................................................... 141
C.3.8.6 Glass Reinforced Plastics (GRP) Pipes and Fittings .................................................................... 141
C.3.8.7 Perforated / Porous Pipes for Sub-Drains .................................................................................. 141
C.3.8.8 Concrete Bedding and Surround to Gravity Pipes ....................................................................... 141
C.3.8.9 Selected Granular or Sand Bedding and Surround to Gravity Pipes .............................................. 142
C.3.8.10 Pipes and Joints Adjacent to Structures, Junctions and Surrounds .............................................. 143
C.3.8.11 Pipes To Be Kept Clean .......................................................................................................... 143
C.3.8.12 Construction of Manhole and Other Chambers ......................................................................... 143
C.3.8.13 Gulley Gratings and Frames ................................................................................................... 145
C.3.8.14 Testing of Gravity Pipelines .................................................................................................... 145
C.3.8.15 Watertightness and Cleanliness Generally ................................................................................ 145
C.3.8.16 Fixing of Valves and Penstocks in Manholes and Chambers ....................................................... 146
C.3.8.17Protective Coating to Chambers and Water Retaining Structures ................................................ 146
C.3.8.18 Maintenance of Drainage Flows .............................................................................................. 146
C.4 GENERAL MECHANICAL & ELECTRICAL ............................................................ 146

C.4.1 Valves ........................................................................................................................................ 146
C.4.2 Gate Valves ................................................................................................................................ 147
C.4.3 Butterfly Valves .......................................................................................................................... 147
C.4.4 Non-Return Valves ...................................................................................................................... 148
C.4.5 Air Release and Vacuum Break Valves .......................................................................................... 148
C.4.6 Pressure relief valves .................................................................................................................. 150
C.4.7 Pressure reducing valves ............................................................................................................. 150
C.4.8 Float valves ................................................................................................................................ 151
C.4.9 Needle valves ............................................................................................................................. 153
C.4.10 Actuators.................................................................................................................................. 155
C.4.11 Electric Motor .......................................................................................................................... 157
C.4.12 Pumps- General ........................................................................................................................ 160
C.4.13 Air Blowers, Vacuum Pumps and Air Compressors .......................................................................... 163
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C.5 ELECTRICAL PLANT...............................................................................................................................164
C.5.1 General ............................................................................................................................... 164
C.5.2 Power Transformers ............................................................................................................. 166
C.5.3 HV Surge Arresters............................................................................................................... 172
C.5.5 Current and Voltage (Potential) Transformers ........................................................................ 182
C.5.6 Switchboards ....................................................................................................................... 183
C.5.7 Power Factor and Power Factor Correction ........................................................................... 185
C.5.8 400V Soft Starters................................................................................................................. 185
C.5.9 Variable Frequency Drive VFD ............................................................................................. 187
C.5.10 LV and ELV Control Equipment and Devices .......................................................................... 191
C.5.11 Other Instruments, Indications and Alarms ............................................................................. 198
C.5.12 Control Panel Cabling .......................................................................................................... 199
C.5.13 LV Distribution Switch Gear ................................................................................................. 200
C.5.14 Electrical Installation ........................................................................................................... 201
C.5.15 Installation Requirements ...................................................................................................... 204
C.5.16 Earthing and Bonding ........................................................................................................... 210
C.5.17 Structural Lightning Protection ............................................................................................. 212
C.5.18 Permits to Work ................................................................................................................... 213
C.5.19 Test of the Installation .......................................................................................................... 213
C.5.20 Instrumentation: Standard Requirements ................................................................................ 213
C.5.21 Surface Protection and Painting ............................................................................................ 218
C.5.22. Specification for Standby Generator ....................................................................................... 222
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SECTION A: SCOPE OF THE WORKS
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Section A : SCOPE OF WORKS
A.1 OBJECTIVES
The Government of the United Republic of Tanzania is implementing the Second Water Supply and Sanitation
Program (WSSP II) as part of its efforts to reduce poverty, improve health, and the quality of life of the urban
population. World Bank Group’s twin goals of ending extreme poverty and promoting shared prosperity,
sustainably. Improving WRM and increasing access to safe water and sanitation are key to improving livelihood
and health of the majority of Tanzanians, particularly the 28 % who fall below the basic poverty line. The project
will support three interlinked objectives, as detailed below:
1. Promoting shared prosperity through support for economic growth,
2. Increasing sustainability by protecting the natural resources base on which these goals depend, and
3. Ending extreme poverty through support for improved resilience within the basins and improved access
to WSS services.
The WSS services component in Dar es Salaam, which houses about 40 % of the country’s urban population and
is a key economic engine of growth, will contribute to the country’s effort to meet the SDG target for WSS.
This activity will provide water supply services to about 206,253 people of Dar es Salaam, who is not connected
to the formal network. The proposed solutions for this population include decentralized stand-alone small piped
water supply (SPS) systems, and connecting the water supply lines to the existing Major schemes which may be
an interim measure pending integration into the grid network as it expands.
The overall objective of this project

i. Is to improve water service by increasing production and distribution of water with good quality to meet the
current and future demands for 20 years from 2020 to 2040.
ii. To build capacity and committee in the sub ward level to utilities responsible for operation and management
of water and sanitation services in the respective towns.
A.2 SUMMARY OF PROPOSED WORKS
The following works has been proposed under this project.
1) Distribution networks for 60,147Mtr

Designing, Supplying, laying, stringing, cutting, jointing and testing of HDPE/ uPVC
Pipe lines including trench excavation works, in all types of soil (including hard
morrum) for required depth according to the drawings and specifications and any other
requirements for installation.
1. HDPE pipe of DN315mm for 531m
2. HDPE pipe of DN250mm for 8,698m
3. uPVC pipe of DN200 mm for 4,107m
6. uPVC pipe of DN90 mm for 2,418 m
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2) Construction of Reservoirs
Designing and constructing RCC storage reservoirs of different capacities including
civil, electrical, mechanical and other contingent works complete in all respect as
per the specifications and terms of the contract.
S. No Location of Type of Capacity (cum)

Reservoir Reservoir
1 Kichangani GSR 2000
2 Nzasa Somelo GSR 2000
ESR – 18m
3 Yangeyange 1000
Staging Height
3) Intake Borewell
Supply, Erection, Testing and Commissioning of Electrically driven Submersible
pumping sets for pumping clear water conforming to relevant ISO Standard, capable of
delivering adequate quantity of water against required head as stated below:
Discharge
S. No Location of Borewell Head (m) Qty. (Nos.)
(cum/hr)
1 KIFURUKWE 103 135 1
2 NZSA SOMELO 60 160 1
3 MGEULE 110 230 1
4) Offtakes and allied works

• Supply and Construction of Prepaid Water kiosks
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SECTION B: PARTICULAR SPECIFICATION
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Supply and Installation of offtakes, pipeline, distribution points, house service connections and allied works at Kichangani,
Kifurukwe and Uvumba areas of KIGAMBONI Municipality and Nzasa Somelo, Yangeyange areas of ILALA Municipality
SECTION B: PARTICULAR SPECIFICATION

B.1 Background
B.1.1 Location of Site
Kigamboni Municipality has four regions namely Kigamboni, Tungi, Vijibweni and Kibada spread over in
an area of 52.5 Square Kilometers with 9 wards and 67 sub wards. The total population of Kigamboni
Municipality is 202,219 (2020).
Kigamboni is a district southeast of Dar es Salaam, Tanzania. The Kigamboni District is divided into two
administrative wards, Mbagala and Kigamboni. Kigamboni Municipality is bordered on the west by Kibada
Secondary School, bordered on the east by Kichichi and Butima ward, and on the north by sea and on the south
by Tongoma-Ponde ward. The contour of the Kigamboni ward varies from a minimum of 3M to a maximum of
66.5 M. Kigamboni can be approached by road within 2 Kilometers from Dar es Salaam and about 600M by ferry
in the sea.
B.1.2 Prevailing Conditions

The Contractor is deemed to be familiar with existing local conditions, and their potential effect (direct or indirect) on
the planning of the works. The Contractor shall make his own investigations in this respect.
These conditions include, but are not limited, to:
B.1.2.1 Climatic Conditions

The Contractor shall make his own arrangements to obtain climatic data from the Tanzania Meteorological Centre
regarding general climatic conditions prevailing at the Site. There are two rainfall seasons: the short rains between
November and December and the long rains between March and May.
Dust is also a particular hazard to site operations. The Contractor shall take necessary measures to acclimatize
himself and his staff about the weather conditions and have a contingent plan to combat the vagaries of weather.
Adequate arrangements as deemed fit shall be made by the contractor to cope up with the situation during rainy
season which occurs twice in a year. Any provision required may be taken by the Contractor in Provisional sum
in the BOQ.
The Contractor shall protect materials in transit as well as at the site. Imports to Tanzania are often routed via the
port of Dar Es Salaam where the shade temperature may vary between 250 C and 300 C, and the maximum relative
humidity is approximately 95%.
B.1.2.2 Access
Access to the proposed intake and WTP site includes dirt roads. The Contractor shall consider the potential for disruption
to access during the rainy seasons, and shall allow for intermittent maintenance works to ensure continuous access.
B.1.2.3 Services
The Contractor shall make provision for the temporary supply of all services necessary for the execution of the works,
including water, electricity, communications including Internet, fuels and consumables etc. The Contractor shall make
all such applications and payments as necessary in order to obtain the services.
The Contractor is deemed to be familiar with the levels of service provided, and shall make all necessary backup
provisions (such as generator sets, water tankers, on-site storage, etc) to ensure that delays are not experienced.
B.1.2.4 Local Materials

The Contractor shall be familiar with the supply of local materials with respect to sources and location, delivery times,
prices, quality and standards of products, sizes, quantities available, reliability and customer service, delivery capability,
etc.
With respect to quarries and borrow pits, the Contractor shall be responsible for all fees, royalties, permits and other
obligations concerning such activities.
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B.1.2.5 NA
B.1.2.6 Laws and Regulations

The Contractor is deemed to be familiar with all laws and regulations pertaining to the implementation of the contract,
including relevant national design and construction standards, environmental regulations, transportation of heavy
equipment by road, minimum wage and employment standards, health and safety regulations, establishing / operating /
decommissioning of borrow pits, disposal of wastes, procedures and regulations related to procurement of imported
goods, local customs, etc
B.1.2.7 Local Labour

The Contractor shall assess and investigate the availability of local skilled and unskilled labour and take this into account
in execution.
B.1.2.8 Ground Conditions

The Contractor is deemed to be familiar with the site soil conditions, including the presence of groundwater. The
Contractor shall carry out his own geotechnical investigations.
The Contractor shall be aware of maximum flood levels, particularly at the Intake site and along the raw water
transmission main, and shall schedule the construction works accordingly.
B.1.2.9 Existing Plant

It is not proposed to undertake any significant works at the existing facilities. Provisional sums have been included in
the Schedule of Rates and Prices for expenditure on any rehabilitation works, as directed by the Employer and Engineer.
B.1.2.10 Operating Conditions

The Contractor shall be aware that there is existing water supply network in these three towns which is under operational
throughout the year.
The construction works shall be carried out such that disruption to on-going operations is minimal. The Contractor shall
be allowed limited shut-down periods during which he can carry out work during operational hours.
B.1.3 Registration in Tanzania
The Contractor shall comply with the requirements to register engineers and the company with the Engineer’s
Registration Board and the Contractor’s Registration Board of Tanzania.
B.1.4 Other Relevant Contracts

During the implementation of the proposed works, the Contractor shall be aware that other contracts may also be taking
place associated with this project. The Contractor shall accommodate all such contracts and shall carry out the Engineer’s
instructions concerning coordination, communication and exchange of information with such contractors.
These other contracts may include:

Works carried out by TANESCO, in relation to this contract, at main switchyard and sub-station at the WTP;
Environmental, social, health and safety impact prevention, mitigation and monitoring programmes.
B.2 Documentation
B.2.1 Contract Drawings
During the course of the Contract, various drawings shall be produced; the requirements are outlined in Table B-3.
Table B-2 Contract Drawings
Type Description
Bid Drawings Drawings issued at time of the Bid indicating the overall arrangement and initial
concept drawings for the components.
Concept Drawings Refined and improved concept drawings following topographic surveys and any
geotechnical investigations.
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Type Description
Drawings for Construction Final drawings suitable for construction and installation, for review and checking
/ Installation by the Engineer.
Fabrication Drawings Detailed workshop drawings for fabrication on- or off-site of specific elements,
such as roof trusses, pipeline supports, etc.
Revised Drawings Any revisions to previously issued drawings.
Drawings Issued by Any other drawing that may, from time to time, be issued by the Engineer for the
Engineer Contractor’s information or instruction. No drawings issued by the Engineer shall
relieve the Contractor of design responsibilities.
As-Built Drawings Drawings indicating all structures, pipelines, plant and equipment as constructed
or as installed. These shall include manufacturers’/suppliers’ drawings and
(Cl.5.6 of the General
sketches.
Conditions apply)
All As-Built drawings shall be reviewed and checked by the Engineer.
From the beginning of the contract the Contractor shall develop and maintain a drawing register system, to the
satisfaction of the Engineer, that includes such details as drawing number, title, description, dates of submission /
comments received / approval, revision letter and description, initials of designer / draughter / checker / approver, and
any other information that allows clear, systematic and unambiguous tracking of design drawings, comments, changes
and approvals.
The register shall also include all design calculations and reports. Drawings shall indicate all revisions, including date
and brief description.
Copies of the drawing register shall be made available to the Engineer.
All drawings shall be prepared in the current version of AutoCAD. All drawings shall be submitted as hard copy; with
the prior approval of the Engineer, drawings may be also submitted electronically for review using PDF format.
Drawings shall be prepared by competent, qualified technicians, experienced in preparing drawings for the type of works
in question, and familiar with standard drafting conventions and symbols, and drawing revision procedures.
B.2.2 Programme of Works
In compliance with Cl.8.3 of the Conditions of Contract, the Contractor shall submit a detailed Programme to the
Engineer for review and comments.
The Programme shall be in bar chart (Gantt) format and shall indicate the major work components (including design and
procurement) and the main sub-activities. The program shall have a unit of time of one month and shall be prepared
using a recognised project management program, licensed copies of which shall be provided for the Engineer and site
supervision team.
The programme shall clearly indicate the various work components by discipline, including specialist sub-contracts and
suppliers, as well as the Contractor’s major plant requirements, in order to demonstrate sequencing and non-conflict of
resources. The Engineer may instruct the Contractor to provide summary versions of the programme or additional detail,
as necessary for review.
B.2.3 Method Statements
The Contractor shall submit detailed method statements to the Engineer, as required under Cl.8.3 (d) of the General
Conditions of Contract.
The method statement shall describe the Contractor’s overall approach to the contract, including issues such as type,
number and layout of Contractor’s buildings, stores and facilities; provision of temporary services; personnel issues
including management structure, supervision and labour; Contractor’s plant and equipment, and maintenance thereof;
quality management procedures; general methods for key work components such as structural works, electrical-
mechanical installation, pipelines etc.; working adjacent to operational water treatment plant and special considerations,
etc.
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From time to time the Engineer may instruct the Contractor to prepare detailed method statements for specific activities.
B.2.4 Environmental and Social Management Plan
Within the time period specified in the Conditions of Particular Application, the Contractor shall submit a project specific
Environmental and Social Management Plan (ESMP) for approval.
B.2.5 Health and Safety Management Plan
Within the time period specified in the Conditions of Particular Application, the Contractor shall submit a project specific
Health and Safety Management Plan (HSMP) for approval.
B.2.6 Progress Reports
The Contractor shall submit a monthly progress report to the Engineer. The format, content and level of detail shall be
determined by the Engineer.
If the Engineer considers it necessary, the frequency of reporting may be increased. Alternatively, the Contractor may
be instructed to provide a special progress report for a particular section of works (that is significantly delayed for
example), on a more frequent basis.
B.2.7 Daily Record
The Contractor shall maintain a Daily Record summarising site activities. The Record shall be in the form of a triplicate
book, with one copy being delivered each day to the Engineer.
The content and format of the Daily Record shall be agreed with the Engineer upon commencement of the contract. The
Record shall include:
• the date,
• weather,
• numbers/movement of labour,
• main areas of work and daily activity/progress,
• deliveries of Plant and Materials to site,
• movement of Contractor’s Equipment on/off site,
• tests, issues, shut-downs, key instructions, accidents, visitors, etc. and any other items of note.
The Daily Record shall allow for comments by the Engineer.
The Engineer may, at his discretion, instruct the Contractor to provide daily labour and plant returns. The Contractor
shall provide the Engineer, if requested, with copies of all delivery notes of Plant and Materials delivered to site.
B.2.8 Test Forms
The Contractor shall prepare, to the satisfaction of the Engineer, test forms to be used for the various components of the
works.
All test forms shall be completed, signed and dated by the appropriate persons conducting the tests. The original copy of
all test forms shall be submitted to the Engineer.
Tests forms shall be submitted to the Engineer regardless of whether the test passes or fails.
B.2.9 Miscellaneous Forms
The Engineer and/or Contractor shall prepare other forms for formalising and recording communications and
information transfer as necessary. These shall include, but are not limited to:
a) Site Instruction form
b) Request for information / inspection / approval form
c) Dayworks form
d) Concrete pour form.
B.2.10 Documents on Completion
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These include As-built drawings, O&M manuals, and any other information, in digital or paper form, required for the
operation and maintenance of the completed Works.
B.3 Design of Works

B.3.1 General
The objective of the Project is to design, supply and construction of water treatment plant / plants of capacity as per table
B-1.
The Contractor shall take full responsibility for the detailed design of all works as described in the Specifications and
drawings. This will include elements of process design, structural and building works, mechanical and electrical design,
control systems, and civil engineering works including pipelines and site works.
The proposed works shall result in complete and operationally functional units, fully compatible to the local site
requirements. The scope of works shall be deemed to include all component parts necessary, regardless of whether the
item is specifically itemized in the Schedule of Prices and Unit Rates or drawings, and shall be in accordance with what
is considered to be standard practice in the water industry.
The Contractor shall bring to the attention of the Engineer, at the earliest opportunity, issues related to the existing
utilities. The Contractor will be required to fully substantiate his concerns and shall provide all necessary technical
documentation and calculations to allow the Engineer to make an informed judgement.
The extent of design work involved depends on the element under consideration. In some cases the Contractor is given
relative freedom in terms of the design, as long as it meets specific minimum requirements, whereas in other cases
recommended number / capacity / size has been indicated.
Notwithstanding the above, the Contractor shall confirm such recommendations, and ultimately shall take full
responsibility for the functionality and performance of the proposed works. Where the Contractor disputes a
recommended size or capacity as indicated in the specifications and/or drawings, he shall notify the Engineer, at the
earliest opportunity, and shall provide suitable calculations and reasons to support his case.
The Contractor shall be responsible for all investigations and calculations necessary to ensure that the Works shall be
sound and fit for their purpose. Dimensions, locations, materials, and other requirements indicated in the Contract shall
be reviewed by the Contractor who shall propose for the Engineer's approval such changes as the Contractor considers
essential to enable him to accept responsibility for the performance of the completed works.
The Contractor’s designs shall take into consideration the requirements of the Environmental and Social Management
Plans and the Health & Safety methodology for construction, operation and maintenance of the completed Works.
B.3.2 Drawings
Drawings indicate the general arrangement of the proposed plant, and do not purport to show the full extent of the Work
required under this Contract. The Bid Drawings are conceptual in nature, intended to provide an indication as to the
general location and scope of work. Given the conceptual nature of the drawings, it is the Contractor’s responsibility to
seek clarification where the limits or scope of work is unclear. No consideration will be given to additional time or
payment, resulting from lack of understanding of the limits or scope of works to be carried out.
All dimensions and elevations, as well as proposed layout of new structures, shall be verified by the Contractor prior to
finalizing the designs. Where locations of structures and plant are indicated on the Bid Drawings, the Contractor shall
adhere to these wherever possible. The Contractor shall seek the approval of the Engineer concerning proposed locations
of structures and plant.
B.3.3 Verification by Contractor

B.3.3.1 Survey and Dimensional Checking
The Contractor shall be responsible for checking the following prior to carrying out design work:
i. Confirm elevations, especially as they relate to the hydraulics through the plant. All elevations shall be
related to a single bench mark;
ii. Confirm proposed distances and lengths;
iii. Confirm location of proposed structures, plant and pipeline routes, including preliminary setting out.
Location of structures and pipe alignments to be selected such that proposed lengths of pipe, electric
cable, etc are minimized;
iv. Confirm elevations of pipelines at key locations. In particular this shall include sections where pipelines
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shall cross. The Contractor shall excavate and backfill all necessary trial holes to confirm such
elevations;
v. The Contractor shall provide the Engineer with drawings and other such documentation confirming all
surveys and setting out
B.3.3.2 Locating Existing Underground Pipelines, Cables and Other Services

The proposed works involves the construction of various large diameter pipelines.
Excavation and backfilling of test pits shall only be undertaken with the prior approval of utility and the Engineer.
Damage to existing pipelines, cables and other services shall be repaired by the Contractor at his own expense and to the
satisfaction of the relevant authority.
B.3.3.3 Raw Water Quality Testing

The Contractor shall allow for additional raw water testing as necessary, to confirm that the proposed units are capable
of producing water that meets the treated water quality objectives.
The Contractor shall also take samples and analyze the water at various stages of the treatment process, as he considers
necessary. For example, the effluent from the grit tanks which comprises the feed water to the clarifiers.
The Contractor shall provide a copy of all such test results to the Engineer.
B.3.3.4 Geotechnical Investigations

The Contractor shall carry out all geotechnical investigations and analyses required as input to detailed design and
construction works. The purpose of the geotechnical investigations is to determine:
i) The soil type, strength and consolidation characteristics at the site of each major structure, including the
new treated water pump station, new raw water pump station, and new low lift pump station, as inputs
to the design of foundations;
ii) The strength and deformation characteristics related to design of thrust and anchor blocks, including
valve chambers with combined thrust wall;
iii) The soil modulus as input for all pipeline designs;
iv) The classification of soils at all work sites, related to the suitability of in-situ soils for bedding, backfill
and/or road construction materials, and identifying the collapsing nature as related to trench / foundation
excavations;
v) The type and permeability of in-situ soils at the site of the proposed sludge lagoon, related to their
suitability as a lining material;
vi) Areas of rock and/or boulders;
vii) The physical-chemical characteristics of the soil and groundwater system, and their individual and
combined capacity to accelerate corrosion processes. The information shall be used in the selection of
the type of coating for ferrous pipes and joint protection, the type of embedment material for pipes, the
selection and design of additional corrosion protection measures for ferrous pipes, the potential to affect
the performance of Ordinary Portland Cement and selection of additives and/or other cement types, and
potential corrosion issues related to buried metal structures;
viii) The characteristics and suitability of the in-situ soils with respect to electrical earthing systems;
ix) The nature, location and movement of groundwater / water table, as inputs to foundation design, pipeline
design and construction methods.
The Contractor shall carry out the following:
i) Soil classification, strength and consolidation tests at a minimum of 3 locations at the site of each major
structure;
ii) Soil classification, strength and deformation tests at the locations of thrust / anchor blocks;
iii) Soil classification and strength tests at approximately 100m intervals along pipeline routes;
iv) Classification of soils at all work sites, including other non-work areas identified as potential borrow pits
for use as bedding and/or backfill material;
v) Electrical resistivity and chemical analyses along each pipeline route and at the site of each major
structure;
vi) Soil classification, percolation and compaction tests at the site of the proposed sludge lagoon;
vii) Soil classification and compaction tests at the sites of proposed access roads and hard-standings;
viii) Locate the existence, level and movement of groundwater throughout the site;
ix) Variety of laboratory tests including, but not limited to, soils classification code, sieve analysis, Atterberg
limits, bulk and dry density, voids ratio, specific gravity, triaxial compression test, direct shear test,
consolidation test, swelling pressure and swelling tests, and various chemical tests including pH,
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conductivity, chloride, sulphate;

x) Take pictures and GPS readings at all sites. Pictures shall include temporary marker board identifying
the location / number, and where necessary shall include a suitable item to indicate scale.
Where the soil conditions are found to vary considerably across the site, the number / frequency of tests shall be
increased, to the satisfaction of the Engineer. No additional payment shall be made for such increases.
The Contractor shall provide a statement in his technical proposal indicating the methods he shall employ to achieve the
above requirements. It is anticipated that the methods will include, but not be limited to, auger/boring, penetration tests,
collection of disturbed and undisturbed samples and logging, trial pits, visual field assessments, electrical resistivity tests,
percolation / permeability tests, laboratory tests, among others.
As a general guideline, penetration tests shall continue to a depth of at least 5 m below the proposed formation level (2
m for pipelines). However, if the readings at that level indicate a layer of weak or otherwise unsuitable material, the tests
shall continue as necessary, until a definitive judgement can be made concerning the suitability of the underlying soils.
No additional payment shall be made in this respect.
Similarly, trial pits shall be dug to the level of the proposed formation level, at least. However, if visual inspection at that
level indicates weak or otherwise unsuitable material, the trial pit shall continue as necessary until the information is
conclusive. No additional payment shall be made in this respect.
Where, in the opinion of the Engineer, the geotechnical investigations and methods being used are inadequate in scope
or quantity, or are inappropriate for the data being sought, the Contractor shall change his methodology to the satisfaction
of the Engineer. The objective of the geotechnical investigations is clear and no additional payment shall be made where
the Contractor is required to change methods, or increase the scope or level of effort of his investigations.
The location of tests / trial pits shall be marked on plans. Borings / test holes etc shall be given appropriate identification
numbers.
The field and laboratory tests and sampling shall be undertaken by experienced technicians only, who are thoroughly
familiar with the equipment and standard methods. All tests shall be carried out in accordance with manufacturer’s
instructions and relevant testing standards.
Samples collected for laboratory analysis shall be place in sealed plastic bags to prevent loss of moisture and general
deterioration of sample.
The Contractor shall backfill all holes and borings immediately upon completion. If it is necessary to leave a hole or
boring open, as authorized by the Engineer, the Contractor shall mark and protect the hole against accidents and/or
damage to the excavation.
The Contractor shall prepare a Geotechnical Report describing all tests and analyses undertaken, test results and charts
and tables, maps etc, and shall include values and recommendations concerning the issues of relevance discussed above.
The report shall also compare the current results with previous soils reports prepared during the recent rehabilitation
works, and provide comment as necessary. The report shall be prepared, signed and stamped by a qualified and
experienced Geotechnical Engineer. The Contractor shall provide five (5) bound colour copies of the final report, and a
CD copy of all editable files and pictures.
B.3.3.5 Shut-Down of Water Treatment Plants if any
For the most part, the new works can be constructed with minimal disruption and interference with Water utility day-to-
day operations.
However, at some point in time, the new works must be inter-connected with the existing plant if any. Typically, this
will involve shutting down the entire WTP, or a section thereof, for a period of time.
Such shut-down periods effectively represent a loss of revenue to the Operator and therefore will be strictly controlled.
The “rules” governing shut-downs are:
i. Maximum of 2 shut-downs per month, whether partial or complete;
ii. Unused shut-downs cannot be accumulated. Therefore, if the shut-down is not used, then it is lost;
iii. Only one shutdown per week is allowed;
iv. Shut-downs will not take place during the last week of the month;
v. The maximum time allowed for a shut-down is 36 hrs;
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vi. The Contractor shall be penalized for loss of revenue in the case of shut-downs that exceed 36 hrs without
acceptable justification;
vii. Work shall be continuous throughout the shut-down period. In particular, it shall not include a rest period.
Rather the Contractor shall allow for multiple shifts of teams and adequate lighting for night-time work;
viii. The Contractor shall submit his request for a shut-down at least 14 days in advance, to facilitate public
announcements;
ix. The Contractor may be penalized for cancelling a shut-down for what-ever reason, after water Utility has
issued public announcements. The penalty shall be determined by the Engineer and water Utility, but may
include the cost of the announcements and/or loss of revenue if applicable;
x. The Contractor shall submit a detailed program and method statement 14 days in advance, for each shut-
down.
Further, the Contractor shall observe the following considerations:

i. A partial shut-down is preferable to closing the entire plant. In this respect, the Contractor may be required
to undertake some temporary works in order to allow continued partial operation. In this respect, the
Engineer’s decision shall prevail as to what is a reasonable amount of temporary works;
ii. Preparation of the program and detailed method statement is a critical part of the overall shut-down procedure.
Refer also to Clause 3.7.15 concerning Tie-in Works for pipelines. The Engineer shall determine if the
planning and preparatory works are satisfactory. Where, in his opinion, the preparations are unsatisfactory,
the Engineer shall have the authority to deny the shut-down, and the Contractor shall have no grounds for
claiming additional time and/or costs.
The program and detailed method statement shall be unique to each shut-down request. However, in general,
these shall include (but not be limited to) the following:
a. Description of the activity(ies) to be undertaken;
b. Proposed dates, times, duration;
c. Materials checklists, including pre-installation verifications, and spares if necessary;
d. Contractors equipment / tools checklists, including standby, spares, consumables, etc.
e. List of teams including identification of key persons and total numbers and skills;
f. Checklist of pre shut-down works to be completed (if applicable);
g. Detailed step-by-step description of activities, including sequencing and dependencies;
h. Tests to be undertaken, if any;
i. Special cleaning / disinfection measures to be undertaken prior to returning to use;
j. Assignment of responsibilities for key actions, eg closing down. starting up plant, switching off/on
power supply, opening/ closing valves, etc and protocols;
k. Identification and quantification of risks and preparation of contingency plans;
l. Particular environmental concerns;
m. Particular health and safety issues;
n. External inputs (by 3rd parties), if any, and measures taken to ensure timely involvement;
o. Logistics including transport, food, shelter, lights etc.
iii. In order to avoid duplicate shut-down requests, the Contractor shall always attempt to maximize the work
undertaken during a shut-down;
iv. Where the proposed shut-down requires draining down the entire WTP (effectively representing a loss to the
Operator), or part thereof, the Contractor shall always maximize the work undertaken during the shut-down.
In some cases this may involve the Contractor having available multiple teams and/or contractor’s plant. No
additional payment shall be made for increasing the number of teams and/or contractors’ plant;
v. The maximum duration shall be 36 hours as indicated above. However, this does not imply that all shut-
downs should necessarily last 36 hours. In this respect, if a particular job can be reasonably accomplished in
(say) 12 hours, then the Contractor shall plan accordingly and endeavour to get the plant back into operation
at the earliest opportunity.
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Concerning application of the rules, as well as the above considerations, the Engineer’s decision shall be final. The
Contractor shall not be entitled to any claim for loss of time or costs where the Engineer denies a shut-down request due
to lack of planning or preparedness, or where the proposed activities are not being maximized.
B.3.3.6 Confirm Scope and Requirements

Based on the above verification checks, the Contractor shall confirm the proposed scope of works, or make
recommendations as necessary. These verification checks shall be carried out immediately upon mobilization to site, and
no consideration will be given to additional time resulting from the lateness of the investigations.
B.4 Design Considerations

B.4.1 General
All designs shall attempt to optimize the following considerations:
i) Reliability, both in terms of process performance and electrical-mechanical plant and equipment.
Processes shall be consistently repeatable and stable over a range of parameters, and not susceptible
to shock hydraulic and/or contaminant loading;
ii) Provide an appropriate level of standby capacity;
iii) Durability of structures, and plant and equipment. Electrical-mechanical plant shall be selected with
consideration to expected lifespan and wearing of parts;
iv) Effectiveness of corrosion protection measures;
v) Availability of local representation for after-sales service, including supply of spare parts, trouble-
shooting and repair services, and the possibility of inspection / maintenance contracts;
vi) Operationally simple;
vii) Appropriate levels of automation, with manual over-ride. Full automation is not desirable;
viii) Health and safety issues, especially with respect to storage and use of chemicals, high voltage power
supplies, heavy movable plant and equipment, rotating equipment, storage and disposal of chemical
and other wastes, deep water tanks, etc
ix) Appropriate levels of safety / shut-off devices to protect plant and equipment;
x) Future expansion. In particular this refers to the sizing of pump stations and other structures, pump
and motor selection, electrical switchgears, and pipelines including blanked off connections for future
use;
xi) Environmental issues including disposal of treatment wastes, chemicals and spills;
xii) Security of plant, both in terms of access by unauthorized personnel (e.g. high voltage equipment),
as well as prevention against theft and vandalism;
xiii) Use of established and proven technologies and equipment. New and un-proven methods and/or plant
(including regional unfamiliarity) shall not be accepted;
xiv) Minimizing operational costs;
xv) Ease of access for normal operations, maintenance and repairs.
B.4.2 Water Quality Standards

The target water quality standards are WHO (fourth edition- 2017) guideline values, which have generally been adopted
by the Tanzania Bureau of Standards (TZS 789:2008).
For the purpose of process design and selection of plant and equipment, the Contractor’s designs shall also comply with
the target water quality requirements described for the individual units (Section 5 of these Specifications).
The Contractor shall identify, at the earliest opportunity, where such target water quality requirements for the individual
units are inadequate in terms of meeting WHO guideline values concerning the final treated water quality.
B.4.3 Design Criteria
The Design Criteria for the various units are indicated under the individual work descriptions.
B.4.4 Codes and Standards
The proposed works to be carried out under this Contract shall be designed, manufactured, installed and constructed to
appropriate International Standards and Codes as well as local national Codes and Regulations. In all cases, the more
rigorous conditions shall apply.
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The Contractor shall indicate relevant codes with his submission of proposed plant and equipment.
B.4.5 Specific Design Requirements
B.4.5.1 General
The Contractor’s design submissions shall include, but not be limited to:
i) Detailed calculation sheets, including assumptions, design criteria, relevant codes, software name and
version (with licensed copy of proprietary programs where appropriate), applied loads, etc;
ii) Scaled drawings including site plans, general arrangement and plant layout drawings, process and
instrumentation drawings, control diagrams, electrical single line and other drawings, structural
drawings, pipeline plan and profiles, special details, alteration drawings, etc;
iii) Hydraulic profiles;
iv) Plant and material schedules;
v) Manufacturer’s shop drawings, where appropriate;
vi) Manufacturer’s specifications, data sheets, dimensional drawings, etc;
vii) Manufacturer’s performance curves;
viii) Manufacturer’s installation / operation / troubleshooting data.
Design documents shall be submitted in duplicate, including soft copy. One copy shall contain original documents. The
Engineer reserves the right to increase the number of copies. The Contractor shall establish and implement, to the
satisfaction of the Engineer, a system that tracks and records all design revisions.
B.4.5.2 Electrical Supply Design
Electrical equipment provided under this Contract shall be designed and suitable for operation and connection to the
TANESCO 3-Phase 50 Hz. 0.4kV power supply system at the plant.
The Contractor shall conduct a full system analysis using recognised software to determine load flows and prospective
fault levels at all equipment in order to determine minimum equipment ratings. The Contractor shall obtain the system
parameters from TANESCO, including peak voltages in order to carry out the system analysis and select equipment.
Maximum demands specified through the Specification for all switchboards shall be used as a minimum basis for the
load flow analysis, which shall be used for design and equipment selection.
The calculated 3 phase or phase-to-earth fault level, whichever is larger, plus a minimum of 30% shall be used as the
minimum design fault level for equipment selection.
System Neutrals shall be effectively earthed.
The Contractor shall prepare a protection co-ordination design, including grading diagrams to ensure the protection of
all equipment is correctly co-ordinated for maximum reliability of the power supply system.
All equipment provided under this Contract shall be suitable for continuous operation with harmonic distortion on the
power systems within the limits normally permitted by the electrical supply authority. The Contractor shall confirm such
limits.
B.4.5.3 Electrical Works Documentation
The Contractor shall submit the following prior to the Contractor commencing any related work associated with
procurement, construction or manufacture:
i) Switch room drawings;
ii) Detailed single line diagrams of all power supply systems;
iii) Circuit diagrams of all items of equipment and systems supplied under the Contract;
iv) PLC drawings including input/output circuit diagrams and rack layout drawings;
v) PLC interface circuit drawings;
vi) Alarm listings;
vii) Functional specification and data table layout of PLC systems;
viii) Instrumentation loop drawings;
ix) Detailed function charts, in approved format, to provide details of the proposed functional operation of
all equipment and systems;
x) Detailed arrangement drawings of the cubicle/cabinets and panels showing general arrangement, major
dimensions, masses, locations of terminal boxes, and all service connections;
xi) Shop drawings for the switchgear including material lists, general arrangements, front views, assembly
drawings, foundation plans, circuit diagrams and wiring and connection diagrams. Overall dimensions,
minimum clearances and door swings shall be shown for all equipment;
xii) Detailed listing and catalogue information and technical data for all electrical equipment, items and
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devices to be provided by the Contractor;

xiii) Arrangement of floor and foundation openings and other foundation details required for panels and
cubicles/cabinets;
xiv) Detailed arrangement drawings of all other items of equipment supplied by the Contractor under the
Contract;
xv) A Schedule of Labels for equipment and devices;
xvi) Proposed testing and commissioning procedure, and list of specified test equipment.
B.4.5.4 Manufacturing Drawings
Contractor shall submit for approval, shop drawings of the switchgear, control cubicle/cabinets and panels showing:
i) The general arrangement including detailed layout of all equipment and connections;
ii) Structural and enclosing elements including sheet metal and sealing details;
iii) Type and rating of equipment items;
iv) Terminal block layouts and identification.
B.4.5.5 Pumps
The duty points provided in the Specifications and on the drawings are preliminary only. The Contractor shall to verify
the actual pump duty points, in all cases. The Contractor shall confirm the duty points for all pumps, with consideration
to the following:
i) Determine the relevant flow. The guaranteed raw water capacity indicated in the Table B-1, which
assumes approximately 2% process losses. The Contractor shall be required to confirm this, based on
his proposed equipment. Discharges for other pumps (e.g backwash and/or dosing pumps) shall be
based on individual flow requirements.
ii) Determine the total dynamic head, including static head, pipeline losses, minor losses, special head
losses (for specific items of equipment), and station losses.
iii) For all pump systems within the WTP site, the Contractor shall confirm the static head (including
variations) by physical survey for design purposes.
iv) Pipeline losses shall be based on measured values, or in the absence thereof, on generally accepted wall
roughness parameters. The values shall consider long-term pumping conditions. Calculations shall
consider the sensitivity of head losses with the roughness parameter. Pipeline lengths within the WTP
site shall be physically measured based on the proposed alignment.
v) Minor losses due to fittings etc, shall be determined using standard hydraulic tables and/or accepted
calculation procedures.
vi) Head losses associated with specific items of equipment shall be based on manufacturer’s published
data, with due allowances for conditions which vary from the stated conditions
The Contractor shall provide charts with both the system curve(s) and pump curve plotted to the same scale, with due
allowance for station losses. Where necessary, multiple system curves shall be plotted reflecting variations in the static
head and/or reflecting a range of roughness (friction) coefficients.
Where variable frequency drives are used, the pump curves shall be plotted at the relevant speeds.
The pump curves shall include power, efficiency, and NPSHR curves. The Contractor shall provide the necessary
calculations, when necessary, to confirm the NPHS available.
The Contractor shall submit the charts, together with all calculations, as well as the manufacturer’s complete data /
specification sheets, to the Engineer for approval.
The Contractor shall select plant that can fulfil the requirements for both scenarios, with the minimum of upgrades (e.g.
change of speed, or change of impeller diameter, etc).
B.4.5.6 Hydraulic Design

All system designs shall be verified hydraulically, including diagrams, to confirm water levels and/or operating pressures
throughout the plant. The diagrams shall indicate water levels / pressures under normal operation as well as with
individual or combinations of process units out of service.
Designs shall ensure adequate free-board under worst-case conditions, as well as non-submergence of weirs and proper
operation of overflows.
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Designs shall indicate cut-in and cut-out water levels and, where necessary shall indicate the cycle times for pumps and
other plant.
Where appropriate, designs shall also indicate, velocities, detention times, detention volumes, weir loading rates,
overflow capacity, etc.
B.4.5.7 Pipelines
The Bid Drawings indicate recommended diameters of the proposed pipelines. The Contractor shall confirm the sizes
with due consideration to velocities (maximum and minimum), head losses, flow requirements and cost, among others.
Where the Contractor proposes a different diameter, he shall provide all necessary calculations to support his proposal.
However, unjustified over-sizing of pipes shall not be allowed.
The Contractor shall identify such locations, early in the contract, and determine the elevation, gradient, direction, size,
material, function, etc of the existing pipe.
Horizontal and vertical alignment drawings shall be prepared for each proposed pipeline at suitable scales. The drawings
shall also indicate, horizontally and vertically pipelines complete with diameters, chainages, elevations and gradients, as
well as other structures. Detailed drawings shall be provided for pipeline crossings, indicating the separation distance,
protective measures if required, and other details.
Ideally, pipelines shall cross one underneath the other with a suitable separation distance. Where this is not possible, the
Contractor shall design a suitable crossing structure complete with calculations and operating and maintenance details.
In general, pressure pipelines are easier to re-align vertically than open channel drains laid to gradient. However, in such
cases, the designer shall check for changes of grade, including sign reversals of gradient. Air valves and/or flushing
points shall be added as necessary.
B.4.5.8 Structural Design

Structural designs shall include all calculations, reinforcement detailing and bar bending schedules.
The relevant design standards, including local building codes and regulations, shall be clearly indicated.
All loads and load combinations shall be identified and considered to determine worst case loading conditions.
Foundation designs shall refer to, and correspond with, the geotechnical investigations.
B.4.6 Reviews and Approvals

The Contractor’s designs will be reviewed and approved by the Engineer. In this context, approval by the Engineer
constitutes a “no objection” and shall in no way relieve the Contractor of his responsibility for the design and ultimate
operation and performance of the completed plant.
The review and approvals procedure is described in Conditions of Contract Clause 5. The Contractor shall allow for such
procedures in his work plan.
B.5 Pumps
B.5.1 General
Workshop acceptance tests for all pumps shall be carried out in the presence of, and to the satisfaction of the Employer
and/or Engineer. If instructed to do so by the Engineer, the Contractor shall nominate an independent and certified agent
to inspect the pumps and witness the tests. The nominee shall be acceptable to the Engineer.
The Contractor shall give the Engineer a minimum of 2 weeks advance notice of any testing.
The Contractor shall submit a Report, together with the certified test certificates, of each test specified hereunder, prior
to delivery of the equipment, for comments by the Engineer. The Engineer’s “no objection” shall not relieve the
Contractor of his obligations under the Contract.
B.5.2 Performance Tests
Each raw water pump and treated water pump shall undergo performance tests in accordance with the latest version of
ANSI/HI1.6-2000 Level 1. Each low lift pump (Alternative RW-2) shall undergo Level 2 performance tests.
Each pump unit shall be completely assembled with its own motor, and tested for the guaranteed values provided in the
Bid/contract, for the following:
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i) Flow rate in MLD;

ii) Total head in meters;
iii) Pump efficiency;
iv) Motor power input;
v) NPSH required, where applicable.
The values for head, efficiency, power input and NPSH shall be plotted in graph form against the flow rate. The flow
rate shall always be plotted on the X axis.
B.5.3 Vibration Tests
Vibration tests shall be carried out in accordance with ISO 10816-1 for all pumps. Factory testing shall give a vibration
severity no greater than 7.1 mm/sec (RMS) for flexible support class, and 4.5 mm/sec (RMS) for rigid support class, as
specified by ISO 10816-3 in Table A.3, Zone Boundary B/C.
B.5.4 Sound Pressure Tests
Sound pressure testing shall be carried out to verify that the pump sound pressure level does not exceed the specified
limit when the pump operates at duty point and shall be tested in accordance with AS1217.5- 7 or equivalent.
The measured sound frequency spectrum shall be included as part of the report.
B.5.5 Tests on Completion
This section of the Particular Specifications shall be read in conjunction with Conditions of Contract (CC) Clause 9,
Tests On Completion, CC Clause 10 Employer’s Taking Over, CC Clause 11 Defects Liability, and CC Clause 12 Tests
On Completion, as well as other referred-to Clauses
In general terms, the sequence of events shall following the order indicated in Table B-3.
Table B-3 Sequence of Tests, Taking over and Defects Liability
CC
Description Comments
Clause
Construction / installation - Construct and/or install plant and equipment in accordance with
requirements of Specifications and drawings
Item specific off-line / “dry” - Eg pressure testing pipelines, leakage testing structures, and
tests other tests that can be conducted pre-final connection to live
system
Commissioning Plan and Test - Prepared by Contractor describing the method and sequence of
on Completion Plan undertaking the Tests On Completion
Tests On Completion 9
i) Pre-commissioning Additional inspections and/or off-line or “dry” tests

tests demonstrating that each item of plant can undertake the next
phase of tests (i.e. the Commissioning Tests)
ii) Commissioning To confirm that equipment is installed correctly and is

tests operational. Adjust flows, timers, water levels and other settings
iii) First proof-of- To confirm that all equipment is functioning correctly and that
performance test the requirements of the Specifications are being met, including
guaranteed performance values
Taking-Over Certificate 10 Upon satisfactory completion of commissioning and the first
proof-of-performance test.
Partial Taking-Over shall not be allowed
Defects Liability Period 11 Commences immediately upon issue of Taking-Over Certificate
Tests After Completion 12
i) Second proof-of- Same as first proof-of-performance test

performance test
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CC
Description Comments
Clause
ii) Third proof-of- Same as first proof-of-performance test

performance test
Performance Certificate 11.9 All defects fixed. Contractor relieved from further contractual
obligations
B.5.6 Commissioning Plan

At least one month prior to the proposed commencement date of pre-commissioning and commissioning of plant and
equipment supplied and installed under this Contract, the Contractor shall submit to the Engineer for consideration a
Commissioning Plan in both hard-copy and digital “.pdf” formats.
The Commissioning Plan shall set out in narrative and summary tabular forms, a list of the proposed pre-commissioning
and commissioning activities to be carried out, for each equipment item, together with proposed start and finish dates.
The format of the summary table portion of the Commissioning Plan shall be similar to Inspection and Testing Plans to
be submitted by the Contractor in support of his Quality Plan.
Any interdependencies and specific sequencing issues concerning the commissioning of equipment items shall be clearly
detailed and shown on the summary table.
The need for any equipment shutdowns, filling of treated water storages or equipment isolation (mechanical or electrical),
shall also be indicated.
As noted below, “dry” or off-line inspections and tests will carried out as much as is practically possible.
The Engineer shall review the Commissioning Plan and advise the Contractor of acceptance or otherwise. If the Plan is
accepted by the Engineer, the Contractor shall make the necessary preparations to commence commissioning activities
as soon as practicable thereafter. If rejected by the Engineer, the Contractor shall attend to any deficiencies noted, revise
the Plan and resubmit to the Engineer for approval. The Contractor shall not be entitled to claim additional time or costs
as a result of having to revise his Commissioning Plan.
A copy of the Commissioning Plan, complete with check-lists indicating that all pre-commissioning and commissioning
activities have been successfully completed, shall be submitted to the Engineer when commissioning activities have been
completed, in both hard-copy and digital “.pdf” formats.
Where necessary, commissioning shall be undertaken in conjunction with the equipment suppliers.
B.5.7 Off-Line/“Dry” Tests
There are various items of work and/or equipment that can be inspected and/or tested off-line or “dry”. Such inspections
/ tests take place before connecting into the live systems and therefore do not interfere with the on-going operations.
Consequently, failure of this type of test has least impact on the WTP operations.
Tests of this nature will include, but not be limited to:
i) Pressure testing of pipelines;
ii) Leakage testing of drains and manholes;
iii) Leakage testing of water-retaining structures;
iv) Certain operational tests that can be carried out manually or by providing temporary power supply,
eg. operation of mixers, valves, motorize actuators etc.
Each one of these tests will require completion of a test form (as described elsewhere in these specifications), which shall
form part of the final documentation.
The off-line / dry tests may be considered as a form of pre-commissioning test described below, with the only difference
being the timing of the test.
B.5.8 Pre-Commissioning Tests
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Pre-commissioning tests and inspections involve the preparation of the plant and its equipment so that it is in a safe and
proper condition and ready for commissioning and operation. It includes all aspects of plant operation such as safety,
electrical equipment, mechanical equipment and instrumentation.
The Contractor shall pre-commission all items of equipment and shall provide additional staff where necessary to prevent
interrupting the main program of work.
B.6 Pumping Equipment

B.6.1 Air General
Commissioning and checking of pump sets shall include but not be limited to:
i) Correct line and level of equipment;
ii) Examination of protective coatings
iii) Grouting of equipment into place;
iv) Filling of correct lubricant charge;
v) Rotation of equipment;
vi) Operation of electrical equipment and controls, including fault protections;
vii) Clearances.
Operational tests shall be carried out with the equipment in service operating under the specified working heads and
actual operating conditions. Tests shall determine power consumption per cubic metre pumped. If necessary, tests shall
be run for at least four (4) hours continuously to give a reliable indication of the performance of the pump sets.
Should the discharge at the specified duty head be less than the guaranteed values, or the total power consumption per
cubic metre pumped be greater than the guaranteed values by an amount greater than two and one half percent (2½ %)
of such guaranteed value, then the Contractor shall alter, adjust or replace the whole or part of the equipment so that it
conforms in every respect with the Specification and guarantees.
Such further tests as may be necessary to prove each pump set conforms with the Specification and guarantees after it
has been altered, amended or replaced shall be made as directed by the Engineer, and the cost of such tests shall be borne
by the Contractor.
B.6.2 Air Scour Blowers, Vacuum Pumps and Air Compressors
Prior to testing, all dirt and other foreign material shall be thoroughly removed from each Air Scour Blower, Vacuum
Pump and Air Compressor, pipework and appurtenances to prevent any damage to the motor-driven equipment item.
Each blower / pump / compressor shall be test run and its performance shall be checked against the specified
requirements. The blower / pump / compressor shall be free from vibration, overheating of bearings and leakage.
B.6.3 Electrical Equipment
During this phase of commissioning, all equipment shall be finally inspected, checked and tested prior to energising the
corresponding system(s). These activities shall include finalisation of on-site tests, operation of circuit breakers, controls,
indication and protection facilities to demonstrate correct functionality.
The Contractor shall advise the Engineer immediately that any equipment supplied under the Contract is ready for Pre-
commissioning, and the Contractor is satisfied that the installation will comply with the requirements of the Specification.
The Engineer will advise the Contractor when the Pre-commissioning can be carried out. The Contractor shall, within
48 hours, arrange the pre-commissioning activities. The Engineer will witness these pre-commissioning activities.
B.6.3.1 Commissioning
Commissioning of the plant comprises inspection and operational tests of all plant, equipment, systems and processes
under actual operating conditions. In addition, it involves providing the necessary for the various equipment, systems
and processes.
During commissioning the Contractor shall ensure that the following has been completed:
i) Activation of alarms by inducing actual fault conditions;
ii) Functional check on interlocks and control systems for the entire plant;
iii) Calibration of all instruments and completion of all Commissioning Test Sheets and Inspection and
Testing Plans;
iv) Testing and commissioning of plant electric, instrumentation and control systems, alarm
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annunciators, set points, and other related items;

v) Commissioning of individual process units;
vi) Commissioning of pumps.
The Contractor shall provide suitably qualified and experienced personnel to supervise the operation of the equipment
up to the date of Taking Over, and attendance during daytime working hours when so required.
Limit switches, flow switches, pressure switches and similar, shall be tested by manually operating the equipment, or by
open or short-circuiting the cable at the equipment end as required, with the switchboard operational.
On-site inspections and/or tests of all equipment, groups of equipment and systems, shall be carried out by the Contractor
at the Contractor’s cost.
The Contractor shall give the Engineer at least two (2) weeks’ notice that equipment is going to be subject to inspection
and testing under the Contractor’s Quality System and shall forward a copy of the Contractor’s Inspection and Test Plan
to the Engineer.
At the Engineer’s discretion, additional inspections of the work shall be performed.
All equipment and labour necessary to perform the Contractor’s tests, and the Engineer’s additional tests, shall be
provided by the Contractor.
If, when material or equipment is inspected and/or tested, the performance is outside the Specification requirements or
the stated tolerance limits, the Contractor shall complete a non-conformance report and forward a copy to the Engineer
The equipment or material shall be deemed to have failed to satisfy the conditions of the Contract and the Contractor
shall replace the non-conforming material or equipment or carry out modifications to rectify the equipment. The
Contractor shall re-inspect and/or retest the material or equipment to verify that the Specification requirements are
satisfied.
If the Engineer has undertaken a test on the non-conforming material, system or equipment and elects to retest the
replaced or modified item, then the cost of retesting by the Engineer, including the Engineer’s direct costs, shall be borne
by the Contractor.
Any delays in delivery or completion as a direct consequence of a failed test and a subsequent re-test will not be accepted
as the basis of a claim for extension of time by the Contractor.
During commissioning the power supply system and its components shall be functionally checked and operated to
demonstrate correct detailed functionality in accordance with the specified requirements. All commissioning checks shall
be recorded on the check sheets as specified.
In general, the Contractor shall carry out commissioning on a switchboard-by-switchboard basis as follows:
i) Wherever possible, redundant equipment shall not be taken out of service and/or removed until the
replacement equipment is commissioned;
ii) Wherever possible, and subject to the specified requirements and shutdown limitations, the
changeover of switchboard loads to the new switchboards shall be delayed until the corresponding
new system has been energised for 2 days.
The Contractor's on-site testing and inspection shall include, but not limited to, the activities and items referenced in the
following clauses/sub-clauses.
B 6.3.2 Inspection
The installation and all equipment shall be inspected in detail for compliance with the specified requirements and to
show that all the equipment as installed is in good order and condition. The Contractor shall prepare detailed inspection
reports to confirm the inspections.
B.6.3.3 Testing
Inspection and testing shall be carried out on electrical equipment and wiring to ensure compliance with the codes, rules,
standards and requirements of the Specifications.
All equipment shall be tested after installation in accordance with the installed test requirements of the relevant standards.
Where applicable, all inspections and tests shall be made prior to equipment being energised. Inspections and tests shall
include all tests recommended in the manufacturer's installation instructions, tests required by any inspecting authority,
the tests set out in the relevant standards, and the tests described in this Specification.
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Before testing and energising a system, all necessary precautions shall be taken, to ensure the safety of personnel and
equipment. All conductors and all electrical equipment shall be properly insulated and enclosed. All enclosures for
conductors and equipment shall be properly earthed. Insulation resistance measurements shall have been made and
approved on all conductors and energised parts of electrical equipment. All protective devices shall be properly set and
operative during the testing period. Tests shall be made in the presence of the Engineer and all deficiencies or
unsatisfactory conditions as determined by him or any inspecting authority as being due to faulty or incorrect installation
shall be corrected by the Contractor in a satisfactory manner, and at the Contractor’s expense.
The Contractor shall cooperate with the Engineer and shall provide assistance at all times for the inspection of the
electrical work performed under this Contract. The Contractor shall remove covers, operate machinery, and perform any
reasonable work, which in the opinion of the Engineer, will be necessary to determine the quality and adequacy of the
work.
B.6.4 Cables
All new cables and all existing cables that have been jointed, re-terminated, relocated or de-energised as part of the work
of this Contract shall be tested as set out below.
The insulation resistance of all cables shall be measured between phases and between each phase and earth with the
voltage applied for a sufficient time for the reading of the testing indicator to become practically steady.
Motor cables shall be measured with the motor disconnected.
Supply cables to switchboards and distribution boards shall be measured with the cable connected to the switches at
either end and with the switches open.
HV cables shall be tested in accordance with the installed test requirements of the relevant standards and to the cable
manufacturer’s recommendations. Where the cable manufacturer recommends that particular types of cables (such as
XLPE cables) are not subjected to site HV testing, then these cables shall be energised at rated voltage for a minimum
period of 1 day prior to placing the cable in service.
B.6.5 Phasing
Installed tests shall include a phasing check of all busbars and main connections in HV switchboards, 400V switchboards
and distribution boards.
B.6.6 Wiring
Wiring tests shall include measurement of the insulation resistance of all power and control cables.
Control circuits shall be measured with push buttons, relays, instruments and the like connected.
Point to point continuity checks shall be carried out on all wiring and cabling.
B.6.7 Protection and Metering Equipment
The Contractor's on-site work associated with Protection and Metering Equipment shall include the following:
i) All protective relays and metering relays and equipment shall be configured and set to meet the
specified requirements and overall functionality of the power supply system under all possible
operating conditions. This shall be carried out in accordance with the manufacturer’s instructions
and to the Engineer’s and the electrical supply authority’s approval;
ii) All protective relays and metering relays shall be injection tested to clearly demonstrate correct
operation and that the characteristics of the installed relays are within the specified tolerances over
the full range. Differential and restricted earth fault protection systems shall be tested by both
primary and secondary injection. Other protection and metering relays and systems shall be tested
by secondary injection;
iii) The calibration of all metering equipment shall be checked on site;
iv) The data communications of all protection and metering relays shall be tested to demonstrate correct
operation under all possible operating conditions.
B.6.8 HV (33kV or 11kV) Switchboards
The Contractor's on-site tests and inspections shall include the following:
i) The insulation resistance of the busbar systems of HV switchboards shall be measured between
phases and between each phase and earth. During measurement all circuit breakers and similar
equipment connected to the busbar shall be open, with the load side of the all switches short
circuited and earthed;
ii) Site high voltage tests in accordance with the relevant standards, the manufacturer’s
recommendations and to the supply authority’s requirements;
iii) Visually check all busbars and joints and major current carrying conductors and parts. Where busbar
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joints are made on-site these shall be correctly tensioned and ductor tested;
iv) All terminations shall be inspected for solid, clean connections. Check of the soundness and
tightness of each wire termination;
v) Wire-to-wire checks of all circuitry and cabling and mark-up of the drawings with any
discrepancies. These tests shall take the form of component-by-component checks and point-to-
point checks using the approved circuit diagrams as reference. Check that each wire is correctly and
legibly numbered and refit number if required;
vi) All control circuits shall be tested for satisfactory operation of all control and indicating devices,
both within and external to the switchgear;
vii) Circuit insulation tests on CTs and VTs;
viii) All protective relays shall be configured, set and injection tested as specified;
ix) Test operation of the over-current and earth fault protection relays by primary injection. Each relay
shall have at least two points on the curve tested;
x) The calibration of all metering equipment shall be checked on site. The movement of all electrical
indicating instruments shall be checked by slowly raising and lowering the measured variable and
observing the instrument indicator. Calibration checks shall be made at full scale for all indicating
instruments. Test equipment for this purpose shall be approved by the Engineer;
xi) All fuse links shall be checked for rating and for correct installation, with particular attention to
correct order of assembly of mounting equipment;
xii) Earth continuity tests shall be performed;
xiii) All relay configuration and setting data shall be recorded and submitted to the Engineer.
B.6.9 Power Transformers
i) All transformers shall be tested in accordance with the manufacturer’s recommendations and results
shall be documented in a high voltage test report;
ii) Other tests shall, as a minimum, consist of a 5kV insulation resistance test between each phase and
between each phase and earth;
iii) Before energising transformers the transformer’s respective 400V main switch shall be opened;
iv) Switchgear shall be tested in accordance with the manufacturer’s recommendations and results shall
be documented in a high voltage test report;
v) Test operation of all switches and circuit breakers;
vi) Test operation of the over-current protection relays with the manufacturer’s test equipment. Each
relay shall have at least two points on the curve tested.
B.6.10 400V Switchboards and Similar Switchgear Cubicles
The Contractor's on-site tests and inspections shall include the following:
i) The insulation resistance of the busbar systems of 400V switchboards and similar equipment shall
be measured between phases and between each phase and earth. During measurement all switches
and circuit breakers connected to the busbar shall be open, with the load side of the all switches and
circuit breakers short circuited and earthed. Insulation resistance values so measured of less than
10 mega-ohms will not be accepted;
ii) Site high voltage tests in accordance with the relevant standards, the manufacturer’s
recommendations and to the supply authority’s requirements;
iii) Visually check, all busbars and joints and major current carrying conductors and parts. Where
busbar joints are made on-site these shall be correctly tensioned and ductor tested;
iv) All terminations shall be inspected for solid, clean connections. Check of the soundness and
tightness of each wire termination;
v) All control circuits shall be tested for satisfactory operation of all control and indicating devices,
both within and external to the switchgear;
vi) All protective relays shall be configured as specified;
vii) All fuse links shall be checked for rating and for correct installation, with particular attention to
correct order of assembly of mounting equipment;
viii) Earth continuity tests shall be performed;
ix) All relay configuration and setting data shall be recorded and submitted to the Engineer.
B.6.11 Distribution Boards
The insulation resistance of the busbar system of all distribution boards shall be measured between phases and between
each phase and earth. During measurements all switches and circuit-breakers connected to the busbar shall be open, with
the load side of all switches short circuited and earthed. Insulation resistance values so measured of less than 1 mega-
ohm will not be accepted.
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All terminations will be checked for solid, clean connections.

Testing of all RCDs is required using a special RCD tester, and in accordance with manufacturer requirements. Testing
using the integral test device is not deemed as adequate.
Earth continuity tests shall be performed.
B.6.12 Sockets
All sockets shall be tested for interruption of all active conductors by the control switch, for correct polarisation and for
circuit identification. If the neutral is also required to be broken, this shall be tested.
B.6.13 Lighting
All lighting systems shall be checked for satisfactory operation from all switching points.
Instrumentation
All Instrumentation shall be site tested and calibrated over the full operating range to demonstrate correct functionality
in accordance with the specified requirements and in accordance with the manufacturer’s recommendations.
Detailed calibration sheets shall be provided for each instrument.
B.6.14 PLC Systems
PLC systems shall be site tested as follows:
i) Each PLC input and output shall be tested from the field device to the PLC memory and to the
operator interface systems;
ii) The PLC system and the plant shall be functionally tested in detail in a step-by-step manner under
all modes, and normal and abnormal operating conditions, to demonstrate full compliance with all
specified requirements;
iii) All operator interface functions shall be tested to demonstrate correct operation;
iv) The functionality of each alarm and protective function shall be tested from the primary initiating
device;
v) PLC data communications systems shall be tested for correct operation.
B.6.15 Variable Frequency Converters and Soft Starters
Variable frequency converters and soft starters shall be site tested by personnel with specialist experience with the
particular units, as follows:
i) The units shall be subjected to all site inspections and tests recommended by the manufacturer;
ii) The units shall be configured with the settings required to meet the specified functionality;
iii) All configuration settings shall be recorded and the units tested to demonstrate correct operation;
iv) The converters / soft starters and motors shall be tested for correct operation with loss and
restoration of power supply.
Site testing of the VFC’s shall include measurements of harmonic current and voltage distortion to demonstrate
compliance as follows:
i) Total harmonic current distortion of the total load current drawn by the VFCs, supplied as part of
this Contract, without standby drives running.
B.6.16 Earthing
All equipment shall be tested and inspected for compliance with the earthing requirements as specified and required by
the electrical supply authority (TANESCO). This inspection shall include visual checking of conductors and checking
of the tightness of all bolted joints. Where visual checking of connections to the plant earth system is not possible,
measurements shall be made of the resistance between the equipment frame and the plant earth system.
Resistance of electrodes to earth and continuity of earth connections shall be demonstrated to the Engineer by means of
testing after the installation has been completed.
B.7 Performance Tests

B.7.1 First Proof-of-Performance Test
Once Commissioning has been completed, and the equipment is operating to the satisfaction of the Contractor, the first
five (5) day Proof-of-Performance Test shall be carried out in the presence of the Engineer to confirm the process and
performance guarantees provided by the Contract.
At least two weeks prior to the proposed commencement of the First Proof-of-Performance Test, the Contractor shall
submit to the Engineer a detailed Proof-of-Performance Test Plan.
29
It shall be the responsibility of the Contractor to develop the Plan, which must be approved by the Engineer. The Plan
can be provided as part of the Commissioning Plan described above.
The Proof-of-Performance Test Plan shall set out how the Test will be conducted, including a description of the
methodology to be adopted, observations to be made and measurements to be taken to confirm that the equipment
supplied and installed under the Contract is operating correctly and that all requirements of the Specifications have been
met.
The Proof-of-Performance Test Plan shall be supported by a program of raw, clarified and filtered water sample
collection and analysis.
A schedule of samples of raw and treated water samples to be taken and analyses to be carried out on each shall also be
included in the Proof-of-Performance Test Plan in tabular form.
The First Proof-of-Performance Test shall be carried out as soon as practicable following the Commissioning of the
equipment.
Upon successful completion of the First Proof-of-Performance Test, the Engineer will issue the Taking Over Certificate,
subject to the Contractor complying with all specified requirements under the Contract.
The scope of First Proof-of-Performance Testing requirements is detailed below.
B.8 Results, Reports and Taking Over

The results of all measurements and calculations shall be presented to the Engineer in a First Proof-of-Performance Test
Report, which shall be provided in both hard-copy and digital PDF formats.
The results are to be recorded on approved Log Sheets and the signed completed sheets shall be provided to the Engineer
or included as part of the First Proof-of-Performance Test Report, in both hard-copy and digital PDF formats.
The plant shall not be taken over by the Principal unless and until the plant operates during the Performance Test:
i) Without significant mechanical, electrical, process or other plant failure. Should plant operation
be interrupted by such a failure, the Engineer will order the re-start of the Performance Test and
all costs associated with its conduct up to completion shall be at the Contractor’s expense;
ii) Produces clarified and filtered water complying with the specified quality requirements
B.8.1 Taking Over Certificate

At the successful completion of the five-day Proof-of-Performance Test period, the Engineer will issue a Taking Over
Certificate.
B.9 Second and Third Proof-of-Performance Tests

Two additional five (5) day Proof-of-Performance Tests shall be carried out by the Contractor during the Defects
Liability Period, at times to be determined by the Engineer. The Engineer will provide the Contractor with at least two
(2) weeks notice of the Test commencement dates.
Nominally, the Second Proof-of-Performance Test shall be carried out mid-way through the Defects Liability Period,
whilst the Third Test shall be conducted at the completion of the Defects Liability Period.
The Second and Third-Proof-of-Performance Tests shall be identical in procedure, scope, testing and reporting
requirements to the First.
Throughout the Defects Liability Period, the Employer shall be entitled to operate equipment as intended and make
measurements and observations to monitor its performance. During the Defects Liability Period, the equipment shall
meet the performance guaranteed by the Contractor, and the Engineer may direct the Contractor to return to site to
undertake any remedial action or works to ensure plant compliance, even though the plant may have successfully passed
Proof-of-Performance Tests.
B.10 Performance Certificate

Upon satisfactory completion of the 2nd and 3rd Proof-of-Performance Tests, as well as rectifying all outstanding defects
to the satisfaction of the Engineer, the Engineer shall issue the Performance Certificate, signifying acceptance of the
Works completing the Contractor’ obligations under the contract.
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B.11 Operational Start-Up Period

The Contractor shall provide a skilled and trained operator / technician at WTP for a period of six (6) consecutive weeks,
commencing at the start of the Defects Liability Period, following completion of Commissioning and the first Proof-of-
Performance Test.
The Contractor shall involve utility staff throughout the Operational Start-Up Period and shall not undertake any of the
tasks without their active involvement and participation.
During the Operational Start-Up Period, the Contractor’s operator / technician shall:
i) Ensure that all new plant and equipment is performing satisfactorily;
ii) Assist utility operating staff to make adjustments as necessary to achieve the correct operating
parameters (eg. flow rates, dosing rates, times, etc);
iii) Monitor utility operating staff performance, particularly with respect to operation of the new plant
and equipment;
iv) Assist utility operating staff to troubleshoot and resolve problems;
v) Provide additional training where necessary;
vi) Assist utility operating staff to carry out routine inspection and maintenance activities in accordance
with the recommendations provided in the Operation and Maintenance Manual to be provided under
this Contract;
vii) Check chemical dosing rates and solution concentrations and provide recommendations for process
improvement;
viii) Carry out regular water quality tests at the locations shown in Table B.6, to monitor performance
(and make adjustments as necessary) of the new plant.
B.12 Spare Parts

The Contractor shall provide a detailed list of spare parts for each piece of plant and equipment provided under the
project. The lists shall indicate the (manufacturer’s) part number, a description, the quantity contained in the item, the
estimated replacement period, and unit price. The Contractor’s purchase price plus shipping and delivery to site, with no
mark-up for overhead or profit.
In accordance with the Engineer’s instructions the Contractor shall prepare spare parts procurement lists for review. The
Contractor shall modify the list until a suitable list is finalized that meets utility requirements and matches the funds
available.
Spare parts that are used for the purpose of rectifying defects during the Defects Liability Period shall be immediately
replaced by the Contractor at his cost.
The quality of spare parts shall not be inferior to that of the original Plant.
Spare parts shall be adequately protected and packed in suitable containers to withstand storage under site conditions,
and shall be handed over with four copies of a detailed itemised list.
As much as practically possible, spare parts shall be interchangeable between the various sections of the Plant and
equipment.
All spare parts shall be delivered prior to the Tests on Completion, and the Certificate of Completion will not be issued
until spares parts have been handed over.
B.13 Specialist Tools

The Contractor shall provide three sets of specialist tools that are required for the installation / operation / maintenance /
repair of the valves and equipment installed under the project. Specialist tools for pipe tapping shall kept in a secure
location and shall not be a made accessible to unauthorized personnel without consultation with the Supervising Engineer
and Water Utility. Pipe tapping equipment shall not be used without the permission or presence of authorized Water
Utility staff.
B.14 Operator Training

The Contractor shall provide training for the operating staff.
The Contractor shall coordinate with utility early in the contract period, to determine the names, positions and job
functions of the personnel to be trained. The Contractor shall make such enquiries through the Engineer.
Contractor shall provide a description of the proposed scope and methods they shall employ to train the operating staff.
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The scope and detail of the Training Program shall be submitted to the Engineer for approval at least fourteen (14) days
prior to the planned commencement of training.
In general, training of the operating staff shall take place at the WTP site. However class-room sessions may be conducted
at other appropriate locations. Where necessary, the Contractor shall provide transport, allowances and refreshments to
the operating staff.
Training shall include, but not be limited to, the following:
i) Detailed description of new plant and equipment including models, capacity, components,
protective devices, etc.;
ii) Understanding and using manufacturer’s documentation;
iii) Function and capabilities of new plant / equipment and component parts;
iv) Operating the new plant / equipment, including starting and stopping sequences, setting of flows
and other parameters, and operator-adjustable set points. In particular, this shall include starting,
stopping and operating the raw water system assuming Alternative RW-2;
v) Explanation of operational actions or sequences that may cause damage, failure or complete
break-down of plant and equipment, or may cause injury or health issues to the operator and/or
others;
vi) Process control and optimizing operations, with a view to minimizing operating costs and wear
and tear of equipment;
vii) Operating and adjusting the PLC and HMIU;
viii) Manual overrides and associated procedures;
ix) Emergency stop procedures;
x) Routine maintenance schedules and spare parts requirements for all motor-driven and other
equipment supplied under the Contract;
xi) Maintenance procedures and replacement of spare parts. Describing which components should
only be handled / repaired by authorized persons, including the possibility of invalidating
manufacturer’s warranties;
xii) Instrument readings and analysis of performance using key indicators;
xiii) Specialist tools and their use;
xiv) Trouble shooting and fault finding;
xv) Health and safety issues related to its usage (HV, chemicals, rotating, high pressure, moving parts,
heat, noise, fumes, etc.);
xvi) Maintaining and updating the O&M manual as a working document.
It is anticipated that the following training sessions will be provided as a minimum:
i) Inspection of plant and equipment pre-installation. The trainer shall describe the various items of
plant and equipment to be installed, including capacity, component parts, purpose, method of
operation, method of adjustment, fault protection, special features, fast wearing / replaceable
parts, start-stop buttons, selector switches, instrumentation, etc.;
ii) Operators to witness and participate in the installation of plant and equipment. This will involve
explanations and hands-on involvement to enable future removal and re-installation where
appropriate;
iii) Operators to witness and participate in the initial setting of plant and equipment, including
trimming valves, timers, water levels, PLC and HMIU during commissioning;
iv) Operators to witness and participate in proof-of performance testing of plant and equipment;
v) Operators to witness and participate in troubleshooting and repairs during Defects Liability
Period;
vi) Class-room type training.
The Contractor shall allow for such training and level of involvement in his work program.
The Contractor shall integrate the training with the contents of the O&M manual such that the two are compatible and
consistent.
Where necessary, the Contractor shall provide specially prepared diagrams, visual aids and instruction manuals, as well
as sample materials, tools and consumables for hands-on demonstration and practice.
Training shall be carried out by a qualified and competent trainer. The Contractor may assume that trainees shall have a
working knowledge of operation and maintenance of the WTP component(s) for which they are responsible. Training
shall be presented in English. However, where necessary, the Contractor shall also provide a technical person who can
translate into Kiswahili.
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B.15 Final Reports

B.15.1 As-Built Drawings
Within four (4) weeks of the commencement of the Defects Liability Period, the Contractor shall deliver to the Engineer
one complete set of record drawings of all works constructed under the Contract, including all underground works such
as pipes, services, cables and conduits.
The Engineer shall review and comment on the draft Record Drawings, and within a further four (4) weeks of receiving
the comments, the Contractor shall produce a final set of drawings.
If, during the Defects Liability Period, the Contractor modifies any of the Works, the modifications shall be included as
amendments to the As-Built Drawings and all other affected documentation.
The Contractor shall provide six (6) sets of colour prints, and six (6) CD’s complete with all electronic drawing files.
The drawing scales shall be such as to clearly indicate all necessary detail, and shall be to the approval of the Engineer.
The Contractor shall undertake all survey and measurement of plant and structures, including re-excavation and backfill
of plant where necessary, drafting, supervision and checking as required to prepare accurate and comprehensive as-built
drawings.
B.15.2 PLC Programs

The latest version of the as-installed PLC program(s) shall be provided as both a paper copy and a full listing (with
descriptors) electronically. These shall include the complete program and documentation listings with address and run
comments and symbols.
B.15.3 Operation and Maintenance Manuals
The Contractor shall provide Operation and Maintenance (O&M) manuals covering the new plant installed under the
contract. The proposed sequence of submissions is as follows:
i) Prepare draft Table of Contents, with a brief description of the contents of each section, and
submit to the Engineer for comments;
ii) Revise the draft TOC to reflect the Engineer’s comments;
iii) Prepare first draft and submit to the Engineer for comments;
iv) Revise the first draft to reflect the Engineer’s comments, prior to operator training;
v) Conduct operator training using draft O&M manuals;
vi) Revise draft O&M manuals based on feedback from training;
vii) Submit to the Engineer for further comments;
viii) Finalize O&M manual to reflect the Engineer’s comments prior to commencement of the Defects
Liability Period.
The O&M manuals shall include, but not be limited to, the following sections:
i) List of suppliers / manufacturers including contact details and key equipment provided by each
supplier;
ii) Register of all items of mechanical and electrical plant, including model no., description, quantity,
nameplate information including unique serial number, etc.
iii) Manufacturer’s specifications; data sheets; performance charts; dimensional drawings; assembly /
installation drawings; bills of materials; packing, storage, installation, maintenance and trouble-
shooting instructions. Information shall be specific rather than generic in nature and the model
number / size / capacity of each item installed shall be clearly identified;
iv) Pump curves shall have the system curve(s) drawn on and the duty points indicated;
v) Copies of Manufacturer’s warranties;
vi) Copies of certificates of tests performed during manufacture and during performance testing on
site;
vii) Spare parts lists for each piece of equipment, with manufacturers part number, name and
recommended replacement period;
viii) Inspection and preventative maintenance schedules for various periods eg. daily, weekly,
monthly, quarterly, six monthly, annually etc. Each inspection and maintenance shall be described
in detail with reference to manufacturer’s information where applicable;
ix) Issues of safety relating to the operation and maintenance of HV equipment, chemicals, moving /
rotating equipment, heavy equipment, deep water plant, working in enclosed spaces, etc.;
x) Operating procedures specific to the plant as installed, including system start-up and shut-down;
isolating / by-passing sections of the plant; adjusting flow / pressure settings; etc.;
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xi) Template O&M forms including, but not limited to, maintenance, repairs, problems /
malfunctions, breakdowns, job sheets, order forms, operational forms and meter readings, etc.;
xii) Water quality testing schedules;
xiii) Monitoring plant performance through use of key performance indicators. Descriptions of each
indicator including normal values, causes / implications of changes in values, corrective
procedures, etc.
B.15.4 Inspections during Defects Liability Period
The Engineer shall carry out inspections of the new plant at regular intervals during the Defects Liability Period. The
Engineer will give the Contractor due notice of his intention to carry out such inspections, and the Contractor shall
arrange for an authorised representative to be present.
The Contractor shall render all necessary assistance during the inspections.
The Engineer shall prepare a report based on the inspections, and shall instruct the Contractor of the necessary works or
repairs to be made, and the deadline for such works to be carried out.
No payment shall be made for works or repairs that are necessary as a result of faulty design, construction, installation,
materials or equipment. The Engineer shall determine if and when payment shall be made and the unit rates that shall be
applied.
B.16 Transmission Pipe Material

Transmission lines is Steel pipe with 3 LPE coated outside and inside food grade epoxy coated. The design of steel pipes
will be checked in accordance with BS 8010 Part 2.8:1992, Code of practice for pipelines – pipelines on land: design,
construction and installation – steel for oil & gas and AWWA M11.
B.17. Drilling and Installation of Bore Well
VES Resistivity Survey
Before starting drilling work at a specific site; VES Resistivity shall be conducted. Based on the Resistivity Survey
and the data available with DDCA Tanzania bore hole site is to be finalized for exploration.
Drilling Rig
A suitable drilling rig equipped with dual rotational drill table head (Reverse Rotation Direction), Pneumatic or
Mechanical drill pipe changing capabilities, with mud pump of sufficient capacity and a Down the Hole Hammer
(DTH) capability for desired drilling depth. The rig shall be equipped with compressors capable of lifting drill
cuttings. The drill pipe shall have flush joints after jointing two pieces.
Drilling process
Depending on the geology and lithological sequence, appropriate drill techniques shall be employed using the
appropriate method for each outstanding geological situation. A 26’’ (650mm) conductor hole (hole opening)
shall be drilled to at least 6m depth and cased. A cement grout shall be poured and left to cure before continuation
with drilling.
For competent formations, down the hole hammer (DTH) using appropriate fluid for drill cutting removal and
transport to the surface is recommended. It should be emphasized that bentonitic mud products are prohibited.
Depending on the potential of the site the consulting hydrogeologist shall recommend the optimum well diameter
and depth to be reamed.
Borehole logging
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The borehole logging shall be conducted as soon as the drilled hole is completed before it is cased and screened.
The drilling contractor is expected to conduct borehole logging to determine formation stratification sequence as
well as identifying water yield zones distribution, aquifer thicknesses and water quality distribution etc. along the
well depth. A total of three runs per well shall be conducted so as to ascertain the correct information for well
design. The recorded information shall include
• Borehole camera log

• Borehole caliper log
• Gamma log
• SP log
• Conductivity
Drill Aids
The drilling fluids expected to be used shall be those which are bio degradable, nontoxic and able to be
completely removed from the well at the end of the drilling operation. No chemical residues shall be tolerated
in the well at any concentration apart from the natural background concentration. Bentonites and bentonitic
additives are prohibited.
Borehole design and testing
Each of the recommended borehole drill site may have peculiar properties. These properties include
geology, topography, depth of water strike, aquifer formation thickness and characteristics as well as borehole
completion depth. Therefore, each borehole may have its specific design as shall be recommended by the
hydrogeologist. However regardless of the peculiar characteristics for each borehole, a general design concept
is recommended for all the boreholes, such general design concept is as provided below.
The Bore Well Assembly
In order to achieve trouble free service at reasonable cost, it is most important to design a bore well for effective
sizes and specifications. A good design should ensure:-
• Highest yield with minimum drawdown.

• Good quality of water with proper protection from contamination.
• Longer life at reasonable cost.
The bore well assembly consists of two main elements i.e. the Casing and the Intake.
Casing portion of bore well assembly serves as housing for pumping machinery. The portion from where water
enters from aquifer to bore well is the Well Screen or Intake.
Casing/Well Diameter
Depending on well depth and expected formation pressure final well diameter shall depend on the amount
of water struck during the bore hole drilling. In the event that a very good aquifer is encountered, then the
completion borehole diameter should be that which is able to accommodate a pump that shall deliver the required
amount of water.
The Well Casing, besides housing the pumping set also protects the borewell from caving in. The length of the
casing pipe is worked out on the basis of static water level, drawdown and the size of pump set to be installed and
its characteristics.
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The diameter of housing pipe of the bore well should be large enough to accommodate the pump required The
pump is lowered in the housing pipe at a depth so that it is set a few meters below the lowest drawdown level as
suggested by pump characteristics.
As per specifications uPVC pipes are to be used. These pipes must be duly inspected before being allowed to be
installed. In the event that the whole depth of the well is to be cased, a blind casing shall always precede the
screen at the bottom of the well. Depending on the competence of the formation, the bottom of the well may or
may not be plugged. Where the formation material is unconsolidated then a cement plug shall be cast at the
bottom.
Well Screening
Well screen or strainer serves as intake section of a well. These screens let the water into the bore hole and keep
the sand out. In the selection of a screen four basic factors should be considered:-
i) It should be structurally strong enough to support the bore hole.

ii) It should be resistant to corrosion.
iii) It should prevent excessive movement of sand into the well.
iv) It should allow entry of adequate quantity of water into the well with minimum friction.
v) Thickness of this screen should be adequate to withstand the tensile load and collapsible pressure exerted
on it after lowering the assembly.
A minimum of 20% open area at 1.0 to 1.5mm slot sizes is expected to be used mostly in the sands and
the pyroclastic aquifers. However, the slot sizes may be changed depending on the mean size of the aquifer
formation material. If the aquifer is unconfined at least the bottom half to full length of the aquifer in the pumping
well shall be screened. However, in the case of a confined aquifer, at least 30% of the bottom of the aquifer shall
be screened. Where the aquifer is fairly thick, the screens may be interspaced with blind casing pipes to the
desired length of the screened portion.
Well Screen Length
The screen length cannot be standardized w.r.to various discharge because the optimum length of well screen is
based on the thickness of the aquifer, available drawdown, and nature of the stratification of the aquifer. In
virtually every aquifer, certain zones (horizons) will transmit more water than others. Thus, the intake part of the
well must be placed in those zones having the highest hydraulic conductivity. Determination of the most
productive layers can be made by one or more of the following techniques:
• Interpretation of the driller’s log and comments on drilling characteristics such as fluid loss, penetration rate,
and pull down and chatter.
• Visual inspection and comparison can be made of samples representing each sediment layer. The relative
transmissibility of each layer is estimated from the observed coarseness, lack of silt and clay, and thickness
of the layer.
• Sieve analyses can be made from samples taken from the various layers in the aquifer. Comparison of grain-
size curves can indicate the relative hydraulic conductivity of each sample. It is highly recommended that
sieve analyses be performed on selected formation samples from well.
• Geophysical logging techniques can help to locate best zones having the highest hydraulic conductivity.
Velocity log also is extremely useful.
Gravel pack
The consulting hydrogeologist shall determine whether to gravel pack or carry out natural development of the
well depending on the nature of the formation. In the event that gravel packing is necessary, then the gravel pack
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material must be well sorted, competent, clean and well rounded. The gravel pack material is expected to be inert
to all prevailing natural chemicals in the ground. Gravel size must be supported by sand sieve and gravel sieve
analysis reports.
A tremie pipe shall be used to deliver both the cement as well as the gravel pack material to the desired depth.
Where the formation material is competent, and if well development has been thorough, then the bottom of the
casing may be left open. The final well design shall always be determined by the consulting hydrogeologist.
Well plumpness
o
The hole is expected to be as straight as possible with a maximum allowable vertical deviation not exceeding 2 .
Thus, casing centralizers shall be installed every 15m interval.
Well development and testing
• Development is an essential operation in the proper completion of any water well. All wells are
developed until they are sand free when pumped at desired rate. Development enlarges water bearing
formation around screen, thereby increasing the effective radius of the well and interns its yield.
• Immediately after installation of the bore well assembly, the bore well has to be subjected to a process
of development to make the bore well ready for operation and also for calibration of the same.
• As per common and accepted practice, the development process also provides information on the yield,
cleans the system of impurities and an appraisal on the condition of bore well.
• The development of the bore well is to be done firstly with the help of suitable capacity of Air
Compressor and there after its calibration is done by using a suitable capacity of Submersible pumping
set.
Natural well development through continuous pumping is the desired practice. Sufficient time is expected to be
used during well development such that the water is sufficiently clean and clear. Well testing and evaluation is
expected to be undertaken professionally so as to determine all important aquifer and well parameters including
Permeability, Transmissivity, Storage coefficient, Specific yield, Well losses, aquifer boundaries etc. This
data will be recorded in a manner that it can be used for future well field studies.
After the well development is sufficiently done, a pre-test pumping should be conducted
Recommended drilling technique
Drilling techniques shall differ from site to site depending on the prevailing geological formation encountered.
The drilling contractor is expected to use any appropriate drilling technique that will conveniently allow him to
reach the desired drilling depth without destroying the aquifer. Such drilling technique shall have to be
approved by the consulting hydrogeologist beforehand.
Borehole formation logging shall be accomplished by collecting drill cuttings at 2m intervals and storing the
drill cuttings in a plastic sachet which will be placed in compartmented sample box indicating the depth from
which the sample originated. The site hydrogeologist shall correctly identify formation characteristics
including colour, texture, hardness, and name the formation type. This information shall be maintained in a site
log book.
If the exploratory hole proves the borehole to have high capacity, then the hole shall be enlarged by reaming to
desired diameter so as to accommodate the appropriate casing and screen diameter to completion. The well head
preservation shall be accomplished by pouring a concrete apron/slab around the casing.
Pumping test and borehole evaluations
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Objectives of a pumping test

A well may be tested for either of the two reasons
i. To provide information about the performance and efficiency of the completed well in terms of yield, the
observed drawdown and the specific capacity. This data is taken under controlled conditions during the
pump test and shall be used for selecting the pumping equipment to be used for long term production in
each borehole.
ii. Another objective of the pumping test is to provide data for which the principal factors of the aquifer
can be calculated. These include Specific yields, Permeability and Transmissivity.
Different types of pumping tests to be conducted
The pumping test evaluation shall involve two test techniques.
(i). Step test and
(ii). Constant rate test
The step test
This shall involve three different pumping rates Q1, Q2 and Q3 respectively being regulated by appropriate
arrangements of the pumping test setup. Each subsequent increasing rate shall last for three hours, while
continuously monitoring the draw down. At the beginning of pumping, both the frequency of water level recording
and pumping rate measurements shall be at shorter intervals. The monitoring frequency will decrease as the
elapsed time increases. As the pumping duration is prolonged, the rate of water level drop in the pumping well
decreases. When the water level in the pumping well remains constant or decrease very very slow,
(whether after or before three hours since the commencement of pumping), the gate valve may be opened to
increase the rate of flow. This shall constitute the end of the first step and the beginning of the second step
respectively. After another three hours of constant pumping, the gate valve shall again be opened further to allow
more water to flow (step 3). The pumping and water level monitoring shall again continue for another 3 hours
at the end of which the pump is stopped. The recovery phase has now started and the rising water level is monitored
until the water level recovers fully or to at least 80% of the original water level before pumping started.
The discharged water shall be released at least 100 meters downstream to make sure that the discharged water
does not infiltrate back into the vicinity of the tested well. If an observation well is available, the monitoring
process will preferably be conducted in this well during the pumping of the test well. The first phase of the aquifer
evaluation shall be completed after the three steps (9 hours later). The aim of the step test is to determine the
potential of the well and determine the pumping rate that shall be used during the continuous testing.
Constant rate test

The second phase of the aquifer evaluation shall start after the pumping well recovers fully or up to 80% of
the original water level. The start of the continuous test shall be planned so as to make sure that frequency of
water level recording is reduced at and after midnight. Depending on the capacity of the well, the continuous
test shall last for 24, or
48 or 72 hours before recovery measurement is begun.
The collected data during both step tests and constant rate test shall be evaluated using different evaluation
techniques to determine the different aquifer parameters such as Permeability, Transmissivity, Storage
coefficient, specific capacity, well efficiency as well as establishing the long-term pumping rate of the well.
Data collection and recording during the test.

The measurements to be taken during a pumping test fall into two groups.
• Measurements of the water level
• Measurements of the flow rate
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Measuring Water level
The most important information from the pumping test include, yield at given time lapse, observed draw down
as well as calculated specific capacity. Other recorded information shall include:
• Name of well or village,

• Name of the District and name of Ward,
• Well location coordinates (GPS),
• Well head ground elevation level
• The Static water level
• Time and date of the test and,
• Pumping rate at specific interval etc.
Measuring the water level fluctuations during pumping tests is achieved by utilizing water level monitoring
devices. These may be based on electrical dippers or sonic detectors.
Water quality sampling and testing
Water sampling is expected to be undertaken during the pumping test in all the fifteen borehole sites. At least
three water samples shall be collected in sufficiently professional way so as to allow for physical, bacteriological
and chemical determination of all- important drinking water parameters as per the Tanzania water quality
standard guidelines. The sampling interval is such that a sample is taken at the beginning, mid-way and at the end
of each pumping test. The samples such taken shall be delivered to a reputable water quality testing laboratory
within twenty-four hours for physical and chemical analysis. For bacteriological analysis, however, less than
twelve hours shall be permitted before the samples arrive at the lab. Two samples of sufficient quantity (at least
one litter each) shall be taken at the end of each test pumping and one sample taken forty- four hours after well
disinfection. It is recommended that the sample bottles shall be of inert material to avoid any reaction, in case of
reactive water. The suggested parameters to be tested for following; -
i. Physical quality
Colour, Turbidity, Odour and taste
ii. Chemical quality

Ferrous, Manganese, Fluoride, Nitrates, Nitrite, Arsenic, Sodium, Total hardness,
Calcium, Magnesium. Potassium Sulphate, Chloride, Lead, Aluminum and Total alkalinity
iii. Bacteriological
Coliform, E. Coli, Salmonellas and Total Bacteria
Borehole Completion Report.
The contractor shall provide a professional detailed completion report upon completion of the drilling works. The
report shall provide in detail the following information.
i. Borehole geologic log detailing the depth and characteristics of encountered geologic stratigraphy, water
strikes and properties of encountered aquifer formation (structures thickness, etc.).
ii. Design of completed Borehole, indicating casing and screen interval.
iii. Pumping test report indicating the recommended long-term pumping rate, aquifer parameters including
Transmissivity, Storage coefficient, and specific yield etc.
iv. Water quality analysis report
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Note: No borehole shall be accepted and no payment shall be made for a borehole due to inadequate
installation or technical incidents done by the Contractor, leading to failure or malfunction of a
borehole.
Site restoration after completion
All completed borehole sites shall be restored to their original state after the drilling activities are
completed. All chemical and fuel spills shall be cleared by removing the contaminated soils and transported and
buried outside the site at an appropriate dump site. All organic materials including food remains, paper, plastics
and metallic materials must be dumped in a dug hole before being burned. The hole must be soil filled after
burning and the site levelled after burning.
B.18 Instrumentation and Flow Meters

B.18.1 General Specification for Instrumentation
General
a) The instruments and equipment supplied shall ensure the highest standard of operational reliability,
suitability for the prevailing ambient conditions at site and shall be obtained from a manufacturer who has
existing adequate facilities, staff and spare parts for service and maintenance.
b) Equipment shall be arranged so that individual equipment can be removed without disturbing the operation
of the remaining equipment.
c) Equipment shall be suitable for the environment where it is installed and suitably rated for any hazardous
area present to the requirements of BS 5345.
d) All instruments, gauges and control equipment that perform similar duties shall be of uniform type,
appearance and manufacture throughout the Works.
e) Instruments of similar type mounted on the same panel shall have the same styles of figures and letters.
Signal Transmission
Analogue values shall be transmitted as linearised 4 to 20 mA d.c. signals.
Status and alarm signals shall be provided by volt-free changeover contacts. Each contact set shall be connected
to three separate terminals.
Signal Transmitters
(a) Transmitting instruments shall be of the two wire, live zero, type producing a 4 to 20 mA d.c. output signal
proportional to input range.
(b) Transmitter accuracy shall not less than +0.5% of span or, for float operated level transmitters, not less
than +0.5% of reading.
(c) The output signal from each transmitter shall not be affected by the output circuit load, including cable
resistance, for its particular application.
(d) Each transmitter shall incorporate an output signal indicator and input and output test points for the
connection of portable instruments for testing and calibration.
Instrument Electrical Supplies

The Contractor shall including all necessary transformers and wiring between instruments necessary for the safe
and efficient operation of the system in accordance with the Tanzania Electric Supply Corporation (TANESCO)
specifications.
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Where electric power is required for instruments, the Contractor shall include all to cabling the instrument from
the local distribution point.
Electrical instruments to be incorporated into the main and sub-switchboards will be in accordance with clauses
as specified elsewhere in this Specification.
Instrument Cables
1. The Contractor shall include all necessary cabling between the instruments and any device being controlled.
Cabling shall be suitable for the environment in which it is to be installed and shall be run on cable trays
suitably segregated from any power wiring.
2. All cables other than power supply cables to facility mounted instruments shall be considered as instrument
cables. All instrument cables shall include individual and overall screen, single galvanised wire armour
and overall PVC sheath.
3. The cables shall be as recommended by the manufacturer of the equipment providing the signal, but shall
not be less than 24/0.2mm.
4. The cores of cables shall be laid up in pairs with approximately one twist per 30mm and shall include an
overall screen of copper braid or aluminium foil. Individual and overall drain wires shall be provided.
5. Parallel runs of instrument cable and other types of cable shall be avoided.
6. Ducts shall be used for all power, control, data and instrumentation wiring which cross roads.
7. Wiring, cables and accessories laid in outdoor ducts shall be waterproof and termite proof.
8. Where ducts cross from one hazardous rated area to another, differently rated one, a suitable proprietary
seal shall be installed.
B.18.2 Particular Electrical and Instrumentation Specification
General
All pipework associated with electronic metering installations shall be suitably earthed.
Testing & Commissioning

1. Before commissioning of a new installation, the complete installation shall be fully tested to ensure that the
equipment is in full working order.
2. All systems that are built off-site shall be subject to factory acceptance tests (FAT) and these tests shall be
repeated once the systems are installed in their final position on site (site acceptance tests – SAT), prior to
the commissioning of such equipment.
• The FAT of software systems shall be performed prior to delivery to site or interface with any site
installed equipment.
• The completed installation shall be proven to be in full working order to the satisfaction of the
Engineer.
• The Contractor shall undertake all testing and commissioning of the completed installations as
follows: -
▪ General Electric Installations: Inspection and testing in accordance with Codes and Standards referred
to herein.
▪ Other Electrical Equipment and Services: Functional testing and commissioning in accordance with
the manufacturer’s instructions.
• The record of all inspections, test results and commissioning settings shall be as detailed in the
standards indicated above. Where the standards offer no guidance, or where no relevant standards are
applicable, the Contractor shall make all recordings in a format to be agreed with the Engineer.
• The Contractor shall provide all instruments required for testing, and evidence of the accuracy of the
test instruments shall be provided.
Test Method
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1. Before undertaking any inspections, tests or commissioning activities, the Contractor shall issue to the
Engineer for approval, a method statement detailing all proposals. This method shall contain as a minimum,
the following: -
• A description, in narrative form, of the tests to be undertaken and the procedures and sequences to be
adopted;
• References to all relevant regulations;
• Conditions, values or events that will demonstrate that the test is satisfactory; including transfer of
metering data from primary instrumentation to local and remote display interfaces and data
management systems;
• Samples of all test sheets, check lists and certificates etc proposed for use;
• Details and photocopies of calibration certificates for all test equipment proposed for use;
• A detailed programme of all inspection, testing and commissioning activities.
2. No tests shall begin until the Contractor’s method statement has been received in sufficient detail to the
satisfaction of the Engineer, and the Engineer has agreed it.
3. The tests shall be carried out in full and schedules completed prior to the witness of the tests.
4. The Contractor shall notify the Engineer one week in advance of his intention to commence witness testing;
the Engineer staff shall witness tests at their discretion.
5. The Contractor shall, at his own expense, rectify all defects and repeat all tests that fail to meet the
requirements detailed in his approved method statement. Where a satisfactory test relies upon the successful
completion of a sequence of tests, any failure of a single test with the sequence shall, on rectification of the
defect, cause the sequence of tests to be repeated from the beginning, at the Engineer discretion.
6. Failure to comply with the above will render the Contractor liable for the costs associated with re-testing.
7. A test and commissioning report shall be produced, collating all the above results.
Instrumentation Testing and Commissioning
1. Testing of all equipment shall be in accordance with the requirements of BS 6739 Part II.
2. Instrument testing work shall only be carried out by personnel that are fully skilled to do the work. Where
unfamiliar specialised equipment is being installed, the testing personnel shall be given supplementary
training on that equipment.
3. All test equipment necessary to test the system shall be supplied by the Contractor.
4. Calibration certificates traceable to national standards shall be available for all test equipment used.
Testing of Instrument Cables
The interconnecting cabling in electrical and electronic instrument circuits shall be tested for continuity,
insulation resistance and routeing, to meet the system requirements.
Pre-Commissioning
All instrument systems shall be tested to ensure that they operate correctly and are ready for commissioning.
Commissioning and Acceptance
1. Commissioning and acceptance of all equipment shall be in accordance with the requirements of BS 6739
Part 12.
2. All test equipment necessary to commission the system shall be supplied by the Contractor.
3. Calibration certificates traceable to national standards shall be available for all test equipment used.
B.18.3 Network Flow-Meters

Water flow-meters installed on Transmission pipelines shall be electromagnetic type suitable for use with drinking
water.
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1. Meters shall have good accuracy repeatability and linearity over the full range of flows. Meters shall be
capable of achieving an accuracy of +/- 0.2% of reading or +/-0.0001m/s up to a maximum velocity of 6 m/s.
2. Meters shall be sized to ensure that the design flow range for the distribution network and customers to be
supplied through the meter is within the optimal flow range of the meter for accuracy and hydraulic
performance purposes.
3. The bodies of electromagnetic water meters shall be manufactured from the stainless steel Type 316 body
with integrally cast flanges or equivalent suitable for water. The metering tube shall be of stainless steel.
4. Materials in contact with water shall be non-toxic and shall not affect the quality of the water. The
electromagnetic flow shall be suitable for water use. The lining shall have the following specification:
▪ PEA- Perfluoro – allkoxy - UKWFBS listed for potable water.
▪ Elastomer – UKWAFBS listed for potable water.
▪ Polypropylene – UKWFBA listed for potable water.
▪ Ebonite, Bonded FEP, Polyurethane and Neoprene
5. Meters shall be suitable for installation in chambers which may be subject to flooding and long-term
immersion.
6. Meters shall be fitted with sufficient cable (min 10m) for connection to the local display and signal interface
unit. Cable connections at the meter body shall be potted.
7. All meters shall be installed in accordance with the manufacturer’s recommendations. On selection and
installation of the meter, particular attention shall be given to distance to changes in direction or diameter of
the pipe, and earthing and bonding of the meter.
8. Installation of sensors, cabling and auxiliary equipment shall be such as to eliminate interference from other
electrical equipment.
9. Details of the Contractor’s proposed meters shall be included with the tender.
10. Digital indicators shall be provided locally and at the nearest Telemetry Outstation kiosk for each meter. The
transmitter display shall be a minimum 16-character (2 line) high temperature LCD alpha -numeric type,
capable of recording flow rate and total flow. The meter shall be either programmed before dispatch from the
manufacturer or be capable of being reprogrammed on site to suit prevailing conditions.
11. Flow-meters shall be battery powered, and fitted complete with long life batteries, with a minimum of 5 years
life for continuous operation. Power supply shall be DC: 11 to 40 V at 20 VA maximum
12. All flows shall be recorded and trended on the relevant SCADA or data logging system.
B.18.4 Meter Installation

1. The installation of water meters shall be carried out in accordance with the guidelines laid down in the current
versions of the following or in accordance with any revisions of the same from time to time: BS 5728:1997
and/or ISO 4064:1993, and/or BS EN 14154:2005 and/or ISO 4064:2005. The Contractor shall prepare his
own drawing based on standards and type of meters to be supplied.
2. All meters and meter reading systems and devices shall be installed and commissioned strictly in accordance
with the manufacturers' specifications, instructions and codes of practice.
3. The installation characteristics of the selected meter, meter reading system and associated devices and sub-
assemblies shall ensure:
Correct metering in compliance with its specific metrological characteristics;
Protection of the meter and Automatic Meter Reading devices;
The safety of personnel and user;
Easy reading of the Meter index and relevant markings both by Water Operator’s personnel and water supply
customers.
It is installed with isolation valves, strainers and provision for cleaning without removing the flow meter.
Meter Tests
Meter tests shall be in accordance with BS 5728:1997 and/or ISO 4064:1993, and/or BS EN 14154:2005 and/or
ISO 4064:2005, and shall be undertaken by an Independent Agency.
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B.18.5 Ultrasonic Level Measurement

1. Sensors shall be suitable for use in sunny conditions and shall have IP68 protection. The sensors shall have
good accuracy, repeatability and linearity over the full range of levels.
2. The transmitters shall be wall mounted.
3. Digital indicators shall be provided for each system at the location and at the control panel (indication to be
external to panel). Installation of sensors, cabling and auxiliary equipment shall be such as to eliminate
interference from other electrical equipment.
4. Each Ultrasonic level measurement system controlling motor starts shall have a low level float protecting the
equipment from dry running.
5. The transmitters shall be suitably mounted with consideration given to maintenance procedures.
6. All installations shall be adjustable, to enable changing of level set-points where necessary.
7. All water levels shall be recorded and trended on the relevant SCADA or data logging system.
B.18.6 Pressure Gauges
1. Pressure gauges shall have 150mm diameter dials, calibrated in metres head and shall be manufactured to
BS1780. All gauges shall be glycerine filled diaphragm type. All pressure gauge components (element,
socket, bolts, screws, etc) shall be made using 316 stainless steel.
2. Isolation valves shall be fitted on all lines with Pressure gauges.
B.18.7 Conductivity electrodes and level relay systems

1. Conductivity electrodes shall be formed from stainless steel tubes encapsulated in PVC sleeving down
to 75 mm from the end of the electrode. The electrode shall be sealed.
2. Where necessary, intermediate insulated support brackets shall be installed to prevent the electrodes
swaying. The intermediate supports shall be installed above normal top water level at the particular
location.
3. An earth electrode shall be provided at each electrode installation.
4. Pipe work shall not be used for the earth.
5. The electrode holders shall comprise a moulded back phenolic body capable of accepting 20 mm BS
pipe.
6. Plated clamping collars complete with cable termination shall be provided to locate the electrode.
7. The holder cap shall also be of moulded phenolic material. A gasket shall be placed between body and
cap. The body shall be arranged to receive screwed conduit.
8. Electrode holders shall permit adjustment in operating levels of not less than 100 mm without
necessitating cutting or extending electrodes.
9. Relay units operating with level electrodes shall have adjustable sensitivity. Electrodes for use in fluids
of low or variable conductivity shall have conductivity discs.
10. Electrodes shall be energised with an alternating voltage not exceeding 25 V open circuit.
B.18.8 Pressure devices

1. Pressure transducer level measuring sensors shall be of the stainless steel submersible type operating on
the piezo-resistive silicon strain gauge principle.
2. Compatible power supply and signal processing units shall be provided with protection against radio
frequency interference and supply transients. The final output shall be a 4-20 mA signal proportional to
level.
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3. Lightning protection shall be provided where applicable.

4. The transducer/cable shall be suitably supported with stainless steel brackets. A bracketed stainless steel
restraining tube shall be provided in deep sumps etc.
B.18.9 Pressure switches

1. Internal parts shall be of stainless steel, bronze or other corrosion resistant material.
2. All pressure switches shall be supplied complete with isolating valves and calibration points to enable
calibration or removal without loss of fluid.
3. Where compensation of more than 2% of the instrument span is needed for the difference in level between
the instrument and the tapping point, the reading shall be suitably adjusted and the amount of compensation
marked upon the dial.
4. Pressure and differential pressure switches shall have contacts with separate “cut in” and “cut out” pressure
values.
5. The nominal pressure values at which pressure switches operate shall be fully adjustable over the whole range
of the instrument and the set value(s) shall be clearly indicated by means of a scale and pointer.
6. Contacts of pressure switches shall be hermetically sealed.
7. The Pressure switches shall be manufactured to IEC Standards. They shall have separately adjustable set
points and span and will be equipped with an integral IP65 terminal box with sufficient space for glanding a
1.5 mm2 PVCSWAPVC cable.
B.18.10 Pressure transducers

1. Pressure monitoring shall be by a transducer suitable for the medium and pressure/level range specified.
2. Each transducer shall be ranged to provide adequate sensitivity over the working range and be capable of
sustaining a 400% over-pressure without damage.
3. They shall be of rugged and waterproof design to IP65, with a stainless steel enclosure having an isolation
diaphragm suitable for either free wire suspension in the medium or provided with an internal pipe
connection, designation “G” to BS 2779: 1986 with a machined surface on the transducer case to
accommodate seal washer.
4. Cable entry shall be made by integral sealed assembly or by 20 mm conduit entry into a sealed watertight
terminal enclosure with provision for transducer venting.
5. A transmitter shall be provided either integral with the transducer or separately mounted as specified, suitable
for operation from the mains or battery supply specified (not greater than 24 V) and converting the signals
received from the transducer to a 4-20 mA signal proportional to the range specified.
6. The transmitter shall have provision for range and zero adjustment.
7. Attention shall be paid by the designer to the negative pressure rating of a transducer in a particular
application.
B.18.11 Flow Switches or Sensors
1. Any flow switch or sensor installed within a suction pipe shall be connected by a swivel arm to the outer part
of the switch. The switch shall be connected to the pipe by a socket with female thread RI.
2. Any flow switch or sensor shall be suitable for its operational location and intended use, and shall have
watertight connections. Only one flow direction shall be possible. All parts, which are in contact with the
water, shall be of non-corrosion material.
B.18.12 Float-Switches
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1. Float-switches shall be corrosion-resistant and mercury-free. Each float-switch shall be fitted with a
stabilizing weight integrated to the suspension cable above the float-switch.
2. The contact of the switch shall change from open to close if the rising float passes its horizontal line.
3. A float-switch shall be suitable for operation in a liquid temperature between 0C and +60C. It shall be of
rugged design, completely watertight, and covered with solid rubber. Flexible vulcanized connection cable
(15m with 3 wires), terminal box IP 68 and protecting PVC pipe of heavy gauge shall be provided to prevent
horizontal movement of the float.
4. Aluminium channel shall be supplied and fitted to side or the roof of each reservoir or storage tank, next to
the manhole access point, with the float switch cable secured to it to prevent them from becoming tangled.
The channel shall be fixed so that it is removable for changing float switches when the reservoir is full.
5. Each float-switch shall be connected with a cable to the Control System.
6. Float-switches shall operate using high-impedance float-switch control relays of the plug-in type. They shall
be supplied by a DC system and shall be designed so that the float switch can be located far away from the
relay. The relay shall be connected to the float switch through a standard 1.5mm 2 copper conductor PVC
insulated SWA cable with the conductors for up to 6 float switches in one cable.
B.18.13 Panel Instrumentation & Anti Condensation Heaters
1. The following instrumentation shall be provided;
(i) A Power meter with a 100 mm display minimum suitable for 3 phase supply shall be provided on each
control panel. Each phase and parameter shall be switch selectable. The parameters shall be KW, PF, Amps
and volts. The Kilowatt and power factor signals shall also be inputted into the PLC.
(ii) Individual ammeters with 100 mm dials shall be provided for each motor. Alternatively intelligent starter
sections may display current on all operator interfaces supplied.
2. The main control panel shall have a suitable digital clock.
3. Anti-condensation heaters shall be provided required on all panels, and on all externally mounted motors.
B.18.14 Marking on fittings:
In order to discourage theft, vandalism and for easy identification, all pipe fittings shall be branded from the
factory by embossing during manufacturing/casting to indicate client name and if possible, project name.
Contractor shall propose installation measures to secure the fitting such as use of heavy-duty lockable covers,
welding or surveillance gadgets like alarms etc.
B.19 Facilities for the Engineer’s

B.19.1 Vehicles
The Schedule of Prices and Unit Rates contains a Provisional Sum for the procurement of vehicles for the Engineer’s
staff.
The PS amount shall cover the purchase, clearance, registration and licensing, and all other costs necessary to make the
vehicles in a ready-to-drive condition.
B.19.2 Operate and Maintain Vehicles

The Contractor shall be responsible for all costs associated with operating and maintaining the vehicles throughout the
contract period. This shall include, but not be limited to:
i) Fuel. The Contractor shall allow up to 200 km per day per vehicle for the duration of the contract;
ii) Engine oil and other fluids and consumables;
iii) Servicing at authorized dealers, in accordance with manufacturer’s service schedule;
iv) Maintaining comprehensive and 3rd party insurances. The comprehensive coverage shall be for the
full replacement value;
v) Experienced licensed drivers provided for each vehicle, including all costs and allowances
associated with providing such;
vi) Undertaking road worthiness test and other mandatory requirements under Tanzanian law;
vii) Providing replacement vehicles while regular vehicles are being serviced or repaired, or are
unavailable for other reasons. The replacement vehicle shall be equivalent to the regular vehicle
and shall be of acceptable standard to the Engineer. Where the Contractor defaults in this
obligation, the Engineer may hire a substitute vehicle and the cost will be recovered from the
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Contractor.
B.19.3 Ownership of Facilities

At the end of this Contract, the facilities provided for the Engineer shall be disposed of as follows:
i) Vehicles shall become the property of the Employer. The Contractor shall allow for all changes of
ownership and registration. The vehicles shall be handed over to the Employer in good condition, fair
wear and tear excepted.
ii) Office equipment including computers, printers, photocopiers, and UPS shall become the property of
the Employer.
iii) Office furniture shall become the property of the Employer.
iv) All other buildings, appliances and equipment shall revert to the ownership of the Contractor.
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SECTION C: GENERAL SPECIFICATION
48
SECTION C: GENERAL SPECIFICATION
C.1 General Requirements

C.1.1 General
Units
Metric units shall be used on all drawings and for all calculations, flow capacities, instruments, etc.. Where these are
quoted in the Specification or shown on the Drawings they are given for reference and identification, and the equivalent
metric units shall be used for all new Plant and on drawings.
Abbreviations
Organisations
ASTM American Society for Testing and Materials
AWWA American Water Works Association
DIN Deutsches Institute für Normung
BS British Standard
IDA International Development Association
IEC International Electrotechnical Commission
ISO International Organisation for Standardization
API American Petroleum Institute
IEE Institution of Electrical Engineers
MOW Ministry of Water
TANESCO Tanzania Electric Supply Company
TANROADS Tanzania Road Authority
Units
°C degrees Celsius
cc cubic centimetres
cm centimetre
g gram
kg kilogramme
kgf kilogramme force
km kilometre
kN kilo-Newton
l/s litre per second
m3/s cubic metres per second
m metre
m² square metre
m³ cubic metre
mm millimetre
mm² square millimetre
N Newton
kW kilowatt
MLD million litres per day
mg/l milligram per litre
g/l gram per litre
kVA kilo volt ampere
kA kilo ampere
A Ampere
mA Milliampere
V Volt
AC Alternating current
DC Direct current
Others
BSCP British Standard Code of Practice
BSP British Standard Pipe (Thread)
CP British Standard Code of Practice
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DI Ductile Iron
DN Nominal Diameter
GMS Galvanised Mild Steel
MDPE Medium Density Polyethylene
HDPE High Density Polyethylene
No. Number
NP Nominal Pressure
OD Outside Diameter
% Percentage
UK United Kingdom of Great Britain and Northern Ireland
O&M Operation and Maintenance
SI International System of Units
GRP Glass Fibre Reinforced Polyester
EPDM Ethylene Propylene Rubber
rpm Revolutions Per Minute
PVC Polyvinyl Chloride
uPVC Unplasticized Polyvinyl Chloride
FSD Full Scale Deflection
PVA Polyvinyl Acetate
NTU Nephelometric Turbidity Unit
masl Metres Above Sea Level
RSJ Rolled Steel Joist
HRC High Rupturing Capacity
DC Direct Current
XLPE Cross Linked Polyethylene
LV Low Voltage
HV High Voltage
SWA Steel Wire Armoured
LSF Low Smoke and Fume
PE Polyethylene
IS Intrinsically Safe
THD Total Harmonic Distortion
Level Datum
Before the commencement of construction work the Contractor shall establish, at a position to be approved by the
Engineer, a steel datum peg which shall be securely concreted in. The level of this peg shall be established and agreed
with the Engineer and all levels used in the construction of the Works shall be referred to this single established datum.
The correctness of this established datum shall be checked at regular intervals during the construction period and agreed
with the Engineer.
Boundaries of Works
The Employer will provide land on which the Permanent Works included in the Contract are to be constructed.
Existing boundary fences and walls shall not be disturbed without the prior approval of the Engineer.
The Contractor shall provide temporary fencing, or immediately install permanent fencing where such is required. Where
the Permanent Works do not include fencing, the Contractor shall submit proposals to the Engineer for fulfilling his
obligations under the Contract, and shall obtain the approval of the Engineer.
Contractor to Work from Points As Directed

The Contractor shall start the work at such points as the Engineer may from time to time direct.
First Aid Facilities / Emergency Vehicles / Emergency Services

The Contractor shall provide and maintain for the duration of the Contract adequate and easily accessible first aid
facilities at the work sites.
The Contractor shall have available at all times a vehicle for the conveyance of sick or injured people to hospital, together
with a person trained in first aid.
The Contractor shall notify the Public Emergency Services (Fire, Police, Ambulance) of the location and intended
duration of the contract prior to commencing work.
C.1.2 Health and Safety
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Laws and Regulations

The Contractor must at all times comply with the following laws and regulations, and any other such statutory
instruments in force, during the planning, design, construction and commissioning phases of the Project:
United Republic of Tanzania: Occupational Health and Safety Act, 2003.
United Republic of Tanzania: Workmen’s Compensation Ordinance, Chapter 263 of the Laws.
United Republic of Tanzania: Workmen’s Compensation Regulations, Chapter 263 under Section 41 of
the Laws.
United Republic of Tanzania: Law Reform (Fatal and Miscellaneous Provisions), Chapter 360 of the Laws.
United Republic of Tanzania: Workmen’s Compensation Ordinance (Amendment) Act, 1966.
Site-Specific Health and Safety Management Plan

The Contractor shall appoint a Health and Safety Manager who shall have responsibility for all safety issues on the
Project. The Contractor must submit a site-specific Health and Safety Management Plan (HSMP), which shall, as a
minimum, address the following in compliance with the laws and regulations listed above:
1. Introduction (including objectives of the HSMP)
2. Hazard Prevention and Control
i) Risk assessment (including description of risk assessment method used);
ii) Prevention, protection and control measures (based on risk assessment performed):
a. Personal protective equipment and clothing: safety goggles, ear plugs, work boots, dusk masks,
protective clothing etc.;
b. H&S and sanitary facilities, equipment, materials and personnel: first-aid kits and stations,
health personnel, safe drinking water, sanitary facilities, accommodations, washing facilities,
domestic waste disposal, etc.;
c. On-site safety measures and procedures to protect workers against accidents and health risks in
the performance of construction-related activities:
i. Site security: access, safety of visitors, separation of work and rest areas, signage, etc.
ii. Handling of raw materials: earthwork, gravel, crushed rock, sand, etc.
iii. Handling of other materials causing dust development, such as cement
iv. Handling of hydrated lime and other activators and additives
v. Handling of asphalt
vi. Hazardous materials management
vii. Handling of inflammable materials
viii. Maintenance of vehicles and machinery
ix. Excavation and trenching
x. Emergency prevention, preparedness and response.
i) Contractor’s participation in HIV/AIDS Awareness and Prevention Program.
iii) Health and Safety Training Program
iv) Provide specifics of training and instruction: topics, frequency, modalities, target audiences,
instructors, training materials, etc.
v) Potential topics:
a) Occupational safety risks and prevention
b) Health risks and prevention
c) Use of personal protective equipment
d) Safe work procedures: general and specific.
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e) Organization and Management

vi) Organizational structure, personnel, equipment, communication and reporting requirements,
accident and incident reports, and procedures and tools to verify and ensure compliance with
occupational health and safety requirements.
vii) Annexes
Annexes should be used, if necessary, to include detailed information on the specific topics of the
HSMP, such as (illustrative list):
a) Accident Report forms.
b) Dangerous Occurrence forms (near misses).
c) Safety Audit Forms.
d) Safety Check List.
e) Safety Rules.
f) List of hospitals, emergency evacuation strategy and other arrangements to treat seriously
injured staff.
g) List of personnel trained in first aid and their places of deployment.
h) List of first aid kits and locations where these will be held.
Safety during Construction
Competence and Fitness for Work
The Contractor shall ensure that all of his/her personnel, agents and sub-contractors shall be trained, competent and fit
to perform the duties assigned to them. They shall be informed by the Contractor of all relevant hazards and given
instruction in corresponding safe methods of working, including but not limited to, the correct use of personal protective
equipment. This requirement for competence and fitness is the responsibility of the Contractor.
Safe Place of Work
The Contractor shall be fully responsible for the adequacy, stability and safety of all site operations and safe methods of
construction for all construction activities arising out of the works.
Personal Protective Equipment

The Contractor is responsible for providing and ensuring usage of all items of Personal Protective Equipment (PPE)
necessary for the various work activities. Such items of PPE shall comply with relevant and applicable standards. Unless
otherwise agreed with the Engineer, these shall include as a minimum:
Safety helmets and safety footwear, to be worn at all times;
High visibility vests shall be worn by the Contractor's staff and visitors, in situations where there is danger
from vehicular traffic or machinery;
Eye protectors (egg. visors, goggles and safety glasses) shall be used for all work activities and situations
that could result in serious eye injury (egg. welding, grinding, using chainsaws, breaking rock, using
chemicals, etc);
Ear protectors shall be used whenever the noise level exceeds 90dBA or whenever using equipment that
causes the noise level to exceed 85dBA;
Safety harnesses shall be used when working at a height of more than 2 meters.
Safety Audit Reports

A safety audit shall be completed each month by the Contractor. The report shall be completed on a standard form
provided by the Contractor and approved by the Engineer. Copies of audit reports shall be provided at site progress
meetings in advance of each progress meeting.
The Engineer reserves the right to carry out safety audits of Contractor’s works. The Engineer shall notify the Contractor
of any defective practices and may request to have these practices improved or prevented within a specified time-period.
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Daily Safety Planning

Before beginning work each day, the Contractor's person in charge of work (charge-hand or foreman) shall take due
consideration of all safety issues. This will involve considering the risks associated with the works in hand and steps
taken to mitigate the risk identified.
The Contractor shall demonstrate that adequate safety planning is undertaken by:
Providing completed safety reports as specified within this procedure;
Ensuring the safety of all persons affected by the Contractor's own activities and/or his employees, agents
and subcontractors;
Ensuring the safety of the Contractor's personnel (including without limitations his sub-contractors and / or
agents working for the Contractor) with respect to all hazards, including those hazards advised by the
Engineer;
Advising the Engineer of any hazards that the Contractor's activities might pose to persons other than the
Contractor's own personnel (including sub-contractors working for the Contractor) or to Employer's plant
and equipment;
Compliance with the legislation including the Contractor's Method Statements by ensuring that, except by
prior and mutual agreement, or in all cases of emergency, all communication on safety related issues shall
be between the Engineer and the Contractor's Representative. Where other persons are given such a role,
their mandates shall be clearly established and confirmed in writing between these two persons. The
Contractor's Representative (or his nominee) shall be present on site at all times while the Contractor's
personnel are working on the site.
Stopping the Works

Breaches of safety procedures by the Contractor shall not be tolerated.
The Engineer shall stop work at any time if unsafe practices are being used, and there is a risk to any individual working
on site or to the general public. The Engineer also reserves the right to insist on the removal from the works of any
individual found to be in breach of these procedures.
Where a particular work practice has been identified as unsafe in the opinion of the Engineer, the Engineer shall inform
the Contractor and instruct the Contractor to rectify or terminate the practice within a specified time.
No consideration will be given to claims for extension of time or additional costs, resulting from delays caused by
breaches of safety procedures.
C.1.3 Minimisation of the Spread of HIV / AIDS and Child Abuse
Scope
This Specification sets out the Contractors obligations with regard to on-site HIV/AIDS awareness campaign and
preventive measures which are to be instituted.
HIV / AIDS Considerations

Given the seriousness of the HIV / AIDS problem, and the perception that projects and personnel involved serve as one
of the principal means of the virus moving from one part of the country to another, the Employer is integrating HIV /
AIDS issues into all of its activities.
Project staff are identified as a vulnerable group by the National Strategic Plan on HIV / AIDS. In this regard, the
Employer, on his part, will implement an HIV / AIDS awareness and prevention campaign by hiring a Non-
Governmental Organization (NGO) to manage all HIV / AIDS awareness and prevention programs. The Contractor, on
his part, will therefore be required to provide only support to this NGO including, but not limited to, allowing his site
employees to attend HIV / AIDS awareness campaigns.
General Requirements
The Contractor shall allow his employees to take part in a continuing HIV / AIDS awareness and prevention campaign
for the duration of the contract.
As part of the campaign the Contractor will be required to display AIDS awareness posters in all buildings frequented
by workers employed on the contract, where such building fall under the control of the Contractor. The awareness posters
will be provided by the NGO managing the HIV / AIDS program.
AIDS awareness shall also be included in the orientation process of all workers employed on the contract. The Contractor
must indicate in the work plan orientation on HIV / AIDS for new staff. The orientation will be conducted by the NGO
managing the HIV / AIDS programs. The Contractor shall make his staff available for HIV / AIDS awareness training
for eight (8) hours during the first month of employment and two (2) hours for each subsequent month.
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The prevention of sexual abuse and exploitation of children will form part of this campaign.
The scope of activities shall be tailored by the NGO managing implementation of HIV / AIDS awareness and prevention
programs as required to meet the perceived needs and priorities of the labourers, determined by participatory approaches,
to ensure they are appropriate, desired and have a public health impact. The scale and frequency of activities may also
be adjusted to suit requirements of the target group. The appropriate timing on this activity will be agreed with the
Contractor.
Contractor Responsibilities
The Contractor and NGO will work closely together to support the HIV/AIDS awareness and prevention activities. This
will ensure maximum effectiveness and integration with construction activities. Specific but not exclusive issues are:
• Scheduling of appropriate timing and duration for the implementation of HIV/AIDS activities as
part of work plan for labourers and supervisors. Designated rest times such as lunch breaks and
pay days should be excluded;
• Identification of suitable individuals for education from recruitment records with the
implementing organization;
• Provision of suitable sites for communication activities and for condom distribution. The
Contractor must provide a meeting room for the training, but condoms will be provided;
• Provision of support as necessary to the NGO.
Timing
Activities will commence at the start of the construction period and continue throughout the construction period.
C.1.4 Environmental Requirements
The Contractor must carry out all works in accordance with Tanzanian Environmental Laws and Regulations,
Environmental Guidelines and Gender Policy, and the requirements of this document.
It is also a contractual obligation for the Contractor to take full cognizance of the environmental and social concerns and
requirements as stipulated in the Employer’s Environmental and Social Management Plan (ESMP) prepared for this
project.
Accordingly, the Contractor shall be required to prepare a site-specific Environmental and Social Management Plan
(ESMP) for the project. This site-specific ESMP shall be based on the Contractor’s evaluation of the requirements of
these Specifications and the Employer’s ESMP. The site-specific ESMP shall be submitted to the Engineer for approval.
The site-specific ESMP shall comply with the guidelines set out below.
The site-specific ESMP is the Contractor’s operative document on how to mitigate, inspect and monitor potential Project
impacts during mobilization, construction and demobilization. In this sense, it is an eminently practical and concrete
instrument.
Based on the above, the structure and content of the site-specific ESMP shall emphasize the following aspects:
1. Executive Summary
2. Introduction
3. Project Description
i. Focus on impact-generating activities (egg., demand of water and materials, earth movement,
etc.);
ii. Environmental liabilities: identify and include a photographic registry of pre-existing environmental
liabilities (egg., gully erosion areas, abandoned borrow pits, unauthorized dumping sites, etc.) that
are not attributable to the implementation of the project
4. Potential Impacts during Mobilization, Construction and Demobilization
i. Apply simple rating of significance;
ii. Quantify / qualify impacts (egg. surface and type of vegetation to be removed, amount and type of
wastes to be generated, noise levels, etc.);
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iii. Identify places where specific impacts will manifest.

5. Mitigation Plan
i. Specify the detailed measures to mitigate the identified impacts (also by location);
ii. Include designs for measures requiring structural solutions (egg., gabions, etc.);
iii. Include the schedule of implementation of mitigation measures in relation to the general construction
schedule;
iv. Health and Safety Plan (detailed);
v. Waste Management Plan (detailed);
vi. Traffic Management Plan (detailed);
vii. Training Program (detailed);
viii. Accident and Emergency Response Plan (detailed);
ix. HIV / AIDS Awareness and Prevention Program (include only a reference to this Program to be
prepared by an NGO);
x. Community Relations Program;
xi. Location and technical specifications for installation and operation of campsites, including
workshops, garages, laboratories, offices, sanitary installations, etc;
xii. Location, and technical specifications for operation of quarries and borrow pits, and procedures for
negotiation with and compensation of land owners where they are located;
xiii. Location and technical specifications for installation and operation of concrete batching, stone
crushing, cement mixing and asphalt plants;
xiv. Location and technical specifications for installation and operation of temporary and permanent
dump sites.
6. Inspection Plan
i. Inspection function: specify frequency, locations and instruments (egg., checklists, site reports,
photo registry, etc.) to conduct site inspections;
ii. Permitting: required environmental permits and schedule to obtain them;
iii. Specific actions and responsibilities: what, who, where, when, how and why
7. Monitoring Plan
i. Specify, for each variable: frequency of measurement, locations, methods/equipment,
units/measures, quality standards, and reporting requirements and periodicity, including
establishment of trends.
ii. Specific actions and responsibilities: what, who, where, when, how and why
8. Organization and Management
i. Specify organizational structure, personnel, resource and equipment requirements, reporting
requirements and periodicity, and inter-institutional communication and coordination mechanisms.
ii. Specific actions and responsibilities: what, who, where, when, how and why
9. Annexes
i. If the Contractor wishes to incorporate information beyond the indicated above, such as the policy,
institutional and regulatory framework for environmental management in Tanzania, biophysical
and socio-economic characteristics of the area of influence of the Project, Environmental
Guidelines or Gender Policy, etc., that information should be included as an annex and not in the
body of the site-specific ESMP. Preferably, such information should not be attached and, further,
if necessary, the pertinent chapter of the ESIA should be referenced.
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ii. Annexes should be used, if necessary, to include detailed information on the specific topics of the
ESMP (egg., inspection forms or checklists, design of structural mitigation measures, photographic
registry of environmental liabilities, etc.).
C.1.5 Contractor's Staff, Communication, Offices, etc.

Language of Correspondence and Records
All communications shall be in the English language. All books, time sheets, records, notes, drawings, documents,
specifications and manufacturers' literature, etc. shall be in the English language. If any of the aforementioned is in
another language a certified translation into English shall be submitted with the documentation concerned.
Contractor's Representation on Site
At least one named responsible senior representative of the Contractor, fully empowered to execute the contract, shall
be immediately available at all times and shall be on the Site during normal working hours.
In the absence of the Contractor's representative a deputy shall be appointed whose name shall be notified to the Engineer
at least one day before absence of the Agent and at least three days before any absence exceeding one day. To the senior
representative (or his deputy) shall be delegated full authority to confer with the Engineer and to take all steps and to
issue all instructions which may be required in an emergency to ensure the safety of all personnel and the Works, and of
all the Employer's and other property on the Site and in the immediate vicinity thereof.
The Contractor shall provide and maintain at the Site, offices for the use of his representative, to which written
instructions by the Engineer can be delivered. Any instructions delivered to such offices shall be deemed to have been
delivered to the Contractor. Such offices shall be erected before commencement of the Works.
Personnel
The Contractor shall ensure that at least one senior member of his field supervisory staff, who is experienced in such
operations and fluent in both English and the language of his labourers, is on site throughout the whole duration of the
work.
The Contractor shall also ensure that all necessary skilled artisans for the operation of all his Plant are on site throughout
the work. The Contractor shall obtain the approval of the Engineer not less than 48 hours before the commencement of
the work in respect of each of such personnel. To gain this approval, the Engineer may require that such operative is
tested in the performance of his duties in the operation of the Plant for which he is in attendance. In particular this
requirement shall apply to all welders, pipe-cutters and crane operators.
The Contractor shall ensure that an adequate number of labourers are in attendance upon the site during the period of the
work.
Public Relations
The Contractor shall designate within his site organisation competent staff whose responsibility shall be to ensure good
public relations.
C.1.6 Contractor's Yards, Stores and Accommodation for Workmen
The Contractor shall make his own arrangements for all land, yards, stores, workshops, offices, etc. required by him for
the purposes of the Contract and for all services in connection therewith.
The locations of all yards, stores, workshops, offices, etc., shall be agreed beforehand with Water Utility and the Engineer
and shall be such as to minimise obstruction and nuisance to the public. In particular, the Contractor shall demonstrate
that he will take such measures as are necessary to prevent pollution of the environment from fuel and oil spillages,
washing of concrete mixers and the like.
The Contractor shall provide and maintain suitable and sufficient shelters and mess rooms for his workmen and
supervisory staff as are customary and necessary.
The Contractor shall provide sufficient closets or latrines to the satisfaction of the Engineer and the relevant authority,
for the use of his personnel. They shall be properly screened and maintained in a clean and sanitary state at all times.
The mess rooms, closets and latrines shall be located in positions to be approved by the Engineer. The Contractor shall
be responsible for making all arrangements for the disposal of waste from mess rooms, closets and latrines.
C.1.7 Precautions against Contamination of the Works and Environment
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The Contractor shall satisfy the Engineer that all his personnel working on the Site are medically fit to be in contact with
public water supply and his personnel shall undergo any necessary medical tests to show that they are free from infectious
diseases and are not carriers of any such diseases. The Employer reserves the right to call for medical certificates in
respect of any employee of the Contractor.
The Contractor shall at all times take every possible precaution against contamination of the Works. The Contractor shall
give strict instructions to all person employed by him to use the sanitary facilities provided.
Throughout the Contract, the Site and all Permanent and Temporary Works shall be kept in a clean, tidy and sanitary
condition.
The Contractor shall at all times take measures to avoid contamination of water courses, drains and the environment by
petrol, oil or other harmful materials.
The Contractor shall include specific detail in the site-specific ESMP regarding their plan for discharge and disposal of
the testing and sterilising waters beyond the requirements of the ESIA. .
The Contractor shall comply with the requirements of the Environmental Management Plan.
C.1.8 Restrictions On Use of Roads
Traffic Restrictions
The Contractor shall not run tracked vehicles or equipment on any public or private road without the written approval of
the Engineer and of the responsible authority or owner, and subject to such conditions as each may reasonably require.
The Contractor shall observe all weight and dimensions restrictions which apply to roads and tracks in Tanzania and he
shall comply with all reasonable restrictions which may from time to time be imposed by the Engineer, Employer, Police,
responsible authority or owner. Where damage to roads and tracks are caused by the Contractor this shall be repaired at
the Contractor's expense.
The Engineer shall have the power to restrict the Contractor's use of any roads, or tracks in terms of direction of traffic,
speed of traffic, numbers of vehicles or their axle loading in order to preserve such roads or to make them safe for use
by the general public.
Where other Contractors require the use of these roads or tracks, the Engineer may prescribe times of usage, or impose
some other form of control, which shall be established and operated by the Contractor, including the supply of traffic
lights, flagmen, traffic cones or drums, and other controls.
Access Roads
All surfaced roads and tracks, and other surfaced areas used by the Contractor for access, shall be continually maintained
by him in good condition. Immediately after ceasing to use any road, track or other surfaced area, the Contractor shall
restore it to the satisfaction of the Engineer and the responsible authority or owner. The provision of this Clause shall
apply also to the shoulders and verges of any existing sealed road used by the Contractor and affected by his operations.
C.1.9 Temporary Water and Electricity Supplies
The Contractor shall, at his own cost, provide at Site an adequate supply of water and electricity both for the execution
of the Works and for the health and safety of his workmen and other persons legitimately on the Works.
C.1.10 Existing Services
General
The Contractor shall make himself acquainted with the positions of all existing services such as sewers, drains, electrical
cables, telephone lines, water mains, etc before any excavation or other work commences. The Contractor shall liaise
with the necessary authorities before and during the execution of such work. Any work near or on the services shall be
done to the complete satisfaction of the respective Authority, or its representative, and the Engineer.
The Contractor shall take every precaution to ensure that all existing services within and near the line of the works, are
located, supported and safeguarded from damage. Any damage caused to any such services attributable to the
Contractor's operations or his negligence shall be made good by the Contractor at his own expense to the satisfaction of
the Engineer, owner or responsible authority.
In the event of the owner or the responsible authority electing to repair such damage the Contractor shall pay the cost of
so doing the work. Should the Contractor fail to pay the cost of the said work within one month of the account being
presented, the Employer reserves the right to settle the account and deduct the sum from monies due or which may
become due to the Contractor.
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Temporary Removal of Existing Services

If it should become necessary to temporarily relocate a service during construction, the Contractor shall obtain
permission from the Engineer and the responsible authority or owner and shall carry out the work at his own expense in
a manner and at times to be approved by such authority or owner and shall subsequently reinstate the work to the
satisfaction of such authority or owner.
In the event of the owner or the responsible authority electing to arrange for the temporary removal of an existing service,
the Contractor shall pay the cost of his or their doing the work. Should the Contractor fail to pay the cost of the said work
within one month of the account being presented, the Employer reserves the right to settle the account and deduct the
sum paid by him from monies due or which may become due to the Contractor.
Permanent Diversion of Existing Services
If, in the opinion of the Engineer and/or of the responsible authority or owner, it should become necessary to permanently
remove or realign a service, the Contractor shall obtain permission, where necessary, from the authority or owner and
shall carry out the work to the satisfaction of the Engineer and such authority or owner.
In the event that the responsible authority elects to carry out the work, the Contractor shall allow them the facilities and
assistance they may require and shall pay the responsible authority, against provision of an authorised invoice and receipt,
for the costs of such works.
Payment for such additional work will be made in accordance with the Contract, provided always that the necessity for
such permanent diversion has not arisen due to the fault of the Contractor.
In the event of the owner or the responsible authority electing to arrange for the permanent diversion of an existing
service, the permanent diversion of which has become necessary due to the fault of the Contractor, the Contractor shall
pay the cost of his or their doing the work. Should the Contractor fail to pay the cost of the said work within one month
of the account being presented, the Employer reserves the right to settle the account and deduct the sum paid by him
from monies due or which may become due to the Contractor.
C.1.11 Care of Boundary Walls and Fences

The Contractor shall not cut through or remove any section of any boundary wall or fence without the prior approval of
the Engineer and the respective owner or responsible authority who will determine the limits of such cutting or removal.
Approval for the cutting through or removal of boundary wall and fences will normally be limited to those crossing the
route of the pipeline and the Contractor shall so conduct his operations as to minimise the extent of such cutting through
or removal.
The Contractor shall repair and reinstate in a manner similar to the original or by other approved means any wall or fence
which he may have cut through or removed with or without the approval of the Engineer or damaged during his
operations and all such repairs and reinstatement shall be the Contractor's sole liability and shall be carried out to the
satisfaction of the Engineer and the responsible authority.
The Contractor shall at his own expense provide temporary fencing and security measures at all times to protect any
affected properties.
C.1.12 Demolition of Contractor's Temporary Works
The Engineer may at any time before the end of the Defects Liability Period give the Contractor notice in writing to
demolish and remove those Temporary Works which are no longer required, whereupon the title to such Temporary
Works shall revert to the Contractor. After the demolition and removal of the Temporary Works as required by the
Engineer, the Contractor shall level, clear, restore and make good the sites and surrounding ground and fill in all latrines,
drains, pits and similar items leaving the whole area in a neat and tidy condition to the satisfaction of the Engineer and
any relevant authority.
C.1.13 Demolition of Buildings and Structures
The Contractor shall present to the Engineer a detailed and systematic procedure concerning the demolition of existing
structures, if any, at least seven days before any demolition work starts.
The Contractor shall give the Engineer an explanation of the method and order of demolition and the steps taken to
ensure the safety and stability of the remaining structures affected thereby.
Unless due notice is given the Contractor shall not be entitled to any claim for delay in his construction program owing
to the refusal of permission to demolish the said structures.
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Backfill, compaction and consolidation of demolished structures shall proceed as mentioned elsewhere in these
Specifications.
Should the demolition as stated above involve the construction of any temporary works, the Contractor should include
the cost in the Schedule of Prices and Unit Rates
C.1.14 Component Life
The Contractor shall design the various structures and mechanical and electrical equipment to be supplied and installed
under this Contract with the following minimum service lives:
i) Reinforced concrete structures and tanks: 100 years,
ii) Buildings: 50 years,
iii) Pipelines: 50 years,
iv) Surface treated steel tanks: 30 years,
v) Mechanical equipment: 15 years,
vi) Electrical equipment: 25 years,
vii) Instrumentation items: 15 years,
viii) Plastic tanks: 15 years.
Corrosion protection for buried and immersed pipelines, concrete and steel structures shall comprise high quality systems
proven to be suitable for the conditions of service expected.
In particular, the internal surfaces of reinforced concrete tanks and process vessels shall be coated with an approved high-
build, two-part epoxy material or approved equivalent, designed to minimise corrosion.
All dissimilar metals shall be insulated from direct contact at any connection or support points by the installation of
insulators manufactured from long-life polymeric material.
C.1.15 Painting and Labelling
All pipework, valves and equipment shall be labelled.
Mechanical, electrical and motor-driven equipment shall be provided with stainless steel tags describing the equipment
item and its tag number.
Stainless steel screws shall be used to secure the label to the equipment item; traffolite labels provided with double-sided
with tape or similar will not be accepted.
Pipework shall be colour coded or provided with appropriate coloured striping in accordance with the General
Specification, with reference to the fluid being conveyed in each section of pipework.
Directional arrow markers shall also be affixed to pipework adjacent to pipework labels.
C.1.16 Access for Inspection
Walkways, handrailing and access stairs shall be provided for maintenance and inspection of all equipment.
All walkways and access ways shall have a minimum width of 900 mm and a minimum clearance height of 2,100 mm
unless otherwise indicated in the drawings, or approved by the Engineer.
C.1.17 Washdown Facilities
Washdown facilities shall be provided to allow cleaning of the new Clarifier and Filters, by the provision reticulated
service water via DN 80 galvanised mild steel or uPVC pipework to locations adjacent to each structure, as well as the
provision of appropriate connection points with hose bibs and isolation gate valves.
Hose connection points shall be located to achieve the above with a maximum hose length of 20 m.
C.1.18 Lifting Equipment
Lifting equipment shall be provided to allow routine maintenance and equipment removal in a safe manner, if access for
cranes or other mobile lifting equipment is not possible.
C.1.19 Provisions for Dismantling
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Dismantling couplings shall be provided in all pipework to allow pipeline cleaning and maintenance and the convenient
removal of valves, flow meters and other in-line devices that may require replacement and/or maintenance.
All items of equipment such as pumps, blowers, shall be able to be readily disconnected from the pipework for
maintenance.
C.1.20 Drains
All water retaining reinforced concrete structures and compartments thereof shall be provided with separate DN 80 drain
valves and interconnecting pipework to an acceptable discharge point, to allow the complete emptying and drainage of
the structure for inspection or maintenance.
C.2 Materials and Workmanship

C.2.1 Standards and Regulations
General
All materials, plant and equipment to be incorporated into the Works shall be designed, constructed, manufactured, tested
and installed in accordance with an internationally recognised Standard, Code of Practice, or Regulation applicable to
that part of the Works.
Such standards, etc. shall include:
• Tanzania Bureau of Standards (TBS)
• International Organisation for Standardisation (ISO)
• British Standard (BS)
• European Standards (EN)
• Deutches Institute für Normung (DIN)
• International Electro-Technical Commission (IEC).
• Code of Practice or British Standard Code of Practice (CP / BSCP)
• American Society for Testing and Materials (ASTM)
• American Water Works Association (AWWA)
Other national or international or other authoritative standards equivalent or superior to those designated in the
Specifications. The Contractor shall demonstrate to the Engineer's satisfaction the equivalence or superiority of
any item of Plant supplied to such alternative standards.
All standards shall be the latest published1 and shall include amendments which are current at the date of manufacture
or construction (as applicable). The Contractor shall supply to the Engineer four copies, in the English language, of all
such standards prior to approval by the Engineer.
Electrical diagrams and symbols on drawings shall comply with IEC 60617.
Electrical systems shall comply with requirements and regulations of the local public electricity supply authority.
Electrical installations in buildings shall comply with the local regulations pertaining to such installations. The Contractor
shall be deemed to have acquainted himself with such requirements and ensure that all electrical systems comply
therewith.
Plant for the electrical installation shall additionally comply with the Regulations of the Institution of Electrical Engineers
(United Kingdom) for the Electrical Equipment of Buildings (Fifteenth Edition) with amendments.
In the event of conflict with Tanzanian regulations, the regulations of the relevant authority in Tanzania shall take
precedence.
1
Every effort has been made to ensure the accuracy of the standards quoted throughout these
specifications. However, notwithstanding the version stated in the text, the Contractor / Contractor shall
ensure that the latest version of the appropriate standard shall apply to these works.
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C.2.2 Samples
General
Before incorporating in the Works, the Contractor shall submit to the Engineer for acceptance, a sample of each material.
Such samples shall be kept at his office for reference.
All the respective kinds of materials used in and upon the Works shall be at least equal in quality to the approved samples.
Each and every sample shall be a fair average of the material it represents. The Engineer shall approve the method by
which each sample shall be obtained
Tests of Materials before Use
Any or all of the material supplied by the Contractor for use in any of the Works shall be subject in advance to such tests
as may be specified in the relevant Standard or the Specification, or as may from time to time be required by the Engineer.
In particular, material in contact with potable water, or with raw water which is to be treated to render it potable, shall
have satisfactorily passed the appropriate tests as laid down by BS 6920 or an equivalent approved standard or code of
practice in operation in the country of manufacture.
Facilities for Engineer to Take Samples
The Contractor shall provide facilities, including labour, for the Engineer to take samples for testing of any of the concrete
or other materials to be incorporated in the Works. Such samples may be taken before or after incorporation into the
Works, or at any stage during construction, at the discretion of the Engineer.
C.2.3 Quality of Materials and Workmanship
General
The materials and workmanship shall be the best of their respective kinds suitable for tropical conditions and to the
approval of the Engineer. The words "to the approval of the Engineer" shall be deemed to be included in the description
of all materials and workmanship to be used in the Works.
The Contractor shall use locally produced material in preference to imported materials provided that they comply with
the Specification and are available in sufficient and timely quantities.
All materials, goods, etc shall be used or installed in accordance with the instructions of the manufacturer or supplier
unless otherwise specified or instructed by the Engineer.
Rejected Materials
Should any materials or manufactured articles be brought on the Site which, in the judgement of the Engineer, are
unsound or of inferior quality or in any way are unsuited for the purpose in which it is proposed to employ them, such
materials or manufactured articles shall not be used upon the Works but shall be branded, if in the opinion of the
Engineer, this is necessary, and shall be removed from Site.
Quality Control
The Contractor shall be responsible for his own quality control and shall provide sufficient competent personnel for
taking and preparing samples and for carrying out necessary tests.
C.2.4 Materials Testing Laboratory
Within 2 weeks of the commencement of work on Site, the Contractor shall provide, and maintain during the execution
of the Works, a concrete and other materials testing laboratory and sample store each having a floor area of not less than
12 m2 in an approved location, for his own and the Engineer’s use.
The Contractor shall ensure a continuous supply of electric power and water to the laboratory at all hours including
nights, and recognised days of rest.
The laboratory shall contain suitable benches, shelves and cupboards, and sinks, and shall be provided with a piped water
supply and appropriate drainage.
The Contractor shall provide and maintain in the laboratory all necessary apparatus and equipment for carrying out the
materials testing programme.
The Materials Testing Laboratory shall be ready for use at an early stage in the Contract to enable the programme of
preliminary concrete tests to be carried out in advance of the start of construction work.
Details of the Contractor's approved layout of the laboratory shall be submitted for the approval of the Engineer before
its construction is started.
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Alternatively, the Contractor must ensure and demonstrate that independent laboratories are available to carry out all the
required tests in this project on Contractor’s costs.
C.2.5 Inspection and Testing During Manufacture
All plant and equipment shall be tested in accordance with the respective standards applicable to the manufactured item.
Pumps shall be tested in accordance with ISO 2548. Each pump shall be tested with its contract motor, and with similar
starting equipment to that provided in the Contract, unless otherwise directed by the Engineer. Pumps shall be tested
with suction conditions corresponding to those under which the pumps will operate on site. The guarantee conditions
shall be applicable to the combined pump and motor unit. The Contractor shall verify that the available NPSH
comfortably exceeds the required NPSH specified by the pump manufacturer.
All parts of a pump subject to pressure shall be submitted to a hydraulic test pressure not less than 1.5 times the maximum
pressure which can occur within the pump under any site operating condition.
All pipework, valves and fittings shall be submitted to a hydraulic pressure test in accordance with the applicable
Standard or Regulation, but in any case to not less than 1.5 times the maximum working pressure.
Valves shall be tested for operation against the maximum operational unbalanced pressure.
Electric motors shall be tested in accordance with IEC 34. In addition to routine tests, one electric motor of each type
and size above 45 kW shall be the subject of a full performance test, including a temperature rise test.
All rotating machinery shall be tested for vibration in accordance with the principles of ISO 2372.
Switchboards and control panels shall be rigorously tested to appropriate Standards. All functions shall be tested by
means of wiring auxiliary switches to the outgoing terminals. Protective relays and instruments shall be tested with their
respective instrument transformers by injection of the operating current and voltage.
Test certificates in triplicate shall be submitted by the Contractor to the Engineer within 28 days of the date of the tests.
Type tests are not acceptable. Test certificates shall be supplied for tests carried out on the actual equipment being
supplied.
The Engineer and a minimum of 2 representatives from the Employer shall witness tests on individual items at the
Manufacturer's Works for pipes and valves. The Engineer shall be given three (3) weeks notice in writing before such
tests are to take place. If the manufacturer of the pipes and valves is located abroad then the Contractor shall cover the
costs for the Engineer and Employer’s staff to attend the witness testing.
C.2.6 Connections to Existing Pipes, Cables, Structures, etc
The Contractor shall be responsible for connections between pipes, cables etc laid by him and existing pipes, cables,
structures etc. The Contractor shall submit to the Engineer a drawing showing the details of the connection.
The Contractor shall be responsible for joining up to and ensuring complete compatibility with existing pipework, cables,
tubing, equipment etc. The Contractor shall therefore allow for all costs related to such connection and tie-ins to existing
system.
C.2.7 Interchangeability
All similar equipment shall be strictly interchangeable as a whole and as regards to its parts.
The type of plant offered must be suitable for standardization in so far as in practicable with the maximum
interchangeability of parts.
C.2.8 Balancing and Noise Control
All items of plant shall operate without excessive vibration or noise. The maximum noise level shall not exceed 85 dB
within 1.85 meter of any item whenever one or more items of the Plant are operating together.
Revolving parts shall be balanced both statically and dynamically such that for any combination of speed and load up to
the maximum, the vibration caused by out of balance forces shall be within acceptable limits.
In the full range of operating speeds, the maximum mechanical vibration caused by out of balance forces of installed
pumps shall not exceed Zone A/B level of severity as stated in ISO1086-3. During pre-commissioning, the Contractor
shall demonstrate that all measuring points, as specified in the Code for vertical and horizontal pumps, have met the
requirement. The method of testing and equipment shall be submitted for prior approval by the Engineer.
Pumps with a rated power greater than or equal to 150 kW shall be supplied complete with permanent monitoring and
alarm system at the following points:
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• Vertical turbine pumps: One unit at the motor flange connection;

• Vertical and horizontal centrifugal pumps: One unit at the motor flange connection and another unit
at the pump end bearing.
C.2.9 Erection of Plant
The Contractor shall provide the services of competent and experienced commissioning engineers for setting to work
the whole of the Plant required under the Contract.
Skilled erectors shall be employed in the erection of the Plant and they shall be technically competent to interpret
drawings, to diagnose faults occurring during the erection and Tests on Completion, and to report on all matters
pertaining to erection.
The erection of the Plant by the Contractor shall be carried out after civil engineering and building work including all
finishes except painting has been substantially completed so as to minimise damage to Plant. Where erection proceeds
simultaneously with adjacent civil engineering or building work the Contractor shall protect the Plant from water, dust,
etc., to the satisfaction of the Engineer.
All necessary modifications to structures and foundations, etc for the Plant, including the forming of all ducts and holes,
shall be carried out by the Contractor.
The Contractor shall carry out all required demolition, excavation, backfilling and reinstatement of trenches and builders'
work including the grouting of all bolts, straps, brackets, steelwork, pipe work, bedplates, etc., when they have been set
in position.
It shall be the Contractor's responsibility to safeguard by means of temporary or permanent supports or otherwise all
pipes, cables, structures and other things which would be liable to suffer damage if such precautionary measures were
not taken. Temporary and permanent safeguards shall be to the approval of the Engineer.
The plugging of walls, floors and ceilings for all fixtures, conduit clips, pipe clips, etc. shall be done by the Contractor.
Making good any damage to surfaces or finishes shall be carried out by the Contractor.
The Contractor shall provide all foundation bolts and fixings as required for the holding down, fixing, locating, etc., of
all Plant and equipment supplied under the Contract. The use of approved foundation bolts with an expanding shell, or
bolts utilising cement in sockets cast into the foundation concrete is to be preferred and the Contractor shall only use rag
bolts where their use is absolutely necessary and authorised by the Engineer. All foundation bolts, nuts and washers shall
be sheradized or similarly corrosion resistant.
The Contractor shall give full details in the Schedule of Particulars of the qualifications and experience of the staff to be
provided for skilled erection and site supervision.
C.2.10 Guarding of Moving Machinery
All moving machinery shall be adequately guarded to prevent injury through accidental contact. In particular exposed
shafting and couplings shall be protected with suitable guards except where they are in normally inaccessible positions.
C.2.11 Rating Plates, Name Plates and Labels
Each item of Plant shall have permanently attached to it, in a conspicuous position, a rating plate of durable material
engraved with the manufacturer's name, type and serial number, together with details of the duty or output, speed,
pressure loading etc.
Each item of Plant including all existing retained items shall be provided with a name plate or label designating the
service of the particular item. The inscription shall be to the approval of the Engineer.
All switchboard cubicles shall be clearly labelled with their functions and the function of each instrument, indicator or
control. Each cable shall be fitted with identification labels. The type of labels and the inscription shall be to the approval
of the Engineer; where identification labels on existing equipment and cables are missing, these shall be supplied.
All rating plates, name plates and labels shall be in English.
C.2.12 Packing for Export
The Contractor shall be responsible for the proper packing, storage and crating and clear identification of all materials
or Plant supplied by him or his Sub-contractors, prior to despatch and shipment from its place of manufacture.
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All materials or Plant shall be packed and marked in accordance with international standards for export from the country
of manufacture. All wooden cases shall be proofed with suitable anti-termite solution. Straw or similar organic materials
shall not be used for packing.
The materials or Plant shall be packed and protected against deterioration in such a manner as to be suitable for transport
by the sea and overland and for 12 months subsequent storage on site.
All materials liable to deterioration from water or moisture shall be packed in cases with waterproof lining.
Switchboards and control panels shall be specially packed for shipment to prevent ingress of moisture. Unless otherwise
agreed by the Engineer, the protection shall include packing in a sealed 0.13mm thick polythene bag and silica gel or
other approved air dryer shall be placed within the unit and sufficient air drawn out to cause the polythene bag to adhere
to the outline of the unit.
Electric motors (and similar equipment) shall, where applicable, be despatched with rotors locked to prevent damage to
the bearings from vibration during transit.
All packages shall be clearly and conspicuously marked with the Contractor's identification mark and the Employers
reference mark.
All separate component parts of mechanical and electrical Plant shall be identified by metal tags tied by wire and
referenced to drawings, installation instructions, packing lists etc. Details of the referencing system shall be submitted to
the Engineer for approval.
C.2.13 Storage on Site
The Contractor shall construct on the Site a storage compound and storage building where he shall place at his own risk
all electrical and mechanical Plant, and other materials delivered to Site and awaiting erection which are not separately
stored (for example at approved pipe stockpiling points). The compound shall be of sufficient size to accept all such
Plant delivered and awaiting erection.
The storage building shall be weatherproof and shall be of sufficient size to accommodate all items requiring covered
storage.
The storage compound and building shall be completed prior to delivery of any electrical and mechanical Plant, or other
materials not suited to stockpiling elsewhere.
C.2.14 Manufacturers' Instructions and Recommendations
The Contractor shall keep on site a file copy and shall provide a copy to the Engineer of all Manufacturers' Instructions
and Recommendations for handling, storage and use of all plant and materials to be incorporated into the Works.
C.2.15 Contractor to be Responsible for Adequacy of Design of Plant
On completion of the Works the Contractor shall provide to the Engineer a statement to the effect that he, the Contractor,
warrants the design and construction of all new units incorporated in the Works to accord with all current relevant British
Standards and Codes of Practice (or, where such governing standards are not available, that there is compliance with
acceptable international standards or with recognised good practice).
C.3 General Civil Engineering Clauses

C.3.1 Earthworks and Demolition
Condition of Site
Before carrying out any work on the Site, the Site shall be inspected by the Contractor in conjunction with the Engineer
and the Operator to establish its general condition which shall be agreed and recorded in writing, and, where in the
opinion of the Engineer it is deemed necessary, by means of photography.
Details recorded shall include the location of all boundary and survey beacons, the condition of buildings, surfaces,
terracing (if any), ditches, watercourses, roads, tracks, fences and other information relating to the Site and elsewhere
(including storage and stockpiling locations) which may be affected by the Contractor's operations.
C.3.1.1 Location of Existing Services
The locations of existing services shown on the drawings are approximate only, and are not necessarily complete. Before
carrying out any demolition or excavation for construction purposes the Contractor shall accurately locate in both line
and level all existing services within the Site whether indicated on the drawings or not, and furnish the Engineer with 3
copies of the relevant information immediately.
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The Contractor shall excavate refill and restore in advance of the commencement of any permanent works such trial
holes as he may require for the location of existing underground services and obstructions.
C.3.1.2 Site Clearance and Topsoil Removal
Site clearance shall be carried out over the areas to be occupied by the permanent Works before beginning excavation
or other work, and shall include the clearance of all trees, stumps, bushes and other vegetation and the grubbing out of
all roots and the removal of all boulders between 0.01 and 0.2 m3 volumes. The limits of the areas to be cleared shall be
as indicated on the drawings or as will be defined by the Engineer.
Following the establishment of ground levels, the Contractor shall strip topsoil, where indicated on the drawings or as
directed by the Engineer to a depth of up to 300 mm. The topsoil so removed shall be deemed to become the property
of the Employer and shall be set aside for re use or disposal as directed by the Engineer.
Topsoil is defined as the surface layer of soil which by its humus content supports vegetation. This layer of soil is
unsuitable, due to weathering and vegetable content, as a formation to roads and concrete structures or as a backfill or
bedding material. The presence, extent and depth of topsoil that needs removal shall be agreed with the Engineer.
Where shown on the drawings or directed by the Engineer, trees shall be uprooted or cut down as near to the ground
level as possible and all timber shall be deemed to become the property of the Employer. The Contractor shall cut and
stack such timber as is salvable as directed by the Engineer.
Bushes, undergrowth, small trees, stumps and tree roots shall, where directed by the Engineer, be grubbed out, burnt and
deposited off the site in dumps to be provided by the Contractor. All holes left by the stumps or roots shall be backfilled
with suitable material in a manner approved by the Engineer.
The Engineer may require that individual trees, shrubs and hedges are to be preserved and the Contractor shall take all
necessary precautions to prevent their damage.
C.3.1.3 Erosion
The Contractor shall take particular care at all times to prevent erosion on every site and elsewhere on land which may
be affected by his operations and the Engineer may impose such reasonable limitations and restrictions upon the method
of clearance and upon the timing and season of the year when clearance is carried out as the circumstances warrant.
C.3.1.4 Ground Levels
Following the completion of Site clearance and before the commencement of any earthworks or demolition the sites
shall be surveyed in conjunction with the Engineer to establish existing ground levels and these agreed ground levels
shall form the basis for the calculation of quantities of any subsequent excavation and filling. These levels shall be taken
before any topsoil is removed.
C.3.1.5 Demolition
A brief description of any structures, or parts of structures, to be demolished or dismantled or relocated is shown on the
drawings.
The Contractor shall be responsible for making himself familiar with the nature and substance of these structures and he
shall be responsible for the method of demolition.
The method of demolition or dismantling for each structure shall be to the approval of the Engineer. Such approval will
not unreasonably be withheld.
The Contractor shall dismantle any buildings, or other structures, where possible, and stack the recoverable materials on
the adjoining land of the owner of such building or structure. Other non-recoverable materials shall be disposed of by
the Contractor to disposal sites and in the manner to be approved by the Engineer.
All material arising from demolition work, except as otherwise provided for in this clause, shall be disposed of by the
Contractor as surplus material.
Any pipes, fittings and valves retrieved from demolished or dismantled structures and pipelines shall if required by the
Employer be delivered to and stacked at one of the Employer's depots to the instructions of the Engineer. Pipes, fittings
and valves not required by the Employer shall be disposed of by the Contractor as surplus material.
Underground structures and chambers shall be demolished to at least 300 mm below finished ground level or foundation
level of any overlying structures, cleared out and filled with suitable materials approved by the Engineer.
C.3.1.6 General Excavation
Excavation shall be made in open cutting unless tunnelling or heading is specified or approved by the Engineer and shall
be taken out as nearly as possible to exact dimensions and levels so that the minimum of infilling will afterwards be
necessary.
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It shall be the Contractor's responsibility at all times to ensure the stability and safety of excavations and the Contractor
shall take all measures necessary to ensure that no collapse or subsidence occurs.
The sides of all excavations shall be kept true and shall where necessary be adequately supported by means of timber,
steel or other type struts, walings, poling boards, sheeting, bracing and the like. All supports shall be of sound design
and construction and shall be sufficiently watertight to permit excavation, concreting and other work to be completed
satisfactorily.
Excavations shall be kept free from water and it shall be the Contractor's responsibility to construct and maintain
temporary diversion and drainage works and to carry out pumping and to take all measures necessary to comply with
this requirement.
In the event of soft or otherwise unsuitable ground being encountered at formation level in any excavation the Contractor
shall forthwith inform the Engineer and shall excavate to such extra depth and refill with compacted granular or other
approved fill or Grade C15P concrete as the Engineer may require. The requirements of this paragraph shall apply also
to the side face of any excavation with which concrete or other work will be in contact except that in the case of a side
face the Engineer may alternatively require that the net dimensions of the concrete or work shall be increased.
The Contractor shall not deposit excavated materials on public or private land except where directed by the Engineer in
writing or with the consent in writing of the relevant authority or of the owner or responsible representative of the owner
of such land and only then in those places and under such conditions as the relevant authority, owner or responsible
representative may prescribe.
C.3.1.7 Over- Excavation
If any part of any excavation is in error excavated deeper and/or wider than is required the extra depth and/or width shall
be filled, at the Contractor's expense, with Grade C15P concrete or compacted granular or other approved fill to the
original formation level and/or dimensions as the Engineer may require.
In pipe trenches where the pipe is not bedded on or surrounded with concrete, the excess excavation shall be filled with
compacted granular material. Excess excavation in rock trenches shall be filled with Grade C15P concrete up to 150
mm below the pipe invert.
C.3.1.8 Mechanical Excavation
Mechanical excavation shall be employed by the Contractor only if the subsoil is suitable and will allow the timbering
of the trenches or other excavations to be kept sufficiently close up to ensure that no slips, falls or disturbance of the
ground take place or there are no pipes, cables, mains or other services or property which may be disturbed or damaged
by its use.
When mechanical excavators are used a sufficient depth of material shall be left over at the bottom of the excavation to
ensure that the ground at formation level is not damaged or disturbed in any way. The excavation shall then be completed
to formation level by hand.
C.3.1.9 Classification of Rock Excavation
The Engineer's decision on the classification of excavated material shall be final. Rock excavation shall be based on the
following guidelines:
"Rock" shall include all material which, in the opinion of the Engineer requires blasting or the use of metal wedges,
hammers or the use of compressed air drilling for its removal or cannot be extracted by ripping with a bulldozer with
flywheel power of 160 kW and single rear mounted heavy duty ripper or on hydraulic excavator with flywheel power of
149 kW fitted with a one cubic metre rock bucket. Individual boulders greater than 0.2 cubic metres in volume shall be
included when their nature and size are such that they cannot be removed without recourse to one of these methods.
Decomposed rock, altered rock, agglomerates, tuffs and hard consolidated bound laterite (hardpan) will not be
considered as rock.
The breaking of concrete or road surface or road base will not be considered as rock excavation.
The Engineer's decisions to the necessity or otherwise of rock excavating methods shall be final.
C.3.1.10 Explosives
The Contractor shall at all times take every possible precaution and comply with the laws and regulations relating to the
handling, transportation, storage and use of explosives and shall at all times when engaged in blasting operations post
sufficient warning flagmen to the full satisfaction of the Engineer. The Contractor shall also provide a special proper
store for explosives in accordance with local regulations and shall provide experienced men with valid Tanzanian
blasting licences, for handling explosives to the satisfaction of the Engineer and the authorities concerned.
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The Contractor shall at all times make full liaison with and inform well in advance and obtain such supervision and
permission as is required from the Police and all Government Authorities, public bodies and private parties whosoever
concerned or affected by blasting operations.
Blasting shall only be carried out on those sections of the Works for which permission in writing shall have been given
by the Engineer and shall be restricted to such hours and conditions as he may prescribe. Such permission shall not be
withheld nor such hours and conditions imposed unreasonably. Blasting within 10 metres of existing water mains and
sewers will not be permitted.
The greatest care shall be taken in the use of explosives, the charges being so placed and of such amount as in no way to
weaken existing structures or the foundations or ground adjacent to the existing and proposed works. The Contractor
shall take all necessary precautions to prevent loss, injury or accident to persons or property and shall be entirely liable
for any accident or damage that may result from the use of explosives.
The Contractor shall submit to the Engineer for his approval details of the intended drilling patterns, depths of holes, the
amounts of explosives at each location and the method or sequence of setting off that he proposes to use.
C.3.1.11 Excavated Materials Suitable For Re Use
In so far as they may be suitable and comply with the Specification, materials arising from excavations may be used in
the Works.
During excavation, the Contractor shall ensure that all material suitable for re use and which he intends for re use are
kept separate and set aside and protected as necessary to prevent loss or deterioration.
The materials forming the surface and foundations of roads, road verges, tracks and footways shall when excavated, and
if required for further use, be carefully separated. All hard materials shall be kept free from soil or other excavated
materials.
In particular, during excavation of pipe trenches the Contractor shall ensure that all granular or other approved material
suitable for filling around and over pipes shall be kept separate and re used for this purpose.
Paving slabs, bricks and similar surfaces shall be carefully removed and stacked. Prior to the commencement of
excavation the number of badly broken and unsuitable paving slabs, bricks etc. on the line of the excavation shall be
agreed with the Engineer.
In verges and other grass surfaces the grass and top soil shall be stripped and separately stacked.
C.3.1.12 Disposal of Surplus, Demolition or Excavated Materials
All surplus demolition or excavated materials shall be disposed of by the Contractor to tips provided by the Contractor
and approved by the Engineer.
The Contractor shall not sell any materials arising from excavation, demolitions and the like carried out on the site.
The Contractor shall not deposit excavated materials on public or private land except where directed by the Engineer in
writing or with the consent in writing of the relevant authority, owner or responsible representative of the owner of such
land and only then in those places and under such conditions as the relevant authority, owner or responsible representative
may prescribe.
Surplus material may not be tipped on the site without the written permission of the Engineer. In the event of such
permission being granted the Contractor shall observe all conditions attached thereto.
C.3.1.13 Backfilling of Excavations
All backfilling of excavations shall be thoroughly compacted in layers not exceeding 150 mm compacted thickness and
by means which will not damage the Works.
Backfilling of excavations for reinforced concrete structures shall be with suitable material approved by the Engineer.
"Granular material" as backfill is defined as unconsolidated laterite, crushed stone, quarry dust, gravel, sand or similar
in which the clay or silt content is not predominant. Topsoil shall not be classified as granular material.
C.3.1.14 Making good Subsidence after Refilling
All refilling, whether over foundations or in pipe trenches shall be thoroughly compacted by ramming and any
subsidence due to consolidation shall be made up with extra compacted material.
Should subsidence occur after any surface reinstatement has been completed the surface reinstatement shall first be
removed, the hollows made up, and then the surface reinstatement re-laid.
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Any subsidence that occurs adjacent to the Site of the Works which is attributable to the Contractor's activities shall be
reinstated to the full satisfaction of the Engineer.
C.3.1.15 Removal of Timbering from Excavations
Timbering shall be removed from the excavations before or during the process of refilling except in so far as this removal
of timber would be likely to cause damage to adjacent property, structures or structure foundations in which event the
Contractor shall leave in the excavation such timbering as he considers necessary or as may be ordered by the Engineer
to prevent damage, the proper repair of which the Contractor shall be solely responsible for in the event of any such
damage occurring.
Timbering means any form of approved excavation support system or part thereof.
C.3.1.16 Reinstatement of Surfaces
All surfaces of roads, fields, paths, gardens, verges, etc. whether public or private which are affected by the operations
of the Contractor shall be temporarily restored by him in the first instance and permanently reinstated in the second
instance when the ground has consolidated fully.
The Contractor shall be responsible for the temporary reinstatement and permanent reinstatement of all surfaces whether
or not the area requiring restoration is within the limits of his excavations if the necessity for the restoration arises from
causes due to the operations of the Contractor. The Contractor's prices shall include for restoring all surfaces so damaged
to their original condition, as no extra payment will be made for any such work. The Contractor shall take all necessary
measures to ensure that no toxic materials that may cause damage to vegetation or livestock or pollute streams or water-
courses are used in any temporary restoration or permanent reinstatement and shall indemnify the Employer against any
claims arising out of the use of such materials.
Temporary restoration shall be carried out immediately after the excavations have been refilled by returning the
excavated material to the position from which it was removed and adding such suitable materials as may be required and
consolidating the various materials as the Work proceeds in order to provide a surface that is adequate for the purpose
that the original surface fulfilled. Temporary surfaces shall be maintained in a condition satisfactory to the Engineer
and/or responsible Authority until the permanent reinstatement is made. In the case of roads, the surface shall be
necessary to consolidate the filling and keep the surface fit for traffic, suitable material being added to all placed which
have sunk or become rough.
For the purposes of temporary and permanent reinstatement in bitumen and murram or gravel surfaced roads the surface
width of trenches shall be increased by 150 mm on each side of the trench for a depth of 75 mm to provide a solid
abutment for the surfacing material.
Reinstatement of murram and gravel surfaced roads shall consist of approved "as dug" material placed in one layer 250
mm thick thoroughly compacted by an approved roller and surface blinded with fine material so as to leave a tight closed
even surface, all to the satisfaction of the Engineer.
Temporary reinstatement of trenches in bitumen surfaced roads shall comprise a layer of compacted hardcore, of
minimum thickness 150 mm, topped with a 75 mm layer of surface material taken from the original surface together
with any additional material to form a satisfactory running surface. The surface shall be well rolled and sealed with a
coat of approved cold applied bituminous emulsion, applied with an approved sprayer at the rate of approximately 2
litres/m². The emulsion shall be blinded immediately with quarry dust or sand approved and then rolled with an 8 tonne
roller.
The quality and grade of bitumen shall be suitable for the climatic conditions of the area and shall otherwise conform to
BS 434.
Permanent reinstatement shall not be made until the ground has consolidated permanently and until approval to do so is
received from the Engineer. It shall be carried out with materials similar to those that were used in the original Work to
the entire satisfaction of the Engineer and/or responsible Authority. In the event of further settlement occurring after the
completion of the permanent reinstatement the Contractor shall forthwith make good the reinstatement to the approval
of the Engineer or responsible authority
Trenches in open ground shall be reinstated to the condition in which the ground was found before excavation was
commenced. The final surface of the trench shall be flush with the surrounding ground.
In verges and other grass surfaces the topsoil shall be removed, stored and replaced after consolidation of the filling and
planted or seeded with approved grass. Should subsidence occur, it shall be made good with additional topsoil and be
replanted with grass or re-seeded. New grass shall be planted if for any reason the grass fails to grow or is destroyed.
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The trenches, channels, gutters and kerbs shall be reinstated to the condition in which they were before excavation was
commenced. The final surface of the trench shall be flush with the surrounding ground.
If at any time any trench becomes dangerous, the Engineer shall be at liberty to call upon the Contractor to restore it to
a proper condition at three hours' notice and should the Contractor fail to carry out the work, have it done at the
Contractor's expense.
If the work or reinstatement as carried out by the Contractor is not to the satisfaction of the Engineer and/or the
responsible authority and should the Contractor not remedy the defect within one week of being ordered to do so by the
Engineer, any remedial work considered necessary may be undertaken by the Employer and/or the responsible authority
at the Contractor's expense.
C.3.1.17 Forming Banks and Filled Areas
Banks and filled areas shall be made and built up to the levels, dimensions and shapes as shown on the drawings or as
may be subsequently directed by the Engineer.
Before any filling is started, the ground on which the fill is to be placed shall be stripped of all grass and topsoil and all
roots, vegetable matter and other unsuitable substances removed.
The filling to be used in the embankments and filled areas shall be material selected by the Contractor and approved by
the Engineer from that arising from surplus excavation, the material being placed according to its nature as shall be
directed, that is, coarse hard material may be placed at the bottom with the fine materials and/or soil placed at the top or
at the surface. The Contractor may import materials if the available material is not sufficient.
The fill shall be placed in layers not exceeding 150 mm thick, each layer being thoroughly compacted by an approved
roller to the satisfaction of the Engineer.
C.3.1.18 Restoration of Borrow Areas, Spoil Tips and Quarries
Any spoil tips, quarries or other borrow areas developed by the Contractor for the purpose of the Works shall be finished
to safe and fair slopes to the approval of the Engineer. Where directed by the Engineer these areas shall be re-soiled and
grassed over or otherwise seeded. Operations of such borrow areas and tips shall be in accordance with the rules and
regulations of the appropriate authority or the owner responsible for them.
C.3.1.19 Top Soiling and Grassing
Where required surfaces shall be soiled with fine sifted soil or silt not less than 100 mm compacted thickness which shall
be raked and brought to a fine tilth. The Contractor shall supply approved material for this purpose or use the material
provided.
Surfaces required to be grassed shall be planted with approved local grass at a spacing of 200 mm x 200 mm. The
grassed areas shall be replanted if the first or subsequent operation is unfruitful or if for any reason the grass is destroyed.
Grassed areas shall be watered and attended until the grass has become well established.
The soiling and planting of the grass in slopes shall be carried out immediately the slope is formed and the grass shall be
kept weeded and cut until the work is accepted at the time of the Certificate of Completion.
The Contractor shall supply attendance during the Defects Liability Period to ensure that all planted grass is kept weeded
and cut, and if necessary watered.
C.3.1.20 Free Draining Fill
Free draining fill for use as backing to walls shall consist of sound hard stone or broken rock or concrete derived from
demolition of structures. The particles shall be roughly cubiform and shall be between 75 mm and 25 mm in size. All
smaller particles, dust, rubbish and organic matter shall be excluded.
C.3.1.21 Hardcore
Hardcore shall consist of sound hard stone or broken rock or concrete derived from excavations or demolition of
structures and shall be graded from 150 mm to 50 mm in size, except that sufficient but not excessive blinding materials
of smaller sizes may be permitted at the discretion of the Engineer.
C.3.1.22 Rock Pitching
Rock pitching shall consist of a free draining mixture of broken hard stone obtained from quarries approved by the
Engineer which shall have a maximum size of 300 mm and which shall not contain more than 5% by weight of material
which will pass 10 mm BS sieve. Between these limits the material shall be reasonably well graded so as to form a free
draining blanket without large voids.
C.3.1.23 Rock Lining
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Rocks for lining and bedding on concrete shall be hard, durable and free from cracks and fissures obtained from approved
quarries or from materials arising from the excavations.
Rocks shall be near uniform, of the size shown, and bedded in concrete as shown on the drawings. The rocks shall break
joint in every direction and fine concrete shall be worked into the joints to secure the rocks.
C.3.1.24 Gabions
Gabions shall be of the hexagonal wire mesh type, with mesh dimensions of 80 mm x 100 mm. The minimum dimension
shall not exceed 83 mm. Wire shall be galvanised prior to weaving the mesh to resist corrosion from water.
All wire used in the fabrication of the gabion and in the wiring operation during construction shall be in accordance with
BS 1052/1980 Mild Steel wire appended having a tensile strength of 3850 kg/mm2.All wire shall be galvanised to BS
443: 1982 'Zinc coatings on steel wire' with the minimum weight of Zinc coating in accordance with Table C-1.
Table C-1 Wire Sizes and Minimum Weight of Zinc
Diameter (mm) Minimum Weight of Coating (g/m2)
Mesh wire 2.7 260
Binding and connecting wire 2.2 240
Selvedge wire 3.4 275
All wire used in the fabrication of gabions and in the wiring operations during construction shall, after galvanising, have
extruded onto it a coating of polyvinyl chloride compound referred to as PVC. The coating shall be black in colour, not
less than 0.4 mm thickness and shall be capable of resisting deleterious effects of exposure.
Gabions shall be of the following standard sizes:
• 2 m x 1 m x 0.5 m
• 2mx1mx1m
• 6 m x 2 m x 0.3 m
Gabions shall be provided with diaphragms to divide the boxes in compartments with a maximum dimension in any
direction of 1 m.
Joints shall be flexible and shall consist of not less than one and a half full turns of wire, at each mesh point of the joint
line.
Gabions shall be as manufactured by Maccaferri, or equivalent. Alternative materials shall be subject to the approval of
the Engineer.
The maximum size of rockfill for gabions shall be 220 mm, and the minimum size shall be 120 mm; however, up to
10% of some smaller blinding material (min. 75 mm) to fill the internal voids between the bigger rocks will be allowed.
Gabions shall be placed in their final positions prior to filling with rock, and shall then be tied together and filled with
rock. After filling with rock the tops shall be closed and securely tied with connecting wire. The larger rocks shall be
placed on the upper face of the gabion in order to present a reasonably closed surface. All assembly, erection, stretching,
filling with rock and final filling shall be in accordance with the instructions as issued by the manufacturer.
C.3.2 Structures (General Requirements)
C.3.2.1 Excavation for Foundations of Structures
The Contractor shall give sufficient notice to the Engineer to enable him to examine foundations well in advance of
concrete being placed and no placement shall occur until such inspection shall have been carried out and the formation
approved.
If the formation has become weathered prior to the placing of concrete the Contractor shall remove the weathered
material and replace it with Grade C15P concrete as directed by the Engineer.
If the Engineer so directs, a bottom layer of excavation of not less than 75 mm thickness shall be left undisturbed and
subsequently taken out by hand immediately before concrete or other work is placed. Similarly, where concrete or other
materials is to be placed in contact with the side face of an excavation the Contractor shall, if the Engineer so directs,
leave undisturbed the last 75 mm thickness of the excavation to that face until it is taken out neatly to profile by hand
immediately before the concrete is placed.
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Areas of excavation which are to receive a layer of concrete blinding or drainage layer under structural concrete shall be
covered with such blinding or layer immediately the excavation has been completed and inspected and approved by the
Engineer.
All surfaces shall be free of oil, water, mud or any material which in the opinion of the Engineer is not desirable.
Excavations for foundations and for thrust and anchor blocks shall be to such depth as shown on the drawings or as the
Engineer may direct and no concrete or other materials shall be placed until the formation has been examined and
approved. Due notice shall be given to the Engineer to enable him to examine the formation well in advance.
C.3.2.2 Rock Surfaces under Concrete Structures

The surface of rock excavation under concrete structures shall be prepared by picking, barring and wedging or other
methods which will leave the rock in as sound a condition as may reasonably be expected according to the rock quality.
Rock surfaces shall be thoroughly cleaned by compressed air and water jet or such means as the Engineer may direct
before concrete is placed.
C.3.2.3 Keeping Rock Faces Dry
The Contractor shall keep free of running water and pools the surfaces of rock upon or against which concrete is to be
placed and no concrete shall be placed until surfaces of the rock are properly drained. Special precautions are to be taken
to prevent running water from washing out cement or concrete while it is setting or in any other way injuring the Works.
Drains and pipes shall be provided in or behind concrete as may be necessary for the temporary conveyance of water
and shall afterwards be grouted up.
C.3.2.4 Structures Liable To Flotation
Certain structures may be liable to float during the course of construction and it shall be the Contractor's responsibility
to take all necessary precautions to prevent flotation. Where continuous pumping is necessary to protect the work this
shall be maintained at all times. Where flanged pipes are provided in the walls or base of the structure, and are intended
for non-potable duty, they shall not be blanked-off until instructions are given by the Engineer to do so.
In the event of pump failure the works for non-potable duty shall be permitted to flood to prevent flotation. If as a result
of this action, damage is sustained by recently-placed concrete to an extent which the Engineer considers to be
detrimental to the Works; such concrete shall be removed and replaced at the Contractor's expense.
C.3.2.5 Backfilling Around Structures
Rectangular Structures
The walls of rectangular pumping station, chambers and other structures may be designed as being supported by
intermediate, ground floor or roof slabs or beams. Backfilling around or loading the walls of such structures shall not
take place until the concrete of the supporting slabs or beams has been cured.
Retaining Walls
The loading of concrete retaining walls or walls of the cantilever type shall not be carried out until such time as the
concrete shall have been fully cured and shall have attained strength of not less than half of the specified 28 day cube
strength.
C.3.2.6 Acceptance Tests
The Contractor shall include in his rates for acceptance tests on completed structures as may be specified or directed by
the Engineer. The Contractor shall include for all labour, materials, water and equipment for conducting the tests and
for proving the performance of the completed structures.
Water excluding structures shall be watertight and shall prevent infiltration of ground or rain water. Leaks shall be made
good to the satisfaction of the Engineer.
Water retaining structures shall be tested as specified. All water retaining structures complete with electrical and
mechanical plant installed in position shall be finally tested, before the issue of the Certificate of Completion, under
conditions fully representative of operating practice.
All leaks or other faults in structures shall be made good and the repaired structure re-tested at the Contractor's cost.
C.3.2.7 Testing of Water Retaining Structures

All water retaining structures shall be tested for water tightness on completion in the following manner. The structure
shall be filled with clean water in stages of one metre and held at each water level for such time as the Engineer may
require. Should any dampness or leakage occur at any stage, the water shall be drawn off and the defects remedied to
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the satisfaction of the Engineer. The procedure shall be continued and finally the structure shall be allowed to remain
full for three days or such other period as the Engineer may decide to allow for absorption, followed by a period of seven
days during which the total permissible loss of water, after allowing for evaporation, shall not exceed 1/1000 of the
capacity of the structure. Notwithstanding the satisfactory completion of the seven day test, should any dampness or
leakage or other defects occur they shall be made good to the satisfaction of the Engineer and the structure re tested until
the water tightness is approved by the Engineer.
The Contractor shall provide a hook gauge to measure variations in the water level during the tests.
The testing shall be carried out before the backfilled and embankments placed.
The Contractor shall be solely responsible for the water tightness of structures and any remedial measures necessary.
In the case of potable water reservoirs and tanks the roof shall be tested for water tightness by flooding (in small areas at
a time if necessary) to a minimum depth of 25 mm. The water shall be left standing for not less than 24 hours and the
underside of the roof shall be examined for dampness or leakage. Any defects shall be made good by the Contractor and
the tests continued until the water tightness of the roof is approved by the Engineer. Where it is not practicable to contain
a depth of 25 mm of water over the roof, an alternative method to the Engineer's approval shall be used.
The water used for testing shall be provided at his own expense by the Contractor and shall be free from impurities and
of such quality as will not pollute or impair the water retaining structure.
The Contractor shall give the Engineer at least 14 days’ notice of the source of water intended for use for testing purposes,
and shall not use the water until the Engineer has approved the source. The notice shall be accompanied with a Water
Quality Tests Results carried out by Contractor.
The Contractor shall be solely responsible for making all arrangements necessary for obtaining water and provision of
all equipment and labour and other things necessary for testing water retaining structures.
C.3.2.8 Cleansing and Sterilizing Water Retaining Structures
The inside of all potable water retaining structures and all interior pipework and fittings shall be thoroughly cleaned and
washed after the water tightness test has been approved by the Engineer to remove all contamination and the water from
these operations shall be removed by squeegees and drained away.
The internal surfaces of the structure shall then be thoroughly washed with clean water containing 20 parts per million
of free chlorine. The chlorinated water shall then be drained away and the structure filled with potable water from which,
after 24 hours, samples shall be taken for analysis to the instruction of the Engineer. If any of the results of the analyses
are unsatisfactory when compared with those of the control sample of the supply water the sterilizing process shall be
repeated until the results of the test are satisfactory.
The costs of the sampling of the analyses and of preparing reports on the bacteriological quality of the water shall be
borne by the contractor till the test reports are cleared satisfactorily.
The Contractor shall not dispose of water used for the 24 hour sterility test unless the Engineer approves.
In the event that water is in short supply in the town, the Contractor may be required to pass the testing water to supply,
and to arrange a temporary disinfection system to remove the contamination which led to failure of the test.
C.3.3 Concrete
C.3.3.1 General
The standard of materials and of workmanship shall not be inferior to the recommendations of the current:
British Standard Code of Practice BS EN 206-1
2000 Concrete Standards
Whichever is applicable to the particular
Or
structures
British Standard Code of Practice BS EN 1992-
3:2006 - Design of concrete structures
Appropriate British Standards
Approved Tanzanian Standards
or
Other equivalent and approved international
standards
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The requirements outlined in the above documents must be read with those of this Section of the Specification and where
any conflict exists between the recommendations of the above and of this Specification, the requirements of the
Specification shall prevail.
As and when required by the Engineer the Contractor shall prepare and submit, before commencing the work, a time
chart (additional to the general programme) detailing the various operations for concrete work.
The Contractor shall, before ordering steel reinforcement, submit to the Engineer for approval in triplicate copies of bar
bending schedules. Three further copies shall be supplied to the Engineer after approval, incorporating any amendments
required by the Engineer.
No material shall be used in the Works until prior approval for its use has been given by the Engineer; neither shall any
change in the nature, quality, kind, type, source of supply or manufacture be made without the Engineer's permission.
Names of manufacturers and test certificates for materials not supplied by the Employer shall be supplied as soon as
possible to the Engineer.
The cost of providing samples and the cost of carrying out tests (except as otherwise provided in the Conditions of
Contract) together with the cost of supplying equipment for sampling and site testing indicated in columns 3 and 4 of
Table 2.3.8 of this Section of the Specification shall be borne by the Contractor.
During the progress of the Works, consignment notes for materials not supplied by the Employer shall be supplied to the
Engineer giving details of each consignment.
The Contractor shall provide all samples required by the Engineer as soon as possible after contract award. No deliveries
in bulk shall be made until the samples are approved by the Engineer. All condemned or rejected material shall be
removed from the site within 24 hours unless agreed otherwise by the Engineer.
A competent person approved by the Engineer shall be employed by the Contractor whose duty will be to supervise all
stages in the preparation and placing of the concrete. All cubes shall be made and site tests carried out under his direct
supervision, in consultation with the Engineer.
All materials which have been damaged, contaminated or have deteriorated or do not comply in any way with the
requirements of these Preambles shall be rejected and shall be removed immediately from the site at the Contractor’s
own expense. No materials shall be stored or stacked on suspended floors without the Engineer’s prior approval.
The use of the word "approved" in this Specification refers to the approval of the Engineer.
C.3.3.2 Mix designs
Requirements
The mix proportions shall be selected to ensure that the workability of the fresh concrete is suitable for the conditions of
handling and placing, having regard to the structural element being constructed, the disposition of reinforcement, and
taking full account of the environment to which it will be subjected.
The minimum cement contents and maximum water/cement ratios of designed mixes shall be as given in Table C-2. In
the event of sulphate exposure precautions requiring lower cement content than those required for normal conditions the
latter requirements shall prevail.
The maximum cement content in any mix shall not exceed 500 kg/m3 for normal structures and 425 kg/m3 for liquid
retaining structures.
In all cases of mix proportioning, the added water shall be included with due allowance for the moisture contained in the
aggregates and shall be the minimum consistent with the workability requirements.
Table C-2 Minimum Cement Content
Normal Conditions
Minimum Cement Content (kg/m3) Maximum
Type of Structural Exposure Water/
Maximum Aggregate Size
Element Conditions Cement
40 mm 20 mm 10 mm Ratio
Liquid Retaining Severe 295 325 356 0.55
Structures, Shafts and
Tunnel Linings
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All Foundations and Buried Moderate 270 300 340 0.60

Structures
Building Super-Structure Moderate 270 300 340 0.60
Additional Requirements when Exposed to Sulphate Conditions (All Structural Concrete)
Concentration of Sulphates Minimum Cement Content (kg/m3)

(expressed as SO3) Maximum Aggregate Size Maximum
Water /
In ground water Cement
In Soil Type of
Parts per 40 mm 20 mm 10 mm Ratio
(Total SO3) Cement
100,000
≤ 0.2 ≤ 30 No Special Precautions -
0.2 – 0.5 30 - 120 OPC 300 330 370 0.50

SRPC 250 280 320 0.55
0.5 – 1.0 120 - 250 OPC Not permitted -
SRPC 300 330 370 0.50
1.0 – 2.0 250 - 500 OPC Not permitted -
SRPC 340 370 410 0.45
> 2.0 ≥ 500 SRPC Ditto but with protective coating 0.45
OPC Ordinary Portland Cement; SRPC Sulphate Resisting Portland Cement
Strength
The characteristic strength of concrete means that value of the 28 day cube strength below which 5% of all possible test
results would be expected to fall.
The relationship between grade of the concrete and its characteristic strength shall be as given in BS EN 206-1:2000.
The grade of concrete to be used in particular locations shall be as given in Table 2.3-2 unless noted otherwise on
Maximum Coarse
Location Grade of Concrete
Aggregate Size (mm)
Blinding Concrete
- General Structures 20 or 40 C15P
- Liquid Retaining Structures 20 C20P
Blinding Concrete - Sulphate Condition 20 C25P
Substructure thickness less than 400 mm 20 C25D
Substructures, walls and slabs more than 400 mm 20 or 40 C25D
Superstructures, Normal Concrete 20 C25D
Liquid Retaining Structures 20 C35A
Fine Concrete 10 C25D
Precast Concrete 10 or 20 C30D
Mixes
Designed Mixes
Proportions shall be determined in accordance with the "Design of Normal Concrete Mixes" published by the United
Kingdom Department of The Environment and obtainable from:
Building Research Establishment and Bookshop, Garston, Watford WD2 7JR, ENGLAND, or other approved methods,
for the requirements set out in this Specification.
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For the purpose of determining the design mean strength of the concrete a margin shall be added to the characteristic
strength for the particular grade of concrete. This design margin shall be assessed on the degree of control reasonably
to be expected in the manufacture of the concrete and shall not be less than 7.5N/mm2 nor less than 1.64 times the
standard deviation. Until such time as the standard deviation has been assessed the margin shall be not less than
15N/mm2.
Details of the designed mixes shall be forwarded immediately to the Engineer for his approval.
Prescribed Mixes
Proportions for the l grades of concrete shall conform to the requirements of Tables C-4 and C-5.
Chloride Content
The total chloride content of the concrete mix shall comply with the requirements of BS EN 206-1:2000 Clause 5.2.7.
Table C-4 Prescribed Mixes - Mass of Dry Aggregate to be used per 100 kg Cement
Grade of concrete
Nominal max.
size of aggregate 40 20 14 10
(mm)
Workability Med. High Med. High Med. High Med. High

Range for
standard sample 50- 65- 50-
80-
(mm) 100 25-75 135 5-55 100 0-45 15-65
170
Range for sample
taken in 40- 15-85 55- 0-65 40- 0-55 5-75
accordance with 70-0
110 145 110
9.2 (mm)
kg kg kg kg kg kg kg kg
C7.5P 1080 920 900 780 N/A N/A N/A N/A
C10P 900 800 770 690 N/A N/A N/A N/A

Total
C15P 790 690 680 580 N/A N/A N/A N/A

Aggregate
C20P 660 600 600 530 560 470 510 420
C25P 560 510 510 460 490 410 450 370
C30P 510 460 460 400 410 360 380 320

N/A not applicable
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Table C-5 Prescribed Mixes - % by Mass of Fine Aggregate to Total Aggregate
Nominal max.
Concrete
Grade of
size of 40 20 14 10
aggregate (mm)
Me
Workability High Med. High Med. High Med. High
d.
C7.5P
C10P 30-45 35-50 N/A N/A
C15P
Grading zone 1 35 40 40 45 45 50 50 55
C20P
2 30 35 35 40 40 45 45 50
C25P
3 30 30 30 35 35 40 40 45
C30P
4 25 25 25 30 30 35 35 40
N/A not applicable
Notes on the use of Tables C-4 and C-5
Note 1 The proportions given in the tables will normally provide concrete of the strength in N/mm2 indicated
by the grade except where poor control is allied with the use of poor materials.
Note 2 For grades C7.5P, C10P and C15P a range of fine-aggregate percentages is given; the lower percentage
is applicable to finer materials such as zone 4 sand and the higher percentage to coarser materials such
as zone 1 sand
Note 3 For all grades, small adjustments in the percentage of fine aggregate may be required depending on the
properties of the particular aggregates being used
Note 4 For grades C20P, C25P and C30P, and where high workability is required, it is advisable to check that
the percentage of fine aggregate stated will produce satisfactory concrete if the grading of the fine
aggregate approaches the coarser limits of zone 1 or the finer limits of zone 4.
Quality Control
The principal basis of control shall be by comparison of the results of the compression cube tests at 28 days, except for
small quantities of concrete whose strength can be otherwise derived and which is permitted for use by the Engineer.
Forty (40) sample cubes shall be made initially in eight samples each day for five days of concreting and thereafter one
sample per 25 m3 of concrete but not less than one sample for each day's concreting.
Where materials are of an unfamiliar grading or type, compression cube tests shall be carried out at 7 days and
adjustments made in advance of the main control methods outlined above.
Cube test results will be examined individually in 10 consecutive sets of four and the standard deviation and mean
strength of each set calculated. The concrete mix proportions will only be acceptable if all of the following requirements
are complied with:
(i) Not more than two results in 40 are less than the characteristic crushing strength
(ii) No value of the average for any set of four results is less than the characteristic strength plus one half of the
design margin.
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(iii) When 40 results have been obtained and the mean strength and standard deviation are calculated, the mean
strength minus 1.64 times the standard deviation shall be greater than the characteristic strength
Where the results do not conform to the above requirements the following action shall be taken:
Adjustments to the mix shall be made to obtain the strength required.
In the case where any result is less than 80% of the characteristic strength the structural implications shall
be considered and action taken as ordered by the Engineer.
For those Prescribed Mixes required to be tested, requirements (i) and (ii) only will be applicable.
Production
Aggregates and cement shall be proportioned by weigh-batching, and water shall be proportioned by volume. Subject
to the prior approval of the Engineer volume-batching of aggregates may be used for small sections of works, but volume
batching of cement will in no case be accepted. The Contractor may, however, so proportion the mix that each batch
shall use a whole bag or bags of cement, the weight of which is known precisely. Where permission has been given for
volume batching of aggregates, all gauge boxes shall be accurate and due allowance shall be made for the bulking of the
aggregates in assessing the correct volume to be used.
The aggregates and the cement shall be thoroughly mixed in a clean mechanical mixer for a period of time agreed with
the Engineer and the water added on the basis of the approved design.
Batching mixing machines shall comply with the requirements of BS 1305. They shall be provided in such numbers
and of such capacity as to ensure a continuous supply of freshly mixed concrete at all times during construction.
Continuous mixing machines shall be used only with the written permission of the Engineer.
Not less than 30 days prior to the installation of the Contractor's plant and equipment for processing, handling,
transportation, storing and proportioning ingredients, and for mixing, transporting and placing concrete, the Contractor
shall submit drawings for approval by the Engineering, showing proposed general plant arrangements, together with a
general description of the equipment proposed for use.
After completion of installation, the operation of the plant and equipment shall be subject to the approval of the Engineer.
Where these Preambles, the Schedule of Prices and Unit Rates or the Drawings require specific procedures to be
followed, such requirements are not to be construed as prohibiting use by the Contractor of alternative procedures if it is
approved by the Engineer, prior to use of such alternatives.
Approval of plant and equipment or their operation, or of any construction procedure, shall not operate to waive or
modify any provision or requirements contained in the Preambles governing the quality of the materials of the finished
work.
C.3.3.2.1 Cement
Cement shall comply with one of the following sub-Clauses (i) to (vi) below as appropriate:-
(i) BS EN 197-1:2000 (Cement. Composition, specifications and conformity criteria for low heat common
cements)
(ii) BS 146 (Portland-blast furnace cement)
(iii) BS 4027 (Sulphate resisting Portland cement)
(iv) BS EN 197-1:2000 (Portland pulverised-fuel ash cement)
(v) A mixture of BS EN 197-1:2000 (Portland cement) and BS 3892: Part 1 (Pulverised-fuel ash for use in
structural concrete) provided that the amount of pulverised-fuel ash is not less than 15% nor more than 35% by
weight of the total cement
(vi) A mixture of BS EN 197-1:2000 (Portland cement) and BS EN 15167-1:2006 (Ground granulated blast
furnace slag for use with Portland cement) provided that the amount of slag is not more than 65% by weight of
the total cement
Pulverised-fuel ash shall have a maximum colour index of 6 (Colour comparator disc reference No. 296570) when
measured using the Lovibond Colour Comparator system as recommended in BS 3892: Part 1 Appendix H, Clause H8.
Cement shall be fresh when delivered to Site and the consignments shall be used in the order of their delivery. The
Contractor shall mark the date of delivery on each consignment and each consignment shall be stored separately and in
such manner as to be easily accessible and identifiable.
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No cement in bags or other containers shall be used unless these and the manufacturer's seals are intact at the time of
mixing.
If the cement is delivered in bags it shall be stored in a waterproof shed or building at a temperature of not less than 8°C
and the bags shall be placed on dry boards above the floor to prevent deterioration or contamination from any cause.
Bulk cement may be used provided it is stored in an approved container.
The Contractor shall not use cement which has hardened into lumps, but subject to removal of the lumps by screening,
the Engineer may allow such cement to be used in non structural concrete mixes.
Cement of different types shall be kept separate in storage and shall not be mixed together in the production of concrete.
C.3.3.2.2 Aggregates
The Contractor shall investigate the proposed aggregate sources in detail and shall submit a comprehensive report with
technical information and data which shall include the following:
i) Location. Only Sources equipped with facilities adequate for the production of the materials as
specified and in such quantities as shall be required for the prompt execution of the Contract shall be
approved.
ii) Petrology of sources and possible or likely variability during the Contract period.
iii) Method of production
iv) Schedule of available and proposed processed aggregates by size, including details of actual screen
sizes to produce each aggregate.
v) Test data as applicable for each aggregate type and size based upon representative samples and tested
in accordance with the appropriate British Standards.
vi) A detailed statement of the aggregate proposed for use in each grade of concrete.
Samples of all aggregate, including fine aggregates and sand shall be submitted to the Engineer for his approval. All
samples shall be taken in accordance with BS 812 and shall weigh not less than the minimum weight indicated on Table
1 of that Standard.
The Contractor shall produce with each consignment or at intervals directed by the Engineer a certificate signed by the
Supplier, or other approved analyst, giving fully detailed chemical and physical properties of all aggregates together with
a sieve analysis carried out in accordance with the appropriate British Standard.
Any changes in the particulars of the aggregates which occur during the course of the Contract must be notified to the
Engineer without delay.
The aggregates shall be stored on Site in separate stockpiles so arranged as to prevent the intermingling of the various
aggregates. The stockpiles shall be suitably protected to prevent contamination of the aggregates from the ground,
rubbish or by leaves, dust or other windblown materials.
Aggregates shall conform to the requirements of "Acceptable Standards" of Table 2.3-8
Building sand for mortar and similar uses and aggregates for concrete shall comply with BS EN 12620:2002 and shall
be perfectly clean and free from all foreign matter and shall not consist of, nor contain argillaceous limestone or shells.
Where the nominal size specified exceeds 37.5 mm the grading shall be subject to the Engineer's approval or in
accordance with his directions.
Unless otherwise agreed with the Engineer, single-sized aggregates shall be used in batching and mixing concrete.
The following impurities in both fine and coarse aggregates shall not exceed the limits stated in the following clauses.
The total chloride content of the concrete mix arising from the aggregate together with that from any admixtures and any
other source, expressed as a percentage of chloride ion shall not in any circumstances exceed 0.1%.
Note: Marine aggregates and some inland aggregates contain chlorides. Both should be selected carefully and
marine aggregates necessitate efficient washing to achieve the 0.1% chloride ion limit. Wherever possible, the total
chloride content should be calculated from the mix proportions and the measured chloride content of each of the
constituents.
Concrete made with some aggregates exhibit Alkali-Silica Reaction (ASR). This phenomenon is particularly detrimental
in structures subject to wetting and their use will not be allowed in such structures.
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Prior to acceptance of an aggregate as inert to alkali reaction the report of a qualified geologist, appointed by the Engineer
on the suitability or otherwise of materials shall be obtained following examination of all types of material that the
proposed sources will yield during the course of the contract. The Engineer may require that samples be taken from
boreholes and for large contracts or contracts extending over a long period then more than one report is to be obtained.
The Engineer may order further tests to be carried out on the aggregates proposed by the Contractor for the structures in
connection with this Contract before permission is given to use the aggregates proposed by the Contractor.
Where allowed by the Engineer to use reactive or potentially reactive aggregates in certain structures the Contractor shall
take all suitable measures to prevent deterioration of concrete due to alkali-silica reaction. Such measures shall include
the use of cement with an acid soluble equivalent of sodium oxide content (Na2 O + O.658K2 O) of less than 0.6%. The
reactive alkali content of the concrete mix shall in no circumstances exceed 3 kg/m³.
The alkali-silica reaction in hardened concrete is also affected by the water-cement ratio. Therefore, where ASR
aggregates are used, with the permission of the Engineer, the water-cement ratio shall be kept to a minimum (in the
region of 0.4).
Aggregates required for use in the construction of concrete water retaining, water excluding and other similar structures
shall have a low drying shrinkage and the water absorption shall not exceed 3%.
The absorption of the aggregates shall be measured in accordance with BS 812, Part 2.
Aggregates of rounded shape or otherwise capable of producing a concrete of good workability with the minimum
addition of water shall be preferred.
Dust or flour resulting from crushing the aggregate shall not be allowed to contaminate the stockpiles. When, in the
opinion of the Engineer such contamination has taken place it shall be removed by an approved means or otherwise the
aggregate shall be rejected.
For mass concrete, in order to improve the consistency of the mix, dust or flour resulting from crushing the aggregate,
may subject to test, be included in controlled quantities to supplement the fine aggregate.
Except where aggregates have been otherwise specified on the Drawings the grading of aggregates shall be as follows:
(i) Coarse Aggregate:
a) 10 mm max. size, graded, for all "fine" concrete.
b) 20 mm max. size, graded, for all reinforced concrete in beams and for walls and slabs not greater
than 400 mm thick.
c) 40 mm max. size, graded, for all reinforced concrete walls and slabs in excess of 400 mm thick.
(ii) Fine Aggregate:
i. Where aggregates conforming to Zones 2 or 3 of BS EN 12620:2002 are available they shall be
used.
ii. For Prescribed Mixes, Zones 1, 2, or 3 aggregates only shall be used.
Fine and coarse aggregates shall be as defined by and be of the quality and nature required by BS EN 12620:2002 and
BS 1201 whichever is applicable. In addition they shall be chemically inert to alkali reaction.
C.3.3.2.3 Water
The Contractor shall supply all water, make all arrangements and pay all charges in respect of such supply. Where water
can be obtained from a public water supply it shall be used.
Where water cannot be obtained from a public supply it shall be tested in accordance with BS EN 1008:2002 and if
necessary shall be treated to assure compliance therewith.
Water for washing and curing shall be such that it will impair neither the strength of the finished concrete nor its
appearance.
C.3.3.2.4 Admixtures
(i) General: The quantity and method of using admixtures shall be in accordance with the manufacturer’s
recommendations and in all cases shall be subject to the approval of the Engineer. Unless otherwise specified
or approved by the Engineer, an admixture shall comply with one of the following:-
i. BS EN 12878:1999 (Pigments for Portland cement and Portland cement products).
79
ii. BS EN 480 (Concrete admixtures except chloride based admixtures).

In all cases the Contractor shall provide the following information for the Engineer’s approval:-
a. The quantity to be used, in kilograms per kilogram of cement and in kilograms per cubic
metre of concrete;
b. The detrimental effects caused by adding a greater or lesser quantity in kilograms per
cubic metre of concrete;
c. The chemical name (s) of the main active ingredients;
d. Whether by the Engineer, the Contractor shall demonstrate the action of an admixture by
means of trial mixes.
Calcium chloride. The use of calcium chloride in any form is prohibited.
Control of Alkali-Silica Reaction
The risk of cracking and expansion due to alkali-silica reaction shall be minimised by compliance with the specification
and guidance notes.
C.3.3.3 Reinforcement
Reinforcement shall be:
i) Plain round mild steel or High Yield steel bars conforming to BS 4449.
ii) Cold worked steel bars conforming to BS 4461
iii) Fabric reinforcement made of cold drawn high tensile bars conforming to BS 4483.
The Contractor shall obtain from his suppliers certificates of the mechanical and physical properties of the reinforcement
and shall submit them to the Engineer for approval, except where reinforcement has been supplied by the Employer. The
frequency of sampling and the method of quality control shall be in accordance with Table 4 and Clause 20 respectively
of these British Standards. All high yield and cold worked bars (except in welded fabric reinforcement) shall be
deformed bars complying with Classification Type T2 for bond strength in accordance with BS 4449. Where galvanised
reinforcement is specified, galvanising shall comply with the requirements of BS 729, Part 1.
Reinforcement shall be stored on Site under cover and supported clear of the ground and in such manner as to make
identification easy. Supports shall be such that distortion of the steel is avoided and contamination and corrosion
prevented.
Bending and Fixing
The Contractor shall provide on Site facilities for cutting and bending reinforcement whether he is ordering his
reinforcement bent or not and shall ensure that a token amount of straight bar is available on Site for bending as and
when directed by the Engineer.
Reinforcement shall be wire brushed and cleaned at the Contractor's expense, before and/or after it is placed in position,
if required by the Engineer.
The bars shall be cold bent in strict accordance with the drawings and the Contractor shall be responsible for the accuracy
of the bending. Bending dimensions shall be worked to the tolerances indicated in BS 8666:2000 and BS EN ISO
4066:2000. Bars in which any errors in bending are beyond the limits of the foregoing tolerances shall be replaced at the
Contractor's cost by correctly bent new bars, or, may be straightened and re-bent cold subject to the Engineer's prior
approval. Any discrepancy or inaccuracy found in the drawings shall be notified to the Engineer immediately.
Bar bending schedules shall be prepared by the Contractor from the details provided on the Contract Drawings, at least
six weeks in advance of the actual requirement on site and submitted to the Engineer for approval.
After bending, reinforcement shall be securely bundled and labelled with weather proof tags or shall be marked with
other approved signs by which it can readily be identified.
Before assembling or fixing the reinforcement the dimensions to which it has been bent shall be checked by the
Contractor against the drawings.
The reinforcement shall be fixed in strict accordance with the drawings as regards cover, spacing and position, and
suitable precautions shall be taken by the Contractor to prevent the displacement of reinforcement during the placing and
compaction of concrete.
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During concreting a competent steel fixer must be in attendance to adjust and correct the positions of any reinforcement
which may be displaced. The vibrators are not to come into contact with the reinforcement.
Where required to support and retain the reinforcement in its correct position the Contractor shall provide templates,
stools or other supports at his own cost. He shall allow for cutting to correct length all corner lacer bars included in the
bar schedules as standard lengths.
Precast concrete support blocks for reinforcement shall be manufactured from Grade C30D "fine" concrete to ensure the
correct cover thickness. They shall be well cured before use and carefully stored on Site to avoid contamination. Plastic
and metal supports, chairs, etc. may be used and shall be subject to the Engineer's prior approval.
In the case of mild steel, a lap of not less than 40 diameters of the smaller bar shall be provided at the junction of two
bars for which the lap is not specifically detailed on the Drawings and, in the case of High Yield steel, a lap of not less
than 50 diameters.
All intersections of bars in walls and slabs and all connections between binders or links and main bars in columns or
beams shall be tied with soft iron wire ties or with fixing clips which shall not be allowed to make contact with the
formwork or to project materially into the specified cover.
Unless permitted by the Engineer, welding of bar reinforcement at intersections or for the joining of bars is prohibited.
Where permission is granted, welding shall be carried out in accordance with the recommendations of the Institute of
Welding for the welding of reinforcing bars for reinforced concrete construction.
When fixed reinforcement is to be left exposed for more than eight weeks, it shall be thoroughly cleaned and painted
with neat cement grout.
Where galvanised reinforcement is used any damage suffered by galvanising shall be made good by the application of
an approved galvanising formulation, before concrete placing is commenced.
Couplers
Couplers for reinforcement shall be either Standard Swaged Splices or Type II Alpha Couplers manufactured by CCL
System Limited or approved equal. Where bars of different diameters are to be joined a CCL Reducer Sleeve or similar
shall be used.
Couplers shall be suitable for the type and size of reinforcing bars and shall be capable of developing 115% of the
characteristic strength of the smaller of the reinforcing bars being joined in both tension and compression. Couplers
shall be installed in accordance with the manufacturer's recommendations. Square twisted reinforcing bars shall not be
used with couplers.
C.3.3.4 Formwork
Requirements
The term "formwork" shall be taken to include centring, formwork, strutting, bracing and the like. The Contractor shall
submit his formwork proposals for checking and approval by the Engineer in advance of the concreting.
Formwork shall be of such accuracy, strength and rigidity as to carry the weight and pressure from the concrete to be
placed on or against it, together with all constructional, wind or other loads likely to be imparted to it, without producing
deformation of the finished concrete in excess of the tolerances outlined in Table C-8.
All formwork shall be sufficiently tight, without plugging, to prevent loss of grout during the vibration of the concrete.
When required by the Engineer joints between formwork facing boards shall be sealed with foam rubber, sealing strips
or other approved material. A foam rubber or polyurethane strip shall be provided around the tops of all walls and
columns before affixing the forms for the next lift.
Faces of formwork shall be clean, free from projecting nails, adhering grout and other imperfections or defects which
would prevent the specified surface finish from being attained. They shall be treated with approved mould oil before
positioning. Great care shall be exercised to prevent reinforcement or steelwork from being contaminated by the oil
during erection of the formwork.
Formwork, which as a result of prolonged use or general deterioration does not, in the opinion of the Engineer, conform
to the particular requirements set out in this clause, shall not be used.
Through bolts or ties will not be permitted in liquid retaining structures. The Contractor shall use only such bolts or ties
as are capable of being removed in whole or in part so that no part remaining embedded in the concrete shall be nearer
the surface of the concrete than the specified thickness of cover to the reinforcement.
Beam soffits shall be erected with an upward camber of 5 mm for each 3 metres of span.
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Top formwork shall be counterweighted or otherwise anchored against flotation.

Boxes for forming holes shall be constructed so as to be easily removable without damaging the concrete during removal.
They shall be properly vented to permit the escape of entrapped air, and shall be capable of being sealed, subsequently
to prevent the loss of grout. The use of polystyrene blocks for the forming of holes, sinkings, etc. will not be allowed
except by express permission of the Engineer. On all external arrises of the concrete 20 mm chamfers shall be formed.
Openings for inspection of the inside of beam, wall, column and similar formwork and for cleaning out purposes shall
be formed so that they can conveniently be closed before the placing of concrete.
All props shall be supported on adequate sole plates and shall not bear directly on or against concrete. They shall be
capable of being released gently and without shock from the supported formwork. No appliance for supporting the
formwork shall be built into the permanent structure without the Engineer's prior approval. Props for upper level support
shall be placed directly over those at lower levels, and the lowermost props shall bear upon work sufficiently mature to
carry the load.
Formwork shall be such as to allow for its removal without damaging the concrete, and in the case of suspended floors,
for the removal of the beam sides and slab soffits without disturbing the beam bottom boards and their props. Before
concreting, the areas which are intended to receive the concrete shall be cleaned by jetting with compressed air, and all
water and extraneous material removed. Where timber is used for formwork it shall be properly cured, free from warp,
straight, clean and free from loose knots.
Where metal forms are used for formwork they shall be of the type strengthened by intermediate ribs or cross bracing.
Moving formwork may be used where in the opinion of the Engineer it is appropriate.
Sawn Formwork
Sawn formwork shall produce an ordinary standard of finish consistent with normal good practice for use where the face
of the finished concrete will not be exposed. The face in contact with the concrete shall consist of sawn timber boards,
sheet metal or other approved material.
Wrought Formwork
Wrought formwork for use on exposed faces and water retaining faces shall produce a high standard of finish consistent
with the best practice. The face in contact with the concrete shall consist of wrought boards tongued and grooved of not
less than 30 mm finished thickness, framed plywood or metal panels or other approved material. Joints between boards
and/or panels shall be arranged in a uniform pattern.
Special Wrought Formwork
Special wrought formwork shall provide the highest standard of finish where the face of the finished concrete is to form
a particular feature. The face in contact with the concrete shall consist of large smooth sheets, unless otherwise specified,
arranged in an approved uniform pattern, with joints coinciding with possible architectural features, sills, window heads,
or changes in direction or surface. Accurate alignment of all joints shall be maintained. Wrought boarding and standard
steel panels shall not be used unless specially faced.
Tolerances
Unless otherwise indicated on the drawings, the tolerances of the finished concrete with respect to the dimensions shown
on the drawings shall not exceed the limits set out in Table C-6.
Table C-6 Tolerances of Dimensions for Finished Concrete
Items Tolerances (mm)
Overall dimensions and Levels ±5

Column sizes
Beam sizes ±5
Wall sizes
Vertical lines out of plumb 5 mm ± 15 mm in every 15 m height
Except that in the case of Sawn Formwork the dimensions of the finished concrete shall be not less than those shown on
the drawings.
Striking and Removal
The recommendations set out in Table C-7 are given as a minimum requirement for striking formwork.
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Table C-7 Striking of Formwork

Sulphate Resisting and Ordinary
Rapid Hardening Cement
Portland Cement
Item Normal Weather (≥ 16° C)
Normal Weather (≥ 16° C)
Days
Days
Beam Sides, Walls, Columns 1 1
Slabs (props left under) 4 3
Beam Soffits (props left
7 5
under)
Removal of props to slabs 8 5
Removal of props to beams 16 8
Shafts and Tunnels 1 1
The removal of props to slabs and beams shall, if directed by the Engineer, be subject to satisfactory results of the relevant
7 day cube crushing tests.
The above striking times are for normal conditions and before deciding on the actual time for each case, the Contractor
shall consider and extend the period if:
i) The span of the structural member under consideration exceeds 6 metres for beams and 3 metres for
slabs. An additional period of one day for each 500 mm of additional span shall then be allowed;
ii) The dead load of the structural member under consideration forms a large proportion of the total
design load;
iii) Constructional loads coming on to the structural member under consideration are being placed soon
after the concreting operations and these loads form a large proportion of the total design load;
iv) The setting of the concrete has been retarded for any reasons;
v) The temperature falls below 8°C. An additional period of half a day shall be added for each day on
which the temperature falls below 8°C. For temperatures falling below 3°C the additional period to
be added shall be one day for each day on which the temperature falls below 3°C;
vi) Any combination of the above points and other considerations which would call for such a precaution
to be taken.
vii) The span concerned is part of a continuous spanning system and the adjacent two spans have not
been cured sufficiently.
C.3.3.5 Concreting
C.3.3.5.1 Requirements
The finished concrete shall be dense, durable, and impervious to the ingress of water, free from cracks and
honeycombing, and resistant to wear and mild chemical attack. Special concretes will be the subject of their own
particular sections.
C.3.3.5.2 Transporting
Concrete shall be transported to the place of final deposit by approved means.
Barrows, spades and other equipment used in the process of transporting concrete shall be thoroughly cleaned before
each day's work or after a long interruption and they shall be free from hardened concrete.
Concrete shall be transported as soon as possible after mixing, by methods which will prevent the segregation, loss or
contamination of the ingredients.
Proper bridging arrangements for traffic over reinforcement shall be provided so that the reinforcement is not distorted,
damaged or displaced.
Where approval is obtained for concrete to be conveyed by chutes, these shall have a slope (not exceeding 1 vertical to
2 horizontal) such as to ensure a continuous flow of concrete. Additional water shall not be introduced to assist the flow.
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If deposition is to be intermittent the chute shall be arranged to discharge into a storage hopper. In no case will a clear
fall of more than 1 m be permitted at the discharge end of the chute.
Where approval is obtained for pumping the concrete, the pump manufacturer's recommendations shall be followed.
The pumps used shall be of adequate capacity and power to ensure delivery of a continuous supply. The Contractor
shall provide adequate alternative arrangements for transporting the concrete in case of a breakdown of the pumping
equipment.
Wherever transport of concrete is interrupted for any length of time (periods of over half an hour shall be treated as such)
the chutes, pumps, pipes and any other means of distribution shall be thoroughly flushed out and cleaned. These shall
also be flushed out immediately prior to resumption of concreting and shall be kept free from hardened concrete. All
washwater used shall be discharged outside the formwork and clear of any freshly placed concrete.
C.3.3.5.3 Placing and Compaction
No concrete shall be placed until the Contractor has obtained approval to do so from the Engineer. When the Contractor
intends to place concrete he shall inform the Engineer in sufficient time to enable him to inspect the reinforcement,
formwork and surface on which the concrete is to be placed and the Contractor shall provide all facilities for such
inspection.
Concrete shall be placed within 30 minutes of mixing, to uniform level, in layers not exceeding 500 mm deep in such
manner as to avoid segregation, and each layer shall be compacted by means of approved vibrators to form a dense
material free from honeycombing and other blemishes. Compaction by hand may be used for small volumes of concrete
only with the prior approval of the Engineer.
At least one internal vibrator shall be operated for every four cubic metres of concrete placed per hour and at least one
spare vibrator for every three shall be maintained on Site in case of breakdown during concreting operations.
Vibration time, the effective radius and other vibration characteristics shall be in accordance with the vibrator
manufacturer's recommendations.
If internal vibrators are used, they shall be withdrawn immediately water or a thin film of mortar begins to appear on the
surface of the concrete. Withdrawal shall be carried out slowly to avoid cavitation.
Internal vibrators shall not be inserted between layers of reinforcement less than one and one half times the diameter of
the vibrators apart. Contact between vibrators and reinforcement and vibrators and formwork shall be avoided.
Vibrators shall not be used to move concrete from place to place in the formwork.
Where two distinct batches of concrete, placed at different periods of time and forming part of the same concreting
operation are required to be formed monolithically with each other, the more mature concrete shall be penetrated by the
vibrator to a sufficient depth to effect plastic movement between the two batches. Where the concrete does not respond
to the action of the vibrator, it shall be deemed to have set, and no further disturbance will be permitted. Unless otherwise
instructed by the Engineer the condition shall be treated as for a "stoppage of work" and the marrying up of the two
concretes shall be effected only when both concretes have properly set.
If external vibrators are used, the formwork shall be strong enough to withstand the forces of vibration.
Temporary or permanent stoppages of work shall be made only against stop ends.
Unless otherwise specified, before placing new concrete against concrete which has already hardened, the face of the
older concrete shall be prepared by the removal of any laitance and loose aggregate, and shall be cleaned by a jet of
compressed air.
When displacers are permitted to be used they shall be so placed that no displacer is within 300 mm of any finished face
or within 500 mm of any other displacer. On completion of any lift, displacers shall be so arranged that they project for
half their height above the surface.
C.3.3.5.4 Concreting in Deep Lifts
Limitations
Any height exceeding 2.5 m from which concrete is poured into formwork to form sections of wall will be considered
within the terms of this Clause.
Concrete in columns may be placed to a height of 4 m with careful placing and vibration and satisfactory results. Where
the height of the column exceeds 4 m suitable openings must be left in the shutters so that the maximum lift is not
exceeded.
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Deep lift construction will not be permitted where the reinforcing bars are to be placed closer than 100 mm to one another
in any direction or, where the clear width at the point of admitting the concrete between one layer of reinforcement and
another (or in the case of singly reinforced walls between reinforcement and formwork) is less than 200 mm.
The method shall only be used where trial sections revealed that, in the Engineer's opinion it can be satisfactorily
employed, in which case the requirements of this Specification shall apply except where they are in conflict with the
requirements of this particular clause, when the latter shall prevail.
Concrete
In order to prevent segregation of aggregates, concrete mixes shall be designed for increased cohesion, or, where suitable,
on a gap graded basis. The use of approved admixtures may be made to achieve this end.
At the same time, the mix shall be such as to limit the amount of bleeding in the concrete, and where in the opinion of
the Engineer the quantity of free water rising to the surface is excessive, the mix shall be corrected before further
concreting is undertaken.
In order to offset any increase in the water cement ratio at the upper levels, the Engineer may require the concrete mix
to be modified for the upper depositions.
A slump of 80 mm shall not be exceeded.
Reinforcement
In order that reinforcement is not distorted or displaced during construction as a result of it being used for gaining access
in or out of the formwork, all intersections of vertical and horizontal steel shall be properly fastened.
All obstructions caused by spacer blocks or chairs shall be eliminated so as to permit an unobstructed passage for the
concrete to the bottom of the formwork. The Contractor may use sliding timber spacers instead of fixed concrete or
plastic spacer blocks to position the reinforcement.
Formwork
In view of the high pressures to be expected from this form of construction extra attention shall be paid to the strength
and stability of the formwork, to the prevention of loss of grout, and to the prevention of displacement of adjacent panels.
The use of through bolts and other accessories which might interfere with the free passage of concrete between and
around the reinforcement shall be reduced to a minimum by the use of properly designed formwork.
Concreting
Particular attention shall be paid to the concreting of the initial sections at the bottom of the formwork to prevent
segregation caused by rebound from the hard surface of the kicker, base and/or lower sections. The initial depositions
shall therefore be made by using trunking methods, or by placing the concrete through openings formed in the sides of
the formwork. Such openings shall not be higher from the hard surface than 2.5m.
In order to reduce differential settlement, and consequently, cracking between two sections of concrete placed at different
intervals of time, concreting between one section and another shall be carried out on a gap construction basis. The gap
shall subsequently be concreted in distinct lifts each not exceeding 2.5m in height. When concreting two adjacent
sections placed at the same time but of different heights, e.g. where boxing out is included, the difference in height shall
not exceed 15% of the height of the deeper section.
Concreting from the upper level of the formwork shall be carried out in such manner as to ensure that concrete is admitted
centrally between the faces of the formwork. For this purpose the Contractor shall make use of trunking or shall use
funnel shaped hoppers extending for a distance of not less than 1.5 m into the formwork. A sufficient number of such
hoppers shall be provided, and/or they shall be capable of movement along the length of the formwork, to enable the
concrete to be placed in contiguous heaps at the base of the pour. Such heaps shall not exceed 460 mm in height.
Where excessive bleeding is in evidence, the excess water shall be removed before placing further concrete.
Compaction
Compaction shall be carried out where possible by manual operation of poker vibrators within the formwork. Where
this is not possible poker vibrators shall be suspended in sufficient numbers to ensure uniform compaction along the
length of wall receiving the concrete, without the need for their withdrawal and re insertion. The means of suspension
shall be such that the vibrators may be progressively and systematically lifted as the concreting proceeds to ensure that
every section of placed concrete is married into adjacent and underlying sections.
The use of vibrators to reposition deposited concrete is prohibited. Surface vibrators attached to the formwork may be
used only to supplement the main means of compaction.
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C.3.3.5.5 Continuous Concreting

Where the Contractor wishes to use a continuous concreting method involving large sections (rafts and walls), he shall
submit a written request to the Engineer for approval. In the request he shall attach details which shall include but not
be limited to the following:
i) Total amount of concrete to be placed in the shift.
ii) Stock of approved concrete materials on site.
iii) Capacity of the batching plant.
iv) Number and type of truck mixers to be deployed for the exercise and movement logistics.
v) Number of skilled and other manpower to be deployed for the exercise in shifts.
vi) Number and capacity of plant to be used in placing concrete (pumps, vibrators, buckets, etc).
vii) Method(s) of monitoring and dealing with the heat of hydration.
viii) Details of protection against rain and floodwaters and how to cope with it.
The Engineer shall consider the above details and other parameters (egg. weather, satisfactory records of cube test results,
availability of adequate working sections where reinforcement placement and the necessary formwork have been
approved etc), before making his decision. The Engineer may order that additional concrete cube moulds be made
available as well as arrangements be made for cube crushing with an approved laboratory to cope with the increased
demand.
The Engineer may order that the concreting works be stopped immediately if in his opinion the quality of the works is
threatened for whatever reason.
C.3.3.5.6 Hot Weather Concreting (Ambient temperatures > 20° C)
Concreting shall not be permitted if its temperature at placing is in excess of 35°C. In order to maintain the temperature
of the concrete below this value the following precautions shall be taken wholly or in part as instructed by the Engineer:
i) All aggregate stockpiles, water lines and tanks as well as the mixer shall be protected from the direct
rays of the sun;
ii) Coarse aggregate shall be cooled by constant watering where possible;
iii) Mixing water shall be cooled by the addition of ice to the storage tanks where necessary;
iv) Rapid hardening cement shall not be used;
v) Where the above precautions are inadequate concreting shall be carried out during the cooler parts of
the day or during the night as may be directed by the Engineer.
When the air temperature is above 20°C loss of mixing water by evaporation shall be considered in arriving at the amount
of water to be added to the mix. In order to maintain the water/cement ratio within permissible limits an approved water
reducing agent shall be included in the mix.
The maximum water/cement ratios indicated may be increased with the Engineer's permission by 0.05 (or 2.5 litres/50
kg of cement) during mixing, but on no account shall water be added to concrete directly or indirectly once it has left the
mixer.
In order to reduce premature drying of the concrete during transporting and placing, all chutes, formwork and
reinforcement shall be cooled by watering when possible, or shall otherwise be protected from the direct rays of the sun.
Any water so used shall be removed by jetting with compressed air before placing the concrete in close contact.
As soon as possible after concreting, the formwork shall be stripped and the surface of the concrete shall be treated.
Where drying winds are encountered, wind shields shall be positioned as directed by the Engineer to protect exposed
surfaces of the curing concrete.
C.3.3.5.7 Wet Weather Concreting
Concreting during periods of constant rain shall not be permitted unless aggregate stockpiles, mixers and transporting
equipment, and the areas to be concreted are adequately covered.
During showery weather, the Contractor shall ensure that work can be concluded at short notice by the provision of stop
ends. On no account shall work be terminated before each section, between one stop end and another, is complete.
Adequate covering shall be provided to protect newly placed concrete from the rain.
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C.3.3.5.8 Holes, Cavities and Fixings

The Contractor shall be responsible for the co ordination of all requirements of his Sub contractors as regards provision
of holes, chases, cavities and fixings and shall, if required by the Engineer, prepare drawings giving details of his and his
Sub contractor's requirements and shall send copies of such drawings to the Engineer prior to construction.
Holes, etc. shall be accurately marked and boxed out for before concreting operations commence and, without the
Engineer's prior approval, no such holes, etc. shall be formed after the concrete has set.
Where bars, if placed to specified spacing would foul holes of size less than 250 mm x 250 mm the full length of the bar
shall be moved to one side and in the case of holes exceeding 250 mm x 250 mm the bars shall be cut on site and lapped
with additional equivalent bars, or as otherwise indicated on the drawings.
Wherever possible, the Contractor shall build in all pipework, ironwork, etc. which passes through walls and floors, and
the pipework, ironwork, etc shall first be thoroughly cleaned and freed from any deleterious matter, and every care shall
be taken to ensure that it is thoroughly encased in concrete.
Unless otherwise instructed by the Engineer all electrical conduits to be positioned within the reinforced concrete shall
be fixed inside the steel cages of beams and between the top and bottom steel layers in slabs and similar members.
The proposed position of all conduits 25 mm and over in diameter which are to be enclosed in the concrete shall be
shown accurately on a plan to be submitted to the Engineer, whose approval shall be obtained before any such conduit
is placed.
Bolts, hooks and other fixings shall be embedded in concrete, or holes shall be drilled and fitted with threaded expanding
anchors to receive the bolts. The Contractor shall ensure that bolts hooks, etc. are accurately positioned. Holding down
bolts for machinery shall be set to template.
Where brick or stonework is to form a facing to the concrete or where the end of a brick or stone wall butts against a
concrete face, galvanised metal ties of approved manufacture to BS EN 845-1:2003 shall be incorporated. The distance
between ties shall be gauged with due regard for the bonding of the walls, and at intervals required by the Engineer.
C.3.3.5.9 Protection and Curing
Newly placed concrete shall be protected by approved means from rain, drying winds, sun and contact with substances
which can adversely affect it.
No traffic or constructional loads shall be permitted on newly placed concrete until it has hardened sufficiently to take
such traffic or load, and only then with the approval of the Engineer.
Concrete shall at no time be subjected to loading (including its own mass) including compressive stress until it has
reached 0.40 of its specified 28 day strength.
Any concrete surfaces, as risers and treads of stairways which might be damaged during the construction of the Works
shall be adequately protected.
All structural concrete shall be cured using methods approved by the Engineer.
The method of curing shall prevent loss of moisture from the concrete. Immediately after compaction and for 7 days
thereafter concrete shall be protected against harmful effects of weather, including rain, rapid temperature changes and
from drying out.
The curing time shall be the number of days given in Table C-8 unless the average temperature of the concrete during
the required number of days falls below 10°C in which case the period of curing shall be extended until the maturity of
the concrete reaches the value given in the table.
Table C-8 Normal Curing Methods
Minimum period of protection for different types of cement:
Equivalent maturity (° C hours
Number of days (where average temp
calculated as the age of concrete in
of concrete ≥ 10°C during whole
Conditions hours multiplied by ° C by which avg
period)
under which temp of concrete ≥ -10°C)
concrete is Type I Type I
maturing
Type IV or Type III Type IV or Type III
Type V Type V
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1. Hot weather 7 4 2 3500 2000 1000

or drying winds
2. Conditions 4 2 1 2000 1000 500
not covered by 1.
Type IV - Low Heat Portland Cement
Type I - Ordinary Portland Cement
Type V - Sulphate-resisting Portland Cement
Type III - Rapid-hardening Portland Cement
Hot weather - Temperature over 16°C
Curing shall be carried out using either of the following basic methods, or any other method agreed with the Engineer.
Methods involving the use of dampened hessian coverings shall not be used. The method adopted for any particular
situation shall be agreed with the Engineer.
Membrane Applied by Spray
Liquid membrane compounds shall be applied to moist concrete surfaces as follows:
(i) Unformed Surfaces
The compound shall be applied immediately after the free water has left the surface.
(ii) Formed Surfaces
The compound shall be applied immediately after removing the forms. If there is appreciable drying, the surface shall
be mist sprayed with water to produce a uniformly damp appearance before the compound is applied.
The compound shall be applied in one or two separate applications to produce complete and uniform coverage of the
surface. If the compound is applied in two increments, the second application shall follow the first within 30 minutes.
The method and rate of application shall be in accordance with the compound manufacturer's instructions.
If rain falls on the newly coated surface before the film has dried sufficiently to resist damage, or if the film is damaged
in any other manner, a new coat of compound shall be applied to the affected area equal in curing value to that originally
applied.
Compound applied to construction joint surfaces, or to other surfaces to which concrete are to be bonded, shall be
removed prior to placing the fresh concrete.
Depending on the surface to which it is to be applied the compound shall conform to the following requirements of
AASHTO M148.
a) Exposed and vertical concrete surfaces Type I D (clear compound with fugitive dye).
b) Unexposed top surfaces of foundations and superstructures Type 2 (white pigmented).
Polythene Sheeting
The concrete surfaces shall be covered with white polythene sheeting as follows:
(i) Unformed Surfaces
The sheeting shall be laid over the surface as soon as possible without marring the surface, and not until initial stiffening
has taken place if a brushed or tamped finish is required.
(ii) Formed Surfaces
The surfaces shall be covered immediately after the removal of the forms.
The sheeting may be in contact with the concrete or made into portable shelters on light weight frames. In both cases,
the sheeting shall be jointed and sealed against the concrete surfaces to prevent wind blowing between the sheeting and
the concrete.
The white polythene sheet shall conform to the requirements of AASHTO M171. On no account shall clear or any other
colour of sheeting be used.
Other Curing Methods
These shall be agreed with the Engineer. Methods involving the use of damped hessian coverings shall not be used,
unless at least 2 layers of continuous hessian are used and they are kept continuously wet and protected from winds
which cause accelerated drying.
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Where the thickness of concrete placed exceeds 1.5 m, the Contractor shall submit for the Engineer's approval proposals
to ensure that, during the curing period:
i) The rate of rise of temperature in the concrete does not exceed 15°C per hour for the first 3 hours;
ii) Thereafter the rate of rise and fall of temperature in the concrete does not exceed 35°C per hour;
iii) The maximum temperature in the concrete does not exceed 70°C; and
iv) The maximum difference in temperature between the core and the surface of the concrete does not
exceed 20º C.
The proposals shall include consideration of:
i) Concrete mix design;
ii) Temperature of mix at time of placing;
iii) Method of curing.
Where required by the Engineer, the Contractor shall carry out temperature measurements in the concrete. The method
and procedure of temperature measurement shall be agreed with the Engineer.
C.3.3.5.10 Joints
Construction Joints
The position of construction joints, when not shown on the Drawings or otherwise required by this Specification, shall
be decided on site having regard to the Plant and labour made available by the Contractor for the manufacture, placing
and compaction of the concrete as well as its curing, the climatic conditions prevailing at the time of concreting, the
nature and size of the formwork, and the conditions of operation of the work. Waterstop shall be provided to all
construction joints on water retaining or excluding structures. The Contractor shall submit his proposals to the Engineer
for his approval at least fourteen days before commencing the work.
Construction joint surfaces shall be treated by the "wash off" method explained below, except where it cannot be
practically effected, in which case they shall be treated the same as for the placing of new concrete against hardened
concrete.
When expanded metal lathing is used for the formation of construction joints a rebate will not be required to be formed.
The expanded metal lathing shall be left in the work and shall not extend closer to the finished surface of the concrete
than 25 mm. It shall be securely fixed to the reinforcement.
The following particular requirements shall also be observed:
Slabs supported on the ground
In order to ensure control in the placing of concrete the Contractor shall provide control boards to form panels not
larger than 15 m2 in area. These shall be lifted as the concreting proceeds except where they are of expanded metal
in which case they may be left in position as part of the permanent works, provided that they shall not extend
closer to the finished surface of the concrete than 25 mm. In the event of a breakdown in the supply of concrete
the Contractor shall ensure that an alternative supply of concrete is made available (to finish the work against the
control boards acting as stop ends). The joint so formed shall then be treated as a construction joint. Where
Ready mixed concrete is permitted, the control boards shall be positioned so as to enclose a volume of concrete
equal to that delivered by each truck.
Construction joints and control joints shall be formed normal to the surface of the retained concrete.
Suspended Beams and Slabs
T-beams shall be formed to their full depth integrally with the adjacent slab and without horizontal joints.
Columns
Where kickers are indicated on the drawings, these shall be cast together with the slab or beam below. Kickers
shall not be cast as a separate operation. Alternatively, the Contractor may adopt “kickerless construction”
methods providing he can satisfy the Engineer that his system is reliable and does not compromise workmanship.
Walls
Horizontal construction joints in walls shall be formed along straight lines coinciding with the full height of the
formwork. The height of the formwork thus controlling the height of the pour shall be determined with reference
to the availability of concrete, the size and amount of reinforcement and the means of compaction available.
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Unless otherwise indicated on the drawings or otherwise permitted by the Engineer for the construction of circular
tanks, concreting shall be carried out continuously for the full circumference without vertical joints. Where
permission is granted for the use of vertical joints the Engineer may order, at no extra cost to the Employer, the
inclusion of an approved type of water stop.
In the case of rectangular tanks, vertical joints shall not be positioned closer to any corner than one metre. They
shall be formed with properly rebated stop ends or, where conditions permit, by the use of expanded metal lathing.
Unreinforced manholes shall be constructed without vertical joints.
The "Wash off Method" of preparing Construction Joints
As soon as possible after concreting, and while the surface is still green, the surface of the concrete forming the
joint shall be freed of loose aggregate and sprayed with a fine spray of water to prevent the formation of laitance.
Subsequently all excess water shall be removed by a jet of compressed air and the surface left clean to receive
further concrete.
Where expanded metal lathing is used for construction joints, this method of surface preparation shall be used in
every case.
Movement Joints
These shall include contraction and expansion joints and shall be as indicated on the drawings.
Contraction joints will be either full contraction joints or partial contraction joints. Where partial contraction joints are
specified a period of at least five days shall elapse between the concreting of the section on each side of the joint.
Where the drawings indicate a contraction gap to be formed in any panel (this gap will not exceed one metre), concreting
on either side of the gap shall be carried out so as to form partial contraction joints at each side of the gap. Prior to the
concreting of the gap section, the joint surfaces shall be cleaned but otherwise left untreated. The concreting of the gap
section shall not be carried out until a period of at least five days has elapsed after completion of the adjacent sections.
Alternate panel construction (other than contraction gap construction outlined above) will be permitted only with the
approval of the Engineer, or in those cases where either the reinforcement is not continuous through the joint or where
the panels are separated by expansion or contraction joints.
Unless otherwise specified or permitted by the Engineer all waterstop shall consist of rubber or PVC. Jointing of
waterstop shall be by vulcanising, except where PVC is specified or permitted in which case joints shall be by fusing or
welding. Materials shall be obtained from an approved manufacturer whose recommendations as to jointing shall be
fully complied with.
C.3.3.5.11 Waterstop and Jointing Materials
Waterstop and jointing materials shall be obtained from an approved manufacturer.
All waterstop and jointing materials which are not required for immediate use shall be stored at all times in a cool damp
place.
Waterstop shall be manufactured of rubber or PVC (polyvinylchloride) as shown on the drawings, and shall be of the
type and size shown on the drawings. Site joints shall be made strictly in accordance with the manufacturer's instructions
and all intersections and junctions shall be obtained prefabricated from the approved manufacturer.
Joint filler shall be manufactured of natural bonded cork or other approved material which remains serviceable when
wet. Joint filler shall be cut and trimmed accurately to suit the joint profile and shall be maintained accurately in position
by means of an approved adhesive. The compressibility of the filler shall be such that it can be compressed to 50%
thickness with a pressure of not less than 0.07 N/mm2 and no greater than 0.4 N/mm2. After 50% compression, the
material should recover to at least 70% original thickness within 30 minutes. On no account shall fibreboard or similar
be used as filler.
Joint sealing compounds shall be approved polysulphide based compounds suitable for sealing joints in horizontal and
vertical/sloping concrete surfaces as appropriate. Sealing compounds shall be applied strictly in accordance with the
manufacturer's instructions and shall completely fill the joint recess. Surface primers shall be from the same
manufacturer as the sealants themselves. Joint sealing compounds shall be entirely suitable for contact with potable
water.
Waterstop shall be located and maintained accurately in position and details of the proposed method of fixing shall be
submitted to the Engineer for approval. On no account shall waterstop be secured by nails or by any other means
involving puncture of or damage to the waterstop material unless purpose made nailing flanges are incorporated in the
design of the waterstop.
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Slip Membrane
The slip membrane shall be "slipstrip" as supplied by Servisied Limited, or similar approved material. The slip
membrane shall be not less than 1.5 mm thick and shall be a plastic preformed strip with low coefficient of friction
specifically manufactured for use as a separating membrane in sliding joints between concrete surfaces. Each sliding
joint shall comprise two layers of the membrane unless otherwise shown on the drawings.
The concrete surface to which the slip membrane is to be fixed shall be finished with a steel float to provide a smooth
true surface free from dust and loose particles.
Expandafoam
Expandafoam shall be supplied from approved material. Expandafoam is closed cell flexible polyethylene joint filler
used where readily compressible low load transfer joint filler is required. Expandafoam shall be fixed in position using
a suitable adhesive.
C.3.3.5.12 Finishes General

All exposed faces of concrete unless otherwise specified shall be hard, smooth and free from honeycombing, air and
water holes and other blemishes.
All projecting imperfections shall be rubbed down with carborundum stone or by other approved means and grit and
dust therefrom shall be thoroughly washed off with clean water.
Surface Finishes
i) Wood float finishes shall be formed by smooth floating the accurately levelled and screeded surface.
Care shall be taken to ensure that the concrete is worked no more than is necessary to produce a
uniform surface free from screed marks.
ii) Steel trowel finishes shall be formed while the concrete is still wet by means of a steel trowel applied
to an accurately levelled and screeded surface
iii) Granolithic finishes shall conform to the recommendations laid down in "Specification for
Granolithic floor toppings laid in situ concrete", as published by the UK Cement and Concrete
Association with special reference to monolithic construction.
iv) Screeded finishes shall be formed by levelling and screeding the concrete to produce a uniform, plain
or ridged surface as specified.
v) Bush hammered or pattern worked finishes.
When exposed aggregate is to be the surface texture, the Contractor shall ensure that a uniform distribution of the coarse
aggregate takes place at the face. The formwork shall be removed as soon as possible from the face to be treated; the
surface shall be thoroughly wetted and wire brushed, and bush hammered or pattern-worked as and when instructed.
Surface retarders shall be used only when permitted by the Engineer.
Bush hammering or pattern working shall not be relied upon to obscure any defects in the concrete face which arise from
formwork imperfections.
Making Good
On no account shall any faulty honeycombed or otherwise defective concrete be repaired or patched until the Engineer
has made an inspection and issued instructions for the repair.
Honeycombed or damaged surfaces of concrete, which in the opinion of the Engineer, are not such as to warrant the
cutting out and replacement of the concrete, shall be made good as soon as possible after removal of the formwork as
follows:
1:1.5 Portland Cement and sand mixture shall be worked into the pores over the whole surface with a fine carborundum
float in such a manner that no more material is left on the concrete face than is necessary to fill the pores completely so
that a uniformly smooth and dense surface of uniform colour is finally presented.
Removal and Replacement of Unsatisfactory Concrete

The Contractor shall on the Engineer's instructions to do so cut out and replace any concrete in any part of the structure
if in the Engineer's opinion:
i) the concrete does not conform to the Specification, or
ii) deleterious materials or materials which are likely to produce harmful effects have been included in
the concrete, or
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iii) the honeycombed or damaged surfaces are too extensive, or

iv) the finished concrete sizes are not in accordance with the drawings within permissible tolerances, or
v) the setting out is incorrect, or
vi) the steel cover has not been maintained, or
vii) the protection, including curing, of the concrete during the construction was inadequate, resulting in
damage, or
viii) the work of making good or other remedial measures the Engineer may indicate are not carried out to
his satisfaction, or
ix) undue deformation of or damage to the works has taken place due to inadequate formwork, or to
premature traffic or to excessive loading, or
x) any combination of the above points has taken place resulting in unsatisfactory work.
C.3.3.6 Testing
Sampling and Testing
The Contractor shall provide on the Site equipment, staff and labour for carrying out the sampling and testing outlined
in columns 3 and 4 of Table C-9, and he shall carry out any or all of these tests at such times and with such frequency as
may be requested by the Engineer.
All equipment shall be calibrated and checked from time to time by an approved agency, as the Engineer may require.
The Contractor shall provide all samples required by the Engineer. Those samples to be tested in an off site laboratory
shall be carefully forwarded by the Contractor to an approved laboratory. Results of laboratory and site tests shall be
kept on site and copies of all test reports shall be forwarded in duplicate to the Engineer.
Each cube shall be marked with a distinguishing number (numbers to run consecutively) and the date, and a record shall
be kept on Site giving the following particulars:-
a) Cube No.
b) Date and time made
c) Temperature and weather conditions
d) Location in work
e) 7-day Test
Date : …………………………………………………………..
Strength …………………………………………………………
f) 28-day Test
Date : …………………………………………………………..
Strength …………………………………………………………
Table C-9 Sampling, Testing and Acceptance Standards
Site Accepted
Materials Test Testing Remarks
Sampling Standards
Cement Ordinary BS 197
Portland
Rapid Manufacturer's Test
BS 197
Hardening Certificate
BS 4550
Sulphate
Resisting BS 4027
Aggregate Description and BS 812 BS EN Whichever is
Classification Sec 2 12620:2002 applicable
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Site Accepted
Sampling Standards
BS 812 BS EN
Particle Size BS 812 Sec 1
Sec 3 12620:2002
Visual
Particle Shape BS 812 Sec 1 and BS Mix
812 Sec 3 Design
Specific BS 812
BS 812 Sec 1
Gravity Sec 3 Requirements
BS 812 )
Density BS 812 Sec 1
Sec 3
BS 812
Voids BS 812 Sec 1
Sec 4
BS 812 BS EN 1992- See Freeze-thaw
Absorption BS 812 Sec 1
Sec 4 3:2006 Cl 6.2.2 Test in this table
Organic
BS 812 Sec 5
Impurities
Adjustment of added
Moisture
BS 812 Sec 5 water for concrete
Content
making
BS EN Ten per cent fines
Mechanical
BS 812 Sec 6 12620:20 value
Properties
02
Water Suitability BS EN 1008 BS EN BS EN 1008 Not required for
1008 potable water
Concrete Compacting BS EN 12350 BS EN Workability Test
Factor Pt 101 12350 Pt
103
Slump BS EN
12350 Pt
102
Crushing BS EN BS 5328, BS Cube test
12350 EN 1992
Water BS 1811 BS 340 Para Precast concrete
Absorption Pt 122 19(b)
Freeze-thaw BS EN 12350 BS 812 Durability test for
Sec. 1 aggregate not
complying with
moisture absorption
requirements of BS
5337 Cl. 21.2
Electrolytic For salt-containing
Efflorescence aggregate or saline
water
Cores BS EN 12350 BS EN BS EN 12350
Pt 6 12350 Pt Pt 120 with ref
6 to concrete
BS EN 12350
strengths this
Pt 120
Specification
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Site Accepted
Sampling Standards
BS EN
12350 Pt
120
Admixtures Compatibility As required Tests by
with cement by independent
Laboratory Laboratory as
required
Cubes shall be forwarded, carriage paid, to an approved Testing laboratory in time to be tested two at 7 days and two at
28 days. No cube shall be dispatched within 3 days of casting.
Authentic copies of all Work Test results shall be forwarded to the Engineer directly from the testing laboratory and one
shall be retained on the site. The test certificates shall indicate all properties as required by BS EN 12350.
The Contractor must allow in his rates for concrete test cubes for all expenses in connection with the preparation and
conveyance to the Testing Laboratory and testing of test cubes and no claim in respect of his failure to do so will be
entertained.
Any batch of concrete which fails to achieve the required characteristic strength shall be removed and made good in
accordance with this Specification. The Contractor shall carry out all such work at his own cost.
Frequency of tests and the number of samples required will be governed by the results of the previous tests, the quality
of the materials revealed during the tests, and the uniformity of that quality. Should it become evident that the quality
of concrete is deteriorating the Engineer may require additional samples to be taken and test cubes to be made and tested
to determine the cause.
Loading Tests
The Engineer may direct that a loading test be made on the works or any part thereof if he deems such test to be necessary
for one or more of the following reasons:
Failure of "Site Cubes" to attain the strength requirements;
Premature removal of formwork;
Overloading of structure during construction;
Improper compaction and/or curing of concrete;
Any other circumstances attributable to alleged negligence on the part of the Contractor, which, in the
opinion of the Engineer, may result in a structure being of less than the required strength;
If the loading test be ordered to be made solely or in part for reasons (a) to (d) the test shall be made at the Contractor's
own cost.
If the loading test be ordered to be made for reason (e), the Contractor shall be reimbursed for the cost of the test if the
result is satisfactory. No extensions to the Contract Duration shall be granted for delays and disruption resulting from
these tests.
Loading test shall be carried out in accordance with the requirements of BS EN 1992.
If the results of the test are not satisfactory, the Engineer will direct that the part of the work concerned be taken down
or removed and reconstructed to comply with the Specification, or that such other remedial measures as he may think fit
be taken to make the work acceptable and the Contractor shall carry out such work at his own cost.
The Engineer may also instruct the Contractor before a loading test takes place to take out cylindrical core specimens
from the structures concerned and have them tested. The cutting equipment and the method of doing the work shall be
to the Engineer's approval. The specimens shall be dealt with in accordance with BS EN 12350. Prior to testing, the
specimens shall be available for examination by the Engineer. If the cores are ordered to be taken solely or in part for
reasons (a) and (d) above, the work involved and the testing shall be made at the Contractor's own cost. If the cores are
to be taken for reasons (b), (c) and (e) above, the Contractor will be reimbursed the cost if the loading test described in
the previous paragraphs proves satisfactory.
C.3.3.7 Special Concrete
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No Fines Concrete
No fines concrete for use in subsoil drainage shall consist of a 1:8 cement/aggregate mix by volume. Aggregate shall be
20 mm to 10 mm graded with no more than 5% passing the 10 mm sieve. Only sufficient water shall be added to ensure
complete coating of the aggregate. One half of this water shall be placed into the mixer first, after which the aggregate
and cement shall be admitted. After partial mixing the balance of the water shall be added until a consistency of mix is
achieved.
Preliminary tests shall be carried out on the site to prove the suitability of the finished concrete, and adjustments made
to the proportions and or grading as may be required by the Engineer.
Air Entrained Concrete
Concrete for roads and those structures where specified, shall include an approved air entraining agent capable of
producing a 5% air entrainment with a tolerance of 0.5%.
The mix shall be purposely designed, having regard for the nature of grading of the aggregates and air entraining agent
being used.
Preference shall be given to the use of air entraining agents which can be administered in fixed calibrated amounts
through a dependable mechanical dispenser or sachet, and which are added to the mixing water.
Frequent air meter tests shall be carried out and the consistency of the air entrainment maintained to the above tolerances
by adjustments in the mix, as may be necessary.
Concrete in Benching
Concreting for benching in manholes, pumping stations and works structures shall consist of Grade C25P concrete unless
otherwise specified. It shall be placed with low workability to the approximate shape required and, while still green,
shall be finished with not less than 50 mm of Grade C25P concrete to a steel trowelled finish and to the contours indicated
on the drawings.
Ready Mixed Concrete
Unless otherwise stated the relevant clauses of BS EN 206-1:2000 shall apply.
Ready mixed concrete shall only be used with the prior approval of the Engineer. The Contractor shall not be relieved
of his obligation to provide concrete to the standard laid down in this Specification by virtue of any approval given for
the use of concrete supplied by others, and the Engineer reserves the right to withdraw his approval at any time
consequent on any deterioration in the quality of the Concrete, or unsatisfactory delivery or any other reason he considers
detrimental to the Works.
Ready mixed concrete manufactured off the site shall be transported in a revolving drum and shall be continuously
agitated until it is used in the work unless otherwise approved. The time interval between adding water to the drum and
placing shall not exceed 90 minutes.
Pneumatically Applied Mortar (Gunite)
Requirements
The pneumatic application of mortar shall be carried out only by Contractors experienced in this type of work and who
are in possession of proper Plant and equipment. Nozzle men employed on the works shall be skilled operators.
The finished product shall be dense, of even texture and colour, and to the requirements of strength, tolerance and finish
set out in this Specification.
Strength
After curing, the mortar shall be capable of producing cored samples with a 28 day characteristic strength of not less
than 27.5 N/mm2.
Materials
Sand, cement and water shall comply with the requirements of this Specification except that the sand shall conform to
the grading of Zone 2 of BS 882 or BS EN 12620:2002+A1:2008.
Proportions
The mix shall be not weaker than one part of cement to four parts of sand by volume, having regard to the adjustments
for bulking of the sand.
Operation
Air and water pressures shall be such as to permit the proper application of the mortar, and shall be determined with
reference to hose lengths and nozzle diameter.
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Mortar rebound, recovered, cleaned and uncontaminated with extraneous matter, may be re used but not for water
retaining structures. It shall be regarded as an equivalent volume of sand which shall not exceed 20 per cent of the total
sand requirement. Rebound which has lodged in the formwork or between reinforcement shall be removed by
compressed air.
Reinforcement shall be completely embedded in the mortar by the proper direction of the nozzle and the mortar shall be
applied as a steady and uninterrupted flow from the nozzle.
Mortar application shall be discontinued at any section of the work where sagging of the mortar is in evidence.
Joints
These shall be formed by sloping the surface to a thin edge. Before applying new mortar, the surface shall be thoroughly
wetted. Laitance shall be removed by the initial discharge of fresh mortar.
Tolerances
The thickness of applied mortar shall be not less than the dimensions shown on the Drawings or greater than 10 mm
over those dimensions, unless otherwise indicated on the Drawings or otherwise permitted.
Protection and Curing
Shall be carried out in accordance with previous clause, Protection and Curing.
Finishes
Unless otherwise specified all surfaces shall be brought to a granular textured finish by means of a wooden float.
Making Good
Any defective work shall be cut out immediately and made good with fresh mortar pneumatically applied.
Cement Grouts
Cement grout shall be mixed in the relevant proportions indicated in Table C-10 using the minimum quantity of water
to ensure the necessary fluidity and to render it capable of penetrating the work.
Table C-10 Cement Grouts
Nominal Mix by Mass
Class
Cement Sand
G1 1 -
G2 1 3
G3 1 10
Cement grout shall be used within one hour of mixing, except where containing a retardant admixture.
Pumped Concrete
Where pumping of concrete is permitted to be used no relaxation of the requirements of this Specification will be
permitted. Particular attention shall be paid to the proper grading of aggregates to prevent bleeding and/or segregation
during the pumping operations. The inclusion of water reducing additives or other materials, including fly-ash, to
improve the flow characteristics of the concrete will only be permitted where it can be shown that they do not adversely
affect the concrete either in the plastic phase or in the finished work.
C.3.3.8 Precast Concrete Units
Requirements
Unless otherwise agreed in writing by the Engineer, all precast concrete units shall be manufactured on site and shall be
true to dimension and shape, with true arises and with perfectly smooth exposed faces free from surface blemishes, air
holes, crazing and other defects, whether developed before or after building-in. They shall comply with the BS 8500.
(Note: Coping blocks and similarly exposed units are particularly susceptible to crazing when the concrete is
manufactured using high water/cement ratios)
The maximum size of coarse aggregate in precast concrete shall not exceed 20 mm except for thicknesses less than 75
mm where it shall not exceed 10 mm.
The compacting of precast concrete shall conform to requirements given elsewhere in this Specification except for thin
slabs where use of immersion type vibrators is not practicable. The concrete in these slabs may be consolidated on a
vibrating table or by any other methods approved by the Engineer.
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Steam curing of precast concrete will be permitted. The procedure for steam curing shall be subject to the approval of
the Engineer.
The precast work shall be made under cover and shall remain under the same for seven days. During this period and for
a further seven days the concrete shall be shielded by sacking or other approved materials kept constantly wet. It shall
then be stacked in the open for at least a further seven days to season before being set in position. Where steam curing is
used these times may be reduced subject to the approval of the Engineer.
Precast concrete units shall be constructed in individual forms. The method of handling the precast concrete units after
casting, during curing and during transport and erection shall be subject to the approval of the Engineer, providing that
such approval shall not relieve the Contractor of responsibility for damage to precast concrete units resulting from
careless handling.
Repair of damage to the precast concrete units, except for minor abrasions of the edges which will not impair the
installation and/or appearance of the units, will not be permitted and the damaged units shall be replaced by the
Contractor at his own expense.
Except where precast work is described as “fair face” or as having “exposed aggregate” or terrazzo finish the moulds
shall be made of suitable strong sawn timber true in form to the shapes required. Unless otherwise described, faces are
to be left rough from the sawn moulds.
Where precast work is described as “fair face” the moulds are to be made of metal or are to have metal or plywood
linings or are to be other approved moulds which will produce a smooth dense fair face to the finished concrete suitable
to receive a painted finish direct and free from all shutter marks, holes, pittances, etc. Where precast work is to have an
“exposed aggregate” or terrazzo finish the moulds shall be constructed to the requirements given for moulds for “finished
fair” work.
The method of achieving the exposed aggregate finish shall be “aggregate transfer” or other approved method.
Weir Blocks and Sills
Aggregates for the making of weir blocks and sills shall conform to BS 1201, except that the use of soft or weathered
limestone coarse aggregate will not be permitted. Fine aggregate shall consist of sand resulting from the natural
disintegration of rock. Blocks and sills shall be tested for water absorption in accordance with BS 340 and shall display
no greater absorption than 2.5% after 10 minutes or 6.5% after 24 hours immersion, the percentage being based on the
dry weight of the test pieces. In addition, they shall exhibit no visible signs of distress when subjected to an approved
freeze thaw test based on thirty cycles of exposure. After such a test the compressive strength of the test piece shall not
be less than 80% of the strength of a similar piece which has not been subjected to the test.
Weir blocks shall be ground to a polished surface on the upper and discharge faces.
Coping Blocks and Weir Blade Holders
These units shall conform to the requirements for weir blocks stated above but without polishing, shall be brought to a
smooth surface on the exposed faces.
Coping blocks of thickness 60 mm or less shall be formed by pressing, by employing pressures not less than 6.5N/mm2
over the entire surface receiving the pressure, before being brought to the required finish.
Kerbs
Precast concrete kerb shall conform to BS 7263: Part 1: 2001, except that coarse aggregate shall conform to BS EN
12620:2002+AL:2008. Fine aggregate shall consist of sand resulting from the natural disintegration of rock.
Approved air entraining agents may be permitted to be used providing that approved adjustments are made to the mix
with regard to water and fine aggregate proportions. In such cases the moisture absorption limits set out in BS 340 may
be neglected subject to the concrete satisfying the freeze thaw test laid down under the heading "Weir Blocks and Sills".
Paving Slabs
Paving slabs shall conform to BS 368 and shall be 50 mm thick unless otherwise specified.
Other Blocks
Blocks used for building work and filter bed walls shall conform to BS 6073: Part 1: 1981.
Wall Units
L shaped wall units shall conform to the requirements of BS EN 206. Where it is not intended to use coping blocks for
the protection of the upper exposed surface of the units, the uppermost 150 mm, for the full width of the unit, shall be
formed with concrete composed of aggregate complying with BS EN 12620:2002+AL:2008. Such concrete shall be
formed integrally with the main body of the concrete.
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Other Items
Manhole ring units, tapers, cover slabs, segments and concrete pipes are referred to under their particular heading.
C.3.3.9 Site Books and Standards
Instructions to be Recorded
The Contractor shall provide and keep permanently on the Site a numbered triplicate book wherein the Contractor shall
record all instructions relating to concrete work issued by the Engineer. One copy of every entry therein shall be sent to
the Engineer on the same day as the entry is made.
Site Diary
The Contractor shall provide and keep permanently on the Site a continuous entry diary wherein the Contractor shall
record details of formwork, construction, placing of reinforcement, concreting and curing operations, striking of
formwork, making good and daily temperature and weather conditions. This diary shall always be available for
inspection by the Engineer.
Copies of Standards and Codes
The Contractor shall provide and keep permanently on the Site the current copies of the following British Standard Codes
of Practice:
BS 812 BS EN 12350 BS 5628
BS 882 BS 4466 BS EN 1992-3:2006
BS 1478 BS 5328 BS EN 206.1:2000
The Contractor shall in addition provide and keep permanently on the Site copies of such other Standards, Codes, Notes
and Specifications as may be required by the Engineer.
Water Retaining Structures - Special Clauses
Note: In the event of any differences between the "Special Clauses" and the previous Specification the provisions of
these "Special Clauses" shall have precedence.
C.3.3.10 Construction Joints in Water Retaining Structures
In water retaining structures, PVC waterstops not less than 130 mm wide and manufactured by an approved
manufacturer, shall be built into all construction joints in external walls and construction joints in roofs of potable water
retaining structures. Construction joints shall be formed at positions agreed by the Engineer.
The cost of forming construction joints shall be included by the Contractor in his general concrete rates.
Watertightness of Structures
The Contractor shall be solely responsible for the watertightness of structures and any remedial measures necessary.
Hydrophilic Rubber Sealer
Hydrophilic rubber sealer shall be co-extruded from chloroprene and hydrophilic rubbers into a cellular strip
approximately 25 mm x 7 mm thick which expands as it absorbs water. The strip shall incorporate an expansion delay
coating to prevent activation during setting of the surrounding concrete.
Hydrophilic rubber sealer shall be applied to the perimeter of all pipes to be built into concrete structures, to existing
concrete walls and slabs at or below water levels which have been demolished and require expansion, and to other
locations as indicated on the Drawings.
The strip sealer shall be bonded to the pipe diameter or on to the face of demolished structures on to which new concrete
is to be placed so as to be at least 100 mm from the wall surface. Where dowel bars are incorporated in bonding new
concrete to old, the sealer shall be placed above the dowel bars on the "wet" side of the structure. Bonding shall be
accomplished using proprietary neoprene or epoxy adhesives to ensure the sealer is not disturbed during placement of
the concrete.
The sealing strip shall be from an approved supplier and application shall be strictly in accordance with the
manufacturer's recommendations.
Waterproof Membranes for Reservoir Roofs
The roofs of new reservoirs shall be waterproofed by the provision of a membrane to be laid on top of the roof slab. The
membrane shall be a cold applied preformed waterproof laminated layer comprising a HDPE carrier film with a solar
reflective surface and a self adhesive rubber bitumen compound complying with the requirements of BS 8102. The
membrane shall exhibit a tear resistance of at least 250 N/mm when tested in accordance with ASTM D1004. Adhesion
to primed concrete to itself shall exceed 1.75 N/mm when tested in accordance with ASTM D100, and a puncture
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resistance of 290 N 65 mm when tested in accordance with ASTM E154. Membranes shall exhibit a water resistance
of not more than 0.14% after 24 hours when tested in accordance with ASTM D574.
Waterproof membranes shall be installed entirely in accordance with the manufacturer's instructions. Membranes shall
be continued up the internal face of the parapet wall and finished centrally under the coping. Adjacent strips of membrane
shall be overlapped to provide a waterproof joint. The provision of a waterproof membrane on the roof slab shall not
relieve the Contractor of his responsibilities to produce a waterproof roof slab which shall have successfully passed a
watertightness test before the membrane is installed.
C.3.4 Site Works
C.3.4.1 Underdrains
Underdrains for reservoirs shall be concrete pipe, laid open jointed in a no-fines concrete surround. Outside the limits
of the reservoir structure the pipes shall be watertight and correctly jointed.
Where shown on the drawings, underdrains shall terminate with a NP 16 ductile iron flange-spigot pipe to which shall
be bolted a double hung flap valve. The DI pipe shall be laid level.
C.3.4.2 Access Roads
General
The Contractor shall be responsible for the execution of the earthworks for access roads in such manner that the finished
requirements and dimensions are obtained. The Contractor shall carry out the work in such a way that excessive drying
and cracking of earthworks and subgrade is prevented.
Embankments and Subgrade
Embankments shall be constructed of approved material obtained from either excavations or borrow pits. It shall be free
from trees, stumps, brush, roots, rubbish and other organic matter.
Where excavated material is unsuitable or insufficient to form embankments the Contractor shall import material from
a site approved by the Engineer.
Embankment material shall be placed in successive horizontal layers not exceeding 200 mm in thickness, before
compaction.
The Contractor shall compact each layer of filing material (prior to placing the successive layer) and the subgrade to
95% of the maximum dry density at optimum moisture content (+5% to -2%) as determined by Compaction Test 13 in
BS 1377: 1975 (Modified Proctor Test).
The Contractor shall programme his work such that subgrade preparation and base course placement follow each other
in close sequence. If the subgrade is not covered immediately by base course and as a result deteriorates or suffers
damage due to traffic or any other cause, then the Contractor shall make good the subgrade at his own expense by re-
compacting or reconstructing as the case may require.
Base Course
The base course shall be either crushed rock which is tough and durable or Type 1 granular material and shall be to the
approval of the Engineer.
The grading shall conform to the following requirements in Table C-11, or such other requirements as may be agreed by
the Engineer:
Table C-11 Grading of Granular Material
Percentage by mass Passing
BS Sieve Size
Type 1 Crushed Rock
75 mm (3") 100 100
37.5 mm (1 1/2") 85 - 100 92 - 100
10 mm (3/8") 40 - 70 40 - 75
5 mm (3/16") 25 - 45 28 - 60
0.600 mm (No 25) 8 - 22 10 - 29
0.075 mm (No 200) 0 - 10 4 - 12
i) The particle size shall be determined in accordance with the requirements of BS 1377.
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ii) The grading shall be within and approximately parallel to the limits specified. The percentage passing
the 0.075 mm sieve shall not be more than one half of that passing the 0.600 mm sieve.
The base course shall have a compacted thickness of not less than 200 mm.
As soon as possible, after spreading, compaction shall be carried out. Compaction shall be carried out with a steel
wheeled roller weighing not less than 8 tonnes and/or a vibratory roller with a static load of at least 1.76kN/100 mm
width or other equipment as directed by the Engineer.
All rolling shall be longitudinal and shall commence at the outer edges of the road and progress towards the centre of the
road.
After the main rolling, binder material, where necessary, shall be spread dry in thin layers and broomed into the interstices
and dry rolling continued until no more binding material will go in. All surplus fines shall be brushed off to expose a
closely knit compact matrix as the finished surface of the layer.
Base course tolerances shall be in accordance with Table C-12.
Table C-12 Base Course Tolerances
Absolute level (mm)
Layer Under 3 m Straight Edge (mm)
+ -
Subgrade (formation) 12 12 15
Sub-base 10 10 10
Base 6 6 6
Bituminous Surface Dressing

Bitumen shall be heated in approved boilers to the temperatures within the limits given in Table C-13.
Table C-13 Bitumen Temperatures
Temperature C
Bitumen Type
Min Max
MC2 80 120
S 125 132 160
No bitumen shall be heated above the maximum temperature given above.

No bituminous work will be permitted in adverse weather conditions or whenever so directed by the Engineer.
Where required by the Engineer immediately prior to the application of primer, the surface of the base course shall be
lightly sprayed with water but not saturated.
Immediately after the area to be primed has been prepared and approved by the Engineer the primer shall be sprayed
onto it.
The rate of spray will depend upon the texture and density of the surface but will usually be in the range of 0.8 to 1.1
l/m2. The quantity used must give complete coverage of the surface with a slight trace of run-off in places. Should the
Contractor find that the coverage is inadequate or there is too much run-off, he shall amend the spray rates.
The prime coat shall be allowed to dry out before anything is allowed to pass over the surface. Where the primer puddles,
the surplus shall be blinded with sand or quarry dust until the free bitumen is absorbed.
Immediately prior to commencing spraying of the bitumen binder, the existing surface shall be thoroughly brushed to
remove loose particles and dust.
The type of binder shall be straight run bitumen of S.125 and the rate of spray shall be 1.2 kg/m2 or as directed by the
Engineer.
Immediately after the binder has been sprayed, clean dry chippings shall be applied at a rate of 19 kg/m2. Should it
become apparent that the supply of stone is about to fail, the bitumen spraying shall be immediately stopped and not
recommenced until an adequate supply of chippings is assured.
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Chippings for surface dressing shall consist of tough durable crushed stone preferably cubical in shape and absolutely
free from visible dust or harmful material such as loam, clay, salt, lime, organic matter or other deleterious substances.
Any contaminated or wet chippings shall not be used in the work.
Chippings shall comply with BS 63 Single Sizes Roadstone and Chippings for 10 mm nominal size chippings as shown
in Table C-14.
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Table C-14 Grading of Nominal 10 mm Chippings

Percentage by Weight Passing
BS Sieve (mm)
BS Nominal Size 10 mm
14 100
10 85 - 100
6.3 0 - 35
5 0 - 10
2.36 0
Directly the chippings have been spread they shall be initially rolled so that the whole area receives at least one pass
within ten minutes of the bitumen being sprayed.
Immediately after the initial rolling, any area which is deficient in chippings shall be made good by hand spreading.
Rolling shall then recommence at the shoulders, working inwards to the centre of the road. The number of passes of the
roller shall be at least two.
Pneumatic tyred rollers are to be used for rolling of all bitumen seal work though finishing with small steel-wheeled
rollers may be used.
Equipment for surface dressing shall be to the approval of the Engineer.
C.3.4.3 Access Tracks
Access tracks shall consist of murram placed in one layer 250 mm thick thoroughly compacted by an approved roller
and surface blinded with fine material so as to leave a tight closed even surface.
C.3.4.4 Paths and Paved Areas
Paths and paved areas shall comprise precast concrete paving slabs bedded in 1:5 cement/sand mortar and laid on a 150
mm layer of compacted hardcore.
Paving slabs shall be 600 mm square and 50 mm thick. Joints shall be grouted up with cement mortar.
The Contractor shall lift and relay at his own expense any slabs which have sunk as a result of consolidation of the
underlying fill or sub-base.
C.3.4.5 Fencing
General
Fencing shall comprise chain link wire mesh 2000 mm high supported on concrete posts, in the locations shown on the
Drawings. Above the mesh the posts shall have cranked tops at an angle of 45°facing outwards 600 mm long, carrying
three lines of barbed wire.
All metal fittings and connectors shall be galvanised in accordance with BS 729 or approved equivalent specification
and shall be supplied prefabricated for bolted connections on site. All bolts and nuts shall be in accordance with BS
4190 or equivalent and shall be galvanised and supplied with shake-proof washers. All nuts of bolted connections shall
be positioned on the inner face of the fence.
Concrete Posts and Struts
Concrete posts and struts shall be of Grade C30P reinforced concrete. The coarse aggregate size shall not exceed 10 mm.
Reinforcement shall consist of a prefabricated cage of four steel bars (diameters as specified in Table C-15) secured by
mild steel stirrups of not less than 2.65 mm diameter spaced at centres not exceeding 200 mm.
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Table C-15 Reinforcement for Concrete Fence Posts

Reinforcement Diameters
Reinforcement Location
(High Yield)
Straining posts - 150 mm x 150 mm 10 mm
Intermediate post - 125 mm x 100 mm 8 mm
Struts - 100 mm x 100 mm 8 mm
Concrete cover to the reinforcing bars shall be not less than 16 mm.
Struts and straining posts shall be suitably shaped, slotted and holed for bolting together.
The posts and cranked tops shall be suitably drilled or holed for stretcher bars and stirrup wires. Straining posts shall be
provided at all ends and corners, at changes in direction or acute variation in levels and at intervals not exceeding 66 m
in straight lengths of fence. Intermediate posts shall be spaced at regular intervals not exceeding 3 m. Holes for all posts
shall be not less than 450 x 450 x 750 mm deep backfilled with Grade C15P concrete; the ends of the posts shall be not
less than 600 mm below ground level and have a minimum concrete cover of 75 mm.
Struts shall be bolted with M12 diameter steel bolts to the straining posts at an angle of 45°, one to each end post and
two for each intermediate straining post. Struts shall be 3250 mm long, overall, and the bottom ends set not less than
600 mm vertically below ground level in holes not less than 600 x 300 mm on plan, with three vertical sides. After
insertion of the struts the holes shall be backfilled to not less than half their depth with Grade C15P concrete and filled
to ground level with compacted earth. The minimum concrete cover to struts shall be 75 mm.
Chain Link Fencing
Wire mesh for chain link fencing shall be galvanised and comply with the requirements of BS 1722: Part 1 Table 1 for
fence type GLS180A or approved equivalent specification. Tension line wires shall be galvanised mild steel wire 4 mm
diameter.
Tying wire and stirrup wire shall be finished with a galvanised coating and shall be 2.5 mm diameter mild steel.
Barbed wire shall comply with the requirements of BS 4102 or equivalent.
Stretcher bars shall be mild steel flat 25 x 4.76 mm and shall be galvanised. They shall be secured to straining posts by
M8 diameter steel bolts.
Line wires shall be attached and strained tightly to each straining post by means of winding brackets and to intermediate
posts by a wire stirrup passed through a hole in the post. The top wire shall be secured 25 mm below the top and the
bottom wire reasonably close to the ground. The intermediate wire shall be secured approximately midway between top
and bottom wires.
The chain link fence shall be strained between each pair of straining posts and secured at each straining post by means
of a stretcher bar threaded through the chain link mesh. The fence shall be attached to the line wires by wire ties space
450 mm apart and to the top brace by wire ties spaced 150 mm apart. The fence shall be secured to the outer face of all
posts and line wires.
Three rows of barbed wire shall be attached and strained to each straining post and secured with stirrup wire to holes in
the cranked top of each intermediate post.
Temporary Fencing
Unless specified otherwise on drawings or directed otherwise by the Engineer, temporary fencing shall be Post and Wire
fencing to BS 1722 Part 3 Type SW 48 using plain wire and round wooden posts, or an alternative approved by the
Engineer which shall not be inferior. Where temporary fencing has to be removed temporarily for the execution of any
part of the works it shall be reinstated as soon as possible and in the meantime the gap in the fencing shall be patrolled
to ensure that no unauthorised crossing of the fence line occurs, and that no animal stock escapes from adjoining lands.
C.3.4.6 Gates
Gates to chain link fencing shall be 2000 mm high and supplied for the clear openings stated on the Drawings and shall
be prefabricated. The outside frame shall be constructed from 48.3 mm x 3.2 mm steel tube and the braces from 42.4
mm x 3.2 mm steel tube. Steel tube shall comply with BS 1775. The chain link shall be shop welded to the frame and
any damage to galvanising made good.
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Each gate shall have a draw bolt with hasp, staple and padlock which may be locked and operated from inside or outside.
Each gate leaf shall be hung on three hinges so arranged that after installation the gate leaf cannot be lifted off from
outside the fence.
C.3.4.7 Catch Drains
On sites where run-off from higher ground towards the works could be significant, the Contractor shall construct catch
drains to intercept run-off and discharge it harmlessly to the side. The Engineer will indicate on site the required
alignment of catch drains and the arrangements for discharge to the receiving watercourses. Locations and lengths of
catch drain shown on the drawings are provisional.
Catch drains shall be excavated with even bottoms and side slopes and shall be lined with stone bedded in 1:2:4 mortar.
The stone used shall be durable non-flakey stone well graded between 150 and 100 mm size, placed in water from a
well-interlocked lining 150 mm thick at minimum.
On completion of lining, catch drains shall have the minimum internal dimensions shown on the drawings with the
upstream edge of the lining set a little below ground level so that water tends to enter the drain rather than run beside it.
C.3.5 Building Works
C.3.5.1 Cement Mortar
Cement mortar for blockwork, rendering, tiling and screeding shall consist of ordinary Portland cement and approved
natural sand mixed by hand or approved mechanical mixer in the proportions by volume of one part cement to five parts
sand unless otherwise specified or shown on the drawings. The cement and sand shall first be mixed dry until the cement
colour can no longer be distinguished from the sand in any part of the mass and the whole shall then be uniformly wetted
by approved means while undergoing further mixing. The water content shall be just sufficient to ensure mixing. The
water content shall just be sufficient to ensure a dense mortar of stiff consistency and adequate workability to permit
trowelling or floating into place. The workability of cement mortar to be used for rendering may be improved by adding
an approved plasticiser in the proportions recommended by the supplier of the plasticiser.
Mortar shall be prepared and used as rapidly as possible after mixing. Under no circumstances shall any mortar be used
that has stiffened by commencing to set. Fresh mortar shall not be mixed with mortar prepared earlier and all batches
shall be used entirely separately.
C.3.5.2 Blockwork
Precast concrete blocks for blockwork shall be solid blocks, ventilation blocks or hollow blocks manufactured from
ordinary Portland cement and aggregates. All blocks shall be manufactured mechanically by compression and vibration.
The mix used shall be not richer than one part cement to six parts of combined fine and coarse aggregate by volume.
Blocks shall be cured for a period of not less than 10 days. After curing all blocks shall be grouped, carefully stacked
and shall not be laid before 28 days after casting. All blocks shall be cast in clean moulds of accurate shape and
dimensions. The tolerance on all dimensions shall be ± 3 mm and no membrane or web of any block shall be less than
40 mm. The minimum compressive strength measured in accordance with BS 2073 shall be 3.5N/mm².
Blocks shall be in three basic sizes as shown in Table C-16
Table C-16 Block Sizes
Basic Size Co-ordinating Size Work Size
200 mm 400 x 200 x 200 390 x 190 x 210

150 mm 400 x 200 x 150 390 x 190 x 140
100 mm 400 x 200 x 100 390 x 190 x 90
The moulds for all blocks, including ventilation blocks shall be approved by the Engineer before casting commences.
All blocks shall be well soaked in water before use and the tops of walls where work has been left off shall be thoroughly
wetted and raked back before work is recommenced. Blockwork shall be bonded in accordance with best constructional
practice with vertical joints staggered. Where required for bond, blocks shall be carefully cut to size. No broken block
or block of improper quality shall be used. Blockwork shall be carried up regularly and no portion shall rise more than
one metre above adjacent portions and at such changes in levels work shall be stepped back. Courses shall be properly
levelled and perpendicular joints, quoins, jambs and angles shall be plumbed as the work proceeds. No joint horizontal
or vertical shall exceed 12 mm thickness. Blocks shall be solid through the full thickness of the wall. Hollow blockwork
shall be filled with Grade C15P concrete as work proceeds, each course shall be filled before the next is placed.
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Blockwork to be left unrendered shall be faced with selected blocks, built with a fair face and pointed as the work
proceeds with a neat flush joint. Blockwork to be rendered shall have the joints raked out to a depth of 5 mm as work
proceeds to form an adequate key.
Blockwork and concrete columns shall be bonded by approved galvanised metal ties cast into the concrete spaced at
alternate courses and extending not less than 150 mm into the block joints.
During construction the top courses of walls shall be adequately protected against heat or rain.
C.3.5.3 Rendering
Rendering shall be carried out in a mix consisting one part cement and five parts of sand gauged by dry volume unless
otherwise directed. Rendering shall be in two coats of 20 mm total thickness and is to be finished with a wood float.
The undercoat which shall have a thickness of 12 mm shall be roughened to provide an adequate key for the finishing
coat.
Surfaces to receive a finishing coat of rendering shall be thoroughly cleaned. Concrete surfaces shall be roughened either
by hand by treating the formwork with an approved retarder and wire brushing after removing the formwork whilst the
concrete is still green to form an adequate key or by treating with an approved cement bonding agent in accordance with
the manufacturer's recommendation. All surfaces shall be dampened as necessary and the rendering applied immediately
afterwards.
The finishing coat shall be applied with a wood skimming float and afterwards trimmed with a feather edge rule to a true
and even surface. Any inequalities shall then be thoroughly scoured with a hand float and filled in. Overworking of the
surface shall be avoided to reduce the tendency of surface crazing.
All rendering shall be protected from the sun and rain by adequate and suitable coverings and the rendering shall be kept
damp while setting. Any cracks or parts which sound hollow when tapped, or other defects in the rendering, shall be cut
out and re-rendered.
C.3.5.4 Plastering
All walls shall be thoroughly cleaned, projecting concrete removed, joints cleaned and walls wetted before applying the
plaster.
Plaster shall be cured in a damp state continuously for 10 days. Improper plaster shall be rejected whether due to cracked
surfaces or improper finish and the Contractor shall cut out such defects and replace with good plaster.
No coat shall be applied before the previous coat has been completed. Each coat shall be properly cured before applying
the next coat.
Plaster shall have an even smooth surface without waviness and surfaces shall be at right angles to each other. Jambs,
columns, beam edges etc. shall be rounded as directed and shall be straight, vertically and horizontally.
Galvanised wire mesh of 12 mm opening shall be used in strips of at least 200 mm in width to cover ducts of pipe
installations, conduits, chases, joints and whenever required by the Engineer. It shall be fixed with special nails, to serve
as a carrier of plaster. Wire mesh shall also be used at all joints between different surfaces receiving plaster (egg.
concrete/blockwork). Metal corner beads of a shape approved by the Engineer shall be placed on the corners and above
the walls to keep plaster in place.
Internal plaster shall be applied in three coats as follows:-
i) Coat 1 (coarse) shall be a minimum of 5 mm thick 1:3 cement and sand mortar with an approved
plasticiser.
ii) Coat 2 (coarse) shall be about 10 mm thick 1:8 cement and sand mortar with an approved plasticiser.
iii) Coat 3 (fine) shall be a finishing coat approximately 3 mm thick of cement: lime: sand in proportions
of 1:4:10. It shall be well rubbed and smoothed down with steel trowels and felt boards flush with
the door jambs.
C.3.5.5 Timber
All timber for carpenter's and joiner's work shall be approved timber properly seasoned, straight cut, free from sap, twist,
shakes, large loose or dead knots etc, and shall be to the approval of the Engineer.
C.3.5.6 Door and Window Frames
Door frames and window frames shall be hardwood.
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Frames shall be properly jointed at corners. Hardwood fixing plugs or metal holdfasts shall be built into the joints of
blockwork or cast into concrete for fixing frames at the rate of one per 900 mm of height.
Joints of window sub-frames shall be drilled, dowelled, glued and screwed.
C.3.5.7 Louvre Windows
Glazed louvres shall be fixed in 'Naco 150' extruded aluminium anodised standard louvre carriers, for 6 mm glass,
supplied complete with all accessories, head and sill beads, screw fixings, extension pieces etc. as required and as
available from NACO or approved equivalent.
Burglar bars shall be 20 mm mild steel bars fixed at 150 mm horizontal centres housed at both ends into hardwood jambs
of the window sub-frames.
C.3.5.8 Insect Screening
Insect screening shall be fitted externally to all windows. It shall consist of approved plastic mesh held in place with
timber battens.
C.3.5.9 Ironmongery
Ironmongery of every description including manufactured articles shall be of the best quality and good design strong
and heavy and to the approval of the Engineer.
Brass, copper or gunmetal articles shall be fixed with brass or gunmetal screws; galvanised articles shall be fixed with
cadmium plated screws and aluminium articles shall be fixed with aluminium screws. All moving parts of ironmongery
shall be properly oiled and left in perfect working order on completion. All locks and padlocks shall be supplied with 3
keys.
C.3.5.10 Glazing
Glass shall be 6 mm thick, 150 mm wide for louvre blades. The louvres shall be raised on the long edges. Obscured
glass shall be used except where shown on the drawings or permitted by the Engineer.
C.3.5.11 Terrazzo
Terrazzo shall be composed of two parts of coloured Portland Cement to five parts by volume of selected clear marble
chippings graded 13 - 3 mm and of a shape, quality and colour approved by the Engineer.
In situ terrazzo shall be laid using a mix matching adjacent terrazzo. The terrazzo shall be thoroughly mixed before
spreading on a 20 mm thick mortar bed and shall be dense, hard and free from air bubbles and other defects. After
hardening it shall be ground to a smooth polished finish. Flooring shall be 20 mm thick and shall be divided into panels
not exceeding 9 m2 by 40 mm x 3 mm ebonite or plastic dividing strips the upper edges of which shall be level with the
finished floor surface.
In situ terrazzo skirting shall be carried up walls for a height of not less than 100 mm and a neat skirting so formed.
Similar skirting shall be applied to concrete plinths and other projecting concrete bases where these are situated in or
alongside an area of terrazzo flooring.
C.3.5.12 Painting (Building Works)
The Contractor shall supply all paints, primers, varnishes, distemper, oil etc., ready mixed in original sealed containers
bearing the brand maker's name identifying the contents and giving directions for its proper use. They shall be used
strictly in accordance with the manufacturer's instructions.
Painting materials shall be of the best quality products of recognised manufacturers, and shall be subject to the approval
of the Engineer. Painting materials shall not be diluted but two different original paints may be mixed to produce the
required colour when not available by itself, and this shall be done according to the Engineer's instructions.
All surfaces to be painted shall be adequately cleaned and prepared to the satisfaction of the Engineer and shall be dry
prior to being painted. The paint shall be well and evenly brushed on, the brushes used being of the correct sizes for the
work. One coat shall always be allowed to dry thoroughly and sufficiently harden before the next coat is applied.
For painting done in several coats each shall be of a different shade or colour from the others.
Any cracks in walls shall be cleaned, filled and puttied up then left to dry before application of paint. Any cracking in
timber shall receive putty and shall be smoothed by sand paper before application of paint.
All hardware and furniture for doors and windows, together with any exposed electrical installations in walls shall be
removed before paintwork commences. Upon completion of all paintwork all such hardware and furniture etc. shall be
re-installed and left in good working order.
Floors, walls and adjacent items shall be covered as protection against staining by paint.
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If in the opinion of the Engineer any painting is unsatisfactory the surface shall be cleaned and repainted.
All colours shall be approved by the Engineer.
Timber shall be well rubbed with sand paper until it is rendered smooth. All timber shall be painted with an undercoat
of ready mixed oil paint. When dry, the undercoat shall be well rubbed down with sand paper. A second coat of the
same ready mixed oil paint shall be applied. A final coat of gloss paint shall be applied leaving no brush traces or
irregularities.
Non-galvanised steelwork and metalwork shall be rubbed and cleaned by wire brushes and in addition to any shop prime
coat shall be primed with red lead of the best quality, followed by a coat of oil paint used for metal works and two coats
of medium oil alkyd enamel.
All ceilings and rendered walls of buildings, both internal and external shall be painted with emulsion paint. Where
surfaces show salt deposits or efflorescence, the Contractor shall carefully neutralise them with a solution of 2 kg of zinc
sulphate crystals dissolved in 5 litres of water brushed on and left to dry. Emulsion paint shall be poly vinyl acetate
(PVA) type obtained from an approved manufacturer and shall be applied strictly in accordance with the manufacturer's
recommendations. Emulsion paint shall be applied in one primer and two finishing coats.
C.3.5.13 Roof Waterproofing
A cement mortar screed shall be laid to the levels and falls indicated on the drawings. The mortar shall be a 1:3 cement
and sand comprising ordinary Portland cement and sand.
The two layer felt roofing shall be laid in accordance with the requirements set out in CP 144 "Roof Coverings". The
screed shall be dry and brushed clean and then primed with a bitumen primer which shall be well brushed in and allowed
at least 24 hours to dry. The first layer of felt shall then be laid, continuously hot bonded to the screeded base. The
second layer of felt shall then be continuously hot bonded to the first layer and laid with lapped joints at all edges with
50 mm minimum side and 75 mm end laps.
Hot bitumen shall be used for bonding at the rate of 1.5 kg/m² laid to even thickness. The bonding compound shall not
be heated to a temperature in excess of that necessary to ensure effective bond.
The top layer shall be evenly coated with cutback bitumen at the rate of 1.7 kg/m² and immediately blinded with fine
sand and dressed with a layer of light coloured chippings or other reflective dressing approved by the Engineer.
The edge of the roofing felt shall be dressed and sealed at the edge of the concrete slab.
On completion roofs shall be left sound, watertight and in a neat and clean condition before handing over and to a
standard which will be to the complete satisfaction of the Engineer.
C.3.5.14 Waterproof Membrane
Where a waterproof membrane is required beneath a structure it shall be laid on a Grade C25P concrete blinding layer.
Where instructed by the Engineer the Contractor shall use Class B waterproof building paper to BS 1521 approved by
the Engineer laid with 150 mm laps sealed with bituminous solution. Where a polythene membrane is used it shall be
of a standard approved by the Engineer.
C.3.5.15 Fixings to Concrete Structures
Where fixings to structures previously constructed are to be made by setting a bolt system into preformed holes such
fixings shall be made either by Rawlbolt Projecting Bolt Type or by using an approved proprietary resin anchor system.
Where thin sections are involved or where stresses are likely to be set up which might cause damage to the structure the
use of the resin anchor system only will be permitted. Only in special circumstances will the Engineer permit rag bolts
to be used.
C.3.5.16 Grouting in Ironwork
All brackets, rag bolts (where approved) and other ironwork for which holes have been boxed out or left in the concrete
of a structure shall be carefully grouted into their correct positions in all particulars.
The grouting in shall be carried out with cement and sand grout in such a manner that there shall be no apparent difference
in the texture or colour throughout the face of the finished structure and that there shall be no seepage of water. Grout
shall be Class G2.
The above instructions shall apply also to the building in of pipes except that Grade C25P concrete shall be used in lieu
of cement grout.
All mortises, etc., left for building in shall be free from any sign of infiltration of water before the building in is carried
out. No reliance shall be placed upon the building in process for the sealing of such leakage.
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Where connections are to be by "casting in" techniques the "cement-in" sockets, used with the Rawlbolt system or other
approved bolt system, shall be accurately set into template prior to placing the surrounding concrete and shall be kept
rigidly in place until the concrete has properly set.
Where resin anchorage is used the Contractor shall ensure that the setting time of the resin is appropriate to the
requirements for setting up, plumbing and aligning the work before it sets. Bolts shall be set to template and hole
diameters shall conform to the recommendations of the suppliers.
Whatever system is used, all bolts shall be cadmium plated.
Where aluminium and steel are combined in any fixing system all mating surfaces shall be treated with a zinc-chromate
based jointing compound prior to connecting.
C.3.5.17 Building Work and installation of Plant
Notwithstanding the tolerances described elsewhere all building work in connection with the installation of machinery
shall be finished true to the dimensions and levels shown in the drawings and to the satisfaction of the Engineer.
C.3.5.18 Bonding New Concrete to Old
The face of the existing work against which new concrete is to abut shall be thoroughly scabbled, hacked and roughened
after which it shall be wire brushed. Before placing the new concrete the face of the existing concrete shall be sprayed
with water to remove any loose matter and slurry, and a mixture of 1 part cement to 2 parts of sand shall be brushed on.
The new concrete shall then be placed immediately.
Where specified, new concrete shall be bonded to existing work by means of an epoxy or polyester resin, applied in
accordance with the manufacturer's recommendations.
C.3.5.19 Isolation of Aluminium
All items of aluminium construction shall be isolated from concrete by the use of bituminous felt or DPC material or
two coats of bituminous paint. The aluminium shall be isolated from dissimilar metal by the use of fibre washers and
spacers.
C.3.6 Metalwork and other fittings
C.3.6.1 General
The Contractor shall be responsible for the detailed design of all items covered by this section of the Specification and
their correct performance. The items shall adhere to the general arrangements indicated on the drawings and be to the
The work shall be prefabricated for site assembly without welding. All bolts and nuts shall be assembled with one
washer under the head of the bolt and with another washer under the nut. All bolts, nuts and washers shall be galvanised
or sheradised.
The Contractor shall submit to the Engineer for his approval three copies of detailed drawings and specifications for all
items to be specially fabricated or tailored for the Works and three copies of manufacturer's drawings and specifications
for standard items. The Contractor shall furnish additional information and calculations if requested by the Engineer.
The Contractor shall allow three weeks for the Engineer to check the details, from receipt by the Engineer of complete
information. No items shall be manufactured or ordered from suppliers until the Engineer has signified his approval of
the details.
Subsequent to approval being given, the Contractor shall submit a further three copies of the drawings, specifications
and other information to the Engineer. Drawings and specifications which have been approved by the Engineer shall
not be departed from without approval of the Engineer.
C.3.6.2 Structural Steelwork
Material for structural steelwork shall comply with BS 4360 and workmanship with BS 449. The steelwork shall be
securely fixed to the foundations or buildings and designed to have such strength and stiffness that its deflection and
movement under the loads to be applied shall be within tolerable limits.
All bolts and nuts shall comply with BS 3693 except for High Strength Friction Grip Bolts which shall comply with BS
4395.
Mild steel electrodes shall comply with the requirements of BS 639 and High Yield Steel with BS 2540.
All structural steel fabrication shall conform to the requirements of BS 153. The use of High Strength Friction Grip
Bolts shall be in accordance with BS 3294.
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All structural steelwork shall be hot dipped galvanised after fabrication and shall be fabricated using welded joints where
possible for shop joints and bolted joints for field assembly.
Alternatively, structural steelwork may be designed in accordance with the American Institute of Steel Construction
Specification for the Design Fabrication and Erection of Structural Steel for Buildings, 1969 Edition and the American
Institute of Steel Construction Code of Standard Practice for Steel Buildings and Bridges, 1972 Edition.
C.3.6.3 Open Mesh Walkways and Covers
Open mesh type walkways, platforms and covers shall be of aluminium or galvanised steel, suitable for a superimposed
load of not less than 6kN/m2 and shall comply with the relevant provisions of BS 4592: Parts 1, 2 and 3. They shall be
provided with suitable angle kerbing frames fixed to the structural steelwork or concrete (using appropriate tangs cast-
in) as appropriate. Kicker plates, 150 mm deep, shall also be provided as appropriate, for safety purposes.
The walkways, platforms and covers shall include all necessary supports not detailed on the Drawings.
Open mesh panels shall be trimmed with full depth nosing bar along all edges and bolted to each other when in place to
help ensure a firm walkway. Panels shall be cut in such a way and fixed so as to provide a continuity of pattern.
Covers shall incorporate a hinged and lockable open mesh access panel with a 750 x 750 mm clear opening, strong
durable hinges and heavy duty non-corrodible padlock. Openings for valve keys shall be just sufficient in size for the
valve key and shall incorporate a cover hinged only.
All panels shall be securely bolted to the supporting structure. Where the supporting structure is concrete, galvanised
mild steel angle curbs shall be provided and securely grouted into rebates left in the concrete such that the tops of the
panels are flush with the top of the concrete.
All steelwork shall be hot dipped galvanised after fabrication.
C.3.6.4 Staircases
Staircases shall be suitable for a superimposed load of 6 kN/m² calculated on the plan area of the stair.
Open mesh type flooring shall be used for the treads and on the landings, and it shall comply with the clause on open
mesh walkways.
Stairs and landings shall be guarded on each side with a continuous handrail which shall be between 840 mm and 1000
mm in height on stairs measured from the tread nosings, and 1000 mm high on landings. Handrailing shall comply with
the clause on handrailing. Each landing shall be provided with a toe kicking strip 150 mm high, from floor level.
The riser/tread dimensions shall fit the formula:
Twice the riser plus the tread shall be not less than 570 mm and not more than 635 mm. Consecutive treads
shall overlap by not less than 16 mm.
Steel staircases shall be hot dipped galvanised after fabrication.
C.3.6.5 Ladders
Ladders shall be of mild steel and shall consist of 65 mm x 12 mm flats and stringers 400 mm apart with 20 mm diameter
solid rungs at a maximum of 250 mm centres shouldered and riveted over. Stringers shall have welded-on feet and
brackets for fixing to floors and walls, which fixings shall be not more than 2 metres apart. Brackets shall be 25 x 10
mm flats.
Where shown on the drawings, stringers shall be extended 1000 mm above the upper platform and suitably opened out
for access, or where ladders are below manhole covers, separate hand holds shall be fixed to the upper platform.
All ladders rising 2500 mm or more shall be fitted with safety hoops. The hoops shall have a diameter of 760 mm and
be of 50 x 8 mm flats at not more than 900 mm centres, fixed to the stringers and with three vertical straps of 50 x 8 mm
flats extending from the top to the bottom hoop.
Steel ladders shall be hot dipped galvanised after fabrication except where the ladders are subject to prolonged immersion
in water where they shall be of Grade 316 stainless steel.
C.3.6.6 Handrailing
Handrailing shall be approximately 1000 mm in height with an intermediate horizontal rail with standards not more than
2000 mm apart.
Handrailing shall be designed for a horizontal loading of not less than 220N/mm2.
Hoops shall be welded on where required for fixing guard chains.
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Toe kicking strips, 150 mm high, shall be provided at the base of all handrailing.
Handrails and standards shall be manufactured from material complying with the relevant provisions of the appropriate
British Standard as shown in Table C-17.
Table C-17 Handrailing Standards
Handrails Standards
Material Solid Tubular Solid Tubular
BS Grade BS Grade BS Grade BS Grade
Mild Steel 4360 43A 1387 - 4360 43A 1387 -
or or
- - 6323 Pt HFW2 - - 6323 Pt HFW2
2 2
Aluminium 1474 6082 1474 6082 1490 LM6 1474 6082
or or
1471 6082 1471 6082
After manufacture, mild steel and aluminium handrails, kicking strips and standards shall be factory hot dip galvanised
or anodised as appropriate, in accordance with BS 729 or BS 1615 Grade AA25.
Adequate provision shall be made for thermal movement.
Access opening in handrailing to ladders and direct drops for more than 300 mm shall be fitted with two rows of safety
chain permanently fixed at one end and hooked or spring clipped at the other.
The handrailing shall be pre-fabricated for site assembly without welding. Fixing flanges shall be bolted to concrete,
using self drilling anchor bolts, or to structural steelwork as appropriate.
C.3.6.7 Guardrail
Guardrail shall be 750 mm in height with a single top rail. In all other respects it shall comply with the specification for
handrailing.
C.3.6.8 Safety Chains
Chains across openings in handrails at tops of ladders shall be mild steel factory applied hot dipped galvanised in
accordance with BS 729 having 3 SWG x 3 links per 100 mm and shall be supplied complete with galvanised or stainless
steel 'S' hooks and split rings.
C.3.6.9 Steel Access Covers
Steel access covers shall be to the duty required and sized to suit the openings shown on the drawings. They shall be
complete with frame and shall be weatherproof (prevent the ingress of water) when closed, and shall in all respects be
strong and durable.
The covers shall be hinged and lockable and provided with stays to prevent the covers opening more than 105°. The
Contractor shall provide with each cover a heavy duty non-corrodible padlock and four keys.
Each cover and frame shall be galvanised and the frame shall be supplied with suitable tangs for casting into the concrete
structure or other fixing for structural steelwork.
C.3.6.10 Floor Duct Covers
Floor duct covers shall be aluminium or galvanised steel chequer plate. They shall generally be suitable for a
superimposed load of 6 kN/m², unless traffic dictates a higher loading. They shall be provided with suitable angle
kerbing frames.
C.3.6.11 Galvanising
Where galvanising has been specified the items shall after fabrication be factory applied hot dipped galvanised in
accordance with BS 729, or where approved zinc coated in accordance with BS 2569 Part 1 to a thickness of 0.15 mm
(0.006").
All items to be protected shall be prepared as specified in the above standards.
Articles altered at the manufacturer’s works in any way after galvanising are to be re-galvanised as specified.
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Articles subject to minor alterations on site or requiring minor repair on site shall be wire brushed to remove all rust and
coated with 3 coats of approved zinc rich cold galvanising compound.
C.3.7 Water Pipelines
C.3.7.1 General
This specification applies in particular to water supply pipework. Pipes, valves and fittings shall comply with the relevant
International and/ or National Specifications as stated hereinafter.
In general, the recommendations contained in EN 1295 pt 1:B.1.1.2 (with regards to pipe design), and BS 8010, EN
1610 and BSCP 2010 or their equal (with regards to general pipe work and its installation) shall be followed in so far as
they are relevant to the prevailing conditions. For design recommendations not covered by EN 1295, reference should
be made to EN 545 for ductile iron pipes; BS 534, EN 10224, EN 10311 and AWWA M11 for steel pipes; BS 2782, BS
EN 1452, BSCP 312, EN 921 and for uPVC; and BS 3284 and EN 12201 for HDPE (PE100) pipes.
At all times latest editions and updated standards and procedures for design and installation shall be used and adopted.
In the same context the Contractor may provide, with the approval of the Engineer, superior materials using other
standards not listed here provided they can demonstrate this to be the case through tests, examples and guarantee
certifications.
The Contractor shall be wary of the worst case scenarios making the installed pipes unsuitable and these can be caused
by such things as unsuitable soils, shallow depths, bedding types and extraordinary traffic loads among other things and
the Contractor shall inform the Engineer when they occur. Such incidences shall be remedied by using a higher class of
pipe (wall thickness and/or yield stress) and / or bedding as directed.
As a general guidance, the pipes proposed for the Contract shall conform to the following international and national
standards unless a superior quality is demonstrated.
C.3.7.1.1 Standards for Pipelines

Pipeline General EN 1295 Section 1.B1.12 – Structural Design of Buried Pipelines, saving that where the
Specification is silent on any pertinent matter, then the alternative relevant part of the SCRN
(egg. AWWA) indicated shall be complied with.
BS 8010 British Standard Code of Practice for Pipelines
Part 2 Pipeline on Land : Design, construction and installation
Section 2.1 1987 - Ductile Iron
Section 2.5 1989 - Glass reinforced and thermosetting plastics
Section 2.8 1992 - Steel for oil and gas
BSCP 2010 – 2 – Design and Construction of Steel Pipeline Inland
Steel pipes & fittings Pipes BS EN 10224

Steel pipes and fittings shall generally comply with BS EN 10224: 2002, ISO 559, AWWA
C200.The minimum steel grade shall be APL 5L X46Specifically, the steel pipes shall
dimensionally conform to BS 534 and BS EN 10224:2002, and in terms of materials,
properties and tests to BS 3600 and BS 3601 and EN 10220, EN 10216 and EN 10217, and
wherever appropriate to EN 10255.
The Contractor shall demonstrate that the thickness and steel grade in accordance with ISO
559 gives a thickness adequate for the pressure calculated in accordance with EN 1295
The coating for buried steel pipes shall be factory applied external protection with triple
layer polyethylene coating (3LPE) as per BS EN 10288 and DIN 30675 Part I for Type III
soil comprising triple wrap system of fusion bonded or sprayed epoxy primer, an
intermediate polymer adhesive layer and an extruded polyethylene coating providing an
overall total film thickness not less than that specified in BS EN 10288. Internal Food Grade
Epoxy Coating shall conform to BSEN 10339.
.
For above ground steel pipes, a triple layer polypropylene coating (3LPP) with
polypropylene as per DIN EN 10286, AWWA-C215 or DIN 30678 shall be used, unless
single layer fusion bonded epoxy is indicated.
111
Protection to site welded joints shall be by a solvent free epoxy coating as per AWWA
C210-97 or a tape wrap as per AWWA M11.
Ductile Iron pipes and Pipes and joints BS EN 545

Fittings Flanges BS EN 1092
Coating and Lining DIN 30675 Part 2 for Type III soil (unless detailed field tests have
proven Type I and II soils to be exclusively present), and DIN 30674 Part 1
uPVC pipes ISO 4422 and BS EN 1452
uPVC pipes and fittings shall be manufactured and installed in accordance to BS EN 1452.
Preference shall be given to uPVC pipes which are not stabilized by lead, tin or other heavy
metals. However, where these are then tests in accordance with DIN 8061 must produce
acceptable results. Other related standards for pipes and joints of uPVC are given in BS EN
1452, and BS 4346.
For laying, jointing and pressure testing these shall conform to the relevant sections of
BSCP 312-2, and for quality control to DIN 8061. All uPVC joints shall be of the spigot
and integral socket type.
Fittings shall in general be steel or ductile iron. Injection moulded uPVC bends and tees shall
be allowed
HDPE pipes & fittings ISO 4427 and DIN EN 12201
HDPE (PE100) shall be in accordance to ISO 4427 and materials used shall be in
conformance to ASTM D2122 .HDPE (PE100) pipes and fittings shall meet the
requirements of BS 3284, BS 5114, EN 12201 Parts 1, 2, and 5, ASTM D2565. The
polyethylene used shall be of a high molecular type with average to high density. Not less
than Third Generation polyethylene known as PE 100 shall be used for the manufacture of
the pipes.
Fittings shall in general be steel or ductile iron whilst electro-fusion jointed bends and tees
shall be allowed providing these are not formed by bending straight pipe below the minimum
radius specified.
C.3.7.1.2 Design Criteria for All Pipelines

Ductile iron pipes are classified as semi-rigid pipes whilst steel and thermoplastic pipes are classified as flexible, and
any design must take the different requirements between the two into account.
Materials data for all pipes is required to enable structural design to proceed. Common to all is the internal diameter,
excluding lining (if any) and where applicable including lining as well as the wall thickness being considered. All flexible
pipes also require the stiffness, [S=E × I/D3] to be taken into account.
In addition, steel requires knowledge of the maximum allowable working pressure, the maximum allowable surge
pressure, the allowable stress and the allowable deflection, whilst uPVC and PE pipes require knowledge of long term
ring bending modulus of elasticity, the allowable deflection, cyclic fatigue and the allowable long term combined stress.
In all cases, hydraulic design shall be based on the actual internal diameter and NOT the Nominal Diameter (DN) as
well as the appropriate roughness (k) in mm.
Except where otherwise indicated, pipes have been designed to allow for the conditions listed in Table C-18. Where in
the opinion of the Engineer, actual site conditions result in loads and stresses greater than allowed for, the Engineer may
require the pipe design to be modified to account for such changes in design assumptions. Unless authorised otherwise
in writing by the Engineer, these criteria shall also be used for any design undertaken during the construction stage.
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Table C-18 Design Criteria
Criteria Units Value Specific design required
Minimum pipe cover

a) Thermoplastic pipes mm 900 May vary with Engineer’s approval
b) Ferrous pipes mm 900
c) Transmission mains mm 900
Minimum Trench Width mm 1½ OD Minimum distance between pipe wall (at
spring line) and trench wall 300 mm
Soil type
Expected native Soil modulus E’3 MPa 2.4 Clayey, silty sand, loose condition
Bedding material With Engineer’s approval
a) Thermoplastic pipes Class S1 / S2 S2
b) Steel (cement lined) Class S3 / S4 S3
c) Steel (other linings) Class S3 / S4 S4
d) Ductile Iron Class S3 / S4 S3
Minimum surround compaction %MPD 90
Operating temperature ºC 29
Traffic loading May be adjusted at Engineer’s discretion to
a) Vehicle axle load kPa 73 suit conditions
b) Overload risk factor % 25
c) Impact factor 1.5
Partial vacuum in pipe - Yes
Operating pressure Bar 20 To suit operating pressure 20bar
Specific design (supported by properly documented calculations) and Engineer’s written approval will be required for
the following situations:
i) Thermoplastic pipes with DN greater than 250mm for which, apart from soil and surcharge loads,
loads due to partial vacuum and cyclic fatigue shall be taken into account.
ii) Road crossings for which, apart from soil and surcharge loads, loads due to cyclic fatigue shall be
taken into account.
iii) Transmission mains for which specific conditions may apply.
The use of uPVC pipes in Pumping Mains is strictly forbidden.
Thermoplastic pipes less than DN 110 may be affected if the native soil modulus is less than the MPa value indicated
above and the Engineer may require the pipe grade to be increased. Trench widths for pipes greater than DN 300 may
be varied with the approval of the Engineer to suit actual site conditions and approved working methods provided that
the Contractor has proven that the minimum compaction specified is being continually bettered.
For ferrous pipes of diameter less than DN 80 mm and where a non-barrier, (that is a metallic type coating) such as zinc
has been specified or approved as part of the protection system, additional onsite protection as indicated herein for buried
screwed joints and joints incorporating bolts must be strictly complied with and no exceptions whatsoever will be
allowed.
C.3.7.1.3 Certificate and Samples from Pipe Manufacturers
Where specifically requested by the Engineer, samples shall be provided by the Contractor. If accepted, shall be used for
the purpose of comparison with all components of a similar nature delivered subsequently. Any subsequent goods
supplied that do not meet the standards of the sample shall be liable to rejection with all consequences to the cost of the
Contractor.
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The Contractor shall within 42 days of award, supply to the Engineer a signed certificate from the pipe manufacturer(s)
stating that the pipes and fittings comply in all respects with the provisions of these Specification and the indicated
National or International Standards, and that they shall conform to the required standards for all raw materials, processes,
quality control, manufacturing, and for fully manufactured products including where appropriate, the handling to
shipment. The pipe and fittings manufacturer’s key personnel shall have at least three (3) years relevant manufacturing
experience especially in regards to plant management, quality control / quality assurance, application of the coating and
lining systems offered in the bid, and selection / batching / mixing of raw materials, and in the case of thermoplastic
pipes, the manufacturer (or licensor in the case of local manufacture under license) shall certify that the requirements of
SABS 966-1:06 Table B.1 have been complied with. The Contractor shall have submitted reasonable documentary
evidence with its bid to support statements made in the bid documents in this regard. The manufacturer shall also state
that they have the ability to carry out the necessary tests during the manufacturing process and tests on the finished
products as required by the respective standards.
The Contractor shall also submit a copy of the pipe / valve manufacturer’s Quality Assurance (QA) System complying
with ISO 9000/9001/9002, together with sufficient information from the manufacturer’s Quality Assurance Plan (in
English) to enable the Engineer and Employer to understand the levels of performance offered.
The Contractor shall furnish the Engineer with a manufacturer’s certificate in respect of every consignment of the
pipeline materials, confirming that all the items of the consignment comply in all respects with the requirement of the
specified standards and of this specification. The original and one copy of such manufacturer’s certificate shall be
delivered to the Engineer prior to shipment in the case of imported pipes and prior to despatch from the factory in the
case of local manufacture.
The original and one copy of such manufacturer’s certificate shall be delivered to the Engineer prior to shipment.
C.3.7.1.4 Inspection and Testing During Manufacture
During manufacture and before despatch of pipes and fittings from the place of manufacture the Contractor shall allow
for inspection by the Engineer and the Employer of all the manufacturing process and tests on raw materials and finished
products. The inspection will include attendance at all pressure and material tests, execution of dimensional checks and
inspection of the workmanship and standard of manufacture with scrutiny of evidence of the materials used in the
fabrication of the Pipeline Materials.
The Engineer and the Employer’s representative shall be allowed full access to all areas at the place of manufacture or
elsewhere where testing, furnishing or preparation of materials for the performance and testing of work under this
Specification is taking place.
The Contractor shall furnish the Engineer with reasonable facilities and space (without charge) for the inspection, testing
and obtaining of such information as he desires respecting the character of material in use and the progress and manner
of the work.
The Contractor shall arrange for such testing at his cost as may be required to be carried out at the place of manufacture
according to this Specification. If there are no facilities at the place of manufacture for making the prescribed tests the
Contractor shall bear the cost of carrying out the tests elsewhere or avail third party to carry out such tests.
The Contractor shall supply test certificates and shall furnish and prepare the necessary test pieces and samples and shall
supply and provide all test rigs, equipment appliances, labour and any other facility required for inspection and testing.
During the duration of the Contract, the Contractor shall propose a schedule for two inspection visits to the pipe
manufacturers’ yard by three representatives of the Employer and the Engineer during the manufacturing and pre-
shipment stages.
C.3.7.1.5 Third Party Inspection of Manufacturers with ISO 9001/9002 Accreditation
As quality assurance is of utmost importance to ensure extended asset lives, all manufacturers of pipes and fittings shall
have facilities to conform to international standards and also carry out tests related to manufacturing process, finished
products and handling to shipment.
In the event during inspections and tests carried out in presence of the Employer and Engineers show inadequacies in
the manufacturing process resulting in non-conformance finished products to an unacceptable level, the Employer will
deploy his agent or third party inspector to carry out independent third party inspection.
In such an event the supply and incorporation of materials from such source shall be stopped immediately until further
notice and the Contractor shall instead provide materials from another approved source. The Contractor shall be required
to replace at his cost all the rejected materials including the cost of this inspection in the event such third party inspection
reveal non-conformance in manufacturing and quality standards. The inspectors shall be provided with full access to
carry out third party inspection including the use of the in-house testing processes.
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C.3.7.1.6 Acceptance of Pipes, Valves and Fittings

Only pipes, valves and fittings that are manufactured using acceptable materials, tested and delivered by firms which
had been proven at the time of Bid to be listed under the ISO standards hereinabove provided for, or alternatively, pipes,
valves and fittings, which have been certified as acceptable subsequent to Third Party Inspection as herein provided,
shall be accepted as conforming to the Contract. Any other pipes, valves and fittings, shall be liable for rejection at the
Contractor's risk, cost and responsibility.
Compliance with the provision of this Clause shall be separate and additional to the Contractor's compliance with the
requirements of Tanzanian customs authorities for pre- or post-shipment inspection of imports into Tanzania. The costs
for such inspection shall also be fully borne by the Contractor.
C.3.7.2 Ferrous Pipes
C.3.7.2.1 General
For ferrous pipes, emphasis is placed on corrosion protection and therefore no compromise will be accepted in pipe
thicknesses, lining and coating, so that the asset life is extended beyond 40 years. Unlike plastic pipes, ferrous pipes can
withstand external pressure and therefore the bedding requirements are less stringent provided however they do not
negatively affect the coating. It is important therefore for the Contractor to ensure that their ferrous pipe manufacturers
are able to supply pipes and fittings with the specified lining and coating materials and that the manufacturing unit from
where pipes are manufactured have at least five years of successful track record in supplying pipes with the required
lining and coating materials. The manufacturer shall also be able to demonstrate that the lining and coating materials
and application provided withstand all the necessary tests as detailed in this specification.
It is important that all international and latest updated standards are applicable for ferrous pipes so that the asset useful
lives are enhanced by providing more robustness and superior lining and coating materials. Standards that provide
superior materials shall therefore apply.
Except where otherwise specifically indicated, all ferrous pipes of DN 80 and above shall be barrier coated.
C.3.7.2.2 Ductile Iron Pipes and Fittings - Materials and Standards

Ductile iron pipes and fittings shall generally comply with ISO 2531:2009or any other equal national or international
standards.
Socketed Pipes
Ductile Iron socketed pipes shall be centrifugally cast in accordance with BS 8010 section 2.1 and EN 545. The minimum
tensile strength shall be 420 N/mm2 and the minimum 0.2% proof stress shall be 300 N/mm2. The minimum elongation
after fracture shall be 10% for nominal diameters DN 60 to 1000 and 7% for nominal diameters DN 1200 to 2000.
All pressure class pipes shall comply with the appropriate allowable operating pressures stated in ISO 2531:2009.
The Contractor shall excavate trial pits along the proposed pipe alignment to a depth of not less than 2.0 metres and
describe in detail or determine the appropriate native soil modulus for each section of pipe, and manufacturers/
contractors will have been required to submit, detailed calculations for the design of the pipe based on these findings.
For pipe sizes DN 300 and greater, the Contractor shall determine the native soil corrosion characteristics in accordance
with DIN 50929 to confirm whether the specified pipe coatings provide adequate protection in keeping with an expected
life of 40 years.
Socketed Joints
Socketed joints shall be of the push-on type to EN 545: 2010 and ISO 2531:2009 unless otherwise specified. The material
used for the rubber gaskets shall be either natural rubber or synthetic elastomer to EN 681 and EN 682, and they shall be
stored in accordance with EN 2230.
As an alternative, DI pipes and fittings between sizes DN 300 to DN 600 mm may have sockets suitable for bolted gland
joints to EN 545.
Flanged Pipes
Ductile Iron Flanged Pipes shall be centrifugally cast to EN 545: 2010 and ISO 2531: 2009.
They shall be joined using a rubber gasket of minimum thickness of 3 mm which shall be reinforcedunless otherwise
indicated on drawings or in Schedule of Prices and Unit Rates. The material used shall be eithernatural rubber or
synthetic elastomer in accordance with EN 681 and EN 682, which shall be stored inaccordance with EN 2230.
C.3.7.2.3 Fittings
Ductile Iron Fittings shall be sand cast in accordance with EN 545: 2010 and ISO 2531: 2009. The minimum tensile
strength shall be 400 N/mm2 and the minimum 0.2% proof stress shall be 300 N/mm2. The minimum elongation after
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fracture shall be 5%. All fittings shall be subjected to a works leak-tightness test using water to a pressure as given in
EN 545.
Fittings pressure ratings shall be appropriate to the operating conditions.
They shall be protected with a fusion-bonded epoxy, thickness range 305 minimum to 406 micron maximum.Socketed
fittings, except for collars, shall be supplied with push-on joints unless otherwise called for. Collars shall be supplied
with mechanical joint.
Flange fittings shall be fixed by rubber gaskets as indicated above for flanged pipes.
C.3.7.2.4 Marking
Each pipe, fitting or accessory shall bear the mark of the manufacturer, and indication of its casting and be marked with
its nominal diameter. As appropriate, each fitting shall bear an indication of its main characteristics. Pipes, fittings and
accessories with a nominal diameter of 300 mm or more shall also bear the year of manufacture. In addition, a referencing
system shall be employed by the manufacturer denoting where pipes and fittings are to be stored and located along the
route of the pipeline.
C.3.7.2.5 Internal and External Protection
Contractors can specify as option other lining and coating materials with evidence and supporting standards that they are
superior and more robust. Contractors should also demonstrate that their manufacturers have good and long track record
of providing such coating and lining materials.
Pipe Coating
All coating for ductile iron pipes shall be barrier coatings and conform to DIN 30675 Part 2 for Type III soil or equal
unless specifically indicated otherwise.
The coating for urban environments and coastal areas for Ductile Iron Pipes shall be a factory applied heat fused
Polyethylene Coating to DIN 30674 pt 1 either by extrusion or sintering, or by any other similar material of superior
coating.
For rural environments and non-coastal areas, Ductile Iron Pipes, as a minimum requirement, shall be externally
protected by a metallic zinc spray coating to DIN 30674 pt3 applied directly to the warm film after annealing and covered
by a layer of bituminous varnish to ISO 8179-2 but shall only be used with an anodic embedment backfill material in
accordance with DIN 30675 Part 2 for Type III soils to the approval of the Engineer, and his price will be deemed to
have included for the cost of this. The mass of sprayed zinc metal shall be not less than 130 g/m2 and the thickness of
the bituminous varnish not less than 70 microns. Such a coating shall not be offered for urban environments and coastal
areas, or for soils with a pH value under 6, nor for peaty, boggy, silty or marshy soils.
Where the coating offered comprises zinc and bituminous varnish, a final coat of whitewash shall be applied generally
in accordance to BS 7873 to reduce heat absorption. The pipe manufacturer shall also provide a polythene sleeve for site
protection purposes. The sleeve shall conform to EN 14628 EN 14628and be of minimum thickness of 200 microns.
In the event that corrosive soils are encountered in rural areas, then the pipes shall be externally protected by a factory
heat applied fused polythene coating by extrusion or sintering, to DIN 30674 Part 1 or equal.
For pipe sizes less than DN 300, if in the opinion of the Engineer native soil corrosion characteristics are worse than
allowed for, the Engineer may require additional protection in addition to anodic backfill materials, pipe sleeving, or
pipe wrapping. For pipe sizes DN 300 or greater, the Contractor shall determine the native soil corrosion characteristics
in accordance to DIN 50929 to confirm whether the specified pipe coatings provide adequate protection in keeping with
an expected life of 40 years.
The Contractor shall test along the alignment of the pipeline to a depth not less than the depth of the required trench.
Where in the opinion of the Engineer, native soil corrosion characteristics are worse than the expected, the Engineer may
require additional protection to be provided involving measures such as anodic backfill material, increased standard of
pipe coatings, pipe sleeving, pipe wrapping or cathodic protection. The Contractor shall be compensated for additional
protection against corrosion required by the Engineer.
Pipe Lining
Ductile Iron Pipes shall be internally lined with a cement mortar, centrifugally applied and conforming to EN 545 and
DIN 2880.
Where the water being carried is specified as being aggressive, the internal face of the cement mortar shall be further
protected by a factory applied epoxy coating.
Coating and Lining Tests
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Tests indicating the durability and robustness of the lining and coating shall be carried as specified in DIN 30670, DIN
30675, and DIN 30678 or equal, and in accordance with the coating and lining specifications.
The supplier shall certify that their lining and coating materials conform to these tests and shall provide the Contractor
testing instruments and train technician to operate the instruments for carrying out these tests in Dar es Salaam.
C.3.7.2.6 Steel Pipes and Fittings - Materials and Standards

Steel pipes and fittings shall generally comply with EN 10224: 2002, ISO 559, AWWA C200, and other international
standards that specify superior pipe thickness and lining / coating materials. All latest and updated international standards
pertaining to steel pipes and fittings shall apply.
For diameters not exceeding 300mm, and for pressure rating of up to 12 bars, the minimum steel grade shall be APL 5L
Grade B. For diameters exceeding 300, and pressure rating exceeding 12 bars the minimum steel grade shall be APL
5L X42.
Standard Pipes and Fittings
Specifically steel pipes shall dimensionally conform to BS 534 and EN 10224, and in terms of materials, properties and
tests to BS 3600 and BS 3601 and EN 10220, EN 10216 and EN 10217, and where appropriate EN 10255. Fittings shall
in general conform dimensionally to BS 534, AWWA C208-01 and AWWA M11, however where specifically required
the lengths of straight barrel sections may exceed or be less than standard dimensions. They shall be manufactured from
pipes that have been manufactured to BS 534, EN 10224, BS 3660, EN 10220, EN 10216-1, or EN 10217-1, and
successfully passed all mechanical, dimensional visual, pressure and non-destructive testing. All new welds made during
the fabrication of the fitting shall be subject to non-destructive testing using either radiological, ultrasonic or dye
penetrants dependent as per the table C.3.7.2.6 and upon the geometry of the weld. Where necessary, fittings shall be
reinforced in accordance with AWWA C208-1 and AWWA M11.
Table C.3.7.2.6
Type of tests on weld quality on pipes at site
SN Pipe (DN) Type of test
1 From DN 80mm Upto DN 700 dye penetrants test
2 From DN 800 And above Ultrasonic test
Fitting ends for use with flexible couplings shall be true ended with the ends appropriately prepared for the type of
coupling required.
Joints for site welding shall comprise a socket and special spigot (bell joint with air chamber) to BS 534 or EN 10311
such that the lining of the spigot shall be undamaged during the welding.
All bolts shall be hot dipped zinc coated and those for bolted sleeve couplings further protected with a topcoat of
aluminium pigmented organic epoxy to their respective standards, unless otherwise indicated on the drawings or in the
Schedule of Prices and Unit Rates.
The Contractor shall demonstrate that the thickness and steel grade provided in accordance with ISO 559 gives a
thickness adequate for the pressure calculated in accordance with EN 1295. The thickness calculation shall take into
consideration the following: the operating pressure, test pressures, pressure transients or surges if applicable, external
pressures, steel pipe strength characteristics, temperature, soil condition, trench width and depth and appropriate traffic
loads.
The Contractor shall excavate trial pits along the proposed pipe alignment to a depth of not less than 2.0 metres and
describe in detail or determine the appropriate native soil modulus for each section of pipe, and manufacturers/
contractors will have been required to submit, detailed calculations for the design of the pipe based on these findings.
Manufacture of Steel Pipes
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The manufacturer shall operate a quality system relating to the manufacture of pipes, and integral joints to the
required specification that shall be no less rigorous than that of EN ISO 9002 to ensure that products consistently
meet the required level of quality.
C.3.7.2.7 Flexible Joints For Steel Pipes
Steel pipes from DN 65 to DN 500, outside chambers, may be plain ended suitable for jointing with flexible couplings
and flange adapters or grooved for thrust-transmitting self-sealing joints, or with socket and spigot with rubber gaskets
as described herein and as indicated in the Schedule of Prices and Unit Rates. Steel pipes from DN 550 upwards shall
be plain ended suitable for jointing with flexible couplings and flange adaptors or with socket and spigot with rubber
gaskets where the joint is specifically approved in advance. Steel pipes within chambers shall be suitable for jointing as
shown on Bid Drawings. Contractor may other type of joining method which shall be reviewed and approved by the
engineer at no additional cost.
Flexible joints shall be bolted sleeve couplings to BS 534 and EN 10311 or flexible grooved joints, with a tapping boss
to BSCP 2010-2 or AWWA C606, and of approved pattern. Flexible couplings shall be coated with fusion bonded epoxy
layer 350 microns thick. Flexible couplings shall be of a mechanical type coupling consisting of a centre sleeve, two end
ring flanges, two wedge shaped sealing rings of Nitrile rubber, and with galvanised nuts and bolts. The main components
shall be made from hot rolled steel for larger diameters and malleable cast iron to EN 1562 or ductile iron for smaller
diameters. If specifically called for, couplings shall be provided with a suitably sized screw plugged hole in the sleeve to
allow for the introduction of molten bitumen for additional internal protection. The manufacturer shall then include the
necessary removable internal backing-up rings of rubber composition and shall further include for all materials for in-
situ jointing and protecting both for remedial works and for internal and external protection at such joints. After jointing,
the exposed part of the bolt shall be provided with a tight fitting polythene protection cap unless capped nuts are used.
Where a manufacturer opts for steel pipes with socket and spigot joints, or such joints are specifically called for, such
joints shall in general conform to BSCP 2010-2, AWWA C200-97 or EN 10224, and the manufacturer shall submit
calculations that the natural sag under 1.5 m of soil load with 90% compaction and a parked vehicle (wheel load and
overload as defined above) will not exceed 2.0% on the spigot end of the pipe with the coating and lining as specified.
The socket and spigot assembly shall be capable of withstanding a works test pressure of not less than 1.5 times the
nominal pressure of the pipeline unless indicated otherwise on the Bid Drawings or in the Schedule of Prices and Unit
Rates. Sockets shall be produced integral with the pipe and be hot formed. Rubber gaskets shall conform to EN 681.
Unless a high pressure seal, they shall have a front lip for dirt removal and a back lip for pressure sealing. Unless
otherwise indicated, the internal faces of the sockets shall be coated in fusion bonded or liquid epoxy. A tight clearance
shall be maintained between socket and spigot and should be in the range 1.6 mm +/- 0.8 mm.
C.3.7.2.8 Flanged Joints

Where specifically called for or deemed appropriate, flanged joints shall be utilised. They shall conform to EN 1092,
drilled to NP 10 except where otherwise indicated, with gaskets made of reinforced elastomer rubber to EN 1514 and of
minimum thickness of 3 mm. They shall be stored in accordance with EN 2230.
Bolts for flanged joints shall conform to ISO 4014-1 threaded to BS 3643, nuts to EN 24032 or ISO 4032 and washers
to BS 4320. Bolts, nuts and washers shall be protected to ISO 4032 or EN 24032 for above ground installation and to
BS 3382-7 for below ground installation and in chambers. Nuts for use with self-sealing joints for steel pipes shall be as
described under the section for service connections. Exposed threads of all bolts shall be fitted with a tight plastic cap
after flange assembly the flange.
C.3.7.2.9 Internal and External Works Protection
Contractors may specify as option other lining and coating materials with evidence and supporting standards that they
are more superior and robust. Contractors should also demonstrate that their manufacturers have good and long track
record of providing such coating and lining materials.
Pipe Coating
All coatings shall conform to DIN 30675 Part I for Type III soil or equal and coating thickness shall conform to DIN
30670 or equal unless a less rigorous type soil is indicated.
All coatings for DN 80 and above shall be of the factory applied barrier type.
The preferred coating for buried steel pipes shall be factory applied external protection with triple layer polythene coating
(3LPE) to EN 10288 and DIN 30675 Part I for Type III soil comprising triple wrap system of fusion bonded or sprayed
epoxy primer, an intermediate polymer adhesive layer and an extruded polyethylene coating providing an overall total
film thickness shall not be less than that specified in EN 10288 or its equal unless single layer fusion bonded epoxy to
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EN 10289 is indicated in the Schedule of Prices and Unit Rates. The epoxy thickness should be sufficient to provide a
holiday free surface.
For above ground steel pipes a triple layer polypropylene coating (3LPP) with polypropylene to EN 10286, AWWA-
C215 or DIN 30678 shall be used, unless single layer fusion bonded epoxy is indicated.
Where a 3LPE or 3LPP coating is specified, the manufacturer shall demonstrate that the adhesion of the coating to the
substrate does not lessen to extent that the PE coating could be easily cut or removed with time underground. The
manufacturer shall carry out abrasive blast cleaning immediately before applying epoxy primer during the same work
shift. In the case where steel plate or bare steel pipe is transported by sea to the place where coatings are applied, the
steel or bare steel pipe as the case may be shall be subject to abrasive blast cleaning as well as phosphoric acid washing
or chromate treatment immediately before applying epoxy primer during the same work shift.
The polyethylene offered shall be HDPE.
For pipe sizes DN 300 and greater, the Contractor shall determine the native soil corrosion characteristics in accordance
with DIN 50929 to confirm whether the specified pipe coatings provide adequate protection in keeping with an expected
life of 40 years. The Contractor shall test along the alignment of the pipeline to a depth not less than a depth of the
required trench. Where in the opinion of the Engineer, native soil corrosion characteristics are worse than expected, the
Engineer may require additional protection to be provided involving such measures as increased standard pipe coatings,
pipe sleeving, pipe wrapping, or cathodic protection. The Contractor shall be compensated for additional protection
against corrosion required by the Engineer.
Protection to site welded joints shall be by a solvent free epoxy coating to AWWA C210-97 or a tape wrap to AWWA
M11 as indicated in the Schedule of Prices and Unit Rates or offered by the manufacturer.
Pipe Lining
For sizes less than DN 80, pipes may be protected by hot dipped zinc (galvanised) coating to EN 10240, and all buried
pipes shall in addition be protected by an organic coatings such or a factory applied extruded polyethylene or by
bituminous or epoxy paint in at least two coats, or alternatively in rural areas only if the risk of subsequent damage is
regarded as very low by a tight fitting and strapped polythene wrap. In addition all threaded joints and any exposed
threads as well as joints incorporating bolts shall be further protected after jointing, and should first be thoroughly
cleaned, prepared and then wrapped in a suitable adhesive tape.
For sizes DN 80 up to and including DN 300, pipes shall either be protected internally in cement mortar or epoxy at the
manufacturers stated option. Cement mortar lining shall conform to BS 534, DIN 2880-1 or AWWA C205. Where the
water being carried is specified as being aggressive, the internal face of the cement mortar shall be further protected by
a factory applied epoxy coating.
For sizes above DN 300 pipes and fittings shall be lined in fusion-bonded epoxy conforming to ANSI/ AWWA C213-
96 or Liquid Epoxy conforming to EN 10339 unless otherwise directed by the Engineer.
If specifically called for elsewhere in this Bid Document, for pipe sizes DN 300 and above, the Contractor shall excavate
trial pits along the proposed pipe alignment to a depth of not less than 2.0 metres and describe in detail or determine the
appropriate native soil modulus for each section of pipe, and manufacturers/ contractors will have been required to
submit, detailed calculations for the design of the pipe based on these findings.
Fittings - Coatings and Linings
Fittings shall be protected externally and internally by fusion-bonded epoxy to EN 10289, or AWWA C213 as specified
by the manufacturer or required in the Schedule of Prices and Unit Rates.
Flexible couplings and self-sealing (grooved) couplings shall be protected externally and internally by fusion-bonded
epoxy to EN 10289.
Self-sealing (grooved) coupling shall, where specified or otherwise allowed, conform to AWWA or BSCP 2010-2. Bolts
and nuts for such couplings shall be hot dipped zinc coated and capped nuts shall be provided. Bolts shall be an exact
pre-determined length so that no bolt thread is exposed but so that the capped nut fully tightens without bearing down
on the top of the bolt.
If specifically called for, a polythene sleeve to ISO 8180 protruding not less than 50 cm on each side of the joint shall be
provided around all flexible couplings outside chambers during underground laying so as to further enhance joint
protection, and shall be of minimum thickness of 200 microns. Such sleeves shall be tightly double-strapped at either
end using a non-metallic strap.
Coating and Lining Tests
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Tests indicating the durability and robustness of the lining and coating shall be carried out as specified in DIN 30670,
30675, 30678 or equal and where relevant to the coating or lining in accordance with the requirements of the coating
and lining specifications.
The supplier shall certify that their lining and coating materials conform to these tests and shall provide the Contractor
testing instruments and train technicians to operate the instruments for carrying out these tests in Tanzania, or if agreed
at the manufacturer’s premises elsewhere.
All coating and lining shall be on site tested for holiday free surfaces using the holiday testers. No pipe shall be laid
having failed the holiday tests.
The Contractor shall be compensated for additional protection against corrosion required by the Engineer.
C.3.7.2.10 Galvanised Steel Pipes and Fittings
Materials and Standards

Hot dipped zinc (galvanised) steel pipes shall only be provided where specifically allowed for in the Schedule of Prices
and Unit Rates and then only in diameters less than DN 80. An acceptable alternative to GS pipes in the diameter range
DN15 mm to DN65 mm is to replace the zinc coating by either a coating of FBE or PE (if necessary after grit blasting
off the zinc), with jointing then made using either similarly protected flexible couplings or flexible grooved joints.
Only heavy or medium duty pipes that as a minimum meet the requirements of the now withdrawn standard BS EN
10255:2004 shall be supplied and all buried pipes shall be wrapped in a polyethylene sleeve. Where threaded joints are
included, the maximum working pressures for GS pipes as given in BS 1387 shall be reduced by 40%. Because threaded
joints are also the weakest point of such pipes both in terms of pressure and corrosion risk, especial care shall be taken
after laying at all such joints.
EN 12502-3:2004, entitled “Protection of metallic materials against corrosion” shall be consulted during design and if
necessary, the minimum thickness of galvanising increased accordingly.
In addition joints, and any exposed threads, should be cleaned, prepared and wrapped in a suitable approved adhesive
tape in accordance with the tape manufacturer’s instructions. In preparing the joint for wrapping and after cleaning this
shall include the application of proprietary mastic adjacent to each side of the socket, tapered up from the pipe to the
socket so as to present a smooth transition between diameters of pipe and socket and facilitate the application of the
wrapping.
C.3.7.3 Unplasticised PVC (uPVC) Pipes and Fittings

PVC pipes and fittings shall be manufactured and installed in accordance to ISO 4422 and EN 1452. Preference shall be
given to uPVC pipes that are not stabilised by lead, tin or other heavy metals. However, where they are then tests in
accordance with DIN 8061, and EN 8063 must produce acceptable results.
Other related standards for pipes and joints of uPVC are given in BS EN 1452, EN 1452 and BS 4346. For laying,
jointing and pressure testing they shall conform to the relevant sections of BSCP 312-2, and for quality control to DIN
8061 and EN 921. They shall be transported, laid, jointed and backfilled in accordance with the manufacturers written
instructions except where this specification is more rigorous in which case this shall be followed.
To ensure that the Employer benefits from superior materials with enhanced useful life, at all times, latest and updated
standards and procedures for design and installation shall be used and adopted but governed by cost effectiveness. In the
same context the Contractor may provide, with the approval of the Engineer, superior materials using other standards
not listed here provided that they do not affect costs or programme and that they can demonstrate the superiority of the
materials through tests and guarantee certifications.
All PVC joints shall be of the spigot and integral socket type. Solvent weld joints or joints with adhesives are not
permitted.
“Bulking up” with Chalk or use of any rework material during manufacture of uPVC pipes is however strictly forbidden
and the Manufacturer shall provide certification to this effect.
The Contractor shall supply pipeline materials to the pressure classes referred to on the Drawings and in the Schedule of
Prices and Unit Rates. In all cases minimum cover shall be 900mm and the bedding shall be restricted to S1, save that
S2 bedding may be used with the approval of the Engineer, but only if he is fully satisfied with the Contractors initial
performance in regards to excavation, embedment, compaction and backfilling.
The maximum allowable deflection after laying of thermoplastic pipes shall be 2%.
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Where specific design is carried out during construction, the equivalent pressure rating shall be calculated taking into
consideration: the operating and test pressures, surges if applicable, external pressures, uPVC pipe strength
characteristics, temperature, soil conditions, trench width, depth, appropriate traffic loads and impact fatigue.
The pressure rating shall be determined by the Contractor to suit the specific application. However the minimum pressure
rating shall be 10 bars.
The following subsections are related to manufacturing, handling, transportation and storage of uPVC pipes and fittings
and shall be in conformance to ISO 4422 and EN 1452–5.
Manufacture of uPVC Pipes and Fittings
All the fittings to be used with uPVC pipes shall generally be steel or ductile iron fittings, and shall have socketed joints.
Injection moulded uPVC bends and tees shall be allowed with prior approval of the Engineer. Steel fittings shall meet
the requirements of BS 3600, BS 3601, EN 10220, EN 10216 and EN 10217.
Aluminium alloy fittings are not permitted.
Suitability of Production Process to meet Long Term Minimum Required Stress
The Contractor shall ensure that his pipe manufacturer is capable of meeting the minimum required stress (MRS) in
Long Term Hydrostatic Tests and shall have carried out such a test in the past 36 months in accordance to appropriate
standards. Such tests shall also have been carried out by the manufacturer at 20º C over at least 10,000 hours with 18
data points, and the minimum required stress for 50 years at 20º C by extrapolation shall be 25MPa.
Quality Control Records
The Contractor shall ensure that the manufacturer keeps accurate records of all types of component raw materials such
as polymer powder, additives, stabilizers, lubricants, etc. Used in the manufacture of uPVC pipes, together with detailed
manufacturer’s test reports carried out on the raw materials, date produced and date received, and batch or lot numbers.
During production, records shall be kept for mixing ratios of all the components used in the uPVC blend and these
mixing ratios shall not be changed without the prior approval of the Engineer.
Pipes shall each be identified individually by a unique number. Such numbers shall be recorded along with the Blend
and Lot number they were manufactured from.
The pipe lot shall be the pipes manufactured during a work shift. The Contractor shall state in its bid the length of shift
the manufacturer intends to use. The number of pipes in a lot shall be the number of pipes manufactured during the
specified shift period.
Polymer Certification
The manufacturer shall state for each batch and lot of pipes and fittings manufactured the K value of the polymer which
shall have certifications from the polymer supplier. If required by the Engineer, tests will be carried out to determine the
K value is in accordance with the relevant standards.
Inspection and Testing during Production
The manufacturer shall be carrying out the necessary inspections and tests during production in accordance to the relevant
ISO standards and such tests shall include all tests relevant for uPVC pipes and fittings as required by BS 2782; and EN
921.
The number of pipes to be tested and the frequency of testing shall be in accordance with SABS 966-1.
Inspection of Pipes and Fittings
The inspection will consists of visual examining the external surfaces of the pipe that must smooth and free of the
following defects:
i) grooving
ii) blistering
iii) scoring (scratches)
iv) cavities
v) impurities
other surface defects which will be deleterious defects
In addition the pipes will be inspected for correct chamfering at 15° to half the wall thickness on the spigot end and
squareness of both ends to the pipe longitudinal axis.
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The numbers of samples that do not comply with the above requirements during inspection shall not exceed the quantities
given in the relevant standards.
Testing of Pipes and Fittings
For each lot, the pipes and fittings shall be tested at the factory before shipment in accordance to the relevant ISO
standards such as ISO 11922, ISO 2507, ISO 3126 / 3127, ISO 9852, ISO 1167 among others for softening temperature,
resistance to creep, pipe dimensions, ovality, thermal reversion, resistance to dichloromethane, freedom from toxicity,
hydrostatic pressures, vacuum, fracture toughness and resistance to impact etc. The whole Lot will be rejected if the
quantity of non-compliant pipes exceeds the acceptable level.
Marking of Pipes and Fittings
Each Pipe or Fitting shall be marked clearly with indelible ink with the following data:
i) the manufacturers trade name or trade mark
ii) the designation uPVC
iii) the pressure class and/or SDR ratio of the pipe
iv) the nominal diameter of the pipe
v) the individual pipe number or fitting number
vi) the week number of manufacture
vii) the Lot Number the pipe belongs to
viii) the Blend Number the pipe belongs to
Release from Manufacturer’s Works
No uPVC pipes and fittings shall be released from the manufacturer’s works until all tests results on the particular Blend
and Lot it belongs are in conformance with requirements. No pipe shall also be delivered before a full lapse of 6 weeks
from its production to allow for positive results of accelerated resistance hydrostatic test pressure testing.
Determination of Pipe and Socket Wall Thickness
All pipes shall be manufactured in accordance to ISO 4422 and EN 1425 and the pressure rating design stated or based
on specific design using the internationally acceptable design code of practice for uPVC pipes.
The Contractor shall demonstrate and obtain approval from the Engineer that the pipe thickness proposed achieve the
necessary operating and test pressures, and can withstand the external pressures and that they are in conformance with
the acceptable international standards for the purpose of its use in this project
Pipe Lengths
Pipes shall be in effective lengths (i.e.. overall length minus the depth of engagement in the socket) of not exceeding 6.0
m length.
Pressure Classification
All uPVC Pipes supplied shall be classified by their PN operating pressure rating and their SDR ratio as required under
this contract.
Protection of Fittings used with uPVC Pipes
All types of fittings shall be protected in conformance to their respective required standards.
i) Protection of extruded uPVC fittings - Protection shall be in conformance to ISO 2035, 2034-5 and
2048 and their other respective standards
ii) Protection of Steel Fittings: - Steel fittings shall be coated and lined with fusion bonded epoxy to EN
10289 with a thickness of between 305 to 406 microns. In addition, for transport, fittings shall be
shrink wrapped in 0.2 mm polythene packing to reduce the risk of transport damage
iii) Protection of DI fittings: - DI fittings shall be coated and lined with fusion bonded epoxy to a
thickness as for the steel fittings above and shall similarly be shrink wrapped in 0.2 mm polythene
packing for transport
C.3.7.4 High Density Polyethylene Pipes and Fittings
HDPE (PE100) pipes and fittings shall meet the requirements of BS 3284, BS 5114, EN 12201 Parts 1,2, and 5, ASTM
D2565 All manufacturing shall be in accordance to ISO 4427 and materials used shall be in conformance to ASTM
D2122.
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HDPE pipes shall be transported, laid, jointed and backfilled in accordance with the manufacturers written instructions
except where this specification is more rigorous in which case this shall be followed.
At all time, latest and updated confirmed standards and procedures for design and installation shall be used and adopted.
This will help ensure that the Employer benefits from superior materials with enhanced useful life. In the same context
the Contractor may provide with the approval of the Engineer superior materials using other standards not listed here
provided they can demonstrate so through tests and guarantee certifications.
The polyethylene used shall be of a high molecular type with average to high density. Not less than Third Generation
polyethylene known as PE 100 shall be used for the manufacture of the pipes. Second Generation polyethylene (PE 80)
shall not be offered. The polyethylene shall be stabilised against the effects of ultraviolet radiation by the addition of
carbon black.
The Contractor shall provide pipeline materials to the pressure classes and SDR ratios referred to on the Drawings and
in the Schedule of Prices and Unit Rates. Unless otherwise indicated on Bid Drawings or in the Schedule of Prices and
Unit Rates, HDPE pipes shall not be used in any pumping mains or in outside diameters exceeding DN 300 mm and the
pressure ratings shall not be lower than PN 10.
In all cases minimum cover shall be 900mm and the bedding shall be restricted to S1 or S2 if specified by the Engineer.
Where S2 material is permitted, it may comprise or include screened ‘as-dug’ materials that meet this requirement.
Where specific design is carried out, the pressure rating shall be calculated taking into consideration the operating and
test pressures, surges if applicable, external pressures, HDPE pipe strength characteristics, temperature, soil condition,
trench width and depth, appropriate traffic loads and impact fatigue.
The maximum allowable deflection of HDPE pipes shall be 5% for electro-fusion joints and 2% for mechanical joints.
For diameters up to and including 110 mm, PE pipes can be supplied in coils of up to 100 m long. For coils of diameters
greater than 63 mm each layer shall be bound separately to facilitate safe unwinding. For diameters from 125 mm
upwards they shall be supplied in lengths not exceeding 12 m. Installation, including jointing (But / Electro fusion) work
on HDPE pipelines, must be directed and supervised by suitably qualified and experienced persons and the Contractor
shall have demonstrated his ability to provide this in his Bid, if necessary from his intended manufacturer.
Inspection and Testing During Production
The manufacturer shall be carrying out the necessary inspections and tests during production in accordance to the relevant
ISO standards and such tests shall include all tests relevant for HDPE pipes and fittings as required by BS 2782. Steel
fittings shall meet the requirements of BS 3600, BS 3601, EN 10220, EN 10216 and EN 10217.
The number of pipes to be tested and the testing frequency shall be in accordance with SABS 966-1.
Electro-Fusion Fittings
All HDPE fittings shall be injection moulded from recognised top quality PE 100 resin and will conform to EN 12201.
Where jointing or connection is not done by electro-fusion, joints shall be of the compression type, or alternatively
ferrous fittings connected by flange assemblies shall be used. Jointing with adhesives, cement glue or threaded joints is
not acceptable.
Fittings shall be suitable to be used in conjunction with pressure pipes from polyethylene manufactured to the appropriate
international standards, and all fittings must be packed in such a way as to allow their use on site without additional
cleaning.
The heating coils contained in each individual fitting and saddle should be so designed that only one complete process
cycle is necessary to fully electro-fuse the fitting to the adjoining pipe or pipeline component as applicable. No heating
element may be exposed and all coils are to be fully embedded into the body of the fitting for protection purposes.
The pipe fixation device shall be an integral part of the body for all fittings in the sizes up to and including nominal
diameter 63 mm and on saddles up to 250mm.
An individual data carrier card in compliance with EN ISO 7810 and EN ISO 7811 containing a magnetic strip and an
appropriate barcode or codes as well as manual setting information for data transfer purposes must be supplied with each
fitting.
All fittings must have moulded-in identification and appropriate product information. Fittings without such identification
will be rejected.
Process voltage of all fittings must not exceed a maximum of 39.5 volts.
Insulated contact heads for the terminal pins are to be provided, and terminal pin size shall be 4 mm in diameter.
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A limited path style fusion indicator acting for each fusion zone as visual recognition of completed fusion cycle should
be incorporated into the body of the fitting or saddle near or adjacent to the terminal.
The design of the fusion indicators must prevent the escape of fusion melt.
All couplers in the sizes up to and including nominal diameter 160 mm must have an easily removable centre stop not
requiring tools for removal.
All internal or externally threaded transition adaptors in the nominal sizes up to and including DN 63 must be designed
with an integrated polyethylene collar from PE 100 for jointing purposes not relying on rubber or synthetic seals for leak
prevention.
Threaded adapter bodies may be from brass or stainless steel and should be of the modular principle, not being supplied
moulded into an electro-fusion fitting socket.
Product Training and Technical Information
The manufacturer or the material supplier shall provide a specialised theoretical and active practical product training
given by qualified instructors to enable installers of the above mentioned products to be able to understand and use the
products correctly and efficiently under site conditions. The courses are to be held on the purchaser’s own premises upon
demand.
The manufacturer is to provide accurate and easy-to-understand assembly instructions in English which can be used at
any subsequent time for reference purposes.
C.3.7.5 Transportation, Handling and Storage

Packing for Transport
Pipes up to DN 300 may be bundled. Larger sizes shall be packed loose. Nesting of pipes is not permitted. Containerised
packing and transportation is also acceptable and if proposed shall be so indicated by the Contractor. All nuts, bolts,
rubber gaskets etc. shall be packed in wooden boxes and protected against the elements.
Fittings up to and including DN 200 mm and flanged pipe pieces up to DN 200 mm and length not exceeding 1 metre
shall also be packed and supplied in wooden boxes. All other fittings and flanged pipes may be packed loose. All flanges
shall be protected with discs of wood, wool, fibre or timber. Bolted gland joints and flexible couplings shall be bundled
if not containerised. Pipe sockets, spigots, plain ends shall be protected by suitable wrapping prior to transportation.
The Contractor shall further have described in his Bid in full detail the method(s) of offloading for imported items or on-
loading for locally manufactured ex-works items, the methods of road/rail transportation and of site off-loading including
the lifting methods intended. He shall further have described in his Bid in full detail the method(s) of stacking and
storage. His Bid shall also be deemed to have included for the transportation as described and for the provision of all
the necessary facilities for offloading at the storage sites, and for proper stacking and storage.
Storage Areas and Pipe Stacking
All pipes, valves and fittings shall be inspected upon arrival at the pipe storage areas for damage to:
i) the pipe or fitting itself
ii) external coatings (if any)
iii) internal linings (if any)
iv) jointing surfaces (incl. sockets if any)
The Contractor shall repair or replace defective pipes and fittings, at the Engineer’s option. All expenses in connection
with such remedial works or replacements shall be deemed covered by the Contractor.
At the time of Bidding the Contractor shall also have stated the approximate areas of land required for the offloading,
and stacking of the pipes and for the storage of the fittings and of any special protection / storage facilities needed for
any particular item(s).
The Contractor shall provide storage of pipes in a manner and in facilities approved by the Engineer. At the latter’s
discretion, ferrous pipes in diameters greater than 200 mm for laying in rural and peri-urban areas may be offloaded
directly in the vicinity of the pipe trench provided the conditions and stacking method meet the requirements indicated
below.
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For pipes of local manufacture, storage may be provided by means of a temporary fenced-off area at the manufacturers
premises, provided a Contractor in his Bid has so indicated his intention, and the area to be fenced off is shown to be
sufficient for the purpose.
Pipes shall be stacked at the pipe storage areas using one or all of the following methods.
i) square stacking for small diameter pipes
ii) parallel stacking using wooden roller boards
iii) pyramidal stacking
All pipes shall be stacked on raised wooden battens at least 100 mm thick and 225 mm wide. A minimum of three
battens per pipe for ferrous pipe lengths not exceeding 6 metres should be used with the outer battens laid 600 mm in
from both pipe end and the middle batten placed equidistant between them. For ferrous pipe lengths greater than 6
metres, four battens shall be used. Pipe stacks shall be suitably wedged and the Contractor shall be deemed to have
included for an adequate number of timber, wedges, etc., in his Bid.
uPVC pipes should be uniformly supported throughout their length or at not more than 1 m centres. Pipe stacks shall be
suitably wedged and the Contractor shall be deemed to have included for an adequate number of timber, wedges, etc., in
his Bid.
Where socket and spigot pipes are stacked, the sockets should be placed at alternate ends of the stack with the sockets
protruding.
Table C-19 indicates the maximum stacking height allowable:
Table C-19 Pipe Stacking
Nominal Pipe Diameter Maximum Number of Layers In Stack
Mm Ferrous pipes uPVC pipes
Up to 100 16 7
150 14 7
200 12 5
250 10 5
300 8 4
350 7 -
400 - 450 6 -
500 - 600 4 -
700 - 800 3 -
900 - 1400 2 -
In addition uPVC pipes shall not be stored out in the sun unless they are protected by a free-venting, opaque cover
(tarpaulin or black polyethylene). Except immediately prior to transfer to trench side, uPVC pipes shall not be stored at
temperatures exceeding 25ºC at all times, whilst the requirements of BSCP 312-2 shall be met with regards to storage,
handling and transport.
i) Vehicle used to transport uPVC pipes shall have flat beds free from projections. Pipes shall be
uniformly supported along their entire length and shall not overhang the end of the vehicle. Upright
side supports on vehicles shall be flat, at 2m spacing and free of sharp edges. Socket and spigot pipes
shall be stacked on vehicles in alternate layers so that the socket carries no load. Thicker wall pipes
shall always be loaded before thin wall pipes.
ii) Where uPVC pipes are delivered from abroad in containers, such containers shall not be exposed to
sunlight on their upper surface during either dockside storage or shipment and all pipes shall be
immediately removed and stored upon arrival on site. Site storage in the supply containers is not
permitted.
iii) Care shall be exercised in the transporting, handling, off-loading and loading of the pipes. For uPVC
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pipes, a minimum of two persons per pipe shall assist in the loading and offloading and pipes shall be
neither thrown down nor dropped or rolled.
iv) Concerning in-country storage, handling and transportation of HDPE Pipes:
v) Before transporting HDPE pressure pipes, the loading surface of the vehicle must be cleaned and free
from projecting nails, screws or other sharp objects. The bottom layer of all pipes must as far as possible
be in contact with the loading surface throughout their entire length and not project beyond it. The pipes
must be secured from slipping and shall not be pulled over sharp edges when loading and offloading.
Pipes shall not be dragged along the ground.
vi) Pipes, fittings and coils of HDPE pipes shall be stored in such a way that they are completely protected
from direct sunlight. When covered they must be well ventilated to avoid accumulation of heat and
resultant deformation. Transparent coverings shall not be used. The storage location shall be flat and
shall, for pipes, support the pipes throughout their length. Stones and sharp objects shall not be present.
Pipes shall not be stacked to a height exceeding 1 m. The pipes must be secured at the sides to prevent
them from rolling. Contact with harmful materials shall be avoided. As far as possible, coils shall be
stored in a horizontal position. The area shall be free of stones and sharp objects. If stored upright they
must be secured to avoid tilting.
vii) HDPE Pipes supplied in coils of up to 63 mm diameter may be unrolled with the coil in the vertical
position. For larger diameters an unwinding device shall be used. A turnstile can be used with the coil
laid in a horizontal position on it or with the coil mounted vertically on a slow moving lorry. The pipe
shall never be removed from a coil in a spiral manner as this may cause kinking. Should kinking
nevertheless occur the Contractor shall cut the pipe on either side of the kink, prepare the ends, and then
use an approved joint after laying. All costs of dealing with kinking shall be to the Contractors expense.
A minimum bending radii of 35 x the diameter shall be observed.
Distribution of Pipes from Storage
Ferrous pipes of ND 200 mm and less may be distributed from storage to the trench side no more than 7 days prior to
laying whilst ferrous pipes above ND 200 mm may be strung out up to 15 days prior to laying.
In all instances when along trench sides, ferrous pipes shall be supported within 1 metre of either end on sand filled bags
such that no part of the wall of the pipe touches the ground, and in the case of pipes over 6 metres long with additional
central sand bags.
All uPVC pipes shall be distributed to the trench side and laid without being out in the sun for more than the day of
installation unless they are to be protected from the sun’s rays in which case this period may be extended at the discretion
of the Engineer up to an absolute maximum of 5 days.
uPVC pipes shall then be supported at not less than three approximately equally spaced intervals so as to be fully clear
of the ground.
HDPE pipes shall be distributed to the trench side and laid without being out in the sun for more than the day of
installation unless they are to be protected from the sun’s rays in which case this period may be extended at the discretion
of the Engineer up to an absolute maximum of 5 days. Pipes not in coils shall then be supported at not less than three
approximately equally spaced intervals so as to be fully clear of the ground.
When pipes are being loaded into vehicles care shall be taken to avoid their coming into contact with any sharp corners
such as cope irons, loose nail heads, etc. Whilst in transit, pipes shall be well secured over their entire length and not
allowed to project unsecured over the tailboard of the lorry.
Pipes may not be offloaded from lorries by rolling them. Pipes shall not be rolled or dragged along the ground.
C.3.7.6 Excavation of Pipe Trenches

i) All trench excavation will, as a minimum precaution, be taped off to alert persons to its existence
ii) Excavations shall be made in open cut unless tunnelling or heading is specified by the Engineer
iii) The maximum length of open excavation shall not exceed 100 metres, except with prior written approval
of the Engineer.
iv) Trenches for pipes shall be excavated to the lines and depths shown on the Drawings, or as directed by
the Engineer, and shall be of sufficient width to give an equal clearance on both sides of the barrel of the
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pipe or pipes such that the total trench width is 3/2 'D' where 'D' is the outside diameter of the pipe, after
allowance has been made for timbering and strutting.
v) Lesser trench widths may only be authorised if the Contractor can prove to the satisfaction of the
Engineer that he can consistently achieve the required compaction for a lesser width. The minimum
trench width is OD + 600 mm
vi) For pipes bedded in concrete sections, the breadth of concrete bedding for the pipes will be equal to the
width of the trench. Excavation for fire hydrants, valve chambers or any other water works structure,
shall be carried out to the levels and outlines of such structures.
vii) Where pipes are not laid on concrete, the bottoms of the trenches as excavated, shall be smooth and shall
be free from stones or other projections. Holes cut out at pipe joints shall be as small as possible. The
trench shall be dug to within 15 cm of its formation and proper grade pegs shall then be set in the bottom
of the trench by the Contractor for the accurate taking out of the rest of the excavation. Grooves about 5
cm deep shall be cut across the trench at the required positions to enable the easy removal of pipe slings.
viii) Where an imported lower bedding layer is not included, and if instructed to do so by the Engineer, the
pipe trench shall be excavated to a depth of 10 cm below the invert of the pipe and be refilled with
suitable ‘as-dug’ material free from stones greater than 20 mm dia. and foreign matter and compacted to
a minimum 90% MPD in order to provide a smooth bed for the pipes.
ix) The materials excavated must not be placed so close to the edge of the trench as to impose a risk of
collapse of the trench walls. The excavation and trenching section of the site-specific Health and Safety
Management Plan should include criteria for the allowable conditions for placement of trench spoils, as
well as maximum trench depths and side slopes of unsupported trenches, requirements for trench shoring,
and restrictions on personnel working in unsupported trenches. During excavation, the Contractor shall
ensure that all material suitable for re-use and which he intends for re-use are kept separate and set aside
and protected as necessary to prevent loss or deterioration. Materials forming the surface and
foundations of roads shall when excavated and if required for further use, be carefully separated. Paving
slabs, bricks and similar surfaces shall be carefully removed and stacked for re-use, or as otherwise
instructed by the Engineer.
x) Where pipes are to be laid under a road formation or in open country, or in cutting, trenches shall
generally be excavated after the earthwork is completed. The Engineer may permit these pipe trenches
to be excavated before the earthwork is complete, but payment for the excavation of the trench will only
be made upon the volume excavated below the road formation.
xi) Trenches shall be bottomed up immediately in advance of pipe laying, although at least 15 metres shall
be prepared in advance of any given pipe. Trenches and joint holes shall be kept free from water, until
the pipes are laid and the joints completed and no ground water shall be allowed to enter the new pipes.
xii) If in the opinion of the Engineer delays in laying are due to the fault of the Contractor and the ground
becomes weathered prior to the laying of the pipes, the Contractor shall remove the weathered soil and
replace it with suitable compacted material to the original formation level at his own expense.
xiii) With the written approval of the Engineer, the Contractor may excavate rock in advance and temporarily
refill the trench with the excavated material until he is ready to proceed with the laying of the pipe.
xiv) Where the trench is in rock or rocky ground the Contractor shall excavate the pipe trench to a depth of
150 mm below the invert of the pipe and refill with compacted granular fill. The Contractor shall obtain
the Engineer's approval and instruction as to which sections of trench should be so treated.
xv) Rock in the form of boulders predominantly above ground level and located within 1 metre of the centre
line of the pipeline shall be removed, if required by the Engineer, who shall determine in each case
whether the removal of the boulder is necessary to achieve the required alignment or profile or to ensure
the future safety of the pipeline.
xvi) Where trench excavation is carried out behind existing thrust blocks, adequate support arrangements
shall be provided to transfer thrusts to the surrounding ground. No additional payment shall be made for
such support.
Headings
Where excavation for pipes in heading is permitted by the Engineer, it shall be carried out to the approval of the Engineer
and to dimensions which will permit a proper inspection to be made. The heading shall be properly and securely
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timbered. The pipe shall be laid on a minimum thickness of 150 mm of Grade C15P concrete. After the pipe has been
laid, jointed and tested the heading shall be filled in short lengths not exceeding 1 metre with Grade C15P concrete or as
directed. Great care shall be taken to ensure that the heading is completely filled with concrete and hard filling shall then
be rammed into the concrete at the crown of the heading. Special precautions shall be taken to prevent a slump in the
concrete and to ensure that no slips or falls of the heading or in the ground above or in the shafts can take place. The
Contractor shall allow for leaving in all timbering.
The Contractor shall be responsible for the proper restoration of any road surfaces, pipes, cables or other things or
property which may be damaged.
C.3.7.8 Pipe Installation
i) Pipes shall only be laid in the presence of the Engineer unless written authority from the Engineer has
been granted
ii) No pipes shall be laid, nor lower bedding placed, until the formation has been inspected by the Engineer.
The Contractor shall provide to the Engineer, a weekly schedule in advance indicating the dates and
approximate times he expects to request such inspections
iii) Pipes generally shall be laid and jointed in accordance with the manufacturer's instructions. Extra
excavation must not be carried out so as to avoid backfill, excessive deviation in joints and other
irregularities. Otherwise, the pipe grade will follow the Drawings, with a continuous (but not necessarily
uniform) fall towards washout-valves and rise towards air-valves.
iv) Prior to laying, damage to linings or coatings shall be repaired in accordance with the manufacturer's
instructions. Where, in the opinion of the Engineer, the damage to a pipe coating is significant and
notwithstanding the repairs made in accordance with the manufacturer’s instructions, the complete pipe
shall be further protected by a polythene sleeve. The sleeve shall conform to ISO 8180 for steel pipes
and EN 14628 for DI pipes and be of minimum thickness of 200 microns. It shall be strapped beyond
the joints of adjoining pipes using a non-metallic strap around the pipe.
v) If the damage is excessive and, in the Engineer’s opinion, cannot be adequately repaired the Contractor
shall replace the pipe(s).
vi) All costs of repairs to damaged coatings and linings, and / or replacement of individual pipes, shall be to
the Contractors account.
vii) For DI pipes, before lowering into the trench or placing in position each pipe or casting shall be slung
and sounded with a mallet to test for hair cracks. Pipes that do not ring true will be discarded. For ferrous
pipes with barrier coatings, the coating, and where appropriate the lining of every pipe shall be inspected
by use of holiday detectors in accordance with NACE RP 0490. Unless otherwise authorised in writing
by the Engineer to carry out such inspections in a nearby storage yard, such inspections shall be carried
out at the trench side immediately prior to lowering into the trench.
viii) Each pipe shall be thoroughly brushed inside and outside prior to laying and no foreign matter shall be
allowed to enter the pipe during or after laying.
ix) At the end of each working day the exposed pipe end shall be stoppered up with a stopper plug of
appropriate diameter and not merely covered in polythene sheet tied around the end.
x) Every pipe shall be laid separately and shall bear evenly upon the lower bedding or concrete for its full
length, holes to receive sockets, couplings or flanges being cut in the bottom of the trench of such size
and depth as to allow the joints to be properly made. The pipes shall be laid to true inverts, straight lines
and falls, each pipe being separately boned between sight rails.
xi) All flanged joints shall be made with jointing rings, which shall be carefully inserted concentric to the
bore of the pipe, so that undue stresses shall not be caused in any of the bolts or on the flanges when
bolting up. The joint ring shall be compressed gradually and evenly by taking a few turns on each
diagonal bolt in succession. Over-tightening shall be avoided. Where one or both of the flanges is itself
of plastic, torque-wrenches shall always be used, and the bolts shall first be hand tightened and then
diagonally tightened progressively to achieve 5%, 20%, 50%, 75% and finally 100% torque. For metal
to metal flanges and if the Engineer is dissatisfied with the degree of care being taken, the Contractor
shall provide and use torque-wrenches for this purpose at no extra cost.
xii) Mechanical joints shall be made in accordance with the manufacturer's instructions. After successful
testing of pipelines, the joints will receive external protection to the Engineer's approval.
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xiii) The threads of any screw connections shall be coated with red lead before the joint is made.
xiv) Concrete anchor blocks shall be provided at bends, tees, stopped ends, etc as shown on the drawings or
as directed by the Engineer.
xv) Where a pipeline crosses roads or railway lines, the pipe shall be sleeved or surrounded with concrete as
instructed by the Engineer, and Contractors shall have been deemed to have made allowance in their
rates at the time of Bidding for compliance with the requirements of the relevant authority.
xvi) For the insertion of valves and other fittings into existing pipelines, pipes may need to be cut. Approved
tools and machines specially made for the purpose, shall be provided and used by the Contractor.
xvii) The Contractor shall provide and fix wooden drumheads to the open ends of the mains, and similar
drumheads shall be used to close the ends of any pipes to exclude dirt and stones, etc. when the pipe
laying is not actually in progress. Wooden markers properly inscribed, shall be left projecting out of
the ground to indicate the ends of all pipes, where these are buried in the ground in open country. In
public highways, a danger sign or other suitable means as approved by the Engineer shall be adopted.
xviii) Marker tapes made of a pigmented low density polyethylene and aluminium foil in a bright colour or
other approved material not less than 100 mm wide and 0.15 mm thick shall be placed in the ground
above the uPVC and HDPE pipelines laid underground as a measure to detect the pipe and at the same
time to reduce the risk of accidental damage which may be caused by future excavations. The tape shall
be laid about 300 mm above the crown of the pipe. The tape shall be continuously labelled with black
printing “DANGER-PLASTIC PIPE alternately in English and Kiswahili. The price tape shall be deemed
included in the price for the supply and installation of the pipe.
xix) For HDPE pipes supplied in coils, the pipe generally shall be laid and jointed in accordance with the
manufacturer's written instructions. A re-rounding and straightening tool shall be used prior to making
each joint. Extra excavation must not be carried out so as to avoid backfill, excessive deviation in joints
and other irregularities. Horizontal alignment shall be as straight and central to the trench as is
practicable, and if necessary, wooden pegs shall be used initially to ensure this until the upper bedding
has been compacted at which juncture they shall be carefully withdrawn.
C.3.7.9 Steel Pipelines

Welded pipelines
• Pipes and specials to be joined by field welding shall be supplied with ends bevelled for welding.
• Field welding of joints shall conform to BS EN 288-9:1999 or API 1104.
• Before welding of joints proceeds, pipe ends shall be completely circular and properly mated up by
means of backing rings.
• At least 4 tack welds equally spaced around the pipe perimeter shall be applied to maintain the root gap
and position of the pipe for completion of welding. A protective plastic or rubber sheet shall furthermore
be placed over the coating adjacent to the joints to protect same from damage caused by welding spatter.
• Root welds shall thereafter be carried out followed by successive filler passes, and capper passes, all in
accordance with the approved welding procedure.
• Wherever it is possible to have entry into a pipe, inside welds shall be applied first. The inner weld bead
shall not extend more than 1mm into the bore of a pipe or special.
• Horizontal weld seams or spiral weld seams at pipe ends shall be placed near the horizontal diameter of
the pipe or special and shall be staggered so that the circumferential distance between longitudinal or
spiral welds intersecting the same circumferential butt weld, is not less than 90mm nor more than 130mm
apart.
• Defects caused by stray welding arc flashes, weld spatter etc. shall be removed by grinding provided that
pipe wall thickness are not reduced to less than the specified minimum thickness, otherwise the portion
containing the defect shall be cut out and repaired.
• During welding of pipes with organic linings, mats of thick rubber felt or other suitable material shall be
placed along the pipe invert to protect the pipe lining for the full distance from the point of access up to
the point of weld or weld inspection. The mats shall be of sufficient width and shall cover a sufficiently
wide area of pipe invert to protect the lining against damage due to access by staff, equipment, inspectors
or fall out from arc weld. Workmen shall wear soft, rubber-soled shoes before entering lined pipes.
• Care shall be taken not to stroke arcs on epoxy-lined areas and protective tapes, if any, at ends of epoxy
lined pipes shall only be removed immediately prior to welding.
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• Pipes may be welded together alongside the edge of the trench. For factory lined and coated pipes, the
maximum length so welded together shall be such that:
• the pipe can be subsequently stored, lifted or handled without damage to linings or coatings;
• the out of roundness at a plane perpendicular to the pipe axis at any point along the pipe length during
storage, lifting or handling does not exceed 4% of the minimum inside diameter (out of roundness being
measured as the difference between the minimum and maximum inside diameter of the plane at the
point);
• safe and easy access to internal tie-in welds are assured for staff and inspectorate with equipment;
• the maximum length does not exceed 36m.
• Snaking into the trench of butt welded sections of pipe shall be permissible for bare steel pipes, subject
to approval by the Engineer of a complete and comprehensive method statement submitted by the
Contractor and provided that the out of roundness as defined and measured above during any stage of
the snaking operation, does not exceed 4% of minimum internal diameter.
• The linings and coatings of pre-lined and coated pipes jointed together outside the trench shall be made
good at these joints outside the trench.
•
Table C.3.7.9
Type of jointing (MS pipe) at site
Sn Pipe (DN) Type of jointing
1 From DN80 Less than DN300 external Welding only / (spigot and socket
as per the pipe availability)
2 From DN300 Less than DN900 external Welding only
3 From DN900 And above Internal and external welding
Pipelines with flexible couplings

• Joints by flexible couplings shall be made only in their final laid position. Before assembling the joint,
care shall be taken to ensure that pipe ends are clean and free from burrs and ridges. Such burrs and
ridges shall be removed if present and linings and/or coatings made good where damaged.
• Pipe ends shall be mated carefully before joints are made. Pipe ends shall be concentric and perfectly
lined up and the coupling shall not be relied upon to line up or to support the pipe.
• Joints shall be made and couplings assembled to the manufacturer's instructions. Bolts shall be placed
with bolt heads alternately pointing in opposite directions.
• Half of the coupling bolts, equally spaced, shall first be partially tightened up in a regular sequence,
using a short spanner. The remaining bolts shall then be similarly tightened. After checking the coupling
alignment, the bolts shall then be finally tightened evenly and in a regular sequence by means of a torque
wrench.
• Where couplings without central registers are used, precautions shall be taken to ensure that the pipe
ends are apart by the same distance as if a coupling with central register had been used and the couplings
shall be carefully centred over the pipe ends.
Flanged joints
• Flanges shall be truly parallel with all bolts evenly firm before being finally drawn up with torque
wrenches to water tightness. Taper gauges shall be used to check that there is a uniform gap before and
after final tightening up of bolts. Bolts shall be tightened in an approved sequence with bolts equally
spaced and at opposite ends tightened equally first.
• The Contractor shall ensure that the correct jointing materials, i.e. gaskets, bolts and nuts are available
when required. Only correct diameter and lengths of bolts and studs shall be used. Flat washers shall be
used under all nuts. The length of bolts and studs shall be such that at least two threads protrude from
the nut when fully tightened. The threads of bolts, studs and nuts shall be thoroughly cleaned and then
coated with a graphite/grease compound immediately prior to assembly.
• Flange faces shall be given two coats of an approved bituminous primer before mating.
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• Flanged fittings shall be so installed that there are no stresses induced into the pipe work, specials or
fittings by forcing ill-fitting units into position or by bolting up flanges with faces not uniformly in
contact with their gaskets over their whole faces.
C.3.7.9 Additional Protection of Joints on Ferrous Pipelines

The completion of the external protection at flexible joints on ferrous pipes and fittings shall be carried out as detailed
below as appropriate and shall be to the satisfaction of the Engineer. The costs thereof shall be deemed to be allowed
for within the Bid.
In all cases where the pipe joint involves the use of nuts and bolts, the exposed threads of every bolt shall first be
thoroughly cleaned and then coated with an approved zinc-rich paint allowed to dry for not less than 24 hours before
proceeding with further protection as indicated below.
Where Pipes and Fittings are to be Concreted in (Wrapping Method)
The external protection to pipes and fittings jointed by mechanical couplings, flanged joints, "Tyton", type or Bolted
Gland joint, or similar shall be completed by wrapping the joint with approved petrolatum tape, prior to which the area
shall have been cleaned by an approved proprietary paste and the area protected by an approved proprietary mastic. It
shall then be wrapped in PVC 'outerwrap' or similar material.
The whole joint shall first be thoroughly cleaned removing all loose rust and extraneous matter and the approved
proprietary paste rubbed well over the whole of the joint and for a few centimetres either side of the joint over the pipe
sheathing. A liberal amount of paste shall be left around all bolt heads, narrow cavities, etc.
The approved proprietary mastic shall be applied to cover all bolt heads and nuts, forced into the annular gap between
the spigot and socket in the case of 'Tyton' type or bolted gland joints, formed as a triangular fillet against the face of
socket or flanges and filled in all gaps and abrupt change in contour to provide an even contour for wrapping.
The approved petrolatum tape shall be applied circumferentially, starting and finishing at the top of the joint care being
taken to smooth and eliminate any air pockets and to form the tape well into all angles and changes in contour. The tape
should extend on to the pipe sheathing on either side of the joint by at least 50 mm and the tape should be applied with
a minimum overlap of 25 mm.
An outer wrapping of 'PVC Outerwrap' shall be finally applied over the approved tape. This wrapping should extend at
least 50 cm on to the pipe sheathing and should be applied with a minimum lap of 50 mm.
Protection to site welded joints shall be by a solvent free epoxy coating as per AWWA C210-97 or a tape wrap as per
AWWA M11.
All the above mentioned materials shall be provided by the Contractor and deemed covered in his rates.
Additional Protection to Flexible Couplings / Flange Adaptors in Chambers and/or Above Ground
Such mechanical joints, e.g. flexible couplings, flange adaptors, etc. in chambers and/or above ground shall have been
factory epoxy coated and shall after installation be cleansed by brushing away soil and then shall have an approved
mastic blanket moulded around them so as to provide a contour suitable for wrapping the component with an approved
petrolatum anti-corrosion tape suitable for tropical climates which shall then be done so as to achieve a clean and neat
good tape finish.
Protection to Flexible Couplings and Flanged Adaptors Fitted to Epoxy Coated Pipe Spigots
Where factory coated flexible couplings have been used on pipes whose exposed surfaces beyond other protection
materials have been factory protected using epoxy, then such joints shall be site protected by a polythene outer wrap
sheathing of minimum thickness 200 microns that shall extend beyond the pipe epoxy coating by at least 50 cm. This
outer wrap shall be double strapped using a non-metallic strap to each pipe end beyond and not to the epoxy coating.
C.3.7.10 Backfilling of Pipe Trenches
i) Before commencing the placing of embedment in the trenches, the Contractor shall obtain approval
from the Engineer as to the methods he proposes to use and he shall demonstrate by means of tests that
the specified compaction can be achieved (according to BS 1377 or ISO 22476 using the “sand
replacement” method). The method of compaction and the testing thereof shall be at all times to the
approval of the Engineer and in general at a frequency of once every 30 metres unless this is specifically
relaxed based on continuously good in-situ test results.
ii) Backfilling shall only take place with the prior approval of the Engineer.
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iii) Typical trench details are shown below
1 Surface 10 Trench bottom

2 Bottom of road construction (if 11 Depth of cover
any)
3 Trench walls 12 Depth of bedding (refer Note 3)
4 Top soil 13 Depth of embedment
5 Main backfill 14 Trench depth
6 Initial backfill a Depth of lower bedding
7 Sidefill b Depth of upper bedding
8 Upper bedding c Depth of initial backfill
9 Lower bedding
Notes:
1) Compaction is the deliberate densification of soil during the construction process, whereas
consolidation is the subsequent time-dependent densification after construction. Attaining cited
minimum compaction requirements is at the Engineer’s discretion
2) The embedment is the arrangement and type(s) of materials(s) around the buried pipeline which
contributes to its structural performance. Attaining cited minimum compaction requirements is
mandatory for embedment.
3) Minimum cover is 900 mm for all pipes. May be reduced at Engineer’s discretion
i) The embedment section comprises all materials below the pipe and surrounding the pipe, extending
300 mm above the crown of the pipe. All material above this point comprises the main backfill
ii) The embedment section comprises the bedding (lower and upper), the side-fill, and the initial backfill
(which extends from the crown of the pipe to 300 mm above the crown)
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iii) The embedment material shall be free from tree roots, lumps, stones, organic matter, fragments of rock
larger than 20 mm, or similar objects, which through impact or by concentrating imposed loads might
damage the pipes. Black cotton soil shall not be used as embedment material.
iv) Where pipes are not to be surrounded in concrete or bedding materials (S1 to S4) described above, the
pipe zone material placed around the pipes shall be selected and screened as necessary, free from and
to the approval of the Engineer.
v) Classification of embedment materials for flexible (steel, uPVC, HDPE) and semi-rigid (DI) pipes is
indicated in Table C-20.
Table C-20 Pipe Embedment Class and Material
Embedment
Embedment Material Allowed Notes
Class
S1 and S2 Class S1: Gravel – single size Normally processed granular materials
Class S2: Gravel – graded where specified as bedding for ferrous
pipes
S3 –S4 Class S3: Sand and coarse grained soil with less These can be “as dug” soils but require
than 12% fines particularly close control when used
with low stiffness pipes. Class S3 shall
Class S4: Coarse grained soil with more than 12%
be used for epoxy lined steel pipes
fines OR
whilst class S4 is suitable for cement
Fine grained soil, liquid limit less than 50%, mortar lined ferrous pipes
medium to no plasticity and more than 25%
coarse grained material
vi) Granular material for beddings shall consist of aggregate to BS 882 and shall conform to the grading
shown in Table C-21
Table C-21 Grading of Bedding Material
Nominal Pipe Grading (mm)

Diameter
(mm) S1 Lower Bedding S2 Lower Bedding
80 - 100 10 single-size gravel 10 single-size gravel

150 10 or 14 single-size gravel 14 to 5 graded
200 - 500 10, 14 or 20 single-size gravel 14 to 5 graded or 20 to 5 graded
> 500 10, 14, 20 single-size crushed rock or gravel 14 to 5 graded or 20 to 5 graded
vii) The embedment material shall be in accordance with the above specifications, and not less than:
viii) Class S3 material for epoxy lined steel pipes
ix) Class S4 material for cement-mortar lined ferrous pipes
x) Class S2 material for thermoplastic pipes
xi) Where the ‘as-dug’ trench material meets the bedding class requirements as specified, or will meet the
requirements through careful screening and processing, the Contractor may incorporate such material
into the embedment, subject to the Engineer’s approval. No additional payment shall be made for
screening and processing.
xii) If the quantity of appropriate embedment material which can be obtained from the pipe trench
excavation (with or without screening) is insufficient, the Contractor shall transport suitable material
from other excavations on site, or from off-site. No additional payment shall be made for such imported
material
xiii) For all bedding classes, compaction shall be not less than 90% Modified Proctor Density (MPD) at
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optimum moisture content (+5% / -2%)

xiv) The placing and compaction of pipe embedment shall only be undertaken in the presence of the
Engineer, unless written authority from the Engineer has been granted.
xv) Sidefill shall be placed simultaneously on both sides of the pipe in layers not exceeding 150 mm
thickness and compacted using hand rammers to achieve the required density, taking particular care to
compact the material under the barrel of the pipe and around joints. Layer thickness is however subject
to consistently achieving 90% MPD or better, failing which layers shall be reduced in depth as
necessary to achieve the necessary compaction.
xvi) This shall be in accordance with Section 3.6 of BS 1377: 1990, Part 4 using a 4.5 kg rammer. In-situ
density tests shall be carried out by the sand replacement method in accordance with BS 1377: 1990,
Part 9 at every 30 metres or as directed by the Engineer.
xvii) Pipes shall never be laid directly on cohesive, rocky or stony material. Where the natural trench bottom
meets the bedding class required, this shall initially be loosened to a depth of 10 cm and then re-
compacted to at least 90% MPD and then the surface loosened on the day of and prior to laying
xviii) In rock excavation, the pipes shall be bedded on concrete or selected granular fill to a minimum
thickness of 150 mm and the exclusion of rocks and other hard material to at least 300 mm around the
pipe, leaving proper joint holes and subsequently making good with selected materials to the Engineer’s
approval.
xix) The main backfill shall be filled with approved backfill material obtained from the trench excavations,
free from clay lumps, boulders and rock fragments larger than 100 mm. The material shall be placed
in layers not exceeding 150 mm thickness and compacted using approved mechanical rammers
xx) The lower bedding for the pipes shall have a minimum thickness of 100 mm in normal trenches, and
150 mm where rock/stones are present and at designated road crossings. Bedding material shall be
compacted in layers not exceeding 50 mm thickness.
xxi) In trenches where there is a continuous accumulation of ground water the trench shall, after obtaining
the approval of the Engineer, be over-excavated by 150 mm and shall be backfilled using compacted
free-draining granular material.
xxii) Where mechanical-ramming of the backfill is employed, the machines shall be to the approval of the
Engineer and soil shall be compacted by hand for a depth of not less than 50 cm to give sufficient cover
to the pipes and obviate risk of damage to them before the mechanical rammer is brought into operation.
The rammer shall not cease to be used on any length of trench until thorough compaction has been
obtained.
xxiii) The pipe trench shall be backfilled entirely without leaving out areas around and at pipe joints
uncovered, for subsequent filling. To facilitate the subsequent location of any suspected leaking joints
during pipe testing, should this become necessary, the Contractor shall provide marker pegs at regular
intervals and/or use a handheld GPS to be able to relocate joint positions.
xxiv) Where minimum cover cannot be maintained, including roads and trafficked areas, then the pipe must
either be laid in a protective ferrous sleeve or be protected by a 150 mm thick reinforced concrete slab
above the pipe. A minimum of a 150 mm layer of appropriate grade bedding material must first be
placed and compacted as a cushion above the crown of the pipe before the slab is laid, and the slab
must extend at least 150 mm out beyond either side of the trench.
xxv) The top of the trench may be mounded to 150 mm to provide for settlement, provided natural drainage
of the ground is not interfered with.
xxvi) Under road crossings, the backfilling to pipes shall be brought up in 150 mm layers, and compacted to
a density not less than 95% Maximum Proctor Density.
xxvii) Pipes crossing under roads under construction should be excavated, the pipes laid, and backfilled after
completion of the road earth works if the road at that location is in cut. In all cases, pipes should be
laid and backfilled in advance of road subgrade processing operations.
xxviii) Under rail crossings, the backfilling to pipes shall be stabilised with 2% ordinary Portland cement. The
backfill shall be brought up in 150 mm layers, and compacted to a density not less than 98% Maximum
Proctor Density.
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xxix) The Contractor shall be responsible for settlement of backfill and erosion of the site up to the time the
contract Defects Notification Period has expired and he shall fill and level any settlement and/or erosion
from time to time, as required by the Engineer and at the Contractor's expense.
C.3.7.11 Making Good Subsidence after Refilling

Should any but very localised subsidence occur of the pipe trench after refilling and before the expiry of the maintenance
period, the Contractor shall first demonstrate that such subsidence is only to the backfilling above the pipe and not to the
pipe, embedment, bedding or sub-soil itself.
Should this not be so demonstrated then the Contractor at his own expense shall, excavate and remove the pipe or pipes
affected and return the bottom of the trench to grade through a process of over-excavation, re-compaction or use of a
lean concrete mix as determined by the Engineer, who shall also determine whether or not the affected pipes may be re-
used or replaced.
The affected section or sections will in any event be liable for a further twelve months maintenance period.
All refilling necessary due to subsidence in pipe trench backfill shall be thoroughly compacted by ramming. Any
subsidence due to consolidation shall be made up by the Contractor at his own expense with extra compacted material.
Should subsidence occur after any topsoil has been replaced, the topsoil shall first be removed before any hollows are
made up before being replaced.
C.3.7.12 Miscellaneous Clauses
A. Assistance by Pipe Manufacturer
The Contractor shall utilise the technical services of the pipe manufacturer, unless he already has in his proposed site
team a person or persons of appropriate competence with proven experience in the laying of pipes of the type and
magnitude to be provided.
The Contractor shall therefore either have clearly stated in his Bid that he has such a person or persons who shall be
named and their CV's provided or he shall indicate the extent, nature and duration of the technical assistance he proposes
to obtain from the pipe supplier. This shall include details of the personnel to be provided, and the time when such shall
be available during the laying and jointing, external pipe protection work, trench backfilling and testing periods.
The cost of the above shall be deemed to have been included by the Contractor in his Bid.
A. Working Width
Prior to excavation, the Contractor shall agree with the Engineer the overall width required for pipe installation.
Clearance shall be limited to this area. However in areas of limited access the Engineer reserves the right to restrict this
width and the Contractor shall not claim for additional monies due to inconvenience associated with such limitations,
e.g. for double handling of materials, supporting of trench sides, movement of pipes into position, etc.
B. Location of Underground Services Etc
The Contractor shall locate existing services prior to excavation. Notwithstanding this obligation and should damage
occur, it will be the Contractors further obligation at his own cost to urgently liaise with the utility organization concerned
and to bear the full cost of the repair or replacement of the damaged article to the entire satisfaction of the Utility
concerned.
C. In-Situ Welding of Steel Fittings and Flanges
Wherever it is necessary to undertake in-situ welding of steel fittings and flanges the work shall be undertaken under
cover, temporary or otherwise. Outside of buildings, the cost of providing such cover shall be deemed included in the
Contractors rates. Only suitably qualified welders shall be employed.
Welding procedures used shall comply with ISO 15607 and EN 288-9.
Prior to deployment of any welder he shall within the preceding 3 months have satisfactorily undergone an ‘approved
testing’ in accordance with EN 287-1 and certification thereof shall be provided to the satisfaction of the Engineer. Each
welder deployed shall at intervals of not more than 6 months undergo similar approved retesting and only those who
pass such retesting will be allowed to continue to undertake the in-situ welding works.
All testing and retesting will be deemed to be covered in the Contractors rates.
D. Thrust Blocks
Pipelines with flexible joints shall be adequately restrained at bends, tees, sluice or butterfly valves, tapers, blank ends,
etc. Thrust blocks shall be constructed from Class 20 concrete to the dimensions indicated on Drawings unless otherwise
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directed by the Engineer. All thrust blocks shall be allowed to cure for at least 7 days and surrounding soil shall be
compacted thoroughly before the hydraulic testing of the pipeline.
Support blocks shall be constructed from Class 15 concrete.
Thrust blocks at proposed tie-in points between old and new pipework will be cast at least 7 days prior to the proposed
tie-in works and pipeline testing, except that where this is impracticable, in which case a thrust wall shall be constructed
(similarly in advance) and the connecting fitting propped initially against this thrust wall by means of a horizontal steel
joist with the contact face curved to the outside diameter of the fitting, and fitted with a protective rubber insert.
Immediately upon completion, the space between the thrust wall and the propped fitting shall be filled with class 20
concrete, thereby permanently encapsulating the steel joist.
E. Pipe Supports
Pipe supports shall meet the requirements of BS 3974-1, PNFS 0001 and MSS SP 58
C.3.7.13 Hydrostatic Testing of Pressure Pipelines
All new pipelines shall be pressure tested. For pipelines within a trench, such tests shall be made before it is reinstated.
Unless otherwise approved, all joints shall be clear of earth, timber, etc to allow visual inspection during the test. Testing
shall commence immediately upon completion of installation and preliminary backfill, and construction of thrust blocks.
In general, the full length of each new pipeline shall be tested as one.
The Contractor shall supply all necessary materials to carry out the test in accordance with the requirements including
force pumps, water pressure gauges, as well as tools for the use of the Engineer, interconnecting pipework, feeding tank,
blank flanges, temporary stop-ends, struts and water for the test. The test section shall be capped or flanged off at each
end and all branches. Testing shall not take place against closed valves.
For a pipeline incorporating flexible joints, testing shall not commence until after all the permanent thrust blocks along
the pipeline have been constructed, cured, and soil around them backfilled and compacted. Capped or flanged ends along
the pipeline shall also be anchored adequately to withstand the force due to test pressure. The Contractor shall submit
his proposals for temporary anchoring to the Engineer’s approval.
After the main has been clear of debris, and all necessary stop-ends and gauges fitted to the Engineer's approval, the
Contractor shall fill up the pipe with water free from silt, sand and grit and bring steadily up to the nominal pressure of
the pipe or incorporated fittings, whichever is the lesser, (except for old pipelines where a lower value may be specified
by the Engineer), and this shall be maintained it with a force pump for 24 hours.
The pressure shall then be increased steadily in increments of 1.0 kg/cm2 with a pause of one minute between each
increment to the specified test pressure for the section. Unless otherwise specifically mentioned, the applied test pressure
shall be measured at the lowest point along the section being tested.
Where the test pressure has not been specified, it shall be assumed to be 50% in excess of the nominal pressure at the
lowest point of the section being tested.
After a period of half an hour, the fall in test pressure shall be recorded and sufficient water again pumped into the line
under test to bring the pressure back to the test pressure. The procedure shall be repeated every half-an-hour for a total
period of 3 hours, or longer, if the Engineer so directs, and the amount of water pumped in shall be recorded.
The rate of leakage shall be calculated from the amount of water pumped in during testing and if it is less than 1 litre of
water per 10 mm diameter of pipe per km of length of pipeline, for each 24 hours and for every 30 m head, the pipe line
will be considered to have passed the test.
Leaks exceeding permissible amounts shall be made good, and faulty pipes, fittings, and specials, shall be replaced by
the Contractor at his own expense and the section tested again before approval is given for backfilling. Payment for the
section will not be certified, until the test has been passed and any remaining backfilling completed.
C.3.7.14 Flushing and Sterilisation
This shall be done in accordance with the recommendations set out in BS EN 806-4:2010. All tested pipework shall be
flushed, cleaned and sterilised by the Contractor at his own expense.
All pipelines for the conveyance of potable water shall be sterilised.
As soon as the whole pipeline has passed a hydrostatic test, test water shall be scoured to ensure a flushing velocity of
not less than 1m/s over the entire length of the pipeline.
Potable water treated with sodium hypochlorite or calcium hypochlorite or chlorine gas to a chlorine concentration of
not less than 5mg/l free available chlorine, shall be introduced into the pipeline or section of pipeline to be sterilised.
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On completion of filling with chlorinated water the chlorine concentration in water sampled at any point along the section
of pipeline filled, shall not be less than 3mg/l free available chlorine.
In determining chlorine concentrations, the Contractor shall satisfy the Engineer that the method adopted does measure
free available chlorine concentration and not total chlorine residuals, the latter being the easier to determine by means of
simple compactors.
Chlorinated water shall be retained for at least 2 hours during which all air valves, inline isolating valves, bypass valves,
branch isolating valves and scours shall be operated in order to expose all interior surfaces of these appurtenances to the
chlorinated water.
After 2 hours retention of chlorinated water in the pipeline, samples drawn at any point along the pipeline shall contain
not less than 0.5mg/l free residual chlorine. Where necessary, additional chlorine shall be injected to maintain chlorine
residuals, provided always that the 2 hours minimum retention time with water containing an initial free chlorine residual
of at least 3mg/l and a final free residual of not less than 0.5 mg/l is maintained.
Samples shall then be taken from a suitable connection and sent for bacteriological examination. The Contractor shall
take the samples in the presence of the Engineer. If the results of the test on the samples show that the water contains
any presumptive or typical coliform organisms in 100 ml of water the mains shall be re-flushed and the whole
disinfection process repeated.
Provided the pH of water used for the disinfection of pipelines can be proved to be less than 7.5 before introduction of
chlorine, the retention period of chlorinated water in the pipeline may be reduced from 2 hours minimum to ½ hour
minimum.
C.3.7.15 Tie-In Works

General
This clause shall apply to any tie-in works between pipelines which involve closing down of part or the entire system. It
shall further apply to any new fitting that has to be inserted into an existing operational pipeline.
The Contractor shall be responsible for the execution of the works except under circumstances where the execution of
the tie- in operation is assumed by Engineer or Employer.
The Contractor shall notify the Engineer at least 14 days in advance of all tie-in works.
Pipes and Fittings
The Contractor shall take delivery of any pipes and fittings required at the tie-in works not less than 96 hours before the
commencement work. The Contractor shall check the suitability of such fittings including checking of all dimensions.
The Contractor shall certify the suitability of such materials to the Engineer not less than 48 hours before the
commencement of tie-in operations.
The Contractor shall prepare a schedule of fittings including those on existing pipes that are to be used for such tie-in or
redeployed elsewhere as instructed on the drawings and shall obtain approval of the Engineer not less than 48 hours
before the commencement of tie in operations of such schedule.
The Contractor shall ensure that all materials are at the site of the works not less than 24 hours before the commencement
of the tie-in operation and shall inform the Engineer who shall check the material against the schedule as approved where
he deems this necessary.
Any non standard fittings which are required for the execution of the tie-in works shall be fabricated under the Engineer's
supervision and shall be hydro statically tested to at least one and a half times the maximum working pressure.
Personnel
The Contractor shall ensure that at least one senior member of his field supervisory staff who has proven experience of
such operations and fluent in English and the language of his labourers is on site throughout the whole duration of the
tie in operation.
The Contractor shall also ensure that all necessary skilled artisans are on site for the whole duration of the tie-in operation.
If necessary, shifts of skilled artisans shall be available to ensure continuous work.
The Contractor shall furnish the Engineer's Representative a list of the key personnel to be involved in the tie-in at least
48 hours before the commencement, and shall get the Engineer's approval at least 24 hours before the commencement
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in respect of such personnel. To gain this approval the Engineer may require that operative is tested in the performance
of his duties in the operation of the plant for which he is in attendance.
The Contractor shall ensure that an adequate number of labourers are in attendance during the period of the tie in
operation.
Plant
The Contractor shall prepare a schedule of the plant and equipment which he proposes to have on site either to use,
including stand-by units, and shall obtain the approval of the Engineer not less than 48 hours before the commencement
of the tie-in operations.
The Contractor shall also ensure that all plant is on site not less than 24 hours before the commencement of the tie-in
operation and shall inform the Engineer who shall check the plant against the schedule as approved where he deems this
necessary.
The Contractor shall demonstrate availability of fuel supply and other consumables, and/or electricity supply including
standby generators if necessary.
Pre Tie-In Works
The Contractor shall execute all works possible before the commencement of the operations which shall include:
i) Excavation and supports to the excavation.
ii) Concrete blinding to the bottom of the excavation and (where instructed by the Engineer) immediate
working areas.
iii) Provision of any required drains and sump of adequate size from which any accumulating water is to
be pumped out
iv) Casting the floor of any chamber which is to be constructed around such tie-in works
v) Casting of any thrust blocks or thrust walls or any other works necessary for effective execution of the
tie-in works as may be required by the Engineer. Concrete works shall be case sufficiently far in
advance to allow adequate strength to develop to withstand the loads for which it is intended to carry.
The Contractor shall complete these works at least 96 hours before the commencement of the tie-in operation or within
a period that may be otherwise set by the Engineer upon issue of the Engineer's instruction to perform the tie-in works,
and obtain the Engineer’s approval not less than 24 hours before commencement of the tie-in operations.
The Contractor shall prepare a programme and method statement, giving details of the proposed scheduling and
sequencing of tie-in works. Approval of such programme by the Engineer shall be obtained not less than 72 hours before
commencement of the tie-in operation. The method statement shall indentify all risks associated with the procedure and
provide appropriate mitigating and/or back-up plans.
Actual Tie-In Works
The Contractor, unless relieved of the responsibility by the Employer or the Engineer, shall first empty the section of the
main on which the tie-in is to be made and shall ensure that the nearest air valves and washouts immediately upstream
and downstream are open and the washout dry.
Where the Contractor is relieved of this operation, which shall be notified to him by the Engineer not less than 96 hours
before the tie-in operation is due to commence, he shall check that air-valves and washouts mentioned above are in the
state described.
When the Engineer is also satisfied that the main is empty of water he shall verbally give the order to commence the
works from which time the Contractor shall be solely responsible for the execution and completion of the tie-in works
unless relieved of such responsibility by the Engineer.
In event that the Engineer directs that the tie-in works be carried out during the night, the Contractor shall provide lighting
(including standby and emergency) and any other measures as the Engineer may direct. The Contractor shall make no
claim when such instruction is given.
The Contractor shall provide all the insurance normally required by the Engineer and the Condition of Contract and shall
obtain an endorsement if necessary to ensure that the insurances remain valid in the event that the Engineer takes over
the direction of the works.
When the Engineer is satisfied that the tie-in works are completed he shall give notice for the main to be re-
commissioned, when this has been satisfactorily accomplished the Contractor shall re-deploy his staff on the Engineer's
verbal instructions of completion of the tie-in.
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Post Tie-In Works

Within 48 hours of the completion of the tie-in works the Contractor shall have completed all permanent works required
to support the plant installed during the tie-in operation, and shall remove all temporary supports within a further 48
hours after the permanent support works have been approved by the Engineer. The temporary supports shall not be
removed before such approval has been given.
Within 14 days from the date of the completion of the tie-in the Contractor shall have completed all the other permanent
works required to allow operation of the plant installed during the tie-in operation, and shall obtain the approval of the
Engineer on the completion of such works.
The Engineer shall issue the Contractor with a notice stating the operations for which the plant installed during the tie-
in operation may be used, which shall remain in force for a period extending for 28 days from the date of approval of the
completion of the Post tie-in works as described above.
Before the expiry of the 28 day period described above the Contractor shall obtain the approval of the Engineer for the
completed works when the Engineer shall issue a notice allowing full operation of the plant on the expiry of the above
mentioned period upon which the Contractors responsibility for the works, unless requested otherwise shall cease.
Valve Chambers
New chambers shall be constructed in accordance with the drawings, and where indicated, shall incorporate thrust walls.
Notwithstanding the size and shape of the valve to be supplied, the Contractor shall ensure that the minimum clearance
as indicated on the drawings are provided within the chamber, and that where chambers have pre-cast roofs the manhole
cover provided shall be of a size sufficient to allow for the removal and replacement of the valve without disassembly.
Valve Chamber Covers
Unless otherwise indicated in the Schedule of Prices and Unit Rates, valve chamber covers shall be reinforced concrete
with a weight of minimum 50 kg per piece and provided with embedded steel device for lifting at each end. They shall
be supplied complete with lifting keys. Except where a chamber is provided with pre-cast roof slabs to facilitate placing
and removal of the valve or valves within the chamber, the clear opening in the chamber cover shall in all cases allow
for this. It will be the Contractor's responsibility to ensure that the covers he provides are of an appropriate clear opening
size.
Surface Boxes
These shall be of cast iron, (hinged and locked) and from an approved manufacturer to BS 5834. They shall be sized to
suit the purpose required and as otherwise shown on the relevant drawings.
The number of keys required (if any) is indicated in the Schedule of Prices and Unit Rates.
C.3.8 Drains, Manholes and Chambers

C.3.8.1 General
The requirements of this section shall apply to drainage works within water treatment works areas.
Drain pipes shall be laid in straight lines and at constant gradient between manholes and chambers.
C.3.8.2 uPVC Pipes and Fittings
uPVC pipes and fittings for gravity drains shall comply with BS EN 1401 and shall be obtained from an approved
manufacturer.
Materials
uPVC pipe shall be SDR 35 (or min stiffness 46 psi for larger diameter), or heavier, manufactured in accordance with
the standards listed above. Pipe shall be furnished in lengths not to exceed 6m. Pipe shall be furnished with integral
bells; gaskets and lubricants shall be furnished by the pipe manufacturer. Pipe and fittings shall be made of PVC plastic
having a cell classification of 12454-B or 12454-C as defined in the standards given above.
Joints
Joints shall be compression type utilizing an elastomeric gasket providing a positive seal against ground water and root
intrusion as well as sewage leakage. Gaskets shall comply with physical requirements specified in the standards above.
Lubricant shall be furnished with gasket and entirely compatible with gasket and pipe material.
Joints shall show no signs of leakage when tested as follows: Typical joint assembly shall be subjected to internal
hydrostatic pressure of 10.8 psig for 10 minutes without leakage; assembly shall also be subjected to internal vacuum of
twenty-two (22) inches of mercury or external pressure of 10.8 psig for ten (10) minutes without leakage. The above
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internal pressure and vacuum or external pressure tests shall be run on a typical joint assembly in concentric alignment
and in a position of angular deflection to at least three degrees (3°).
Testing and Inspection
Testing and inspection of all pipe shall be done at the factory with a certified copy of test results furnished to the Engineer
before any pipe is shipped or installed. Tests shall be done in accordance to the standards listed above and shall include
: Pipe and Fitting Dimensions; Pipe Flattening; Impact Resistance; Pipe Stiffness; Joint Tightness (see Part 2); and
Extrusion Quality. At least 1% of the production of each size furnished for this project shall be tested.
Marking
Each pipe section shall be marked with the following information:
Manufacturer’s name or trademark; nominal pipe size; PVC cell classification; Legend “Type PSM DR 35 or PS46 PVC
Sewer Pipe”; Standard Reference
Installation
Bedding for uPVC pipes shall be either type S1 or S2. The bedding material shall be shaped to provide continuous
support for the PVC pipe throughout its length except at bells. Blocking shall not be used to bring the pipe to grade.
Whenever it is necessary to cut a joint of pipe in order to fit the trench conditions, the cutting may be made with either
hand or mechanical saws or plastic pipe cutters. The cut shall be square and perpendicular to the pipe axis. The cut end
shall be beveled to as closely resemble the factory bevels as possible.
Assemble all joints in accordance with recommendations of the manufacturer.
C.3.8.3 Ductile Iron Pipes and Fittings for Gravity Drains

Ductile iron pipes shall be manufactured by an approved manufacturer and shall conform to BS EN 416-1:2009 or BS
EN 416-1:2009. They shall be zinc coated externally with approved bitumen varnish or wrapping.
All pipes shall be provided with an approved type of flexible joint unless flanged or required otherwise as stated in the
Schedule of Prices and Unit Rates, Specification or drawings.
All buried ductile iron pipework laid outside structures shall be surrounded with polyethylene sleeving complying with
the requirements of the Specification.
The application of the sleeving shall be carried out generally in accordance with the ductile iron pipe manufacturer's
instructions.
Polyethylene sleeving shall be used to wrap all ductile iron bends and fittings in accordance with the pipe manufacturer's
instructions.
The Contractor shall be solely responsible for the provision of all equipment and materials necessary for the sleeving
application.
Pipe flanges shall conform to Type NP16 of the above Specifications unless otherwise required owing to working and
test pressures. Special flanges shall be to BS 5500 with drillings to suit adjoining components.
Cast iron drains laid under buildings shall conform to BS 437 and their fittings to BS 1130.
All pipes shall be coated in accordance with the above mentioned Standards.
Laying and Jointing Ductile Iron Pipes
The pipes shall be solidly bedded on the bottom of the trenches and joint holes shall be as small as possible and shall be
filled in compactly before refilling of the trenches is commenced.
Flexible joints shall be made in accordance with the manufacturer's recommendations which the Contractor shall be
deemed to have obtained before starting the laying of pipes so jointed.
In the case of flanged or bolted gland pipes and fittings all joint rings, bolts, and nuts and washers shall be supplied, and
the tightening of the bolts shall be evenly done all round.
C.3.8.4 Vitrified Clay Pipes and Fittings
Vitrified clay pipes and fittings shall be EN 295 Extra Strength clay pipes and fittings and shall comply with standards
listed above including compliance for absorption tests.
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All pipes and fittings shall be marked in accordance with international standards and shall be from the Works of a
manufacturer licensed by that Institution and approved by the Engineer.
Joints shall be of a flexible type in accordance with EN 295.
Immediately upon award of the Contract, the Contractor shall submit to the Engineer for his approval a sample pipe of
each diameter, and these pipes shall be delivered and kept at the office of the Engineer for reference. All pipes used upon
the Works shall be equal in quality to the approved samples.
Junctions on clay pipe shall be of similar material and suitable for use with flexibly jointed pipes.
Before any length of pipe is laid it shall be stood or slung vertically at the side of the trench and 'rung' with a wooden
mallet. Any damaged or cracked pipe shall be rejected.
Pipes shall be laid true to line by means of a line stretched along the side of the pipes and true to levels by means of a
straight-edge 4 m in length kept inside the pipes and pulled forward to pegs boned in at suitable intervals between sight-
rails set to the proper levels. The pegs shall be removed as the pipe is laid.
The Contractor shall ensure that stones are excluded from each joint by filling the open annular gap of the joints in
accordance with the Manufacturer's recommendations.
Any instructions regarding laying and jointing of the particular pipes used for the Contract shall be obtained from the
makers by the Contractor and adhered to in every respect including the use of all special equipment recommended.
C.3.8.5 Concrete Pipes and Fittings

All concrete pipe shall be reinforced to BS EN 1916:2002, Class H. All joints shall be of the spigot and socketed flexible
type approved by the Engineer.
The main pipe and branches of all junctions shall be of the same strength classification and shall have the same internal
dimensions as the pipes with which they are to be used.
The pipes, bends and junctions delivered to the Site shall be certified by the pipe manufacturer to have complied with
EN 1916 and other relevant standards, or other approved standard and one copy of the certificate shall be delivered to
the Engineer before the goods are unloaded.
Where the pipes are required to be of Extra Strength they may, unless otherwise specifically called for, be reinforced
either with cast-in steel or by an external wrapping of fibre glass and resin, applied by an approved manufacturer.
The Contractor shall provide all facilities for and shall carry out jointly with the Engineer (if so required) a full visual
inspection of all pipes, bends and junctions for manufacturer's defects and other faults or damage. Before any pipe, bend
or junction is laid it shall again be carefully examined and sounded with a wooden mallet. Any pipe found to be cracked
or otherwise defective shall not be used on the Works.
The Contractor shall ensure that stones are excluded from each joint by filling the open annular gap of the joints in
accordance with the Manufacturer's recommendations.
The pipes shall be laid true to line and gradient in the manner specified for vitrified clay pipes. Specific instructions
regarding laying and jointing of the pipes shall be obtained by the Contractor from the manufacturer of the particular
pipes to be used for the Contract and adhered to in every respect including the use of all recommended special equipment.
C.3.8.6 Glass Reinforced Plastics (GRP) Pipes and Fittings
Glass reinforced plastic pipes and fittings shall comply with the relevant provisions of EN 1115-5 1996. The pipes shall
be obtained from an approved manufacturer having a proven record of manufacture of GRP pipes and fittings. Pipe
strength and bedding calculations shall be supplied by the manufacturer. The manufacturer shall provide detailed laying
and bedding instructions which shall be rigidly adhered to.
C.3.8.7 Perforated / Porous Pipes for Sub-Drains
Perforated uPVC pipes and fittings for subsoil drains shall be supplied and installed in accordance with BS 4962: 1982.
Concrete porous pipes for subsoil drains shall be supplied and installed in accordance with BS 5911-114:1992.
C.3.8.8 Concrete Bedding and Surround to Gravity Pipes
Where a concrete bed to pipes is to be provided the excavation shall be taken out to the proper depth to receive the
concrete and the pipes shall then be laid to line and level and jointed on precast Grade C20P concrete blocks solidly
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bedded on the floor of the trench. When the pipes are jointed the trench bottom shall be cleaned and the concrete for the
benching, hunching or surround as the case may be shall be carefully placed under and around the pipes, special care
being taken to pack the concrete solidly under the pipes.
The concrete bed and protection shall extend along the length of the pipe to within 100 mm of the joint collar and a gap
shall be left adjacent to the joint. This gap shall be backfilled with approved excavated material.
All precautions shall be taken to avoid damage to the pipes during the placing of concrete. The precast blocks shall be
not less than 300 mm x 150 mm x 150 mm and shall be notched to receive the barrel of the pipe and shall be placed
immediately behind the joints. The depth of the blocks shall be such as to suit the thickness of the bedding required in
accordance with the drawings.
For pipes of 600 mm dia. and over, and on ground of soft formation, the concrete bed shall be cast in two layers. A bed
of 50 mm thickness shall be placed to receive the concrete blocks and after the pipes are jointed the remainder of the bed
shall be cast.
C.3.8.9 Selected Granular or Sand Bedding and Surround to Gravity Pipes

All trenching and bedding shall conform to specifications. All ductile iron and steel pipes laid in rock or on mass concrete
infill and all uPVC pipes shall be laid on granular bedding or as otherwise detailed on the drawings.
Granular bedding material shall consist of non-flaky broken stone or gravel, graded 20 mm to 5 mm size and shall have
a Compaction Fraction not greater than 0.3 as ascertained by the test method described at the end of this clause.
Sand bedding material shall consist of approved local sand which material shall have a Compaction Fraction ascertained
by the test method described below of not greater than 0.3. The Contractor shall provide all necessary testing apparatus
for the use of the Engineer on site. Frequency of tests shall be at the discretion of the Engineer.
Before placing pipe bedding material the trench bottom shall be prepared and all loose stones, lumps of clay, rock
projections, boulders and other hard spots removed. The approved bedding material shall then be laid over the full width
of the trench to such depth that after the pipes have been laid to line and level, the thickness of bed beneath the barrel of
the pipes is not less than 200 mm or as otherwise stated in the Schedule of Prices and Unit Rates or on the drawings.
The bedding material shall be evenly spread and carefully compacted and where the bedding beneath the pipe exceeds
200 mm in thickness it shall be placed in two separate equal layers. Any clay, large stones and other unsuitable material
falling onto or into the bed from the trench sides or from any other source shall be immediately removed.
Should hand ramming fail to produce even compaction the Engineer may require mechanical compaction to be used,
and the Contractor shall not be entitled to claim any extra payment on such account.
Timbering or any other form of trench support should be withdrawn, whenever possible, as the bedding material is placed
so as to avoid disturbance of the bedding by later removal.
Pipes shall be laid and jointed as specified elsewhere. Any adjustments to line and level must be made by adding or
removing bedding material under the body of the pipe and not by wedging and blocking. All hard objects or timber shall
be removed before laying the pipes.
After the pipes have been laid correctly to line and level the bedding material shall be brought up to half diameter of the
pipe and compacted as before and so as to prevent any voids under the pipe barrel and give uniform support all round.
Care shall be taken not to disturb the pipeline from its approved position at this stage and as the subsequent backfilling
of the trench proceeds as specified elsewhere.
For uPVC pressure pipe and where sand or granular surround is billed, the pipe shall then be covered with bedding
material compacted as before to a depth of 150 mm above the top of the pipe barrel, or as otherwise shown on the
drawings.
Where ground water conditions are such that the bedding material would be likely to act as a carrier for ground water
from higher to lower ground, the Engineer may instruct flow barriers of suitable selected soil to be inserted in lieu of
bedding material. Such barriers to be erected at reasonable intervals close to flexible joints in the pipe, without alteration
of the rate for bedding etc.
Compaction Fraction Test
Apparatus required:
i) Open-ended cylinder 250 mm long and 150 ±5 mm internal diameter (150 mm diameter pipe is
suitable)
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ii) Metal hammer with striking face 38 mm diameter and weighing 1 kg.
iii) Rule.
Method:
Obtain a representative sample (*) more than sufficient to fill the cylinder (viz. about 10 kg). It is important that the
moisture content of the sample should not differ from than of the main body of material at the time of its use in the
trench.
Place the cylinder on a firm flat surface and gently pour the sample material into it, loosely and without tamping. Strike
off the top surface level with the top of the cylinder and remove all surplus material. Lift the cylinder up clear of its
contents and place on a fresh area of flat surface. Place about one quarter of the material back in the cylinder and tamp
vigorously until no further compaction can be obtained. Repeat with the second quarter, tamping as before, and so on
for the third and fourth quarters, tamping the final surface as level as possible.
Measure down from the top of the cylinder to the surface of the compacted material. This distance in millimetres divided
by the height of the cylinder (250 mm) is the Compaction Fraction of the material under test.
(*) To obtain a representative sample, about 50 kg of the proposed material should be heaped on a clear surface
and divided, with a spade down the middle into two halves. One of these should then be similarly divided, and
so on until the required weight of sample is left.
C.3.8.10 Pipes and Joints Adjacent to Structures, Junctions and Surrounds
A flexible joint shall be provided as close as is feasible to the outside face of any structure into which it is built, compatible
with the satisfactory completion and subsequent movement of the joint, and not more than 500 mm away from the
manhole.
The length of the next pipe (rocker pipe) away from the structure shall be in the range 525 mm to 750 mm for pipes up
to 450 mm nominal diameter and shall not exceed 1000 mm for pipes up to 750 mm nominal diameter.
Similarly a flexible joint and rocker pipe shall be provided at either side of any length of concrete bedding or surround
to the pipeline and at either side of the main body of any lateral junction set in the pipeline. In the event that the lateral
pipe and junction are to be surrounded in concrete extending beyond the length of the junction fitting then flexibility
shall be provided as required for concrete surrounds.
The provision of the necessary short pipe lengths and additional flexible joints shall be included in the rates for the
pipeline.
C.3.8.11 Pipes To Be Kept Clean
All pipes must be kept thoroughly clean and no water will be allowed to flow in laid pipes during the construction of the
Works unless by special written permission of the Engineer. The Contractor shall make all necessary provision for the
temporary conveyance by means of troughs or other approved methods of any drainage water during the execution of
the Works and he shall be entirely responsible for the cleansing of any ditches, channels, drains, etc. into which he may
discharge such water.
A wooden ball or similar approved 25 mm less in diameter than the diameter of the pipes under inspection shall be
passed through each length of sewer when so ordered by the Engineer and any obstruction found shall be removed by
the Contractor.
All pipelines shall be subjected to inspection for cleanliness before the issue of the certificate of Completion.
C.3.8.12 Construction of Manhole and Other Chambers
Construction
All manholes and chambers shall be completely water-tight. Particular attention shall be given to the joints between the
pipes and the manhole walls to ensure that high levels of ground water do not cause leaks into the manholes or chambers.
Manholes shall be constructed from precast concrete sections or in-situ concrete.
Manhole step irons built into concrete as the work proceeds or built into precast units during manufacture shall be spaced
300 mm apart vertically and horizontally unless otherwise detailed.
Where valves are directed to be fixed in a chamber, etc. the necessary frames shall be placed in position using approved
expanding shell bolts or an approved proprietary resin anchor system.
The invert and benching of each manhole or chamber shall be completed before the cover slab is placed and shall be
formed as shown on the drawings.
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Where a high strength concrete topping is required, the invert and benching shall be formed in Grade 20 concrete with a
screeded finish and the concrete shall be applied as soon as practicable thereafter. Grout for use with the separate
application of high strength concrete topping shall be Class G1.
Where the finished surface is to be in-situ concrete, the concrete shall be Grade 20. Channels shall have a Fair finish
and benching a Steel Trowel finish.
The main invert channels shall be laid in uPVC channels to the fall of the pipeline. All branch drains shall be connected
to the main drain channel with half-channel bends of a proper angle and radius to lead with the run of the main drain
channel, the bends being as "slow" as possible. The invert of the branch drain shall where possible be at least 75 mm
above the invert of the main drain. Where it is found impossible to give a satisfactory lead with a uPVC channel the
Engineer may direct the invert channel to be formed in Grade 20 finished with a 50 mm thickness of Grade 30 fine
concrete.
Precast Concrete Manholes
Precast concrete ring units and cover slabs shall comply with the relevant provisions of BS 5911: Part 2.
Precast ring units which bed onto in-situ concrete bases shall be manufactured so that imposed vertical loads are
transmitted directly via the full wall thickness of the unit. For joints between units and the underside of slabs, joint
profiles shall be capable of withstanding applied loadings from such slabs and spigot-ended sections shall only be used
where the soffit of the slab is recessed to receive them.
The jointing material for manhole units shall be approved proprietary bitumen, resin mastic or polymer sealant, with the
concrete surfaces primed with an appropriate compound.
Safety Chains
Safety chains will be required to be fixed across the opening into any manhole exit pipe exceeding 600 mm diameter.
Chains will be secured to the wall of the manhole using galvanised hooks and eyes of appropriate size set into or securely
bolted to the concrete wall.
Mild steel safety chain shall be 8 mm nominal size Grade M(4) non-calibrated chain, Type 1, complying with BS EN
818. After manufacture, mild steel safety chains shall be hot dip galvanised in accordance with BS 729.
Manhole and Chamber Access Covers
The manhole and chamber access covers shall comply with BS EN 124:1994. Part 1 or BS EN 124:1994 and be obtained
from an approved manufacturer and shall be to the internal minimum clear opening as specified in the Schedule of Prices
and Unit Rates and the drawings.
All manhole and chamber access covers in road and footpaths shall be to an approved Heavy Duty pattern unless
otherwise specified. The frame and lid shall have key holes formed with sealed pockets underneath to prevent ingress
of sand, grit and surface water and shall be of an approved non-rocking pattern. The covers and frames shall have
accurate seating faces to prevent rocking and the ingress of sand or water, and shall be tight fitting to resist overflow
conditions or unauthorised removal. The seating faces shall be coated with graphite grease before installation of the
cover.
A supply of keys for use with every type of manhole cover and surface box shall be handed over by the Contractor at
the completion of the Contract on the basis of one set of keys for each 50 covers or part thereof.
Manhole and chamber cover frames shall be set to the required level and, where for precast concrete manholes, on at
least two and not more than four courses of Class B engineering, bricks, Grade 20 in-situ concrete or special purpose
concrete brickwork or precast concrete cover frame seating rings. The frames shall be set to level and bedded in cement
mortar and haunched over the base and sides of the frame with Grade 30 concrete.
It shall be the Contractor's responsibility to establish the finished road levels from the appropriate authority and fix the
covers accordingly.
Surface Boxes
These shall be of cast iron, (hinged and locked) and from an approved manufacturer to BS 5834. They shall be sized to
suit the purpose required.
The number of keys required (if any) is indicated in the Schedule of Prices and Unit Rates.
Surface boxes shall be set in cement mortar to the correct camber and fall.
Manhole Step Irons
Manhole step irons shall be of galvanized malleable iron and shall conform in all particulars to BS EN 13101:2002.
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Ventilation Columns
Ventilation columns shall consist of a bonded glass fibre tube 150 mm internal diameter set in a very solid cast iron base,
supplied by an approved manufacturer. The column shall stand at least 9 m high above ground.
The top of the column shall be fitted with cast aluminium or a copper wire heavy duty screen. The cast iron base of the
ventilation column shall be carried at least 900 mm below ground level and be bedded in Grade 25 concrete. The joint
between the column and its base shall be caulked and sealed with mastic in accordance with the manufacturer's
recommendations. The concrete base shall be finished 200 mm below ground level and the surface shall afterward be
properly reinstated. After erection of the column, the cast iron base shall be painted in three coats of an approved colour.
Handholds and Railing
Handholds and handrailing within manholes and chambers shall consist of 32 mm nominal bore factory applied hot dip
galvanized medium steel tube to BS EN 10255:2004 with galvanized forged steel standards and approved galvanized
bases and fixings.
Handholds shall be 600 mm long with 150 mm projection and complete with wall bosses.
Handrailing shall be in accordance with the specification. Access openings shall be secured by stainless steel chains and
spring clips fixed at the same levels as the double rails.
C.3.8.13 Gulley Gratings and Frames
Road gully gratings and frames shall be of approved type and manufacture in cast Grey or Ductile Iron and shall be of
heavy duty Non-rocking Pattern designed for wheel loads of 11.5 tonnes and generally in accordance with BS EN
124:1994.. Single gullies of nominal size 450mm x 500mm shall have a large water way with aluminium water way of
1100cm2.
Gulley frame shall be set in cement mortar and haunched with Grade C25/10 concrete.
It shall be the Contractor’s responsibility to establish the finished road levels from the appropriate Authority and fix the
gratings accordingly.
C.3.8.14 Testing of Gravity Pipelines
All new sewers and gravity pipelines shall be water tested, before the pipes are backfilled, for leakage out of the pipeline
in the presence of the Engineer under a minimum head of 1.2 m above the pipe soffit or, if higher, the ground water level
at the upstream end and a maximum head not exceeding 6.0 m at the lowest point of the pipeline under test. The water
loss from within the pipeline shall not exceed 10 ml per cm of diameter per kilometre per hour.
After temporary reinstatement of the trench and before the final reinstatement all new sewers shall be tested in the
presence of the Engineer for the infiltration of ground water into the pipeline. The water flow into the pipeline shall not
exceed 10 ml per cm. of diameter per kilometre per hour.
In every case the water for testing the pipes shall be left in the pipes until they are covered with earth or other trench
filling materials to a depth of at least 1.25 m or to ground level if this is less, over the top of the pipes and until permission
is given by the Engineer for the water to be released. If after the Engineer has approved the sewer and has given
permission for the trenches to be refilled the pipes become damaged and lose water from any cause and/or admit subsoil
water the Contractor shall have the pipes uncovered and the defect made good and the pipes retested as before to the
satisfaction of the Engineer and all at the Contractor's expense.
The Engineer may, exceptionally, permit the use of air or smoke tests in which case air or smoke shall be pumped into
the test length until a pressure equivalent to 100 mm of water is indicated on a 'U' tube gauge. The pressure shall not fall
below 75 mm at the end of the five minutes.
The Contractor shall provide all labour, water, plugs, caps, bends, pumps, gauges and other needful appliances for
conducting the tests and no pipes or other work shall be covered up until they have been seen and passed by the Engineer
as being absolutely watertight.
C.3.8.15 Watertightness and Cleanliness Generally
The manholes, chambers, etc., shall be substantially watertight, with no identifiable flow of water penetrating the
permanent Works, and shall be clean throughout and may be tested as requested by and in the presence of the Engineer.
The Contractor shall provide all labour, water, drain-stoppers, bends, pumps, gauges and other needful appliances for
conducting the tests and shall remedy any leaks or other defects.
The Contractor shall remedy any defective or leaky pipes, etc. and remove all dirt, silt or other obstructions from them
or failing the Contractor doing this the Engineer may arrange to do so and deduct the cost of the same from any monies
due to the Contractor. Such action shall not relieve the Contractor from any damages for which he may be liable in the
event of the Works not being completed in the Contract time.
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The Contractor shall include in his rates and prices for all water tightness tests.
C.3.8.16 Fixing of Valves and Penstocks in Manholes and Chambers
Valves and penstocks shall be fixed in manholes and chambers before the benching is constructed. They shall be fully
tested for ease of operation and water tightness and shall be thoroughly coated with grease. Care shall be taken in
constructing the benching to ensure that the valves and penstocks are protected during the concreting, etc., and they shall
be left free from cement or other obstruction.
Where a valve or penstock is to built into the benching of a manhole or chamber it shall be encased in a 75 mm casing
of lime mortar up to 25 mm below the finished surface of the benching blocks so that the body can be cut out if necessary
at some future date and cement rendering shall be carried over the lime mortar encasing up to the greased faces of the
frame.
C.3.8.17Protective Coating to Chambers and Water Retaining Structures
Internal concrete surfaces of manholes and water retaining structures shall be primed with an approved two pack epoxy
primer and painted with an approved solvent-free epoxy resin modified with coal-tar pitch. For potable water retaining
structure, the coating shall be certified to be safe.
All coating work shall be carried out on completion of backfilling and testing of sewers, manholes and chambers and
after all leaks and weeps, if any, have been located and cured. The internal surfaces shall be thoroughly dried before
application of the primer.
C.3.8.18 Maintenance of Drainage Flows
Where existing live WTP drains are to be replaced or temporarily cut the Contractor shall make arrangements for
drainage flows to be maintained by use of temporary by-pass pipes, over-pumping or other methods. The Contractor
shall submit details of his proposed method to the Engineer for approval prior to commencing the relevant section of the
Works.
In addition to WTP drainage flows, all other flows of water through existing pipes, ditches, drains, ducts, culverts and
the like shall be maintained. In some locations these flows may be seasonal or tidal and the Contractor shall ensure that
adequate diversions are maintained in places where such variable flows are known to pass.
C.4 General Mechanical & Electrical

C.4.1 Valves
General
Isolating valves up to and including DN 300 shall be gate valves, and valves larger than DN 300 shall be butterfly valves,
except where otherwise specified on drawings or in Bill of Quantities.
By pass and gear arrangement shall be provided for all gate valves and butterfly valves for sizes 400 mm and
larger.
All valves shall bear an identification mark on the upper body that shall include:
i) Name of the manufacturer and/or his trade mark
ii) Nominal diameter (DN)
iii) Nominal pressure (PN)
The manufacturer’s full technical specifications shall be supplied to the Engineer in triplicate by the Contractor for
approval prior to confirmation of any order for valves.
The valve body shall be cleaned and shot blasted to ISO 8503 Parts 1 to 4 before being internally and externally protected.
All isolating valves shall be protected by fusion bonded powder epoxy or equivalent, internally suitable for potable water
and to a minimum thickness of 150 microns, or in aggressive soils of 300 microns thickness.
All valves shall be designed for a maximum permissible pressure of 16 bar except where otherwise specified. All valves
shall close when the stem rotation is in a clockwise direction unless otherwise specified.
Contractors shall supply full technical details of the proposed valves to be supplied. Preferably, these should be of the
same type and manufacture as the existing valves. If the Engineer considers the proposed valves to be inappropriate he
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will reject them and instruct the Contractor to provide a suitable alternative. No additional payment shall be made where
such changes occur.
All valves for use in water supply shall conform to BS EN 1074.
C.4.2 Gate Valves
Unless otherwise specified gate valves of nominal diameters up to and including DN 300 shall be resilient seated and
made of epoxy coated cast ductile iron in accordance with BS 5163 Parts 1 and 2. The epoxy coating shall be not less
than 150 microns thickness. The gate shall be ductile iron and completely rubber encapsulated, the gate valve being of
pocketless type with a straight through port.
The gate sealing shall be ensured by compressing of the rubber. Wedge/gate guides of wear resistant plastic with high
gliding features shall be provided in the body, optimally placed to guarantee low wear and tear of the gate and low
closing torques.
Gate valves of nominal diameter larger than DN300 shall be of metal seated design with replaceable bronze facing
seal/seat rings.
Gate valves shall be capable of sustaining a maximum permissible differential working pressure of 16 bar except where
otherwise indicated on drawings or in Schedule of Prices and Unit Rates. Gate valves shall be provided with integral
flanged ends unless otherwise indicated.
Unless otherwise specified the face to face dimensions of gate valves with integral flanged ends shall be in accordance
with EN 558 and EN 12627 basic series 14 (short) or basic series 15 (long).
Gate valves shall be of the non-rising stem type except where specifically indicated otherwise. The stem seal shall be of
toroidal sealing rings (O-rings) with at least two such seals. Seals shall be capable of being replaced with the valve under
pressure and in the fully open position.
The bonnet gasket shall be of elastomer (suitable for potable water). The bonnet studs or Allen screws shall be corrosion-
protected. In addition the studs/allen screws shall be placed in countersunk holes in the bonnet and completely sealed
with wax or a suitable material, which could be removed by low-temperature melting in case they have to be
disassembled.
The gate valve bodies shall be works cleaned and shot-blasted in accordance with ISO 8503 Parts 1 to 4 before being
coated internally and externally. The body, the bonnet and the gate of the valve shall be made of ductile iron to EN 1564,
the gate being encapsulated with elastomer EPDM, nitrile or equivalent.
The operating stem shall be made of stainless steel at least equivalent to ISO 10088 Part 1.4021, except in areas of
aggressive soils where this shall be to ISO 10088 Part 1.44404.
The stem nut shall normally be made of high tensile brass to BS 1981, except in areas of aggressive soils where this shall
be aluminium bronze to EN 12167.
Furthermore and in aggressive soils, outside bolts and nuts shall be made of stainless steel to ISO 10088 Part 1.4301 or
as detailed on drawings.
Stuffing boxes shall be designed to have soft packing fitted and arranged so that it can be re-packed under pressure.
All valves shall be suitable for operation from the closed position by a 13 kg "push-pull" effort (total 26 kg) at the rim of
the hand-wheel or tee key. Gearing and by-pass shall be provided where required or where shown on the Drawings.
Valves shall be tested to 1.5 times the normal working pressure.
C.4.3 Butterfly Valves
Butterfly valves for manual operation shall comply with BS 5155 and EN 593 and shall be double flanged, resilient and
metal seated tight shut-off design and of the eccentric disc type supported from two shafts placed in self-lubricating
bearing bushes.
Butterfly valves shall be capable of sustaining a maximum permissible differential working pressure of 16 bar except
where otherwise indicated on drawings or in Bill of Quantities.
Butterfly valves shall operate with a clockwise closing direction. The valve disk shall rotate though an angle between
0° and 90° inclusive. Butterfly valves shall be installed with shaft in horizontal position and the bottom half of the disc
opening in the direction of flow.
The sealing ring shall be made of EPDM rubber and shall be attached at the disk edge circumference by a retaining ring
without adjustment to form a resilient and durable seal.
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The valve disc seal shall be replaceable without dismantling the operating mechanism, disk or shafts, and without
removing the valve from the pipeline.
Butterfly valves shall be equipped with an irreversible and proportional worm gear operator. This shall be either with or
without an additional primary reduction gear placed within a waterproof housing depending upon nominal valve
diameter and maximum working conditions, as stated in the Bill of Quantities.
The operating mechanism shall be permanently lubricated, not in contact with the water, and provided with an
OPENED/CLOSED proportional position indicator in order to indicate the disk angular position. The mechanism shall
be sized in order to minimise torque for ease of manual operation under maximum differential pressure and shall be with
high class enclosure IP67 to ISO 60529. They shall be self-locking and designed to hold the valve in any intermediate
position between fully open and fully closed without creep.
Valve body, disk and disk retaining ring shall be in ductile "SG" iron casting to EN 1563 or EN 1564. Disk shafts shall
be in stainless steel to EN 10088:1.4021, complete with non-corrodible bearings.
The valve body shall be cleaned and shot blasted to SSRN 937 and internally and externally protected with a paint
suitable for potable water.
Butterfly valves shall be works pressure tested in accordance with BS 6755 and EN 12266 Parts 1 and 2.
i) Body test at a minimum pressure of 1.5 times the maximum permissible pressure
ii) Seal test at a minimum pressure of 1.1 times the maximum permissible pressure.
Butterfly valves shall be suitable for flange connections. Wafer type valves may be used where appropriate to suit the
existing pipework arrangement.
Valves shall allow flow in either direction and shall be satisfactory for duties including flow regulation, frequent
operation, and for applications involving valve operation after long periods of inactivity.
Butterfly valves used for flow regulation shall have gunmetal disc seating’s. Those used as isolating valves shall have
resilient disc seating and shall be drop tight.
The Contractor shall ensure that there is sufficient clearance between the disc and the adjoining pipework to ensure that
all butterfly valves operate freely, from fully open to fully closed and vice versa, under all conditions.
C.4.4 Non-Return Valves

Non-return valves shall have bodies made from bronze for sizes up to DN 100 mm and they shall be of the swing pattern
or spring return disc type and shall be rated for at least PN 10 or greater as specified. The ends shall be either screwed
to EN 10228-1 or flanged to EN 1092-1, PN 10 or as the installation demands.
For sizes greater than DN 100mm, they shall be tilting swing check type with top hinge, extended shaft and adjustable
counterweight in order to reduce or eliminate the slamming effect. For the new RWPS and new TWPS check valves, a
no-flow switch with appropriate and adjustable mechanism shall be provided,
Check valves shall be double flanged free acting type specially designed for use in pumping systems, giving rapid non-
slam closure, and low head loss characteristic when the door is in the open position. Check valves shall comply with the
general requirements of BS EN 12334:2001 and to suit particular condition.
The valves shall have cast iron body and door with gunmetal or nickel bronze alloy door seating, and an access cover of
adequate dimensions for removal of the door. The hinge pin shall be of stainless steel carried in non-corrodible bearings.
Check valves shall have the following features:
i) Detachable cover plate of ample dimensions to facilitate inspection and withdrawal of the flap.
ii) Cast iron flaps to close on to gunmetal seats.
iii) Hinged pin of bronze or stainless steel with bronze bushes.
iv) Flanged ends.
All check valves shall be suitable for insertion in either horizontal or vertical pipework as may be required.
C.4.5 Air Release and Vacuum Break Valves
Automatic air relief and vacuum break valves (air valves) shall be of the anti-shock anti-surge type (Ventomat or similar)
designed to meet the following requirements.
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The required valves shall provide all of the functions described below.
• Pipeline filling
• Uninterrupted high volume air discharge through the large orifice.
• Pipeline draining or Column Separation
• Uninterrupted high volume air intake through the large orifice.
• Pipeline full and operating
• Discharge of dis-entrained pressurised air through the small orifice.
The air release and vacuum break valve shall be of a compact single chamber design with solid cylindrical High Density
Polyethylene control floats. These shall be housed in a tubular stainless steel or corrosion protected body with epoxy
powder coated cast iron, or stainless steel ends secured by means of stainless steel tie rods.
The valve shall have an integral surge alleviation mechanism which shall operate automatically to limit transient pressure
rise or shock induced by closure due to high velocity air discharge or the subsequent re-joining of separated water
columns. The limitation of pressure rise must be achieved by deceleration of approaching water prior to valve closure.
Relief mechanisms that act subsequent to valve closure are unacceptable.
Large orifice sealing shall be effected by the flat face of the control float seating against a nitrile rubber ‘Ó’ Ring housed
in a dovetail groove circumferentially surrounding the large orifice. Discharge of pressurised air shall be controlled by
the seating and unseating of a small orifice on a natural rubber seal affixed to the control float.
The intake/discharge area shall be equal to the nominal size of the valve i.e. a 150 mm valve shall have a 150 mm
intake/discharge orifice.
The valve construction shall be proportioned with regard to material strength characteristics, so that deformation, leaking
or damage of any kind does not occur by submission to twice the designed working pressure.
The valve design shall incorporate an over pressure safety feature that will fail without an explosive effect, such as is
normally the case when highly compressed air is released suddenly. This feature shall consist of easily replaceable
components such as gaskets, seals or the like.
The air valve shall be provided with a separate isolating valve.
Unless otherwise specified all air valves shall be provided with an integral flanged inlet with studs appropriate to EN
1092-1 NP 10 or as the installation demands and complying with the appropriate nominal pressure.
All air valves at new installations shall be fitted to an air accumulator fitting, with the branch diameter not less than 60%
of the diameter of the main. Where necessary, a concentric taper either integral with or as a separate fitting shall be
inserted between the branch and the isolating valve immediately beneath the air valve and an abrupt diameter change
between branch and isolating valve shall be avoided.
Air valves shall be of approved manufacture.
Diaphragm Valves
Diaphragm valves used for chemical solution flow control shall be of standard pattern double flanged type to BS 4504
or BS EN 1092:2002 with PVC body, bonnet and hand-wheel. The diaphragm shall be of tabbed EPDM and bolts
washers and nuts shall be cadmium plated steel.
Diaphragm valves shall comply with the general requirements of BS 5156 or BS EN 13397:2002.
They shall be designed such that the operating spindle and other gear is isolated from the fluid or chemical. All parts of
the valve in contact with the fluid or chemical shall be resistant to corrosion or have corrosion resistant linings bonded
to them. Valves handling slurries or sludge shall be of the straight-through type.
Diaphragms shall be flexible, reinforced, supported in all positions and suitable for the fluid being handled.
Ball Valves
Ball valves shall be in accordance with BS 5159 or BS ISO 7121:2006. They shall be designed so that the port area has
a full bore (i.e.. free area through the valve to be not less than the inside area of pipe of the nominal valve size).
Hand-Wheels and Valve Caps and Valves
Where hand-wheels are specified, they shall have cast into them the words 'open' and 'closed', together with an arrow
indicating the direction for such opening or closing.
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Valves for tee-key operation shall be provided with valve caps.

Valve Keys
These shall be of mild steel with ends to suit either valves to BS 5163 Parts 1 and 2, valves to EN 593 or valves to EN
12360 or 12288 fitted with valve caps, dimensioned to the appropriate Bid Drawing.
Safety Valves- Valves shall be spring loaded type (Direct loaded Safety valve) as per EN ISO 4126-1February 2004 to
be installed on the delivery line of pumps inside the pump chamber as per the design pressure (rating) of respective
pumps.
C.4.6 Pressure relief valves

1. Pressure sustaining valves shall be capable of maintaining a constant pressure in the main upstream of the
valve. These may be used to reduce excess pressures when installed in a branch main.
2. Pressure relief valves shall be designed to prevent the pressure in the pipeline immediately upstream of the
valve rising above a preset value. The valve shall remain closed at lower pressures.
3. Adjustment of the pressure at which the valve opens to relieve pressure shall be made by a screw on the relay
valve or by changing weights as appropriate.
4. Operation shall be achieved in a similar manner to the pressure reducing valve except that the relay system
shall be actuated by the upstream pressure.
5. Construction of the valve shall generally be in accordance with the specification for pressure reducing valves.
6. A pressure gauge indicating upstream pressure shall be incorporated.
C.4.7 Pressure reducing valves

General requirements
1. The upstream pressure of this type of valve can vary from a full static head in a pipeline to the minimum
residual static head during the maximum anticipated flow rate. The pilot valve system, where applicable,
shall be capable of efficient functioning under the full range of inlet pressures.
2. On closing, the valve shall have a linear flow velocity reduction characteristic to reduce pressure surges.
Alternatively, the closing cycle should be inversely proportional to increasing dynamic pressure, by means
of an automatic adjustable pressure sensitive controlled pilot valve assembly, which will induce a reduction
in closing speed with increased dynamic inlet pressure. This assembly shall prevent continued closing when
the inlet pressure exceeds the system design pressure.
3. The Contractor shall further prevent prolonged valve closing rates that could result in excessive velocities
at high-pressure differentials across the valve seat. This could cause rapid erosion of coating, cavitation
damage and possible reservoir spillage.
4. Configurations incorporating automatic surge suppression and surge relief will be considered an advantage.
5. Resistance to cavitation damage is essential and the maximum permissible flow rates through the valve at
the respective maximum differential pressures across the control valve, shall be quoted.
6. Valves which offer a built-in resistance against cavitation damage of the downstream equipment e.g. the
valve, pipeline and control circuitry will receive preference.
7. Mechanical break pressure devices i.e. orifices may be utilised to assist with pressure reduction, provided
that this will not have an adverse effect on the discharge rate at the anticipated specified minimum dynamic
inlet pressure and result in excessive noise and vibration.
Valve construction
1. If hydraulic control activators prove impractical, an alternative control system incorporating electric
solenoid activators may be considered.
2. All control and pilot valves shall be clearly and permanently labelled.
3. Diaphragm-actuated control valves with single or double diaphragm control chambers will be acceptable,
providing that the main shaft is double guided in suitable renewable bearings, preventing excessive wear,
during flow velocities exceeding 3m/s.
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4. Preference will be given to control valves with an open assembly feature, which permits the Inspection of
the control valve’s internal operating mechanism, the seat, plunger, main shaft, etc. without the removal of
the valve from the pipeline.
5. The control valve shall be provided with a dirt trap or strainer system containing a removable 100 - 200 μm
strainer cartridge and a suitable scour plug to flush accumulated debris. This shall be situated in the spool
pipe on the upstream side of the valve preventing interference of the normal functioning of pilot valves and
the obstruction of the main valve seat. The free flow area of this unit shall be larger than the actual control
valve seat area.
6. Stainless steel trimmed control valves including the main valve seat, plunger assembly and shaft with epoxy
powder coated steel or cast iron accessories are preferred to bronze trim. Pinned stainless steel valve seats
are preferred to epoxy glued seats.
7. Pressure gauges shall be permanently mounted up and down stream of the valve on the control system to
indicate all required pressures.
8. All pilot valves shall be supplied sealed, using sealing wire and lead seals, to prevent unauthorised
tampering.
9. Pilot valve components subject to wear e.g. valve seats, pressure sensing membranes, shafts, hydraulic seals,
resilient seats, etc. shall be readily available as replacement spare parts.
Operational requirements
The Contractor shall be responsible for selecting suitable valves to meet these operational requirements. Where
required, the Contractor shall include for any tapers or smaller bypass assemblies to meet the required duties.
Flow control valves:

1. Flow control valves shall be designed to prevent the rate of flow rising above that specified for the particular
application, regardless of the operating pressures in the system upstream or downstream of the valve
2. The valve operation shall be achieved by the operation of a relay valve responding to the pressure difference
measured across an orifice in the flow upstream of the valve.
3. The construction of the valve shall be generally in accordance with that specified for pressure reducing
valves above.
C.4.8 Float valves

1. The ball float valve shall be an equilibrium type, single beat design which will be fitted inside the tank or
reservoir and which automatically controls the rate of filling.
2. The valve will shut off when a predetermined level in the tank is reached. It shall be of right angled design
with a long actuating lever for slow closure.
3. Shut off shall be drop tight and the valve shall have a lined removable cylinder and be easily maintained. The
face and piston seals shall also be easily replaced.
4. The upstream pressure of this type of valve can vary from a full static head in a pipeline to the minimum
residual static head during the maximum anticipated flow rate.
5. The valve system where applicable shall be capable of functioning efficiently under the full range of inlet
pressures.
6. On closing, the valve shall have a linear flow velocity reduction characteristic to reduce pressure surges.
Valve construction
1. All control valves shall be clearly and permanently labelled
2. Preference will be given to control valves with an open assembly feature, which permits the Inspection of the
control valve’s internal operating mechanism, the seat, plunger, main shaft, etc. without the removal of the
valve from the pipeline.
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3. Maximum working pressure shall be 10 bar.

Description Material
Body Cast iron BS EN1561 EN-GJL-250
Cylinder Cast iron BS EN1561 EN-GJL-250
Fulcrum Bracket Cast iron BS EN1561 EN-GJL-250
Valve Centre Cast iron BS EN1561 EN-GJL-250
Float Polypropylene
Seat Ring Gunmetal BS 1400 LG2-C
Valve Guide Gunmetal BS 1400 LG2-C
Lever Mild steel BS EN970 220M07
Fasteners H/T steel
Operating and maintenance manuals

1. Seven copies of Operating and Maintenance Manuals shall be supplied. A Draft copy of the manual shall be
submitted for approval simultaneously with the drawings for manufacturing purposes.
2. The purpose of these documents is to simultaneously provide a permanent and accurate record of all the
equipment provided as well as a usable guide in simple language covering operating, maintenance and fault
finding procedures.
3. The manuals shall be securely bound in A4 size, hard backed plastic/waterproof 4-ring binders, with clear
pockets on the spine and front cover for the insertion of title slips, giving the Contract Number, Scheme, and
a description of the valve supplied.
4. Drawings larger than A3 size, index and other title pages shall be contained in separate plastic pockets, bound
in the appropriate section.
5. The sections shall be separated by plastic dividers, clearly and visibly marked to match the index, and shall
be set out as follows:
(a) Title page;
(b) Index;
(c) Specification and Technical Schedules;
(d) General description with test certificates and final test certificate relating to any tests carried out;
(e) Operating Instructions: These shall be clear, concise and easy to follow and must include, where
applicable, pre-start, safety and shut down procedures;
(f) Routine maintenance and lubricating schedule;
(g) Fault diagnosis and repair procedure;
(h) Detailed schedule of plant components giving materials, corrosion protection, part numbers, etc.;
(i) Spare parts list: Suppliers/Agents details must be provided;
(j) Drawings. They shall include; general arrangements, assembly drawings, hydraulic and electrical
diagrams, parts and material list in A3 and flow discharge curves. Suppliers/Agents ORIGINAL
brochures and instrumental literature shall also be incorporated in the manual.
Operating instructions
• An approved operating instruction notice board made of engraved Aluminium with painted lettering shall
be supplied with the following indicated thereon:
(a) Concise operating instructions;
(b) The numbers of the valves and pilot valves;
(c) The pilot valve piping.
• The notice board shall be mounted above the control system and piping.
Commissioning
• The Contractor shall prepare for commissioning by making use of preliminary factory settings of
the control and pilot valves. No commissioning shall be permitted unless the Contractor is able to
convince the Engineer that the required preparation backed by calculations, where necessary, has
been made.
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C.4.9 Needle valves

• The valves shall be provided with multi-turn electric actuators, a reversing contactor starter and an
electronic controller to progressively open the valve as the water level in the reservoir compartment
falls and close the valve as the water level rises.
Valve construction
• The valves shall have:
(a) A divided body of streamlined shape;
(b) Internal, robust slider-crank mechanism;
(c) External stem gearbox for easy operation;
(d) Linear regulating characteristics;
(e) Piston guide on guide rails;
(f) Actuating shaft supported in maintenance-free bushes on both sides;
(g) Shaft-hub connection by means of parallel key;
(h) Pressure-balanced piston with open piston bearing;
(i) Piston seal with precision O-ring, main seal with enclosed profile ring.
Operational requirements
• The needle valves shall be rated at PN25.
Needle valve control

• The Contractor shall design, supply, install and commission a level control system for the needle
valves. For each valve, the system shall comprise:
(i) An ultrasonic level sensor mounted in the relevant reservoir compartment;
(ii) An electronic controller to receive the signal generated by the level sensor and
progressively open and close the needle valve;
(iii) A reversing contactor starter to adjust the valve opening via the electric valve actuator.
• Separate control systems are required for each reservoir compartment.
• The system shall be designed to progressively open the valve on falling water level and close the
valve on rising water level so as to achieve a modulating action.
• Rapid valve closure shall be avoided. The control system is subject to the approval of the Engineer.
Operating and maintenance manuals

• Seven copies of Operating and Maintenance Manuals shall be supplied.
• The purpose of these documents is to simultaneously provide a permanent and accurate record of
all the equipment provided as well as a usable guide in simple language covering operating,
maintenance and fault finding procedures.
• The manuals shall be securely bound in A4 size, hard backed plastic/waterproof 4-ring binders,
with clear pockets on the spine and front cover for the insertion of title slips, giving the Contract
Number, Scheme, and a description of the valves supplied.
• Drawings larger than A3 size, index and other title pages shall be contained in separate plastic
pockets, bound in the appropriate section
• The sections shall be separated by plastic dividers, clearly and visibly marked to match the index,
and shall be set out as follows:
(a) Title page;
(b) Index;
(c) Specification and Technical Schedules;
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(d) General description with test certificates and final test certificate relating to any tests
carried out;
(e) Operating Instructions: These shall be clear, concise and easy to follow and must include,
where applicable, pre-start, safety and shut down procedures;
(f) Routine maintenance and lubricating schedule;
(g) Fault diagnosis and repair procedure;
(h) Detailed schedule of plant components giving materials, corrosion protection, part
numbers, etc.;
(i) Spare parts list: Suppliers/Agents details must be provided;
(j) Drawings. They shall include; general arrangements, assembly drawings, hydraulic and
electrical diagrams, parts and material list in A3 and flow discharge curves.
Suppliers/Agents ORIGINAL brochures and instrumental literature shall also be
incorporated in the manual.
Operating instructions
• An approved operating instruction notice board made of engraved aluminium with painted lettering
shall be supplied with the following indicated thereon:
(a) Concise operating instructions;
(b) The numbers of the valves and actuators;
(c) The regulating system.
The notice board shall be mounted above the control system and piping.
Commissioning
• The Contractor shall prepare for commissioning by making use of preliminary factory settings of the
control and pilot valves.
• No commissioning shall be permitted unless the Contractor is able to convince the Engineer that the
required preparation backed by calculations, where necessary, has been made
Shop Testing
• All valves shall be Shop tested on liquid service for performance and for water tightness and resistance
to distortion under internal pressure.
• Test shall be carried out on the valves under test pressure and there shall be no leakage through the
metal or permanent deformation of any casting.
• All joints and seats shall be watertight.
• The Engineer or his representative reserves the right to witness any or all tests at no extra cost to the
contract.
Shop Painting
• The unfinished surfaces shall be thoroughly cleaned of rust, sand, scale and foreign substances prior
to painting.
• Surface preparation shall conform to “Commercial Blast Cleaning”.
• Unless otherwise specified, interior surfaces shall be painted with two coats of cold-applied, tasteless
and odour less bituminous paint.
• Exterior surfaces of valves shall be painted with one coat of “Epoxy Phenolic Shop Primer as per
manufacturer’s standards.
• All machined surfaces shall be painted with an approved anti-rust compound.
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• All damaged shop-painted surfaces shall be touched up before finish paint application.
Identification Tags
• Each valve shall be fitted with a numbered bar tag of 37 mm diameter corresponding to its tabulated
number.
Certificates of Installation
• On completion of installation and testing, the manufacturer's certification of the correctness of the
installation shall be submitted to the Engineer.
C.4.10 Actuators
Hand Actuators including Headstocks
Hand operated valves and penstocks shall be fitted with cast iron hand-wheel actuators not exceeding 500 mm diameter
incorporating any necessary gearing to allow opening and closing against the maximum unbalanced head without undue
effort. Gearing shall be totally enclosed. The direction of closing shall be clockwise and the direction of movement for
opening and closing shall be clearly embossed on the hand-wheel.
Gate position indicators shall be fitted to all actuators.
Actuators for flow control valves shall be fitted with suitable low gearing to allow precise control.
All valve operating hand-wheels shall be located in a convenient position for operating by a person standing at floor
level, or on an operating platform, and all necessary extension spindles and headstocks shall be provided. Intermediate
guide brackets shall be provided for all operating spindles exceeding 1.5 m in length and as required to provide rigidity.
Headstocks shall be of the non-rising stem type with cast iron columns and casings complete with a graduated position
indicator. The pillar shall not be less than 750 mm high measured from the base to the hand-wheel and shall be drilled
for fixing. Bevel gearing, when required, shall be provided in totally enclosed oil bath, or grease lubricated bevel gear
housing equipped with oil-impregnated bushes and ball thrust bearings.
All hand operated valves and penstocks shall be provided such that electric actuators may be fitted in the future without
the need for major modification.
Electric Valve Actuators
General
Electric actuators shall be suitable for outside installation and all components shall be housed in waterproof enclosures,
to IP 55 or better, which shall incorporate an anti condensation heater.
The whole actuator shall be of easily maintained, robust construction and shall be sized to guarantee the penstock or
valve opening or closing at the maximum differential pressure specified herein. The operating speed shall be
approximately 300 mm/minute unless otherwise specified.
Major component items shall be coupled via flanged mating faces secured by stainless steel bolts.
The gearbox shall be of the wormgear totally enclosed, oil bath lubricated type, having a cast iron enclosure suitable for
operating at any angle and provided with the appropriate filling and drain plugs. The actuator drive bushing shall be
easily detachable for machining to suit the valve stem or gearbox input shaft and the length of the drive nut shall not be
less than twice the spindle diameter.
The drive shall incorporate a lost motion feature to provide the additional torque required to unseat the valve from the
Òpen' or `Closed' position in the event of the valve being in either position for an extended period. This movement shall
give a hammer blow of sufficient force to free the valve.
The output shaft shall be hollow to accept a rising spindle where appropriate, and incorporate thrust bearings of the ball
or roller type. The design shall preferably permit the gear case to be opened for inspection without releasing the spindle
thrust or taking the penstock/valve out of service.
Motors
All motors fitted to actuators shall be specially designed for the application and of the squirrel cage induction type for
operation from the supply system specified.
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The rated output of the motors shall be determined by the Contractor in relation to the requirements of the mechanical
Plant described elsewhere in this specification, and starting torque shall be at least 10% in excess of maximum service
requirements.
The motors shall preferably be 4 pole 1500 revs/minute machines designed with adequate thermal capacity to ensure
that the actuator and starter can adequately perform, without overheating, the number of successive opening and closing
operations called for in the specific requirements, and in no case shall this number be less than three.
Each motor shall be fitted with a thermostat or thermistor arranged to stop the motor in the event of dangerously high
temperature in the motor windings due to over-current or an abnormally high number of starts per hour.
Manual Operation Interlock
The actuator shall have a hand-wheel for manual operation which will be at standstill during motor operation. A lever
shall be provided for engaging the hand-wheel drive, and this shall be interlocked so that when starting the motor the
hand-wheel is automatically uncoupled without danger to the operator. Provision shall be made for the lever to be
padlocked in either position to prevent hand or motor operation as required.
Position Monitoring
A mechanical position indicator, showing the open, closed or intermediate positions of the valve on a visible dial, shall
be incorporated in the actuator housing.
Torque and Limit Switches
All switches shall be accommodated within the actuator housing and all contacts and mechanism shall be of sealed,
rustproof and robust construction and have a self-cleaning wiping action. Adjustable torque limiting devices and
switches shall be provided to trip the starter in the event of mechanism overload due to obstructions or jamming etc.
They shall be mechanically latched to prevent torque tripping during unseating.
Limit switches shall be arranged to trip the starters when the `fully open' or `fully closed' positions are reached. Should
the manufacturer consider it desirable (to ensure proper seating) the travel may be stopped in the `fully closed' position
by the torque limit switches, but in this case the `fully closed' limit switches shall still be provided, although they will be
adjusted to be inoperative.
Auxiliary Switches
Auxiliary changeover switches shall be provided to operate at each end of the travel, in order that they may be used for
remote controls or indications monitoring the Òpen' and `Closed' positions.
Terminal Facilities
All electrical components shall be wired out to terminal blocks in a common terminal chamber incorporated in the
actuator housing but separated from all actuator components by means of a watertight seal.
Each terminal shall be labelled to correspond with the diagram of connections and shall be capable of receiving 2.5 mm²
copper conductors. AC and DC terminals shall be clearly segregated.
Terminal blocks shall comprise shrouded anti tracking mouldings of melamine phenolic or comparable material with
provision for securing conductors by screw clamp connectors or other approved vibration proof devices.
The terminal chamber shall be provided with three tapped conduit entries, 1 mm x 32 mm ET and 2 mm x 25 mm ET or
as otherwise specified. These holes shall be plugged with suitable plugs during transit and storage to prevent ingress of
moisture or foreign matter.
Any conduit entries not used after cabling is completed shall be plugged with threaded brass blanks and the threaded
joints made watertight by using suitable tape or jointing compound.
Starters and Control Gear
The actuator motor shall be controlled through integrally mounted electrically and mechanically interlocked contactors,
rated for switching the motor direct on line, adequate for the duty requirements and complete with all necessary auxiliary
contacts for the functions specified herein.
The control circuit shall operate at 24V DC derived from a suitably rated transformer/rectifier with one side of the
secondary winding connected to earth or as otherwise specified. Primary and secondary windings shall be protected by
cartridge type fuses.
The method of control and operation shall be as called for under the specific requirements and the actuator shall be
provided with any facilities called for therein to suit the method of control, whether this is automatic or by hand. Local
controls integrally mounted on the actuator shall consist of push buttons for Òpen', `Close' and `Stop' functions, together
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with a Remote/Off/Local selector, lockable in all positions. The "Stop" button shall be effective in both local and remote
settings and operate directly in the contactor control circuit.
Actuator Isolators
The switch shall have a slow make and break mechanism of the two position rotary pattern arranged to isolate the 3
phase supply and all other control circuit supplies to the actuator. The ratings and number of poles required for each
duty shall be as necessary for the specific requirements, the isolator rating being based on the actuator average load
current being switched normally off load, but emergency on load.
Each switch shall be incorporated in a heavy duty, hoseproof, cast aluminium enclosure to IP55, having external fixing
lugs and adequate seals and drip shields on the operating shaft and cover. Austinlite rotary type EXO 190 or equal.
Switch positions shall be 90° apart, clearly and permanently inscribed or embossed as ÒFF' and ÒN' on the cover, and
the switch handle shall incorporate provision for the switch to be padlocked in both the ÒFF' and ÒN' position. The
ÒFF' position to be to the left of centre or vertical, the ÒN' position to the right or horizontal.
It shall be possible to remove the switch cover for access to the terminal without disturbing the switch or its mounting
base. The enclosure shall be suitable for mounting on, or adjacent to, the penstock pedestal. If mounted on the penstock
pedestal, cabling between the isolator and the actuator above may be arranged through conduit connections, suitable for
disconnection should it be necessary to remove the actuator assembly complete.
C.4.11 Electric Motor

• Electric motors shall be manufactured to the requirements of BS 4999 and BS 5000.
• All motors shall be of high efficiency type with efficiency level of not less than IE2. The motors shall be
continuously rated at least 10% above the maximum power absorbed by the pump within the specified
operating range.
• Motors driven through VFD must be compactable to VFD.
• The motor shall be squirrel cage induction type, totally enclosed fan cooled.
• The motors shall be designed to operate from a 3 phase 400V ± 10%, 50 Hz supply having the star point earthed
and a phase sequence running R-Y-B anticlockwise.
• Motors to be coupled with Raw Water Pumps shall be designed for 1500 RPM & those to be coupled with
Clear Water Pumps shall be with 3000 RPM.
• Motor shall be insulated to Class F with Class B temperature rise. Materials shall be based on a resin bonded
system being inherently water repellent.
• The complete motor interior including rotor and stator windings and core shall be finished with 2 coats of
suitable anti-tracking oil and water repelling paint.
• The motor shall be designed for an ambient temperature of 40oC.
• Motors for both indoor and external use shall be constructed with BS 5490, IP.55 enclosure and Class ICO.141
method of cooling for LV motors.
• Motors shall be fitted with grease lubricated ball and/or roller bearings incorporating effective seals to prevent
grease leakage.
• Motors shall be CMR rated to allow continuous running and a starting/stopping sequence to adequately meet
the duty cycle.
• Motors of 50kW and above shall be fitted with thermistor high winding temperature protection.
• Motor terminals shall be protected with corrosion resistant grease after installation.
• Terminal boxes shall be provided, suitable for PVC/SWA/PVC or XLPE/SWA/PVC cables for all external
cabling connections.
• All boxes shall be bonded to the main frame earth and the frame of each machine shall be provided with means
of connecting an earth protective conductor.
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• Each motor above 5 KW rating shall be fitted with an anti-condensation heater of sufficient rating to maintain
the motor at 5°C above ambient temperature when the motor is at rest.
• The heaters shall be connected into the motor starter circuit such that they are switched off when the motor is
running.
Mechanical Features
Enclosure
• The motor shall have TEFC enclosure. The motor shall have integral longitudinal ribs for effective heat
transfer.
• The stator and end shields shall be machined to close tolerances for providing perfect alignment and fits.
• The terminal box shall be of cast iron. All joints in the terminal box shall be sealed with gaskets.
• In addition to above, the motor shall also have drain holes at their lowest position as a standard feature.
Core
Both the rotor and the stator shall be made of high quality magnetic steel.
Windings
• The stator and the rotor windings shall consist of modified polyester enamel covered copper wire
conforming to relevant standard.
• The motor shall be wound with dual coat copper wire as per relevant standard.
• Winding shall be joint less to avoid hot spots and enhance service life and reliability.
Insulation
• The motor shall be provided with Class F insulation. The slot liners shall be provided either with double
cuffing or edge binding at the slot mouth portion to strengthen the insulation.
• For impregnation purpose, Class F varnish or resin with vacuum pressure impregnation shall be used.
Epoxy gel coat shall be sprayed on all winding overhangs to provide mechanical rigidness to the
windings for withstanding the electrical and mechanical stresses.
• Surge testing shall be carried out on all the windings in addition to all other tests ensuring healthiness of
windings.
• The overhangs of the slip ring motor shall be banded with resin glass tapes under controlled tension, to
prevent flaring under centrifugal force caused by over-speed.
Rotor
The rotor shall be wound with copper wire or strip.
Shaft
The shaft shall be made of C 40 (EN8) steel. Shaft bars above 50mm diameter shall be ultrasonically tested
for detection of flaws, before taken up for machining.
Terminal Box
• Terminal boxes of motor shall be rotatable in steps of 90o. This feature has been incorporated in order to
facilitate the cable entry from any direction. The terminal box shall be fitted with trifurcating box.
• There shall be sufficient space below the terminal box to facilitate the cable entry from the bottom as
the trifurcated box ends below the level of motor feet.
• The terminal box provided for the standard motor is of dies cast aluminium alloy or cat iron.
• As a standard practice, for cast iron body motors, the terminal box is provided on the right hand side,
when viewed from the driving end. If required, terminal box can be provided on left-hand side as viewed
from the driving end or on the top.
• In the case of Star/Delta starting, the terminal box shall be of double Decker type for easy termination
of two cables.
• Anti-rotating socket arrangement shall be provided in addition.
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• Clearance and creep age distances in the terminal box shall be as per relevant standard.
Cable Glands
• Standard TEFC motors shall be provided with threaded cable entry. These holes are plugged with PVC
plugs.
Finish
• All castings and MS components shall be provided with red oxide primer and aluminum components
with zinc chromate primer.
Electrical Features
Direction of rotation
• Motors shall be capable of rotating in either direction. The direction of rotation of the motor can be
reversed by interchanging the two phase connections.
• Motor shall be provided with arrow plate to indicate the direction of rotation.
Insulation Class
• The induction motors shall be provided with Class “F” insulation.
• The following details show the maximum temperature rise at the ambient temperature of 40 degree
Celsius and the Hot Spot temperature for the respective Class of insulation. The Hot Spot Allowance is
an empirical value expressed in Celsius by which the hottest spot of the winding can exceed the mean
temperature rise of the winding.
Earthing
• Earthing pads shall be provided on the stator of the motor. M12 screws and washers shall be provided
for earthing on either side of the motor. Additional earthing shall be provided inside the terminal box of
the motor for the safety purpose.
Duty
• The various operating cycles of the driven machines can be classified into nine basic duties, ranging
from S1 to S9. The motor shall be of S1 continuous duty type.
• The motor shall be suitable to operate at constant load of sufficient duration of thermal equilibrium to
be reached.
Overload
• The motor shall be designed to withstand overload upto1.6 times its rated torque for 1.5 seconds without
installing or abrupt change in speed at rated supply conditions.
Thermistors
• A combination of different ranges of thermistors shall be provided in the motor for Alarm and Trip
facilities.
• Three Nos. thermistors connected in series shall be placed inside of each of the phase windings of the
motor.
• This gives protection against single phasing and overheating due to excess load of the motor.
• During normal operation the thermistors carry a current of few milli Amperes, which is sufficient to
actuate a relay in control unit.
• This in turn allows the contactor-operating coil to hold the starter in the “Run” position. If the winding
of the motor heats up to such an extent so as to bring the temperature of the thermistor up to the “Curie
Point”, the increase in resistance causes the relay to open and the contactor to disconnect the motor
supply.
• The leads of the thermistors are brought to a separate auxiliary terminal box provided in addition to the
main terminal box.
Space Heaters
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• Space Heaters shall be provided over the winding of the motor. The main function of the heaters is to
heat the windings, when motor is in idle condition or kept in storage, in order to prevent moisture or dew
settling over the windings, and thereby reducing the insulation resistance.
• Supply must be switched “OFF” before switching “ON” the motor. The space heaters shall be of rating
50/60 W, 240V single phase.
• The space heater leads shall be brought to a separate auxiliary terminal box.
Test Requirements
• Following type tests shall be conducted by the manufacturer on the motor of the same design, rating and
construction shall be submitted for verification.
• If the type test reports are not available, the following tests shall be carried out on one of the supplied
motor of the same design, rating and construction.
i. Temperature Rise
ii. Power factor and rated load
iii. Locked rotor torque
iv. Starting (locked rotor) current
The following tests shall be conducted at the manufacturer’s works in accordance with the applicable standards;
i. No load losses and current (Routine test on each motor)
ii. High voltage (dielectric) test (Routine test on each motor)
iii. Vibration test (Routine test on each motor)
iv. Efficiency test at rated load (basic test on one motor of each rating and design)
Base Frame for Motor & Pump
• The common base plate for pump & motor shall be fabricated from mild steel section to resist vibration
and distortion. Suitable holes for grouting shall be provided so as to ensure properly and accurately
aligned bolts doweled to the base plate.
• Foundation bolts shall be complete with nuts & washers.
C.4.12 Pumps- General

Workshop acceptance tests for all pumps shall be carried out in the presence of, and to the satisfaction of the
Engineer.
• If so instructed by the Engineer, the Contractor shall nominate an independent and certified agent to
inspect the pumps and witness the tests.
• The nominee shall be acceptable to the Engineer. The Contractor shall give the Engineer a minimum
of two weeks advance notice of any testing.
• The Contractor shall submit a report, together with the certified test certificates, of each test specified,
prior to delivery of the equipment, for comments by the Engineer.
• The Engineer’s “no objection” shall not relieve the Contractor of his obligations under the contract.
Performance Tests
• Each pump shall undergo performance tests in accordance with the latest version of ANSI/H11.6-2000
Level-1. Each low lift pump shall undergo level-2 performance tests.
• Each pump unit shall be completely assembled with its own motor and tested for the guaranteed values
provided in the contract for the following:
I. Flow rate in MLD;
II. Total head in Meters;
III. Pump efficiency;
IV. Motor power input;
V. NPSH required, where applicable.
The values for head, efficiency, power and NPSH shall be plotted on a graph against the flow rate. The flow
rate shall be plotted on the X axis.
Vibration Tests
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Vibration tests shall be carried out in accordance with ISO 10816-1 for all pumps. Factory testing shall give
a vibration severity no greater than 7.1mm/sec (RMS) for flexible support class, and 4.5mm/sec (RMS) for
liquid support class, as specified by ISO 10816-3 in Table C.22, Zone Boundary B/C, given below:
Table- C. 22
Support Class Zone Boundary RMS displacement RMS Velocity

µm mm/s
Rigid A/B 18 2,3
B/C 36 4,5
C/D 56 7,1
Flexible A/B 28 3,5
B/C 56 7,1
C/D 90 11,0
Sound Pressure Test

• Sound pressure testing shall be carried out to verify that the pump sound pressure level does not exceed
the specified limit when the pump operates at duty point and shall be tested in accordance with
AS1217.5-7 or equivalent.
• The measured sound frequency spectrum shall be included as part of the report.
Horizontal/Vertical Centrifugal Pump Units

Design, Workmanship and Construction
• The Pump shall be designed and built for continuous operation and suitable for starting against an open
valve.
• Similar pumping units shall be of identical design and manufacture with corresponding parts
interchangeable
• Castings shall be free from flaws and imperfections and machined surfaces shall be finished true
• All joints shall be machined and all castings shall be shop faced for nuts.
• All similar parts shall be made to similar gauge wherever possible.
• The inside and outside corners and edges of all castings shall be rounded off, wherever possible, with
fillet and chamfers.
• All screws, bolts and nuts shall be metric standard, as specified under CLASS 1.8. No patching,
plugging, shimming or other such means of overcoming defects, discrepancies or errors shall be resorted
to without the written permission of the Engineer.
• The drives shall have adequate capacities to run the pumps at all conditions of operation. All pumps
shall be statically and dynamically balanced.
Pump Type and Configuration

• The required pump type is a horizontal end suction and axially split volute casing pump, left or right side
horizontal drive installation, or equivalent design, electric motor driven surface centrifugal pump.
• The centrifugal pumps shall comply with the relevant clause of the general specification.
• All pumps and associated equipment are to be derated for an ambient temperature of 35 degree Celsius
and an altitude of 1200 m mean average spring level.
• Pumps are to be selected to transfer water from any water level in the suction well to the receiving tank,
having due regard to the range of water levels and possible friction losses.
• When pumping against the maximum head with all pumps in operation, each pump must have an
adequate throughput for cooling
• With one pump running alone, the selected pump must not overload its motor when pumping against the
minimum possible head
• The pump curves must be sufficiently steep to avoid excessive drawdowns when pipe friction losses are
low
• The selected pumps shall be free from cavitation at all times
• The pumps shall be protected against low water level in the sump using an electrode probe and a
protection relay (installed in the starter box of the centrifugal pump compartments).
• The metering instruments shall be calibrated in metric units, namely cubic meter for water meter and
meter or bar for pressure gauge.
• The pressure gauge shall be connected by a three-way cock.
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• Surge vessels sized for the pipeline system will be installed on the common discharge pipe on the sites
shown in the drawings.
Scope of Supply
The supply shall include the following items, among others, as indicated in the corresponding drawings;
• Pumps with power and control cables, pump control panel
• Suction and delivery piping
• Non-return valves
• Gate valves
• Butterfly valves
• Air release valves
• Pressure gauges
• Pressure switches
• Pressure reducers
• Piping to connect pump to the suction reservoir outlet pipe
• Piping to connect pump to the discharge (collector) pipe
Pump Control
• The pumps will be controlled from a common control panel installed in the pump control room.
• The pumps will be automatically controlled from high, start and low level control probes installed in the
reservoir and pressure switches installed on the delivery line.
• The motor control panel to be installed in the control building shall be provided with a start stop switch
as well as provision for the indication of general fault and operation status.
• To protect the pumps against cavitation risk, a third level electrode will be installed in the reservoir so
that pumps would not be started until the level in the reservoir has reached a set level.
• The pumps shall also be provided with the following automatic cut-outs, to stop the pump and indicate
a fault, at the local panel.
Low reservoir level

High reservoir level
Pump start sensor status
High delivery pressure (closed valve);
Phase failure;
Over current;
Under voltage, or
Over voltage.
• The pump operation status and tank levels indication will be transmitted to the central CONTROL
PANEL in the pump control room.
Pump Construction
• Casing:
• Cast Iron Volute Casing of JL 1040, Ductile Cast Iron of JS 1030, Ni – Resistant, Duplex Steel or as
specified by Manufacturer
• Close grained high tensile cast iron to ASTM A-278 class 25 or equivalent; or ductile from ASTM A-
395;
• Back pall out design with flanged suction and discharge nozzles cast integrally with the main pump
casing;
• Suction and discharge flanges to ANSI clam 125, faced, drilled and spot faced;
• Provide tapped openings for drain and gauge connections;
• Hydrostatic to 1.5 times the sum of maximum suction pressure and shut off head; and
• Provide lifting lugs or eye bolts.
• Impellers:
• Cast Iron of JL 1040, bronze of G-CuSn10, Duplex Steel or as specified by Manufacturer;
• Enclosed, non-overloading type, secured to the shaft by a key and locked in place; and
• Statically and dynamically balanced.
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• Wearing Rings:
• Bronze, Chromium nickel steel, Duplex Steel or as specified by Manufacturer
• Provide wearing rings for casing and impeller;
• Renewable bronze or a combination of bronze and stainless steel; and
• Where suitable, double labyrinth type design is preferred.
• Shaft:
• Quenched and tampered steel, Chromium Steel, Duplex Steel or as specified by Manufacturer
• Adequately sized to take all kinds of loading without vibration and fatigue failure;
• Fitted with sleeves of corrosion-resistant iron- chromium alloy (11 to 14% Cr.) or equivalent, easily
replaceable design. Provide O-ring type seals to prevent leakage.
• Stuffing Boxes:
• Uncooled soft – packed stuffing box or uncooled, single – acting, unbalanced bi – directional mechanical
seal or as specified by manufacturer;
• With an operating pressure of more than 16 bars, mechanical seal, balanced by hydraulic means; or
• Designed for integral water scaling;
• Bronze lantern gland packed with PTFE or Nitril Synthetic Fibre or equivalent, non-asbestos, and non-
toxic packing material;
• Provide drip boxes and tapped drainage opening to allow collection of waste SCW water to drain; and
• Provide defector or slinger rings to prevent entry of water into the bearings.
• Bearings:
• Grease lubricated on both sides, maintenance free, deep groove ball bearing, sealed for life or as specified
by manufacturer
• Designed to take line and thrust loads under all operating conditions; or
• Anti-friction type, sized and rated for at least 100,000 hours B-10 Bearing Rating Life;
• Pump Accessories
• Couplings:
• forged steel, gear type flexible shaft coupling or Fenner “tyre type” with spacer to connect pump and
motor;
• designed to transmit full power limit end play of motor; absorb angular and parallel misalignment as
well as axial movement due to vibration or thermal expansion and contraction of pump and motor;
• Provide coupling guard of expanded metal construction, properly anchored to the base plate.
• Base plates:
• heavy cast or welded steel common base plate with machined hub for mounting both pump and motor;
• provide: grouting holes; drilled lugs for anchor bolts; drain gutter around pump area, fitted with 25 mm
dia. drain connection;
• Both pump and motor shall be assembled in the shop for initial alignment and doweling.
C.4.13 Air Blowers, Vacuum Pumps and Air Compressors

Prior to testing, all dirt and other foreign material shall be thoroughly removed from each Air Blower, Vacuum Pump
and Air Compressor, pipework and appurtenances to prevent any damage to the motor-driven equipment item.
Each blower / pump / compressor shall be test run and its performance shall be checked against the specified
requirements. The blower / pump / compressor shall be free from vibration, overheating of bearings and leakage. The
required specification is tabulated below:-
Process Data
Discharge Pressure 0.4 kg/cm2 g
Quantity 2 (1 working and 1 standby) each for existing and new
filter units
Location Indoor
Noise level Limited to 80dB(A) @ 1m distance from equipment
Mechanical Data
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Drive type Motor

Pressure Ration (P2/P1) 1.4:1.0
Motor Data
Insulation Class F
Enclosure IP 55
General
Material Casing: CI, Impeller: CI
Acoustic Enclosure Acoustic hood- Galvanized Steel Plate
C.5 Electrical Plant

C.5.1 General
All plant and equipment supplied under this Bid shall be new unless otherwise specified.
Local Authorities and Public Utilities
The Contractor shall carry out all liaisons and produce all information to ensure that the requirements of the Local
Authority, Local Fire Officer, and Electricity Utility are met. All approvals necessary from Statutory Authorities for the
Works shall be the responsibility of the Contractor. The Engineer shall assist wherever possible on request.
Material
All material shall be new and material of a given type shall be of a single manufacturer throughout the work. The
Contractor shall be responsible for the handling, care and safekeeping of all the equipment and materials associated with
the work of this Contract.
Installation
All equipment shall be located and installed so that it is readily accessible for operation and maintenance by personnel
of average height and build and without requiring special tools or equipment.
The Engineer reserves the right to require changes in location of equipment, prior to roughing in, without incurring any
additional costs or charges.
Electrical work shall be performed in co-operation with other trades in order to secure the best arrangement of the work
as a whole.
All work shall be carried out in accordance with best current trade practices and to the satisfaction of the Engineer and
the power supply authority.
Locks
All locks and locking systems shall comply with the site master key requirements if any and shall be approved by the
Engineer. Devices required to be lockable shall be suitable for padlocks having a 6 mm hasp.
Permits
The Contractor shall arrange and pay for all permits, inspections and other costs incidental to providing the electrical
installation.
Underground Services
The Contractor shall note the presence of existing underground services and their approximate location and levels.
Extreme care shall be exercised by the Contractor to ensure that there is no damage or interruption to these services.
This applies particularly to work carried out in the vicinity of existing plant.
Service Conditions
The project area is categorized into tropical climate zone.
In choosing materials and their finishes, due regard shall be given to the service conditions under which the plant shall
be called upon to work. The Contractor shall submit details of his usual practices which have proven satisfactory and
which he/she recommends for application to the parts of the work, which may be affected by project area climatic
conditions. The materials and finishes used shall be approved by the Employer. All equipment and materials used shall
also be rodent and vermin proof.
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Environment
Unless otherwise specifically stated in Technical Specifications or Scope of Works, any equipment, component and
assembly shall be designed for continuous operation under the service conditions indicated in Table C-23
Table C-23 Service Conditions for Electrical Equipment / Components
Parameter Max Min
Ambient air temperature

Outdoor +45°C 1°C
Indoor +45°C 1°C
24 hour average maximum +37°C 1°C
Relative humidity 30% - 99%
EMC Class (IEC 61000) Industrial environments
Maximum wind velocity 40 m/s
Rainfall conditions
Average 627-1260 mm/year
Maximum 303 mm in 24 hrs
Pollution (IEC 60815) Heavy :class III
Annual mean isokeraunic level Max 180 thunderstorm days
Wherever ambient temperatures exceed the specified 45°C, the rating of the plant shall be reduced accordingly.
All air cooled equipment shall be cooled with convection (i.e. without fans) provided other cooling methods are not
explicitly allowed for in the specifications.
The equipment shall as far as possible not generate undue vibrations or bothersome noise.
Tropicalization
All equipment must be designed for operations in the severe tropic climate conditions and fully comply with climatic
aging tests as per IEC 60932-class 2.
Where specific service conditions have not been specified, the Contractor shall submit details of his usual practice which
have proven satisfactory and which he recommends for application to the parts of the work, which may be affected by
tropical conditions.
Metals
Iron and Steel are generally to be painted or galvanized as appropriate. Indoor parts may alternatively have chromium or
copper-nickel plates or other approved protective finish. Small iron and steel parts (other than stainless steel) of all
instruments and electrical equipment, the cores of electromagnets and the metal parts of mechanisms shall be treated in
an appropriate manner to prevent rusting.
Screws and Nuts
The use of iron and steels shall be avoided in instruments wherever possible. Steel screws shall be zinc, cadmium or
chromium plated or where plating is not possible owing to tolerance limitations, shall be of corrosion resisting steel.
Instrument screws (except those forming part of a magnetic circuit) shall be of brass or bronze.
Springs
Springs shall be of non-rusting material, egg., phosphor-bronze or nickel silver or similar.
Rubbers
Neoprene and similar synthetic compounds, not subject to deterioration due to the climatic conditions, shall be used for
gaskets, sealing rings, diaphragms, etc.
Tropicalization to be in compliance with:
i) Climate Graph No. 8 of the IEC 60721-2-1,
165
ii) Test B: Dry Heat IEC 60068-2-2

iii) Test Bd: Damp Heat, Cyclic IEC 60068-2-30.
Location of Equipment
The Contractor is cautioned that space for installing electrical equipment in areas of the plant and buildings will be
governed by the location of other equipment, which will in most cases have precedence over electrical equipment. Prior
to commencing installation, the Contractor shall liaise with other Contractors and the Engineer to co-ordinate the final
location of equipment, fittings, cables and supports to be installed under this Contract, with equipment and services to
be installed by others. Failure to co-ordinate the location of equipment in this way and obtain the Engineer's written
approval may result in the Contractor being required to relocate equipment, fittings, cables and cable supports at his own
expense.
Outdoor Equipment
All outdoor equipment shall have a minimum enclosure rating of IP56 unless a higher rating is specified or shown on
the Drawings.
Cabling and Control System Arrangements
The cabling and controls specified and/or shown on the Contract Drawings are based on available data pertaining to
particular types of equipment and design. If the Contractor offers equipment which requires a different arrangement of
cabling and controls, then acceptance of the Contractor’s equipment does not relieve the Contractor of their responsibility
to provide a complete and operable system including the necessary changes to the cabling and controls at no additional
cost.
Electrical Surge Protection
Electrical surge protection shall be provided for all outdoor signal connections – i.e. external to buildings and outdoor
control cubicle/cabinets. The protection shall be completely compatible with the connected equipment to provide
protection of equipment against surges and transients induced in signal and power lines and antennas by lightning or
electrical switching.
Analogue Protection shall be provided for use on externally connected 4-20 mA DC signals at the loop power supply
voltage with a resistance of less than 40 ohms. It shall be rated to withstand a peak impulse current of at least 10 kA for
an 8/20 micro-second pulse (8 micro-second rise time, 20 micro-second exponential decay time) for line-to-line and line-
to-earth transients and arranged to fail to the short circuit condition.
Electrical surge protection shall be earthed in accordance with manufacturer’s instructions.
Numbering Systems
The Contractor shall number and identify all items of equipment, circuit breakers, fuses, relays, switches, instruments,
control panels, cubicle/cabinets, junction boxes, cables, wires and the like with approved numbering systems and in
accordance with the Employer’s requirements. All such numbers shall be used exclusively on all documentation and
labels.
C.5.2 Power Transformers
General
Power transformers shall:
i) Be in accordance with IEC 60076
ii) Be outdoor, ground mounted and weatherproof
iii) Be two winding fully insulated type
iv) Be oil immersed type – ONAN
v) Have off-circuit tapping’s as indicated
vi) The neutral of the secondary windings shall be brought out to a terminal for direct connection to
earthing system
vii) Have fully enclosed air insulated cable boxes for the primary and secondary terminations
viii) Have all external bolts and fasteners of stainless steel
ix) Be fitted with internal current transformers as specified and shown on the Drawings
x) Be manufactured of materials and components that will not contaminate the oil and free from PBC
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Transformer Ratings and Data
Sr. No. Item 11kV Distribution 33kV Distribution
1 System Voltage (max.) 12 kV 36 kV
2 Rated Voltage HV 11 kV 33 kV
3 Rated Voltage LV 400 V 400 V
4 Frequency 50Hz +/-5% 50Hz +/-5%
5 Number of Phases 3 3
6 Connection HV Delta Delta
7 Connection LV Star (Neutral brought Star (Neutral brought

out) out)
8 Vector Group Dyn-11 Dyn-11
9 Type of cooling ONAN ONAN
Audible sound levels (Decibel’s) at rated voltage and frequency for liquid immersed distribution transformers
shall be as below (NEMA Standards)
0-50 48
51-100 51
101-300 55
301-500 56
750 57
1000 58
1500 60
2000 61
2500 62
i) Transformers shall be suitable for service with fluctuations in supply voltage upto plus 12.5% to minus
12.5%.
ii) Maximum temperature rise above ambient : 50°C top oil / 55°C winding
iii) Insulation Level :Refer below:
Sr. No. Voltage (kV) Impulse Voltage Power Frequency

Voltage (kV)
(kV Peak)
1 0.400 - 3
2 11 95 28
3 33 170 70
Transformer Losses
Contractors shall declare guaranteed values for no load loss and load loss of the total losses for each type of transformer
offered. The positive tolerance stipulated in the standards will not be accepted. The declared guarantees must be
achieved. The Employer reserves the right to reject any transformer which does not achieve its declared guaranteed
values during the witness tests at the Manufacturer's works. In the event of transformers yielding losses which are either
equal to or below the guaranteed values, the Contractor will not be entitled to any premium for the reduction in losses
below the guaranteed values.
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Fault Withstand
All transformers shall be capable of withstanding on any tapping and without damage the thermal and dynamic effects
of external short circuits. For this purpose the design short circuit level for each system voltage is to be stated in the
Technical Schedules.
Evidence shall be submitted with the Bid as to the extent to which the manufacturer has proved or is able to provide
either by calculation or test the ability of the specified transformers to withstand short circuit.
Cores
Cores shall be built from non-ageing low loss, high grade, cold rolled grain oriented silicon alloy electrical steel or strip.
The whole core assembly shall be securely and rigidly clamped to ensure that noise and vibrations is maintained in
service at a minimum level consistent with current good practice. All structural steel associated with the core shall be
shot blasted to remove scale and then varnished or provided with an approved surface finish.
Means shall be provided for lifting the core from the tank and the core shall be efficiently bonded to the tank by means
of copper tape or other approved means for oil immersed transformer.
Windings
The windings shall comprise high conductivity copper or aluminium conductors insulated with Class 'A' material or
better.
Both primary and secondary windings shall be of uniform insulation.
Adequate provision shall be made for free circulation of oil round and between the windings so that a low temperature
gradient between conductors and oil is assured and any danger of excessive local heating is eliminated.
Tappings shall be brought out from the outermost layer of coil.
Each completed core winding assembly shall be oven and vacuum dried before impregnation. During the drying process,
coil clamping pressures shall be adjusted to compensate for insulation shrinkage so that no further shrinkage will take
place after assembly. The completed core winding assembly shall be secured to the transformer main tank by means of
a clamping structure.
Transformer Terminals
All terminals shall be brought out through oil tight porcelain bushings to their respective chambers. The arrangement of
the internal connection and bushings shall be such that the transformer tank cover with the core and windings may be
lifted bodily from the tank without disturbing the cable boxes or bushings. In this respect, transformers with corrugated
tanks and bushings mounted on the tank cover will not be accepted.
Transformer Cable Boxes
Cable termination boxes shall be provided for the termination of vertically ascending high voltage and low voltage
cables. The cable boxes shall be fully air insulated and shall be suitable for terminating the cables as shown on the
Drawings.
Cables shall be terminated in metal enclosed boxes complete with all fittings necessary to terminate the cable and cores
and having sufficient space for segregating the cores and maintaining the electrical clearances applicable. To facilitate
easy handling, handles shall be provided on covers of cable boxes. Ventilation by means of breathing hole to avoid
condensation shall be provided, the design of which shall be to the approval of Engineer
The breathing hole shall be provided with a fine stainless steel mesh filter to protect against entry of insects. All cable
boxes shall be supplied with suitable glands and their bottom plate shall be made detachable for ease of termination.
Suitable compression type lugs shall be used for termination of conductors. The cable boxes shall be provided with heat
shrinkable termination kits for HV cables. Use of coverings/boots over lugs is not acceptable. Each kit shall be supplied
complete with tinned copper braids for earthing purposes. Provision shall be made for earthing the cable boxes, cable
glands and cable earthing braids.
The cable boxes shall be suitable for withstanding the high voltage tests applicable to the cables connected therein in
accordance with the relevant standards and including BS 6622 and 5467.
Strong channel iron supports anchored to the transformer plinth, with metal cleats, shall be provided to secure the vertical
power cables in position at the cable boxes. The channel iron shall be treated with anti-corrosive paint and painted the
same colour as the transformer.
Earthing of Transformers
All metal frame work of the transformer, gauges, etc. shall be effectively earthed. Method of earthing and selection of
earthing bar/conductor sizes shall be in accordance with earthing Regulations and Codes.
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Two earthing terminals, each capable of carrying the maximum possible earth fault current of the lower voltage without
damage for a duration equal to the short circuit period for which the windings are designed, shall be provided on each
transformer. They shall be located on either side of the transformer, near to the bottom of the tank to facilitate connection
to the sub-station or station earthing system. The bolts and nuts shall be of stainless steel grade 304 or 316.
Neutral Earthing
The star point of each winding shall be brought out through the tank and suitably terminated in the corresponding winding
cable box.
Off Circuit Tap Changers
Winding taps shall be provided on the primary windings (higher voltage windings).
An externally operated off load/circuit tap changing switch shall be provided and fitted with a positive locking device to
enable the switch to be locked at any desired tapping but not in any intermediate position between adjoining taps. A brass
weatherproof padlock with three keys shall be provided. Tap changing shall be possible by a person in standing position
and a indicator shall be provided to show the position of the tapping connection at which the transformer is operating.
A warning label to instruct the operator to isolate the transformer before operating the switch shall be fitted near the
switch.
On Load Tap Changers
Transformers with rating more than1000kVA shall be provided with on load tap changer.
Transformer Tanks
Each transformer shall be enclosed in a suitably stiffened welded steel tank so that it may be lifted and transported
without permanent deformation or oil leakage.
Top plates shall be weld sealed for ratings up to 800kVA. Ratings greater than 800kVA shall have gasketted removable
top cover plates.
The tank and bolted top cover shall be designed in such a manner as to leave no external pockets in which water can
lodge, no internal pockets in which oil can remain when draining the tank, or in which air can be trapped when filling
the tank. All external surfaces shall be easily accessible for painting.
Pockets shall be provided for a stem type thermometer and for the bulbs of dial type temperature indicators where
specified. These pockets shall be located in the position of maximum oil temperature and it must be possible to remove
any bulb without lowering the oil level in the tank. Captive screwed caps shall be provided to prevent the ingress of
water to the thermometer pockets when they are not in use.
For cooling purposes, the tanks shall have built on radiators connected to the sides of the main tank through machined
flanges. Alternatively, tanks shall be fitted with cooling tubes which may be either directly welded onto the tank sides or
welded onto separate headers. Tanks and radiators or cooling tubes shall be so designed as to facilitate external painting
at site without the use of special brushes and to prevent any accumulation of moisture. Radiators shall be made detachable
by the provision isolating valves lockable in the open position. Drain and air plugs shall also be provided.
The tanks and radiators (or cooling tubes/fins) shall be pressure tested and capable of withstanding without any oil leak
or excessive permanent deformation, a hydraulic test pressure equal to 15kPa gauge plus normal static head of oil for 24
hours.
Each transformer shall also have a over pressure relief device of the self-resetting type designed to protect the tank from
damage and to control the expulsion of oil under internal fault.
All tanks shall be capable of withstanding full vacuum to enable the evacuation of the nitrogen before oil filling or the
vacuum required by the recommended drying out procedure, whichever is greater.
Lifting lugs shall be provided, suitable for the weight of the transformer, including core, windings, fittings and oil. Each
tank shall be provided with four jacking lugs. The same or additional lugs shall be suitably positioned to enable
transformers to be supported on continuous beams for the purposes of transport.
Tanks shall be provided with skid bases. Detachable under bases shall not be used. The base of each tank shall be so
designed that it is possible to move the complete transformer in any direction without injury when using rollers, plates
or rails. Where the base is of channel iron construction it shall be designed to prevent retention of water.
Tanks shall be provided with suitable hand holes to facilitate access to connections between windings and the bushings.
It shall be possible to remove any bushing without removing the tank cover.
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Metalwork finishing shall be of the highest workmanship and in accordance with the current best trade practices. Painting
shall be as specified and shall be suitable for the installed environment for the transformer life. Full details of painting
shall be provided with the Bid.
Valves
Each transformer shall be provided with a filter valve at the top and one at the bottom of the main tank, mounted
diagonally opposite each other, for connection to oil filtering equipment. A drain valve shall also be provided at the
bottom of the tank. This valve shall also be provided with suitable oil sampling device so that oil samples may be taken
with the transformer alive.
The outlet of all filter and drain valves shall have female threads. Blank flange plates shall be fitted to all pipe and valve
ends. Flanges for oil pipework and valves shall comply with relevant local standards and BS 4504 or BS EN 1092:2002.
All valves up to and including 100 mm bore shall be made of gunmetal. Subject to the approval of the Engineer, valves
larger than 100 mm bore may have cast iron bodies with gunmetal fittings.
Every valve shall be fitted with a nameplate permanently inscribed with an approved inscription which will indicate the
purpose of the valve.
Valves other than those specified will not be accepted unless approved in writing by the Engineer, before manufacture.
Joints and Gaskets
All joint faces shall be suitably machined and arranged to prevent the ingress of moisture or leakage of oil by the use of
suitable gaskets. Oil resisting synthetic rubber shall be used as a bonding medium for cork or similar material.
Transformer Fittings and Accessories
All transformers shall be provided with the following:
i) Stainless steel rating and diagram plates.
ii) Lifting lugs for tank, covers and conservator
iii) Haulage Lugs
iv) Four Jacking pads
v) Earthing terminals – two off
vi) Prismatic oil level gauge
Transformers with ratings greater than 2000kVA shall be provided with the following:
• Conservator tank with drain valve, supports and accessories.
• Dehydrating breathers shall be of the silica-gel cartridge type constructed from heat resistant
glass tubing with strong metal shield.
• Radiator valves
• Sampling valves
• Drain valve
• Filter valves
• Auxiliaries (egg. alarm and trip contacts) junction box
• Transformer monitoring and protection devices as specified.
• Current transformers as specified and shown on the Drawings.
• Other fittings and accessories as specified or recommended by the manufacturer.
Transformer Fittings and Accessories
Sealed type transformers shall be fitted with a spring-loaded self-resetting pressure relief device actuated by excess
pressure within the tank. The setting shall be suitable for application with the coolant used and actuate a manually
resettable switch to initiate a remote trip.
Aspirated type transformers shall be fitted with a Bucholz gas and oil actuated relay of approved make. The relay shall
be of the double float pattern with both alarm and trip contacts, an inspection window and terminal box suitable for
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conduit entry. Petcocks shall be provided at the top for the release of the gas and at a lower level for testing the operation
of the relay by compressed air.
Over temperature protection shall be provided by a scaled dial indicating thermometer fitted with two adjustable contacts
arranged to initiate alarm and trip circuits.
In addition transformers rated at greater than 2MVA shall be provided with the following:
• Magnetic oil level gauge (with alarm and trip contact) – minimum 150mm diameter dial.
• Oil temperature indicator (with alarm and trip contacts) – minimum 150mm diameter dial fitted
with a manually resettable pointer to indicate the maximum temperature attained.
All necessary indication, tripping relays, alarm relays, etc., associated with this protection and monitoring shall be
supplied and mounted on the respective switchgear.
All tripping relays and alarm relays/indicators shall have manual reset relay contacts and flag indicators or equivalent.
All indicators and gauges shall be so located as to permit easy reading by a person from standing position.
Alarm and trip circuit contacts shall adjustable voltage-free changeover contacts and shall be rated not less than 5 Amp
minimum at 110 volts DC.
Dehydrating Breathers
Dehydrating breathers shall be of the silica-gel cartridge type constructed from heat resistant glass tubing with strong
metal shield. The breather design shall ensure uniform circulation of air through the charge. The whole assembly shall
be constructed to form a robust and durable unit.
Transformer Auxiliary Junction Boxes
Wiring from protection devices, indicators, level switches, current transformers and other auxiliary components shall be
connected to an independent common junction box at a convenient position on each transformer and easily accessible
from the transformer plinth level. Junction box shall be weatherproof and vermin proof – IP55 minimum.
Wiring between gauges and the junction box shall be carried out in silicon rubber or heat resistant PVC insulated copper
wire of 2.5 mm2 minimum cross section and encased in heavy gauge conduit. Sleeve type identification ferrules shall be
fitted to both ends of every wire.
Painting
All exterior surfaces of tanks, covers, radiators, etc., shall be thoroughly degreased and cleaned of all rust and scales by
shot blasting, following which a coat of epoxy resin or zinc chromate primer shall be applied over all metal surfaces.
Two further under coats of durable good quality oil and weather resisting alkyd resin paint of an approved quality shall
be applied and the final coat of gloss alkyd resin enamel paint shall be applied after completion of all Works Tests. The
final coat shall be of a colour to the Engineer’s approval. The total paint thickness shall not be less than 200 microns
measured magnetically.
In order to ensure complete surface coverage, tanks fitted with plate radiators or multi-layer cooling tubes shall be flood
painted.
The interior of transformer tanks, oil filled chambers and cable boxes shall likewise be thoroughly cleaned of all rust and
scales and then painted with a suitable hot oil resisting alkyd resin paint. The thickness of the paint shall not be less than
30 microns.
All painting shall be made good at Site prior to commissioning.
Manufacturer’s standard painting systems which provide equivalent or better protection will be considered if full details
are provided with the Bid.
Transformer Oil
Transformer oil shall be of the mineral type complying with local standards, BS 148; and shall be of the grade
recommended by the manufacturer. The oil shall not contain any PCB additive.
Prior to despatch from manufacturer's works the transformers shall be thoroughly dried out and filled with enough oil
for export shipment to cover core and windings with the space above oil level filled and sealed with dry air or nitrogen
under pressure. The balance of oil necessary for service plus 10% shall be supplied and contained in sealed, clean non-
returnable steel drums. The name of the oil manufacturer shall appear on the drums.
Noise and Vibration
The average noise level of each transformer when measured in accordance with IEC 551 shall not exceed 80 dB(A) at
1m.
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The vibration level of the transformers shall also be kept to a minimum and shall not produce excessive stresses on any
of the components or parts of the transformers or associated supports.
The Employer reserves the right to reject any transformer not complying with the specified noise level or agreed vibration
level requirements.
Rating Plates and Valve Plates
The following plates or alternatively a suitable combined plate shall be fixed to side of the transformer tank:
A rating plate showing data specified in the standards. This plate shall also include a space for Serial Number.
A diagram plate, in an approved manner, showing the internal connections and voltage vector relationship of the
various windings in accordance with the standards with the transformer voltage ratio for each tap position and
also a plan view of the transformer depicting the correct physical location of the respective terminals.
For ratings over 2MVA, a plate showing the physical location and function of all valves, gas release cocks, etc.
This plate shall also warn operators to refer to maintenance instruction manuals before applying the vacuum
treatment.
The plates shall be of stainless steel or other approved material suitably engraved so as to render the writings permanently
legible.
C.5.3 HV Surge Arresters
Scope
This specification covers the requirements for the design, manufacturing and test of 33kV metal-oxide type surge
arresters without spark gaps for AC system. Surge arresters will be transformer tank mounted and fitted to each phase
conductor/terminal.
Surge arresters shall be fitted at all points where a significant change of impedance occurs, e.g., ground mounted
transformer, overhead and underground interface
Construction
The surge arrester shall be metal-oxide type without spark gaps and constructed as per the requirement of IEC 60099-4.
The surge arrester shall be outdoor, explosion proof, non-linear resistor type or gapless type, and heavy duty substation
class type, designed for a rated surge current of 10 kA.
The metal-oxide used shall be of quality to ensure thermal stability under service duty of the surge arrester.
The completed surge arrester shall be housed in a spiral type solid core with silicon polymer housing. The housing shall
withstand the lighting impulse voltage of the arrester.
The surge arrester shall be sealed (end caps) with a controlled permanent seal to ensure no moisture absorption or
deterioration of the metal-oxide element for the surge arrester.
The steel plates or straps shall be galvanized as per the requirement of BS 1461.
The earth side of each arrester shall be station type, single pole, and gap-less type.
The surge arrester shall be supplied with fixing accessories and fitted with suitable connectors. The steel plates or straps
shall be galvanized as per the requirement of BS 1461.
The mounting brackets shall be suitable for both horizontal and vertical mounting on a steel channel.
Ratings
The rating of the surge arrester shall be as indicated in Table C-24.
Table C-24: HV Surge Arrestor Rating
System Voltage 11 kV 33kV
Rated Voltage 10kV 30kV

Maximum continuous voltage rating (r.m.s.) 7.6kV 24kV
Nominal discharge current 5kA 10kA
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Long duration discharge class 1 1
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C.5.4 HV Switchgear – General Requirements

General
This Clause applies to the Main Switchboard, TWPS switchboard and the RWPS switchboard.
Switchgear provided under this Contract shall be:
Factory-built, type tested assemblies;
Proven in service under similar operating conditions;
Of a type commonly in use by electrical supply authorities in Tanzania;
Of a type with maintenance and support services readily available in Tanzania.
All switchgear provided shall be suitable for operation with the following auxiliary supplies:
48V DC tripping, control and protection circuits.
220 V AC spring wind motor circuits.
HV switchgear shall be designed for continuous operation at full load for at least 40,000 hours without maintenance,
which will require the busbar system to be de-energized.
HV Switchgear Standards
Switchgear and associated control gear shall comply with the standards referenced including the following:
IEC 298 A.C. Metal Enclosed Switchgear and Control gear
IEC 60694 Common Specification for High-Voltage Switchgear and Control gear
Standards
IEC 56 HV AC circuit breakers
IEC 60265-1 High Voltage Switches - Part 1 : Switches for Rated Voltages Above 1 kV
and Less Than 52 kV
BS 159 HV busbars and busbar connections
IEC 71/BS EN 60071 Insulation coordination
IEC- 62271 Part 200 (2003) High-voltage switchgear and control gear
BS 5311 AC circuit breakers above 1 kV
The requirements of the electrical supply authority and other statutory

bodies having jurisdiction over the Works.
Ratings of 33 kV & 11kV Switchboards
Minimum ratings for 33kV & 11 kV circuit breakers shall be determined in conjunction with the system analysis and
not less than the following:
i) rated power frequency withstand voltage 70kV & 28 kV respectively;
ii) rated impulse withstand voltage (kV peak) 170kV & 95 kV respectively;
iii) rated frequency 50 Hz;
iv) rated current – 1600 A & 630 or 1250A respectively;
v) rated short circuit withstand current 25 kA for 3 sec.,
HV Switchgear Definitions
Anti-pumping device is a device to prevent inadvertent continuous closing and opening of a switching device. Anti-
pumping devices for circuit breakers and latched contactors shall prevent reclosing after a close-open operation as long
as a close signal is received by the switching device. Anti-pumping devices for contactors with a holding coil shall
prevent continuous closing and opening due to a fault in the control circuit.
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Buscoupler is a mechanical switching device to connect two busbar systems of a double busbar arrangement.
Bussection (or bustie) is a mechanical switching device to connect the busbar systems of two sections.
Construction and Arrangement of HV Switchgear and Control Gear
Unless otherwise specified, HV Switchgear and Control gear shall:
i) Be of the metal-clad, withdrawable type, having a single busbar system;
ii) Consist of a number of separate panels assembled into one or more sections to form a switchboard;
iii) Have compartments segregated by means of earthed metal partitions;
iv) Have enclosures that are free standing and self-supporting;
v) Be arranged with no more than one circuit breaker for each full vertical compartment or tier;
vi) Have busbar sections electrically interconnected by a bussection / bustie where shown on the Drawings;
vii) Have HV switchgear cubicles constructed of sheet steel minimum 2mm thick and shall comply with the
requirements specified in Clause “Equipment Enclosures and Cubicles”;
viii) Have facilities for extension of the switchgear and control gear provided at both ends of each
switchboard;
ix) Have operational equipment or metering apparatus located at levels between 0.2 m and 2.0 m above the
finished floor level;
x) Be arranged to provide ready access to components requiring periodic maintenance;
xi) Be of dust-proof and vermin-proof cubicles with the degree of protection at least IP 31. The floor where
the switchboard is placed shall not be considered to be part of the enclosure. With the door of the LV
compartment opened, the degree of protection shall be at least IP 20 towards any live part inside the
compartment and IP 30 towards any equipment terminals installed on the door which can be alive when
the door is opened;
xii) Be arranged so that equipping and commissioning of spare panels as well as connecting main, control
and auxiliary cabling shall be possible whilst the switchgear is alive and in operation. Cable installation
work on functional units and equipment work on spare panels shall be possible without de-energizing
adjacent units;
xiii) Have anti-condensation heaters complete with control thermostats and isolators for each tier;
xiv) Have indicators (egg. neon type) to indicate circuits are alive;
xv) Have separate internal fuses or circuit breakers for the supply to each control, protection and metering
circuit. The arrangement and fusing (or circuit breakers) of control, protection and metering supplies
shall be to the Engineer's approval.
The Contractor shall provide a sketch showing the general arrangement of their proposed switchboards with their Bid.
HV Switchgear Busbars
HV Switchgear busbars systems shall:
i) Be located in separate, air filled compartments;
ii) Be of high conductivity copper of not less than 99.9% as defined in IEC 28 – also applicable protective
/ earthing conductors;
iii) Be individually fully insulated in order to avoid arcing faults in case of a short circuit. Insulation shall
be continued as far as practicable into the switching device and cable compartments up to the next current
protective device;
iv) Have provisions made at the bolted connections to enable accessibility for maintenance and extensions
when appropriate;
v) Have joints which are silver-plated or tinned. Connections and joints shall have a continuous current
rating not less than that of the busbars. Bolts for joints shall be high tensile strength bolts effectively
secured against loosening.
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Earth bars shall be rated for the specified short time current of the switchgear and shall be provided along the complete
length of the switchgear and arranged suitable for earthing the cables.
Busbars, supporting insulators and connections shall be adequately dimensioned and type tested to withstand the
minimum electrical and mechanical stresses due to short-circuit currents specified for each switchboard.
Cabling to HV Switchgear
Provision shall be made in the feeder circuit compartment to terminate the cables in accordance with BS 5372. Cable
compartments shall be of adequate size for splitting, sealing and terminating single or multi-core cables including the
utilization of stress cones.
Cable entry cover plates and associated glands shall be suitable for terminating the cable sheath and steel/aluminium
armour of cross-linked polyethylene (XLPE) cables. Cover plates shall be earthed by means of copper conductors.
Cover plates and cable glands for the termination of single core cables shall be made of non-magnetic metal. Glands
shall be insulated from frameworks or cover plates.
Termination compartments for HV and LV (including control and protection) connections shall be effectively
segregated.
Provisions shall be included inside cable compartments for earthing the screen and armouring of each cable
independently.
Ratings of HV Switchboards
Ratings of HV Switchboards shall be in accordance with the requirements specified and shown on the Drawings for each
particular switchboard.
HV Switchgear - Name, Instruction and Warning Plates
General
Name plates, identification plates, instruction plates and warning plates shall be provided in accordance with all relevant
codes, standards and regulations; including the requirements of the electrical supply authority.
Name plates, identification plates, instruction plates and warning plates shall be provided with indelible inscriptions in
English.
Plates mounted on the outside of equipment shall be fixed by self-threading stainless steel screws or pop rivets.
Nameplates
The following information shall be included on the nameplate installed on the outside of the assembly:
i) Manufacturer's name or trade mark;
ii) Type designation;
iii) Contract number;
iv) Year of manufacture;
v) Service voltage;
vi) Rated frequency;
vii) Rated current of busbar system;
viii) Type of circuit breaker/contactor;
ix) Rated voltage of auxiliary circuits;
x) Rated peak and short time withstand current and withstand time; and
xi) Degree of protection.
Instruction and Warning Plates
When operation sequences of certain equipment in the assembly are not evident, instruction plates shall be fixed near
the point of operation. Instructions shall be given as far as possible in a pictorial manner.
In locations where dangerous situations may inadvertently be created, warning plates shall be installed, identifying the
danger points. Locations may be either in a compartment or on the exterior of an assembly.
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Prominent warning labels shall be provided such as: "Warning High Voltage - Circuit May be Live"
Each circuit breaker and panel of HV switchgear shall be provided with an identifying name plate on the front which
clearly displays the circuit number and name to the Engineer’s approval.
HV Circuit Breakers
HV Circuit Breakers – General
HV circuit breakers shall be vacuum break type, 3 pole, indoor, trip free mechanical switching devices complying with
the referenced standards.
Rated voltage, rated insulation level, rated short-circuit breaking current and rated duration of short-circuit shall be as
specified and shall not be less than the corresponding ratings assigned to their associated switchgear or control gear.
Circuit breakers shall be the self-aligning withdrawable type. Isolating contacts fitted to the ends of circuit breaker
bushings shall consist of a number of copper fingers, individually spring-loaded. Contact points shall allow flexibility
when the circuit breaker is plugged into the spouts.
Unless otherwise stated in the Contract, circuit breakers of the same rating shall be fully interchangeable, unless with the
Engineers approval, different auxiliary switch arrangements are adopted to meet different interlocking requirements.
HV Circuit Breakers – Mechanism
HV circuit breakers mechanisms shall be of the trip free type so that circuit breakers shall be free to open during their
closing operation immediately their tripping devices operate.
The minimum requirements for spring operated mechanisms shall include the following features:
i) Circuit breakers can be closed and then tripped when they are open and the springs are charged;
ii) There shall be sufficient energy to trip, close and then trip the circuit breaker when the circuit breaker
is closed and the spring is charged;
iii) Mechanical indication (or approved equivalent indicators) shall be provided to indicate the state of the
spring;
iv) Unless otherwise approved, motor spring charge mechanisms shall be provided with means for
charging by hand.
Rated operating sequences to BS 5311: Part II shall be 0-3min-CO-3min-CO. Stored-energy closing operations shall
comprise springs charged by dependent power closing with manual release. Rated supply voltages of the shunt opening
release shall be as specified.
The switchgear shall be provided with all interlocks necessary to prevent any incorrect operation.
Electrical tripping and closing devices shall be suitable for operation from the specified battery systems but shall operate,
with their coils in the following DC voltage range when measured at the terminals of the DC batteries:
i) Spring charging motor 80 - 120% of rated voltage;
ii) Closing release coil 80 - 120% of rated voltage; and
iii) Shunt trip release coil 50 - 120% of rated voltage.
HV circuit breakers shall be provided with open and closed indication and a trip button.
HV Circuit Breakers – Isolation / Withdrawal
Withdrawable circuit breakers shall be mounted in carriages (truck) of folded steel construction capable of being inserted
into the switchgear. Two normal positions with clear indication as "Engaged (In Service)" and "Isolated" (or test position)
shall be available. If the circuit breaker is used for earthing, then additional positions will be required and this
arrangement shall be to the Engineers approval.
Automatic safety shutters covering the busbar and circuit spouts during isolation of the circuit breaker shall be provided.
Safety shutters shall be capable of being padlocked in the closed position. Either or both sets of shutters shall be kept
open for testing or maintenance purposes which shall be automatically closed when the circuit breaker is inserted into
the compartment. Busbar shutters shall be painted red and labelled "BUSBAR". Circuit shutters shall be painted yellow
and labelled "CIRCUIT". Busbar shutters in bussections shall also be painted red and labelled "BUSBAR A" and
"BUSBAR B" together with an arrow showing the direction of the busbar.
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Position selectors (or other approved means) shall be provided at circuit breaker compartments in the enclosure, which
can be padlocked to select any serviceable positions of the circuit breaker. Circuit breakers shall be able to be inserted
into service positions and operated in that selected position only.
For horizontally isolated circuit breakers the minimum requirements of the interlocks for circuit breakers shall be as
follows:
i) Circuit breakers closing shall not be possible with undefined truck position;
ii) Circuit breakers racking out shall not be possible with circuit breaker closed;
iii) Circuit breakers racking in shall not be possible with circuit breaker closed;
iv) Opening of circuit breaker compartment door shall not be possible with truck in service or in
undefined position;
v) Circuit breakers racking in shall not be possible with circuit breaker compartment door open;
vi) Additional interlocks to ensure safety during earthing and circuit breaker operations shall be provided
to the Engineers approval.
For vertically isolated circuit breakers the minimum requirements of the interlocks for circuit breakers shall be as follows:
i) Circuit breakers shall not be able to be inserted into housings unless they are in the "Isolated" (fully
lowered) position;
ii) Circuit breakers shall not be able to be closed unless they are in the "Engaged" (fully raised) or
"Isolated" (fully lowered) position;
iii) Circuit breakers shall not be able to be raised or lowered unless they are open;
iv) Circuit breakers shall not be able to be raised in any position other than those which have been
selected by the position selector;
v) Additional interlocks to ensure safety during earthing and circuit breaker operations shall be provided
to the Engineers approval.
HV Circuit Breakers - Secondary Circuits
Connections in the secondary circuits between fixed (switchboard housing) and moving portions (circuit breaker
truck/carriage) of the equipment shall be by means of self-aligning plugs and sockets.
Secondary wiring shall not be mounted direct to metal. To accommodate and support the wiring, covered plastic
channels, insulated tubes or plastic strips shall be used. The filling factor for channels and tubes shall not exceed 70%.
Individual terminals shall be provided for each external conductor for bus wiring and outgoing control circuits.
HV Circuit Breaker - Control Facilities
HV Circuit Breakers shall be provided with control facilities as specified and shown on the Drawings.
All circuit breaker control, protection and indications shall operate from the specified DC supply – except spring charging
which shall operate on the specified AC supply.
HV Switchgear / Circuit Breakers – Spare Auxiliary Contacts and Signals
Each circuit breaker unit shall have spare auxiliary contacts and signals as specified and shown on the Drawings; and
shall include those as listed below:
i) At least two (2) spare contacts for each of: CB Open, CB closed, Isolated and In Service status for
each circuit breaker;
ii) Spare Inputs and Outputs from the protection and metering relay(s);
iii) Voltage transformer secondary circuit connections from each voltage transformer.
These spare auxiliary contacts and signals shall be wired to terminals in each compartment.
HV Switchgear / Circuit Breakers – Earthing
Earthing of HV switchgear shall be provided as specified for each particular switchboard and unless otherwise specified
shall be by means of one of the following:
i) Integral earthing switches. The integral earthing switches shall be applicable to every unit for both busbars
and feeder circuits;
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ii) Or, an earthing truck for each switchboard. The earth truck switch shall be rated for fault making duty;
iii) Or, where approved by the Engineer, an earth position for the circuit breakers - applicable to every unit for
both busbars and feeder circuits.
Safety interlocks, to the Engineers approval, shall be provided for earthing switches and/or earthing trucks. Means shall
be provided whereby the electrical tripping of the circuit breaker or earthing truck is rendered inoperative during earthing
operations both when the circuit breaker/earthing truck is closing and when the circuit breaker/earthing truck is closed
in the earthed position.
Padlocking facilities shall be provided for locking the earthing switches and facilities in the open and closed positions.
When the earthing switch has been applied in a compartment, a withdrawable switching device shall not be inserted into
the service position of the compartment concerned.
Clear instructions shall be installed on the switchgear showing the methods of earthing.
HV Fuses
HV fuses shall be of the high rupturing capacity, short circuit current limiting type – suitable for operation at the rated
short time current and shall comply with IS 9385 High voltage fuses or BS 2692/IEC 282-1.
HV fuses shall have been type tested and ASTA or equivalent certificates for breaking tests for a homogenous series as
listed in the standards.
HV Switch Disconnectors
Where provided, HV switch disconnectors shall be rated to match the switchgear ratings and shall have been type tested
and type tests shall be certified by an authority approved by the Engineer.
Motor Starters
Motor starters shall contain all necessary contactors, timers, fuses, etc.
The following controls and indication shall be provided on the front of each motor starters compartment:
i) Current indication;
ii) Motor START/STOP push buttons;
iii) Local/remote switch, where appropriate;
iv) Motor AUTO/OFF/MANUAL selector switch, where appropriate;
v) ON/OFF/FAULT indication lights;
vi) Motor fault reset push button;
vii) Hours run counter.
Hours run counters shall be of the non-resettable cyclometer type with 6 figures and indication that the meter is working.
HV Switchgear / Circuit Breakers – Control, Protection and Monitoring
HV Switchgear and each circuit breaker compartment shall be provided with control, protection and monitoring devices
and functions as specified and shown on the Drawings; and shall include those as listed below:
i) Current transformers as shown on the single line diagrams;
ii) Voltage transformers as shown on the single line diagrams;
iii) Each circuit breaker compartment shall be provided with the following control selector switches as a
minimum:
i. one (1) manual “Trip/Neutral/Close” pistol-grip type selector switch arranged to
Close the circuit breaker from this switch as referenced above. The Trip position
shall be arranged to Trip the circuit breaker under all possible conditions and
regardless of the position of the “Local/Remote” selector switch. Additional Trip and
Close contacts shall be input to the protection relay.
iv) Each circuit breaker compartment shall be provided with the following DC indicating lamps as a
minimum:
a. one (1) red labelled “Circuit breaker ON”
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b. one (1) green labelled “Circuit-breaker OFF”

c. one (1) amber labelled “Auto Trip on Fault” – operated from the protection and metering
relay(s)
d. one (1) green labelled “Breaker in Test” or approved mechanical indicator.
e. one (1) red labelled “Breaker in Service” or approved mechanical indicator.
v) Circuit breaker compartments shall be provided with electronic protection relay(s) to provide
protection and metering functions.
Rubber Mats
Each switchboard shall be provided with a rubber insulating mats as specified.
Matting shall comply with BS921:1976, suitable for use as a floor covering near electrical apparatus rated up to 650
VAC. The BS number, date of manufacture, the manufacturer’s name, and the words “650V maximum” shall be clearly
marked on the matting.
Protection and Metering Relays and Facilities
General
Protection and metering relays and devices shall be provided as required to meet the protection and metering functions.
Protection and metering relays shall be compatible with the switchgear and shall be rated to match the specified ratings
of the switchboards with which they are associated. Protective and metering relay systems shall be suitable for operation
on the plant power supply and with levels of harmonic distortion as specified.
The grouping of protection and metering functions shown on the Drawings are indicative and multiple protection and
metering relays and devices shall be provided where required to provide the required functionality.
Protection Relays
Protection relays shall:
i) Be multifunction electronic type relays or individual relays as required to provide the protection
functions specified;
ii) Be a proven in service with the particular switchgear and other associated equipment;
iii) Be provided complete with all ancillary equipment and devices to perform the required functions;
iv) Comply with BS EN 60255-1:2010or BS EN 60255-6:1995;
v) Have contact ratings and performances in accordance with the relevant standards and suitable for the
duty;
vi) Be suitable for operation with the current and voltage transformers provided;
vii) Have operation indicators for each protective element and these shall be installed within the same
relay;
viii) Have hand-reset devices operable without opening the relay case;
ix) Have trip contacts compatible with the circuit breakers;
x) Have alarm contacts for each trip function;
xi) Have provision to prevent unauthorised resetting and adjustment of protection relays;
xii) Be semi-flush mounted on the front door operating face of the equipment, and shall be of the dust-
tight type. Relay cases shall be provided with covers and gaskets to render them dust-tight.
The Contractor shall be responsible for configuring and setting the protection relays to the approval of the Engineer.
Electronic protection relays shall be configured and set to:
i) Provide the protection functions specified;
ii) Provide over-current protection in accordance with the settings specified;
iii) Provide for safe operation and protection of the power supply system;
iv) Provide over-current protection in accordance with applicable codes, standards and regulations;
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v) Display of each trip and alarm condition;

vi) Provide ease of use by operators;
vii) Provide a default display(s) as required by the Engineer;
viii) Provide interlocking and inter-tripping as specified and shown on the drawings
Configuration of multifunction protection relays shall be undertaken by personnel with a specialist and detailed
knowledge of power supply system protection and the particular protection relays.
Protection Functions
Protection Functions shall include the following for each HV circuit breaker and each withdrawable 400V air circuit
breaker:
i) 3 phase over-current fault protection including: IDMT over-current, definite time over-current and
instantaneous over-current;
ii) Earth fault protection including: including: IDMT over-current, definite time over-current and
instantaneous over-current;
iii) Transformers rated greater than 1000kVA shall be provided with differential and restricted earth fault
(REF) protection;
iv) The protection supplying transformers shall be provided with inrush current blocking;
v) Circuit breaker trip coil circuit supervision;
vi) Under-voltage alarm for each bus. Under-voltage relays for 3 phase applications shall be 3-phase type
that sense low voltage and loss of a phase for a preset time.
Over-current and earth fault protection shall be of the inverse definite time type with various selectable curves and with
high set instantaneous elements that can be set to infinity if required. Current settings shall be adjustable between 5%
and 240%. Time multiplier characteristics shall be adjustable from 0.05 to 1.00.
Transformer differential protection shall be provided for the 33/0.4kV or 11/0.4kV transformers and shall:
i) Operate on the zone protection principle, with high level of sensitivity, speed and accuracy for
operating conditions within the protected zone, such as all types of transformer internal faults, phase-
to-phase and phase-to-earth faults;
ii) Provide a high level of stability and tolerance for through fault (outside zone) conditions;
iii) Incorporate facilities for matching current transformer ratios and tappings;
iv) Provide for inrush current blocking
Restricted earth fault protection as shown on the Drawings shall be high impedance type. Resistors and other auxiliary
components associated with the relays shall be furnished to provide a complete and functional system.
Metering Relays and Devices
Where metering functions are required on relays they shall be capable of displaying the following parameters; all
parameters for each set shall be displayed simultaneously:
i) 1 System Volts, System Current, System kW
ii) 2 System Volts Total Harmonic Distortion (THD) %, System Current THD %
iii) 3 Volts L1 – N, Volts L2 – N, Volts L3 – N
iv) 4 Volts L1 – L2, Volts L2 – L3, Volts L3 – L1
v) 5 Volts Line 1 THD %, Volts Line 2 THD %, Volts Line 3 THD %
vi) 6 Current L1, Current L2, Current L3
vii) 7 Current Line 1 THD %, Current Line 2 THD %, Current Line 3 THD %
viii) 8 Neutral Current, Frequency, Power Factor
ix) 9 kVAr, kVA, kW
x) 10 kW Hr Import (7 digit resolution)
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xi) 11 kVAr Hr Import (7 digit resolution)

xii) 12 kW Hr Export (7 digit resolution)
xiii) 13 kWAr Hr Export (7 digit resolution)
xiv) 14 kW Demand, Current Demand
xv) 15 kW Maximum Demand, Current Maximum Demand
Relays with metering functions shall:
i) Have accuracy with an error of less than ±1.0% for all parameters;
ii) Be capable of having 4-20mA output option fitted at a later date;
iii) Be programmed by the Contractor for the installed condition;
iv) Have a label indicating the current range, egg. 0-1250A.
Safety Devices
In addition to the electrical protection specified elsewhere herein, safety cut-outs shall be provided to protect equipment
against any operating conditions which could arise and which would be liable to cause damage to the equipment for
example: lack of water at pump suctions, high bearing temperature, cooling water no flow etc.
C.5.5 Current and Voltage (Potential) Transformers
General
This clause is applicable to current transformers (CTs) and voltage transformers (VTs) installed throughout the works,
including those in HV switchgear, switchboards, control panels, distribution boards and electrical cubicles.
Current Transformers (CT)
CTs shall be of the ratios and minimum class specified and shown on the Drawings and shall be constructed so as to
withstand without damage the rated short time current and duration of the switchgear with which they are associated.
Current transformers installed where the switchboard rated short time current is not specified, shall be constructed so as
to withstand without damage the maximum prospective fault current available at the point of installation until clearance
of the fault by protective devices takes place.
All current transformers shall be capable of withstanding for one minute without damage the effects of an accidental
open circuit in the secondary circuit with full load current in the primary.
Current transformers shall be of the epoxy-encapsulated type, suitable for primary PVC cables or busbars to be passed
through. Two turn primary arrangements may be used with the Engineer's approval where an overall rationalisation of
current transformers will result. The secondary winding of each core or neutral point shall be earthed at one point only
via a removable bolted link. Links shall also be provided for all CT secondary connections to allow the connection of
test instruments and the short-circuiting of secondary windings.
Metering current transformers shall comply with the requirements of the standards referenced. Unless otherwise
specified or shown on the Drawings, metering CTs shall be of accuracy class 1 or better with rated burdens not less than
15 VA or 125% of the actual connected burdens.
Protection CTs shall comply with the requirements of the standards referenced and shall have an accuracy class of 5P or
better. The accuracy limit factor shall be a minimum of 20 and a greater value where required to match the short time
current rating of the switchgear with which they are associated. The product of the VA rated burden and rated accuracy
limit factor shall be 150 minimum.
Type test certificates of current transformers of the same type and rating shall be provided to the Engineer for approval
not more than 12 weeks after commencement of the work.
Where an overall accuracy is specified for a metering function, then current transformers of higher accuracy shall be
selected to match the specified overall accuracy.
Voltage (Potential) Transformers (VT)
Unless otherwise specified, voltage transformers shall be uniformly insulated and of cast resin construction. VTs shall
be of the fixed type protected by HV fuses and shall be readily removable for replacement. The minimum class, category
and ratio of each voltage transformer shall be as specified and shown on the Drawings. The connected burden shall be
not more than 75% of the rated burden of each voltage transformer. The secondary circuits of all voltage transformers
shall be fused in an approved manner.
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Voltage transformers shall be suitable for operation on the plant power supply systems under all possible supply
conditions.
Voltage transformers shall be vacuum impregnated or encapsulated resin insulated type air cooled and constructed to BS
EN 61558. Each transformer shall be fully accessible, capable of being fully isolated for maintenance purposes and fitted
with primary and secondary protection.
Rating Plates for Current and Voltage Transformer Data
Each CT and VT shall be provided with a rating plate upon which the information specified in the relevant Standard is
clearly marked. Such rating plates shall be located in such positions that, when the transformers are installed in position
the rating plates shall be readily readable after opening doors or unbolting cover plates.
A connection plate shall also be fixed on the fixed part of switchgear in which current and voltage transformers are
mounted. Such plate shall show the secondary connections and polarities and shall embody adequate reference for phase
identification of secondary terminals. Transformer serial numbers shall also be included.
C.5.6 Switchboards
33kV-11kV Switchboard Auxiliary DC Power Supply Systems
The Contractor shall provide battery backed 24V DC tripping supplies for switchboards provided under this contract.
The switchboard auxiliary power supply shall have a voltage of 24VDC and consist of a metal floor mounted enclosure
with 24V battery charger, batteries and DC distribution board. The auxiliary power supply shall be suitable for supplying
all switchboard protection and metering requirements, including circuit breaker spring charging motors if applicable.
The connected load shall consist of the 33kV or 11kV switchboard equipment specified in this Specification plus an
additional 33%.
The requirements for components mounted in the 24 V DC system cubicle are specified throughout the Specification.
The 24 V battery system shall be capable of supplying the 150% of the connected load with loss of mains power supply
for a period of not less than 24 hours of mains power supply failure, including 20 operations of the main incoming circuit
breakers. The batteries shall be sealed lead acid type and shall have a minimum capacity of 65 Amp/hours.
The power supply shall be an approved unit suitable for battery charging and instrument supplies use and shall be rated
to supply 150% of the connected load at 24 VDC. Output voltage shall be adjustable to 27.6 V. The battery charger shall
be capable of charging the fully discharged battery to 80 % charge in 6 hours and at the same time supplying the
maximum battery loading of the connected load. The battery charger shall also be capable of supplying load without
batteries connected. The battery chargers shall comply with AS 4044.
The battery charger shall be protected against overload and short circuit and shall provide an alarm contact output on
loss of mains power.
The DC system shall also be arranged to disconnect the battery from the load when the battery voltage falls below 21.2
volts.
The following shall be flush mounted on the front panel of the DC system cubicle:
i) DC Voltmeter – 72 mm2
ii) A charger output DC ammeter of accuracy class 1.5 to AS 1042. - 72 mm2
iii) A load DC ammeter and fused voltmeter, of accuracy class 1.5 to AS 1042. - 72 mm2
iv) LED alarm indication - including charger fail, low battery volts, fault
v) Indicating LED/lamp for battery charger healthy.
Each DC system shall include a voltage-free changeover alarm contact that operates when the charger fails and/or the
DC output voltage falls out of a preset range.
DC distribution shall be by means of moulded case thermal magnetic two pole circuit-breakers. The circuit breakers
shall be readily accessible on opening the cubicle door.
A rating plate shall be affixed to the DC system cubicles.
400V Switchboards
General
400V switchboards shall:
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i) Comply with IEC 60439.1 and the standard specifications;

ii) Be a form 3B type switchboard to IEC 60439.1;
iii) Be front and rear access type and suitable for cabling from the front;
iv) Have a minimum IP52 enclosure rating;
v) Be delivered to the site as a fully assembled, wired and tested unit.
The requirements for components mounted in Switchboard are specified throughout the Specification.
Main Switchboard Ratings
Switchboards shall be rated as follows:
i) Rated voltage - 400 V
ii) Rated current – main busbars - As per requirements
iii) Rated diversity factor - refer clause 4.7 IEC 60439.1
iv) The Contractor shall determine the required:
v) Rated short time withstand current for 1 second;
vi) Rated short time peak current
The Switchboard shall be fitted with rating plates detailing the ratings in accordance with IEC 60439.1
400V Switchboard Dimensions and Construction
Dimensions and configurations of the switchboards shall be determined to suit the switchroom and functionality
required. The switchboards shall have provision for future installation of additional circuit breaker feeders or motor
starters as shown on the drawings, and associated cabling.
The switchboards shall have provision for extension on at least one side.
The switchboards shall be mounted on a 75mm high galvanised steel plinth.
The switchboards shall be constructed as specified.
The Contractor shall provide a sketch showing the general arrangement of their proposed switchboards with their Bid.
Main Switchboard Busbars
400V switchboards shall contain a three-phase busbar system with each phase being suitably segregated and/or insulated
from the next.
The Switchboard and busbars shall have been type tested for temperature rise and short time current rating as determined
by the system analysis. Busbar type test certificates shall be submitted prior to commencing any associated work.
Full-length earth and neutral bars shall be provided.
400V Switchboard Incoming Supply Section
400V Switchboard shall be provided with separate metal enclosed incoming supply compartments, which shall
incorporate withdrawable air circuit breaker main isolators rated as shown on the Drawings. The air circuit breakers
shall have protection including a display of line voltage, instantaneous phase current and maximum demand.
The terminals for the main incoming cables shall be segregated from all other protection, control and indicating devices,
and outgoing cables.
Bus-Tie Section
Where shown on the Drawings 400V switchboards shall be provided with a separate metal enclosed compartment for
the busbar tie comprising a withdrawable air circuit breaker rated for the capacity of the busbar. The air circuit breaker
does not require protection and shall be interlocked with the incomers as specified and shown on the Drawings.
400V Switchboard Circuit Breaker Feeder Compartments
Separate metal enclosed feeder compartments shall be provided as shown on the Drawings and shall be designed to
allow for continuous operation at rated current.
Air circuit breakers shall be provided with a protection relay having adjustable long time, short time and earth fault
protection.
Moulded case circuit breakers with ratings above 160A shall have adjustable thermal and magnetic settings.
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400V Motor Starters

Each motor starter shall comprise where applicable: a circuit breaker (for main circuit protection isolation); contactor(s);
motor thermal overload; auxiliary control and fault relays; thermistor protection/relay, motor heater controls; and devices
as specified and shown on the Drawings.
Motor starter components shall be selected to provide type 2 coordination.
Motor circuit breakers shall be fitted with a means for padlocking in the OFF position.
Unless otherwise approved, motor starter control circuits shall operate at 24V DC.
The following controls and indication shall be provided on the front of each motor starter compartment:
i) Current indication;
ii) Motor START/STOP push buttons;
iii) Local/remote switch, where appropriate;
iv) Motor AUTO/OFF/MANUAL selector switch, where appropriate;
v) ON/OFF/FAULT indication lights;
vi) Motor fault reset push button;
vii) Hours run counter (motors over 5kW only).
Hours run counters shall be of the non-resettable cyclometer type with 6 figures and indication that the meter is working.
Soft starter type motor starters shall comply with the specified requirements.
C.5.7 Power Factor and Power Factor Correction
General
The overall power factor of the Plant under any load or operating condition shall not be lower than 0.95 lagging. Power
factor correction capacitors rated at 85% of the no-load kVA of the motor shall be provided for each motor of above 5
kW rated output. In addition capacitors shall be fitted to smaller motors as necessary to maintain the minimum overall
power factor specified above.
Where the Contractor considers that overall correction rather than individual correction is advantageous on technical
and/or financial grounds he shall offer this, with a statement setting out the reasons for doing so.
Power factor correction capacitors shall comply with BS 1650 and be suitable for operation over the temperature range
0°C / +45°C. Each capacitor bank shall be fitted with discharge resistors and striker pin fuse protection, all to be enclosed
within a sheet steel housing having a terminal box with separate bolted access cover and an external earthing terminal.
Means shall be provided for monitoring fuse failure visually. For HV applications, the fuse pins shall be arranged to
also operate a trip bar which shall initiate a warning light on the motor starter.
Warning labels shall be fitted to the capacitor and motor terminal boxes, inscribed as follows:
"WARNING - EQUIPMENT CONNECTED TO STORED ELECTRICAL CHARGE. ISOLATE AND
EARTH ALL TERMINALS BEFORE HANDLING".
C.5.8 400V Soft Starters
Soft starters shall be certified to IEC947-4-2 and shall be marked accordingly. Preferential consideration will also be
given to those soft starters which are UL listed, CSA certified and are approved for CE or C-tick marking.
Each soft starter is required to start its connected motor/load combination at the duty cycle/cycles listed below at an
ambient temperature of 45°C and an altitude of 1,000 meters without de-rating.
e.g. (continuous operation) AC53a: X-Tx: F-S
(by-passed operation) AC53b: X-Tx: Off time
Where X = Start current, expressed as a multiple of full load current
Tx = Start time, expressed in seconds
F = Duty cycle, expressed as the % on time per hour
S = The number of starts per hour
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Off time = The time between ramps, expressed in seconds

Soft starters shall be of the closed loop current control variety and provide both constant current and current ramp start
modes as standard.
Current feedback to the soft starter shall be via 3 current transformers (1 per phase) selected to ensure saturation does
not occur during the starting and stopping cycles. The current transformers shall be provided as part of the soft start
package.
Open loop voltage controllers or current limiting devices that operate without CT feedback will not be considered for
motor starting applications exceeding 75 kW.
Each phase of the soft start shall consist of inverse parallel connected SCRs for full wave control, supported by transient
over-voltage protection and snubber networks.
Each soft start unit shall be capable of providing pre-start protection features as detailed herein. On receipt of a start
signal, the soft starter shall perform a system analysis and automatically configure for the following:
i) Supply circuit;
ii) Motor circuit and connection method (line or inside delta operation);
iii) Phase sequence;
iv) Supply voltage;
v) Supply frequency;
vi) Integrity of internal power circuits - that is, SCRs healthy
Should an abnormality be detected during pre-start checks, the soft starter shall trip without application of power to the
motor terminals and provide indication of the fault cause.
Soft starters shall be capable of un-interrupted operation on a fluctuating supply with the following tolerance:
i) Power circuit: 180 to 220 V AC;
ii) Control circuit: 200/400 V AC, +10%, -15%
In addition the soft starters shall be able to ‘ride through’ voltage dips to 0 volts for a period not exceeding 0.5 seconds.
The supply frequency tolerance of each soft starter shall be 48-52 Hz automatically configuring – that is, without the
need for special calibration.
Programming of the soft starters, starting, stopping and protection parameters shall be via a digital keypad data entry
system ensuring simple and accurate settings of all parameters.
Each soft starter shall provide independent adjustments for start current, start (acceleration) and stop (deceleration) ramp
times. These shall be user adjustable in the range detailed below.
i) Constant current start - Maximum start current setting 50 to 550% FLC adjustable in 1% increments;
ii) Current ramp start - Initial start current setting 50 to 550% FLC adjustable in 1% increments.
Maximum start current setting 50 to 550% FLC adjustable in 1% increments;
iii) Start ramp time - 1 to 30 seconds adjustable in 1 second increments;
iv) Stop ramp time - 0 to 100 seconds adjustable in 1 second increments;
v) Each soft starter shall provide the following motor and system protection functions as standard.
vi) Programmable thermal modelling for accurate l2t motor overload protection;
vii) Phase imbalance and phase loss protection;
viii) Phase sequence and phase loss protection;
ix) Under-current/under load protection;
x) Electronic shear pin protection;
xi) Starter over temperature protection;
xii) Shorted SCR protection.
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In addition to the protection systems detailed above, each soft starter shall provide an overload trip pre-warning facility
via local indication device.
All protection functions within the soft starter shall be fully operational irrespective of whether the soft start system is
configured for continuous or bypassed operation.
Soft starters which employ the uni-start / uni-stop control algorithms will be regarded as the preferred option for all
pumping applications.
The soft starter offered shall provide individual indication for each of the protection functions detailed above and for the
following:
i) Power on;
ii) Start/run;
iii) Up to speed;
iv) Installation fault
a. open circuit input or output
b. phase loss input or output
c. incorrect motor connection
d. failed SCR
In addition to the fault and status indication detailed above, the starter shall provide a readout of programmed parameters,
motor run current, current drawn at time of trip and motor thermal capacity.
Each soft starter shall provide relay outputs for:
i) Start/run - main contactor control;
ii) Up to speed - bypass contactor control;
iii) Start/run - healthy operation (energised on completion of pre-start checks);
iv) Fault trip - remote fault indication
The soft starter shall be used with line and bypass contactors that are to be controlled directly from the relay outputs
detailed above. On receipt of a start signal the soft starter shall energise the line contactor and maintain this state until
completion of the stop ramp or on detection of a fault condition. On reaching full output voltage the soft starter shall
energise the bypass contactor and maintain this state until a stop signal is received. Simultaneous de-energization of both
line and bypass contactors shall only occur when the stop ramp time is set to 0 seconds and/or on detection of a fault
condition.
Line and bypass contactors shall conform to the relevant sections of this specification.
All control wiring from and to external control devices shall be via clearly labelled removable plug terminals.
The soft starter shall be able to operate at an ambient temperature of 45°C at the stated duty cycle without de-rating.
The supplier of the soft starter shall be able to computer model the application and required duty to ensure accurate starter
selection has been made.
The supplier shall preferably have a service agent based in Tanzania with facility for the service of the supplied
equipment.
The supply frequency tolerance of each starter shall be 48-52 Hz automatically configuring - that is, without the need for
special calibration.
C.5.9 Variable Frequency Drive VFD

General:
The VFDs should be fitted in LT panels fabricated of 14sg CRCA sheet steel, as per RAL 7032 shade of powder coating
of 75-100 microns with matt finish.
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The VFD should be able to accept emergency stop on operation of Emergency stop push button with least operating
time. VFD upto 45KW can be installed in Power cum MCC panel. 55KW and above VFDs shall be individual
starter(read VFD starter) to be installed near to the pump set so that operator can see the pump starting without any
malfunction of any type like leakage of seals/joints or whatsoever.
General Specification VFD

The Variable Frequency Drive shall be a Clean Power voltage source, advanced Pulse-Width Modulated, space vector
technology motor controller which utilizes the latest IGBT technology and surface mount construction to afford efficient
use of available space, prudent energy consumption and reliability.
The VFD should be of latest design, build and features. Should be able to drive all the types of AC motors that are
available like Induction motors, Permanent Magnet Motor, Synchronous Reluctance Motor (Syn RM). VFD should be
with V/f and vector control with/without encoder.
All Variable Frequency Drive(s) shall be supplied with an input AC line reactor of minimum 2.5% impedance.
Input (AC) Line Reactor shall be designed to address performance issues and to provide proper transient protection of
the VFD input power devices.
Input (AC) Line Reactor shall be factory mounted and wired within the VFD enclosure.
The Variable Frequency Drive(s) shall operate satisfactorily when connected to a bus supplying other solid state power
conversion equipment which may be causing up to 10% total harmonic voltage distortion and commutation notches up
to 36,500 volt/microseconds, or when other VFD’s are operated from the same bus.
Individual or simultaneous operation of the VFD’s shall not add more than 5% total harmonic voltage distortion to the
normal bus, nor more than 10% while operating from standby generator bus, To meet or exceed IEEE 519, 1992.
The Variable Frequency Drive shall maintain a displaced power factor of 0.95 or better, at all speeds without external
correction capacitors, and shall have a continuous output current rating of 110% of nameplate current.
The VFD shall be have wide output frequency range upto 500HZ. Braking, with over magnetization for stopping
without brakes to prevent water hammering.
The inverter output shall be generated by power transistors which shall be controlled by six (6) identical base driver
circuits, which shall yield an adjustable voltage up to rated voltage three-phase, Alternating Current (AC) power for step
less motor speed control from 20 percent to 100 percent of base speed.
This motor controller shall produce an adjustable Alternating Current voltage/frequency output. It shall have an output
voltage regulator to maintain correct output Volt/Hertz ratio despite incoming voltage variations.
The Variable Frequency Drive(s) shall not induce excessive power losses in the motor. Worst case Root Mean Square
(RMS) motor line current measured at rated speed, torque and voltage shall not exceed 1.05 times the rated RMS motor
current for pure sine wave operation.
• Speed search for coasting motors.

• Protective functions should be there like stall prevention, over temperature prevention.
• Self-monitoring of main working components – Fan, IGBTs, Capacitors, charging circuits; with alarm when
reaching a certain life time.
• Fast navigation should be possible.
• The VFD shall have PID Control (With Sleep Function)
• Energy Saving Control
• Parameter Backup Function
• Momentary Power Loss Ride Through
• The VFD Should be CE marked
• The VFD should have auto Tuning Automatic, rotating and static.
• VFD should have IP20 degree of protection.
• Overload capacity of 50% for one minute in one hour.
• Programming /interface should include four arrow keys and one select function keys.
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• VFD should be safe as with IEC 61800-5-as per IEC 61800-5-2, tested according IEC/EN61508 (SIL3) and
ISO/EN13849-1 (PI e, cat 3).
• Should have off-line and online programmable wizard parameter and drive configuration tool without any
power supply (So that can be programmed and sent to site as plug & play to save costly remote site visits).
• Shall be suitable to harsh environment as per IEC 60721-3-3, Class 3CS (Chemical gasses), Class 3S2 (Solid
Particles).
• Should be able to support wide range of communication should be possible: CANopen, CC-Link, Device Net,
Ethercat, Ethernet/IP, MECHATROLINK-II, MECHATROLINK-III, Profibus –DP, Profinet and LON works
etc.
• Three phase control with operation voltage: 380 V to 480 V AC, in -15% to +10% bands at 50 Hz ±5% voltage
input.
• It should have energy saving features.
• It should have regenerative capacity to stop pump as soft as possible in the event of power failure.
• It should have communication port compatible to SCADA.
• VFD shall have a 8 Digital (sink/source); and 3 analog, 1 pulse, 24Vdc power supply inputs.
• VFD should have 6 photo coupler, 2 relay, 2 analog (current/voltage) outputs with 24 VDC.
• Programming interface should be mini USB on front cover; digital operator with blue tooth.
• VFD LCD should have Real time clock and data logging.
Product features
The VFD shall comply with the following technical requirements:

• The VFD should have Conformal coating for better dust and moisture protection.
• Should be able mobile device (smartphone or tablet) connectivity is achieved through using built-in USB port
or wireless communication with Bluetooth LCD keypad option so that at remote location trouble shooting or
minor adjustments are possible. Parameter and failure code description including trouble shooting assistance
should be integral to achieve benefit of connectivity.
• Co-ordination, Semi-Conductor Fuses is must along with Line Contactor AC3 for Isolation.
• The contractor shall make arrangements for harmonic mitigation light by providing input choke integral or
discrete.
• It should have auto tuning facility to read motor parameters.
User interface
The VFD shall have a detachable keypad with graphical LCD display. The keypad shall have start and stop buttons,
information button for access to a built-in manual and an USB-port for connection to a PC. The keypad of each VFD
shall include a “POWER ON” light
• a VFD fault light
• a VFD run light
• manual stop push-button
• manual start push-button
• a fault reset push-button
• An “AUTOMATIC” push-button and increase/decrease pushbuttons.
The VFD’s shall be software programmable to provide automatic restart after any individual trip and/or condition
resulting from either over current, over voltage, under voltage, or over temperature.
For safety, the variable frequency drive shall shut down and require manual reset and restart if the automatic reset/restart
function is not successful within a maximum of three attempts within a short time period.
A speed droop feature shall be included which reduces the speed of the VFD on transient overloads. The drive is to return
to set speed after transient is removed.
If the acceleration or deceleration rates are too rapid for the moment of inertia of the load, the drive is to automatically
compensate to prevent VFD trip.
Automatic restart after drive trip and/or utility failure. Automatic or Manual restart after VFD trip and/or utility failure
shall be Software selectable.
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Speed profile: Individual adjustable settings for start, stop entry, slope, and minimum and maximum speed points.
Process Signal Inverter: Software selectable to allow speed of VFD to vary inversely with input signal.
A critical speed avoidance circuit: will be included for selection of two critical speeds with a rejection band centered on
that speed. The VFD will ignore any speed signals requiring drive operation within the rejection band.
Proportional and Integral set point process controller with menu driven selection and programming via door-mounted
keypad.
The VFD shall be able to determine the motor speed and resume control of a motor which is spinning in either direction
without tripping. The VFD shall be able to successfully Pick Up a spinning load.
A door-mounted membrane keypad with integral 2-line, 24-character LCD display shall be furnished, which is capable
of controlling the VFD and setting drive parameters, and shall include at a minimum the following features:
The digital display must present all diagnostic message and parameter values in plain English engineering units when
accessed, without the use of codes. The keypad module shall contain a “self-test” software program which can be
activated to verify proper keypad operations. The digital keypad shall allow the operator to enter exact numerical settings
in plain English engineering units. A plain English user menu shall be provided in software as a guide to parameter
setting, (rather than codes). Drive parameters shall be factory set in EEPROM and resettable in the field through the
keypad.
Environmental conditions
• The VFD shall have coated PCBAs to withstand harsh environments
• The VFD shall support operational temperature of -25°C to +60°C with de-rating of maximum 2% per 1°C
above 50°C
• The VFD shall be able to operate on up to 1000 meters above sea level.
Motor starting, stopping and operation

• The VFD shall have pre-program functions.
• Stand still brake, to keep the load still before start
• Motor heating, to keep the motor well-tempered before start.
• It should have pump application software.
• Open Loop Vector Control
• Close Loop vector Control
The VFD shall have the following start ramps available:

• “S”- start ramp
• Torque start ramp
• Torque boost.
• ± 0.2 % Speed Accuracy in Open Loop Vector Control.
• The VFD shall have possibility for speed upto 150% of rated speed if required.
• The VFD shall have Torque Control, to eliminate water hammering and prolong lifetime of the pump system.
• The VFD shall include 200 % starting Torque feature to be able to start heavy loads.
• The VFD shall have the following three types of current Limit:
• Current Limit
• Dual Current Limit
• Current Ramp
Built-in motor protections

The VFD shall integrate motor and load protections,
The VFD shall also be able to present a warning before tripping for each protection.
The VFD shall have the following motor protections available
• Electronic Overload Protection as per class 10A, 10, 20, 30
• Locked Rotor Protection
• Motor Under load Protection
• Current Imbalance Protection
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• Overvoltage and Under Voltage Protection

• In case of Phase Reversal it should run the motor in correct direction.
• It shall also have input for PTC and PT100.
Fault Indication & Fault Diagnostic

It should have Built-in diagnostics to show fault and cause with time stamping.
The VFD shall provide following fault detection, to protect both the starting equipment, the load and the VFD
itself
• Phase loss
• High current
Low control supply voltage
ENCLOSURE
The manufacturer’s illustrated operating instructions and parts list shall be mounted within the Variable Frequency Drive
enclosure door.
Provide an Input circuit breaker, interlocked with the enclosure door, with through-the-door handle to provide positive
disconnect of incoming AC power.
Mounted on the cabinet door shall be the selector switch, motor fault light, power ON light, motor ON” VFD light and
motor ON LINE light.
Door-mounted meters shall be provided on all units 3 Horsepower and larger:
Analog ammeter (0 - 110%)
Analog voltmeter (0-600 VAC)
Analog kW meter (0-110%)
5-digit elapsed timer non resettable type.
All Variable Frequency Drive components shall be factory mounted and wired on a dead front, grounded, enclosure
suitable for bottom or top conduit entry.
The Enclosure shall have louvers at lower end and exhaust at top side of enclosure.
The enclosure shall have space heaters.
The enclosure shall have spare Semiconductor fuses two numbers.
The enclosure shall have IP 54 degree of protection.
Enclosure shall have fault level equal to fa.
C.5.10 LV and ELV Control Equipment and Devices

Scope
This clause is applicable to electrical and control equipment and devices installed throughout the works, unless particular
applications have more specific requirements, which are specified or shown on the Drawings.
General
Wherever possible, and unless otherwise specified, electrical and control equipment and devices shall be standardised
throughout the Works.
All equipment shall be set out in a uniform manner for all similar equipment and all similar components shall be fully
interchangeable.
All equipment shall be arranged to facilitate servicing, and shall be readily accessible for routine inspection and testing
and normal replacement and maintenance of components without the necessity of major dismantling.
Equipment shall be arranged to allow adequate space for the installation and termination of all internal and external
wiring.
Equipment manufacturers and types referenced are specified to comply with the plant standards.
Contactors
Contactors shall be block type, air break. Contactors shall be selected based on uninterrupted (continuous) duty, AC4
utilisation category, motor rated full load current and minimum size 16 A at 400 V AC. Contactors shall be rated for not
less than 1 million electrical (AC3) switching operations. Motor contactors shall be Sprecher and Schuh or approved
equal. Each contactor shall have not less than one spare normally open and one normally closed auxiliary contact.
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Contactors shall be mounted with sufficient clearance to other equipment and to its enclosure to allow full access for
maintenance, removal and replacement of coils and contacts, without the need to disconnect wiring or remove other
equipment.
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Control Relays and Timers

General
All relays of the same general function, manufacture and rated coil voltage shall have identical terminal configuration.
Unless otherwise specified or shown, all relays shall have continuously rated coils. Relays of the same function shall be
of the one manufacture and model.
Plug-in types shall be attached to the receptacle base by a captive clip, which may be applied or released without the use
of tools.
Block Type Control Relays
240 V AC control relays and timers shall be moulded block construction type, rail mounted and shall be Sprecher and
Schuh CS4, Syrelec or approved equal. Minimum contact rating shall be 5 A at 220 V for AC applications
Block type control relays shall have provision to fit add-on contact blocks, timers and similar accessories.
PLC Output and Interface Relays
PLC output relays shall be terminal type relays of the same make as the general terminals.
PLC interface relays and miniature control/auxiliary relays shall be plug in type and provided with rail mounted bases.
PLC interface relays and miniature control/auxiliary relays shall be Finder type 40-51/52 series with 95-75 bases or
approved equal.
All miniature relays shall be fitted with indicating LED’s and all DC relays shall be fitted with suppression diodes.
Contacts shall be rated at not less than 5 A, 250 V, 50 Hz and 5A, 24V DC.
Timers
Timers shall be suitable for continuous operation under the specified conditions with operating characteristics suitable
for the application. Repeat accuracy of +/- 3% of the pre-set adjustment over the timing range. Unless otherwise
specified, timer relays shall be Syrelec or by add-on blocks to the specified block type relays.
Thermistor Relays
Thermistor relays shall be Sprecher and Schuh RT7 type or approved equal.
Under-Voltage / Phase Fail Relays
Under-voltage relays shall be provided where specified or shown on the Drawings for sensing of loss of power supplies
to switchboards, control panels, distribution boards and similar equipment.
Under-voltage/phase fail relays shall:
a) Be 3 phase type which sense low voltage and loss of a phase;
b) Have adjustable voltage and operating times;
c) Detect and operate on single or multiple phase loss.
Indicating Lights and Push-Buttons
Unless otherwise specified or shown on the Drawings, indicating lights and push buttons shall operate at 24 V dc.
Indicating Lights
Indicating lights shall be of "oil-tight" design. The indicator light shall utilise single hole mounting with a 22.5 mm hole
Indicating lights shall permit removal of lens and lamp from the front without disturbing the lamp base or wiring.
Indicating lights shall have a projecting glass or high quality heat resistant plastic lens.
Each indicator light shall have an engraved label plate mounted directly above or below the lens.
Where not identified on the Drawings the lens colour of indicator lights shall be in accordance with the relevant standard
Unless otherwise specified, indicating lights shall have LED cluster type lamps (high intensity/bright type).
Lights for 110 and 240 V ac supplies shall be of the integral transformer type.
Indicating lights which are not provided with a means of testing via the PLC, shall be press-to-test type.
Indicating lights and push buttons located in control rooms and switch-rooms shall have minimum enclosure rating of
IP65. All other indicating lights and push buttons shall have minimum enclosure rating of IP66.
Push-Button Switches
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Push-button switches shall be suitable for single hole mounting and shall match the associated indicating lights with
which they are mounted. Contact blocks shall be removable without disturbing the operator. Contact blocks shall be
rated at 10 A, 250 V, 50 Hz and contacts shall be pure silver.
Pushbuttons fitted to switchgear or control panels shall be of "oil-tight" design with coloured buttons and engraved label
plate suitable for single hole mounting with a 22.5 mm hole. Field mounted pushbuttons and those installed in field
mounted local control stations shall be 30 mm type.
Push-button operators shall be coloured red for stop and green for start, any other push-button operator shall be black.
Press-to-test indicating lamps shall also comply with this Specification.
Emergency and latched stop push buttons shall have a large mushroom operator, coloured red, with approved mechanical
latching device padlockable in the off position.
Instruments and Meters
General
All instruments shall incorporate magnetic screening, have mechanical zero adjustment from the front of the instrument
without dismantling and shall be suitable for use on ferromagnetic panels of any thickness.
Instruments of all types shall be marked with instrument transformer ratio, accuracy class and serial number.
All voltage supplies to voltmeters, kilowatt-hour meters and voltage transducers shall be separately protected by fuses
or circuit breakers.
Unless otherwise specified, ammeters and voltmeters shall be of accuracy class 1.5 and shall be of the flush mounting
type.
Analogue instruments shall have shock-resistant jewel bearings and damped movements with facility for external
adjustment of the zero. Impact resistant and non-reflective glass shall be provided.
Scales shall be black lettering on white background with black pointer, capable of indicating the maximum value of the
variable being measured. Markings indicating a normal maximum loading shall be red.
Accuracy shall be class 1.5 or better. Instruments and meters shall be Crompton or approved equal.
Ammeters
Unless otherwise specified, AC Ammeters installed on switchboards, panels and cubicles shall be 72 mm square
instruments with moving iron movement, 90 degree scale and shall be of accuracy class 1.5.
Motor ammeters shall be 48mm square and shall have compressed over-scaling to 6 times full scale, and red lines shall
be provided on the ammeter scales to indicate the full load current of the circuit. Minimum scale readings shall not be
less than 10% of the full load reading.
Unless otherwise specified, ammeters shall be Crompton 243 series or approved equal.
The main supply ammeters shall be a combination ammeter and maximum demand indicators with 96 mm square
minimum size bezel and shall be Crompton 244 series or approved equal. The ammeter shall have an accuracy class 1.5
and maximum demand indicator accuracy class 3.0.
Ammeters may be directly connected in circuits having a rated full load current not exceeding 25 amp. Ammeters in
circuits having a rated full load current above 25 amp shall be current transformer operated and shall employ 5 amp
movements.
Voltmeters
Unless otherwise specified, AC Voltmeters installed on switchboards and cubicles shall be 72 mm instruments with
moving iron movement, 90 degrees scale and accuracy class 1.5. Voltmeters shall be Crompton 243 series or approved
equal.
A voltage selector switch shall be provided for measurement of phase-to-neutral voltages
Rotary Selector Switches
This clause is applicable to all rotary switches used for control and mounted on electrical enclosures, including,
switchboards, control panels, cubicles, junction boxes and similar enclosures. Rotary selector switches shall comply with
AS3947.
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The switch body shall be mounted on the rear face of the enclosure and shall be retained securely. The escutcheon shall
cover the mounting hardware.
Rotary switches shall have a continuous metal shaft from which all contacts shall be operated. Operation of the switch
shall be by a handle attached to the centre shaft by a metal-thread screw. Switches shall be cam indexed at 45 degrees
and shall have bezel with an escutcheon. Switches shall have stops to prevent rotation beyond engraved positions.
Switch contacts shall be pure silver, continuously rated at 10 A 240 V AC and 5A 24 V DC.
Rotary switches shall have an AC-11 utilisation category.
Rotary selector switches shall be Kraus and Naimer type or approved equal.
Motor control selector switches shall be capable of being padlocked in the OFF position.
Terminals
This clause includes all extra-low; low and medium voltage terminals used in terminating cables in electrical enclosures,
including switchboards, control panels, cubicles, racks and terminal cabinets, junction boxes and similar enclosures.
The grouping and arrangement of all terminals shall be to the Engineer's approval.
Terminals shall be Klippon or approved equal.
Analogue Signal Terminals: Analogue signal terminals used to terminate screened cables shall be rail mounted hinged
test link type. Analogue signal shall be provided with sockets for test plugs.
PLC Input/Output Terminals: PLC input/output terminals shall be rail mounted and where shown on the Drawings, shall
be hinged test link type.
Low and Medium Voltage Terminals: Low voltage terminals shall be mounted on a steel rail. Terminals shall be of the
clamping type on both sides unless otherwise specified and minimum terminal size shall be suitable for 4 mm2 stranded
conductor.
Current Transformer Terminals: Current transformer secondary terminals shall be rail mounted test link type and shall
be rated for the maximum fault current specified for the associated current transformers. Current transformer secondary
terminals shall be provided with sockets for test plugs.
PLC I/O Surge Diverters
A 3-stage transient barrier shall be installed in series with each wire of the circuits to be protected.
The barriers must be suitable for balanced and unbalanced circuits or for low voltage, low current power supplies.
The clamp voltage of each barrier is to be as low as possible while being above the normal maximum operating voltage
of the protected circuit.
The barriers may use GDT primary diverters but the secondary diverter/clamp must be a semi-conductor device such as
a Tranzorb or equivalent. This mix of technologies will provide fast response to transients and a high single-shot surge
rating.
The design of the barrier must include suitable decoupling impedance between the primary and secondary surge
diversion elements to ensure the surge and transient performance of the barrier is optimised.
The barrier must have a single-shot surge rating of at least 20KA (8/20uS). Test results confirming this performance
level must be available on request. Calculated or theoretical results are not acceptable.
The barrier design must include internal, automatic, self-resetting over-current protection.
The enclosure shall be a metal or flame retardant plastic to UL94 V-0.
Enclosure style shall be DIN 43880, suitable for attachment to 35mm DIN rail. Minimum acceptable environmental
rating is IP20.
Barriers shall be Erico UTB30S or UTB30D type or approved equivalent.
Control Transformers
Control transformers, for extra low voltage control circuits, shall be double-wound with earthed screen. The screen and
one side of the secondary winding shall be earthed to the control panel frame.
Fuses
Unless otherwise specified or shown on the Drawings fuses shall be HRC type and shall be suitable for industrial
application.
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Fuse rated voltage, current and frequency shall be as specified and shown and shall be appropriate to the application.
400 V fuses shall have a rated breaking capacity of not less than 50 kA.
Unless otherwise specified, fuses shall have a general purpose characteristic.
Fuse-holders shall be of the fully shrouded type.
Separate fusing shall be provided to each individual equipment item and functional group of components and equipment.
The grouping of fused circuits shall be to the Engineer’s approval.
Circuit Breakers
General
Circuit breakers shall have interrupting capacity of not less than the prospective fault level at the point of connection.
Unless otherwise specified or shown on the Drawings, circuit breakers shall be mounted exposing only the handles and
rating plates and shall be of the same manufacture throughout the works.
Circuit breakers shall be selected to provide the best possible discrimination.
Each circuit breaker shall be fitted with an approved engraved label, which incorporates the device/ equipment number
and clearly describes the load.
Air Circuit-Breakers
General
400V air circuit breakers (ACBs) shall be 3 pole, fully metal clad and with earth terminal.
Air circuit breakers shall be mounted in the switchboards strictly in accordance with the circuit-breaker manufacturer’s
instructions and requirements.
Air circuit breakers shall be mounted with the front of the circuit breaker protruding through and flush with the
compartment door. Air circuit breakers shall be lockable in the open position with a 6mm hasp padlock.
Operating Mechanism
Provision shall be made to enable each circuit breaker to be padlocked to prevent closure.
Contact ratings and performances shall be in accordance with IEC 60947-2
ACB’s shall have built in protection for instantaneous short circuit interruption.
Withdrawable Air Circuit Breakers
400V withdrawable air circuit breakers (ACBs) shall be of the horizontal draw-out type.
The racking gear shall be lockable and shall be fully interlocked to prevent withdrawing the circuit breaker when it is
closed. Lockable shutters shall be provided on bus and load sides. The racking mechanism shall lock the ACB in three
distinct positions; connected, test and isolated.
Rating
The 400V air circuit-breaker shall be rated as follows:
a) Nominal voltage 400 V
b) Frequency 50 Hz
c) Short Circuit withstands (minimum) are shown in Table C-25.
Table C-25 Rating of Air Circuit Breakers
Breaker Rating Short Time Current Rated Breaking Rated Making Current
(Amps) (kA for 3 seconds) Current (kA) (kA)
1600 50 50 105
2000 50 65 143
2500 65 85 187
3200 65 85 187
400V air circuit-breakers shall have a continuous current rating of not less than 110% of the associated transformer rating
with the circuit breaker installed in the MCC/switchboard enclosure.
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Auxiliary and Racking Contacts

The following spare auxiliary and, where applicable, racking contacts shall be provided and wired to terminals for each
circuit breaker:
a) Two normally open and two normally closed auxiliary contacts
Moulded Case Circuit-Breakers
Unless provided with current limiting, moulded case circuit-breakers shall be rated for the prospective fault currents as
shown on the drawings.
Type test certificates shall be provided to confirm all ratings.
Facilities shall be provided to padlock motor starter and distribution circuit breakers in the open position.
Moulded case circuit-breakers shall be flush mounted exposing only the handles and shall be of the same manufacture
throughout the works. Circuit-breakers of the same current rating shall be of the same type.
Moulded case circuit breakers in form 3 feeder and motor starter compartments shall be mounted at the back of their
compartment and be operated with a proprietary rotary handle mounted on the compartment door. The rotary switch
handle shall be interlocked so that the compartment door cannot be opened while the circuit breaker is switched on. This
interlock shall be defeatable by an authorised person.
Moulded case circuit-breakers shall incorporate thermal and magnetic over-current protection. The magnetic protection
shall be adjustable for circuit-breakers rated at or greater than 200 Amps.
Moulded case circuit-breakers for the supply of capacitors shall be rated accordingly.
Circuit-breakers shall be selected to provide the best possible discrimination with the fuses and circuit breakers shown
on the Drawings.
Miniature Circuit Breakers
Miniature circuit breakers and chassis/busbars shall be mounted inside the switchboards and control panels as specified
and shown on the Drawings.
Miniature circuit-breakers shall be Terasaki DinT or approved equivalent
Unless provided with current limiting, case circuit-breakers shall be rated for the prospective fault currents as shown on
the drawings.
Circuit breakers shall be mounted so that the "ON-OFF" and current rating indications are clearly visible with the cover
or escutcheon in position (unless noted otherwise), and so that arc discharges from the circuit breakers are directed away
from live metal and insulation. Operating toggles shall be aligned in the same plane.
Sufficient space shall be maintained around the circuit breakers to allow all incoming and outgoing cables, including
cables to spare poles, to be installed and terminated without overcrowding.
Circuit-breakers shall be rated for the prospective fault current and shall be selected to provide the best possible
discrimination.
Each circuit breaker shall be fitted with an approved engraved label, which clearly describes the load.
Circuit breakers supplying plug socket outlets or lighting shall be residual current device type.
Circuit Breakers in 400V Distribution Boards
Circuit breakers installed in 400 V lighting and general purpose power distribution boards shall be mounted in busbar
chassis and shall have interrupting capacity of not less than 6 kA. Approved current limiting fuses rated at 160 Amps
maximum shall be provided where the remote supply fuses or circuit breakers do not provide equivalent current limiting.
Circuit breakers shall be
i) Terasaki Din T series, or approved equal;
ii) Mounted direct to the busbars;
iii) Mounted behind an escutcheon exposing only the operating handles;
iv) Provided with earth-leakage protection where supplying socket outlets and lights.
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Switches and Fuse Switches

This clause is applicable to air-break isolators, switches and fuse switches supplying power consuming devices. All
switches shall have definite indication of the contact position and shall guard against false indication, in particular for
the case of welded contacts.
Switches shall have short circuit current ratings appropriate to the specified prospective fault currents and supply fuse
sizes. Switch current ratings specified and shown are ratings based on uninterrupted duty as detailed in AS3947.
Switches installed in power supplies to motors shall be rated to break motor locked rotor current and shall have minimum
rating of AC23.
Fuse-switches shall have a manual closing handle with provision for padlocking in the OFF position. The handle shall
be retractable when not in use. Fuse switches, when fitted with the largest fuse, shall be suitable for operation on a system
with the installed prospective fault current or 50 kA - whichever is the higher.
Fuse switches shall be rated as follows:
i) Rated short time withstand current when fitted with largest fuse size they will accommodate - the
installed prospective fault current or 50 kA - whichever is the higher;
ii) Rated short circuit making current - 105 kA minimum;
iii) Rated to break rated load current and where applicable, motor locked rotor current.
Type test certificates shall be provided to confirm all ratings.
Fuses shall be bolted tag type complying with BS 88 and shall be an approved type to provide current limiting of
downstream devices
C.5.11 Other Instruments, Indications and Alarms
General
The operating push buttons, switches or handles of all circuit breakers, motor starters, isolators, etc. shall be located on
the front of cubicles, or for cubicles of the desk type, on the face of the desk. There shall be visual indications of the
"ON" and "OFF" positions.
All operations of power on, running, stopped, fault and alarm circuits shall be clearly individually indicated on the fascia
of the switchboard, by lamps.
Fault and alarm lights shall remain on until the associated fault or alarm condition has been cleared and the system reset.
An audible alarm shall also be provided to indicate operation of any major fault or alarm function. An “alarm accept”
shall cancel alarm but leave the fault lamp illuminated until fault is cleared. The clearance of the audible alarm shall not
prevent further alarms activating the audible alarm for additional faults.
Indicating lamps shall incorporate a lamp test feature either individual push to test or a common lamp test button.
Start push buttons shall be of the shrouded type; Stop push buttons shall be of the mushroom headed, stay-put, twist to
release type. Stop push buttons shall be operative in both manual and auto modes of control. All push buttons shall have
a label indicating their function.
Indicating lamps on panels shall be rated to withstand not less than 20% continuous over-voltage and shall be so designed
that the heat from the bulb does not discolour the panel. Account shall be taken of the lamp's local ambient conditions.
Indication lamps and push buttons shall be coloured in accordance with IEC 73 (BS 4099 or BS EN 60073:1993) as
amended by current site practices. Flashing indication lamps shall be arranged in accordance with BS 4099, as amended
by current site practice.
Indicating lamps shall be provided for duties as on existing equipment and general site practice. Particular indicating
lamps shall also be provided as called for in the Detailed Scope of Works. If necessary, rationalization shall be applied
between sites by agreement with the Engineer.
All electrical indicating instruments shall comply with BS 89 and BS 3693, be moving iron type and to Class 1.5 or
better. Instrument size shall be 96 mm square with quadrant scale.
Instruments shall be flush mounted on the cubicles and effectively sealed against ingress of moisture, dust and inspects.
Instrument mounting height shall not exceed 1.80 metres above floor level. Unless otherwise specified instrument full
scale deflection shall be at least 120% of the normal operating point (i.e.. nominal voltage or full load current).
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Ammeters in motor circuits shall be capable of withstanding the starting current of the motor and shall have a compressed
overload scale for this purpose. The full load current shall be defined with a red line. Voltmeter scales shall have a red
line indicating normal volts.
All voltage circuits of instruments shall be protected by a fuse in each unearthed phase, situated as close as practicable
to the point of connection.
Current transformers (CT) shall have short circuit ratings not less than those of the circuits with which they are concerned,
and shall fully comply with BS 3938.
One side of the secondary winding of all current transformers shall be earthed. The rated burden of each CT shall be a
minimum of 150% of the designed load burden.
Where specified, capacitors for correcting power factor shall be incorporated in the panel. Such capacitors shall comply
fully with BS 1650.
All motors shall be provided with emergency stop push buttons mounted on or adjacent to the motors which shall lock
out the control circuit and shall require a key to reset the circuit. Local motor isolators shall also lock out the motor
control circuit when in the "OFF" position.
Labels
Each switchboard shall be provided with a main title label where specified and circuit designation labels shall be fixed
to the front and rear cover of each circuit compartment.
Panels with front and rear access shall have circuit designation labels fitted to the outside of all the rear covers in addition
to any necessary warning labels. Rear covers covering more than one sub-section shall have duty labels fitted for each
sub-section.
All indicators, instruments, relays, control switches, push-buttons, fuses and other ancillary apparatus shall be provided
with labels clearly stating their function. All compartments within the switchboards and panels shall be similarly
identified.
All label inscriptions shall be to the approval of the Engineer.
Labels fitted to the front of the switchboards/control panels/starters shall be sandwich type white/black/white;
yellow/black/yellow for warning and red/white/red for danger labels or as approved by the Engineer.
All labels shall be fixed square to the equipment by means of screws or rivets of nylon or non-corrodible material. Labels
affixed with adhesive will not be accepted.
C.5.12 Control Panel Cabling
Control wiring shall be 600 volt grade tri-rated heat resistant PVC insulated multi-stranded copper wire to BS 6231. The
minimum size shall be 1.5 mm² stranded conductor.
Conductor colours shall be:
i) 400 VOLT:
e. Red Phase: Red
f. White Phase: White or yellow
g. Blue Phase: Blue
h. Neutral: Black
i. Earthing: Green/Yellow
ii) 220 VOLTS AC:
j. Control Active Red or brown
k. Neutral: Black or light blue
iii) 24 VOLTS AC:
l. Control Active: Purple
m. Common Purple
iii) 24 VOLTS DC:
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n. Positive: Purple
o. Negative: Purple
iv) Instrumentation:
p. 4 to 20 mA Loop: White, or screened cables with white/black pairs
All terminals shall be referenced and detailed on the schematic diagram to be submitted under the Specification
requirements. Each cable core shall be identified with interlocking ferrules of white PVC with black identification
numbers/letters at each end of the cable core.
It shall be possible to safely gain access to any terminal of any component so as to be able to remove and replace the
wire from that terminal without recourse to special tools, and without the need to disturb other components.
All wiring shall be neatly run bunched in neat forms. All wiring accessories of plastic material, such as cleats, conduits,
strapping, etc., shall be non-corrodible and resistant to flame propagation.
Crimped pin extensions shall be fitted to all control circuit cables to prevent wandering strands before being inserted into
Klippon type terminal blocks.
Cabling shall enter the panel from below with front or rear access as required. Cables shall be easily glanded using
external boxes or internal gland plates. Cable glands shall be used for all external wiring entering panels, boxes or remote
equipment. The cable entry point into the gland shall be sufficiently sealed to prevent the ingress of dust etc.
All the glands shall be supplied by the Contractor and shall be of the brass compression pattern so designed that any
strain on the cable is taken by the steel wire armouring. The glands shall incorporate watertight seals on both inner and
outer sheaths and have a separate armour clamping ring to ensure a good mechanical connection for the earth continuity
path. The glands shall be secured with heavy duty locknuts and the whole assembly is to be protected by an overall
plastic sleeve, suitably sealed to prevent atmospheric attack.
Glands fitted to unthreaded gland or adaptor plates, non-metallic equipment, or where specified for circuits likely to pass
high fault currents, shall include a brass earthing tag and connections arranged to effectively bond the gland body and
gland plate via a protective conductor to an effective earth point within the panel.
Where necessary cable tray work shall be provided for supporting and fixing cables and full glanding and terminating
equipment and facilities shall be provided. Gland plates shall be mounted not less than 150 mm above the cubicle
bottom. It shall be possible to terminate all cables without requiring access to live interiors. Sufficient space shall be
allowed between gland plate and the cable termination point without recourse to bending large cables (above 16 mm²).
Primary cabling shall be completely isolated from all control wiring, etc. and auxiliary terminals shall be likewise isolated
from primary terminals.
All terminal boards and terminal blocks shall be of a type providing a positive mechanical clamp on connection.
Terminals for the connection of all external cabling shall be situated near their respective gland plate and at minimum
distance of 300 mm from it. For large cables (above 16 mm²) the termination shall be so placed as to not require the
bending of the cable to enter the termination.
Separate terminals shall be provided for incoming and outgoing connections and not more than two wires shall be
connected to any one terminal.
C.5.13 LV Distribution Switch Gear
Switches
Switches shall be of the air break pattern, enclosed in zinc sprayed heavy duty, cast metal or sheet steel cases suitable
for industrial surface mounting or flush cubicle mounting as specified.
Switches shall be rated in accordance with BS 5419 or BS EN 60947-3:1992 and be fitted with solid or HRC fuse links
as appropriate in each phase and a neutral link, all contained within the switch case, with the terminals accessible from
the front of the switch. Phase barriers and contact shrouds shall be provided with an interlock to prevent withdrawal or
access when the fuse switch is in the ÒN' position.
Each switch shall have a free handle control mechanism to prevent inching and damage to contacts, be fitted with ÒN'
and ÒFF' position indicators and have provision for locking in the ÒFF' position. When padlocked in the ÒFF'
position, interlocks shall prevent the unit door being opened.
The moving contacts of fuse switches shall be readily withdrawable as a complete unit for maintenance when the
remainder of the board is live.
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Distribution Fuseboards
Fuseboard cases shall be of rust proofed, zinc sprayed, heavy gauge sheet steel, having a flush fronted door with
concealed hinges and a resilient sealing gasket.
The interior shall be assembled from all-insulated shrouded fuse carriers and bases of the 440V pattern, fitted with phase
dividing barriers and all live parts being fully shrouded.
Circuit identification charts shall be fitted to the inside of all fuseboard doors.
All fuse carriers shall be fitted with fuse-links of the same current rating as the carrier, unless different current ratings
are called for under the specific requirements. The Contractor shall however confirm fuse ratings with the Engineer
before fitting fuses to the carriers.
Fuse-links shall be of the HRC cartridge type to BS 88, Class Q1, having screw fixings to the carriers.
Moulded Case Circuit Breakers
Moulded case circuit breakers shall be of the quick make, quick break, trip-free type complying with BS 4752 or BS EN
60947-2:1992 and shall be complete with thermal/magnetic releases, except for those units serving as isolators only.
Multi-pole breakers shall be a common trip bar and trip elements on each pole to ensure that any abnormal condition on
any one pole will cause all poles to open simultaneously.
Visual indication of open, close and trip conditions shall be provided and where specified padlocking facilities in the
ÒFF' position shall also be provided.
Miniature Circuit Breakers
Miniature circuit breakers shall be of the quick make, quick break, trip-free type complying with BS 3781 Part 1 and BS
EN 60439 Part 12, or EN 60439:1991, for distribution boards. Circuit breakers shall be complete with thermal /
magnetic or magnetic/hydraulic releases. Multi-pole breakers shall have a common trip bar and trip elements on each
pole to ensure that any abnormal condition on any pole will cause all poles to open simultaneously.
Visual indication of open, close and trip conditions shall be provided, and where specified padlocking facilities in the
ÒFF' position shall also be provided.
Distribution MCB Boards
Miniature circuit breaker distribution boards shall be totally enclosed, metal clad, flush fronted units, with a hinged front
door, all in accordance with BS 4649. The interior shall be assembled from all-insulated miniature circuit breakers with
bolted connections and with switch dollies arranged for vertical operation. Phase dividing barriers shall be provided and
all live parts shall be screened from the front. Circuit identification charts shall be fitted to the inside of all distribution
boards.
Circuit Lists
A list of circuits in approved form shall be supplied and fixed behind a "Perspex" sheet on the inside of all distribution
boards which are provided or rewired under this Contract.
The draft lists together with a "Perspex" envelope shall be submitted to the Engineer for his approval before the final
copies are prepared.
Residual Current Circuit Breakers
The circuit breaker shall be arranged to isolate each live conductor simultaneously within 30 ms if the residual leakage
current through the device exceeds 30 mA.
The circuit breaker shall be housed separately or incorporated into other composite enclosures, include provision for
testing the tripping operation under earth leakage conditions by means of a built-in resistor and push button, and require
manual resetting.
C.5.14 Electrical Installation
General
The electrical installation shall comply with the current edition of the Regulations for Electrical Installations published
by the Institution of Electrical Engineers (IEE Wiring Regulations) and the requirements specified herein where these
differ from the IEE Wiring Regulations.
The installation shall be arranged in a neat and orderly manner which may involve running out of direct lines in order to
conform to building outlines etc, and to utilise any holes provided in the structure for cabling purposes. Unnecessary
crossing of cables will not be accepted and due care should be given to this when selecting runs. Each cable shall be in
one continuous length and no straight through joints will be permitted except as agreed with the Engineer.
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It shall be the entire responsibility of the Contractor to programme the whole of his work to ensure that the various parts
of the electrical installation are executed at the proper stages of the construction.
HV power cables shall be 3800/6600 volt grade, copper conductored XLPE insulated, multi-core armoured, PVC
sheathed.
LV power cables shall be 600/1000 volt grade, copper conductored PVC and/or XLPE insulated multi-core and single-
core armoured PVC sheathed.
Cables up to 10 mm2 shall be PVC insulated. Cables of 16 mm2 and above shall be XLPE insulated.
Cable types and relevant standards are as follows:
ii) Cross linked polyethylene cables shall have stranded, copper conductors with cross linked
polyethylene insulation. Multi core cables shall be laid up in an extruded bedding, single wire
armoured and sheathed overall with PVC, to BS 5467 (XLPE/SWA/PVC type);
i) Single core cables shall have aluminium wire armour;
ii) PVC armoured cables shall have stranded copper conductors with extruded PVC
insulation, PVC sheathed, single wire armoured and sheathed overall with PVC
(PVC/SWA/PVC type). Cables shall be in accordance with BS 6346;
iii) PVC insulated wiring cables shall be 450/750 volt grade single core stranded copper
conductors PVC insulated to BS 6004 (PVC wiring type);
iv) Telephone cables shall be thermoplastic insulated multi-pair cables having twisted pairs
of copper conductors (telephone type);
v) Instrumentation cables shall be polyethylene insulated copper conductors with twisted
individual pairs screened, polyethylene bedded, steel wire armoured and PVC sheathed
overall, all in accordance with BS 5308 Part 1 Type 2. Conductors shall be 0.5 mm²
stranded 16/ 0.2 mm (PE/IS/SWA/PVC type);
vi) Earth and bonding cables shall have stranded copper conductors PVC insulated and
sheathed (PVC/PVC type);
vii) Flexible cables shall have stranded, tinned copper, flexible conductors, EP rubber
insulated and CSP sheathed all in accordance with BS 6007 (flexible type);
viii) Flame retardant cables shall be EP rubber insulated, tinned copper conductors in a CSP
sheath, braided with galvanised steel wire (single cores having phosphor bronze wire) and
protected with a CSP sheath overall, generally in accordance with BS 6883.
Cable insulation shall be coloured follows. Both ends of each cable core shall be identified where applicable with black
numbering on a white background PVC interlocking ferrule.
Phase: Red, Yellow, Blue
Neutral: Black
Earth: Green or Green/Yellow
Live (single phase circuits): Red or Brown
Neutral (single phase circuits): Black or Light Blue
DC Circuits: Grey
Care should be taken that servings and sheathings of cables are not damaged during installation. Should any part be
damaged, the damage shall be made good to the entire satisfaction of the Engineer. Under no circumstances should
cables be allowed to bend less than 8 times their diameter.
At all points where cables rise into the floor mounted equipment, the vertical portion of the cable shall be securely cleated
to the metalwork of the equipment in a neat manner to ensure that the cables are properly supported and that no undue
strain is put on the cable, the cable termination or the Plant. Where vibration or expansion is a consideration, adequate
precautions and vibration loops shall be made at the appropriate position.
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Cables entering cubicles provided with sealed covers of timber or sheet steel shall be accommodated by drilling or
dividing the covers with clearance holes as necessary to allow the cable to pass through and be terminated at glands or
gland plates provided within such cubicles, so that the covers when replaced prevent entry of dust, vermin and insects.
Selection of Cable Runs
The route and arrangement of all cables and the position of equipment and wiring points shall be marked out on site by
the Contractor and agreed by the Engineer before any work is put in hand. Where cable routes have been agreed, the
Contractor shall be entirely responsible for measuring the lengths of cable to be ordered and ensuring that the cables are
supplied in the correct length.
All cables shall be armoured. Cable warning tapes shall be laid immediately over the line of the cables buried in the
ground and at 300 mm below ground level. Cable route markers shall be supplied at every 30 m along cable runs and at
changes of direction.
Armoured cables other than those laid in the ground shall be suspended on cable racks, cable tray, cleats or cable hangers
supplied under this Contract which shall be arranged for bolting to steelwork, brickwork or concrete as required. Lighting
and small power cables shall be protected by conduit or trunking as appropriate.
Where cables are run on open surfaces and exposed to the sun a metal shield shall be fitted over them. Similarly where
cables are run up walls they shall be suitably mechanically protected to a height of 2 m above ground or floor level.
Lighting and Small Power
Lighting and small power distribution boards shall comply with the relevant parts of BS EN 60439. They shall be
complete with incoming isolation switches and circuit breakers as required. The distribution boards shall generally be
three phase and neutral type (TP & N). Enclosures shall have a minimum protection of IP 54.
Lighting installations shall be designed to give the following light levels after 2000 hours of operation and assuming a
0.8 maintenance factor (figures shown are the average Lux levels):
i) External Areas 50
ii) Pump houses and other operational buildings 150
iii) Offices 300
iv) Light values on faces of MCC's/ control panels 300
Light fittings shall comply with all relevant British Standards. Fluorescent tube fittings shall be of the switch start type
complete with all separate control gear for each lamp and be complete with a capacitor to ensure that the power factor is
a minimum of 0.85. Fluorescent fittings shall have a glass reinforced plastic (GRP) body and acrylic diffuser and be
suitable for installation in a tropical climate. All fittings shall have a minimum enclosure protection of IP 54.
Weatherproof fittings shall have minimum degree of protection to IP 55.
Bulkhead fittings where used shall be suitable for industrial installations and have a minimum degree of protection of IP
55.
Self-contained luminaires to provide emergency lighting in accordance with BS 5266 shall incorporate two fluorescent
tubes as appropriate and a maintenance free nickel cadmium battery, capable of preserving the light output for a period
of 3 hours without mains supply, together with an automatic recharging circuit with a monitoring indicator to restore the
charge within 24 hours. The units shall not be damaged by mains outages exceeding 3 hours. The units shall be of the
non-maintained type. Where there is normally sufficient daylight, the emergency lights shall be controlled by a photo-
electric unit to inhibit their operation in daylight.
Lighting within pump halls and other large indoor areas shall be by high bay luminaires incorporating suitably rated
SON/T lamps. Luminaire bodies shall be of enamelled sheet steel, reflectors shall be of high purity aluminium.
Outdoor building floodlights shall comprise a corrosion resistant wall mounting bracket with a lamp fitting having a
minimum ingress protection rating of IP 55. The fitting shall be equipped with a suitably rated SON/T lamp and integral
control gear.
Roadway light fittings shall be of the side entry type with semi-cut off light distribution, and be equipped with a suitably
rated SON/T lamp. The fitting shall be mounted on a folding 5 metre column incorporating a single bracket arm, burial
root, fuse cut out and control gear. The column material shall be hot dipped galvanised mild steel. The upper section
may only be lowered by use of a specially designed device to assist the operation. At least one lowering device shall be
provided.
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Electric crane installations shall be suitable for operation from a 400 V 3 phase 50 Hz AC supply. Electric motors shall
be of the high torque type. Control gear, isolators, etc. shall be housed in a suitable dust-proof and weatherproof
enclosure. The crane cross conductor system shall comprise a multi-core PVC insulated and PVC sheathed flexible cable
festooned on free running ball bearing trolleys running in a rigid box section track fixed to the crane beam.
Cables for staff housing shall be PVC insulated with PVC sheath and copper earth conductor, complying with BS 6004,
for cables below 16 mm². The cables shall be clipped to walls/ceilings or battens as appropriate. Cables of 16 mm² and
above shall be to BS 5467.
Fused spur units shall be double pole 13 A switched type in surface mounted metal-clad boxes suitable for industrial
installation and complying fully with BS 1362.
Socket outlets in offices and control rooms shall be twin 13 A switched types in surface mounted metal-clad boxes
suitable for industrial installation and complying fully with BS 1363. Elsewhere 13 Amp switched socket outlets shall
be iron-clad with screw cap cover.
All switches shall be water and dust sealed suitable to provide a reliable installation in the environment of a water
treatment works. The switches shall be of heavy duty design to match the switched sockets specified above and shall
not be less than 20 Amp rated.
Light switches shall be 20 Amp rated with required number of gangs and ways in a surface mounted metal-clad box
suitable for industrial installation and complying fully with BS 3676 or BS EN 60669-1:1996.
Weatherproof light switches are to have a minimum degree of protection of IP 55.
All equipment shall be securely fixed and mounted.
C.5.15 Installation Requirements
General
Equipment shall be located so that it will be readily accessible for operation and maintenance by personnel of average
height and build and without requiring special tools or equipment.
Voltage drop shall be allowed for, in determining the size of power cable and conductors. The volt drop between the
main switchboard and the terminals at the load end of each final sub-circuit shall not exceed 3.5%.
Cables
Cable Installation - General
All cables shall be installed, terminated and tested in accordance with manufacturer's instructions and recommendations
with particular regard to:
i) Size and type of terminals;
ii) Dies and compression devices;
iii) Jointing and sealing compounds and boxes; and
iv) Bending radii.
Cabling not on cable ladder shall be installed in conduit as specified unless shown as direct buried.
Unless otherwise approved cables shall be installed in concealed spaces. Exposed cabling or conduits shall not be
installed on the exterior walls of buildings.
Cables shall be carefully installed to ensure that the insulation is not damaged nor is likely to be damaged in service.
Cables shall be installed without en-route joints.
Cables to be installed in underground pipe ducts or conduits shall be drawn in such that the cable is not damaged either
by excessive mechanical strain, abrasion or severing of insulation.
During drawing-in, rollers shall be placed in cable pits to ensure smooth movement and that changes of direction are
accomplished with radii not less than the minimum bending radius recommended by the cable manufacturer. Attachment
of the cable(s) to the drawing rope shall be by suitable hooks or cum-a-longs, together with a swivel coupling to prevent
damage to the cable.
Generally, cables shall be routed to outside plant locations via underground pipe ducts, trenches and/or individual pipe
conduits. Within trenches and buildings and on or within structures, groups or cable shall be run on cable support
systems.
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Power cables shall not be run in the same conduit, duct or tray as control, instrument or programmable Controller signal
cables.
The location of cables and conduits is dependent upon the final equipment and fittings to be installed and shall take due
account of the final termination points of all equipment and structural/architectural and mechanical limitations.
Underground cable routes shall be identified over the entire length by orange PVC "Terra Tape" or approved equal.
In addition concrete markers shall be firmly installed at ground level at any change in direction of cables or at every
100m in a straight run. The blocks shall be complete with non-rusting metal arrows indicating the direction(s) and
whether cables are HV or LV.
Effectively seal all openings, ducts, trenches, cable ways or the like made for the entry of electrical conduits and cables
through external walls of buildings, with an approved weatherproof concrete grout, and for those through internal walls
of buildings, with a weak mix concrete or by other prior approved means.
All openings are to be made weatherproof by the installation, if necessary, of flashing and/or rain hoods to prevent the
entry of water, driving rain and/or water seepage.
There shall be no more than 1 conductor per screw or tunnel type terminal.
Each end of every conductor shall be terminated with a suitable crimped type terminal.
Crimping of terminals shall be done strictly in accordance with instructions supplied by the manufacturer of the crimped
terminals selected for the job.
TPS cable shall not be used in any area that will normally expose the cable to view or damage without being enclosed
in conduit. Above false ceilings, in masonry blocks, wall cavities, etc., TPS cable may be installed without additional
mechanical protection. Where it is necessary to conceal TPS cable in plaster, mortar or cement, conduit shall be used to
facilitate the enclosure and protection of the cable. TPS cable shall only be used for lighting and general purpose power
within the drive train offices.
Power cables associated with VFD drives shall be segregated by a minimum of 300mm from 24VDC and
instrumentation cabling.
Cables installed on ladder forming part of multi cable parallel three (3) phase circuits shall be spaced to prevent de-rating.
Cable Installation - In Trenches
Trenching for direct-in-ground cable installation shall be neatly excavated to a depth sufficient for LV cables to greater
than 600mm below surface level and HV cables 750mm below surface level or the minimum required by local standards.
The bottom of the trench shall be cleared of rock, stones and other material which could damage the cable. A 50 mm
sand bedding layer shall then be placed in the bottom of the trench. Following laying of the cable it shall be covered
with a layer of sand or approved selected fine filling to a depth of 50mm above the cable. PVC or concrete slabs shall
then be placed. A PVC marker tape shall be placed 150mm above the PVC slabs.
After cable laying and slabbing has been approved, backfilling shall be compacted in layers to a density similar to the
surrounding soil. A period of at least two weeks shall be allowed for natural settlement, after which the ground surface
shall be reinstated to the original level. All excess soil shall be removed from site.
Cables installed direct buried underground forming part of multi cable parallel three (3) phase circuits shall have a
minimum gap of 150mm between circuits for de-rating purposes.
Cable and Core Identification
Approved tags shall be used for cable identification at both ends of cables near cable glands and in each cable pit. Each
core of control cables shall be identified at all terminals by slip on ferrule type markers. Coding shall be subject to the
Allowance shall be made for up to 13 alphanumeric digits.
The cable code number shall be attached using Critchley type K markers on a carrier strip with alpha numeric designation
or equivalent.
Alternatively approved heat shrink markers may be used. Heath shrink markers must be heat shrunk to the core and
must provide a digit of at least 2.0mm height when fully shrunk.
Every code number shall be clearly visible and accessible.
Cable Glands
Cable glands shall comply with BS 4121 "Mechanical Cable Glands".
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Compression type cable glands as manufactured by `CMP' or approved equivalent shall be provided to accommodate
the entry of all power, control and instrument signal cables at each enclosure.
Where ever possible cable glands and cable entry to enclosures shall be at the bottom. Unless otherwise approved, cables
shall enter outdoor cubicles at the bottom.
Cable glands shall provide a moisture proof seal onto the cables sheathing. Glands shall be correctly sized to suit the
particular cable in each instance. When fitting to armoured cables, cable glands shall be provided with a swaged end to
produce a completely captive armour lock assembly. When required for earthing purposes, cable glands shall be
provided with slip-on earth tags.
Conduits
General
Generally all conduits shall be installed on the `draw-in loop in' system. No wires shall be installed until all conduits are
in place. Where cabling requires mechanical protection then metallic conduit shall be used or PVC conduits shall be
mechanically protected to approval.
No conduit less than 20mm shall be installed for any part of the installation.
All conduits shall have a minimum spare space capacity of 25% for future additions except where otherwise specified.
Conduits shall be installed in such a manner to allow easy draw-in and replacement of cables; draw-in boxes shall be
used where necessary to enable draw in for long runs of cables and shall not exceed spacing of 20m. A draw wire shall
be installed in each conduit. The draw wire shall be tagged as such.
Wherever inaccessible or concealed conduits change direction, the conduit shall be set with as large a radius as
practicable.
Single conduit runs shall have their ends bushed via nylon bushings wherever cables exit onto neighbouring cable trays
or to enclosures.
All screws or fastenings used for fixing conduit saddles shall be plated or galvanised.
Conduit saddles shall be two holed and finished to match the conduit. Saddles shall be provided within 150 mm of
fittings and terminations.
An appropriate approved conduit coupling arrangement shall be provided and suitably fixed to conduits crossing
structural expansion joints. Approved expansion joints shall be fitted at appropriate intervals along straight sections of
conduit.
All conduits shall be run concealed wherever possible in wall cavities, roof spaces, floor slabs and masonry walls.
All elbows and tees shall be of the inspection type.
Conduit shall be continuous and shall enclose the cables over the entire route length inclusive of changes in route
direction.
Rigid PVC Conduits and Thermoplastic Pressure Pipe
Rigid PVC Conduit and fittings shall be of high impact strength heavy duty type. All fittings and accessories shall be
secured with an approved solvent cementing compound. Screwed joints shall not be permitted.
Rigid PVC conduits will not be permitted in the following locations, unless otherwise specified:
i) Where exposed to mechanical damage;
ii) Where exposed to direct sunlight;
iii) Where subject to an ambient or contact temperature exceeding 60°C or below 5°C;
iv) Where buried in concrete slabs without the knowledge of the Engineer.
Rigid PVC conduit shall be installed so as to enable cables to be `drawn-in' after erection and junction boxes are to be
provided for this purpose.
Rigid PVC conduit shall be securely fastened with two-hole saddles at a maximum spacing of 460 mm, where necessary
to eliminate sagging in the conduit additional saddles shall be provided. Where rigid PVC conduit is installed across
rafter or joists in roof spaces, it shall be fastened to the side of a timber batten.
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Where any straight section of rigid PVC conduit exceeds 3800 mm in length, an approved expansion joint shall be
provided for each 3800 mm or part thereof along the entire length of the straight section. Conduit clips shall be installed
so as to allow the conduit to move freely, longitudinally, while expanding or contracting.
All sets and bends in rigid PVC conduit shall be made using approved internal springs of correct size to prevent wall
collapse. Conduits in which any collapse of walls is evident will not be accepted and shall be replaced
Thermoplastic pressure pipe and fittings shall be category "A", heavy duty, rigid uPVC tubing suitable for plain
connections.
Thermoplastic pressure pipe shall be installed in accordance with the requirements for rigid PVC conduit.
Flexible Conduits
PVC sheathed flexible metallic conduit shall be used for final connections to plant devices subject to vibration or where
mechanical protection is required. The flexible metallic conduits shall be complete with oil-tight, water proof end
fittings. Where cables are required to enter an enclosure via cable glands, the flexible conduit end fittings shall be
attached via a bracket secured to the device or nearby structure at a short distance from the cable gland.
A sufficient length of flexible conduit and cable shall be positioned and mounted where applicable to permit the
positional adjustment of equipment without electrical disconnection or same, as for example, for adjustment no-flow
limit switches and the like.
Flexible PVC hose shall be used to enclose buildings wire between rigid PVC or metallic conduit and final devices, egg.
switches, generally power outlets, light fittings, etc. Screw in hose fittings shall be used to terminate the PVC hose at
the conduit and final device.
Metal Conduits
Metallic conduits are generally not acceptable without approval of the Engineer.
Surface Conduit Installation
Conduit run on the surface and exposed to view shall be run parallel to walls, doors and structural members. The conduits
shall be symmetrically set and evenly spaced with sufficient saddles to eliminate sagging.
All elbows, tees, draw-in boxes and other fittings shall be of the inspection type and shall be securely fixed individually.
Underground Conduit Installation
All underground pipe conduits to be installed by the Contractor shall be heavy duty uPVC electrical duct pipe, unless
otherwise specified.
All underground conduits shall be arranged for drawing in of cables after assembly. Changes of direction shall be
accomplished wherever practicable by large radius setting of the pipe rather than by the use of fittings.
Where block-outs are provided in concrete structures for conduit entry these are to be grouted after all conduits are in
place.
All underground conduit joints shall be effectively sealed against entry of water or moisture.
All spare conduits and ducts are to be effectively plugged and sealed. An approved draw cord shall be left in each conduit
for the pulling of future cables.
The Contractor shall determine the location of existing services, mark the proposed location of excavation and obtain
the Engineer's written approval prior to proceeding with excavation.
All cable trenches shall be backfilled with excavated soil and shall be restored to original condition with the addition of
topsoil to a depth of 50 mm and reseeded where appropriate. All excess spoil and other excavated material shall be
removed by the Contractor from the site. Concrete or bitumen surfaces shall be reinstated to the same standard or better
as surrounding surfaces. Tie rods shall be used to fix new concrete with existing concrete.
Conduits Cast In Concrete
Conduit cast-in-situ shall be securely fixed to the steel reinforcement with heavy binding wire to prevent the movement
of the conduit during the pouring and vibrating of the concrete.
The open ends of conduit shall be closed with end caps as soon as they are installed and all boxes not provided with
cover plates shall be suitably sealed to prevent the ingress of concrete, etc., and so arranged that they may easily be
located.
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Draw-in boxes shall not be installed (except for grid systems) in the floor surface but shall be diverted to columns or
walls nearby as necessary.
Standard robust wall boxes of the pressed steel type shall be used, as required, for installing flush with the structural
surface, for recessed conduit installations, together where necessary with an approved manufactured steel or bakelite
cover plate as required fitted with brass screws.
Elbows and tees shall not be used.
Conduit cast into slabs shall be:
i) Strictly located so that structural strength is not affected;
ii) Located so that the placement of the reinforcement is not affected;
iii) Placed so that each conduit is at least 20 mm above formwork, 20 mm below surface and spaced by
diameter of largest conduit.
Concealed Conduit
Conduit recessed in walls shall be fixed in chases cut in the brickwork to a depth to permit a full 10 mm covering of
cement and sand before plastering.
Concealed conduits recessed in walls shall be secured in position where necessary by crampets driven into wooden plugs.
Conduits to be installed in fair faced brick walls without cavity shall be accurately installed in the centre of the wall area
before brickworks are commenced. It will be the responsibility of the bricklayer to cut bricks to clear the conduit.
Cable Ladder and Cable Tray
The Contractor shall supply and install the cable trays and ladders with all the necessary bends, raisers, reducers,
expansion joints and other fittings as required.
Cable ladder and trays shall be manufactured from hot dipped galvanised steel.
Cable ladder and trays shall be supported on galvanised steel brackets having a material thickness of 6 mm minimum.
Cable ladder and trays and ladders shall have supports at not more than 2 metre centres and intermediate supports at
joint. Where brackets are used to support cable trays and ladders, they shall be spaced such that the loaded cable tray
and ladder does not deflect more than 5 mm.
All cable trays and ladder fittings, brackets, bolts, nuts and washers shall be hot dipped galvanised steel and shall match
the cable tray and ladder type in use.
Where cable trays and ladders have been cut or damaged during erection, the resulting exposed metal shall be cold
galvanised treated and suitably painted to prevent corrosion.
All cable ladder and trays exposed to sunlight shall be fitted with lids of similar material. All lids shall be peaked.
Cables laid in cable ladder and trays, shall be arranged to minimise cross-overs and shall be secured at frequent intervals
by means of approved metal cable straps of adequate size and strength for the cables involved.
Cable ladders and trays shall be sized to allow for a minimum spare capacity of 50% for future additions.
Junction Boxes
Weatherproof junction boxes shall be of aluminium (10 gauge) or rigid UV stabilised impact resistant plastic, unless
otherwise specified.
The enclosure shall be water and dust tight to IP55 to AS 1939 and shall be complete with threaded cable entries.
Adaptor plates with moulded threaded entries to suit screw-in cable glands shall be provided for junction boxes with
knockout type cable entries.
Junction boxes shall contain a set of moulded block rail mounted tunnel terminals numbered from 01 upwards.
Total number of terminals shall be 25% in excess of the number of incoming cable cores.
Adequate space shall be available within the junction box enclosures to accommodate all wiring including possible future
connections.
Mechanical Protection
The Contractor shall supply and install approved mechanical protection on all electrical equipment and cabling installed
as part of this Contract under the following conditions:
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i) When mounted within 1.5m above a floor or access platform;

ii) Where subject to damage during normal plant operation and maintenance;
iii) On which scaffolding and/or planks may be placed, or which may be used as means of access for
abnormal plant maintenance;
iv) When and as directed by the Engineer.

Conduits and/or cables (other than single core cables) requiring mechanical protection shall be installed in galvanised
steel pipe or other prior approved means.
Sheet metal covers installed to provide mechanical protection of equipment shall be constructed to withstand the shock
loading likely to occur in the area. They shall be constructed of minimum 14 gauge galvanised steel material.
Sheet metal covers installed to provide mechanical protection of equipment shall be constructed so as to totally enclose
such electrical equipment and associated conduits and/or cables.
Any device installed for the mechanical protection of conduits and/or cable shall be free of burrs and sharp edges.
Additional bushing, sleeving or other prior approved means shall be provided as required to ensure adequate bending
radius and to prevent conduit and/or cable damage.
All conduit and cable runs shall be separately grouped where possible, and all supports, brackets, saddles and clips spaced
so that no appreciable sag occurs in such conduits and cables.
Fixings shall be installed at spacings which ensure that the runs remain straight, and in every case the distance between
such fixing shall not exceed one metre.
Where three or more conduit or cable runs are separately grouped together, they shall be mounted on suitable sized
conduit racks, cable trays or ladders as applicable. Single or double runs may be fixed direct to walls or supporting
structures. Holes shall not be drilled through the flanges of RSJs or channels and shall be located to the Engineer's
approval.
Conduits and cable shall be supported by saddles, cleats or other prior approved means so that no weight is taken by
conduit terminations or cable glands, and so that no force is exerted on core terminations.
Supports for cable trays, ladders and conduit racks shall be fastened using "Terrier" anchors or other prior approved
means.
Brackets and Fixings
All necessary brackets for mounting of equipment wiring systems, etc, shall be provided by the Contractor. In general
brackets shall be fabricated from mild steel sections or plate of adequate size and thickness and shall be hot dipped
galvanised after completion of fabrication and drilling.
Fixings shall be by means of galvanised bolts, nuts and washers. Fixings into brickwork or concrete shall be by means
of galvanised expansion bolts excepting that plastic plugs with stainless steel screws or locking pins may be used for
securing conduit saddles. All holes for fixings shall be neatly drilled to the correct size and depth. Explosive powered
fixings shall not be used.
Fixings to structural steel shall be in the form of the clamping to webs, rails, etc. Drilling or welding of structural steel
members will not be permitted.
Wall and Slab Penetrations
Unless specifically shown on the Contract Drawings, the Contractor shall be responsible for providing all wall and slab
penetrations required to complete the work of this Contract. All wall and slab penetrations shall be approved by the
Engineer prior to proceeding and the penetrations shall be neatly finished and flashed to match the surrounding surface.
Where openings are shown or required to be made in concrete structures, the Contractor shall employ methods approved
by the Engineer which do not damage or distress the neighbouring concrete or fixtures. Openings shall not be larger
than required for the proper execution of the works.
Reinforcement shall be cut back to provide 15 mm minimum cover from the face of permanent openings. Where
openings are to be subsequently filled reinforcement shall not be cut without the permission of the Engineer. Additional
reinforcement shall be provided at large openings as shown or as directed by the Engineer.
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Labels
All equipment and devices shall be labelled with approved labels unless otherwise specified. Indoor labels shall be
engraved laminated plastic (egg. traffolyte) with black letters on a white background and outdoor labels shall be engraved
aluminium or stainless steel. Warning notices shall be white letters on red background.
Labels shall be provided for all items of equipment and control devices including instruments, relays, fuses, terminals
and switches and shall include device references shown on circuit diagrams and fuse-link current ratings. Marking shall
include labels for each control, indication, circuit designation and rating, protection devices, current-limiting fuses,
warning notices for operational and maintenance personnel, and the like. Labels and warning signs shall be provided to
the supply authority requirements.
Each label shall be located such that it is visible from a normal observing position and clearly associated with the
component, or group of components it identifies. Where practicable, labels shall be positioned immediately below the
component. Where there is access to rear connections of a panel mounted component, an additional label shall be affixed
to the rear of the panel, to carry the code letters or reference symbol of the component.
Each plug-socket outlet, circuit breaker circuit, light switch and light fitting shall be fitted with a laminated plastic label
engraved with the circuit number.
Labels shall be screw-fixed adjacent to its relevant item of equipment, but not to the equipment.
Lettering height shall generally not be less than the following:
i) Designation: 15 mm
ii) Main switches: 10 mm
iii) Feeder control switches: 10 mm
iv) Identifying labels: 5 mm
v) Equipment labels within cubicle/panels: 3 mm
vi) Warning notices: 5 mm
C.5.16 Earthing and Bonding
General
The earthing for all equipment and the provision of earthing systems, electrodes and connection shall be in accordance
with the recommendations in the “Guide for safety in substation grounding” IEEE No. 80 – 1986 and the requirements
of IEC 62305, BS 7430 and this Section.
Extent of Work
The Contractor will be required to prepare installation drawings and schedules of material to be provided. These drawings
and schedules shall be submitted to the Engineer for approval together with calculations of step, touch and mesh
potentials.
Design of Earthing Systems
The Contractor shall submit a preliminary design for the earthing systems for approval. This shall include measurement
of soil resistivity, calculations of resistance, potentials and current ratings for current flowing into or out of the ground.
The earth shall also be connected by 70mm2 copper conductors to the isolators, and substations.
Earthing points shall be provided such that the combined resistance of all earthing points does not exceed five 5 ohm
under any climatic condition.
Resistance of electrodes to earth and continuity of earth networks shall be demonstrated to the Engineer after installation
has been completed.
Earthing Points
The number of earthing points necessary shall be verified by site earth resistivity tests after the signing of the contract.
Earthing points: each shall consist of not less than four and not more than eight 16mm diameter copper rod electrodes,
each 1.8 meters and driven or drilled into undisturbed ground at spacing of not less than the length of the rods. Each
electrode shall be complete with approved non-ferrous clamps for the connection of earthing conductors and with a
hardened steel tip and cap for driving by means of a power hammer.
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Earthing of Equipment
The tanks of transformers and frames of all electrical apparatus shall be connected to earthing electrodes. All
disconnected bases, earth terminals, transformer neutral points, and surge arrester bases shall be connected to earth
electrodes. Surge arresters installed for the protection of transformers shall be connected by direct low reactance paths
both to the transformer tank and the transformer station earth electrodes.
Disconnected operating mechanisms and controls not integral with the circuit breaker shall be connected to earth.
All metalwork associated with the electrical installation but not forming part of a live conductor, including exposed
conductive parts and extraneous conductive parts, shall be solidly and effectively bonded and earthed in accordance with
the codes and regulations.
Jointing and Bonding
Connections to plant shall be made using the earthing terminals. Stranded earthing conductors shall be terminated with
sweated or crimped cable lugs.
All buried splices and connections shall be carried out by brazing or by an approved method of exothermic welding. Any
such brazed or welded connections shall be subject to the examination and approval of the Engineer prior to back filling
of the trenches.
Main Earth Terminal Bars
A solid copper main earthing terminal bar shall be provided in the switchroom of each substation. The earth terminal bar
shall be located in an approved position near the main incoming switch or switchboard.
The main earthing terminal bars shall be for the connection of the circuit protective conductors, the main equipotential
bonding conductors and the earthing conductors to create the equipotential zone. The main earthing terminal bars shall
be connected to the earth via groups of electrodes and earthing conductors.
Main earth terminal bars shall be of copper bar not less than 50 x 10 mm in cross section, and shall be mounted
approximately 400 mm above floor level. All connections of earthing cables to the main earth bars shall be bolted, and
all earthing cables terminated with approved earthing clamps. Space shall be left on each earth bar for the future
termination of 50% additional terminations.
Each earth bar shall be secured to the wall and located in an approved manner. The Contractor shall stand the earth bars
off the wall by approximately 50mm.
Connections shall include copper disconnecting links for the purpose of testing.
Connection to Electrical Supply Authority Earthing System
If required by the electrical supply authority, the Contractor shall provide connections to the electrical supply authority
earthing system in accordance with electrical supply authority requirements. Earth links shall be provided where required
by electrical supply authority.
Equipotential Earth Bonding
Main equipotential bonding conductors shall be copper and connecting all the extraneous conductive parts of other
services within the premises to the main earthing terminal of the installation including main water and gas pipes, other
service pipe and risers and exposed metallic parts of the building structure liable to transmit a potential. Connections
shall be made as near as practicable to the point of entry of the non-electrical services into the premises concerned, and
shall be on the installation side of the possible breaks in the system, such as gas meter or water meter.
The main equipotential bonding conductors shall be connected to extraneous conductive parts of the non-electrical
services by means of a copper connector-clamp of an approved type suitable for the particular applications. All contact
surfaces shall be clean and free from non-conducting materials, such as grease or paint, before the connector-clamp is
installed.
Unless otherwise specified or shown on the Drawings, the cross section area of a main equipotential bonding conductor
shall not be less than half of the cross-sectional area of the associated earthing conductor of the installation subject to the
regulatory minimum and maximum sizes.
Supplementary Earth Bonding
Supplementary bonding of extraneous conductive parts shall be required whenever such conductive parts are likely to
be accessible simultaneously with other extraneous conductive parts of exposed conductive parts, and are not electrically
connected to the main equipotential bonding by means of permanent and reliable metal-to-metal joints of negligible
impedance.
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The supplementary bonding conductors shall be copper and connected to the extraneous or exposed conductive parts by
means of a copper connector-clamp of an approved type suitable for the application. All contact surfaces shall be clean
and free from non-conducting materials, such as grease or paint, before the connector-clamp is installed.
For conduit installations, the supplementary bonding conductors shall be terminated at the earthing terminal of the nearest
conduit box forming an integral part of the conduit installation.
Circuit Protective Conductors
Circuit protective conductors also called grounding or earthing conductors shall be formed by a separate conductor/cable,
or be part of the same cable as the associated live conductor of the wiring system. Flexible conduits, PVC conduits, the
exposed conductive parts of equipment shall not form part of the circuit protective conductors.
Circuit protective conductors shall be provided for all circuits, unless otherwise approved by the Engineer. Circuit
protective conductors shall be sized to the requirements of all relevant standards, codes, regulations, the electrical supply
authority, and shall provide the required earth fault clearance times.
For every socket outlet, luminaire or equipment item a separate circuit protector conductor shall be provided connecting
the earth terminal of the item to the outside of the enclosure accommodating the item.
For every length of flexible conduit, a separate circuit protective conductor shall be provided inside the conduit to ensure
the earth continuity of the installation between the two ends of the conduit.
Provision shall be made in an accessible position for disconnecting the protective conductor from the main earthing
terminal or the earth electrode to permit testing and measurement of earthing resistance.
No switching device shall be inserted in a protective conductor.
The ends of each low voltage conduit and wireway shall be connected tightly to the metallic enclosure of switchboards,
distribution boards, panel boards, machines or equipment. Jumpers shall be required at the connections of wireways and
metallic enclosures.
Where a protective conductor does not form part of a cable and is not formed by, or not contained in, steel conduit,
trunking, ducting or other metallic enclosure of a wiring system, the cross sectional area shall not be less than 2.5mm2.
Earthing for other Equipment
The power supply earthing systems shall be separate to the earth systems provided for:
i) Instrumentation and control systems to the requirements of the instrumentation and control systems
supplier;
ii) Telephone and communications systems
Labelling of Earthing System
At the main earthing terminal bars and each earth electrode, a permanent label marked with the words ”SAFETY
ELECTRICAL CONNECTION – DO NOT REMOVE” in English shall be permanently attached to the final
earthing leads connection.
In addition, individual labels shall be attached to the individual connections to the main earth terminals. These labels
shall describe each particular connection.
The size of lettering shall be 6mm and the laminations shall be green white green.
C.5.17 Structural Lightning Protection
Structural lightning protection systems shall be of the Faraday cage type with horizontal conductors on the roof structure
and down conductors on the outside walls of the structure.
The horizontal conductors shall be installed along the outer perimeter of the roof ensuring that no part of the roof is more
than 9 m from the nearest horizontal conductor.
All metallic projections on or above the main surface should be bonded to and from part of the conductor network.
The number of down conductors should be decided as follows:
A structure having a base area not exceeding 100 m² may have only one down conductor. Areas exceeding 100 m² shall
have one plus one for every 300 m² or part thereof in excess of the first 100 m² or one for every 30 metres of perimeter.
Down conductors should be distributed around the outside walls of the structure.
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Earth electrodes of hard-drawn copper rods with minimum dimensions of 12 mm diameter shall be driven into the ground
as close as practicable to the structure and end of the down type conductor.
The horizontal and down conductor shall be copper strip 25 mm x 3 mm.
The rods shall be installed in sections coupled by screwed connectors where necessary to penetrate the substrata of low
resistivity.
Each of these earth terminations should have a resistance to earth not exceeding the product given by 10 ohms times the
number of earth terminations to be provided.
The whole of the lightning protective system should have a combined resistance to earth not exceeding 10 ohms.
Each down conductor shall be provided with a testing joint in convenient position for testing.
The fixing clamps shall be leaded gunmetal type and fixing bolts and screws shall be phosphor-bronze.
C.5.18 Permits to Work
All switching and isolation of electrical power will be subject to the granting of a permit to work. The permits will be
issued by the Engineer in consultation with operational management at the site.
C.5.19 Test of the Installation

The whole installation shall be tested before being energized. The tests shall be conducted as stipulated by the Current
edition of the IEE Regulations and the test results recorded and submitted to the Engineer.
C.5.20 Instrumentation: Standard Requirements
General Design
All instrumentation equipment shall be designed and selected in accordance with good engineering practice and to the
relevant standards. Equipment shall be robust and reliable and require minimum maintenance. Instrument transmitters
shall be properly sited in order to facilitate ease of maintenance. Instruments shall generally be of an electro-mechanical
or electro-pneumatic design to assist fault finding and repair. The use of sophisticated electronic equipment shall be
avoided. Indicating instruments shall be fitted with linear scales and shall have a circular dial not less than 200 mm
diameter, unless particularly specified to the contrary.
Panel mounted instruments shall be flush mounted. The maximum range of indicating and recording instruments shall
be at least 25% in excess of the normal maximum indication. For flow measuring instruments where allowance for
future flow increase is specified the instrument shall be rated for the future flow.
Temperature and Humidity
All supplied equipment shall function without error over the temperature range 10°C to 50°C at a relative humidity of
over 90%.
Enclosures
Instrumentation and hardware mounted in the field shall be rated IP 55 indoors and IP 65 outdoors as a minimum. Where
a sensor is maintained below the flood line it shall be submersible. Where a unit is fitted in a panel or other enclosure, it
shall preserve the design IP rating of that enclosure. Instrument panel enclosures shall comply with IEC Publication 144
Class IP 54 for indoor panels and IP 55 for outdoor panels.
Mould and Insect Damage Prevention
All parts of the equipment shall be constructed of such materials or so treated as to prevent the formation of mould,
fungus or any corrosion at the ranges of temperature and relative humidity specified. The equipment shall be resistant
to insect damage.
Voltage and Frequency Tolerance
Equipment shall be capable of working from a supply whose voltage and frequency may vary ±15%, and tolerate any
transients that could be experienced in such an environment without programme corruption or system failure.
Lightning Protection
The correct system earthing and lightning is critical to the safe and reliable operation of the instrumentation.
Lightning surge diversion equipment shall be supplied and fitted in the following applications:
i) Any communication lines provided under this Contract;
ii) To all analogue instrument/signal loops.
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Lightning protection units shall be solid state unfused, and shall automatically return to normal operation after diverting
a surge.
Individual lightning protection units shall bolt directly onto a lightning earth busbar, the whole assembly being mounted
inside a non conductive box. This box shall be mounted separately from instrument panels, unless a dedicated section is
provided, completely boxed off from all other equipment.
The lightning protection units shall be located close to the chosen earth point in order to achieve a short straight
connection.
The earth conductor shall be physically removed from the vicinity of protected cables as far as is practicable. The earth
conductor shall be copper, and shall have a maximum length of 10 metres. Conductor sizes shall be a minimum of 16
mm2.
The earth connection shall be short and direct, avoiding bends if possible. Any necessary bends in this cable shall have
a gentle radius. The location of the lightning protection units shall be chosen with this in mind.
The lightning earth conductor shall be connected to an earth system, the location of which and the method of connection
shall be agreed by the Engineer.
Standards
The following specifications shall be used and complied with in the design and installation of the control system and
instrumentation:
i) IEE - Guidelines for the Documentation of Software in Industrial Computer Systems. ISBN 086341
046 4;
ii) BS 6739 - Instrumentation in Process Control Systems: Installation Design and Practice;
iii) The relevant British Standard shall be used for any item, installation or application not covered by
either of the above, egg. BS 5792 or BS EN ISO 6817:1997 - electromagnetic flow meters.
Cable Segregation
The spacing required for segregation between instrument signal and power cables, is defined in BS 6739 1986, Section
10. The spacing between instrument signal cables and power cables, not defined in BS 6739, (i.e.. those rated above 10
amperes), up to a rating of 100 amperes with a voltage range of 50 to 400, shall be 400 mm.
The spacing required for segregation between instrument signal cables and power cables rated above 100 amperes and
higher voltages than 400 shall be decided for the particular works.
The routing of cables for data highways in relation to all other cables shall be decided for a particular works.
Electro-Mechanical Level Indicators
Electro-mechanical level indicators shall be provided for water level measuring applications. Indicators shall be
connected to buoyant floats, the floats being located in suitably sized uPVC stilling tubes. Float tensioning shall be
achieved either by a pulley weight or by a durable spring tensioning mechanism. The float shall be connected to the
indicator drum or pulley by stranded stainless steel wire.
All moving parts within the indicator assembly shall be fabricated from high grade stainless steel. Non-moving parts
shall be fabricated from high impact plastic or aluminium alloy with a heavy galvanised paint finish.
The indication dial shall be of such a size as to offer good visibility and feature black numbers on a white background.
A removable cover shall be fitted over the whole indicator assembly. The cover shall have a window for viewing the
level indicator.
The indicator shall comprise a sealed potentiometer rated to give an analogue output of 4-20 mA at 24 V DC.
Two adjustable micro-switches shall be fitted to the indicator for use with level alarm indications.
All level indicators of this type shall be mounted above ground on rigid stainless steel brackets.
Float Switches
Level switches of the buoyancy type shall consist of a mercury switch with changeover action enclosed in a non-
corrodible material. A balance weight shall also be incorporated in the switch to counteract the buoyancy effect of the
specific gravity of the particular fluid. The connecting cable shall be factory sealed into the switch.
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Level switches shall be installed with a minimum to two metres of spare connecting cable neatly coiled at a supporting
bracket. The connecting cable fixing shall facilitate any alteration in operating level within the limit of the spare cable.
Conductivity Electrodes and Level Relay Systems
Conductivity electrodes shall be formed from stainless steel tubes encapsulated in PVC sleeving down to 75 mm from
the end of the electrode. The electrode shall be sealed.
Where necessary, intermediate insulated support brackets shall be installed to prevent the electrodes swaying. The
intermediate supports shall be installed above normal top water level at the particular location. An earth electrode shall
be provided at each electrode installation. Pipework shall not be used for the earth.
The electrode holders shall comprise a moulded back phenolic body capable of accepting 20 mm BS pipe. Plated
clamping collars complete with cable termination shall be provided to locate the electrode. The holder cap shall also be
of moulded phenolic material. A gasket shall be placed between body and cap. The body shall be arranged to receive
screwed conduit.
Electrode holders shall permit adjustment in operating levels of not less than 100 mm without necessitating cutting or
extending electrodes.
Relay units operating with level electrodes shall have adjustable sensitivity. Electrodes for use in fluids of low or variable
conductivity shall have conductivity discs. Electrodes shall be energised with an alternating voltage not exceeding 25V
open circuit.
Level Sensors
The level sensors of a two wire system incorporated with atmospheric pressure compensation termination are required
and shall be of a type to give 4-20 mA or 0-5VDC signals for PLC inputs and/or HMIU. Each unit shall be calibrated to
read true Relative Levels. The sensor units shall be of a high performance type with long term accuracy of ±0.25% or
better and shall be of a hastelloy/stainless steel wet parts construction.
Each sensor shall be installed within a stilling tube in order to eliminate the effect of water waves and surges and with
the sensing head at approximately 100mm off the channel floor. All sensor head cables should be match marked for ease
of cleaning and re-lowered to its exact position. The sensor termination enclosures for the atmospheric pressure
compensation shall be installed in a cabinet or junction box above flood level.
The sensor cables shall be one-piece and contain no joints before the termination enclosures.
The level sensor ranges shall be selected and calibrated for the intended purposes but shall have proof pressure at least
three times the selected range.
Pressure Gauges and Switches
Pressure gauges shall be provided on all pump delivery and suction pipes, they shall be 150 mm diameter and of an
approved type and pattern, calibrated in metres water column. Gauges shall be connected through a three way isolating
cock so that air can be released to the atmosphere. All necessary connections, piping and fixing clips shall be provided.
Gauges shall be mounted on walls or pump plinths with a capillary connection to the pump.
Pressure gauges shall comply with BS 1780 or BS EN 837-1:1998. Pressure gauges and switches shall have over range
protection up to 1.5 times the maximum anticipated line pressure.
Internal parts shall be of stainless steel, bronze or other corrosion resistant material and submerged in. liquid damper.
All pressure gauges and switches shall be supplied complete with isolating valves and calibration points to enable
calibration or removal without loss of fluid.
Where compensation of more than 2% of the instrument span is needed for the difference in level between the instrument
and the tapping point, the reading shall be suitably adjusted and the amount of compensation marked upon the dial.
Pressure and differential pressure switches shall have contacts with separate "cut in" and "cut out" pressure values.
The nominal pressure values at which pressure switches operate shall be fully adjustable over the whole range of the
instrument and the set value(s) shall be clearly indicated by means of a scale and pointer.
Contacts of pressure switches shall be hermetically sealed.
Pressure Transducers
Pressure monitoring shall be by a transducer suitable for the medium and pressure/level range specified.
Each transducer shall be ranged to provide adequate sensitivity over the working range and be capable of sustaining a
400% over-pressure without damage. They shall be of rugged and waterproof design to IP 65, with a stainless steel
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enclosure having an isolation diaphragm, suitable for either free wire suspension in the medium or provided with an
internal pipe connection, designation 'G' to BS 2779 : 1973 with a machined surface on the transducer case to
accommodate seal washer.
Cable entry shall be made by integral sealed assembly or by 20 mm conduit entry into a sealed watertight terminal
enclosure with provision for transducer venting.
A transmitter shall be provided either integral with the transducer or separately mounted as specified, suitable for
operation from the mains or battery supply specified (not greater than 24V) and converting the signals received from the
transducer to a 4-20 mA signal proportional to the range specified. The transmitter shall have provision for range and
zero adjustment.
Attention shall be paid by the designer to the negative pressure rating of a transducer in a particular application.
Transducers shall be installed with an isolating valve and its output shall be connected to the PLC or HMIU as the case
may be.
Flow Meters
Electromagnetic Flow Meters
The electromagnetic flow meter shall comprise the following material combinations (or equivalent). The materials shall
be as follows or better:
Body MS Grade 250, fusion bonded epoxy
Internal liner Hard Ebonite Rubber
Primary element Ingression Protection IP68
The flow meters shall be a full body electromagnetic type with connecting PN flange to match up with the system
maximum working pressure and surge head where required and shall meet the following requirements
i) Overall accuracy of ±0.25% or better for full scale;
ii) 4-20 ma and digital output signals for flow rate and totaliser, all calibrated in MLD;
iii) Enclosure rating of not less than IP68;
iv) Temperature stability between -10ºC to +65ºC
v) Built-in self-cleaning sensor and earthing stainless steel electrodes;
vi) The converter with digital display unit showing flow rate in l/s, total flow and accumulated volume;
vii) The signal cable shall be one piece without joints and fully earthed screen;
viii) Earth shall be provided where required.
The converter shall be housed in the control room or in the central control console and its output flow rate signal shall
provide the feedback to the main PLC and HMIU where required.
The method of meter installation shall comply with the manufacturer’s instructions.
Turbine Flow Meters
Bulk flow meters for diameters greater than 150 mm, the meters shall be inclined in-line turbine type meters to BS 5728,
EN 14184-3 and EN 14154 suitable for installation in horizontal or vertical mains. Each meter shall have a register
calibrated in cubic metres, with straight reading counters. The meters shall be capable of measuring accurately ± 2.5%.
For diameters of 150 mm and less, and if so specified, then a combination water meter shall be provided so as to give an
accuracy of ± 2.0%. All meters shall be supplied complete with a removable strainer, and if so indicated on the Drawings
with extended registers of the nearest but shorter standard length to that indicated.
End flanges shall be drilled to EN 1092-1, NP 16 and shall be supplied complete with flange gaskets, bolts, nuts and
washers.
Human Machine Interfacing Unit (HMIU)
This unit, 24DC operated and door mounted, shall be of an integrated type (egg. Horner OCS551-NHP or equivalent)
comprising Control, I/O and operator interface – including a touch screen and a colour display and shall interface with
PLC via Modbus using CAT5 cable and RJ-45 connectors. The unit shall be programmed to permit the operator to view
the following but not limited to:
i) Detail of faults and historical alarms as specified in Part 2 of this specification;
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ii) Total running hours of each pump;

iii) Running speed of each pump;
iv) Flow rates and total flows data over the past 12 months where flow meters are specified;
v) Pump suction and discharge manifold pressure transducers;
vi) Water levels and trend over a 12 month period;
vii) Various pump settings in Auto Mode;
viii) DC Voltage
The data shall have adequate memory capacity to store data for at least 12 months and shall store it in a progressive
manner and only the oldest data shall be spilled over when the memory is full.
The unit shall contain the main screen menu with an overall mimic diagram of the pump station with the following colour
codes:
i) Green Pump running
ii) Red Stop
iii) Flashing amber Warning
iv) Flashing Red Faults
v) Blue Bar (RL) Water levels
vi) Station flow rate - active figure (MLD), etc.
The unit shall be configured to provide user friendly screens.
However, the pump operation parameters s can be changed and adjusted via HMIU but only accessible by entering the
correct using User’s Name and Password. The pump parameters would comprise:
i) Pump Cut-in / Cut-out reduced levels for LLPS;
ii) Station output flow set point (MLD) for new RWPS;
iii) Reset faults, if already rectified, for all pumps.
Programmable Logic Controller (PLC)
The PLC meeting IEC61131-3 shall be a microprocessor base with non-volatile memory and 24 VDC operated. It shall
be capable of operating under extended temperature ranges and immune to electrical noise. It shall be rack mounted with
expandable I/O external I/O modules.
Separate PLCsare required as the main controller and monitoring unit for the proposed RWPS and proposed TWPS.
Uninterruptable Power Supply (UPS)
Battery Charger
The battery charger shall be of the constant-voltage type, suitable for continuous operation.
The charger shall be capable of maintaining the battery within the limits of ±2% of the nominal voltage for any output
of the battery, between no load and full load.
The AC input supply to the charger will be single-phase 230V, 50Hz with a tolerance of ±6%.
The charger shall contain suitable protection against overload and HRC type fuses for protection of the transformer
primary winding.
When selected to the appropriate charging condition by the charge selector switch, the charger shall produce the
following outputs:
i) A “trickle” (float) charge capable of adjustment to meet any load up to the standing load and keep the
battery in a fully charged state; and
ii) A manually selected “gas” (boost) charge, which shall be capable of charging the battery from a fully
discharged condition to an equivalent of 120% of the rated terminal voltage. Under this condition the
rate of charge shall be such that 100% of the battery capacity will be available in less than 10 hours.
217
Incorporate the following equipment in the charger and shall be visible, and, where required, accessible from the front
of the cubicle. Label each item with traffolyte labels:
i) One (1) selector switch to select rate of charge and labelled “TRICKLE” - “GAS”.
ii) Volt free contact outputs for connection to PLC shall contain the following
iii) Charger Failure
iv) Battery Voltage Low
v) Battery Failed
Battery
The battery shall comprise the required number of individual cells of Nickel Metal Hydride type, complete with all
necessary inter-connectors, terminals, electrolyte, etc.
Each cell shall be contained in a high-impact translucent polystyrene container, fitted with a lid to prevent ingress of
dust. A screw-in type vent plug shall be fitted in the lid to prevent the escape of electrolyte but such as to permit the
escape of gas during charging and thus avoid the build-up of pressure.
The capacity of the battery shall be adequate to copy with the following duty cycle but shall not be less than:
i) Standing load to suit the combined load;
ii) Battery is to provide 12 hours back up standing load and a voltage drop not less than 10% without
being charged.
C.5.21 Surface Protection and Painting
General
The whole of the Plant shall be adequately protected against corrosion during transport and storage and in service.
Surfaces shall be prepared and protective coatings applied at the manufacturer's works or supplied for application on site
as specified hereunder. Items not particularly specified shall be given a protective or decorative coating compatible with
the remainder of the Plant. Items of Plant having a manufacturer's standard finish may be left with such finish, subject to
the approval of the Engineer.
All primers and paints shall be good quality named brands supplied by a reputable manufacturer, and shall be applied
strictly in accordance with the manufacturer's instructions. Before the application of any coat of paint or protection the
surface shall be clean and dry, and all coats shall be allowed to dry adequately before application of a further coat.
Primers and paints shall be mould resistant, and suitable for service in the climatic conditions on site.
Finished colours shall be as instructed by the Engineer.
Where surfaces are specified to be blast cleaned, the cleaning shall produce a surface finish to BS EN 7079:2009 second
quality, or BS 7079:2009, or to Swedish Sa 2.5 standard. The surface roughness shall not exceed 100 microns. The first
protective coat shall be applied within 4 hours of completing the cleaning process. As an alternative to blast cleaning
where appropriate, an approved pickling process may be used. In such cases the first protective coating shall be applied
to the surface while it is still warm and after it has completely dried.
For site coatings the Contractor shall supply sufficient materials to carry out the work including a reasonable allowance
for wastage and for all brushes, cleaners, etc. The Contractor shall also allow for the supply of reasonable quantities of
materials for making good any damage to works applied coatings after erection of the Plant.
Where the fluid is potable water passing directly into the supply system, all coatings in contact with the water shall be
non-toxic type specifically designated by the manufacturer for use in contact with potable water, and which will not
impart any taste or odour to the water.
The Contractor shall submit to the Engineer for approval the paint and coating manufacturer's technical specifications
before any coating is carried out or paint ordered for site application.
Where site painting is carried out in two or more coats of the same colour then each shall be of a different shade.
Preparation and Protection of Surfaces of New Plant
Pre-treatment
General comments
Temporary protection of steel materials, prior to and during manufacturing is not included in this specification. Blast
cleaning and painting should as far as possible be done after the component is welded, machined and approved.
218
Components which cannot be blast-cleaned after the final machining should be blast-cleaned and primed with one coat
of an approved primer prior to the machining. Components which shall be heat treated shall be primed directly
afterwards. The final coat should be applied when the component is machined.
Cleaning, Blast Cleaning, Dust Removal
Areas, which are contaminated with, grease, cutting oil, etc shall prior to further treatment be de-greased.
The de-greasing agent must not have a negative effect on the coating system, which will be used. After de-greasing all
surfaces shall be blast-cleaned to Sa 2 1/2 SIS 055900/ISO 8501. Grit and dust should then be thoroughly removed with
brush and vacuum cleaner or with compressed air free of oil and water.
The first coat of paint shall be applied as soon as possible after cleaning. Any blast-cleaned areas, showing signs of re-
rusting, shall unless otherwise agreed to be re-blasted, prior to the application of the first coat of paint. Other cleaning
methods, for instance wet blast-cleaning, may only be used when previously approved by the Buyer
Surfaces soiled with dust, oil, soluble salts etc., prior to the application of the last coat of paint, must be cleaned prior to
further painting-
Application of paint shall never be carried out under such conditions that dust, grit etc. may settle on the wet or not cured
paint film.
Cleaning of Welding Seams
Erection welding made after the construction has been blast-cleaned and painted, shall unless otherwise is approved by
the Buyer, be blast-cleaned to Sa 2 ½. Deteriorated paint film and greyish-white deposits (due to welding) along the
seam shall be removed by the same blast-cleaning operation to at least 50 mm to each side of the weld. Visible deposits,
outside this area, should be washed away with fresh water or removed by grit sweeping if water is not available. The
same procedure shall be applied to any surface near welding seams, which have been treated.
If blasting is not possible, an alternative treatment (see below), shall be subject to the Engineer’s approval for surfaces
exposed to water or cold air. For surfaces exposed to water or cold air. For surfaces, exposed to air to air, the alternative
methods may be applied without any pre-agreement. Alternative methods of cleaning:
i) Grinding of welding seams
ii) Otherwise, treatment as mentioned in article 4.3. Paint film damaged by the grinding process
deposits, must be removed before top coating is applied. The roughness of the grinded surface
must be sufficient to ensure satisfactory paint adhesion
iii) Brushing of welding seams and surrounding areas with rotating wire brush to st 2 (SIS 05
5900/ISO 8501). The seam is then sprayed or brush coated with a 10% solution of phosphoric
acid. After minimum one hour, the seam shall be rinsed with fresh water to remove all traces of
acid.
Metallic Coating
Hot Dip Galvanizing
Hot dip galvanizing should be done according to the appropriate BS. The surfaces shall be blast-cleaned before
galvanizing takes place.
Prior to painting, the surface should be cleaned to ensure a good paint adhesion. Alternative methods for cleaning are
i) Alternative 1: Light blasting (Sweeping). The coating thickness after blasting must not be less than
70 microns;
ii) Alternative 2: The surface is washed with a solvent containing a suitable emulsifying agent and is
then rinsed with fresh water.
Unless otherwise agreed upon, Alternative 1 shall be used.

For alternative 1 paint may be applied directly without any etch primer. When alternative 2 is used, a thin coat (maximum
15 microns) of etch primer should be applied on all surfaces which will be exposed to water prior to painting.
Hot Spraying with Zinc or Aluminium
219
Hot spraying shall be applied according to appropriate BS. Unless otherwise agreed, the minimum thickness on the zinc
coating shall be 80 microns. The cleaning process after spraying is not generally required. The coatings have normally
sufficient roughness and may also be quite porous. A suitable procedure for sealing shall therefore be proposed. This
shall be subject to approval of the Engineer in each individual case.
Painting
Application Methods
Paint shall preferably be applied by means of air less spray. Where air less spray does not give a satisfactory result, brush
or glove shall be used.
Hot spraying, shall be subject to the Buyer's approval. Equipment especially adapted for this purpose shall be used. The
amount of thixotropic agent in the paint must be correct and suitable for hot application.
The labelling and storing of the paint must be such that no mistaking with other types is possible. “Dry spraying” must
be avoided. The Manufacturer’s recommendations as to the maximum temperature shall be followed, but the temperature
must in no case exceed 70°C. A minimum of 3 coatings shall be applied. Heating of the paint to Max 35°C (at the pistol)
to improve sprayability, is not considered to be hot spraying neither is any final curing by increased temperatures.
Priming
The component shall, after blast-cleaning, be primed with a zinc-rich Epoxy primer containing at least 90% by weight
of metallic zinc in the dry film. The temperature shall be kept above +10°C. If nothing else is agreed upon, the thickness
of the dry film shall not exceed 25 microns. If these terms cannot be complied with the type of primer, should be agreed
upon separately.
If zinc salts (white deposits) or other corrosion products have been formed on the primer coat, these shall be removed
by grit sweeping, followed by rinsing with fresh water, prior to any application of paint.
The primer shall be applied right to the edge of plates, ever when the edge will be subject to later welding. Unless
otherwise agreed, upon primer shall not be used at site when painting welding seams or areas damaged during erection.
Zinc-rich primers shall not be used on components with metallic coatings.
General Iron and Steelwork
Prior to coating or hot dip galvanising, all iron and steel shall be blasted cleaned and greased to BS 7079. The first coat
shall be applied immediately after cleaning. Any blast cleaned areas showing signs of rusting shall be re-blasted.
Protective coatings shall be to system reference SH7, Table 4H of BS 5493 or BS EN ISO 12944. Undercoats and finish
coats shall preferably be applied by means of airless spray. Where airless spray does not give satisfactory result, high-
build brush application shall be used.
All galvanising shall be factory applied hot dip galvanising.
Duct Covers, Manhole Covers, Walkways and Ladders
Steel or cast iron: Hot dip galvanised.
Aluminium: Uncoated.
Ductile Iron Pipework and Fittings
All coatings shall be in accordance with the specifications.
Other coatings requirements are described below:

Surface preparation The surface shall be clean and free from rust
At Manufacturer's works External coating shall be in accordance with the specificationsand will
include Metallic Zinc coating, and bitumen based coating and
polyethylene sleeving. In corrosive soils, tape wrapping and
polyethylene sheathing will be applied.
Site coating of external surfaces:
i) Within buildings exposed Two coats of aluminium sealer followed by two coats of oil based
to view undercoat and one coat of gloss finishing paint
ii) Out of doors exposed to Two coats of aluminium sealer followed by two coats of high build
view and in contact with chlorinated rubber paint
220
process water
iii) In covered ducts or Two coats of bituminous aluminium paint
chambers
iv) Buried pipework Joints bolts etc. painted two coats of black bituminous paint. No further
protection to pipe surfaces unless specified otherwise
Steel Pipework and Fittings in Pumping Stations etc.

Surface preparation: Blast cleaned internally and externally.
At Manufacturer's works: Internal and external surfaces
100% solids thermosetting fusion bonded epoxy resin Scotchkote 206N or similar approved. Minimum dry film
thickness 300 microns applied by fluidised bed method.
Cast Iron Valves
Surface preparation The surface shall be clean and free from rust
At Manufacturer's works All gate valves and other valves should be supplied with fusion bonded
epoxy and comply with AWWA C213 specification.
Site coating of external surfaces:
i) Within buildings exposed Two coats of aluminium sealer followed by two coats of oil based
to view undercoat and one coat of gloss finishing paint
ii) Out of doors exposed to Two coats of aluminium sealer followed by two coats of high build
view and in contact with chlorinated rubber paint
process water
iii) In covered ducts or Two coats of bituminous aluminium paint
chambers
iv) Buried pipework Joint bolts etc. painted two coats of black bituminous paint or 2 coats of
fusion bonded epoxy paint. No further protection to pipe surfaces
Pumps, Compressors, Motors and Bedplates

Surface preparation The surfaces shall be thoroughly de-rusted, de-greased and cleaned
At Manufacturer's works:
i) Internal surfaces of Two coats of high built epoxy pitch paint, each coat having a minimum
ferrous pump casings thickness of 125 microns
ii) Other surfaces Two coats of zinc chromate or zinc phosphate primer
iii) On Site Two coats of oil based undercoat and one coat of gloss finishing paint
for indoor Plant. Two coats of high build chlorinated rubber paint for
outdoor Plant
Typical Approved Finishes
Typical approved finishes (with compatible primers) based on BS 5493 are given below.
g) Steelwork and ferrous castings exposed above water/sewage level
Either high build micaceous iron oxide or chlorinated rubber to give a minimum total dry film thickness of 300
microns or, one coat of two pack epoxy primer and further coats of epoxy paint to give a total dry film thickness of
270 microns.
h) Steelwork below water/sewage level.
Either epoxy system as above or coal tar epoxy paint system to give a minimum total dry film thickness of 450
microns.
i) Ferrous castings and fittings without substrate below water sewage level
Coal tar epoxy paint system to give a minimum total dry film thickness of 450 microns. These coatings shall be
subject to the Holiday test.
221
The surface of all non-ferrous parts usually painted shall be cleaned, rubbed down, stopped, filled and given one
priming coat of paint.
Any damage occurring to any part of a painting scheme shall be made good to the same standard of corrosion
protection and appearance as that originally employed. Any finish coat applied on site shall be considered for
decorative purposes only.
Manufactured articles to be galvanised shall be hot dip galvanised after complete fabrication and no bending,
cutting, drilling, riveting or threading shall be permitted after galvanising.
The care of galvanised articles when transporting, storing and erecting them shall be in accordance with the
recommendations of BS 729. The renovation of small areas of damaged coating not exceeding 40 mm² shall be in
accordance with Appendix D of BS 729 and subject to the Engineer's approval.
Switchboards and Instrument Panels

The protection and painting of switchboards and instrument panels shall be completed at the manufacturer's works. After
completion of fabrication of the cubicles, and before assembly of any components, surfaces shall be thoroughly cleaned
and chemically etched, followed by two coats of epoxy resin primer, and two coats of epoxy resin finishing paint applied
by spray to give an overall thickness of not less than 100 microns.
Bolts and Fixings
All bolts, nuts and washers which must be removed during normal maintenance and servicing of the Plant or are in
contract with process water or sewage shall be of stainless steel to BS 970, Part 4.All bolts, screws, washers and other
fixings for anchoring the Plant to walls, floors, ceilings etc. shall be of corrosion resistant materials or shall have a
protective surface treatment to the approval of the Engineer.
C.5.22. Specification for Standby Generator

C.5.22.1 SPECIFICATION FOR NEW STANDBY DIESEL GENERATOR
General
The Contractor shall size, supply, handle into position, install, set to work and commission a new automatic mains
failure standby diesel generator set complete with exhaust system, fuel supply system, control panel and fire
protection system as shown on the drawings and described in this Specification.
The Contractor shall take due account of the altitude, temperature and humidity of the location of installation and
shall provide a generator set which shall deliver, after de-rating, the continuous load as specified by the contractor
at 400V, 50Hz and 0.8pf. In addition the generator set shall be capable of sustaining 10% overload for one hour
in any twelve hours. The minimum step load capability of the generator set shall be 100%, after duration, of the
indicated continuous load.
The generator shall be connected to the electrical network by the Contractor via the existing switchboard.
Unit Selection
The Contractor is fully responsible for the selection of the generator based upon the requirements set out in this
specification. He shall take into account all loads that are to be connected to the set including any diversity that
may be appropriate. he is to provide full calculations supporting the selection of the generator at tender stage.
Engine
The engine shall be a 1500 rpm, four stroke, direct injection, water cooled type and suitable for diesel fuel, and
complete with the following:-
a) Dry type combustion air filters.
b) Lubricating and fuel oil filters.
c) Coolant and lubricating oil circulating pumps.
d) High pressure fuel injection pump and fuel solenoid.
e) Heavy duty electric starter motor together with 24V DC electric starting control system.
f) Set mounted generator and regulator to charge starting batteries when set is running.
g) Engine driven pusher type radiator fan.
h) Coolant flow thermostat and bypass system.
i) Electronic governor for speed control to BS 5514 Class A1.
222
j) Sensor switches to initiate automatic shutdown for engine fail to start, low oil pressure, high coolant temperature
and engine overload.
k) Set mounted oil pressure gauge, coolant temperature gauge and rpm gauge.
Radiator
The Contractor shall include for tropical type radiator, set mounted with pusher fan and drive and rated for the
required heat dissipation of the engine under 10% overload conditions at an ambient temperature of 50 deg.C and
connected to the discharge louvre via a 500mm long flexible canvas connection.
Alternator
The alternator shall be a brushless, self-exciting, self-regulating, self-ventilating, drip proof, screen-protected
type, conforming to BS 5000 or equivalent and radio interference suppression to BS 800 or equivalent. A solid
state voltage regulator shall maintain an output voltage within + or - 2% from no load to full load, 0,8 to unity
power factor, cold to hot and inclusive of permitted engine speed variations. The voltage regulator shall provide
recovery from transient voltages to within 3% of the steady state value in 0,3 seconds upon application of full
load at a power factor of 0.8 lagging.
The Contractor shall be responsible for providing an alternator which shall fully match the associated engine
taking due account of the necessary derating factors applicable to its location on site.
The rotor and stator insulation shall be to Class F or better, allowing 100 degrees C ambient.
The Contractor shall provide the Engineer with details of short circuit capacity of the alternator.
Construction
The engine flange shall be coupled to the alternator by fully flexible coupling with protective guard. The coupling
shall ensure full alignment of engine and alternator and shall satisfy the torsional requirements of the
engine/alternator combination.
To ensure consistent, long lasting alignment, this monobloc unit shall be mounted on a robust single fabricated
steel channel base frame. The base frame shall have adequate mechanical strength suitable for the static and
dynamic loads applicable to the engine alternator combination.
The base frame shall also be provided with lifting facilities and fixing positions of anti-vibration mountings.
Anti-vibration Mountings
The complete generator set and base frame shall be mounted on anti-vibration mountings in order to avoid
excessive vibrations being transmitted to the building structure.
The mountings shall be selected to provide at least 95% reduction in vibrations to the building structure and shall
be suitable for the static and dynamic loading of the generator set. The Contractor shall ensure that the anti-
vibration mountings are not "short-circuited" during installation. In particular flexible single core cables shall be
used for connections between alternator and control panel and between engine and starting batteries. Final
connections of fuel lines and exhaust auto engine shall be via flexible pipes.
Battery and Charger

The Contractor shall provide 24V DC heavy duty starting batteries floor mounted adjacent to the generator base
frame or set mounted and connected to the engine via flexible cables.
The batteries shall have ample capacity to give a minimum of 6 consecutive starts each of ten seconds cranking
at 0 degrees C when in a fully charged condition. The batteries shall also sustain the fire alarm system for the
generator room. The battery terminals shall be protected by a purpose made hardwood board to be provided by
the Contractor. A fully automatic, constant potential battery charger shall be provided within the generator control
panel and powered from the mains to keep the batteries charged when the set is not running. The charger shall be
provided with trickle and boost charging facilities. Battery charging shall be by the constant potential charger
when the set is on standby and by an engine driven battery charging alternator when the set is running.
Generator Control Panel

The Generator Control Panel shall be a floor mounted, rust protected sheet steel enclosure with lockable hinged
front cover and suitable for bottom entry/top exit of service cables.
223
The cubicle shall be suitably ventilated and shall incorporate all internal wiring, output terminals and labels etc.
The Control Panel shall be provided with following:

Indicating meters
a) alternator output voltmeter
b) battery voltmeter
c) Ammeters (one for each phase plus battery charging ammeter)
d) Kilowatt meter
e) frequency meter
f) hours run meter
Timers
g) three attempts to start timer and circuit with automatic lockout if engine fails to start by the end of the 3rd
starting cycle.
h) fail to start
i) set run down
j) protection hold off
Engine Control Switch

k) Manual/auto/stop
Indicating lamps for alarm conditions:

l) fail to start
m) low oil pressure
n) high engine temperature
o) engine overload
p) engine over speed
q) alternator low voltage
r) alternator high voltage
s) low fuel level
t) high fuel level
The above indicating lamps shall be provided with lamp test facilities. Under alarm conditions the appropriate
lamp shall be illuminated and an audible alarm on the Control
Panel shall sound. The audible alarm shall be re-set by a Control Panel mounted re-set pushbutton. The particular
indicator light shall however be switched off only on repair of the indicated faulty condition. Remote signaling
facilities shall be provided for remote indication of any of the above alarm conditions via a single lamp and buzzer
at the main reception as shown on the drawings. An externally mounted alarm siren shall also be provided.
Switchgear of the rating indicated on drawings:

u) Triple pole, output moulded case circuit breaker with thermal overload and magnetic short circuit trips. The
Electrical Contractor shall provide the Engineer with the characteristics of the MCCB.
v) Clearly labelled control fuses.
Electromagnetic Changeover Contactors

The essential services switchboard section shall comprise the equipment detailed on the drawings. The
electromagnetic changeover contactor assembly with associated controls shall be located in the generator control
panel.
Operation
Operation of the changeover contactors shall occur if one or more of the following conditions arise:-
(i) Total loss of normal supply.
(ii) Normal supply healthy but loss at any of the changeover contactor terminals.
(iii) A reduction in voltage of more than the set value on either all or one of the phase voltages sensed immediately
prior to each phase conductor termination at the changeover contactor. The set values shall be adjustable from –
ve 20% to +ve 20% of normal voltage.
Changeover contactors shall operate via time delay relays adjusted to allow the generator to run up to speed and
take up load. The time delay relays shall be adjustable between 0-60 seconds and shall finally be set on site by
224
the Contractor to "sequence-in" the load. On restoration of the supply or on the voltage returning to a stable value
within the prescribed limits the load shall be shed from the generator and connected to the normal supply in the
following sequence:-
(iv) Normal supply failure.

(v) Generator running and on load.
(vi) Restoration of normal supply.
(vii) Stable voltage at each load section for two minutes above 90% of normal voltage.
(viii) Load section changes over in the same timed sequence as described for the generator start condition.
Characteristics
Contactors shall comply with BS 5424 or equivalent with the following characteristics:-
(i) Electromagnetic.
(ii) Air break.
(iii) Be mounted within an enclosure within the switchboard such that protection is
afforded against persons making contact with live or moving parts and against the ingress of dust in accordance
with BS 5420 Table 3, numeral 6 or equivalent and tested in accordance with BS 5420 Table 7, numeral 6 or
equivalent.
(iv) 4-pole with auxiliary contacts as indicated on the drawings.
(v) Suited for operation on a.c. 3 phase 4 wire 50 Hz system.
(vi) Operational voltage of 400V and control circuit 230V a.c. 50 Hz and rectified supply to economized coil.
(vii) The rated insulation voltage shall not be less than the operational voltage.
(viii) The rated current of the contactor shall comply with BS 5424 Clauses 4.32, 4.3.21 and 4.3.22 or equivalent.
(ix) The conductors shall be rated for uninterrupted duty.
(x) The making and breaking capacities of the contactors shall be suitable for types of loads indicated elsewhere
and comply with BS 5424 Clauses 4.3.5, 4.3.5.1, 4.3.5.2. or equivalent.
In addition to the above characteristics the contactor shall comply fully with BS 5424 or equivalent and be tested
as detailed in section 8 of BS 5424 or equivalent.
Auxiliary contacts are required on the contactors to:-
(xi) Interlock electrically between the two contactors.

(xii) Signal the generator to start or stop.
In addition to the electrical interlock the contactors shall be constructed with a mechanical interlock to operate in
parallel with the electrical interlock and prevent the two contactors both engaging at any given time. Key
interlocks are indicated on the drawing to enable the contactor to be isolated for maintenance purposes, with an
interlocked by-pass circuit to the relevant section of bus-bar. The contactor housing is to be mounted in one section
of the control panel.
A face mounted key operated switch shall enable the generator signal to be by-passed before isolation takes place.
The key switch shall have an auxiliary contact to indicate that the generator sensing circuit is by-passed and the
by-pass circuit from the non-essential switchboard is in operation.
The non-essential services switchboard section shall comprise the equipment indicated on the drawings and where
applicable match the specified requirements for the essential services section.
(c) The automatic change-over contactors and the associated control and sensing circuits shall be incorporated
into the generator control panel.
(d) The Contractor shall also install and commission a remote indicator panel at the main reception for the remote
indication of generator alarm signals where this has been specified.
Fuel Tank
The engine shall be suitable for operation on diesel fuel. The generating set shall be supplied complete with
integral daily service tank. The Contractor shall supply and install a gantry mounted bulk storage tank of capacity
as detailed in the Bills of Quantities. The Bulk Storage Tank shall be provided complete with a contents gauge,
filler cap, feed and return lines, drain valve and plug. Final connections of fuel lines onto engine shall be carried
out via flexible pipes. A wall mounted, hand operated, semi-rotary pump shall also be provided by the Electrical
225
Contractor and piped to the Daily Service Tank. All fittings (fuel cap etc.) on the integral daily service tank shall
be capable of withstanding the pressure from the bulk storage tank.
The hand-operated pump shall be provided with 8 meters of flexible hose complete with filter and filler cap.
Exhaust System
The Contractor shall supply and install an exhaust system comprising residential type silencers, flexible bellows,
90 degree elbow, bird mesh and a length of tail-pipe as required.
The exhaust system shall be connected to the engine via the flexible bellows to limit vibrations transmitted to the
building structure, and shall be fixed on hangers suspended from the underside of the roof slab.
The exhaust system shall be fully lagged along its entire length to limit the temperature rise within the generator
room. Lagging shall comprise 75mm thick Rocksil insulation clad with 22 gauge aluminium. The Contractor shall
ensure that any external lagging shall be weatherproof.
Louvres
The Contractor shall include for inlet and discharge louvres to suit the generating set offered. The louvres shall
be constructed of aluminium or steel and shall keep out rain and vermin from the generator room. The louvres
shall also be provided on the inside with a steel wire mesh of 25mm maximum pitch. The louvres shall be to the
requirements of the generating set manufacturer.
Tests and Commissioning

The Contractor shall include for the Engineer to visit the works of the Generator Manufacturer in order to inspect
progress and also to witness testing of the generator at the works.
Final site commissioning shall also be witnessed by the Engineer but after satisfactory preliminary tests and
submission of results by the Contractor to the Engineer. The Contractor shall be responsible for the supply of test
loads and fuel for successful site commissioning. After successful site commissioning the Contractor shall
completely fill the Daily Service Tank and Bulk Storage Tank with fuel prior to handover.
The final site commissioning shall comprise full functional mechanical and electrical tests plus four hours
continuous load test - 2 hours at 50% full load, 1 hour at 100% full load and 1 hour at 110% full load. The
Contractor shall be responsible for providing the test loads. The Contractor shall record the load, coolant
temperature, engine speed and oil pressure every 15 minutes during the load test. He shall then provide the
Engineer with two copies of the test certificates.
Handbooks and Drawings

The Contractor shall submit to the Engineer 3 sets of drawings and operating instructions/maintenance manuals
prior to final site commissioning. The final form of these documents shall be subject to the approval of the
Engineer.
226

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THE UNITED REPUBLIC OF TANZANIA

DAR ES SALAAM WATER SUPPLY AND SANITATION AUTHORITY

OFF-GRID WATER SUPPLY SCHEME IN DAR ES SALAAM

TENDER NO. TZ-DAWASA-221519-CW-RFB

Construction of off-grid Water Supply Distribution Networks in ILALA and

DAR ES SALAAM WATER SUPPLY AND SANITATION

A. Scope of Works Outlining the objectives and scope of the project;

B. Particular Specification Describing the configuration and physical characteristics

SECTION B: PARTICULAR SPECIFICATION ................................................................. 11

SECTION C: GENERAL SPECIFICATION ....................................................................... 49

C.1 GENERAL REQUIREMENTS ...................................................................................... 49

C.3 GENERAL CIVIL ENGINEERING CLAUSES ............................................................. 64

C.4 GENERAL MECHANICAL & ELECTRICAL ............................................................ 146

The overall objective of this project

A.2 SUMMARY OF PROPOSED WORKS

The following works has been proposed under this project.

1) Distribution networks for 60,147Mtr

S. No Location of Type of Capacity (cum)

4) Offtakes and allied works

SECTION B: PARTICULAR SPECIFICATION

B.1.2 Prevailing Conditions

B.1.2.1 Climatic Conditions

B.1.2.4 Local Materials

B.1.2.6 Laws and Regulations

B.1.2.7 Local Labour

B.1.2.8 Ground Conditions

B.1.2.9 Existing Plant

B.1.2.10 Operating Conditions

B.1.4 Other Relevant Contracts

These other contracts may include:

Revised Drawings Any revisions to previously issued drawings.

B.2.10 Documents on Completion

B.3 Design of Works

B.3.3 Verification by Contractor

B.3.3.2 Locating Existing Underground Pipelines, Cables and Other Services

B.3.3.3 Raw Water Quality Testing

B.3.3.4 Geotechnical Investigations

conductivity, chloride, sulphate;

B.3.3.5 Shut-Down of Water Treatment Plants if any

Further, the Contractor shall observe the following considerations:

B.3.3.6 Confirm Scope and Requirements

B.4 Design Considerations

B.4.2 Water Quality Standards

devices to be provided by the Contractor;

B.4.5.6 Hydraulic Design

B.4.5.8 Structural Design

B.4.6 Reviews and Approvals

i) Flow rate in MLD;

i) Pre-commissioning Additional inspections and/or off-line or “dry” tests

ii) Commissioning To confirm that equipment is installed correctly and is

i) Second proof-of- Same as first proof-of-performance test

ii) Third proof-of- Same as first proof-of-performance test

B.5.6 Commissioning Plan

B.5.8 Pre-Commissioning Tests

B.6 Pumping Equipment

annunciators, set points, and other related items;

All terminations will be checked for solid, clean connections.

B.7 Performance Tests

B.8 Results, Reports and Taking Over

B.8.1 Taking Over Certificate

B.9 Second and Third Proof-of-Performance Tests

B.10 Performance Certificate

B.11 Operational Start-Up Period

B.12 Spare Parts