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SITE PREPARATION AND

EARTHWORKS

PROJECT CODE: SEPA15014

UTAPATE TERMINAL

SITE PREPARATION AND EARTHWORKS

DOCUMENT NO.: SEPA15014-MFSTD-CV-00-SPC-001

Transmittal No: UTAPATE TERMINAL/DET/PTSPL/TR-0743

0 07 Dec 2022 ISSUED FOR APPROVAL KA CN ASK

REV. DATE PURPOSE BY. CHECKED APPROVED


UTAPATE TERMINAL
NNPC E&P LTD, NOSL & BADUGO
Doc No.: SEPA15014-
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SITE PREPARATION AND EARTHWORKS Rev No. : 0

REVISION DESCRIPTION SHEET

Rev.
Paragraph Reference Revision Description Date
No.

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Contents

1. INTRODUCTION........................................................................................................................5
1.1. PURPOSE.............................................................................................................................5
1.2. SCOPE..................................................................................................................................5
1.3. ABBREVIATIONS.................................................................................................................5
2. SPECIFICATION, CODES & STANDARDS.................................................................................6
2.1. CONFLICTING REQUIREMENTS........................................................................................6
2.2. ORDER OF PRECEDENCE.................................................................................................6
3. UNIT OF MEASUREMENT.........................................................................................................6
4. TECHNICAL REQUIREMENTS..................................................................................................6
4.1. SITE INVESTIGATION..........................................................................................................6
4.2. ENVIRONMENTAL...............................................................................................................6
4.3. DELIVERY, HANDLING & STORAGE..................................................................................7
4.4. PROTECTION.......................................................................................................................7
4.5. TOLERANCES......................................................................................................................7
4.6. DEFINATIONS......................................................................................................................8
4.7. PREPARATION...................................................................................................................13
4.8. CLEARING AND GRUBBING.............................................................................................13
4.9. ACCESS ROADS................................................................................................................14
4.10. SITE SURFACE WATER MANAGEMENT AND DEWATERING.......................................15
4.11. EXCAVATION.....................................................................................................................16
4.11.1 General Requirements.........................................................................................................16
4.11.2 Temporary EXCAVATION SUPPORT.................................................................................16
4.11.3 STRIPPING..........................................................................................................................17
4.11.4 COMMON EXCAVATION....................................................................................................17
4.12. FILL & COMPACTION........................................................................................................17
4.13. PIPE BEDDING...................................................................................................................19
4.13.1. DEFINATIONS......................................................................................................................19
4.13.2. EXCAVATIONS.....................................................................................................................19
4.13.3. FILL.........................................................................................................................................20
4.13.4. PLACING & COMPACTION................................................................................................23
4.13.5. FILLING AROUND AND OVER SUBSTRUCTURES & FOUNDATIONS.....................23

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4.13.6. BACKFILLING AROUND MANHOLES..............................................................................24


4.14. CLEAN-UP..........................................................................................................................24
4.15. GRADING............................................................................................................................24
5.0 QUALITY ASSURANCE / QUALITY CONTROL (QA/QC)........................................................24
5.1 GENERAL.....................................................................................................................................24
5.2 SAMPLES.....................................................................................................................................24
5.3 WORKMANSHIP..........................................................................................................................25
5.4 INSPECTION & TESTING............................................................................................................25
5.6 WORK PERMITS..........................................................................................................................25
6.0 APPENDICES................................................................................................................................25
APPENDIX 1: FIELD COMPACTION TRIALS – SUGGESTED PROCEDURE
APPENDIX 2: INDICATIVE COMPACTION VALUES
APPENDIX 3: GEOTEXTILES

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1. INTRODUCTION

1.1. PURPOSE

Purpose of this document is to provide the requirements for site preparation and
earthwork (excluding) Tank Foundation) to be performed for MFS Tank Farm Projects at
Akwa Ibom, Nigeria.
1.2. SCOPE

The Main Flow station facility (MFS) is a centralized facility handling the production from
various reservoirs and surrounding Satellite fields. Both will be developed in a phased
manner. The total design capacity of the Main Flow Station is to handle 100,000 BLPD of
well fluids in two trains (2 x 50%) in phase 1 with a provision in piping and layout to add 4
x 50,000 BLPD for phase 2 and 250 MMSCFD of associated & non-associated gas and
150,000 BWPD of formation / injection water in phase 1.

Oil will be separated, stabilized, stored, pumped and metered prior to entering the sub-
sea export pipeline for further offshore transport. Gas will be separated, compressed,
dehydrated dew point controlled and re-compressed prior to entering the pipeline
delivering to LPG extraction/Petrochemical plant. Water will be separated, treated and
stored prior to inject in selected reservoirs to maintain reservoir pressure or help in
enhanced oil recovery.

The Tank Farm shall consist of seven (07) Nos. each of 0.5 MB storage tank in Phase
1 and a space provision of five (05) Nos. each of 0.5 MB storage tank in Phase 2.

1.3. ABBREVIATIONS

SHORT NAME DESCRIPTION


MFS Main Flow Station
NNPC Nigerian National Petroleum Corporation
NNPC E&P Nigerian National Petroleum Corporation Exploration and Production
BS British Standards
CBR California Bearing Ratio
HSE Health, Safety, Environment
OSHA Occupational Safety and Health Administration
SPMDD Standard Proctor Maximum Dry Density

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2. SPECIFICATION, CODES & STANDARDS

All the works shall be performed and tested in accordance with the latest ASTM relevant
codes and standards from the regulatory agencies and institutes.
2.1. CONFLICTING REQUIREMENTS

In case a conflicting requirement is mentioned between individual documents, the conflict


shall be reviewed, discussed, analysed and design basis shall be developed by for
company’s approval in a technical query format based on precedence of documents as
mentioned in clause no. 2.2 as below with sound engineering practices. In all such cases
of conflict COMPANY’s decision shall be final.
2.2. ORDER OF PRECEDENCE

In case of conflict between the requirements of this specifications and the reference
codes, standards and specifications, the following precedence shall apply:
1. The Laws, Standards and Regulations of Nigeria.
2. Project Standard and Specifications.
3. Accepted Practice of Company
4. Process Industry Practices (PIP) / Good engineering practice.
5. International oil and gas industry Codes, Standards and Recommended
Practices (all where specified in the above or, where none of the above is
applicable, as proposed by CONTRACTOR and Approved by COMPANY.

3. UNIT OF MEASUREMENT

All dimensions, quantities and units of measurement used in drawings and calculations
may be given in MKS units

4. TECHNICAL REQUIREMENTS

4.1. SITE INVESTIGATION

The CONTRACTOR shall be deemed to have carried out his own investigation in the Site
of Works and verified the information provided by COMPANY. The CONTRACTOR
should satisfy himself as to the nature of the ground quality and distribution of materials to
be excavated, filled, spoiled, borrowed and make himself conversant with the local
conditions to be encountered during the execution of the Works.
4.2. ENVIRONMENTAL

CONTRACTOR is liable to protect the general environment from damage. Notify the
COMPANY immediately in the event of any spills or potential incidents; affecting the
environment.

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Provide equipment and facilities to keep the works area dry of both surface and sub-
surface water and to remove sediments from water prior to discharge. Dewater
continuously as required to avoid work stoppages & to protect the works in progress.

For site environmental criteria, refer to BASIS OF DESIGN (Doc. No. SEPA15014-
MFSTF-PS-40-DBS-001)
4.3. DELIVERY, HANDLING & STORAGE
Quoted rates shall include all material’s sourcing, transporting, delivery, handling and
storage at site, including all suitable tools & tackles, machinery, labour etc., dewatering,
protection by shoring & strutting etc., coordinating with other contractors for sequencing
as required for type or work till its successful completion.

Store aggregates and granular materials separately from other materials. All materials
shall be protected from contamination and segregation prior to their usage.

Remove from site or relocate on site all the materials that become segregated or
contaminated with foreign matter as directed by the COMPANY.
4.4. PROTECTION
Protect the work and the work of others from damage during construction/installation.
Make good all damage caused at no cost to the COMPANY. Immediately notify the
COMPANY of any contact or damage to buried utilities or structures.

Support, brace, and protect utilities, structures and properties adjacent to and within all
excavations.

Protect all excavations from collapse by providing safe side slopes to excavations.

Use adequate shoring to the approval of the COMPANY where the excavation is too close
(i.e. within 2.0 m plus the depth of the excavation) to a building, or load bearing structure.
Ensure that any shoring is structurally adequate and prevents movement of the
surrounding structures.

Also protect the excavations from the inflow of water from natural surface drainage.
Obtain approval of the COMPANY for the construction of temporary berms and/or ditches
to divert water away from excavations.

Adequate procedures and techniques such as use of cable detectors, test pits and
trenches should be adopted to avoid damage to underground services.
4.5. TOLERANCES

Work complying with the following tolerances will be accepted.

Stripping and Bulk Excavations

 True line +/- 30 mm;


 True level +/- 30 mm.

Placement of Embankments, Berms and Mass Fill

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 True line +/-75 mm;


 Mass Fill true level +/- 25 mm;
 Berms & Embankment true level +75 mm, - 0 mm.

Road Subgrade

 True line +/- 50 mm;


 True level +/- 25 mm.
4.6. DEFINATIONS

Earthworks

Include stripping and stockpiling, rough grading, common excavation, disposal of


unsuitable ground material and excess material, placing and compacting of fill, borrowing
of suitable fill material as required to complete the works.

Stripping

Removal of ground surface including shrubs and tree roots

Common Excavation

Excavation of all native earth materials that can be removed without drilling and blasting,
except those materials classified under stripping.
Authorized Over-excavation

Additional excavation defined and required by the COMPANY as a result of unsuitable


natural soil conditions.

Unauthorized Over-excavation

Additional excavation obtained by the result of the CONTRACTOR’s operation or over-


excavation by CONTRACTOR’s error. Replacement fill shall be placed and compacted in
accordance with this specification, at no additional cost to the COMPANY.

Unstable or Unsuitable Ground

As applied to existing ground, means either materials in a loose state, materials which are
too wet, materials containing organic or other deleterious matter, materials having poor
characteristics of grading and compaction, materials having other characteristics which
would result in undesirable settlement or ground movement under loading from
foundations, fills or other superimposed loads, or materials which do not meet the
requirements of the specifications provided. However, this definition permits compacting,
drying, dewatering and any other remedial work, improvements or processing where such
action is required or permitted by the specifications or the CONTRACTOR.

Unstable or Unsuitable Fill

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As applied to fill material, means either too wet, too dry, containing organic or other
deleterious matter, having poor characteristics of grading and compaction, having other
characteristics which result in undesirable settlement or other movement of the fill or
within the fill, or otherwise not meeting the requirements of the specifications. However,
this definition permits soil-conditioning (drying, dewatering, watering), compaction, and
any other processing or reprocessing to make the material stable and suitable prior to
incorporating it into the fill as permitted by the specifications or the CONTRACTOR.

Sound or Suitable Ground

As applied to existing ground, means undisturbed materials, being compact and having
the required bearing capacity, stability and other required characteristics as determined by
the COMPANY.

Sound or Suitable Fill

Meaning material free of deleterious matter, suitably graded and can be compacted to a
stable mass after any handling or re-handling and have the required bearing capacity and
stability characteristics as determined by the specifications or the COMPANY

Soil Improvement
Soil improvement, if required, shall be in accordance with site specific final Geotechnical
investigation report and soil improvement specifications & procedure as given by
Geotechnical Investigation consultant.

Top Soil

Refers to soil found at ground surface, containing organic matter. Topsoil may contain
vegetation, roots and rich content decomposed derivatives from the same.

Native Earth

Refers to layers of earth found below the topsoil.

General Fill

General fill material shall be used as fill only at locations where installation or structures or
equipment is not planned and in open areas where only grading is required to reach
elevations and compacted as specified and noted on the drawings.

This terminology does not apply to granular fill of road base and sub-base, structural
foundations, pipe embedment or other imported fill material.

The extent of use of general fill shall be subject to prior COMPANY approval. Properties
and characteristics for general fill shall meet or exceed the following criteria:

 Type of soil – Inorganic granular or silty soil;


 Gradation.
BS Sieve Size Percent Passing

75 mm 100

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0.063 mm 0 – 35
 Liquid limit = 40 max.

Fill shall be placed in layers not exceeding 200mm loose measurement. A capping
layer, as stipulated afterwards, shall be used every three layers. The final layer
shall require a capping layer.

General fill shall be compacted to at least 90% SPMDD of the modified Standard
Proctor Density in accordance with ASTM D698.

Construction Fill Materials

The CONTRACTOR shall submit to the COMPANY proposals regarding the materials,
their source and the plant for spreading and compacting, filling and backfilling. Imported
filling material shall only be used if excavated materials are not in full compliance with the
required relevant fill type as described below. Contaminated material for construction
works arising from site works shall be disposed/removed to a disposal area approved by
local authorities and COMPANY.

Sourcing of material for earthwork including fill material namely engineering fill, structural
fill and general fill supply is part of CONTRACTOR’s scope. Samples of the imported
material shall be delivered to the site for inspection, testing (including sieve analysis) and
compaction trials. Compaction of fill layers shall be in layers of minimum of 200 mm for
general fill and minimum 150mm for structural / engineered fill and these values shall be
confirmed with trial tests during execution stage as specified in these specifications.

The purpose of the compaction trial is to determine and optimize layer thickness, moisture
content, roller types and number of passes required to produce compacted fill that meets
the specification requirements.

The CONTRACTOR shall carry out the compaction trials generally as described in
Appendices 1 and 2 of this specification and shall satisfy the COMPANY that all specified
requirements regarding compaction can be achieved. All the specified compaction tests
shall be carried out during these trials.

The CONTRACTOR shall use the filling/backfilling materials per the following
classifications:

Engineering Fill

Engineering fill material obtained from excavation on site or other areas, which could be
placed and compacted as specified. Naturally occurring earth materials free of timber, top
soil, roots, boulders and other organic debris. This terminology does not apply to granular
fill of road base and sub-base, below structural foundations, pipe embedment or other
imported fill material.

Properties and characteristics for engineering fill shall meet or exceed the following
criteria:

 Type of soil – Inorganic granular or silty soil;

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 Gradation.
BS Sieve Size Percent Passing

75 mm 100

37.5 mm 80 – 100

5 mm 20 – 90

0.6 mm 10 - 50

0.063 mm 0 – 35
 Liquid limit = 40 max;
 Plasticity index, minimum of 4 and maximum of 15.

Field testing for each layer at each location shall be conducted to determine compacted
density at a minimum frequency of two (2) tests per 1200 m3 of fill placed, with a
minimum of two tests per layer.

Fill shall be placed in layers minimum 300mm loose measurement subjected to


compaction trials.

Engineering fill shall be compacted to at least 95% SPMDD of the modified Standard
Proctor density in accordance with ASTM D698.

Structural Fill

Structural fill shall be used as per the following criteria with 1:1 slope for axial load
dissipation in the soil.

Properties and characteristics for structural fill shall meet or exceed the following criteria:

 Type of soil – Inorganic granular or free-draining soil;


 Gradation – uniformly graded.
BS Sieve Size Percent Passing

50 mm 100

37.5 mm 85 – 100

10 mm 45 – 90

5 mm 30 – 80

0.6 mm 8 - 45

0.063 mm 0 – 15
 Liquid limit = 25 max;
 Plasticity index, minimum of 4 and maximum of 12.

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Field testing for each layer at each location shall be conducted to determine compacted
density at a minimum frequency of two (2) tests per 800 m3 of fill placed, with a minimum
of two tests per layer.

Fill shall be placed in players minimum 150mm loose measurement subjected to


compaction trials.

Structural fill shall be compacted to at least 95% SPMDD of the modified Standard Proctor
density in accordance with ASTM D698.

No imported fill shall be used in the works until it has been approved by the COMPANY.

Fill material used overlying or within 500 mm of concrete structures or cement bound
materials shall have a soluble sulphate content not exceeding 2.5g/litre when tested in
accordance with Test 10 of BS 1377. The amount of soluble chlorides within fill material
shall be limited to less than 10,000 ppm. COMPANY will require seeing sample test
results for the fill material indicating the soluble sulfate and chloride content.

Bedding Material

Bedding material shall be used to backfill around underground pipes and cables. Bedding
material shall comply with the following properties unless approved by COMPANY.

BS Sieve Size Percent Passing

5 mm (#4 sieve) 100

2 mm (#10 sieve) 80 – 100

63 microns (#230 sieve) 0 – 10

Capping Layer

Capping layer can be engineering fill

Cement-Sand Mix

Should any excavation be made below the required levels as shown on the drawings,
CONTRACTOR shall fill up such excavation to the proper level with cement-sand mix
(1:10) with sufficient potable water content to hydrate the cement.

Cement shall be type I Portland cement conforming to ASTM C150 and sand shall be
clean durable sand, free from organic matter, and plasticity index shall be 6 or less when
tested in accordance with ASTM D4318.

The sand cement mix shall be placed in 200 mm maximum thick layers, loose measure,
and thoroughly rodded and tamped in a manner that shall fill all voids. Materials not
placed and compacted within four (4) hours after mixing shall be rejected. Sand-cement
mixtures shall not be placed in standing or free water. A minimum of one sample shall be

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taken at random for testing to represent the production. However, the COMPANY shall
have the option to ask for more samples to be tested on the CONTRACTOR’s expense.

On-Grade Surfacing / Base

Sound, hard, durable, inert rock, free from flakes, shale, clay, organic matter or other
foreign material produced by crushing and screening rock from a quarry.

Sub-Grade/Sub-Base

Sound, hard, durable, inert rock, free from flakes, shale, clay, organic matter or other
foreign material produced by crushing and screening rock from a quarry.

Sand

Sand material is to consist of clean sand with some gravel with less than 5% passing 75
micron size. The select sand is to be free from organic impurities, plastic fines, and other
deleterious substances and is to be well-graded such that the ratio of the D60 size to the
D10 size is less than 4.
4.7. PREPARATION

Set out the works and maintain all control points and bench marks to ensure accuracy of
the works.

The locations of existing buried pipelines, cables, conduits and structures, where shown in
the Contract Documents, are not guaranteed as to accuracy and/or completeness.
Confirm their location before commencing excavation and clearly mark such locations to
prevent disturbance during the work. Record the site verified location of all existing,
abandoned or re-routed utilities on the applicable as-built drawings.

Any trial excavations deemed necessary for locating the position of underground services
shall be excavated by hand, by hydrovac, or by other appropriate measures approved by
the COMPANY.

If damages to existing facilities or structures occurred during earthworks operations; repair


all damages at no additional cost to the COMPANY.

Topographic survey will be done prior to all site work and made available for all site
construction survey and control scope.

4.8. CLEARING AND GRUBBING

CONTRACTOR is responsible for clearing, site grubbing and grading, earth movement
and levelling the construction sites.

Clearing

Before starting work, conduct with the COMPANY a condition survey of existing bench
marks and monuments, buried utilities, service poles, wires, paving, structures, buildings,

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active nests or other species and other plants or structures which need to be preserved
that may be affected by work;

Clear the area within the limits of all vegetation, both living and dead, all minor man-made
structures, all rubbish and other materials which, in the opinion of the COMPANY, are
unsuitable for use in the works.

Grubbing

Grubbing is to consist of the removal and disposal of wood or root matter including
stumps, roots and root systems on and below the ground surface.

While grubbing in areas where underground utilities are present, care is to be exercised
ensuring the utilities are not damaged or disturbed. If damages occur to existing utilities
during grubbing operations; repair all damages at no additional cost to the COMPANY.

Clear all undergrowth, bushes and debris remaining from clearing operations.

The grubbing operations include the stripping of surface material to a depth shown on the
drawings or as directed by the CONTRACTOR.

Grub cleared areas immediately prior to commencement of earthworks.

Extract all stumps, roots and logs embedded in the ground surface in accordance with the
drawings. Collect all material and stockpile near the edge of the worksite or as directed by
the CONTRACTOR.

Backfill all remaining holes with sound material to prevent infiltration and ponding after
grubbing. Compact the backfilling material to at least the relative density of the material
existing in adjacent ground.

Disposal

Do not bury any materials resulting from clearing and grubbing operations. Dispose off all
materials, as directed by the COMPANY. Disposal of materials in areas other than those
designated by the COMPANY is not permitted.

CONTRACTOR shall dispose the stripped soil (top 200mm) at a convenient location
outside the plant area and within the vicinity of project, as approved by COMPANY.
4.9. ACCESS ROADS

Any existing access roads used for the purpose of the works shall be maintained by the
CONTRACTOR.

Maintain all existing, temporary and permanent access roads for the duration of
performance of contract.

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Construct and maintain any additional temporary access roads as may be required to
perform excavation and fill activities. The location of temporary access roads, not shown
on the drawings, will be approved in writing by the COMPANY.

Construction of additional access roads includes improvement of existing roads which the
CONTRACTOR may require to perform the work.

4.10. SITE SURFACE WATER MANAGEMENT AND DEWATERING

Surface water management shall be compatible with the contract drawings. The
CONTRACTOR shall submit plans and details of proposed methods and controls covering
the following aspects of the work:

Dewatering

Excavations shall be kept free from water at all times. The responsibility for removing
water shall rest with the CONTRACTOR and no claim for expense shall be entertained.
All dewatering methods and disposal of water shall be approved by COMPANY.

Surface Water Management

Prevent water from accumulating in excavations. Employ dewatering methods, such as


temporary sumps and pumps to remove excess water.

Carry out regular inspections and cleaning of the protective measures. Repair or replace
non- functioning control measures such as clogged filter materials as directed by the
COMPANY.

Ground Water Control

Provide system(s) consisting of sumps, pumps, pipelines, ditches and related earthwork
necessary to achieve the control of groundwater seepage within the work. Provide
sufficient standby power for the operation of all required system equipment.

The system(s) must be capable of lowering and maintaining the groundwater level below
the excavation bottom and slopes (min 1 m) to permit construction to be conducted on a
dry and stable foundation.

When the bottom of excavation or fill surface is below the ground water table surface that
the excavation or fill surface will be saturated by groundwater and become soft, take
measures to lower the groundwater surface sufficiently to maintain the stability and
integrity of the excavation.

Inspect at regular intervals (not exceeding 12 hours) to verify that the pumps are
operating. Decrease the time interval between inspection checks to correspond with the
type and nature of weather to the satisfaction of the COMPANY.

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4.11. EXCAVATION

4.11.1 GENERAL REQUIREMENTS

Prepare slopes and ensure the stability of excavations to prevent collapse of the
excavation sides by traffic, equipment or other superimposed loads near the excavations.
All excavations shall be in accordance with Health and Safety Regulations.

Excavate, load, transport, place and compact earth material in the works ensuring
excavations and compactions to the required lines, levels and grades.

During excavation for foundations, the bottom 150 mm layer of excavation shall be left
undisturbed and subsequently removed manually only when the blinding concrete is about
to be placed in order to avoid softening or deterioration of the surface of the excavation.

Dispose off unsuitable materials and surplus excavated materials in the designated
disposal areas only as directed by COMPANY

4.11.2 TEMPORARY EXCAVATION SUPPORT

Where temporary support for excavations is required, the CONTRACTOR will design,
supply, install and maintain sheet piling, bracing and shoring as required to resist
applicable earth pressures and surcharge loads. Submit details to the COMPANY for
review prior to the start of the Work.

Design the sheet piling, bracing and shoring to comply with applicable laws and
regulations.

Prevent voids occurring outside the sheet piling. Promptly fill and compact any voids that
occur.

As the work progresses, remove temporary sheet piling, bracing and shoring in a safe
manner. Promptly backfill any voids as the support material is withdrawn. Obtain the
approval of the COMPANY if any temporary support materials will remain in place. If
temporary materials are left in place, ensure the top of any material is at least 800 mm
below the final grade unless otherwise instructed.

Where sheet piling, bracing, and shoring has been installed and is to be removed,
proceed by withdrawing it in stages consistent with the progress in placing and
compacting fill such that no movement occurs in the sides of the excavation. During the
withdrawal, fill the voids formed promptly and completely and compact the fill using
rammers suitable for working in confined spaces. The CONTRACTOR is fully responsible
for the operations and should coordinate activities ensuring adequate support is always in
place.

4.11.3 STRIPPING

Excavate and remove the surface and stockpile in designated stockpile locations without
mixing or contaminating soils.

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Prior to commencing the grading and backfilling operations, stripping the surface to 200
mm depth is required to remove all loose debris/visible surface vegetation root, waste
concrete and asphalt layers and any soft, weak or otherwise unsuitable soils from the
ground surface. These unsuitable materials shall be totally removed from the site and
shall not be used for backfilling purpose.

4.11.4 COMMON EXCAVATION

Notify COMPANY when the excavations reach the design limits specified. If inspection by
the COMPANY indicates that the exposed, undisturbed naturally occurring material is
unsuitable, remove the unsuitable material and replace it with approved compacted fill as
directed by the COMPANY.

In areas that have been over-excavated by the CONTRACTOR (beyond the specified
tolerances), backfill using approved material to the neat lines. No additional compensation
will be paid for backfilling to comply with the design limits.

4.12. FILL & COMPACTION

4.12.1 PREPARATION OF AREA

Ensure that upon completion of excavation to the required grade, the COMPANY inspects
the surface.

Acceptance Criteria for Sub-Grade Preparation in Fill-Zones

Where the areas being prepared are located within “zones in fill”, the criteria of
acceptance of grading surface by the COMPANY are:

 Top of surface elevation is constructed to a tolerance of +/- 25mm as specified in


Section 4.5;
 COMPANY has inspected the fill-soils;
 Top of sub-grade surface is sloped to drain as specified;
 Top of sub-grade surface has been compacted as specified.

4.12.2 PLACEMENT OF FILL

Construct fill embankments on prepared subgrade that has been accepted by the
COMPANY.

Coordinate fill operations with the remainder of the works. Do not cover any stripped
existing ground or the works until authorized by the COMPANY, then place the fill
materials as soon as possible.

Obtain approval from the COMPANY prior to beginning subbase or base fill. Ensure that
the limits of subbase fill are stacked prior to construction. Grade the compacted surface of
both subbase and base layers to the specified cross slopes and re-compact after grading.

Compact each lift within +/- 3% of optimum moisture content to the specified percentage
of maximum dry density as determined by ASTM D698.

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Water used for compaction of structural fill shall be clean potable water. Brackish water
may be used for compaction of other types of fill provided that the salt content does not
exceed 30 grams/litre (30 ppt).

Lift thicknesses are given as a guideline and may be varied in consultation with the
COMPANY.

Acceptance Criteria

The density of each lift is considered satisfactory when;


1. The test results average is not less than indicated, and;
2. All individual test results have a maximum tolerance of 1% below the minimum
compaction percent of the standard proctor.
Prevent damage and disturbance to stripped existing ground, other work and existing
buildings and installations.

Keep heavy equipment at a safe distance, clear of structures and other installations.
Within the safe distance, place fill by hand or other suitable means and compact it by
means of hand guided power rollers or tampers to avoid damage to the structures and
installations.

Around structures and other installations not designed as retaining walls, fill uniformly on
all sides and prevent unbalanced loadings.

For earth and granular fill, deposit the fill material as near as practical to its final location
and spread it in uniform layers prior to compacting. Make each layer the full width of the
fill required at its elevation, with the layer horizontal except for a slight slope to promote
surface drainage in the event of rain while the layer is exposed and except as required to
suit the required elevations of the completed fill.

For earth and granular fill, compact each layer to the required density before placing
further material on it. Conduct in-place density tests using methods outlined in ASTM
D2922 and/or ASTM D1556. Adjust and control the moisture content to the specified
requirements as determine by ASTM D698 by adding water or drying the fill material as
and when necessary. Add water and dry the fill material by means of suitable equipment
capable of producing uniform results throughout the fill material.
Distribute the materials well as far as practical so as to prevent voids and form a solid fill.
Construct the fill to full width and to the required final cross-section as placing of the fill
progresses. After initiating the fill, dump the material on the surface of the fill already
placed and push the material forward with a bulldozer or equivalent. Advance the fill with
a concave front face on the fill and the edges of the fill well in advance of the center. Do
not dump over the sides of the fill. (This method is intended to assist towards getting a
dense surface on the fill).

Where fill is placed on a sloped grade, place fill beyond the specified limit of construction
and trim back to the required grade to ensure that the fill meets the specified density
requirements.

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For concrete fill other than concrete bedding, place and cure the concrete in accordance
with ACI 301 and “Specification for Concrete Works”. Produce a dense surface but do not
trowel or otherwise make the surface smooth.

Dispose of rejected materials in the designated disposal areas only and rough grade
those materials in the disposal areas to facilitate drainage.

Supply additional fill material required for common and embankment fills from borrow pits
identified by the COMPANY.

4.13. PIPE BEDDING

4.13.1. DEFINATIONS

Bedding

The section of the trench extending from the bottom of the excavation or top of backfilled
material resulting from over-excavation to the bottom of the pipe.

Haunching

The section of the trench from the top of the bedding to the elevation of the pipe spring
line.

Pipe Cover

The section of the trench extending from the elevation of the pipe spring line to a defined
cover above the top of the pipe.

Embedment

Same material used for bedding and haunching.

Encasement

Same material used for bedding, haunching and pipe cover.


Trench Backfill

Material used above the pipe cover to close the trench.

4.13.2. EXCAVATIONS

In accordance with Section 4.11, “Excavation” and the specific requirements mention
below.

All trench excavation must be in accordance with OSHA requirements and as


recommended by the project Geotechnical Investigation report.

Unless otherwise accepted in writing by the COMPANY, the open trenches for buried
services should be limited to 30 m in advance of the installation of the services.

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Where pipes are to be placed in embankments, the pipe trench is to be excavated only
after the embankment is completed to a minimum of 600 mm or one (1) pipe diameter
above the top of pipe, whichever is greater.

Unless otherwise indicated by drawings, the minimum trench width is to be the external
pipe diameter plus 0.6 m.

The minimum bedding thickness is to be 150 mm.

If the native soil at the trench bottom is disturbed, compact to 95% of modified dry density
in accordance with ASTM D698.

If during excavation, the bottom of the trench is near or below groundwater or is soft or
unstable as defined in Section 4.6.1 remove such materials to the width and depth
indicated by the COMPANY. Lay geotextile then backfills over the excavation with
granular backfill material compacted in 150 mm layers. Cover the entire upper surface of
the granular material with a single layer of geotextile before placing bedding
aggregate/sand. For geotextiles, refer to Section 6.0 “Appendices” – Appendix 3 of this
specification.

4.13.3. FILL

1. Class AA Pipe Bedding

Material

Blinding Concrete Mix (C12/C15 – 28 days Cylindrical / Cubical compressive strength).

Placing

Not less than 150 mm depth for the full width of trench below the required underside of
pipe, leaving recesses for pipe jointing, placed immediately ahead of pipe laying; after
laying and jointing the pipe and before bottom concrete layer has set, place concrete
uniformly on both sides of pipe and to not less than 150 mm above the pipe for full width
of the trench. Reference Doc. “Specification for Concrete Works”.

Compaction

Using vibrators or equivalent. Use the proper type of concrete vibrators designed for use
on each particular application.

2. Class A Pipe Bedding (Concrete Embedment)

Materials

Blinding Concrete Mix (C12/C15 – 28 days Cylindrical / Cubical compressive strength).) –


to spring line of pipe.

Pipe Bedding Aggregate – from spring line of pipe to 300 mm above top of pipe.

Placing

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Blinding Concrete Mix (C12/C15 – 28 days Cylindrical / Cubical compressive strength). –


Not less than 150 mm depth for the full width of trench below the required underside of
pipe, leaving recesses for pipe jointing, placed immediately ahead of pipe laying; after
laying and jointing the pipe and before bottom concrete layer has set, place concrete
uniformly on both sides of pipe to the spring line of the pipe. Reference Doc.
“Specification for Concrete Works”.

Pipe Bedding Aggregate – After the concrete has set, place the granular material in layers
of 150 mm thickness before compaction. Place material simultaneously on both sides of
the pipe.

Compaction

Blinding Concrete Mix (C12/C15 – 28 days Cylindrical / Cubical compressive strength).–


by vibrator or equivalent. Use the proper type of concrete vibrators designed for use on
each particular application.

Pipe Bedding Aggregate – not less than 90% of relative density determined by ASTM
D698, with simultaneous compaction on both sides of the pipe.

Application

As specified on the drawings.

3. Class B Pipe Bedding (Aggregate Encasement)

Material

Pipe Bedding Aggregate for all encasement material.

Placing

Not less than 150 mm compacted depth for full width of trench below required underside
of pipe, placed ahead of pipe laying; after laying and jointing the pipe, place material
simultaneously on both sides of the pipe and to 300 mm over the top of the pipe in layers
not exceeding 150 mm thickness before compaction.

Compaction

Not less than 90% relative density determined by ASTM D698, with simultaneous
compaction on both sides of the pipe.

Application

As specified on the drawings.

4. Class C Pipe Bedding (Sand Encasement)

Material

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Bedding sand sub-base material.

Placing

Bedding sand of not less than 150 mm compacted depth for full width of trench below
required underside of pipe, placed ahead of pipe laying; after laying and jointing the pipe,
place bedding sand simultaneously on both sides of the pipe and to 300 mm over the top
of the pipe in layers not exceeding 150 mm thickness before compaction.

Compaction

Not less than 90% relative density determined by ASTM D698, with simultaneous
compaction on both sides of the pipe.

Application

As specified on the drawings.

5. Class CC Pipe Bedding (Sand Embedment, Common Fill Cover)

Material

Bedding sand – for embedment material (up to spring line of pipe).


Common Fill – for remainder of fill (pipe cover material).

Placing

Bedding sand not less than 150 mm compacted depth for full width of trench below
required underside of pipe, placed ahead of pipe laying; after laying and jointing the pipe,
place sand simultaneously on both sides of the pipe up to spring line of pipe. Place
common fill simultaneously on both sides of the pipe not exceeding 150 mm thickness
before compaction.

Compaction

Not less than 98% maximum density determined by ASTM D698, with simultaneous
compaction on both sides of the pipe.

Application

As specified on the drawings.

6. Class D Pipe Bedding (Common Fill Encasement)

Material

Common Fill

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Placing

After laying and jointing pipe, place common fill simultaneously on both sides of the pipe
in layers not exceeding 150 mm thickness before compaction.

Compaction

Ensure recess is in undisturbed trench bottom. Not less than 98% of modified density
determined by ASTM D698, with simultaneous compaction on both sides of the pipe.

Application

As specified on the drawings.

4.13.4. PLACING &


COMPACTION

Unless otherwise directed, perform no earthwork construction during periods of rain or


other unsuitable conditions.

If required, provide the required actions to produce satisfactory conditions to ensure


continuation of the works during rain or other unsatisfactory conditions, if such
continuation of the works is necessary to suit the contract schedule.

Remove any water which has accumulated before any bedding is placed. Dewater as per
Section 4.10.

Ensure pipe zone fill is worked in under pipe haunches. Use hand tamping if haunches
are not accessible by powered equipment.

Water jetting or hydraulic compaction shall not be permitted.

No particle size for within pipe embedment zone or backfill to be over 25 mm in its
greatest dimension.

Common backfill materials above the pipe embedment zone to be backfilled in


accordance with Section 4.12, “Fill & Compaction”.

4.13.5. FILLING AROUND AND


OVER SUBSTRUCTURES
& FOUNDATIONS

To prevent movement or damage, fill around structures and over substructures and
foundations shall be brought up evenly on each side and shall be placed over the
foundation after 7 days of casting the concrete and protective coating been applied and
that great care shall be taken with the first layers of fill over the top of the structure.
General fill layer shall be 200 mm fully compacted with mechanical rammers.

4.13.6. BACKFILLING AROUND


MANHOLES

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The space around the manhole walls and the faces of the excavation and the spaces
above the chamber roofs and around shafts shall be backfilled with selected excavated
material in layers of 200 mm loose depth and fully compacted with mechanical rammers.

4.14. CLEAN-UP

During the course of the work keep the work area clean and remove all waste and surplus
materials no longer required to areas designated and approved by the municipality.

At the completion of the works, leave the work areas clean, free of debris and remove all
equipment, waste and surplus materials from the whole site and leave the Site in a clean
and safe condition to the satisfaction of the COMPANY.

Prevent spillage of oil, fuel or other contaminants. If any spillage occurs, promptly clean
up the spillage, and disposal to be at controlled dumpsite. The CONTRACTOR is liable for
all spillages.

Dispose of used oil, used filters and other contaminants to areas designated and
approved by the municipality and in a manner satisfactory to the COMPANY.

4.15. GRADING

For grading requirements, refer to section 11 of “Civil And Structural Design Basis”.

5.0 QUALITY ASSURANCE / QUALITY CONTROL (QA/QC)

5.1 GENERAL

For the Project Quality requirements refer to “Project Quality Plan”.

5.2 SAMPLES

Samples

Obtain a sample not less than 45 kg, typical of each type of fill material from each
proposed source. With each sample, submit test results to the COMPANY confirming that
the material complies with the gradation and physical requirements specified.

The COMPANY review and acceptance of any sample will not mean approval of the entire
source. All materials supplied from any source are subject to further sampling, testing and
approval/rejection, whether incorporated into the work or not.

Test Reports

Submit test reports showing the results of gradation, moisture content, compaction,
physical requirements and other tests.

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5.3 WORKMANSHIP

Perform all work using only trained and experienced personnel.


Review by the COMPANY of CONTRACTOR’s drawings or other documents, or release
of material for shipment by the COMPANY inspector, shall not relieve the CONTRACTOR
of responsibility for compliance with the contract.

5.4 INSPECTION & TESTING


Submit an Inspection and Test Plan in accordance with this specification.

The CONTRACTOR is responsible for Quality Assurance.

CONTRACTOR is responsible for Quality Control. All testing and inspection of materials
and construction work to be undertaken by the CONTRACTOR and approved by the
COMPANY.

When individual tests fail to meet the specified standard, the frequency of testing shall be
carried out at 20 m intervals in both directions from the location of the failed samples.

No additional compensation or extension of time for completion is permitted due to time


required to make tests and to interpret results.

Where the Work fails to meet the test requirements of this specification, the
CONTRACTOR is to undertake appropriate corrective action and adjustments at its own
cost and to the satisfaction of the COMPANY.

5.6 WORK PERMITS


The CONTRACTOR shall be responsible for obtaining all permits relating to Earthworks
(excavation in particular) and shall bear all costs involved. The CONTRACTOR shall
abide by all conditions, etc. specified in the permits.

6.0 APPENDICES
Contractor has to submit the detailed method statement for the proposed compaction
trials with the proposed plant equipment to determine and optimize layer thickness,
moisture content, and number of passes required to produce compacted fill that meets the
specification requirements.

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APPENDIX 1: FIELD COMPACTION TRIALS – SUGGESTED PROCEDURE

A test area 20 m long by 15 m wide should be prepared on the actual site of construction
from which the topsoil has been removed. The fill material to be used should then be
spread over this area in three strips 5 m wide, the depth of the loose material in the strips
being varied over the range of thicknesses. Normally, the range of values investigated
would be from 150 mm to 450 mm. No adjustment should be made to the moisture
content of the fill material that, apart from minor fluctuations, should be in its natural
moisture condition.

The test area should then be compacted with the plant it has been decided to use and the
mean bulk density, moisture content and dry density of the full depth of each strip should
be determined after 2, 4 and 8 passes for all types of plant (except for sheepsfoot rollers,
for which the density and moisture content determinations should be made after 4, 8 and
16 passes). The densities of the soil should be determined by the core-cutter, sand
replacement, gamma radiation or Nuclear Density Gauge (NDG), whichever is most
suitable, and the mean of five determinations should be obtained for each soil condition.
NDG must be combined with more robust physical testing (sand replacement, core cutter
or water replacement tests) to ensure the NDG is accurate and reliable. Samples of the fill
material should be taken and the maximum dry density and optimum moisture content
determined (BS 1377).

This procedure should be repeated, if possible, at two other moisture contents, the values
suggested being the optimum moisture content given by the BS compaction test (BS
1377) and an intermediate moisture content between this value and the natural moisture
content of the soil. If the natural moisture content of the soil is similar to the optimum
moisture content, it is suggested that the additional tests be conducted at moisture
contents 3 % on either side of this value. These tests should be conducted with fresh fill
material laid on an adjacent area from which the topsoil has been removed.

The dry density and moisture content test results should be compared against the
maximum dry density that is achieved at the Optimum Moisture Content, to determine the
percentage of compaction achieved in the construction trial. This degree of compaction
should be compared with the requirements of the specification to ensure compliance. Soil
resistance to penetration can be measured to verify the compaction trials, using Cone
Penetration Test (CPT). CPT measurements shall have associated water pressure
measurements. The test procedure has been described in detail, but it can usually be
considerably shortened by noting the trend of the early results, and by the experience of
the engineers
carrying out the tests. These trials take about a week to complete and could be started as
soon as the necessary plant arrives on the site, while the preliminary clearing operations
are in progress. The trials can thus be completed before the main construction starts.
From the results of the trials and knowledge of the costs of the various procedures, it is
possible to determine the most economical procedure to be adopted to obtain the
specified degree of compaction, and the subsequent control work can then be finalised.

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APPENDIX 2: INDICATIVE COMPACTION VALUES

The following table provides the typical compaction efforts required to achieve a sufficient
degree of compaction by means of various equipment on different types of fill material.
Due to the inherent variability of fill materials and the non-standard compaction equipment
that may be proposed, a construction trial shall be carried out to confirm the proposed
method will meet the specific design requirements.

DEFINITIONS AND REQUIREMENTS ASSOCIATED WITH THE TABLE

The depth of compacted layer is the height by which the embankment is raised by each
successive compacted layer.

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The number of passes is the number of times that each point on the surface of the layer
being compacted has been traversed by the item of compaction plant.
The compactive effort of each compactor is a function of the mass of the machine and the
compaction plant. In the table above, the mass per metre width of roll is the total mass of
the roller divided by the total roller width. Where a smooth-wheeled roller has more than
one axle, the machine shall be assessed on the basis of the axle giving the highest value
of mass per metre width.
A tamping roller is a machine with a roll or rolls from which “feet” project. The projected
end area of each “foot” shall exceed 0.01 m2 and the sum of the area of the feet shall
exceed 15 % of the surface area of area of the cylinder. The requirements for a tamping
roller apply to machines that have 2 rolls in tandem. If only one tamping roll traverses
each point on the surface of the layer on any one pass of the machine, the minimum
number of passes shall be twice the number given in the table.
(i) For pneumatic-tyred rollers, the mass per wheel is the total mass of the roller divided
by the number of wheels.
(ii) In assessing the number of passes of pneumatic-tyred rollers, the effective width shall
be the sum of the widths of the individual wheel tracks together with the sum of the
spacing between the wheel tracks provided that each spacing does not exceed 230 mm.
Where the spacing between wheel tracks exceeds 230 mm the effective width shall be the
sum of the widths of the individual wheel tracks only.
F. Vibrating rollers are self-propelled or towed smooth-wheeled rollers having means of
imparting mechanical vibration to one or more rolls.
The requirements for vibrating rollers are based on the use of the lowest gear on a self-
propelled machine with mechanical transmission and a speed of 1.5 km/h to 2.5 km/h for
a towed machine, or a self-propelled machine with hydrostatic transmission. If higher
gears or speeds are used an increased number of passes shall be provided in proportion
of the increase in speed of travel.
Where the mechanical vibration is imparted to two rolls in tandem, the minimum number
of passes shall be half the number given in the table above for the appropriate mass per
metre width of one vibrating roll. If one roll differs in mass per metre width from the other,
the number of passes shall be calculated as for
the roll with the smallest value. Alternatively, the machine may be treated as having a
single vibrating roll with a mass per metre width equal to that of the roll with the higher
value.
Vibrating-type rollers operating without vibration will be classified as smooth wheeled
rollers.
Vibrating rollers shall be operated with their vibratory mechanism operating only at the
frequency of vibration recommended by the Manufacturers. All such rollers shall be
equipped or provided with a device automatically indicating the frequency at which the
mechanism is operating.
G. Vibrating-plate compactors are machines having a base plate to which is attached a
source of vibration consisting of one or 2 eccentrically weighted shafts.
The mass per unit area of base plate of a vibrating-plate compactor is calculated by its
working condition by its area in contact with compacted soil.
Vibrating-plate compactors shall be operated at the frequency of vibration recommended
by the Manufacturers. They shall normally be operated at travelling speeds of less than 1
km/h but if higher speeds are necessary the number of passes shall be increased in
proportion to the increase in speed of travel.
H. Vibro-tampers are machines in which an engine-driven reciprocating mechanism acts
on a spring system through which oscillations are set up in a base plate.
I. Power rammers are machines that are actuated by explosions in an internal combustion

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cylinder, each explosion being controlled manually by the operator.


J. In the case of power rammers and dropping-weight compactors, one pass will be considered as
made when the compacting shoe has made one strike on the area in question.

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APPENDIX 3: GEOTEXTILES

The geotextile material used for a specific application shall be based on the material
having adequate strength, permeability, thickness, porosity and roughness properties
necessary to satisfy the requirements for that application. The Manufacturer/Supplier’s
product data, including installation, handling, storage and repair instructions shall be
submitted to the COMPANY for review and approval. The installation contractor and
manufacturer experience shall also be submitted for review and approval. In locations
where there are large differences in temperature between day and night, the Method
Statement shall indicate the time of day when precautions to be taken. Typically, in these
circumstances, the lining is installed in the early morning and covered with sand to avoid
excessive rippling of the sheet due to increase in temperature during the day.

For geotextile liners that are required to be impervious, the installation contractor shall
provide approval to the design and placement of the sub-base. In addition, the following
shall also be submitted:
a) Shop drawings, which includes the following items:
 Panel layout drawing,
 Details of joining procedures,
 Special construction details;
 Anchoring details,
 Temporary anchors,
b) Qualifications and experience documentation of key field installation personnel;
c) Field inspection and handling instructions;
d) Storage requirements for the materials,
e) Sub grade acceptance criteria;
f) Seaming / welding procedures for hot wedge welding, extrusion welding);
g) Quality control testing methods and test procedure for test welds, non-destructive
seam testing, double wedge seam air pressure test, vacuum box test, non-destructive
installed sheet continuity test (if applicable), spark testing, vacuum box testing,
destructive testing;
h) Post installation general precautions to prevent damage including general
operational requirements and placement of drainage or cover material.
i) Welding of an HDPE geotextile liner shall only be permitted if the following
conditions are met:
 temperature of HDPE liner and ambient temperature are higher than 5 °C (40 °F);
 wind speed is lower than 8 m/s (18 miles/hr);
 relative humidity is lower than 90%;
 no water is present on the HDPE liner.

The friction coefficient and durability of the geotextile shall be considered when designing
slopes of topping material above the material. This is important in cold regions where the
melting conditions may cause a failure of the topping/ finishing materials. In some cases,
where an impermeable barrier is required, a three component liner is selected, where the
top and bottom layer serve to moderate any impact or liquid effects to the performance of
the geotextile layer.

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