Syabas Specification 2007

SYABAS
393257-T
SYABAS' STANDARD SPECIFICATIO N

FO R PIPE LAYING W ORKS
FIRST EDITION : M AY 2007
Prepared by :
Planning and Design Division
SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

First Edition : May 2007
STANDARD SPECIFICATION FOR PIPE LAYING WORK

TABLE OF CONTENTS
A.
GENERAL
B.
EXCAVATION
C.
HANDLING OF PIPE AND SPECIALS
D.
STEEL PIPES AND SPECIALS
E.
DUCTILE IRON PIPES AND FITTINGS
F.
HIGH DENSITY POLYETHYLENE (HDPE) PIPES AND FITTINGS
G.
ARCYLONITRILE, BUTADIENCE, STRYENE (ABS) PIPES AND FITTINGS
H.
DUCTILE IRON FERROUS SADDLES
I.
VALVES
J.
DUCTILE IRON PILLAR HYDRANTS
K.
STAINLESS STEEL WATER METER STANDS
L.
CONCRETE WORK
M.
FORMWORK
N.
STEEL REINFORCEMENT
O.
PILING WORK
P.
BRICKWORK
Q.
PAINTING WORK
MISCELLANEOUS

SECTION A: GENERAL
1.0
SCOPE OF WORKS
A.1
2.0
PROGRAMME AND PROGRESS OF WORKS
A.1
3.0
CONSTRUCTION SITE
A.1
4.0
PREPARATION OF THE WORK AREA
A.2
4.1
Detection of Existing Utilities and Services
A.2
4.2
Isolating of Valve
A.2
4.3
Trench Excavation / Cutting of Metalled Premix Road
A.3
4.4
Dewatering of Trench
A.3
5.0
REINSTATEMENT WORK
A.4
5.1
Normal Earth Shoulder
A.4
5.2
Shoulder with hard standing / tiles
A.4
5.3
Metalled Premix Road
A.5
6.0
SETTING OUT AND RE-SURVEY
A.6
7.0
PROVISION OF SURVEY INSTRUMENTS AND CHAINMEN
A.6
8.0
ORDERING MATERIALS
A.7
9.0
MATERIALS AND WORKMANSHIP
A.7
10.0
SUPPLY OF MATERIALS BY SYABAS
A.8
11.0
REQUIREMENTS OF OTHER CONTRACTOR
A.8
12.0
PUBLIC UTILITIES AND OTHER SERVICE
A.9
13.0
PUBLIC AND PRIVATE ROAD
A.10
14.0
WORK THROUGH PRIVATE LAND
A.11
15.0
CONTRACTORS FACILITIES
A.11
16.0
SAFETY AND SECURITY MEASURES
A.11
17.0
DAMAGES TO EXISTING WORK
A.12
18.0
PROTECTION OF WORKS
A.12
19.0
SITE DRAINAGE
A.12
20.0
PIPE DUMPS
A.13
21.0
FIRST AID BOX
A.13
22.0
CONTRACTORS PLANTS
A.13
23.0
CLEARING UP AND REINSTATEMENT ON COMPLETION
A.14
24.0
S.O.S APPROVAL
A.14
25.0
DAYWORK
A.14
26.0
COVERING UP OF WORK
A.15
27.0
SIGNBOARDS
A.15
28.0
CLAUSES RELATING TO WORK OR MATERIALS NOT REQUIRED IN THE WORKS
A.16
29.0
EMPLOYEES SOCIAL SECURITY ACT
A.16
30.0
DELAYS AND STOPPAGES
A.16
31.0
WARRANTY
A.16
32.0
STATUTORY HOLIDAYS
A.17

33.0
CONTRACT DOCUMENTS
A.17
34.0
EXPLANATION OF THE DOCUMENTS
A.18
35.0
CONTRACTOR'S AGENT
A.18
36.0
PROJECT DIARY
A.19
37.0
CO-ORDINATION MEETINGS AND PROGRESS REPORTS
A.19
38.0
TRANSPORT
A.20
39.0
ASSISTANCE TO SUPERINTENDING OFFICER'S REPRESENTATIVE
A.20
40.0
SUPERINTENDING OFFICER'S APPROVAL
A.21
41.0
TEMPORARY ACCESS ROAD
A.21
42.0
WORK OUTSIDE NORMAL HOURS
A.21
43.0
FORMS FOR MONTHLY STATEMENTS
A.21
44.0
TEMPORARY CONNECTIONS DURING CONTRACT PERIOD
A.22
45.0
OBVIOUS WORK
A.22
46.0
STATUTORY REGULATIONS AND APPROVAL
A.23
47.0
NOISE
A.23
48.0
DELAYED TAKING OVER
A.24
49.0
FIRE
A.24
50.0
SUPERVISION
A.24
51.0
PIPE BALANCE AND EXCESS MATERIALS
A.24
52.0
RIGHT TO OPERATE UNSATISFACTORY EQUIPMENT
A.25
53.0
SUPPLY OF CLEAR WATER FOR TESTING AND COMMISSIONING
A.25
54.0
TRAINING OF OPERATORS
A.25
55.0
LABELS
A.25
56.0
APPLICATIONS FOR PAYMENT
A.26
57.0
REQUIREMENT OF CONSTRUCTION INDUSTRY DEVELOPMENT BOARD
A.27
58.0
ENVIRONMENTAL POLICY
A.27
58.1
General Policy
A.27
58.2
Compliance with Environmental Legislation
A.27
58.3
Environmental Co-ordination
A.28
58.4
Environmental Audit
A.28
58.5
Environmental Training
A.28
58.6
Close-Out
A.29
59.0
SURVEY WORK
A.29
59.1
Scope of Services
A.30
59.2
Accuracy of Survey
A.31
59.3
Survey Plan and Scales
A.32
60.0
AS-BUILT DRAWINGS
A.32
61.0
MANUFACTURERS WORKS INSPECTION AND TESTING
A.33

SECTION B: EXCAVATION
1.0
GENERAL
B.1
2.0
SITE CLEARING
B.1
3.0
EXCAVATION GENERALLY
B.1
4.0
EXCAVATION FOR PIPE TRENCHES
B.2
5.0
ROCK EXCAVATION
B.3
6.0
USE OF EXPLOSIVES
B.4
7.0
WEATHERED ROCK EXCAVATION
B.4
8.0
UNAUTHORIZED EXCESSIVE EXCAVATION
B.4
9.0
ADDITIONAL EXCAVATION ORDERED BY THE S.O.
B.5
10.0
TIMBER LEFT IN EXCAVATION
B.5
11.0
EXCAVATION IN ROADS
B.5
12.0
CROSSING WATER-COURSES ETC.
B.6
13.0
INSPECTION
B.6
14.0
BACKFILLING OF EXCAVATIONS OTHER THAN PIPE TRENCHES
B.6
15.0
BACKFILLING OF PIPE TRENCHES
B.6
16.0
APPROVED FILL MATERIAL
B.7
17.0
ROAD REINSTATEMENT
B.7
18.0
REMOVAL OF SURPLUS
B.8
19.0
EMBANKMENTS
B.8
20.0
SOILING AND TURFING
B.9
21.0
LEVELS TO BE RECORDED
B.9
22.0
CARE OF EXISTING SERVICES
B.9
23.0
HEDGES, FENCES AND WALLS
B.10
24.0
MACKINTOSH PROBES
B.11
25.0
UTILITY SURVEYING AND MAPPING
B.11
26.0
MEASUREMENT OF GENERAL EXCAVATION
B.11
27.0
MEASUREMENT OF TRENCH EXCAVATION
B.12
28.0
MEASUREMENT OF FILLING
B.14
29.0
PAYMENT FOR TRENCH EXCAVATION AND RESTORATION
B.14
30.0
MEASUREMENT OF TOP SOILING AND TURFING
B.15
31.0
PAYMENT FOR TURFING
B.15
32.0
PAYMENT OF FEES TO AUTHORITIES
B.15

SECTION C: HANDLING OF PIPES AND SPECIALS

1.0
GENERAL
C.1
2.0
ORDER FOR PIPES AND SPECIALS
C.1
3.0
HAULING AND HANDLING
C.1
4.0
RECORDS
C.2
5.0
LAYING OF PIPES AND SPECIALS
C.2
5.1
C.2
Prospecting
6.0
PIPE ALIGNMENT AND COVER
C.3
7.0
PIPE-LAYING IN GROUNDS WITH HIGH WATER TABLE
C.3
8.0
DANGERS OF FLOTATION
C.3
9.0
TEMPORARY CESSATION OF TRENCH EXCAVATION
C.4
10.0
EXAMINATION OF PIPES AND FITTINGS
C.4
11.0
REPAIR OF LINING AND SHEATHING
C.4
12.0
LAYING PIPES AND FITTINGS
C.5
13.0
SPECIALS
C.6
14.0
PIPE CUTTING
C.6
15.0
WELDING OF JOINTS
C.6
15.1
C.6
Welding Procedure
16.0
WELDING PERSONNEL
C.6
17.0
MAKING WELDED JOINTS
C.7
18.0
AIR TESTING OF WELDED JOINTS
C.7
19.0
COMPLETION OF SHEATHING AT WELDED JOINTS
C.7
20.0
COMPLETION OF INTERNAL LINING AT WELDED JOINTS
C.8
21.0
PAYMENT FOR MAKING INTERNALLY AND EXTERNALLY WELDED SLIP AND COLLAR JOINTS
C.8
22.0
MECHANICAL COUPLING AND FLANGED JOINTS
C.8
22.1
C.8
Making Joints with Mechanical Couplings and Flange Adapters
23.0
MAKING FLANGED JOINTS
C.9
24.0
PIPELINE INSPECTION
C.9
25.0
TESTING OF PIPELINES
C.9
25.1
Testing Pipelines
C.9
25.2
Testing of MS/DI Pipelines
C.12
25.3
Testing HDPE Pipelines
C.12
26.0
PAYMENT FOR PRESSURE TESTING PIPELINES
C.13
27.0
COMMISIONING OF PIPELINE
C.13
28.0
MISCELLANEOUS
C.13
28.1
Measurement of Steel Pipes and Fittings
C.13
28.2
Concrete Protection to Pipes
C.14
28.3
Thrust and Anchor Blocks
C.14
28.4
Valve Chambers
C.14
28.5
Crossing Over Streams, Culvert and Rivers
C.15

29.0
30.0
28.6
Swabbing of Pipelines
C.15
28.7
Sterilization of Pipelines
C.15
28.8
Flushing of Pipelines
C.16
28.9
Payment for Sterilizing Pipelines
C.16
28.10
Clearing Up
C.16
28.11
ABS Maker Posts
C.16
28.12
Painting Pipe-work and Valves in Chambers
C.17
28.13
Painting Pipework Above Ground
C.17
28.14
Payment of Fees to Authorities
C.17
PIPE JACKING
C.17
29.1
General
C.17
29.2
Performance Requirements
C.18
29.3
Approval of Owner
C.19
29.4
Jacking Operation
C.19
29.5
Safety
C.20
29.6
Design of the Jacking Pipes
C.21
29.7
Welding of Pipe in the Field
C.21
29.8
Grouting at Welded Joints
C.22
29.9
Internal Lining at Welded Joints
C.23
27.10
Connections at Ends of Jacked Pipeline
C.23
HORIZONTAL DIRECTIONAL DRILLING METHOD PIPE INSTALLATION
C.23

SECTION D: STEEL PIPES AND SPECIALS

1.0
2.0
3.0
4.0
GENERAL REQUIREMENTS
D.1
1.1
Scope
D.1
1.2
Definition
D.1
1.3
Standards and Codes of Practice
D.1
1.4
Submissions
D.2
GENERAL REQUIREMENTS OF PIPES AND FITTINGS
D.3
2.1
Pipes and Fittings
D.3
2.2
Steel Pipes
D.3
2.3
Workmanship and Welding Standards
D.5
2.4
Jointing of Pipes
D.5
2.4.1
D.5
Pipe Ends
2.5
Flanged Joints
D.6
2.6
Mechanical Couplings, Flange Adaptors and Expansion Joints
D.7
2.7
Pipes for Closing Lengths
D.8
2.8
Collars
D.8
FITTINGS AND SPECIALS
D.8
3.1
D.8
Bends, Tees, Tapers etc.
PIPELAYING AND HANDLING
D.9
4.1
Pipe-work for Laying Above Ground
D.9
4.2
End Protection
D.9
4.3
Handling
D.9
4.4
Protection in Transit
D.10
4.5
Inspection
D.10
4.6
Markings of Pipes and Fittings
D.10
4.7
Measurement
D.11
4.8
Miscellaneous
D.11
4.9
Physical Testing
D.11
4.10
External Coating
D.11
4.11
Wrapping
D.11
4.12
Inspection of External Pipe Coating
D.12
4.13
Painting Coated Pipes and Fittings
D.12
5.0
SPUN CONCRETE LINING AT FACTORY
D.12
6.0
INTERNAL PROTECTION AT PIPE ENDS
D.14

SECTION E: DUCTILE IRON PIPES AND FITTINGS

1.0
GENERAL
E.1
2.0
PIPES
E.1
3.0
MANUFACTURING PROCESS
E.1
4.0
DIAMETER AND SHELL THICKNESS
E.2
5.0
COATING AND LINING FOR PIPES
E.2
6.0
INTERNAL LINING OF CEMENT MORTAR
E.3
7.0
RUBBER RING / GASKETS
E.4
8.0
TESTING AND INSPECTION
E.4
9.0
PACKING
E.4
10.0
MARKING ON DUCTILE IRON PIPES
E.4
11.0
PRE- DELIVERY INSPECTION AND EVALUATION
E.5
12.0
CERTIFICATION
E.5
13.0
JOINTING AND ASSEMBLY
E.5
13.1
Jointing Instruction
E.5
13.2
Method of Assembly
E.7
14.0
CUTTING
E.7
15.0
OVALITY CORRECTION
E.11
16.0
HANDLING OF LOOSE POLYETHYLENE SLEEVING ADDED PIPE
E.11
17.0
JOINT PROTECTION METHOD OF TYTON AND K TYPE JOINTS
E.13

SECTION F: HIGH DENSITY POLYETHYLENE (HDPE) PIPES AND FITTINGS

1.0
GENERAL
F.1
2.0
MATERIAL
F.2
3.0
COLOUR
F.3
4.0
PIPE CLASSIFICATION AND DIMENSION
F.3
5.0
TOLERANCE
F.4
6.0
LENGTH
F.4
7.0
APPEARANCE
F.4
8.0
ROUTINE TESTS
F.5
9.0
PIPE MARKINGS
F.5
10.0
PIPE FITTINGS
F.5
10.1
Types of pipe fittings
F.5
10.2
Spigot Fittings
F.5
10.3
Electrofusion Fittings
F.6
10.4
Mechanical Joints and Fittings
F.6
10.5
Backing Ring (Slip On Flange) to suit HDPE Pipe
F.8
10.6
Storage
F.9
10.6.1 Storage At Depot
F.9
10.6.2 Storage On Site
F.10
11.0
PRE DELIVERY INSPECTION AND EVALUATION
F.10
12.0
HANDLING, TRANSPORT AND STORAGE
F.10
12.1
General
F.10
12.2
Transport and Delivery
F.11
12.3
Off Loading
F.11
12.3.1 Bundled Pipes
F.11
12.3.2 Coiled Pipes
F.11
12.3.3 Fittings
F.12
13.0
CERTIFICATION
F.12
14.0
HDPE PIPE JOINTING
F.12
15.0
JOINTING BY BUTT FUSION
F.12
15.1
General
F.12
15.2
Butt Fusion Jointing Equipment
F.18
15.2.1 Butt Fusion Jointing Method
F.20
Electrofusion Socket Jointing
F.24
15.3.1 General
F.24
15.3.2 Equipment
F.24
15.3.3 Electrofusion Jointing Procedure
F.25
15.3

15.4
15.5
16.0
17.0
18.0
19.0
20.0
Electrofusion Saddle Jointing
F.26
15.4.1 General
F.26
15.4.2 Equipment
F.27
15.4.3 Electrofusion Saddle Jointing Method
F.27
Mechanical Joints
F.29
MAIN HDPE PIPE LAYING
F.30
16.1
Preparation Of Pipes
F.30
16.2
Laying Of Pipes
F.30
INSTALLATION OF SERVICE PIPES
F.31
17.1
General
F.31
17.2
Laying of Communication Pipe
F.31
CONNECTION TO HDPE PIPE
F.32
18.1
Connection to HDPE Pipe
F.32
18.2
Connection to Pipes of Other Materials
F.32
JOINTING OF SERVICE PIPES
F.32
19.1
Jointing of HDPE Service Pipes
F.32
19.2
Jointing of Dissimilar Service Pipes
F.32
19.3
Testing and Commissioning of Service Pipes
F.33
REPAIR METHODS
F.33
20.1
Repairs To HDPE Pipe
F.33
20.1.1 General
F.33
20.1.2 Emergency Repairs
F.33
20.1.3 Permanent Repairs Using Fusion Joints
F.34
20.1.4 Permanent Repairs Using Mechanical Joints
F.34
20.1.5 Repairs to HDPE Service Pipe
F.34
20.1.6 Squeeze-Off Closure Technique
F.34

SECTION G: ACRYLONITRILE, BUTADIENCE, STYRENE (ABS) PIPES AND

SPECIALS
1.0
GENERAL
G.1
2.0
COLOUR
G.3
3.0
SCOPE OF SUPPLY
G.3
4.0
SOLVENT CEMENT
G.5
5.0
JOINTING
G.5
6.0
SUPPORT
G.6
7.0
SAFETY PRECAUTION
G.7
8.0
JOINTING PROCEDURE
G.8
9.0
NOTES ON JOINTING
G.9
10.0
USAGE OF SOLVENT CEMENT
G.10
11.0
SOLVENT CEMENT WELDING DRYING TIMES
G.10
12.0
SOCKETS
G.11
13.0
PIPE MARKINGS
G.11
14.0
INSTALLATION OF SADDLES
G.11
15.0
CONNECTIONS ABS TO OTHER PIPE SYSTEMS
G.12
16.0
FLANGED JOINTS
G.12
17.0
THREADED CONNECTIONS
G.13
18.0
INSTRUMENTATION CONNECTIONS
G.14
19.0
BURIED PIPES
G.15
20.0
HYDROSTATIC PRESSURE TESTING
G.16

SECTION H: DUCTILE IRON FERROUS SADDLES

1.0
GENERAL
H.1
1.1
Scope
H.1
1.2
Referenced Documents
H.1
1.3
Definitions
H.3
1.3.1
Ferrous Saddle
H.3
1.3.2
Polyamide Adaptor
H.3
1.4
2.0
Types of Ferrous Saddle
H.3
1.4.1
Saddle Type A
H.3
1.4.2
Saddle Type B
H.3
1.5
Illustration
H.4
1.6
Materials.
H.4
1.6.1
Body
H.5
1.6.2
Bolt, Nut and WasherM.
H.5
1.6.3
Sealing Gasket
H.5
1.6.4
Polyamide Adaptor
H.5
1.7
Effect of Non-Metallic Products on Water Quality
H.5
1.8
Workmanship
H.5
1.8.1
Casting
H.5
1.9
Nominal Sizes
H.6
1.10
Dimension and Tolerances
H.6
1.10.1 Boss Dimensions
H.6
1.10.2 Tapping Dimensions
H.6
1.10.3 Bolts, Nuts and Washer Dimensions
H.6
1.10.4 Sealing Gasket Dimensions
H.6
PROTECTION AGAINST CORROSION
H.7
2.1
Surface Preparation
H.7
2.2
Degreasing
H.7
2.3
Abrasive Cleaning
H.7
2.4
Pre-Treatment
H.7
2.5.
Coating
H.8
2.5.1
General
H.8
2.5.2
Body
H.8
2.5.3
Fasteners
H.8
2.6
Coating Application
H.9
2.7.
Tests on Applied Protections
H.9

3.0
Holiday Test
H.9
2.7.2
Cure Test
H.9
2.8
Repair
H.9
2.9
Sampling
H.9
2.10
Protection Against Damage in Storage; Transport and Handling
H.10
TESTING
H.10
3.1
H.10
3.2.
4.0
2.7.1
Testing
3.1.1
Test Requirement
H.10
3.1.2
Strength Testing
H.10
3.1.3
Functional Testing
H.10
3.1.4
Corrosion Testing
H.11
3.1.5
Water Absorption Test
H.11
3.1.6
Cathodic Disbondment test
H.11
3.1.7
Adhesion Test
H.11
3.1.8
Chemical Resistance Test
H.12
3.1.9
Visual Inspection
H.12
3.1.10 Short Term Pressure Testing
H.12
Production Testing
H.12
MARKING
H.12
4.1
H.12
Marking

SECTION I: VALVE
1.0
2.0
3.0
GENERAL
I.1
1.1
Approved makes and Brand of Valves
I.1
1.2
Drawings
I.1
1.3
Manufacturing Report and Instruction Manuals
I.2
1.4
Quality Assurance
I.3
1.5
Notice of Deliveries
I.4
1.6
Marking
I.4
1.7
Inspection
I.4
1.8
Delivery, Install and Commission
I.5
1.9
Site Conditions
I.5
1.10
Valve Agent
I.5
MATERIAL AND WORKMANSHIP
I.6
2.1
Standard and Codes of Practice
I.6
2.2
Materials
I.7
2.3
Samples and Test on Samples
I.7
2.4
Test Certificates
I.8
2.5
Independent and Local Tests
I.8
2.6
Testing Facilities
I.9
2.7
Certificates of Quality and Warranty
I.9
2.8
Rejected Material
I.9
REQUIREMENT
I.10
3.1
General Requirement
I.10
3.2
Valve, Fittings and Actuators
I.13

SECTION J: DUCTILE IRON PILLAR HYDRANT

1.0
GENERAL
J.1
2.0
TYPE OF PILLAR HYDRANT
J.1
3.0
MATERIALS
J.1
4.0
DIMENSIONS
J.2
5.0
COATING
J.4
6.0
TESTING
J.5
7.0
MARKING
J.5
8.0
ACCESSORIES
J.5
9.0
FLANGE JOINTS
J.6
10.0
PRE-DELIVERY INSPECTION AND EVALUATION
J.6
11.0
CERTIFICATION
J.6
12.0
PACKAGING
J.7
APPENDIX 1
J.8
APPENDIX 1A
J.9
APPENDIX 2
J.10
APPENDIX 2A
J.11
APPENDIX 3
J.12
APPENDIX 4
J.13
APPENDIX 5
J.14
STANDARD INSPECTION PROCEDURE (BLASTING)
J.18
APPENDIX 6
J.22
APPENDIX 7
J.25

SECTION K: STAINLESS STEEL PIPE AND WATER METER STANDS

1.0
GENERAL
K.1
2.0
MATERIAL
K.2
2.1
Pipework for Stainless Steel Meter Position
K.2
2.2
Pipework for Plumbing
K.3
2.3
Concreting
K.5
3.0
DIMENSIONS & THREADING REQUIREMENTS
K.5
4.0
TESTS AND INSPECTION
K.5
5.0
MARKING FOR METER POSITION
K.5

SECTION L: CONCRETE WORK

1.0
CONCRETE
L.1
1.1
Scope
L.1
1.2
Concrete Production at the Site
L.1
1.3
Test Certificates
L.1
1.4
Aggregate Samples
L.2
1.5
Records of Concreting
L.2
1.6
Concrete Mixes
L.2
1.7
Construction Joints and Lifts
L.2
1.8
Cement
L.3
1.9
Storage of Cement
L.3
1.10
Aggregates
L.4
1.11
Storage of Aggregates
L.4
1.12
Water
L.5
1.13
Admixtures
L.5
1.14
Test Equipment
L.6
1.15
Grades of Concrete
L.6
1.16
Free Water/Cement Ratio
L.7
1.17
Limits of Salt Content
L.7
1.18
Workability
L.7
1.19
Design of Concrete Mixes
L.8
1.20
Trial Mixes
L.8
1.21
Material Batching
L.9
1.22
Mixing Concrete
L.11
1.23
Ready-Mixed Concrete
L.11
1.24
High ALumina Cement
L.11
1.25
Preparing for Concreting
L.11
1.26
Transporting Concrete
L.12
1.27
Placing Concrete
L.12
1.28
Concreting in Hot Weather
L.12
1.29
Compaction
L.13
1.30
Attendance of Steel Fixer and Carpenter
L.13
1.31
Curing of Concrete
L.13
1.32
Construction Joints
L.14
1.33
Dimensions and Surfaces of Finished Concrete
L.14
1.34
Unformed Surfaces
L.15
1.35
Building in Plant and Grouting- in
L.16
1.36
Structural Precast Concrete
L.16
1.37
Installation of Precast Concrete Units
L.17
1.38
Prestressed Concrete
L.18

1.39
No-Fines Concrete
L.18
1.40
Precast Concrete Products
L.19
1.41
Sampling and Testing of Aggregate
L.19
1.42
Sampling and Testing of Concrete
L.20
1.43
Compliance with Specified Requirements
L.20
1.44
Non-Compliance
L.20
1.45
Cutting and Testing of Core Samples
L.21
1.46
Inspection Procedures
L.21
1.47
Concrete Protection Systems
L.22
1.48
Concrete Protection Procedures
L.24
1.49
Machinery Bases and Closure of pocket
L.24
1.50
Measurement of In-Site Concrete
L.25
1.51
Measurement of Form Opening of Build in Plant
L.25
1.52
Measurement of Grouting Back The Opening
L.26
1.53
Measurement of Precast Concrete
L.26
1.54
Sizes and Sequence of Concrete Pours
L.26
1.55
Cleaning to Water Retaining Structures
L.27
1.56
Testing of Water Retaining Structures
L.27
1.57
Disinfection of Water Retaining Structures
L.28
1.58
Chlorine Bearing Solution/Mixture for Disinfection
L.29
1.59
Sealing Compounds
L.30
1.60
Joint Fillers
L.30
1.61
Waterstops
L.31
1.62
Movement Joints
L.31
1.63
Structural Tests
L.32

SECTION M: FORMWORK
1.0
GENERAL
M.1
1.1
Scope
M.1
1.2
Submissions
M.1
1.3
Materials
M.1
1.4
Design and Detailing
M.1
1.5
Formed Surfaces - Class of Finish
M.2
1.6
Erection of Formwork
M.2
1.7
Removal of Formwork
M.3
1.8
Building in Plant
M.4
1.9
Dry-Pack Mortar
M.4
1.10
Defects in Formed Surfaces
M.5
1.11
Movement Joints
M.6
1.12
Sliding Planes and Joints
M.7
1.13
Inspection and Testing
M.8
1.14
Measurement of Formwork
M.8

SECTION N: PILING WORK

1.0
2.0
3.0
4.0
1.1
General
N.1
1.2
Soil Investigation Reports
N.1
1.3
Handling of Piles
N.1
1.4
Pitching and Driving of Piles
N.1
1.5
Pile Driving Plant
N.1
1.6
Extension of Piles
N.2
1.7
Piling Programme
N.2
1.8
Records
N.2
1.9
Nuisance and Damage
N.3
1.10
Safety Precaution
N.3
1.11
Definition
N.3
PRE-CAST REINFORCED CONCRETE PILES
N.4
2.1
General
N.4
2.2
Reinforcement
N.4
2.3
Pile Shoes
N.4
2.4
Formwork and Casting of Pile
N.5
2.5
Curing, Stripping, Handling and Storage of Piles
N.5
2.6
Tolerance in Piles Dimension
N.5
2.7
Length of piles
N.6
2.8.
Pitching and Driving
N.6
2.9
Repair and Lengthening of Piles
N.7
2.10
Cutting and Stripping Pile Head
N.8
STEEL H-BEARING PILES
N.8
3.1
Pile Sections and Dimensions
N.8
3.2
Straightness of Piles
N.8
3.3
Strengthening of Piles
N.8
3.4.
Marking of Piles
N,9
3.5
Handling and Storage of Piles
N.9
3.6
N.9
3.7
Lengthening of Piles
N.9
3.8
Preparation of Pile Heads
N.9
PRESSURE TREATED TIMBER PILES.
N.9
4.1
Species of Timber
N.9
4.2
Definitions
N.10
4.3
Quality
N.10
4.4
Sizes
N.03
4.5
Workmanship
N.10
4.6
Preservative Treatment
N.10
4.7
Inspecting and Testing
N.10

5.0
4.8
Marking
N.10
4.9
Warranty
N.11
4.10
Delivery and Stacking
N.11
4.11
Pile Head
N.11
4.12
N.11
4.13
N.12
4.14
Defects on Piles while Driving
N.12
4.15
N.12
PILE TESTING
N.12
5.1
General
N.12
5.1.1
Type of Tests Necessary
N.12
5.1.2
Safety Precautions
N.12
5.2
Definitions
N.12
5.2.1. Compression Pile
N.12
5.2.2
Anchor Pile
N.13
5.2.3
Test Pile
N.13
5.2.4
Reaction System
N.13
5.2.5
Kentledge
N.13
5.2.6
Maintained Load Test
N.13
5.2.7
Constant Rate of Penetration Test (CRP)
N.13
5.3
Supervision
N.13
5.4
Reaction System
N,13
5.4.1
General
N.13
5.4.2
Kentledge
N.13
5.4.3
Anchor Pile and Ground Anchor
N.14
5.5
Testing Equipment
N.14
5.6
Preparation of a Working Pile to be Tested
N.15
5.6.1
General
N.15
5.6.2
Driving Records
N.15
5.6.3
Cut-off Level
N.15
5.6.4
Pile Head of Compression Test
N.15
5.6.5
Notice of Test
N.16
5.7
Settlement Measurement
N.16
5.8
Test Procedure
N.16
5.8.1
General
N.16
5.8.2
N.16
5.8.3
Constant Rate of Penetration Test
N.17
5.9
Presentation of Results
N.17

5.10
5.9.1
Submission of Results
N.17
5.9.2
Schedule of Recorded Data
N.17
Interpretation of Test Results
N.18
O.18
5.12
5.11.1 Measuring Equipment
N.18
5.11.2 Kentledge
N.18
5.11.3 Ground Anchors and Temporary Piles
N.19
Load Testing of Bakau Piles
N.19
5.12.1 General
N.19
5.12.2 Arrangement of Test Piles
N.19
5.12.3 Pile Cap
N.19
5.12.4 Test Procedure.
N.19
5.12.5 Interpretation of Results
N.19

SECTION O: STEEL REINFORCEMENT

1.0
GENERAL
O.1
1.1
Scope
O.1
1.2
Submission
O.1
1.3
Steel Reinforcement
O.1
1.4
Steel Wires and Bars for Prestressing
O.1
1.5
Accessories
O.2
1.6
Detailing
O.2
1.7
Cutting and Bending of Reinforcement
O.2
1.8
Storage of Reinforcing Bars and Fabric
O.2
1.9
Storage of Prestressing Wire and Bars
O.2
1.10
Fixing of Reinforcement
O.3
1.11
O.3
1.12
Measurement of Steel Reinforcement
O.4

SECTION P: BRICKWORK
1.0
GENERAL
P.1
2.0
MORTAR
P.1
2.1
General
P.1
2.2
Cement
P.1
2.3
Admixtures
P.1
2.4
Sand
P.2
2.5
Water
P.2
3.0
BRICKS
P.2
4.0
BRICKWALLING
P.2
5.0
BOND
P.3

SECTION Q: PAINTING WORK

1.0
General
Q.1
2.0
Painting to Metal Works
Q.2
3.0
Painting to Masonry Works
Q.2
4.0
Completion of Painting Work
Q.3

SECTION R: MISCELLANEOUS
1.0
Fence and Gate
R.1
2.0
Manholes and Valves Chambers
R.2
3.0
Pre-cast Chambers
R.3
4.0
Washout
R.3
5.0
Indicator Post
R.3
SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WOKS

A- GENERAL
1.0
SCOPE OF WORKS
The Works covered in this Contract comprise the provision by the Contractor at his
own risk and cost which comprise all materials, scaffoldings, tools, plants, labour,
transports, water, power, profit and attendance, overhead and everything else
necessary for the construction and completion of the Works to the entire approval of
the Superintending Officer hereinafter referred to as the S.O.
The Conditions of Contract for the Works, which is embodied in the Form of
Contract, shall be read in conjunction with this Specification. If the Tenderer
considers that any of the clauses in the Conditions of Contract involves additional
expenses not covered elsewhere, the Tenderer shall allow for monetary value for
such clauses in his Tender, otherwise, it will be deemed to have been included.
2.0
PROGRAMME AND PROGRESS OF WORKS

Within 30 days after the acceptance of tender, the Contractor shall submit to the
S.O. for his approval three (3) copies of a detailed programme in Microsoft Project
format showing the time order, procedure and method in which the Contractor
propose to carry out the Works, and shall whenever required by the S.O. or his
representative, furnish for his information particulars in writing of the Contractors
arrangement for carrying out such work and other construction plants and temporary
works if any, which the Contractor intends to supply, use or construct as the case
may be. The submission to and approval by the S.O. or his representative of such
programme or the furnishing of such particulars shall not relieve the Contractor of
any of his duties or responsibilities under this Contract.
If at any time it should appear to the S.O. that the actual progress of the Works does
not conform to the approved programme referred to herein, the Contractor shall
produce, at the request of the S.O. a revised programme showing the modifications
to the previously approved programme necessary to ensure the completion of the
whole Works within the time set for completion.
3.0
CONSTRUCTION SITE
The location of the Site is shown on the Drawings. The Contractor shall be deemed
to have inspected the Site before tendering and to take into account all the
conditions there, such as means of access, facilities for transport, storage and
movement of plants and materials, and any other contingencies liable to affect his
tender price, as no claim for extra payment in this connection will be entertained.
The Contractor shall be liable for and shall indemnify SYABAS against any damage,
expense, liability, loss, claim or proceedings whatsoever whether arising at common
law or by statute in respect of personnel injury to or death of any person
whomsoever or to any property arising out of or in the course of or by reason of the
visit to the Site.
P:\zRAZMANN\SPEC\A-GENERAL1.DOC
A.1

4.0
PREPARATION OF THE WORK AREA
4.1
Detection of Existing Utilities and Services

The Contractor shall investigate, and have full knowledge of the position of existing
utilities and underground services such as drains, pipes, electric cables, culverts, etc.
He shall take all necessary precaution as part of his work. He shall undertake the
following:-
4.2
i.
Detailed utility detection using radio and or ultrasonic machine. The drawings
must be submitted to the S.O in 2 set in A1 size, coloured to differentiate the
type of services. The type of utility, size and depth shall be clearly indicated.
ii.
Where necessary, trial pits and exploration trenches to ascertain the exact
portions of these services shall be excavated, well ahead of pipe repair /
maintenance excavation, in places where they are known or thought to be and
elsewhere and these shall be backfilled with approved materials.
iii.
All damages to the existing services shall be made good to the satisfaction of
SYABAS and the relevant authorities. SYABAS shall be identified against any
action taken against the Contractor/developer due to their negligence.
Isolation of Valves
Before any excavation, SYABAS representative and the Contractor shall jointly locate
all value pipelines in the area. (This is based on their working knowledge of the water
distribution system or based on maps / water reticulation plan of the area and / or from
their past experience).
1. Ascertain the type, size and estimated length of pipe that may be affected due to
the excavation and repair works. The information will enable the maintenance
team to mobilize the appropriate tools, spare parts, etc. The information will be
important in estimating the volume of water loss due to pipe bursts or pipe leaks .
2. Sketch the location plan and the distribution network layout in a Record Form for
updating and record purposes.
3. SYABAS representative shall identify all isolating and scour valves affected by the
pipe to be repaired as well as valves located in the vicinity. It is important to
ensure that water scouring will not result in flooding of the area, in particular the
area for excavation.
Prior to excavation, shut the isolating valves as identified. As a direct effect, the
pipeline pressure will drop and hence, water will stop. When this has been
confirmed, the scour valves may be opened to discharge the remaining water
from the main prior to excavation work.
4. However, if water pressure neither drops nor leakage subsides after closing of
the identified valve, then SYABAS representative and his team may need to
locate any possible unknown inter-connections.
A.2

5. When the inter-connections have been identified, the isolating valve shall be
shut to facilitate repair work. Update the sketch of the pipe layout in the attached
Record Form. The sketch shall then be submitted to SYABAS representative upon
completion.
4.3
Trench Excavation / Cutting of Metalled Premix Road

The trench shall be excavated by such method as allowed by SYABAS for proper
maintenance and repair work.
1. Trench excavation shall be carried out by such methods and to such lines,
dimensions and depths to allow for the proper construction of the works.
2. As a general guide, the approximate width of trench excavation is as per Table1.
Table1: Width of trench and road cutting based on pipe diameter
Pipe OD with sheathing
(D) mm
< 500 mm
> 500 mm but < 750mm
> 750mm
Clear width of trench

excavation
Clear width of metalled

premix road cut
D + 450 mm
D + 600 mm
D + 900 mm
D + 1050 mm
D + 1200 mm
D + 1500 mm
3. Under no circumstances shall the Contractor be allowed to place excavated

materials by the road-side. Excavated materials shall be carted away to a waiting
lorry and transported to dump site to be determined by the Contractor.
4. In cases where the trench depth exceeds 1.5 m, sheet pile wall or strutting of
trenchs wall shall be provided to prevent any untoward incident such as cave in
from happening.
4.4
Dewatering of Trench
The Contractor shall note that certain parts of the pipeline may be laid in ground with
high water table, especially in areas adjacent to the streams, river crossings and ponds.
1. The Contractor shall allow cost for dewatering and keeping all the excavations and
trenches dry for the pipeline repair work to be carried in a safe manner during the
execution of the work.
2. Dewatering shall be carried out using dewatering pump with long hose. The
dewatering pump shall have the capacity to drain a trench ( 1m x 1m x 1.5m )
within 5 minutes ( 70 igpm ).
A.3

5.0
REINSTATEMENT WORK.
Reinstatement work for the following types of road shoulder are described
accordingly.
1. Normal earth shoulder.
2. Shoulder with hardstanding / tiles.
3. Metalled premix road.
5.1
Normal earth shoulder

1. Excess water shall be pumped out from the trench using suitable sized pump
before any maintenance and repair work is carried out.
2. Under no circumstances shall soft and unsuitable materials be used as backfill
materials.
3. Approved backfill shall be compacted in layer of 150 mm thick. The plate type
compactor shall be used.
4. After backfilling has reached approximately 100mm below the existing ground
surface, the existing top soil is shall reinstated.
5. The finished ground level shall be slightly higher than the original ground level.
6. All surplus materials shall be removed from the site.
Please refer to Arahan Teknik No. 1 for diagrams of section and plan view of the
reinstatement works.
5.2
Shoulder with hard standing / tiles

1. The affected hard standing / tiles shall be cut using road cutter.
2. Excess water shall be pumped out from the trench using suitable sized pump
before any maintenance and repair work is carried out.
3. The trench will then be backfilled with approved sand, sufficiently watered
down and compacted in layers of 150 mm thick. Plate type compactor shall be
used.
4. The backfilling of compacted sand shall be carried out to a level suitable to
receive crusher run.
5. 300 mm thick crusher run shall be laid on top of the compacted sand.
Compaction of crusher run shall be carried out using Plate type compactor.
6. Compaction of the crusher run and premix, especially on the road pavement,
shall be carried out using vibratory roller.
7. Any over-break of concrete hard standing and tiles is to be cut square.
8. Concrete screed shall then be laid on top of the compacted crusher run and
level adjusted to suit the existing ground level.
9. All surface finishes shall be reinstated to their original conditions.
Please refer to Arahan Teknik No. 1 for diagrams of section and plan view of the
reinstatement work.
A.4

5.3
Metalled premix road

1. The affected metalled premix road shall be cut using road cutter.
2. Excess water shall be pumped out from the trench using suitable size pump before
any maintenance and repair work is carried out.
3. After the pipe has been repaired, the trench shall then be backfilled with sand,
sufficiently watered down and compacted in 150 mm layers. Sand shall be laid in
150 mm layers on both sides of the pipe simultaneously and thoroughly compacted
around the pipe alternately on either side of the pipe until it reached the base course
of formation level. Compaction shall be carried out using Plate Compactor.
4. Crusher-run is to be laid in layers of 150 mm thick. Compactions of crusher run
shall be carried out using a Plate Compactor. The crusher run shall be reinstated to
the original thickness of the road, but subject to a minimum thickness of 300 mm.
5. Additional make-up crusher run shall then be added to the excavated area and
compacted accordingly.
6. After the whole surface of the crusher run has been compacted, the surface shall
be brushed to remove loose stones and debris.
7. A layer of bituminous tack coat shall be applied at a rate of not less than 270
ml/m2, paying particular attention to all square cut edge and all around manhole
to be installed where applicable.
8. The premix shall be reinstated to its original thickness ranging from 60 mm to 100
mm thick ACWC 20 depending on the Class of the road.
9. All compaction of premix shall be carried out using a Plate Compactor.
10. Make-up premix shall be added 3 days after the completion of the work to
reinstate settlement.
Please refer to Arahan Teknik No. 1 for diagrams of section and plan of the
reinstatement works.
6.0
SETTING OUT AND RE-SURVEY

The Contractor shall be responsible for the true and proper setting out of the Works
and for the correctness of the positions, levels, dimensions and alignment of all parts
of the Works as stipulated in the Conditions of Contract (Form PWD 203ARev.10/83).
Before the commencement of the Works, the Contractor shall undertake
topographical survey of the area and forward this information to S.O, in order for
S.O. to establish the lines and level of the Works. The Contractor shall verify the
dimensions and levels shown in the Drawings and shall notify the S.O. of any
discrepancy, which may affect the dimensions or levels of any part of the Works.
After clearing and grubbing, and before any excavation of any part of the Site is
carried out or the Works thereon begun, the Contractor shall take and record level
of any such parts, in the manner specified or as agreed with the S.O. shall form the
basis of measurement and payment. The Contractor shall carry out to the S.Os
instructions all extra surveys required to resolve any doubts, which may arise as to
the correctness of any survey or record and the S.Os decisions shall be final
regarding what shall be recorded as the correct dimensions and levels.
A.5

The levels and dimensions, which have been agreed by the S.O, shall form the basis
of measurement for the appropriate Works.
7.0
PROVISION OF SURVEY TEAM AND CHAINMEN

The Contractor shall provide and maintain for the sole use of the S.O., a survey team
led by a registered surveyor complete with instruments and chainmen. All
instruments and equipment shall be in good operational condition, duly calibrated.
Thus, may call upon their services any time, to provide surveys of any site and the
surveyor shall prepare the drawings in the specified format. He shall endorse the
drawings he has prepared as part of his professional services.
Additional instruments to be provided and kept available by the contractor are as
follows:
Aluminium leveling staff 5 metres long in 1 sections with attached bubble,
sopwith reading 1 no.
Flexible steel tape 4 metres long on plastic case, graduated in metres and
millimeters - 1 no.
Linen tape 30 metres long in leather graduated in metres and millimeters 1
no.
The Contractor shall provide as many full time or part-time chainmen as may be
required by the S.O.
8.0
ORDERING MATERIALS
The Contractor shall be responsible for placing his orders for all materials and
articles required to be supplied by him at the earliest possible date for the
completion of this Contract.
Before placing any order for materials or articles to be incorporated in the Works,
the Contractor shall submit to the S.O. for his approval, a complete description of
such items and the names of the suppliers from whom he propose to obtain them.
Where so directed, the Contractor shall submit samples and test certificates for
approval. The Contractor shall not place any order without the approval of the S.O.
which may be withheld until samples have been submitted and satisfactorily tested.
The source of supply shall be approved by the S.O.
Additional testing of materials and complete pipes, fittings and specials may be
carried out at any time by the S.O. Any of the materials, pipes, fittings and special
not complying with this Specification shall be rejected by the S.O.
Unless specifically provided for in the Specification or the Bill of Quantities, the cost
of any testing including the supply of materials, pipes and fittings carried out on
A.6

samples submitted by the Contactor shall be borne by SYABAS. If, the tests show
that the materials, pipes and fittings to be not in accordance with the requirements
of this Specification, the said batch of material will be rejected. The contractor shall
remove all the rejected materials out of the site immediately. For further quality
control, the S.O may require testing of other materials, whether installed or not. The
cost of testing shall be boned by the contractor. If results show similar trend, then
the material must not be further used. The contractor must demonstrate how
rectification measure can be implemented on all installed items.
9.0
MATERIALS AND WORKMANSHIP

All materials and articles to be incorporated in the Works shall be new and of the
kind and quality described in the Contract and shall be at least equal to the
approved samples.
In all cases where materials and articles are specified to comply with Malaysian
Standards or British Standards, the Contractor shall, if required, obtain from the
manufacturers and supply the S.O. the appropriate certificate of compliance with the
Standard.
The Contractor shall use materials and articles of Malaysian origin to the exclusion
of imported materials and articles. The Contractor shall allow for this special
requirement in the Tender. Under no circumstances will the Contractor be permitted
to use imported materials and articles unless the Contractor can prove to the
satisfaction of the S.O. that local materials and articles are not of an acceptable
standard.
If no Standard is indicated, the relevant Malaysian Standard, British Standard or
other Standard shall apply in the order of priority as listed.
10.0
SUPPLY OF MATERIALS BY SYABAS

If the Contractor fails for any reason to supply any materials, which the Contractor
has contracted to supply or if he fails to supply any such materials in sufficient time
to enable the Contract to be completed by the agreed Date for Completion, then in
either event SYABAS may supply any portion, or all of such materials.
If the Contractor fails for any reason to supply any materials, the cost in respect
thereof to be borne by the Contractor shall be either the current market rate or the
actual cost to SYABAS and any other charges, whichever is the greater.
The cost to be borne by the Contractor as detailed above shall be deducted from
monies due or to become due to the Contractor under this Contract. No claim for
lost of profit under the Conditions of this Contract shall be deemed to have arisen.
No action taken by the S.O. under this clause shall, in any way, affect or modify the
right of SYABAS to claim for damages in the event of the Contractors failure to
complete the Works by the agreed Date of Completion.
A.7

11.0
REQUIREMENTS OF OTHER CONTRACTOR

The Contractor shall afford every facility to other contractors on the Site and to allow
them to carry out their work unhindered. The Contractor shall maintain constant and
careful liaison with them to ensure the correlation of the respective Programmes of
Works and the accurate laying and building-in of pipes, formation of ducts, and the
likes as the Works proceed. The S.O. will do everything possible to assist in the
maintenance of this liaison and co-operation and the Contractor shall be prepared to
assist in the progress of the Works by other Contractors generally by carrying out
construction and laying operations in the order required.
The Contractor shall take all reasonable precautions to avoid any damage to other
Contractors work and/or property. The Contractor shall be entirely responsible for
making good, at his own expense, any such damage caused by, or due to, any
action or lack of action on the part of the Contractor.
No claims for extra shall be entertained for any additional work, which arises
through lack of co-operation between the Contractor and other Contractors.
All costs involved in complying with this Clause shall be deemed to have been
covered by the Contract Rates or Sum unless specifically provided for in the Bill of
Quantities.
12.0
PUBLIC UTILITIES AND OTHER SERVICE

a. If utility is given as a guide, then the client shall not be held for any responsibility.
b. The Contractor shall be responsible for locating all services including drains, pipes,
cables and the like whether above or below ground level and shall adopt such
methods of working as will ensure that no damage is caused to the services. The
Contractor shall make good at his own expense any damage whatsoever to existing
services resulting from his operation to the approval of and in accordance with the
instructions of the authority or owner concerned and shall keep SYABAS
indemnified at all times from all claims which may be bought against SYABAS for or
on account of any damage to the said services.
The cost of deviating or realigning any of these services shall not be borne by the
Contractor but the Contractor shall provide and maintain at his own expense any
temporary works necessary to support or protect the services affected by his
excavation to the satisfaction of the authorities or owners concerned.
The Contractor shall attend to the authorities or owners concerned and afford them
all facilities necessary to enable them to undertake any work required to deviate
those services or to prevent interruption of such services during the progress of the
Works.
All costs involved in complying with this Clause shall be deemed to have been
covered by the Contract Rates or Sum unless specifically provided for in the Bill of
Quantities.
A.8

13.0
PUBLIC AND PRIVATE ROAD

All operations necessary for the execution of the Works and for the construction of
any temporary Works shall, so far as compliance with the Contract permits, be
carried out so as not to interfere unnecessary or improperly with the convenience or
the access or use and occupation of public or private roads and footpaths or to or of
properties whether in the possessions of the SYABAS, the Government or of any
other person and the Contractor shall save harmless and indemnify SYABAS and the
Government in respect of all claims, demands, proceedings, damages, costs, charges
and expenses whatsoever arising out of or in relation to any such matters.
No private road or footpath shall be blocked or obstructed by the Contractor without
the prior consent of the owner/ occupier and the prior approval of the S.O.
No public road shall be blocked or obstructed by the Contractor without the prior
consent of the authorities and the prior approval of the S.O.
The Contractor shall be responsible for providing, operating and maintaining all
traffic signs, traffic control signals, barriers and lightings as detailed in the Drawings
unless otherwise directed by the S.O. The signs, barriers and lightings shall be
repositioned or removed as required during the progress of the Works.
If the Contractor fails to comply with the requirements of this Clause, the S.O. may
carry out such works as he deems necessary and to charge the Contractor with the
actual cost including any other charges. Such cost and charges shall be deducted
from any monies due or which may become due to the Contractor under this
Contract, and the Contract Sum shall be adjusted accordingly. No action by the S.O.
under this Clause shall relieve the Contractor of his obligations or affect or modify
the right of SYABAS under the Contract.
14.0
WORK THROUGH PRIVATE LAND

The Contractor shall be responsible for obtaining the consent of private owner and
occupier to the use of such land or private roads for temporary access to the working
space along the pipeline route or for other temporary purpose. Before entering
private land for the purpose of commencing construction, the Contractor shall
confirm in writing to the S.O. that he has obtained such consent.
The Contractor shall pay all costs, expenses, retails, compensations or any other
disbursements required of him in complying with this clause. No reimbursement
will be made to the Contractor in this respect. The Contractor shall note his
responsibility to the Conditions of Contract shall apply to the whole of the land
occupied or used by him for the purpose of the works.
15.0
CONTRACTORS FACILITIES
The Contractor shall, at his own expense, provide and maintain in good condition
throughout the Contract Period such temporary buildings, tanks, stores, temporary
sanitary conveniences, access roads and other facilities as may be necessary for the
execution, completion and maintenance of the Works. The location of all such
A.9

facilities shall be subjected to the approval of the S.O. All such facilities shall
comply with the requirements of the Local Authorities.
16.0
SAFETY AND SECURITY MEASURES

The Contractor shall take all necessary safety precautions on the Site and shall
conduct his operations on the Site and shall conduct his operations in a manner so
as to ensure the safety of the S.O. and his staff, the Contractors employees and the
public.
The Contractor shall, at his own expense, provide and maintain to the approval of
the S.O. all notices, warning signboards, fencing, watching and lighting necessary to
ensure the security of the Works and the safe keeping of the materials and tools
stored on the site. If required by regulation or authorities, a qualified and
experienced safety officer to the SOs approval shall be deployed. The rates is
deemed included as part of the contract.
17.0
DAMAGES TO EXISTING WORK

The Contractor shall be responsible for any damage to road verges, drains, ditches,
turfing areas, or other structures, which may result from the construction work or the
passing of his vehicle, plants or equipment of whatever kind to or from the Site of
the Works. The contractor shall make good such damage at his own expense
immediately after it occurs to a standard acceptable to the S.O.
Any existing structures and obstructions, which are designed to be removed shall be
demolished, broken up, removed and disposed off as approved by the S.O.
18.0
PROTECTION OF WORKS
From the commencement of the Works until the date stated in the Certificate of
Practical Completion for the whole of the Works, the Contractor shall take full
responsibility for the care thereof. In case of damage, loss or injury to the Works, or
any part thereof, from any cause whatsoever, the Contractor shall, inform the S.O in
writing. He shall make proposals, submit method statement for the S.Os approval.
After the S.O. has consented to the work, the contractor shall at his own cost, repair
and make good the same so that at completion the permanent works shall be in
good order and condition in every respect as per requirements of the Contract. The
contractor is not allowed to undertake any repair work until he has received specific
instruction from the S.O. The S.O. shall also not delay his approval unless he has
specific reasons or comments on the proposed rectification measures.
19.0
SITE DRAINAGE
The Contractor shall make proper provision for the drainage of water from the Site of
the works including rainfall run-off from surrounding areas, which drain onto the
Site.
A.10

The Contractor shall at no extra cost to SYABAS provide, form, fix, maintain and
work as and where directed by the S.O. such pumps, chutes, walls, drains, bunds
silt traps and other temporary works necessary for the proper drainage of the Site so
that no flooding, silting or other damages or disturbances is caused in the areas
surrounding the Works or to the Works for the duration of the Contract.
20.0
PIPE DUMPS
The Contractor shall be solely responsible to find a suitable pipe dumps and stores
to store the pipes, valves and fittings supplied by or to the Contractor.
The Contractor shall allow in his Contract Rates for expenses incurred in locating,
hiring, preparation and reinstatement to original condition of pipe dumps and stores.
The Contractor shall be responsible for obtaining the consent of the owner, tenants
or occupier of lands to the use of such land for storing of the pipes, valves and
specials. The Contractor shall pay all cost, expenses, rental, compensation or other
disbursement, which may be incurred by him in negotiations with the owner, tenant
or occupier and during the subsequent use by him of such land for these purposes.
No reimbursement will be made to the Contractor in this respect. The full cost
thereof shall be deemed to be included in the Contract Rates.
21.0
FIRST AID BOX

The Contractor shall be required to provide a complete approved first aid outfit and
shall keep it in a metal box in his Site Office. The outfit shall be in the charge of
either the Contractors Site Representative or some other responsible person who
will be on the Site during all working hours to ensure that the first aid outfit is
available without delay at all times when work is in progress. The person in charge
of the first aid box shall be trained in simple first aid duties.
22.0
CONTRACTORS PLANTS
All mechanical plants used by the Contractor in the execution of the Works shall be
of such type, size and method of the working as the S.O. shall approve.
The S.O. shall not unreasonably withhold approval for the use of any plant but if, in
the S.Os opinion, circumstances arises which made it desirable that the use of any
plant should be suspended either temporarily or permanently, the Contractor shall
change the method of performing the work affected at the Contractors own cost and
the Contractor shall have no cause for claim if any order issued by the S.O. result in
any plant having to stand idle for a period of any duration whatsoever or having to
be removed from the Site.
23.0
CLEARING UP AND REINSTATEMENT ON COMPLETION

On completion of the Works, the Contractor shall dismantle and remove from the
Site, all his plant, equipment, temporary buildings and unused materials. The
Contractor shall fill in and make good all holes and temporary excavations, dig up
A.11

and remove all temporary roads if directed, clean out all gutters, clear away all
rubbish, and leave the whole of the Site of the Works in a clear and tidy condition
acceptable to the S.O.
The Contractor shall clean and wash all windows, paintwork, walls and floors, and
shall leave permanent buildings, tanks and other structures in a clean and tidy
condition ready for use by SYABAS.
24.0
S.O.S APPROVAL
Any S.Os approval given to any portion or stage of the Works shall not absolve the
Contractor from his liability to make good any defects which may be discovered or
occur subsequently during the Defects Liability Period of the Contract.
25.0
DAYWORK
The S.O. may order in writing that any additional or substituted work be executed
on a day-work basis. The Contractor shall then be paid for such work under the
conditions set out in the Day-work Schedule included in this Contract and at the
rates and prices agreed to by both parties.
The Contractor shall furnish to the S.O. such receipts or other vouchers as may be
necessary to prove the amounts paid and before ordering materials shall submit to
the S.O. quotations for the same for the S.O.s approval.
In respect of all work executed on a day-work basis, the Contractor shall during the
continuance of such work deliver each day to the S.O. an exact list in duplicate of
the names, occupation and time of all workmen employed on such work and a
statement also in duplicate showing the description and quantity of all materials and
plants used thereon or therefore. Upon agreement by the S.O., one copy of each list
and statement shall be signed by the S.O. and returned to the Contractor. At the end
of each week the Contractor shall deliver to the S.O. a priced statement of the
labour, materials and plant used. All price statements, which have been agreed to
between the Contractor and the S.O. shall be incorporated in the subsequent
certificate or payment.
The rates shown shall include all allowances for administration and profit, all
traveling and accommodation expense, statutory overheads such as EPF
Contributions, SOCSO, holiday pay, annual and sick leave as appropriate where
these apply. Rates shown for Plant shall be the complete compensation required by
the Contractor for the operation of this Plant, including the cost of the operator, fuel
and transportation and maintenance.
In the case of materials used in labour work, the Contractor shall be paid the
complete on site cost of any materials used, plus a maximum allowance of fifteen
percent to cover purchase of material and organization by the Contractor etc
including profits.
Payments for day labour work will only be certified for the actual hours worked. No
payment will be made for standby time caused by inclement weather.
A.12

26.0
COVERING UP OF WORK
Before any part of the Works be permanently covered up, the Contractor shall give
due notice to the S.O. of his intention. The S.O. shall, without unreasonable delay,
examine and measure if necessary, the said part of the Works unless the S.O.
considers it unnecessary and advises the Contractor accordingly.
27.0
SIGNBOARDS
Where specified in the Bill of Quantities, the Contractor shall provide, erect, paint
and maintain signboards as shown on the relevant drawing or as directed by the
S.O. The signboard shall be erected at a prominent position at the site as approved
by the S.O. and the Contractor shall pay all charges in connection with this,
including obtaining permission, licences and fees etc.
On completion of the project, the Contractor shall dismantle and clear away the
signboard as directed by the S.O.
28.0
CLAUSES RELATING TO WORK OR MATERIALS NOT REQUIRED IN THE

WORKS
Any clauses in this Specification, which related to work or materials, not require in
the Works shall be deemed not to apply.
29.0
EMPLOYEES SOCIAL SECURITY ACT

Notwithstanding anything to the contrary contained elsewhere in the Contract
Documents, the Contractor shall cause all Sub-Contractors whether nominated or
otherwise to comply with the requirements of the Employees Social Security Act,
1969 as described under Clause 35 of the Conditions of Contract (PWD 203A Rev.
10/83) The Contractor shall be responsible to submit to the S.O. whether demanded
or not, the Employers Code Numbers of the Sub-Contractors and Social Security
Numbers or copies of Form 2 or Form 3 if the Social Security Numbers are not yet
available, of all employees employed by them.
30.0
DELAYS AND STOPPAGES

All delays and stoppages in the progress of the Work arising from disputes as to the
quantity of materials, the insufficient supply of materials, plants, etc and all damage
or injury caused to the work of the Contract, or to the adjoining or adjacent works,
buildings, streets, land, etc, in consequence of such delays and stoppages shall be
solely and entirely at the risk and cost if the Contractor.
31.0
WARRANTY
A.13

The accepted tender under this Contract shall deemed to warrant that,
notwithstanding that any part of the equipment supplied has been satisfactorily
factory tested and/or inspected on site before installation, if any equipment or part
thereof shall fail to perform its specified function under test or during the Contract
Defects Liability Period, and it is determined that such failures are the responsibility
of the Contractor, then all costs of replacing all faulty equipment or parts thereof
shall be borne by the Contractor.
For equipment supplied but not manufactured by the Contractor, a guarantee shall
be provided by the Contractor that he shall arrange any necessary repair or
replacement of defective equipment that fails within the warranty period of the
installation, free of charge.
The operation staff, using the knowledge gained during the Contractors training
scheme and using the documentation supplied, will endeavour to identify any faulty
equipment or sub-assemblies held as a spare part and will return these, at the
Contractors cost using his nominated freight carrier, for repair by the Contractor.
If the operating staff is unable to determine the cause of any system problems with
telephone assistance from the Contractor, the Contractor shall dispatch at his cost
within 3 days, if the system is totally inoperative, or within 10 days for a fault
affecting only redundant equipment, specialist engineering staff to remedy the
problem.
The Contractor is required to provide, within the Warranty period, a maximum 3
day turnaround (excluding weekends) on all repairs and/or equipment replacement.
The operating staff will not undertake any repairs unless authorised by the
Contractor.
32.0
STATUTORY HOLIDAYS
Extension of time will not be allowed for statutory holidays.
33.0
CONTRACT DOCUMENTS
The Contractor shall be deemed to have fully examined the Contract Documents,
have read each and every Clause and all details therein and have had full
opportunity to consider the same and make necessary investigations in relation
thereto. He shall not make any claims or any other occasion because of
misunderstanding of the Contract Document or because of lack of information.
If the Contractor considers that any of the conditions and/or instruction in the
Contract Document involves additional cost, he shall allow for the same in the
Tendered Price as no claim extra in this connection will be entertained.
All parts and sections of the Specification shall be read in conjunction with one
another and unless particularly specified otherwise, the provisions and requirements
A.14

of any Clauses under any one section apply to the Works under the Contract where
Work is of as similar nature.
Drawings are included in the Contract Document. Further drawings may be issued
to the Contractor as work progresses.
34.0
EXPLANATION OF THE DOCUMENTS

In the event that additional information is required, the Contractor shall make a
written request for the details required by him. A period of two (2) weeks shall be
allowed by the Contractor for the details to be prepared and delivered to him.
No claims for costs arising from delays to the job will be entertained where in the
opinion of the S.O. a delay has occurred through the Contractors failure to comply
with the requirements of this clause.
35.0
CONTRACTOR'S AGENT
A competent, duly authorised, and responsible site agent or representative of the
Contractor shall be appointed. The agent's name, qualification and experience shall
be submitted to and approved, in writing, by the S.O. prior to appointment and who
shall have full authority to act for and bind the Contractor. The agent shall reside on
the Site and shall have an office thereon. This agent shall attend at the S.O.s office
at all reasonable times when required to do so. He shall be fluent in Bahasa
Malaysia or English and all correspondence will be conducted in either of these
languages.
The agent shall be stationed on the site for the duration of the contract. If Contractor
desires to replace his agent, the name of the proposed new agent shall be submitted
to the S.O. for approval prior to replacement.
In the event of the agent being absent from the works for any period exceeding 3
consecutive days, he shall notify the S.O. in writing of the name of his responsible
and fully authorized deputy. In any case, the agent shall always inform the S.O. in
advance, should he intend to be absent from the Works.
36.0
PROJECT DIARY
The Contractor shall keep a daily project diary, which shall record the major events
of each day. The format shall be approved by the S.O.s Representative and as a
minimum, it shall include:Weather record for the day
Number of operatives present on site; categorised by trade or skill
Number of items of major plant; giving make, model and physical location on
site
The locations and description of major activities on site
At the end of each week the Contractor shall give a copy of that weeks diary to the
S.O. duly signed and dated.
A.15

37.0
CO-ORDINATION MEETINGS AND PROGRESS REPORTS

Meeting shall be convened by the S.O. from time to time to facilitate co-ordination
of various works necessary for completion of this Contract. The Contractor shall
attend the meetings when so directed in writing by the S.O.
Any person attending the meeting on behalf of the Contractor shall be deemed to act
on the Contractors behalf, and any agreements made shall be binding on the
Contractor.
The Contract sum shall include allowance for attendance at monthly meetings or
any other meetings called during the cause of this Contract.
At monthly intervals, the Contractor shall submit to the S.O. four (4) copies of the
written detailed progress report in the form of up-dated progress chart in Microsoft
Project and supported by other bar charts indicating the stages of work in all main
operation as aspects, design, ordering of materials, manufacture, inspection and
delivery. These reports shall be accompanied by such additional information in
approved standard form, as may be required by the S.O. The report shall reach the
S.O. before the seventh of each new month. The reports shall be forwarded
promptly so that on receipt by the S.O., the information contained therein is not
more than 7 days out of date.
38.0
TRANSPORT
The Contractor shall provide and keep available at all times during the period of
construction and such times during the period of maintenance as shall be required
by the S.O.'s Representative, in the performance of his duties in this Contract the
following means of transport:i)
ii)
New 4-door four wheel drive manually geared petrol vehicles of not less than
1300cc capacity complete with air-conditioner and other necessary
accessories.
New motorcycles of not less than 100 cc. Each motorcycle shall be equipped
with two crash helmets.
The quantities required shall be as stated in the Bill of Quantities.

On completion of the Contract, the vehicles will be reverted to the Contractor. In
the event of the vehicles breaking down or otherwise not being available, the
Contractor shall within 24 hours provide alternative vehicles of a similar type.
The vehicles shall be comprehensively insured to permit the Contractor's drivers and
the S.O.'s Representative to drive or ride.
The Contract Rates for transport shall cover all costs of providing running and
upkeep of the transport including depreciation, taxes, comprehensive insurances,
licenses, fuel, oils, lubricants, repairs and maintenance.
A.16

39.0
ASSISTANCE TO SUPERINTENDING OFFICER'S REPRESENTATIVE

The Contractor shall render all necessary assistance to the S.O.'s Representative and
shall provide and maintain a sufficient supply of pegs, poles, sight rails, paint, lines,
spirit levels, stores, and tool sets required for checking the setting out of the Works,
as well as suitable protective clothing, rubber boots and the like. The Contractor
shall provide as many full time or part time chainmen as may be required.
The cost of the labour, plant and materials required by the S.O.'s Representative's
staff for checking the setting out of the Works, inspection and supervision of the
Works, and for the sampling and testing of materials for which no separate item is
provided in the Bills of Quantities, shall be included in the Contract Rates generally.
40.0
SUPERINTENDING OFFICER'S APPROVAL

Wherever the S.O.'s approval is given to any portion or stage of the Works before
the succeeding portion or stage of the Works is allowed to be carried out, such
approval shall not absolve the Contractor from his liability to make good any
defects, which may be discovered or occur subsequently during the Defects Liability
Period of the Contract.
41.0
TEMPORARY ACCESS ROAD

The Contractor shall at his own expense and risk provide, operate and maintain to
the satisfaction of the S.O. all temporary roads used by him and his vehicles for
access to the site. These access roads shall be maintained such that access to the
site is possible at all times for the S.O. by means of light vehicles.
The Contractor shall also be entirely responsible for any damage caused by his staff
to any other roads used for access to the site and obtaining any approval from the
authorities in connection with the use of the road.
42.0
WORK OUTSIDE NORMAL HOURS

No work shall proceed outside normal working hours without the prior approval of
the S.O. and such other Statutory Authorities as may be required. This applies to
work before 7.00am on any day or later than 5.30pm on any day, and on Sundays,
and Public Holidays. The Contractor shall be liable for payment to the S.O. for cost
of any additional supervision or inspections made necessary by work outside the
time specified.
It is anticipated that works may have to be carried out during the night and the
Contractor shall allow all necessary cost in executing work at night.
43.0
FORMS FOR MONTHLY STATEMENTS

Monthly statements submitted pursuant to the Conditions of Contract may be
proposed and prepared by the Contractor or adopted from any format approved by
the S.O. Such forms shall be provided by the Contractor and shall be printed to the
A.17

approval of the S.O. as soon as practicable after the receipt of the S.O.'s Order to
commence the works. Each statement shall be fully detailed and six (6) copies shall
be submitted to the S.O. through his Representative.
44.0
TEMPORARY CONNECTIONS DURING CONTRACT PERIOD

The Contractor shall make his own arrangements for supply of water and power
required for the Works. All costs associated with the supply of water and power
supply shall be paid by the Contractor and shall be priced accordingly.
Should the Contractor wish to connect to any water mains where such mains exist,
the Contractor shall obtain the express approval of the S.O. in each and every
instance. The repair of damage occasioned by the Contractor to any water supply
fixture of fitting shall be charged to the Contractor.
The Contractor shall arrange for and pay all costs connected with the installation of
temporary power supplies for use during the Contract Period. The cost of all power
used shall be borne by the Contractor.
Contractor shall be responsible to ensure water and power supply are made
available all the time including during testing and commissioning. All cost incurred
will be charged to the Contractor accordingly.
45.0
OBVIOUS WORK
The intent of this Contract includes the survey, preparation of detailed drawings or
shop drawings, manufacture, test, supply, erection and commissioning of all pipes
and fittings for the proper completion and operation of the Works. Notwithstanding
that these documents have been drawn up with all possible care, if any details of the
Works have not been included within this Specification or detailed on the Drawings
but the necessity of which might reasonably be implied from the above stated intent,
and, such details are usual or essential to the completion of the Works, the same
details shall be deemed to be included within this Contract whether so particularly
itemised or specified or detailed or not, at NO additional cost to the Contract.
The word `approved' or `to be approved' used in conjunction with equipment or
material, the make of which is not defined, shall mean that the S.O., shall select or
reject a type from samples or drawings, which the Contractor shall provide and that
the S.O. decision shall be final.
46.0
STATUTORY REGULATIONS AND APPROVAL

The Works and all Plant, Equipment and materials forming part of this Contract shall
comply in all respects with the relevant Malaysian Statutory Regulations, Bye-Laws
and Orders currently in force; and the Contractor's attention is drawn particularly to
the Regulations of the Machinery Department, Chief Electrical Inspectors
Department, Tenaga Nasional Berhad, Suruhanjaya Tenaga, local authorities, JKR,
etc.
A.18

The Contractor shall be responsible for obtaining the necessary approvals from the
relevant Departments and Authorities for all items of Works under this Contract. It
shall also be deemed that the Contract Price includes the attendance to local
authorities, Chief Electrical Inspector, Fire Officer, the Machinery Inspector, etc. and
all costs to ensure conformity with current regulations of the above-named
Departments. The approval of Equipment and materials by the relevant authority
shall not prejudice the right of the S.O. to reject such Equipment or materials which
may not comply with the Specification.
The supply of all danger notices, warning notices, etc. to the requirements of the
Chief Electrical Inspector and other relevant Departments or Authorities shall be
included in the Contract.
The Contractor shall allow for and obtain all necessary permits and licenses, etc.
required from the relevant authorities in connection with the carrying out of the
works and pay all deposits, fees, royalties in connection therewith. The Contractor
shall also allow for the costs of arranging for inspection by officials of Local
authorities from time to time during the Contract period and defect liability period.
47.0
NOISE
The S.O. operates and enforces a policy of noise reduction. The Contractor is
required to adopt this policy. Prior to the use of any plant or the commencement of
any noisy work on the site, the Contractor is required to submit a noise assessment
report. These are to be agreed with the S.O. and relevant authorities.
The Contractor shall comply with the NR Ratings stipulated by the Department of
Environment (Kementerian Sumber Asli dan Alam Sekitar).
48.0
DELAYED TAKING OVER

If, due to circumstances beyond the control of the Contractor, the Works cannot be
put into service on completion or Commissioning and Acceptance Tests cannot be
carried out on completion of works, the Defects Liability Period as defined in the
Conditions of Contract shall commence either from the date on which the tests on
completion are carried out or from the date on which the Works are put into service,
whichever is the earlier.
49.0
FIRE
All rubbish, packing, discarded or surplus materials shall be removed from the site
periodically and shall not be burned on site.
50.0
SUPERVISION
The Contractor or his authorised representative shall be fully responsible to ensure
all the works included in the Contract are faithfully executed and commissioned in
accordance with the provisions of the Contract Documents.
A.19

The Clerk of Works, Inspector or Resident Engineer (R.E) appointed for the purpose
of supervising work under this Contract will be responsible for:-
51.0
(i)
Keeping records of the progress of the work as required by the S.O.
(ii)
Inspecting the works in progress from time to time to ensure accord with the
design intent.
iii)
Verifying and recording the quantity of any works carried out by day labour
under a variation order or for the purpose of monthly payment.
PIPE BALANCE AND EXCESS MATERIALS

The Contractor shall be responsible for pipe balance and excess materials. The rate
for transportation and removal of excess materials to Contractors own site is
deemed to be provided for in the Bills of Quantities, unless otherwise specified.
The Contractor is required to submit in a format to be agreed with the S.O.s
Representative details of materials supplied, laid, left over and loss items, all to be
incorporated in an overall pipe balance list. The said list shall be endorsed by the
Contractor and the S.O.s Representative and attached to the Final Certificate for
submission to the S.O.
Pipe balance and excess materials shall not be measured for payment.
A.20

52.0
RIGHT TO OPERATE UNSATISFACTORY EQUIPMENT

Irrespective of accepted works testing by certificate and/or witness, the Contractor
shall be responsible for ensuring that the equipment installed on site performs as
guaranteed and specified. Equipment that fails to meet these requirements shall be
made good at no cost to the S.O. Equipment that continues to fail to meet the
required performance as guaranteed and specified shall be liable to rejection and
shall be replaced by the Contractor at no cost to the S.O. The S.O. reserves the right
to continue using the rejected Plant or Equipment until the replacement is available
at no additional cost to the Contract.
53.0
SUPPLY OF CLEAR WATER FOR TESTING AND COMMISSIONING

Upon completion of installation, the Contractor shall supply clear water at his own
cost for testing and commissioning of the works until the completed Works are
handed over to the S.O.
54.0
TRAINING OF OPERATORS
Following the complete acceptance testing of all the Equipment installed under the
Contract, and satisfactory commissioning of the Plant, the Contractor shall give full
training to the plant operators in the proper procedures for operation and
maintenance of all items of Equipment provided under the Contract. The Contractor
shall allow in his Tender Price for such training to be carried out.
55.0
LABELS
When instructed by the S.O., mechanical equipment items shall have an
identification plate securely fixed to the body. The identification plates and labels
shall be of approved non-corrodible metal and the data shall be engraved or
stamped. Neither glue fastening nor painted nor printed on data shall be acceptable.
Data required for mechanical equipment shall include the manufacturer, the date of
manufacture, the country of manufacture, the operating conditions and supply
conditions that might be applicable.
The direction of opening of valves shall be permanently indicated by arrows on
handwheels or operating levers. All valves shall be clearly labelled with the
appropriate function and identification.
56.0
APPLICATIONS FOR PAYMENT

Unless instructed otherwise by the S.O., each of the Contractor's applications for
payment pursuant to the Conditions of Contract shall be numbered consecutively
and shall be submitted in minimum six (6) identical copies to the S.O.'s
Claim shall be accompanied by Bill of Quantities giving the following detailed
particulars: -
A.21

(a)
Every item for which payment (in whole or in part) is being claimed up to the
date of the application, listed in the manner and in the order of the Bill of
Quantities.
(b)
The amount of payment being claimed in respect of each item (quantities or

percentage of Works completed to be stated where appropriate),justification of
proof of completed works or stages of completion, sketches, drawings, etc.
(c)
Details of Variation Orders, if any, approved by the S.O., with the amounts to
be added or deducted in respect of each,
(d)
A summary of Day-work, if any, ordered by the S.O.,
(e)
A summary (or Summaries), grouped in the same manner as in the Schedule of

Prices, showing the total gross value of work done to the date of the
application,
(f)
The deduction in respect of retention money, details being given where

necessary,
(g)
The resulting net total amount claimed,
(h)
The deduction in respect of amount previously certified for payment,
(i)
The resulting amount claimed as payment due on the application.
(j)
The provision of pipe logs properly endorsed by all parties.
A fixed date for measurements shall be agreed upon with the S.O. on a monthly
basis for which measurements for Works completed are conducted. This fixed date
shall not vary from month to month without the prior and written consent of the
S.O.
The application for payment shall be duly certified by the S.O.'s Representative and
the Contractor's Site Agent.
57.0
REQUIREMENT OF CONSTRUCTION INDUSTRY DEVELOPMENT BOARD

The Contractor is required to be registered with the Construction Industry
Development Board (CIDB) and shall undertake to pay the Board a levy on fee in
accordance with the latest requirement.
A.22

58.0
ENVIRONMENTAL POLICY
58.1
General Policy
The Contractor shall implement an Environmental Quality Management (EQM)

programme within one (1) month of award of the contract, the contractor shall
provide details, the methodology and procedures for effective management of
environmental impact during the design, construction, reclamation and maintenance
of the project. The EQM Programme shall conform to SYABAS Policy and be
subject to the S.O.s approval.
58.2
Compliance with Environmental Legislation
The Contractor shall comply with all applicable laws, regulation, guidelines and
terms and condition of approvals issued by the Deputy of Environment. The EQM
shall cover both the construction stage and operation stage, addressing, among other
things, to submit report and the application of the Occupational Safety and Health
ACT 1994, Occupational Safety and Health (Use and standards of exposure of
Chemical Hazardous to Health/Regulation 2000-JKKP Dept), Environmental Quality
Act and Regulation, Occupational Safety and Health (Control of Industrial Major
Accident Hazards) Regulations 1996 (or CIMAH Regulations), the Emergency
Response Programme (ERP) and Erosion and Sediment Control Plan (ESCP). The
Contractor shall take into account the condition of approval of the scheme issued by
Jabatan Alam Sekitar when preparing the EQM.
58.3
Environmental Co-ordination Plan
The Contractor shall develop an Environmental Co-ordination Plan (ELP) that

describes the environmental co-ordination procedures and implementation of the
EQM programme. This Environmental Co-ordination Plan shall be submitted to the
S.O.s Representative by Contractor, for approval. The Plan shall be for the duration
of the Contract award. It will outline but not necessary be limited to:
a)
b)
58.4
How environmental matters will be address during engineering design?

How environmental protection procedures will be implemented during all
phases of construction?
Environmental Audit
The Contractor, in consultation with the S.Os Representative, shall develop

procedures for the audit of performance of the Work. Contractor shall permit free
access at all times to S.Os Representative for the completion of environmental
audits of performance. The Contractor shall expect, at anytime, worksite visits and
compliance audits of regulatory terms and conditions by the Department of
Environment (DOE). The Contractor shall develop procedures to address these sites
visits and shall notify S.Os Representative supervisory personnel of the intent and
content of any meetings, discussion and correspondence with the Department of
Environment.
A.23

58.5
Environmental Training
The Contractor shall provide on site construction inspection and audit training for
Engineers or Supervisors designated by S.Os Representative. The purpose of the
training is to provide S.Os Representative personnel with a complete understanding
of environmental inspection and co-ordination of all phases of construction
reclamation and maintenance activities. The Contractors environmental specialist
will co-ordinate the training activities and report to the S.Os Representative on the
status and progress of training.
58.6
Close-Out
Upon completion of work, the Contractor shall hand over all minutes of meetings,
correspondence, reports and other records pertaining to discussion meetings, site
visits and compliance audits by the Department of Environment (DOE).
On an on-going basis, the Contractor shall keep the S.Os Representative informed
of all communications and correspondence with the Department of Environment
(DOE). Upon completion of the activities, the Contractor shall hand over to S.Os
Representative, copies of all minutes of meetings, correspondence, reports and
records pertaining to dealing with such parties.
59.0
SURVEY WORK
The Contractor shall engage a licensed surveyor registered with the Institution of
Surveyors to carry out ground survey of the work.
Complete topographical survey of the site shall be completed within 30 days after
the acceptance of the tender. This information shall be forwarded to S.O. for design
updating.
Survey works shall include:
Planimetric control
Height control
Monumenting
Strip survey corridor of minimum 20m
Longitudinal profiling
Presentation of survey data shall be according to standard pipeline survey format
(plan and longitudinal section) including overall plan approved by the S.O. Three (3)
sets of the drawings shall be issued in hard copy format (A1 size), three (3) sets of
the drawings in A3 size and soft copy format (ACAD drawings in drawing format).
All hardcopy drawing shall be signed and stamped by a registered surveyor.
The Contractors surveyor shall update the survey data during the construction for
preparation of as-built drawings, which shall include
Recording of actual work done.

A.24

Cost for this survey works shall include provision of drawings and CDs.
59.1
Scope of Services
The scope of service to be provided by the Surveyor shall include:(a)
Obtaining all necessary topographical maps, certified plans, revenue sheets
(b)
Discussions with the relevant authorities before commencing the Works
(c)
Study all relevant information and maps provided/available and obtain

additional data if necessary for the proper execution of the Works
(d)
Set out a control traverse connecting the above to the nearest State Grid net
and provide height control from existing bench marks (BM)
(e)
Set out a control traverse for the proposal pipeline route carry out a strip
survey at 1m contours and setting out of routes
(f)
Establishment of Special Types of Reference Marks
(g)
Performance of all fields survey works necessary to locate accurately the

location and dimensions of the following features
i.
Locations and description of all topographic features such as roads,

tracks, mines and a description of surface features
ii.
Location and extent of all existing grave sites, burial plots and holy
ground, if these are evident on the ground
iii.
Location and extent of all existing and proposed structures which will
influence the design of the scheme to the extent that such information is
available, at the time of survey, from the Local Offices of the Authorities
concerned.
iv.
Location and depth, within the specified survey of all existing service
conduits both overhead and exposed such as water mains, Tenaga
National Berhad (TNB) cables, drainage pipes or channels (indicating
discharge direction), Telecom cables; including location of all associated
chambers, valves, valve boxes, pits, inspection chambers and other
similar appurtenances.
v.
Location and extent of swampy and waterlogged areas as can be

determined at the time of survey
vi.
Bridges and culverts
A.25

The following information and details are required only where relevant to design of
pipelines.
i.
Cross-section and plan views showing reduced levels of the structure,

details of wing-walls, headwalls, piers, pavement width and existing
service conduits. Maximum flood levels should be indicated (to the
extent that this is obtained from local sources) and source of information
to be advised.
ii.
Highest known flood level of the area surveyed
iii.
Baseline from which reference can be made, preferably to tie up with

existing boundary stones.
iv.
Any other information which may be required for design
v.
Property boundary stones within the specified survey shall be located. If

found, they should be tied to the proposed control traverse line
(h)
59.2
Preparation of drawings suitable for design.

Accuracy of Survey
All work shall conform to the standard of accuracy given below and any work found
not conforming to any of the following requirements shall be rejected and resurveyed without any additional cost.
The maximum allowable error for all measured distance shall not exceed 1 in 4,000.
The maximum allowable error in all levels shall not exceed 0.02 K m where K is
the distance in kilometer. Daily work shall be tied back to the starting point of the
day.
59.3
Survey Plan and Scales
The Surveyor shall prepare the following survey plans based on the data and
information of the field surveys:-
60.0
(a)
Computer drawn plans, in State Grid Net where possible to a scale of 1: 1000
or other suitable scale to fit A1 size for the incorporating all features detected.
(b)
Computer drawn location plan
AS-BUILT DRAWINGS
As built drawings shall be produced by the Contractor on a continuous basis and as
soon as possible after the construction of the various system, or within one month
after completion of the work. For this purpose, an item has been allowed in the Bill
A.26

of Quantities. The standard and details to which such as-built plans shall be drawn
up as directed by the S.O.
The Contract Price shall be deemed to include the cost of preparation, supply and
delivery of all original drawings and information duly certified by the Contractor and
his surveyor as follows: a)
5 full sets of drawings in paper (A1 size)
b)
5 full sets of drawings in paper (A3 size)
c)
1 full set of drawing in digitised format (Auto-cad in the released to be
approved by the S.O)
All such printed drawings shall be well bounded with thick covers.
All drawings submitted to the S.O. shall be in accordance with the following
guidelines:(a)
Each Drawing shall have a Title Block indicating the Title of the Job, Title of
the Drawing, Scale, Date, Contractor's Name and Address, Revision Index and
Drawing No.
(b)
On each Drawing, details such as pipe invert level, size, valves, bends, etc
shall be indicated as clearly as possible to include all the works to be carried
out on site. Such details shall be provide presented in both plan and
longitudinal section.
(c)
Plan and longitudinal section of pipe profile drawings showing invert level of
pipe, alignment of pipe, details of pipe particulars.
(d)
Details drawing showing air valves, washout, valves chamber, crossing pipe
bedding method, jointing etc.
(e)
Each drawing shall be certified by a qualified Professional Engineer and

Surveyor.
(f)
The drawing shall incorporate S.O.s GIS mapping requirements.

Failure to observe any of the above shall delay the approval of the shop
drawings and the Contractor shall be held entirely responsible for such delay
and no extension of time shall be allowed.
*Standard symbols and legends for SYABAS requirement as per Standard Drawing.
61.0
MANUFACTURERS WORKS INSPECTION AND TESTING

All items of equipment and materials: pipe, specials and valves shall be subjected to
inspection and testing before despatch unless officially waived in writing by the S.O.
All inspection, examination and testing at the manufacturers works shall be carried
out strictly in accordance with the appropriate Malaysian Standard, British Standard,
International Standard or such other standard as may be approved by the S.O.,
A.27

unless otherwise specified to ensure that the equipment and materials being
supplied meets the requirements of the Specification.
The fulfilment of the declared guarantees shall be verified at the Manufacturers
work tests.
All costs inclusive of S.O.s travelling, accommodation and other related expenses to
be incurred by the manufacturer in carrying out witness testing of the equipment
and/or materials shall be included in the contract sum.
The Contractor shall give sufficient notice to the S.O. before the intended date of
inspection and testing at the Manufacturers Works as per Specification. Details of
testing, measurements and recording instruments including calibration certificates
shall be submitted to the S.O. for approval. All instruments shall be calibrated and
certified by an approved independent testing authority not earlier than one (1)
month before the tests.
The S.O. and S.O.s representative will each nominate an authorised representative
to inspect and examine the equipment and material and witness tests at the
Contractors premises or at Manufacturers Works. The S.O.s representative will
endorse all copies of Manufacturers Certificates of successful tests witnesses by him.
When the S.O. or S.O.s representative witnesses a test, they shall be given a copy
of the test certificate immediately. When tests have been conducted in the absence
of the such representative, this fact should be noted by the Contractor on the test
certificate.
Upon the satisfactory completion of all tests required by the Specification for an item
of equipment and materials, the Contractor shall send to the S.O., four (4) copies of
particulars of the tests carried out, readings obtained, performance calculations and
details of calibration certificates referred to in the previous paragraphs. Test
certificate shall be submitted in booklet forms and securely bound.
No material or item of equipment and materials shall be delivered to Site until its
certificate has been approved in writing by the S.O. The approved by the S.O. of
the results of any inspection or test shall not prejudice the rights of the S.O. to reject
the equipment and materials, if it fails to comply with the Specification when
erected or to give complete satisfaction in service.
A.28

B EXCAVATION
1.0
GENERAL
Excavation work shall include site clearing, the removal, hauling, proper utilization
or disposal of all excavated materials and the construction, shaping and finishing of
all excavations and embankments over the entire extent of the Works in conformity
with the Drawings and this Specification.
2.0
SITE CLEARING
The Contractor shall remove and dispose off trees and bushes within the site of the
Works as and wherever directed by the S.O. However, all trees and bushes within 2
metres of either side of all pipelines to be laid under the Contract shall be removed
and disposed off. Site clearing shall include clearing, grubbing, demolishing,
breaking up and removing all trees, shrubs, vegetation, stumps, structures such as
walls, fences and other obstruction within the Site except those which have been
designated to be retained. Materials suitable for disposal by burning shall be burnt at
locations and on periods as approved by the S.O.
3.0
EXCAVATION GENERALLY
The Contractor shall carry out all excavations in such manner and order as approved
by the S.O and in whatever material as may be found. All excavated materials shall
be deposited so that it will cause as little damage and inconvenience as possible.
All excavations shall be carried out to the required lengths, breadths, depths,
inclinations or curvatures as may be necessary for the proper construction of the
Works or as shown on the Drawings. All excavations shall be sufficient to provide
for the necessary working space, shuttering and any other temporary structures
required during construction. Where so directed by the S.O. the turf and top sub-soil
shall be reserved and stacked separately until required for re-use in reinstatement.
Top soil shall mean the top layer of soil which can support vegetation.
Unless otherwise stated, the excavation, whether in open cut or in trench, shall be
proceed in such portions at a time as the S.O. may approved and shall not in the first
instance be carried down to a depth nearer than 150mm above formation level. The
last 150mm of depth to formation level shall be carried out by manual labour
immediately in advance of placing concrete screed, concrete or pipe laying.
The bottom of all excavations shall be carefully trimmed and leveled, well rammed
and consolidated to ensure good solid foundations.
The contractor shall be responsible for keeping dry all excavations, whether in open
cut or in trench, so as not to interfere with the work in progress. He shall without
extra cost to SYABAS provide, form, fix, maintain and work as and where directed
by the S.O. such pumps, wells, drains, bunds, and other thing necessary to
effectively deal with all water which may collect or find its way into the excavations
from any cause whatsoever. Nevertheless, all methods employed for dealing with
P:\zRAZMANN\SPEC\B-Excavation1.doc
B.1

the water shall be to the approval of the S.O. Such approval shall not relieve the
Contractor from his liability for any damages to the Works or adjoining land and
property or water courses due to his operations.
The Contractor shall be responsible for the stability of the excavations at all times.
He shall, without extra cost to SYABAS and to the approval of the S.O., slope the
sides of the excavations and or provide and fix strong and sufficient timbering to
support the sides and or bottom of the excavations to prevent against collapse, and
shall maintain the same until, in the opinion of the S.O., the construction work is
sufficiently advanced to permit the timbering to be withdrawn. Timbering shall be
removed only under the personal supervision of the competent foreman.
The Contractor shall be responsible for any injury to the Works or consequential
damages caused by or arising out of the removal of timbering and any advice,
permission or approval given by the S.O. relating to the removal of the timbering
shall not relieve the Contractor from his responsibility under the Contract.
The Contractor shall carry out any diversion and subsequent restoration of such
existing river, water-courses, land springs, ditches etc. wherever encountered during
the execution of the Works, whether shown on the Drawings or not.
4.0
EXCAVATION FOR PIPE TRENCHES

Before commencing the excavation of pipe trenches, the routes of the pipelines shall
be pegged out accurately. Strong sight rails shall be fixed and maintained at each
change of gradient, and at as many intermediate points as may be necessary but not
exceeding 100 metres apart. On these rails shall be marked the centre line and level
to which the pipes are to be laid, and such rails shall be maintained in position and
at the correct level from the time the excavation commences until backfilling is
completed. The run of pipe trenches opened up ahead of pipe-laying operations at
any one time shall not be more than:
100 metres if the pipe-laying operations are in an urban area,
300 metres if the pipe-laying operations are in the side-tables of a trunk road,
or
600 metres if the pipe-laying operations are in unoccupied land schemes or

housing estates under development or are in the side-tables of minor rural
roads.
The S.O. may, at his absolute discretion, vary the distances stated above if he
considers that traffic, road or weather conditions or road side-table limitations
warrant the variation.
Unless the S.O. permits otherwise, the trenches shall be excavated to the widths
given in Table B1 below.
B.2

TABLE B1 Widths of Pipe Trenches.

External Pipe Diameter, D
(mm)
Not exceeding 460
Exceeding 460
*600 for pipe 500mm 750mm
*900 for pipe > 750mmm
Width of Trench
(mm)
D + 450
D + 600* or 900*
Where pipes are to be laid on a concrete bed, the width of the excavation at the
bottom of the trench shall be the width of the underside of the concrete bed. At all
joints the trench shall be so excavated as to give a working space of not less than
300mm all round the joint. Where bends are made by deflecting pipes at joints the
trench shall be widen to permit this operation. The sides of the trench shall be cut
vertical, and where necessary, shall be protected against caving in by timbering to
the approval of the S.O.
The trench shall be excavated to the depths intended or shown in the Drawings and
shall be finished and trimmed accurately to level and grade.
Where no invert levels are shown or indicated the bottom of the trench shall be
graded so that the pipe invert slopes evenly between the adjacent invert levels.
Should the ground be so wet or soft that, in the opinion of the S.O. it does not from
a firm base for the pipe, or should rock be encountered at the bottom of the trench,
the trench shall be excavated 250mm below the level intended or shown in the
Drawings and then brought back to the correct level with good selected earth or
sand well rammed into place. Such deepening of pipe trench and filling back shall
be treated as a variation under the terms of the Contract. Should the bottom of the
trench be inadvertently excavated below the specified level, it shall be bought back,
at the Contractors expense, to the correct level with good selected earth or sand
carefully rammed into place.
5.0
ROCK EXCAVATION
Rock shall mean those geological strata of hard material which necessitate the use of
blasting or approved pneumatic tools for their removal. Solid boulders found in
trench excavation and foundation pits shall be considered as rock if such boulder is
of size each exceeding 0.08 cubic metre or each exceeding 0.17 cubic metre if
occurring in general excavations.
Shale and clay boulders shall not be classified as rock. The S.O.s decision as to
whether or not the material of the excavation is to be classified as rock shall be final.
Notwithstanding the above, rock shall not include materials which in the judgment
of the S.O. can be loosened with a tractor mounted and drawn ripper of the
following description:
B.3

The Contractor shall be entitled to extra payment for rock excavation only if
reasonable notice is given to the S.O. to examine and measure such material prior to
breaking up. The volume of rock excavated shall be taken as its volume in-situ
before it is broken up.
6.0
USE OF EXPLOSIVES
The Contractor shall not use any explosives without the written approval of the S.O.
In the event where the approval for the use of explosives cannot be given or where
an existing approval is withdrawn by the S.O. due to whatever reason the Contractor
shall carry out the Works using other means approved by the S.O.
Where written approval is given by the S.O. for the use of explosives, the Contractor
shall comply strictly with all rules and regulations laid out by the relevant authorities
pertaining to the use of these explosives and shall be solely responsible for
procuring any permit required from the relevant authorities for the use of explosives.
The greatest care shall be taken by the Contractor during all blasting operations is to
ensure that no injury be done to persons or damage to property or finished work. All
blasting shall be performed at the entire risk and responsibility of the Contractor.
7.0
WEATHERED ROCK EXCAVATION

Weathered rock shall mean those geological strata of hard material, which
necessitate the use of tractor mounted and drawn ripper as specified below:Tractor Unit : Plant with a minimum weight of 20 tonnes and net horsepower
rating of 200 h.p. The tractor unit is to be in good condition and operated by
experienced personnel skilled in the operation of ripping equipment.
Ripper Unit : The ripper to be attached to the tractor shall be the most efficient
parallelogram type recommended by the tractor or ripper manufacturer. The
ripper shall have shanks in good condition with sharpened cutting point.
to loosen the material sufficiently to permit a bulldozer to remove the material.
Weathered rock shall be residual rock altered by physical and chemical processes to
the extent that it is decomposed or disintegrated or fractured or loosely laminated or
jointed, but retains sufficient strength to necessitate ripping.
The Contractor shall give reasonable notice to the S.O. to examine any weathered
rock prior to breaking up and to allow the S.O. to measure the extent and depth
before further excavation.
The S.O.s decision as to whether or not the materials of the excavation is classified
as weathered rock shall be final.
8.0
UNAUTHORIZED EXCESSIVE EXCAVATION

Unless otherwise directed or approved by the S.O., if any excavation including rock
excavation is carried beyond the limits on or against which permanent work is to be
B.4

supported in accordance with the Drawings, the Contractor shall at his own expense
be required to fill the excess excavation with Grade 20 mix concrete or other
suitable materials acceptable to the S.O.
9.0
ADDITIONAL EXCAVATION ORDERED BY THE S.O.

If after excavating the sites on which the various parts of the Works are to be
constructed, it is found that any part of the formation is unsuitable to provide a
satisfactory foundation, such portion shall be further excavated to such depths as the
S.O. may direct and refilled to the correct formation level with Grade 20 concrete or
other selected materials acceptable to the S.O. Such extra excavation and refilling
shall be treated as a variation under the terms of the Contract.
10.0
TIMBER LEFT IN EXCAVATION

If, in the opinion of the S.O., it is necessary to leave in position any timbering, the
Contractor shall be paid at the rate stated in the Bill of Quantities provided that, in
the opinion of the S.O., the necessity of leaving the timbering has not arisen from
carelessness or negligence on the part of the Contractor.
11.0
EXCAVATION IN ROADS
No trench is to be excavated in the carriageway unless specific approval has been
given by JKR Road Section or the local authority. The whole operation of excavation
and reinstatement of the trench shall be completed as quickly as possible. The
Contractor shall ensure that minimum interference to traffic flow is maintained at all
times.
A joint site inspection shall be arranged by the Contractor before commencement of
work if so requested by JKR Road Section or the local authority. After pegging out,
the Contractor shall inform the local JKR office or the local authority and the police
of the actual date of commencement at least one week in advance of and on the day
of commencement.
If specific approval has been given to lay services across the road by open
excavation, the required width specified by JKR or local authorities and to ensure
that the top edges of the excavation are neat and straight.
All materials from the excavation, if accepted for backfilling shall be neatly stacked
outside the carriageway. Where there is no place to stack the excavated materials
outside the carriageway, all excavated materials shall be removed from the work site
immediately after excavation.
Where specific approval has been given by JKR for half width construction, the
traffic lines may be reduced to not less than 4.0 metres wide and where necessary,
the shoulder should be strengthened by the Contractor to accommodate traffic load
to the satisfaction of the S.O. and at the Contractors cost.
Trenches shall be provided with adequate shuttering, walling and struts to prevent
the adjoining road pavement from cracking and subsiding.
B.5

If a road diversion is required, the Contractor shall build it to the specifications of

JKR Road Section or the appropriate local authority. It shall be maintained in good
motorable condition until the reinstatement is completed.
Carriageway excavation across important and busy road and junctions shall be
carried out during off-peak hours e.g. Saturday afternoons, Sunday or at night. The
S.O. will specify the appropriate times based on the merits of each case and such
conditions shall be strictly adhered to by the Contractor.
12.0
CROSSING WATER-COURSES ETC.

Where the pipeline crosses underneath streams, culverts and other water-courses,
the Contractor shall be deemed to have allowed for all additional measures
necessary for the proper construction of the pipeline especially maintaining the flow
of water.
13.0
INSPECTION
Until the S.O. has inspected and approved the excavation, no concrete shall be
placed and no pipes shall be laid upon the surface prepared by excavation. Any
work built on foundations which have not been approved by the S.O., shall on the
order of the S.O., be uncovered or removed by the Contractor and the foundations
reinstated all at the Contractors own expense.
14.0
BACKFILLING OF EXCAVATIONS OTHER THAN PIPE TRENCHES

Backfilling of all excavations shall not be carried out until the works therein have
been inspected and approved by the S.O. In backfilling excavations other than pipe
trench excavations, approved portions of the excavated materials shall be employed.
Where required, approved materials shall be brought to site for backfilling works.
The materials shall be deposited and spread in layers of not more than 300 mm
deep, and each layer shall be thoroughly rammed by a mechanical vibrating tamper
or smooth wheel roller and watered if required.
If so directed by the S.O., the backfilling shall be finished off slightly proud of the
surrounding ground to allow for settlement, but the contractor shall make good any
settlement, which may occur during the construction of the works and during the
Defects Liability Period of the Contract at his own expense.
15.0
BACKFILLING OF PIPE TRENCHES

After the pipe laying has been approved by the S.O. and before the pipelines are
tested, only sufficient backfilling of the trenches to prevent snaking and to
maintain the pipes in position will be permitted, but all joints shall be left exposed.
However, in the case of uPVC pipes, complete backfilling is required before testing.
In low lying ground or any other locality where the trench may be filled with water
and cause floatation of the pipes, or elsewhere as my be decided by the S.O. , the
backfilling shall follow the pipe laying as closely as possible.
B.6

In backfilling pipe trenches, only approved materials free from stones or rocks or
other hard materials shall be carefully spread along the trench bottom between the
pipes and the trench walls to a depth of about 150 mm and shall be hand rammed.
Further layers each of about 150 mm thick of the same materials shall then be
spread and rammed in the same manner up to the top of the pipes. The reminder of
the backfilling may consist of coarse materials free from boulders and large earth
clods. It shall be placed in layers each of 150mm thickness and hand or
mechanically rammed until the backfill is 300mm above the top of the pipes. The
rest of the trench backfill shall be in layers each of 300mm thickness and compacted
by a mechanical vibrating tamper to finish off slightly proud of the surrounding
ground. The degree of compaction of each layer shall not be less than 95 percent of
the dry density obtainable using the BS Standard Compaction Test. The Contractor
shall have to make good any settlement to avoid formation of drains at gulleys
within the refilled trenches.
16.0
APPROVED FILL MATERIAL

Approved fill material to be used as backfill to the top of the pipes shall be uniform
low plasticity granular material. The material shall be free from all organic or other
materials subject to decay. Highly plastic or expansive soils or clay shall not be
used. The filling material shall be readily compactable to its maximum density and
must not form mud, or otherwise breakdown when wet.
Should the material being placed as fill or backfill while acceptable at the time of
section, become unacceptable to the S.O. or his representatives due to exposure to
weather conditions or due to flooding or have become puddled, soft or segregated
during the process of the works, the Contractor shall, at his own expense, removed
such damaged, softened or segregated material and replaced it with fresh approved
material.
Where the pipeline crosses a road, approved sand shall be used as fill material up to
the road formation level.
17.0
ROAD REINSTATEMENT
Road reinstatement works shall be carried out by the Contractor to a standard
equivalent or superior to the road condition existing prior to excavation and to the
approval of the S.O.
All backfilling shall be done by the Contractor with approved sand. No organic soil,
broken pre-mix or stones are to be used. The sand shall be compacted 150mm
layers. The degree of compaction of each layer below the pavement course shall not
be less than 95 percent of the dry density obtainable using the BS Heavy
Compaction Test. The Contractor shall bear the cost of such tests and shall make
good any works which are found to be unsatisfactory.
Sand material shall be deposited in layers on both sides of the pipe simultaneously
and thoroughly compacted and around the pipe working alternately on either side of
the pipe until the trench have been filled up to 150m above the top of the pipe
except for pipes laid in roads where the sand backfill shall be brought up to the base
B.7

course formation level. The sand vibrator and/or by an approved system of water
jet. The topping of the refilling for trench excavation as described above the backfill
with excavated material.
Where necessary the Contractor shall adjust the moisture content of the refill
material either by drying out or by adding water to assist the compaction of the
material.
The Contractor shall reinstate the road pavement by replacing, in the proper
sequence, any block or metalling removed, provided the block or metalling is in
good condition and to the approval of the S.O. The road surface shall be reinstated
with new materials of the type existing on site. Edges of the reinstated road
pavement shall be straight and neatly finished to match the existing road to the
satisfaction of the S.O.
For pipe trenches the Contractor shall be as required by the authorities or as
follows:
Along major roads Immediately after backfilling,

Along minor roads within 3 days after backfilling,
Cross trench within 24 hours after backfilling,
Pilot pits immediately after backfilling.
If the Contractor fails to carry out the reinstatement to the satisfaction of the S.O. or
any further reinstatement that may be necessary of any trenches across roads and
footpaths, the S.O. or the appropriate authority may proceed with such repairs and
the cost of such reinstatement shall be deducted by the S.O. from any payments due
or to become due to the Contractor.
18.0
REMOVAL OF SURPLUS
The contractor shall dispose off all surplus excavated materials, earth, rubbish and
waste matters to an approved tip to be provided by him unless otherwise directed by
the S.O. If surplus spoil is tipped into or fill materials obtained from private property,
the operations shall be executed with the approval of the owner and occupier of the
same. The Contractor shall have no right of ownership to the surplus materials
excavated.
19.0
EMBANKMENTS
Embankments and filled areas shall be made by depositing approved soil in regular
layers not more than 300 mm in loose thickness. Each layer shall be well compacted
with approved mechanical rammers or rollers before the next layer is placed.
Compaction shall continue until the soil is at a density not less than that of any
adjacent cuttings in the in situ state. All practical steps shall be taken to avoid the
inclusion of excess water in the fill and the finished surface of each layer shall be
sufficiently even to prevent the ponding of rain water in ruts and hollows. The S.O.
may direct the filling to stop in inclement weather. In dry weather effective
consolidation shall be assisted by watering. If the soil of the fill or the previous layer
of compacted soil is too moist for further effective compaction, compaction shall be
deferred until in the opinion of the S.O., it has dried sufficiently. The Contractor
B.8

shall disk harrow the soil to aid the drying if so directed by the S.O. The fill
materials shall be obtained from the surplus excavated materials at the site of the
works or from approved borrow pits.
20.0
SOILING AND TURFING

The exposed surfaces of all embankments and cuttings as well as flat areas where
directed by the S.O. shall be properly graded and covered with top soil at least 80
mm in depth before turfing. The surface shall be loosen by raking before placing of
top soil. Turf shall be freshly cut, approved runner grass. For spot turfing, the slabs of
grass shall not be smaller than 200 mm square and shall be set at 300 mm centres.
Turf shall be firmly bedded or pegged into the earth surface to ensure satisfactory
rooting.
The Contractor shall water and maintain the turf in good condition until all areas to
be grassed are substantially covered with healthy, well established, firmly rooted
grass and planted areas shall be free from erosion channels. All bare areas shall be
made good at the Contractor s own expense.
21.0
LEVELS TO BE RECORDED
Before the surface of any part of the site is disturbed or the commencement of each
stage of filling the Contractor shall take and record levels of any such part, in the
manner specified or as agreed with the S.O. in his presence and such levels when
agreed with him shall form the basis for measurement.
The Contractor shall obtain the S.O.'s prior approval to the proposed methods of
obtaining and recording this information and shall afford the S.O. all facilities to
attend and check each survey and recording. The Contractor shall give to the S.O.
notice of his intention to carry out such survey work at least 24 hours in advance of
the commencement of the survey. The Contractor shall carry out to the S.O.'s
instructions, all extra surveys required to resolve any doubts which may arise as to
the correctness of any survey or record and the S.O.'s decision shall be final
regarding what shall be recorded as the correct survey.
A similar procedure shall be adopted to record any rock surface limits and levels
before they are blasted or excavated.
Each survey drawing with agreed data shall be referred to as a "Record Survey"
which shall be signed by the Contractor and the S.O. and shall form the basis of
measurement of the appropriate work. The Contractor shall supply four copies of
each Record Survey to the S.O.
22.0
CARE OF EXISTING SERVICES

Information relating to the positions of all existing mains, cables, culverts, pipes,
drains or services of any kind shall be ascertained by the Contractor.
Notwithstanding any information which may be furnished by the authorities or the
S.O., the Contractor shall be responsible for ascertaining from his own inspections
of the site and from the respective supply authorities and other public authorities the
positions of all mains, pipes and cables whether underground or overhead, within
B.9

or near the site. Where services are shown on the drawings or where there is
evidence of services in the ground, the Contractor shall also determine their exact
positions. In addition the Contractor shall watch for and determine the position of
any services which may not have been marked.
Where Trench Excavation is carried out close to or across the line of sewers, pipes,
cables and other services the Contractor shall provide temporary adequate supports
to secure the services and where such sewer, pipe, cable or other service is
temporarily displaced or disturbed it shall be restored to its original state. If
restoration or any service to its original state cannot be achieved then it shall be
replaced and made good. The cost of excavating around any service which crosses
the trench and of temporally supporting it while pipelaying is undertaken, shall be
deemed to be included in the rates for excavation.
All damage to services shall be made good to the satisfaction of the S.O. and the
authorities concerned. The cost of making good any damage shall be deemed to be
included in the rates for excavation. In the event that any damaged services shall
only be repaired by the authority concerned, all costs whatsoever relating to the
repairing of the damaged service undertaken by the authority shall be at the
Contractors expense. Where damage to a service had already existed prior to
excavation or other work, repair of the damaged service shall be undertaken by the
Contractor, if so ordered by the S.O. and the Contractor shall be paid on Daywork
for repairing such service.
Where in the opinion of the S.O., construction of the pipeline cannot reasonably be
carried out unless the sewer, pipe, cable or other service is permanently severed or
permanently diverted or permanently supported the Contractor shall undertake such
work is so ordered by the S.O. Any such work if carried out shall be to the
satisfaction of the S.O. and of the authority concerned and shall be paid for at
Daywork where necessary and at the appropriate Contract Rates.
Where pipes are laid under culverts they shall, subject to other provisions in the
Contract and to the S.O.s instructions, be given a concrete surround extending for
600mm clear on each side of the culvert, and a concrete half haunch to the culvert
shall be provided over the width of the trench cast directly on top of the concrete
surround. The cost of all work in removing any piles and concrete bend under
culverts and of temporarily supporting the culvert during pipelaying shall be
deemed to be covered by the rates for the items in the Bills of Quantities for pipe
crossing under culverts.
23.0
HEDGES, FENCES AND WALLS

Where the Trench Excavation passes under barrier such as hedges, fences and walls
the Contractor shall, as a temporary measure during construction of the pipeline,
provide temporary fencing for any parts of such barriers as have had to be removed.
After trenches have been refilled and surfaces reinstated, the Contractor shall carry
out work as the S.O. may order for permanent restoration of such barriers. In the
case of a hedge the section removed shall be replaced by new plants of the
appropriate variety and where ordered by the S.O. the plants shall be protected
from livestock on both sides by an adequate post and barbed wire fenced. During
B.10

the Defects Liability Period all hedges replanted in the above manner shall be
inspected and any dead plant replaced by the Contrator.
24.0
MACKINTOSH PROBES
The apparatus used shall be the standard JKR probes or the normal Mackintosh
probes.
Probing shall stop when the resistance has reached 400 blows/0.30m penetration or
the depth has reached 15 metres, whichever is reached earlier, unless directed
otherwise by the S.O.s representative.
Mackintosh probes shall be measured by the penetration depth in to the ground.
25.0
UTILITY SURVEYING AND MAPPING

The Contractor shall carry out utility surveying and mapping as required by the
authorities and also part of the contractors duty to locate buried utilities and
structures at the work area. The survey and mapping work shall determine locations
of underground utilities and shall present the information on drawing to S.O. for
approval.
Surveying technique shall be:
The Pulse Ekko System or
The Radio Detection Method

The following information shall be made available to the S.O. for each area:
A plan showing all the utilitiess provision
Depth, type and size of utilities below ground
Manhole or opening position
Other relevant and useful information

The service shall cover all costs associated with sourcing of information from
utilities or relevant parties, prospecting, trenching, field works and plotting works.
26.0
MEASUREMENT OF GENERAL EXCAVATION

Items in the Bill of Quantities for General Excavation except where expressly
indicated otherwise, shall apply to excavation whether Bulk or Incidental Excavation
in any material and shall include not only for all work in connection with
excavation but also for disposing of the excavated material on the Site as backfill or
to permanent spoil tips or to embankments or backfilling as specified or off the Site
to the Contractor's disposal tips and any necessary double handling. No separate
payment shall be made in respect of forming spoil tips as indicated in the Drawings
or at designated areas as directed by the S.O. on site.
Items for "Excavation in Rock" measured extra over General Excavation Items, shall
include for any allowance the Contractor considers necessary to cover overbreak
and the making good thereof.
B.11

All work in connection with excavation and subsequent disposal of excavated

material as specified shall be valued by measurement of such items as are set forth
in the Bills of Quantities for "excavation" and, where appropriate, of the further
extra over items for Rock. All such measurements unless otherwise specified shall
be excavated to the specified levels and limits described herein or shown on the
Drawings, no allowance being made for bulking. No separate measurement shall
be made in respect of Excess Excavation or the backfilling thereof.
Incidental Excavation for removal of unsuitable material shall (unless it is held to be
Excess Excavation) be measured as the volume ordered by the S.O. to be excavated
beyond the nominal dimensions of general excavation and shall include for the
disposal of the excavated material off the Site and for refilling the excavation with
approved material emanating from excavation elsewhere.
Quantities against items in the Bill of Quantities are based on ground levels
obtained from survey data. Existing ground levels shall be determined from joint
surveys carried out by the Contractor at the present of the S.O. at the
commencement of construction.
Excess Excavation and the backfilling shall not be measured for payment.
27.0
MEASUREMENT OF TRENCH EXCAVATION

Items for Trench Excavation shall apply to excavation in any material and shall
include not only for all work in connection with excavation but also for refilling of
trenches spreading and compacting excavated material over pipeline reserve as
directed and for disposal of surplus material, for temporary fencing and, in fields, for
the stripping and subsequent reinstatement of the top surface all as specified.
Trench Excavation shall be measured by length along the centre line of the pipeline
at the various depths stated in the Bill of Quantities and the Contractor shall be
deemed to have made his own assessment (subject to any specific requirements of
the Contractor) of the widths of Trench Excavations necessary for the proper
construction of the works including all allowances to provide support for the
excavations, to accommodate joints and bends in the pipeline and to provide
working space. The length of Trench Excavation shall be measured through and
including any space occupied by manholes, chambers, thrust blocks and the like.
No extra payment shall be made for trenches which are curved in plan or elevation.
The depth of Trench Excavation for pipes shall be measured normal to the profile of
the ground along the centre line of the trench from the original ground level of
where appropriate from the ground level remaining after the completion of any
general excavation down to the specified invert level of the pipe plus the thickness
of the pipe barrel and plus, where appropriate, the specified thickness of bedding
for the pipe.
The sides of Trench Excavation shall be deemed to be vertical in all materials and
the nominal widths defined in Clause 4 shall apply to any depth of trench and
whether or not bedding or surround to the pipe is specified.
Trench Excavation and all work in connection therewith as specified shall be valued
by the measurement only of such items as are set forth in the Bill of Quantities,
B.12

except where expressly provided for otherwise by the inclusion in the Bill of
Quantities of any of the following further items :Incidental Excavation for Structures situated in the pipeline shall be measured only
to the extent that the net excavation required to accommodate the structures falls
outside the nominal dimensions of the Trench Excavation.
Incidental Excavation for removal of unsuitable material shall (unless it is held to
be excess Excavation) be measured as the volume ordered by the S.O. to be
excavated beyond the nominal dimensions of Trench Excavation and shall include
for the disposal of the excavated material off the site and for backfilling the
excavation with approved material emanating from Trench Excavation elsewhere or
for backfilling the excavation with the grades of concrete ordered by the S.O.
Rock, measured E.O. Trench Excavation items, shall be measured as the volume of
Rock within the nominal limits of Trench Excavation in Rock. When measured E.O.
Incidental Excavation items it shall be measured as for those items.
Excess Excavation and the backfilling thereof shall not be measured for payment.
Trench Excavations in roads and in footpaths as specified shall be measured (E.O.
Trench Excavation) as the area calculated by multiplying the length of trench so
excavated by its nominal width. The stripping of the top surface and the surface
reinstatement of Trench Excavation in road verges, fields, etc. shall be included in
Trench Excavation and shall not be separately measured.
Crossing hedges, fences and walls shall include for all temporary measures for
dealing with such barriers as specified and shall be measured as the length of such
barriers so dealt with within the nominal width of Trench Excavation. Any
permanent measures required by the S.O. shall be ordered by him as additional
work.
Crossing rivers culverts and other watercourses shall include for all additional
measures necessary to make the crossings as specified. Only such crossings as may
be itemised in the Bill of Quantities will be measured (E.O. Trench Excavation) for
additional payment. The length of measured for payment for crossing natural
watercourses shall be defined as the width of the waterway along the pipeline at the
time of construction of the crossing (except flash floods and floods).
Overhaul of refill or excavated materials (E.O. Trench Excavation or Excavation in
borrow areas) shall apply in cases where the S.O. orders material to be transported
from locations of excavation which are more than five thousand metres from the
areas to be filled.
28.0
MEASUREMENT OF FILLING
Items in the Bill of Quantities for filling shall include not only work in connection
with working and supplying of fill materials, within or outside the site transporting,
placing, spreading, watering, drying, compacting and grading approved fill materials
but also field tests, supervision, disposing of reject material and condemned material
at spoil tips on or off the site and construction and maintenance of necessary access
roads, bridges and drainages.
B.13

Fill material shall be measured as the volume placed after filling has completed.
Joint measurement of fill levels shall be taken once the required level has reached.
No allowance shall be made in the measurement for filling for settlement during
construction.
The Contractor shall be deemed to have made due allowance for any delays to
filling occasioned by sampling and testing materials from fill and borrow areas as
specified by the installation and testing of measuring instruments for fill.
The earthworks and all work in connection therewith as specified shall be valued by
the measurement of only such items as are set forth in the Bill of Quantities. No
separate measurement for payment shall be made in respect of any part of this work
unless separate items are expressly provided for in the Bill of Quantities.
Excavation of reject material in borrow areas shall be measured as the volume lying
between the surface recorded after stripping topsoil but before excavation of
unsuitable material starts, and the surface recorded before excavation of suitable
material starts.
If the Contractor excavates unsuitable material from the ground surface with the
intention of later using the underlaying material as a borrow area, and then does not
work the area as a borrow area to the extent required by the S.O., then such
excavation of unsuitable materials shall not be measured for payment.
29.0
PAYMENT FOR TRENCH EXCAVATION AND RESTORATION

Payment for trench excavation shall be made in two stages, as follows :(a)
75% of the total amount due will be paid on completion of pipe-laying.
(b)
The remaining 25% for any length, will be due on completion of restoration of
the final surface, including reinstatement of all surface damage, completion of
chambers, thrust blocks, etc.
Payment for the second stage shall be due only after restoration of any length has
been inspected and approved by the S.O. and by any relevant authority. Payment
for the separate items in roads, footpaths, etc. will be made at the same time as the
second stage payment for excavation.
30.0
MEASUREMENT OF TOP SOILING AND TURFING

Items where included in the Bill of Quantities for spreading topsoil shall include for
obtaining topsoil from spoil tips on the site, hauling and spreading all as specified.
The rate shall include spreading a layer of fertilizer with N : P : K of 10 :15 :10%
prior to turfing.
Items where included for turfing shall include for all work in connection with turfing
as specified, and for cutting and trimming and weeding at least once a month until
the end of the Defects Liability Defects.
B.14

Topsoil shall be measured as the areas so treated, and except where expressly
indicated otherwise items shall apply to sloping as well as to horizontal surfaces.
Topsoil and turfing of re-filled trenches shall be included in items for Trench
Excavation and shall not be separately measured for payment.
31.0
PAYMENT FOR TURFING

Payment for continuous turfing shall be the area covered by the turves provided.
Where spot turfing is required the distance between the centre lines of divots in the
form of a triangular pattern shall not exceed 500 mm and the percentage of the area
covered shall be agreed and payment made on the total area spot turfed multiplied
by the percentage.
Turfing will be paid for in two parts :(a)
at fifty percent of the Contract Rate when the turfing has been carried out;
(b)
at fifty percent of the Contract Rate at the issuance of the Certificate of

Practical Completion when the S.O. is satisfied that the grass has established
itself.
Where grass fails to establish itself, the Contractor shall turf the relevant area again
at no extra cost to the S.O.
32.0
PAYMENT OF FEES TO AUTHORITIES

The Contractor shall pay to all Authorities or developers all deposits, fees and
charges required to be paid in relation to the execution of the works or to any
temporary works.
If after due notice to the Contractor calling his attention to the necessity for the
payment of fees and/or charges to the Authorities the Contractor has failed to make
payment, the S.O shall be entitled to pay such fees and/or charges direct to the
Authorities concerned out of any moneys at any time due to the Contractor under
the contract and such payment shall be deemed to be payment made to the
Contractor under and by virtue of the Contract.
The cost of all fees and charges payable by the Contractor shall be deemed to be
included in the Contract Rates unless otherwise expressly provided for in the Bill of
Quantities.
B.15

C - HANDLING OF PIPES AND SPECIALS

1.0
GENERAL
The Contractor shall supply all the pipes and specials required unless otherwise specified
and construct and complete the pipeline and all associated works as shown on the
Drawings and included herein under the Contract.
2.0
ORDER FOR PIPES AND SPECIALS

The quantities of the items in the Bill of Quantities are only approximate and shall be
ascertained by the Contractor after the pipeline profiles are determined by joint survey.
Where a pipe special is to be used for connection to existing works, the Contractor shall
manufacture the special after he has ascertained the existing pipe diameter, flange and
other details at the exact location where it is to be laid.
Excess order of pipes and fittings shall be the responsibility of the Contractor and shall be
at his own cost.
3.0
HAULING AND HANDLING

Great care shall be exercised to ensure that the pipes and specials are not subject to any
kind of shock or sudden load during hauling and handling.
Attention is drawn to the Contractor that thin wall pipes, defined as pipes with a
diameter/plate thickness ratio greater than 125, shall be so handled, stored and
transported as to prevent distortion or damage to the pipes and shall not be moved in
any manner involving rotation of the pipe about the longitudinal pipe axis. Thin wall
pipes during delivery and when in transit around the Site shall be supported on three
rubber covered saddles shaped to give at least 90 circumferential support and shall be
firmly held in position at each saddles by straps tightened by turnbuckles in such a
manner that the external coating is not damaged. One saddle shall be at the centre of
the pipe length and the other two shall each be positioned at a distance one-fifth of the
pipe length from each end of the pipe.
Thin wall pipes in temporary storage or strung out along the pipeline reservoir routes
shall be supported on hessian bags filled with fine sawdust straw or similar and shaped
so as to give continuous support under at least 40-50 of the circumference. The
positions of supports shall be the same as that for pipes during transit. The underside of
the pipes shall be kept clear of the ground by at least 100mm.
The Contractor shall be unloaded the pipe using hydraulic crane and to ensure cover are
not dislodged during handling.
All pipes and pipe specials shall be lifted by means of reinforced canvas slings. The
pipes shall be lifted by two reinforced canvas slings at least 300mm wide suspended
from a lifting beam so that the slings are positioned approximately one-fifth of the pipe
length from each end of the pipe. On no account shall the pipes and specials be
P:\zRAZMANN\SPEC\C-Handling of pipes and special1.doc
C.1

dropped or let fall onto the ground and under no circumstances shall the pipes or pipe
specials be lifted by means of hooks to the ends of pipes and pipe specials.
All the open-ends of pipes and specials shall be kept closed by means of end-caps or
polyethylene sheets approved by the S.O. before delivery to site from the factory.
After delivery to site, these end-caps or polyethylene sheets shall not be removed until
the pipes or specials are ready to be laid in place. All open ends of pipes and specials in
the trenches shall remain covered to prevent the entry of any dirt, mud, stone and
contaminant. The cover shall also be water tight to prevent the entry of dirty water.
The Contractor shall be deemed to have allowed the cost of providing the above
necessary measures in the Contract Rates for supply and laying.
Any damage to or loss of materials shall be made good, or the damaged or lost materials
replaced, by the Contractor at his own expense and if approved by the S.O. damaged
materials shall be returned to the manufacturer for repair as directed by the S.O.
4.0
RECORDS
The Contractor shall keep full and detailed records including item numbers, size of each,
and location of all pipes and specials which are :
delivered to Site
declared to be defective
used in the Works
cut, broken or removed from Site
The Contractor shall keep such records continuously up to date, and shall have them
available for inspection by the S.O. at any reasonable time.
5.0
LAYING OF PIPES AND SPECIALS
5.1
Prospecting
The Contractor shall prospect for the position of buried or otherwise hidden obstructions
such as existing services, drains, pipes, cables, culverts, etc. Trial holes and pilot
trenches to ascertain the exact positions of these shall be sunk, well ahead of pipe-laying
and excavation, in places where they are known or thought to be and elsewhere and
these shall be backfilled with approved materials immediately and in any case not
exceeding 24 hours and subsequently reinstated. Approved marker posts shall be
erected to mark the position of all located services, drains, etc, and these shall not be
removed until reinstatements have been completed. The S.O. shall instruct further
prospecting if he is not satisfied with the sufficiency of the Contractors prospecting.
Where necessary the Contractor shall make arrangements prior to trench excavation
proper for the temporary or permanent support or diversion of services, drains, etc, to the
approval of the S.O. and the authority concerned. The full cost of prospecting shall be
deemed to be included in the Contract Rates for excavation unless separate items are
provided in the Bill of Quantities.
C.2

Attention is drawn to Clauses concerning the responsibility of the Contractor for the
security of existing services. The Contractor shall be deemed to have allowed for the
unavoidable delay of the Works due to any obstruction he may encounter with the
existing services and no claim for any extra costs on account of this will be allowed.
6.0
PIPE ALIGNMENT AND COVER

The routes of the pipelines shall be as shown on the Drawings or as directed by the S.O.
Pipes shall be laid to a minimum gradient of 1 on 500 unless otherwise ordered by the
S.O. Where the gradient of a pipeline is 1 on 20 or steeper, pipes shall be laid on an
ascending gradient starting from washout (low point) and finishing at the air valve (high
point).
Pipes shall be laid in straight lines on plan but curves of long radius shall be obtained by
deflecting up to a maximum of 5 for spherical type and 2 for hemi-spherical type at
welded slip joints and using short pipe lengths if necessary.
The minimum cover to the top of pipes shall be 1000mm unless otherwise specified.
Before commencing excavation the route of the pipeline shall be pegged accurately.
Strong sight rails shall be fixed and maintained at each change of direction and gradient,
and at as many intermediate points not more than 35 metre apart as may be necessary.
On these rails shall be marked the centre line and the level to which the pipe is to be
laid.
7.0
PIPE-LAYING IN GROUNDS WITH HIGH WATER TABLE

The Contractor shall note that some parts of the pipelines will be laid in grounds with
high water table, especially in areas adjacent to streams, river crossings and ponds.
The Contractor shall allow for all costs for thickening of bitumen thickness to 10mm, for
dewatering, keeping all the excavations and trenches dry for the whole pipe-laying work
and in a safe manner during construction and the Contractor shall price these works
accordingly.
8.0
DANGERS OF FLOTATION
Although flotation of pipes in completely refilled trenches or of the completed works will
not occur, the Contractors attention is particularly drawn to the danger of flotation of
pipes laid in trenches left unrefilled and allowed to be flooded with water in the partially
completed works.
The Contractor shall, immediately after pipes have been laid, jointed and approved by
the S.O., refill and compact excavated materials to at least two thirds of the length of the
pipe trench leaving only sufficient space un-refilled to allow for the completion of the
external joint. Notwithstanding this, the Contractor shall make all necessary provision to
avoid the flotation of any pipe during the construction stage.
Any damage caused by flotation of pipes, specials or fittings in un-refilled trenches shall
be made good to the satisfaction of the S.O. at no extra cost.
C.3

9.0
TEMPORARY CESSATION OF TRENCH EXCAVATION

If in the opinion of the S.O. there is undue delay in:
refilling pipe trenches,

testing the pipelines,
removing surplus material
general tidying up of areas where pipes have been laid and
partial restoration or maintenance of surface
The S.O. may order that no further trench excavation shall be opened until the
outstanding work has been carried out to his satisfaction and the Contraction shall have
no ground for a claim on this account.
10.0
EXAMINATION OF PIPES AND FITTINGS

All pipes and specials shall be thoroughly brushed through, cleaned and carefully
examined for cracks and flaws both internally and externally immediately prior to laying.
Materials damaged in any way shall be shown to the S.O. who will give instructions
regarding remedial work or otherwise.
Where ends to be jointed by welding are coated with ensis oil at the place of
manufacture the ends shall be thoroughly cleaned with the ensis oil removed.
The ends of pipes and specials shall be wire brushed if necessary and thoroughly
cleaned to remove all traces of rust and dirt.
Should any pipe or specials be found to be damaged, it shall be excluded out to the
satisfaction of the S.O. In general no pipe shall be laid if an end has suffered distortion
from the circular and a mechanical coupling or socket cannot be fitted or, if damage to
the internal and/or external protection has not been satisfactorily repaired.
11.0
REPAIR OF LINING AND SHEATHING

Only specially competent and skilled workers shall be employed to carry out repair work
to damaged linings and sheathing.
Small cracks and flaws in the internal mortar lining of steel pipes and specials may, with
the prior approval of the S.O. and if they are accessible, be repaired on Site. Such cracks
may be repaired by cutting out a 9mm x 9mm dovetailed key and making good with a
semi-dry mortar (proportion 1 part cement to 2 parts coarse sand) well tamped into the
groove, and cured by keeping it damp for 7 days. Alternatively, small cracks may be
caulked with any epoxy resin filler.
The external sheathing of steel pipes and specials shall be made good wherever the steel
has been exposed or the thickness of the coating does not adhere tightly to the steel.
Where the steel has been exposed all rust and dirt shall be removed carefully by wire
brushing or otherwise, and when perfectly clean and dry, a coat of approved special
quick drying primer applied before re-fettling. Small stones which may have become
embedded in the sheathing shall be picked out and the coating refettled by heating
C.4

locally with a blow lamp and smoothing over with a fettling knife. Additional external
jointing material shall be added wherever necessary.
All defects to linings and sheathings shall be made good to the entire satisfaction of the
S.O. Where in his opinion the damage is such that satisfactory repairs on Site will not be
practicable, e.g. when damage or cracking is extensive and/or inaccessible, the pipes or
specials in question shall be either returned to the factory for proper repair or replaced
completely. The Contractor shall be responsible in either case for all costs involved in
this respect and for any delays to construction work thereby caused. The compound
used for repairing sheathings shall be compatible with the sheathing material and shall
be approved by the S.O.
12.0
LAYING PIPES AND FITTINGS

All pipes and fittings shall be laid to the lines and levels shown on the Drawings or as
otherwise directed by the S.O. No pipe shall be laid until the pipe trench has been
inspected and approved by the S.O. The trench shall be kept sufficiently dry for making
joints.
No pipe shall be rolled into place for lowering into the trench. If a crane is used for
handling the pipes into the trench, the pipes shall be slung with slings passed around the
outside. A recess shall be formed in the trench foundation beneath to permit each sling
to be withdrawn without damage to the coating or sheathing. All struts at the ends of the
pipes and pipe specials shall not be removed until they are ready for engagement.
Before any pipe or special is lowered into the trench, it shall be cleaned by using water
jet where necessary and re-examined for cracks and flaws whilst hanging in the sling. All
excavated are in the trench must be dry and clean. If undamaged it shall be placed in
position ready for jointing. Except for pipework to be embedded in concrete, all pipes
and specials shall be placed on a solid and even foundation for their full length. Pipe
and specials shall be placed in position singly and the order of laying pipes shall be
subject to the approval of the S.O. Working space of 450mm gap beneath the pipe joint
area is required for proper jointing and cleaning. If any sewer pipe is damaged during
trench excavation and causes flooding in trench, 65% concentration calcium
hypochlorite shall be used to disinfect the pipeline and the excavated trench.
Joint holes shall be formed in the excavation as necessary for the convenient and proper
making of the joints, and each pipe or special shall be individually set for line and level
using boning rods.
Pipes and specials to be embedded in concrete shall be held firmly in position and
protected from damage while the concrete is being placed. Should any pipe become
either partially or wholly clogged before final acceptance of the work, it shall be cleaned
out or replaced by the Contractor at no extra cost.
After laying, the interior of pipes or specials shall be carefully cleaned again to remove
any debris, dirt, stones or other matter that may have entered during laying. Except when
work is actually proceeding, all open ends of pipes and specials in the trench shall be
kept closed by means of a fine wire gauge wooden stoppers or other approved means, to
prevent the entry of dirt, stones and the like, but such stopper shall allow the entry of
water.
C.5

13.0
SPECIALS
The approximate positions of all specials are shown on the Drawings. The exact
positions shall be determined on Site by the Contractor to the approval of the S.O.
14.0
PIPE CUTTING
Where it is necessary to cut pipes to provide closing lengths or for laying pipe specials or
in the repair of damaged or chipped pipes, the cutting shall be neatly and accurately
performed so as to leave the end of the pipe truly normal to the axis of the pipe.
15.0
WELDING OF JOINTS
15.1
Welding Procedure
All electric arc welding equipment shall be to the approval of the S.O. The Contractor
shall submit details of the welding procedure, which he proposes to adopt for the S.O.s
approval. Details shall include:
Make, type and gauge of electrodes
Size, shape and number of runs in welded joint
Direction of welding
Current strength
The Contractor shall make test specimens on pipes of the same size and thickness on the
pipelines to be welded. These pipes shall be supplied by the Contractor. The joints shall
be tested in the presence of the S.O. for each procedure proposed in accordance with
the requirements of Clause 7 of BS 4515.
Only procedures approved in writing by the S.O. shall be adopted in the welding of the
pipelines, and change from one procedure to another will not be permitted without
submitting the new procedure for re-testing.
16.0
WELDING PERSONNEL
Only the most highly skilled welders shall be employed on the Works, and every welder
before commencing any joint welding shall prepare specimens for testing in accordance
with Clause 7 of BS 4515 for each welding procedure proposed by the Contractor. Every
welder shall be tested in accordance to Clause 8 of BS 4515. The Contractor shall be
responsible for the preparation, setting up, provision of specimen, all necessary
equipment and materials for the testing of welding personnel.
The S.O. will advise the Contractor in writing which welders pass the performance
qualification test. Only these welders will be allowed to weld the pipe joints and the
S.O. shall be at liberty to withdraw his approval to any welder responsible for making
joints, which fail to meet the required standard.
17.0
MAKING WELDED JOINTS

Where the steel pipes are to be jointed by welding it shall be by means of an internal
and an external circumferential electric arc weld at each joint.
C.6

Before placing the pipes together the portion of the sockets and spigots to be welded
shall be cleaned to a bright metallic finish, the spigot end shall then be placed in the
socket and forced inside so that the spherical surfaces are in contact and that the gap
between the pipes at the end of the spigot is nowhere greater than 1.5mm. For
longitudinally welded pipes, the longitudinal welds on adjacent pipes shall be at least 15
out of line. Details of the socket and spigot welded joint are shown on the Drawings
Where pipes are to be jointed by a steel split collar, the pipe ends and the collar shall be
cleaned to a bright metallic finish. The collar shall then be placed on the ends of the
pipes so that the space between the pipe ends shall be about 25mm from the centre line
of the collar. The collar shall be clamped tightly onto the pipes using the lugs and
welded longitudinally. After completion of the internal and external circumferential
welds, the lugs shall be removed and the longitudinal weld completed.
The weld shall be of the convex full fillet type for lap welded joints made manually by
the metal arc process using approved types of electrodes. Each time the arc is started it
shall be manipulated to obtain complete fusion of the weld metal with the pipe and any
previously deposited weld metal. Before welding over any previously deposited weld
metal all slag shall be completely removed and the weld metal and the adjacent pipe
metal shall be cleaned by wire brushing.
All welds shall be subjected to inspection by the S.O. and shall comply with the
requirements of Clauses 9 and 11 of BS 5135 for freedom from undercutting, fusion
penetration and soundness.
18.0
AIR TESTING OF WELDED JOINTS

After each joint has been welded it shall be air tested in the presence of the S.O.
The annular space between the two welds shall be air tested to a pressure of 1.7MPa.
While this pressure is maintained for a minimum period of ten minutes, the welds shall
be examined carefully for leakage. Any defective welding shall be treated as directed by
the S.O. The tap holes shall be then sealed off with welding after each joint has been
satisfactorily tested. The Contractor shall provide all necessary gauges, pumps, etc, for
the air testing.
19.0
COMPLETION OF SHEATHING AT WELDED JOINTS

After the S.O. has advised the Contractor in writing that a welded joint has passed the air
test the external sheathing shall be completed to ensure continuity of protection along
the pipeline.
Bare metal shall be thoroughly cleaned to a bright metallic finish and it shall be
immediately coated with a primer solution. The primer shall be applied cold by brush.
As soon as the primer has set the sheathing shall be completed by running hot bitumen
into a metal mould placed over the joint and overlapping the sheathing by 75mm on
either side of the joint. The bitumen shall be Type 2 of BS 4147.
C.7

Priming and sheathing material for the purpose shall be provided by the Contractor
including the supply of all the necessary mould boxes and funnels required to form the
protective mould and whiting for use in lining the mould boxes prior to each pour. The
Contractor shall also supply all necessary boilers to heat the bitumen to the application
temperature recommended by the manufacturer.
20.0
COMPLETION OF INTERNAL LINING AT WELDED JOINTS

On completion of the external sheathing the steel exposed by the gap in the internal
lining, together with the adjacent lining shall be thoroughly cleaned and wire brushed.
The adjacent lining shall be wetted with thick cement slurry but no accumulations of
water in the gap shall be allowed. The internal lining shall then be made from one
volume of cement to two volumes of fine aggregate to ensure a smooth continuous lining
throughout the pipeline. Where necessary wire mesh may be introduced for ease of
completing thick concrete lining particularly those of spherical type joints.
21.0
PAYMENT FOR MAKING INTERNALLY AND EXTERNALLY WELDED SLIP AND

COLLAR JOINTS
The Contract Rates for making internally and externally welded slip and collar joints
shall cover the cost of providing, operating and maintaining all services, plants,
equipments, fuels, materials of all kinds, apparatus space of all types and everything
necessary for air testing, making good and/or completion of internal lining and external
coating, protecting pipe ends and completing external protection of the welded joints all
as specified.
22.0
MECHANICAL COUPLING AND FLANGED JOINTS
22.1
Making Joints with Mechanical Couplings and Flange Adapters

Mechanical couplings and flange adapters joints shall be installed in strict accordance
with the instruction given by the manufacturer and to the S.O.s approval.
Before jointing, the ends of each pipe shall be wire brushed to remove any protective
material adhering to the coating, together with any protuberances which may have been
caused by rubbing of the packing material and also be removed all rust at exposed
places due to stripping of the bitumastic coating. The ends shall than be recoated with
quick drying solution so as to produce a smooth coat of uniform thickness.
On completion of the joint the surfaces of the coupling and adapter shall be painted with
a quick drying primer and an external sheathing mould formed to enclose the coupling
and ends of the adjoining pipes. This work shall be carried out by specially competent
and skilled men in strict accordance with the instructions given by the manufacturer.
The primer and sheathing material compatible to the sheathing material on the pipes and
the mould boxes and funnels required to form the protective mould and whiting used for
lining the mould boxes prior to each pour shall be supplied by the Contractor, who shall
also supply the necessary boilers to heat the sheathing material to the application
C.8

temperature. The Contract Rates for making coupling and adapter joints shall cover all
costs in complying fully with the requirements of this Clause.
Mechanical couplings and flange adapters located in chambers shall be painted with two
coats of bituminous paint.
23.0
MAKING FLANGED JOINTS

When making flanged joints care shall be taken to see that the rings remain in position
undistorted while the bolts are tightened and the ring may be fastened to the bolts with
cotton thread, or stuck to the flange with rubber solution. The use of jointing paste will
not be permitted. The bolts shall be tightened in regular sequence starting from opposite
sides of the bolt circle and then going round in this way until every bolt is tight.
Excessive tightening of flanged joints shall be avoided. For precise tightening, preset
torque wrench shall be used.
Flanged joints located in chambers shall be painted with two coats of bituminous paint
but flanges which will be subsequently buried in trench and not encased in concrete
shall be carefully wrapped with Denso tape as manufactured by Winn and Coales Ltd.,
or similar approved material.
24.0
PIPELINE INSPECTION/CLEANING
On completion of the pipeline, the Contractor and S.O shall inspect and cleaning the
pipeline according as follows:
i.
>1100mm
= Physical Cleaning / Inspection Internally
ii.
600mm 1100mm = Air scouring or swabbing or pigging and full bore scouring
also be allowed / CCTV
iii.
>600mm
= Air scouring or swabbing or pigging and full bore scouring
also be allowed / CCTV
All report shall be provided to confirm the pipe is clean, to be signed by the
consultant/contractor and witnessed by SYABAS.
25.0
TESTING OF PIPELINES.
25.1
Testing Pipelines
After a length of the pipeline has been completed it shall be tested as a whole against
stop ends. The stop ends shall be supplied to the S.O.s approval and fixed by the
Contractor and shall be properly strutted to ensure that no movement can take place and
they shall be of sufficient strength to withstand the full test pressure which is to be
applied.
Testing shall be carried out over completed pipeline by each gang as follows:
No
Description of Pipeline
Max length
1.
Trunk main
3km
2.
Reticulation Pipe
2km
C.9

Testing shall be carried out where possible between air valves but not against adjacent
valves. Testing shall not be carried out until the backfilling of the pipe trenches except at
the joints, have been completed. Backfilling at flexible joints shall be left uncompleted
to facilitate inspection joints during testing.
Temporary marker posts shall be installed immediately after testing at all junctions
between tested lengths.
Before any length of pipeline is subjected to test pressure, care shall be taken to ensure
that all weight thrust and anchor blocks intended to prevent vertical and lateral
displacement of pipes or specials have been properly completed. All valves shall be
checked before the test to ensure that they are in working order.
Prior to filling the line with clean water for water testing, the line shall be thoroughly
inspected jointly with the S.O. to ensure that the line is cleaned from stones, dirt, debris,
plastic paper or any other matter that may have entered after laying of pipework.
The water for filling and testing the pipeline shall be obtained from an approved source. .
It shall be free from silt, contamination and pollution. All water sources used for testing
must be clean and free bacteria and preferably source from SYABAS pipeline. SYABAS
must approve first for water source other than from SYABAS pipeline. SYABAS shall
ascertain and verify the water quality of other water source on water quality tests carried
out by developer. The Contractor shall make all arrangements necessary for conveying
the water to the point of filling. The test ends shall be tapped for suitable size test
connection. The Contractor shall supply all necessary apparatus including pipework,
pumps, pressure gauges and automatic pressure recorder and carry out all work
necessary to test the pipeline. Pressure gauges are to have a dial at least 200mm in
diameter, and are to be checked against a guaranteed standard unit before use and at
other times as the S.O. may direct. The pressure recorder or single channel logger shall
have a 24 hour chart to record the pressure drop continuously. The test pressures to be
applied shall be to SYABAS requirements.
The field pressure shall be carried out first. Each section of the ABS., HDPE and Steel
pipeline shall be tested to the respective pressures as shown in Table 1. Ductile iron
pipes shall be tested to the pressures given in Table 2 respectively. When more than one
material of pipe is used on the same pipeline or pipe network, the lowest of the field
pressure test values stipulated shall be used.
After the section of the main has been filled with water for a period of not less than 7
days for lined pipes and 1 day for another unlined pipes, more water shall be pumped
into the section to raise the pressure slowly increments of 1 bar with a pause of one
minute between each increment. Should any appreciable drop in pressure be noted
during any of these pauses the test shall be stopped until the cause of the pressure drop
has been investigated and rectified. An engine driven pump may used until 90% of the
test pressure has been attained, and thereafter only a hand operated pump shall be used.
The pressure test shall be considered to have been passed when the pressure gauge
shows no reduction in pressure during the specified one minute pause and also during
the period of 10 minutes after full test pressure has been attained. If these conditions are
not satisfied a thorough inspection of the section of the main shall be made. All defects
shall be repaired and the test shall be repeated.
C.10

The leakage test shall then follow. The pressure shall be reduced to the relevant leakage
test pressure as shown in Table 1 and 2. The pressure shall be maintained as constant as
possible for a period of 24 hours. Make-up water shall be pumped into the section of the
main from time to time to maintain this pressure. The leakage calculated as 0.34 litre per
cm of pipe diameter per km of pipe per 24 hours per 1.0 bar of water pressure. If this
specified rate of leakage is exceeded a thorough inspection of the section of the main
shall be made. All leaks discovered shall be repaired and the section shall be tested
again.
Every section of all pipelines shall be tested as described above in the presence of the
S.O. Testing may be carried out between sluice valves but not against the gates of
valves.
Table 1: Test Pressures for Field Pressure and Leakage Test of ABS, HDPE and Steel Pipe
CLASS /
SERIES OF
PIPE
TYPE OF
PIPE
ABS
MAXIMUM
PERMISSIBLE
WORKING PRESSURE
(BAR)
12
15
12.5
15
15
10****
PN 12
PN15
PN 12.5*
PN15**
HDPE
** *STEEL
*
**
***
****
PRESSURE FOR
PRESSURE TEST
(BAR)
PRESSURE
FOR LEAKAGE
TEST
(BAR)
PRESSURE FOR
LEAKAGE TEST
FOR PIPELINE
WITH FERRULE
CONNECTION
(BAR)
15
15 X 1.5
15
15 X 1.5
15 X 1.5
15
12
12
12
12
12
10
6
6
6
6
6
6
Electrofusion Saddle Tapping.

2 Half Saddle Tapping c/w Gasket.
Steel pipes are capable of withstanding a working pressure of more than 15 bars. If
these pipes are used to their maximum working pressure i.e. half the factory
hydrostatic test pressure, all valves used shall then be of the appropriate rating
If field working pressure > 10 Bar, test pressure to 15 bar.
Table 2: Test Pressure for Field Pressure and Leakage Test of Ductile Iron
Nominal
diameter
(mm)
Maximum Permissible Working

Pressure (bar)
Pipes
*80 300
*350 - 600
16.0
16.0
16.0
16.0
12.5
12.5
Pipes with
Welded on
flanged
PN
PN 25
16
Flanges
12.5
12.5
12.5
12.5
12.5
1.2.5
16.0
16.0
16.0
12.5
12.5
-
Pressure for Pressure Test

(bar)
CastOn
Pipes
12.5
8.0
5.0
5.0
5.0
-
21.0
21.0
21.0
21.0
15.5
-
C.11
Pipes with
Welded on
flanged
PN
PN 25
16
Flanges
17.5
17.5
17.5
17.5
17.5
-
21.0
21.0
21.0
17.5
17.5
-
Pressure for Leakage Test (bar)
CastOn
Pipes
18.5
13.0
10.0
10.0
10.0
-
16.0
16.0
16.0
16.0
12.5
12.5
Pipes with
Welded on
flanged
PN
PN 25
16
Flanges
12.5
12.5
12.5
12.5
12.5
-
16.0
16.0
16.0
12.5
12.5
-
CastOn
12.5
8.0
5.0
5.0
5.0
-

Pipes of these diameters are capable of withstanding working pressure higher than 16
bar. If these pipes are used to their Maximum Working Pressure, i.e. half the Factory
Hydrostatic Test Pressure given by supplier, all valves used shall then be appropriate
rating. The pressure used during the pressure test shall then be 5 bars higher than the
selected working pressure. Pressure for the leakage test shall be the same as the selected
working pressure.
25.2
Testing of MS/DI Pipelines

All pressure and leakage test shall be recorded by a continuous chart recorder or
electronic pressure logger according to SYABAS requirements. All charts to be properly
endorsed by S.O or his representatives.
25.3
Testing of HDPE Pipelines (Whole system inclusive of fittings, tapping tees and com
pipes).
Testing Procedure
During first stage, a test procedure of 1.2 times the maximum working pressure (For PN
12.5 Working Pressure = 10 bar) shall be applied to the section test. The test section
should then be allowed to stand without make-up pressure with the allowable drop a
maximum 10% of the test pressure. If there is no leak of the test water after at least 1
hour under pressure, then proceed to second stage test.
The pressure is then reduced by rapidly bleeding water form the system to a nominal
pressure (8 bar). The control valve is then closed and the pressure readings are recorded
at intervals of 5 minutes for 2 hours by an automatic pressure recorder/ chart recorder. A
sound pipeline without leaks should exhibit a stable constant pressure over the time of
measurement after the initial rise in pressure (visco-elastic response of PE pipe), but the
final pressure must not be less than 8 bar.
All recording should use electronic lodger/chart recorder and not manual recording.
Graph shall be plotted and certified by all parties immediately during test or after
plotting from computer. A standard leakage test from certified by all parties during test
shall be submitted.
The section is considered to have passed the leakage if the procedure and results from
the graph plotted complied to requirement.
References:
The following reference publications provide pressure testing information:
ASME B31.1. Power Piping, Section 137, Pressure Tests (Ref 6)
PPI TR-31 Underground Installation of Polyolefin Piping, Section 7 System
Testing (Ref 1)
PPI Inspection, Test and Safety Consideration
JKR Tender Specification for Polyethylene (PE) Pipe Systems for Water Supply
MWA Guideline
SAJ PE Pipe Testing Procedure
C.12

26.0
PAYMENT FOR PRESSURE TESTING PIPELINES

The rate for testing pipelines shall include for the supply of clean water and all
necessary testing apparatus, pumps, gauges and pipe-works, the cost of supervision and
labour in testing and retesting, if necessary and all other work, materials and
equipment in complying with the requirements of testing of pipelines.
27.0
COMMISSIONING OF PIPELINE
Pipe shall be commission over completed pipeline by each gang as follows:
No
Description of Pipeline
1.
Trunk main
2.
Reticulation Pipe
Max length
5km
3km or Not Exceeding
1500 Properties
28.0
MISCELLANEOUS
28.1
Measurement of Steel Pipes and Fittings

Spigot and socket ended straight pipes shall be measured in linear metre, their lengths
being defined as their effective lengths as laid measured along the centre line of the pipe.
The effective length shall mean the net length of the pipe as laid, after deduction of the
length of overlap at any spigot and socket joint to be made with the pipe. Plain ended
pipe shall be measured and paid by effective length as laid. Pipe specials shall be
measured by numbers unless otherwise specified.
The Contract Rates for supplying and laying steel pipes and specials shall include for the
full cost of manufacturing, testing, transporting, storage at Site, hauling and handling,
repairing, lining and sheathing where necessary and laying in position in the Works
ready for jointing and/or building in together with other costs incurred in complying with
the requirements of the Specifications for which no separate items are included in the
Bill of Quantities.
28.2
Concrete Protection to Pipes

Pipes shall be bedded and haunched or fully surrounded in concrete where shown on
the Drawings or as directed by the S.O. Where concreting is required a sufficient
amount is to be placed and left to set in position before the joints are made to prevent
any subsequent movement of the pipes when further concrete is placed.
In order to allow relative movement between pipes, flexible joints shall not in general be
partially or completely cased with concrete. Concrete bedding and haunching or
surround shall be omitted for a distance of 150mm from the face of flexible joints except
as may be otherwise directed by the S.O.
In general pipes shall be bedded on or protected by concrete in the following
circumstances:-
C.13

28.3
A 150mm bed and partial haunch where the pipe is in rock

A 150mm surround where the pipeline is under stream and ditches.
Thrust and Anchor Blocks

Bends, tapers, tees and other points where horizontal thrust will occur shall be supported
with concrete blocks. The cover between the side of the pipe and the excavated face of
the ground which will subsequently take the thrust shall in no circumstances be less than
150mm.
Where pipes are laid at gradient steeper than 1 in 12 anchor blocks in concrete shall be
provided at the middle of pipes as follows:
Gradient exceeding
1 in 12
1 in 8
1 in 3
Anchor blocks
Every third pipe
Every second pipe
Every pipe
Details of thrust and anchor blocks are given on the Drawings. The dimensions shown
may, however, be amended by the S.O. after examination of the ground prior to
concreting, having regard to the likely thrust developed under test pressure and the
actual nature of the ground. Additional anchor blocks may also be needed.
For horizontal bends in cross-fall ground, care shall be taken to ensure that additional
cover over the pipes is allowed in order that the same passive resistance may be
developed as would be the case in level ground.
For thrust and anchor blocks to fulfill their purpose they must abut against undisturbed
ground. Where timbering has been used in the excavation it shall be withdrawn as the
concrete is being placed.
28.4
Valve Chambers
The operation of all valves including scour and air valves shall be checked by the
Contractor and any necessary adjustments made to ensure correct operation. Valve
chambers shall be constructed in accordance with the details shown on the Drawings or
as directed by the S.O. The same care shall be taken as for thrust blocks to ensure that
concrete transmitting thrust abuts against undisturbed ground.
The Contractor shall first obtain from the manufacturers the minimum required size of
the chambers. The S.O.s approval shall be sought should there be any variation. The
Contractor shall pay all subsequent costs due to any such variations.
Drainage from valve chambers to suitable outfalls shall be provided as directed by the
S.O.
28.5
Crossing Over Streams, Culvert and Rivers

Details of pipe-work and support arrangements of over-crossings at streams and rivers are
shown on the Drawings. The Drawings also list pipe specials which are required for
C.14

each crossing. The lines, and levels of the pipe-work shall be as shown on the Drawings
or as directed by the S.O.
28.6
Swabbing of Pipelines
When the final connections have been made and the pipelines have been tested to the
satisfaction of the S.O. the pipelines shall be cleaned by using hard grade polyurethane
foam swabs.
The recommended density of the swabs to be used is 30 to 40 kg/m3. The recommended
speed of the swabs is about 0.6m/s.
The swabs shall be at least 50 mm bigger in diameter than the internal diameter of the
pipe for small size pipe (i.e. 100mm, 150mm, and 210mm). For large diameter pipes of
300mm and above, it is advisable to use a size at least 100mm bigger than pipe internal
diameter. The length of the swab shall be 2 times the pipes diameter.
The cylindrical shaped cleaner was propelled by differential hydraulic pressure using a
pumper truck to provide water pressure (generally 15 to 26 bars for 30 to 40 seconds). A
temporary launch point (possibly a wye or tee) shall be used to enter the foam plug into
the flow of water or it may be inserted into the first joint of pipe laid and remain until the
cleaning process is begun.
As the plug moved through the pipelines, it pushed the debris downstream. A small flow
or bypass around the plug assisted in suspending and carrying the debris to the discharge
end of the pipelines.
After the cleaner has been received at the end of the system (usually fitted with
temporary piping to direct flow to ground level), the pipelines were tied into the desired
final connector.
28.7
Sterilization of Pipelines
The section of the main to be sterilized shall be filled with water mixed with a solution
of chloride of lime containing about 40 milligrams per litre of chlorine. The Contractor
shall have to adopt a dosing system to sterilize the line effectively. The system shall be
provided with a set up of temporary equipment, chemical mixing tank mixer, dosing
pump and other necessary accessories for the solution to be injected into the lines when
potable water will be introduced gradually. After the main has been filled with
chlorinated water, it shall be closed and left for at least 24 hours. The main shall be
deemed to have been sterilized if the samples of water taken from various tappings on
the main show a chlorine residual of 0.2 ppm.
After the main has been sterilized to the satisfaction of the S.O. it shall be flushed with
clean water.
Pipeline shall be filled with solution of Calcium hypochlorite 65% to 40 ppm level and
left for 24hours.
The main shall be deemed to have been sterilized if water samples taken from various
locations of the pipeline show a total chlorine level of more than 10ppm after 24hours.
C.15

28.8
Flushing of Pipelines
Flushing shall be carried out after disinfection has been achieved. Water sources that
being used for flushing must be clean and meet treated water quality. Flushing shall
proceed systematically from water supply source to en of pipe system. Procedure to be
used in flushing shall be discussed and agreed to by SYABAS and the Contractor/
Consultant prior to beginning of flushing works.Flushing of pipeline is deemed to be
complete only when the turbidity level of the water is less than 2 NTU and pH level less
than 9.0, residual chlorine is more than 0.2 ppm, E.coli and total coliform are absent.
Report on flushing shall be completed and signed by Contractor / Consultant and
witnessed by SYABAS personnel.
28.9
Payment for Sterilizing Pipelines

The rate for sterilizing and flushing the pipeline shall include the supply of clean water,
the full cost of supplying, transporting to and storing on the Site, hauling, handling and
mixing chemical, the cost of all apparatus for dosing and measuring the chemicals, the
cost of supervision and labour in testing and all other work, materials and equipment in
complying with the requirements of Clause 26.7.
28.10
Clearing Up
During the progress of pipe-laying work the Contractor shall clear up the Site and
remove from the surface of the ground all temporary buildings, plants, materials, litter,
rubbish and surplus spoil which may have been left on the ground or in and about the
Works or lands temporarily occupied by the Contractor and he shall leave in a clean and
sightly condition all and any lands occupied by him. Clearing up of the Site as herein
specified shall follow closely on the refilling of the trench.
28.11
ABS Maker Post.

The Contractor shall provide and fix ABS maker post as shown in Drawing No.
SYABAS/MARKER POST/2006/01. The indicator post is made up of a 750mm x 50mm
dia. Class 9 ABS (Acrylonitrile Butadiene Styrene) straight pipe, with a 50mm diameter
end-cap solvent cement welded at one end and a 50mm full-face flange at the other end.
The Indicator post shall be set with 50mm thick lean concrete which shall be laid under
the Indicator post before pouring 200mm x 200mm mass concrete (1:3:6) . Refer to
Drawing No. SYABAS/MARKERPOST/06/01.The top 50mm shall be covered with top
soil and the indicator post shall be installed as indicated in the drawing or as directed by
the S.O.
Indicator post shall be measured by number. The rate for the supplying and fixing
indicator posts shall include for all necessary concrete, excavation and backfilling.
28.12
Painting Pipe-work and Valves in Chambers

After installation the exposed surfaces of all pipe-work, valves and fittings in chambers
shall be properly cleaned, primed and painted thoroughly with two (2) coats of approved
polyurethane paintwork to 100 micron (min. dry finished thickness)
C.16

The paint required for these purposes shall be supplied by the Contractor and approved
by the S.O. and SYABAS. The cost of supplying primer and paint and painting pipe-work
and valves shall be included in the rates for laying pipes and the installation of valves.
28.13
Painting Pipe Work Above Ground

Steel pipe-work for installation above ground including stream and river over crossings
shall be painted with two (2) coats of high solid epoxy to 150 micron (min. dry finished
thickness). After installation this pipe work shall be painted with two coats of approved
polyurethane paintwork to 100 micron (min. dry finished thickness).
28.14
Payment of Fees to Authorities

The Contractor shall pay to all authorities or developers all deposits, fees and charges
required in relation to the execution of the Works or to any Temporary Works.
If after due notice to the Contractor calling his attention to the necessity for the payment
of fees and/or charges to the Authorities the Contractor has failed to make payment, the
Employer/S.O. shall be entitled to pay such fees and/or charges direct to the Authorities
concerned out of any moneys at any time due to the Contractor under the Contract and
such payment shall be deemed to be payment made to the Contractor under and by
virtue of the Contract.
The cost of all fees and charges payable by the Contractor shall be deemed to be
included in the Contract Rates unless otherwise expressly provided for in the Bill of
Quantities.
29.0
PIPE JACKING
29.1
General
Pipe jacking shall be the process of installing pipes below a surface obstruction by
driving them successively through the in-situ soil from one pit (the jacking pit) to another
(the receiving pit) such that the finished pipe forms a watertight continuous conduit
between the pits on the desired alignment.
Plans and details of the equipment, materials and the method of construction to perform
and complete the work shall be submitted by the Contractor and must be approved by
the S.O. before commencing these operations. Approval by the S.O. shall not relieve the
Contractor of his sole responsibility for the efficiency, reliability and soundness of the
method employed in completing the work in a satisfactory manner.
The Contractor shall satisfy himself as to the soil conditions along the pipe jacking route
and if he judges it to be necessary, he shall carry out further soil investigations at his own
cost.
It shall be the responsibility of the Contractor to maintain stable soil conditions at the
jacking face to prevent loss of ground above the jacking operation and movement of the
surrounding earth. The methods of maintaining face stability and preventing ground
movement and subsidence shall be by means of compressed air or other plenum
methods where fluid slurry or earth pressure is applied to the tunnel face. Alternatively,
C.17

unstable ground ahead of the jacking face may be stabilized by the injection of suitable
chemicals. Methods which require dewatering of the ground will not be accepted, nor
will methods which may lead to significant ground loss. The Contractors proposal must
be submitted to the S.O. for his approval.
Movement or settlement of structures, utilities and pavement shall be monitored by the
Contractor during the jacking operation and reported to the S.O.. If movement or
settlement occurs which in the opinion of the S.O. may cause damage, the contractor
shall take immediate action to prevent further movement, settlement or damage. He
shall repair at his own cost any damage and restore structures or pavements to the
satisfaction of the S.O..
The Contractor shall be responsible for inspecting the location and familiarizing himself
with the conditions under which the work will be performed and with all necessary
details as to the orderly execution of the work. The omission of any details shall not
relieve the Contractor of full responsibility for the satisfactory installation of the work in
its entirety. No monetary or other claims made by the Contractor on the grounds of want
of knowledge will be entertained.
The Contractor shall survey the location of pipe-jacking prior to any commencement of
work to identify the exact location of an existing box culvert. The exact location of the
pipe jacking shall be confirmed by the S.O.
29.2
Performance Requirements
The centre-line of the fully jacked pipeline shall at all points along its length be within
75mm of the required alignment in the horizontal plane and 25mm in the vertical plane.
No movement, upheaval or settlement of soil, which in the opinion of the S.O. may
cause damage to structures, utilities or pavements shall be permitted.
The fully jacked pipeline shall pass the water-tightness test specified for the pipelines in
trench.
29.3
Approval of Owner
Before commencing preparations for pipe jacking the Contractor shall obtain the written
consent to his proposed procedures to the Owner or Owners of the land, services and
structures below which (or close to which) the jacked pipeline will pass.
29.4
Jacking Operation
The Contractor shall be fully responsible for the materials, equipment and facilities
required in conjunction with jacking the pipes.
Before starting work, the Contractor shall submit to the S.O. for approval, a detailed
schedule of the entire jacking operation. Approval of such schedule shall not relieve the
Contractor of his responsibility to provide a fully satisfactory installation. The Contractor
shall include with his submission evidence that he has successfully completed a jacking
installation using procedures similar to those proposed.
C.18

Where chemical stabilization of soil is used, a chemical grout shall be pressure injected
into the soil over and ahead of the pipe jacking to stabilize the soil. The chemical grout
used shall have a demonstrated history of success for stabilizing soils similar to that
through which the pipe is to be jacked.
Where a mechanical shield is used, the Contractor must provide proof that the particular
model of shield has been used successfully in soils similar to that on the site. The crew
for the operation of the shield must be specialist, with experience in the use of that
particular type of machine.
After the jacking operation has begun, the Contractor shall work continuously and
expeditiously in accordance to programme until the complete length of jacked pipes is
installed. This continuous work where required shall not be constructed as overtime
work.
During jacking and excavation, the Contractor shall constantly ensure that the internal
lining of the jacking pipes is not damaged, and he shall remove the excavated spoil to
the jacking pit by conveyor to minimize traffic on the invert.
The pipes shall be jacked into place true to line and level. The maximum tolerance
allowable in the displacement of the center-line of the jacked pipe from the design
center-line is 75mm in the horizontal plane and 25mm in the vertical plane but there
shall be no back-fall at any point.
The pipes for the jacking operation shall not exceed 3m long. The pipe ends shall be
jointed by thrust sleeves before the pipeline is jacked. Details of how the pipes are to be
lowered into the pit and welded shall be submitted to the S.O. for approval.
The Contractor shall be required to furnish and install and remove to the extent required,
thrust blocks or whatever provisions may be required for backing up the jack employed
in jacking the pipe forward. The jacking pit shall also be equipped with steel rails or
beams embedded in concrete for placement and alignment of each pipe during the
jacking operation.
The Contractor shall be fully responsible for the design and construction of the jacking
and receiving pits, thrusting wall, installation of jacking equipment, sheeting, bracing,
etc., and for the efficient execution of the jacking operation. Full details of the proposals,
including plants, shield machines, equipment, operating procedures, jacking pits and
intermediate jacking stations etc., shall be submitted to the S.O. and shall be fully
satisfactory to him before construction. However, review of the plans shall not relieve
the Contractor from his responsibility to provide a safe and satisfactory jacking pit. On
successful completion of the jacking operation, jointing of the length of jacked pipes,
hydraulic pressure testing of the pipelines and after the connections at the extreme ends
of the jacked pipeline have been made, the Contractor shall remove completely the
jacking pits and receiving pits together with all the temporary works.
The Contractor shall be required to monitor closely the progress of the jacking operation.
Daily site records of thrusting pressures, rates of thrusting, the line and level
measurements of the jacking pipes and any movement or settlement of existing structures
shall be properly maintained and shall be submitted to the S.O.
C.19

For the sections of the pipeline crossing under roads, railway or structures along the
pipeline route, the Contractor shall be required to incorporate in his tunneling method
measures to arrest settlement or upheaval of the soil so as to safeguard the integrity of the
structures and other properties. The Contractor shall ensure that the traffic flows along
railway lines and roads are not affected in any way of his work.
29.5
Safety
The minimum of plants shall be used in the pits, and any which produces noxious gases
or is operated by electricity at a greater voltage than 240V shall be permanently outside
the pit at ground level.
A ladder shall be fixed permanently in the receiving pit. Two ladders shall be
permanently fixed on opposite sides of the driving pit, one on each side of the pipe
jacking line. These ladders shall be kept clear of obstructions to allow rapid exit in an
emergency. Excavated materials and plant other than small tools shall not be passed via
the ladder but shall be handled by crane.
Pits shall be securely fenced to prevent unauthorized persons from entering in.
All persons entering the pits shall wear safety helmets constantly, and shall leave the pits
for meal breaks, rests and the like.
At the beginning of each shift and after any break for refreshment or other reason, the
Contractor shall provide and use an approved instrument to check for noxious gases
before anyone re-enters either pit.
All costs associated with the provision of safety equipment and measures shall be
deemed included in the Contract Rates.
29.6
Design of the Jacking Pipes

The Contractor shall design the pipes to be jacked and the pipe joints in accordance with
the jacking procedure and operation prepared by the Contractor. Four (4) copies of a
detailed specification giving full particulars of the jacking pipe, pipe joint and
construction method proposed shall be submitted. The design shall be submitted with
full detailed calculations and drawings (4 sets each) to the S.O. for approval before
construction commence. The detailed design shall be prepared, checked and approved
by any experienced & qualified Professional Engineer registered with the Board of
Engineers Malaysia. The design shall take into account the following requirements:
Diameter of the pipes for the jacking shall be as specified and shall not be less than
10mm thick. The pipes as specified shall be lined internally with 25mm thick
concrete and externally cladded with reinforced concrete. The outer diameter of
the steel pipe shall not be less than 970mm.
The length of each pipe shall not exceed 4m and the pipe ends shall be suitable for
jointing with internal split collar by fillet welding in the field.
Each length of pipe shall be provided with steel thrust flanges at the pipe ends
designed to take the jacking load applied and transfer the load to the next pipe.
C.20

29.7
The transfer of the jacking load shall be through the external reinforced concrete
cladding by means of a steel thrust collar between the trust flanges of the pipes.
The thrust collar shall be fitted onto the pipes with flexible rubber rings to prevent
ingress of water into the pipe from outside.
Welding of Pipe in the Field

After jacking of the whole pipeline is completed, the pipes shall be jointed by internal
steel split collars. The pipe ends and the collars shall be cleaned to a bright metallic
finish. The collar shall then be placed inside the ends of the pipes so that the air release
hole will be at the crown of the pipe ends with the air release pipe extending vertically
up into the space between the pipe ends. The collar shall be clamped tightly against the
pipe such that the gap between the outside surface of the collar and the inside surface of
the pipe at the fillet weld locations do not exceed 1.6mm anywhere. After completion of
the internal collar, the longitudinal butt weld at the split ends of the collar shall be
carried out.
Weld shall be of the convex full fillet type for lap welded joints made by manual or
semi-automatic metal arc process using approved types of electrode. Each time the arc is
started it shall be manipulated to contain complete fusion of the weld metal with the
pipe metal and any previously deposited weld metal. Before welding over any
previously deposited weld metal all slag shall be completely removed and the weld
metal and the adjacent pipe metal shall be cleaned by wire brushing.
All welded joint shall be inspected visually and tested by ultrasonic examination in
accordance with BS 3923 in the presence of the S.O. before any grouting or concrete
lining at the joints can be carried out.
All welds shall comply with the requirements of BS 5135 for freedom from undercutting,
fusion penetration and soundness. Any welds showing cracks or other cavities, slag,
inclusions, porosity, or in which the weld metal tends to overlap onto the parent metal
without proper fusion, in excess of the amount permitted in Part II of API Standard 1104
shall be cut out and re-welded to the satisfaction of the S.O..
All welds performed in the field shall be subjected to a 100% ultrasonic examination.
Clearance and acceptance of the ultrasonic examination shall be in accordance with BS
3923. The S.O.s instructions given as a result of the examination of ultrasonic results
shall be final.
The Contractor shall submit his proposals to the S.O. for site ultrasonic examination.
The size, number and make of ultrasonic equipment proposed shall be stated. The
Contractor shall provide adequate equipment and qualified and experienced personnel
to deal with the ultrasonic examination.
The S.O. reserves the right to carry out any independent ultrasonic examination of the
welded joints as he may deem fit. Such independent ultrasonic examination shall be
carried out by an Inspector appointed by the S.O.
C.21

The Contractor shall provide such assistance, labour, materials, electricity supply,
ultrasonic examination equipment and other apparatus as may be necessary to allow a
thorough and extensive independent examination to be carried out.
29.8
Grouting at Welded Joints

After the S.O. has advised the Contractor in writing that a welded joint has cleared the
ultrasonic examination; the void at the joint between the thrust collar and the welded
collar shall be completed by pressure grouting. The Contractor shall provide all plants
and equipment for mixing and injecting grout. The composition of the grout shall
consist of 1 part of cement to 2 part of sand slurry, the crushing strength of which when
set shall be equaled to that of the internal lining of the pipe.
Grout shall be injected at a pressure which will enable the whole void between the
thrust collar and the internal collar to be filled up completely. Grout pipes shall be
secured to the grout holes in such manner that no leakage shall occur during grouting.
Grouting shall start from the bottom hole upwards with all other holes left open and shall
continue until grout escapes from the two holes on the horizontal diameter of the collar
joint. The bottom hole shall then be plugged and sealed off by welding. Grout shall be
injected through both the horizontal holes. When grout escapes through the vertical
hole at the crown of the collar, the two horizontal holes shall be plugged by welding.
Grouting shall continue through the top most hole until all air is expelled by the grout
escaping through the air release pipe. The grout hole and the air release hole at the
crown of the collar shall finally be plugged. All grout holes and the air release pipe shall
be plugged by depositing weld to the full depth of the thickness of the internal collar.
The Contractor shall ensure that fouling of the equipment and lines is prevented by
constant circulation of grout and by periodic flushing out of the system with water.
Flushing shall be undertaken with grout intake valve closed, the water supply valve
open, and the pump running at full speed.
29.9
Internal Lining at Welded Joints

After completion of pressure grouting of the void at the joint between the thrust collar
and the welded collar and plugging of the grout holes and air release pipe, the internal
lining shall be completed to ensure continuity of protection along the pipeline. The bare
metal and the adjacent lining shall be thoroughly cleaned and wire brushed. The
adjacent lining shall be wetted with thick cement slurry but no accumulation of water in
the gap shall be allowed. The gap between the concrete lining shall then be filled with
1:2 by volume cement-sand mortar to ensure a smooth continuous lining throughout the
pipeline.
29.10
Connections at Ends of Jacked Pipeline

The connections at the extreme ends of the jacked pipeline shall be made only upon
successful completion of the hydraulic pressure test of the jacked pipeline.
C.22

The connections at the two ends of the jacked pipeline will be made at the jacking or
receiving pits. The Contractor shall maintain and keep these pits intact and in a safe
condition to facilitate the connections. The Contractor shall remove all other temporary
works and any concrete blocks including cutting and removing part of the walls of the
pits that are in the way of the pipe-work connections.
When the Contractor has completed the connections of the pipelines and has completed
the protection of these connections with sand or concrete surround, he shall then
backfill the pits with well compacted sand. The removal of the temporary bracings and
struttings shall be carried out systematically together with the backfilling of the pits to
prevent collapse of the pit walls. The walls of the pits shall only be removed when the
backfill of the pits are completed.
30.0
HORIZONTAL DIRECTIONAL DRILLING METHOD PIPE INSTALLATION

The Contractor shall design the Horizontal Directional Drilling (HDD) method in accordance
with the pipes provided by the Contractor. The design shall be submitted with full detail
calculations to the S.O for approval before construction commences.
The drilled pipes shall be designed to withstand in conjunction with the jacking load
applied, the external loads derived from the overburden load from the site.
Excavation material shall be removed from the conduit as the work process progresses. And no
accumulation of excavated material within the conduit will be permitted. Should appreciable
loss of ground occurs, the voids shall be backpacked to the extent practicable with neat cement
grout. After the completion of the drilling operation, the contractor shall fill up the voids, if
there is any, at the interface between the external surface of the pipe and the surrounding earth.
This shall be carried out be pressure grouting with neat cement grout through the grouth holes
provided around the pipe.
(a)
Submittals
i.
Contractor shall submit the following shop drawings, product data as well as design
calculations prepared, checked and approved by a Professional Engineer registered
with the Board of Engineering Malaysia :-
ii.
Horizontal directional drilling experience meeting the requirements of works.
iii.
Detailed construction scheduling plan complying with overall work progress prior to
the pre-construction meeting.
iv.
Prior to construction, submit the type and capacity of the drilling rig to be used on
the project, include manufacturer, pullback and push torque. Contractor to verify
that allowable pipe stresses of the pipe will not be exceeded by the drilling rig.
Submit information on the type of locating and tracking system. In addition, submit
type and capacity of mud mixing system. Include proposed composition of drilling
fluid, viscosity, and density.
v.
Prior to construction, submit a drawing showing proposed crossing configuration,

including entry and exit angles, radius of curvature, and entry and exit points.
Drawings to include location and dimensions of the starting area at both entrance
and exit pits. Also include information on the diameter of the pilot hole and size
and number of pre-reamers used for development of the borehole.
C.23

vi.
Prior to construction, submit information on the method to address and mitigate

obstruction problems during drilling, reaming, and potential problems of product
pipe becoming stuck during pipe pull back, emergency procedures when drilling
through existing underground utilities, or other events that lead to work stoppage.
Procedures must comply with all regulations.
vii.
Prior to construction, submit information on the method of slurry containment,

method of recycling drilling fluids and spoils (if applicable), or method of containing
drilling fluids or spoils and transporting drilling fluids and spoils off-site (including
anticipated volume), and identify method and disposal site for drilling fluids and
spoils. All material must be disposed in accordance with local, state, and federal
regulations.
Prior to construction, submit plan for cleanup and disposal of spills and fracouts
(drilling fluids, hydraulic fluids) including measures to contain and clean the affected
area. Include details for cleanup of surface seepage of drilling fluids and spoils. All
material must be disposed in accordance with local, state, and federal regulations.
viii.
ix.
Prior to construction, submit information on the method to address and mitigate

collapse or subsidence of surface roadways, adjacent utilities during drilling,
reaming and installation of the pipe.
The Contractor shall maintain a logbook that includes driller notes and records for bores
using steering and tracking system. Data will include pipe number, depth, pitch, steering
commands, and notes. Log must also include rig performance parameters (thrust, pullback,
torque, drilling fluid circulation, drilling fluid composition), ground conditions, obstructions
encountered, time shift started and ended, footage during the shift). Logbook will include
information on drilling fluid (composition, viscosity, density). This logbook must be
available for review throughout the project and must submitted to the Engineer and Owner at
completion of project.
At the completion of the horizontal directional drilling, the pipe log indicating the horizontal
and vertical position at 5 or 10 meter intervals along the pipe to confirm conformance with
the depth and line shown on the Drawings. This submittal shall include the type and
manufacturer of tracking equipment used, date of most recent shop calibration record, and
the method to ensure the data was captured. No payment for any footage of pipe will be
made until its corresponding log is submitted to the S.O and SYABAS.
(b)
Quality Assurance
The horizontal directional drilling shall be performed by the drilling company who is
experienced in the installation of sewer pipelines utilizing the horizontal directional
drilling method.
The Contractor shall submit data on the horizontal directional drilling companys
experience. The drilling company shall have at least three previous successful projects
of 15-inch diameter or larger of High Density Polyethylene (HDPE) pipe utilizing the
horizontal directional drilling method and at least one previous successful on-grade
installation of 18-inch diameter or larger. The drilling company shall provide an
installation list including the following information: City or District, project name and
location, contact person and phone number, contract amount, project environment
(river crossing, urban area), date of installation, pipe diameter, pipe material,
maximum length of each bore, and total length of directional drilling.
C.24

(c)
Pipe
All pipe installed by the horizontal directional boring method shall be PN10 High
Density Polyethylene (HDPE) pipe.
The butt-fusion method for pipe joining shall be carried out in the field by qualified
fusion technicians following the pipe and fitting manufacturers specifications. The
joints shall be smooth, uniform, and de-beaded while supplying the proper melt,
pressure, and alignment. It shall be the sole responsibility of the contractor to provide
an acceptable butt-fusion joint.
All joints shall be made available for inspection by the S.O. before insertion.
(d)
Directional Boring System

Contractor to provide a pneumatically or hydraulically operated, fluid assisted remote
guided boring system capable of installing the pipe by trenchless methods per the
Drawings without damage. The equipment shall be designed to provide accurate
control of both the line and the grade of the boring head.
Contractor to provide pumps, compressors, tools and all equipment certified as
suitable by the system manufacturer to install the new pipe without stressing or
damaging the pipe.
Contractor shall provide a circulatory and recovery system that will recover the
bentonite or other drilling fluids. Contractor shall supply water for mixing drilling fluid.
(e)
Protection
The Contractor shall field verify the location and depth of all existing utilities,
including service connections, to be paralleled or crossed prior to the start of
directional drilling operations. The Contractor shall modify alignment, depth or grade
as necessary to avoid utilities and minimize the number of peaks and valleys along the
alignment.
The Contractor shall expose all utilities that they will be crossing with horizontal
directional drilling. All major utilities (high pressure gas, fiber optic, high voltage
electric, major pipe lines, water and sewer lines, etc.) should be exposed every 30
meter at minimum, if parallel within 1.5 meter of excavation area to verify depth and
location of the utility. If the location is not accurate, the utility owner should be
contacted immediately.
(f)
General Pipe Installation

Install pipe by the directional drilling methods unless conditions require open trench
installation. Obtain Owner approval prior to open trench construction.
Install pipe by continuously pulling the pipe into place from insertion point to exit
point without causing damage to the pipe being inserted. Provide lubricants as
required by the pipe manufacturer to avoid stressing the pipe past its elastic limit.
Contractor shall provide rollers or alternative apparatus to prevent damage to the pipe.
C.25

Provide installation and receiving pits as necessary for complete installation of the
pipe. The excavation of the installation and receiving pits shall be incidental to the
work.
The Contractor shall not start the pullback unless it can be completed without
interruptions. Contractor shall coordinate scheduling with the S.O.
The Contractor shall provide sediment and erosion control measures to prevent drilling
fluid or borehole cuttings from entering the adjacent parcels to the construction limits.
The pilot hole shall establish the horizontal plane of the pipeline. A plot of length
versus elevation versus left/right variance will dictate the actual as-built plan and
profile of the pipeline. Data feedback and electronic guidance systems shall be used
to provide confirmation of position.
Reaming shall consist of using an appropriate tool to open the pilot hole to a slightly
larger diameter than the carrier pipeline. The percentage oversize shall depend on soil
types, soil stability, depth, drilling fluid hydrostatic pressures, etc. Normal oversizing
shall be from 120 to 150 percent of the product pipe diameter. Drilling fluid shall be
forced down the hole to stabilize the hole and to remove soil cuttings. The Contractor
shall carefully monitor the reaming operations to prevent damage to adjacent utilities.
The Contractor shall maintain accurate alignment and grade control and shall
determine the pipe elevation (above mean sea level) at intervals not exceeding 100
meter.
The pipe shall be installed by continuously pulling and/or pushing the pipe into place
through the drilling fluid along the reamed hole pathway from insertion point to exit
point without causing damage to the pipe and pipe joints being inserted. The pullback
speed shall be within the pipe manufacturers recommendations.
Drilling
fluid/lubricants shall be provided as required by the pipe manufacturers
recommendations and specifications to avoid stressing the pipe and joints past the
materials elastic limits. Proper pipe handling, cradling, bending minimization, and
consistent insertion velocity shall be recorded.
Any bits, drills, reamers, or other tools lost or stuck in the hole shall be removed at the
Contractors expense. If tools cannot readily be removed, Contractor may at
Contractors option abandon the hole. The Contractor will seal the borehole and redrill the crossing. No payment shall be made for any lost equipment, material, or
work on abandoned holes.
Drilling fluid to be used to facilitate the installation of the pipe shall be adjusted within
acceptable limits such that ground heaving and subsurface cavity formation through
erosion are prevented.
A variation greater than 18 inches from the horizontal and 0.5 percentage points
from the designated grade may be sufficient reason for the rejection of the pipe, and
the pipe shall be re-bored to proper grade if so directed by the S.O. at no cost to the
Owner.
The alignment shown on the Drawings shall be adhered to unless existing physical
obstructions prevent otherwise. The number of setups and the length of pipe
installation per set up as shown on the Drawings is merely a suggested layout to
achieve the alignment shown on the Drawings. The Contractor shall be ultimately
C.26

responsible for determining the number of set ups required to install the pipe to the
alignment shown on the Drawings. The number of setups shall be incidental to the
work.
The Contractor shall supply portable mud tanks or construct temporary mud pits to
contain excess drill fluids during construction. Spent drilling fluids and cuttings shall
be confined to the entrance and exit pits. The Contractor shall take all necessary
precautions to minimize the damage to the adjacent properties. Any drilling fluid that
enters the pipe shall be removed by flushing or other suitable methods. Upon
completion of the bore, contractor will dispose of any drill cuttings and excess drill
fluids in a manner consistent with the local and state regulations. If working in an area
of contaminated soil, the slurry shall be tested for contamination and disposed in
accordance with local and state regulations. The disposal of the drilling fluids and any
necessary flushing of the pipe shall be incidental to the work.
The Contractor shall be responsible for cleanup and restoration, due to hydro-fractures
from excessive pressure in the drilling fluid. Contractor shall prevent drilling fluids
from entering streams or other water bodies and municipal storm or sanitary sewer
lines (unless prior approval is obtained from the S.O). No additional payment shall be
made for cleanup costs required by S.O., or regulatory agencies due to loss of drilling
fluid.
Pits excavated to permit connection of bored pipe shall be backfilled, and disturbed
areas shall be restored to their original state or better. Sections of sidewalks, curbs,
and gutters or other permanent improvements damaged during horizontal directional
drilling operations shall be repaired or replaces at the Contractors expense. The
backfilling of the boring and receiving pits shall be incidental to the work.
C.27

D - STEEL PIPES AND SPECIALS

1.0
1.1
Scope
This section of the Specifications covers the requirements for the manufacture and
testing of welded steel pipes together with fittings complete with internal and
external protection systems.
1.2
Definition
The following terms shall have the meanings hereby assigned to them except where
the context clearly renders these meanings inapplicable.
Pipes means straight pipes, whether whole or in cut lengths.
Fittings or pipe specials means tees, bends, tapers, collars, flange adapters, blank
flanges, expansion joints, mechanical joints, ring girders and similar accessories.
1.3

The following Standards and Codes of Practice are referred to in this section of the
Specification. The Standard or Codes shall be the latest edition current at the time of
its preparation unless otherwise specified for particular application.
API
5L
Line pipe
API
5LS
Spiral-weld line pipe
API
1104
Standard for welding pipelines and related facilities
BS Handbook 21
Methods for sampling and analysis of iron, steel and

other ferrous metals
BS 12
Specification for Ordinary and Rapid Hardening

Portland cement
BS 534
Steel pipes, fittings and specials for water, gas and

sewage
BS 903
Methods of testing vulcanised rubber
BS 1154
Specification for natural rubber compounds (high

quality)
BS 2494
Materials for elastomeric joint rings for pipework and

pipeline
P:\zRAZMANN\SPEC\D-Steel Pipe&Special1.doc
D.1

1.4
BS 2569
Sprayed metal coatings
BS 4147
Hot applied bitumen based coatings for ferrous

products
BS 4232
Surface finish of blast-cleaned steel for painting
BS 4360/Part 2/2169
Weldable structural steels
BS 4504
Flanges and bolting for pipes, valves and

Fittings Part I : Ferrous
BS 5292
Jointing materials and compounds
BS 5500
Unfired fusion welded pressure vessels
AWWA Mll
Steel pipe design and installation
BSEN 10025:93
Hot rolled products of non-alloy structure steel

Technical delivery condition
BSEN 1092-1:2002
Flanges and their joints circular flanges for pipes,

values, fittings and accessories PN designated. Part 1:
Steel Flanges.
Submissions
The Contractor shall provide drawings, calculations and data in respect of the
following:For pipes and fittings:
-
drawings with descriptions to show the method of forming pipes and fittings in
standard lengths from steel sheets or strip
For joints:
-
drawings for spigot and socket joints showing allowable tolerances and
arrangements to permit air testing of completed joins on Site.
For welding procedure :

-
details of plant, methods, materials , make and size of electrodes, number of

runs and current strength for each type of weld.
For internal lining :

-
full details of method of lining and curing including details and sieve analysis
of materials to be used and type of cement.
D.2

For internal coating :

-
full details of coating process to be used, including details of the bitumen and
the inner and outer wrappings.
2.0
GENERAL REQUIREMENTS OF PIPES AND FITTINGS
2.1
Pipes and Fittings

All pipes and fittings shall be provided by the Contractor and delivered to the Site.
Unless otherwise shown or specified, the Contractor shall at his own cost, supply all
pipes and fittings required for the works and should be new and of makes approved
by SYABAS. Each items supplied shall be suitably marked to permit identification
with items in the Bill of Quantities.
2.2
Steel Pipes
Steel pipes shall be manufactured, except where stated otherwise hereunder, in
accordance with API Specification 5L or API Specification 5LS. Material for pipes
shall be made from carbon steel plate to Grade 43A of BS 4360 Part 2 1969 or
better with a minimum lower yield stress of 245N/mm2 supplied in plate or strip
form as of appropriate for the method of pipe manufacture. The pipes shall be
formed by the automatic submerged arc process, with either a longitudinal seam or
a spiral seam at the option of the Contractor. With the method of manufacture
decided upon, the relevant standard will then apply i.e. API Specification 5L for
longitudinal seam pipe or API Specification 5LS for spiral seam pipe. The API
standards shall be referred to hereunder as Std 5L/S and shall be deemed to apply to
all pipe sizes, including those whose outside diameter (OD) falls outside the upper
limit covered by the standards.
The Contractor shall provide a ladle analysis of the steel used for the pipes in
accordance with Clause 6.1 of BS 4360 Part 2 1969. Check analysis of the finished
pipe shall be taken in accordance with Clause 6.2 of BS 4360 Part 2 1969 and
Clause 3.4 of Std. 5L/S. In case of dispute, the methods of chemical analysis shall be
in accordance with BS Handbook No.21.
At the discretion of the S.O. test certificates may be required from approved
independent inspection agencies for all materials used in the manufacture of the
pipes and specials and the cost of this shall be deemed to be included in the
Contract Rates.
With every consignment of pipes, valves and fittings delivered under this Contract,
the Contractor shall furnish a certificate worded as follows :This is to certify that the quality of the pipes, valves and fittings delivered in this
consignment is not inferior to the sample for which the Contract was awarded or
to the quality laid down in the Specification whichever is applicable.
The thickness of steel plates shall be in accordance with Table 1 subject to the
rolling margins for plates as shown in Table 4 of BS 4360 Part 2 :1969 unless
otherwise stated in the Bill of Quantities.
D.3

The thickness of pipes used for branch pipe-work off the main pipelines or for use in
forming fittings shall be the greatest of the following :
The thickness necessary to provide the same outside diameter to wall thickness
ratio specified for straight pipes;
The minimum thickness shown in Table 6.2 of Std 5L or Table 6.1 of Std 5LS
for pipes of the appropriate diameter (or the nearest equivalent therein);
The thickness determined to be necessary in the design of fittings as shown on

the Drawings.
Standard length straight pipes shall be manufactured with not more than three
circumferential joints and with an effective length as shown in the table below:
Finished Internal Diameter (mm)
450 to 1200
Below 450
Standard Length (m)

9 -10
6
Thickness of Steel Pipes

Nominal
Diameter
(mm)
100
150
200
250
300
350
400
450
500
600
650
700
800
900
1000
1100
1200
1300
1400
1500
1600
1700
1800
1900
2000
2100
2200
Finished
internal
Diameter
(mm)
93.7
149.1
204.0
257.8
313.8
361.7
415.5
469.4
522.7
628.0
651.2
701.2
801.2
901.2
1000.0
1100.0
1210.0
1300.0
1400.0
1500.0
1600.0
1700.0
1800.0
1900.0
2000.0
2100.0
2200.0
Minimum
Steel Plate
Thickness
(mm)
4.1
4.1
4.1
4.1
5.8
5.8
5.8
5.8
5.8
6.5
7.4
7.4
7.4
7.4
8.0
9.5
10.0
11.0
11.0
13.0
13.0
13.0
13.0
13.0
14.0
14.5
15.0
Concrete
Lining
Thickness
(mm)
10
10
10
10
10
13
13
13
13
13
13
19
19
19
19
19
25
25
25
25
25
25
25
25
30
30
30
D.4
External
Diameter
(mm)
121.9
177.3
232.2
285.0
245.4
399.3
453.1
507.0
560.3
667.0
692.0
754.0
854.0
954.0
1054.0
1157.0
1270.0
1372.0
1472.0
1576.0
1676.0
1776.0
1876.0
1976.0
2088.0
2189.0
2290.0
Factory
Hydraulic
Test Pressure
(bars)
70
70
70
70
70
63
56
50
45
42
39
39
39
34
30
30
30
29
29
26
26
26
26
26
25
24
23

The allowable tolerance on standard length pipes shall be 150mm. Standard

length pipes and truly circular standard straight pipes shall be supplied. All standard
pipes shall have ends formed as specified below for joints capable of angular
rotation. Truly circular standard straight pipes required for cutting purposes shall be
truly circular throughout the length.
All pipes whether manufacture with a longitudinal or spiral seam shall be subjected
to non-destructive testing of seam welds and skelp and welds in accordance with
Section 7 of Std 5L or Section 7 of Std 5LS as appropriate.
2.3
Workmanship and Welding Standards

As a control on weld quality the Contractor shall be required to take and submit
100%untrasonic test and 3% radiographs for all welds for the S.O.s clearance. The
clearance and acceptance of these radiographs shall be in accordance with API
Standard 1104 unless otherwise directed by the S.O. Where the above tests are not
possible, the contractor may propose magnetic particle or dye penetration test. The
cost of this shall be deemed to be included in the Contract rates.
Weld defects shall include cracks, leaks, laminations, lack of complete penetration,
lack of complete fusion, dents exceeding one eighth of the specified wall thickness
and undercutting or reduction in pipe wall thickness adjacent to a weld exceeding
0.5mm in depth.
Slag inclusions and gas pockets or voids considered to be minor imperfections may
be accepted if the maximum size and distributions does not exceed the limits shown
in Section 9 of Std 5L or Section 7 of Std 5L/S.
Where radiographic examination reveals defects in the welds the S.O. will either
reject the length of pipe containing such defects or will permit the Contractor to
carry out repairs and to submit radiographs of such repairs for clearance. Lengths of
pipe containing defects in welds after repair will be liable to be rejected.
If defects in welds are found in a length of pipe or fitting, the welds of the pipes and
fittings immediately before and after the defective pipe or fitting in the production
line shall be radiographed until the S.O. is satisfied that all the welds are considered
satisfactory. The cost of such radiographs and radiographs of repaired welds shall be
included in the Contract rates and shall not form part of the 3% of all welds
specified in the first paragraph of this Clause.
2.4
Jointing of Pipes
2.4.1
Pipe Ends
Ends of pipe to be jointed shall generally be as follows :
Spigots and sockets for jointing in trench or above ground for pipes and fittings
with diameter 700mm and above
Plain ends for use with welded collars, mechanical couplings or flange
adaptors for pipes and fittings with diameter 700mm and above
Flanged for pipes and fittings below 600mm in diameters
D.5

The spigot and socket joints for the spherical type shall be designed to take angular
deflection of up to 5 degrees from the axial to accommodate changes of pipe
gradient and/or direction at individual joints. For hemispherical type, the angular
deflection shall be up to 2 degrees.
Spigot and socket joints shall be of the spherical or hemispherical sleeve type with a
minimum penetration of the formed ends. The joint design shall provide for the
contact surface of the spigot end and the sleeve end to be formed to the same
spherical radius which shall be more than 50% of the outside diameter of the barrel
of the pipe for the spherical type and shall not be less than 50% of the outside of the
barrel of the pipe for the hemispherical type. The minimum penetration of the
spigot into the socket shall not be less than four times the pipe thickness and this
overlap shall be obtained at the maximum deflection of 2 to 5 degrees. At zero
deflection the minimum overlap shall be the minimum penetration as above
increased by such allowance as is necessary to ensure contact between the spigot
and socket over the specified maximum amount of joint movement. The joint
engagement tolerance in any position shall not exceed an average of 1.60 mm with
maximum isolated gaps of 2.00 mm adjacent to the weld seams.
Pipe ends of the spherical or hemispherical type shall be formed by hydraulic
pressing using a full circle die or expanding former capable of forming ends
consistently to a constant spherical contact surface through the pipe production run.
The internal surface of the socket and the external surface of the spigot shall be
ground smooth along the pipe axis.
The external surface of the plain ended pipes shall be similarly prepared.
All sockets shall have two tapped holes spaced at 90 degrees apart on the
circumference. They shall be of not less than 6mm diameter and shall be provided
with matching plugs to facilitate the air pressure testing of field welds. These tapped
holes shall be located within the end 30mm of the sockets and shall be cleared of
welding runs.
Ends prepared for butt welding shall be subject to manufacturing tolerances in
accordance with Table 6.3 of Std 5L or Table 6.2 of Std 5L/S.
Plain ends for use with mechanical joints or flange adaptor joints shall be truly
circular with a diameter tolerance of + 1mm over a distance of 225 mm from the
pipe ends.
2.5
Flanged Joints
All flanges shall be of steel, welded to the pipe by the electric arc process or other
approved method. They shall conform in all respects with the requirements of BS
4504 or BS 5500 unless otherwise specified. They shall be of the raised face type
and shall be truly faced over their whole width. Bolt holes shall be drilled off centre
lines, truly in line end to end with the longitudinal axis. All flanges shall be rated as
16 bar. All flanges shall be adequate to withstand test pressures for the fittings to
which they are attached.
D.6

All materials required for use in the making of flanged joints including nuts, bolts,
washers and joint gaskets shall be supplied by the Contractor. The cost of this shall
be deemed to be included in the Contract Rates. Joint gaskets shall be contained
within the bolt pitch circle and shall be made from 4.5mm thick rubber to BS 1154
Class Y3 reinforced with two layers of fabric in accordance with BS 5292. Each bolt
shall be supplied and installed with a nut and two washers and each bolt shall be of
sufficient length to show two threads past the nut when so installed. All bolts and
nuts shall be stainless steel.
Test certificates for the flange material shall be supplied. The finish on flange joint
surfaces shall be in accordance with Clause 4.4 of BS 4504.
Blank flanges shall be designed and supplied by the Contractor for an end loading
equivalent to the rating pressure of the flange. Lifting eyes or handles and air release
cocks shall be provided where necessary.
Thrust flanges shall be designed to withstand a longitudinal force equal to the
loading applied to a blank flange of equivalent diameter.
2.6
Mechanical Couplings, Flange Adaptors and Expansion Joints

Mechanical coupling for jointing plain ended pipes shall be of Viking Johnson
Coupling type or approved make capable of maintaining a water tight joint over a
range of axial movement between the pipe ends of at least 80mm and with up to 3
degrees angular deflection between the longitudinal axis of the pipes.
Flange adaptors for jointing plain ended pipes to fittings shall be of an approved
make capable of maintaining a watertight joint over a range of axial movement of at
least 25mm and an angular deflection.
All necessary couplers, joint rings, nuts, bolts and washers, etc. required for
completing joints shall be supplied by the Contractor and deemed to be included in
the Contract Rates.
Coupling shall be supplied with or without a central register or locating plugs as
required. The central collar shall be at least 1.5mm thicker than the equivalent
standard pipe thickness.
Every coupling, flange adaptor and expansion joint shall be capable of withstanding
without leakage, the pressure required for the works hydraulic test of the section of
pipeline in which it will be incorporated. The pressure rating shall be clearly
stamped on all couplings and adaptors. The rubber joint rings shall be Type 1 to BS
2494 having a hardness range of 45-65 degrees measured in accordance with BS
903 and tensile stress-strain properties detailed in Table 3 corresponding to the
relevant hardness.
All metallic parts are to be de-scaled to second quality standard in BS 4232
protected in accordance to the Specification.
All welding protrusion shall be machined finished. Mechanical couplings and
flange adaptors shall be hydraulic tested at the place of manufacture one in every
five for each size of coupling and adaptor.
D.7

2.7
Pipes for Closing Lengths

Pipes to be used for closing lengths shall be correctly sized over their full length so
that accurate alignment for split collar joints can be obtained. All such pipes shall be
clearly marked.
2.8
Collars
Collars shall be provided for jointing cut pipes closure pieces or by means of
internal and external fillet welding. Minimum lengths of collars shall be 250mm.
Collars may be provided as single split collars with temporary bolts and lugs.
Collars shall have two tapped and plugged holes of not less than 6mm diameter to
permit air pressure testing of the joints after field welding, one on each side of the
collar clear of the welding runs and approximately 24mm from the edge of the
collar. The collar shall be 1.5mm thicker than the equivalent standard straight pipe
thickness.
Collars shall make close contact around the circumferences of both pipes connected
and the gap between the ends of a split collar after tightening shall not exceed 3mm.
Split collar ends shall be prepared for butt welding in the same manner as plain ends
of pipes prepared for butt welding in accordance with Std 5L/S. The tolerance of the
collars shall be such that nowhere shall the gap between the inside surface of the
collar and the outside surface of the pipe at fillet weld locations exceed the
tolerances permitted for spigot and socket joints.
The overlap on each pipe shall not be less than 75mm. Collar joints shall not be
required to take any deflection.
3.0
FITTINGS AND SPECIALS
3.1
Bends, Tees, Tapers etc.

Special items such as bends, tapers, tees, etc. shall be formed from completely lined
pipes as specified by suitable insertion of rubber spacers during lining operation.
The coating and lining on the straight pipes shall be cut back from the ends to be
welded or cut for a sufficient distance to ensure that no material which is intended
to remain part of the coating/lining is damaged or affected by the welding or cutting
process.
Pipe specials shall be designed to withstand the full specified factory test pressures.
Compensation plates and gusset plates shall be in accordance with BS 5500.
Welding shall be of a standard equal to that of straight pipes. Fillet welds shall be
subjected to air tests where appropriate and/or magnetic crack detention tests.
The outside diameter of specials shall conform to the outside diameters of the
standard straight pipes and each butt weld subjected to a 100% radiographs test.
The ends of plain ended specials shall be truly circular and shall conform to the
tolerance required for the fitting of mechanical couplings and flange adaptors.
D.8

4.0
PIPELAYING AND HANDLING
4.1
Pipe-work for Laying Above Ground

Uncoated steel pipes and fittings required for installation above ground shall be
protected by painting as specified in Section N.
4.2
End Protection
The concrete lining and the external coating of pipes and fittings to be jointed by
welding shall be omitted for a sufficient distance from the ends to prevent damage to
the protection during site welding.
The unlined surfaces shall be protected with a suitably approved ensis oil or similar
material during manufacture so that extensive cleaning of the surface is not required
before and after jointing on site.
4.3
Handling
Coated pipes shall be lifted and moved only by wide non-abrasive slings or by other
means acceptable to the S.O. Wire ropes, chains and hooks shall not be permitted to
come in contact with the coating. No pipe shall be moved by rolling.
Coated pipes shall be stacked in one layer only and in such a manner that the
coating is not damaged. Adequate packing between pipes for this purpose must be
supplied by the Contractor. Coated pipes must be kept clear of the ground and
rested on padded sleepers or supports.
The pipes shall be so handled, stored and transported as to prevent undue distortion
and shall not be moved in any manner involving rotation of the pipes about the
longitudinal pipe axis.
The pipes shall be lifted by means of two reinforced canvas slings at least 300mm
suspended from a lifting beam so that the slings are positioned at a distance of onefifth of the pipe length from each end of the pipe.
The Contractor shall provide suitable timber end struts and sufficient intermediate
struts to strengthen the pipes to the S.O.s approval to prevent distortion during
handling and delivery.
4.4
Protection in Transit
All pipes and fittings shall be protected prior to dispatch from the manufacturers
works. All flanges shall have wooden discs bolted on. All other ends of pipes and
fittings shall be protected against impact damage and entry of foreign matter. The
protection shall take into account the end use intended for the pipes and whether or
not the final protection has been completed.
Pipes and fittings shall be wrapped or cushioned so that no load is taken directly on
the external coating.
D.9

4.5
Inspection
All pipes and fittings to be supplied under the Contract shall be inspected by the
S.O. at the Contractors premises or at the places of manufacture if manufactured at
other premises.
The Contractor shall provide such office facilities, assistance, labour, materials,
electricity supply, fuel, stores, apparatus and instruments ultrasonic thickness
indicators and high voltage holiday detectors as may be necessary to allow a
thorough and extensive inspection to be carried out.
The S.O. shall be entitled at all times during manufacture to inspect, examine and
test on the Contractors premises or at the places of manufacture if manufactured at
other premises, the materials and workmanship of the pipes and fittings. Such
inspection, examination or testing including the inspection by the S.O. shall not
relieve the Contractor from any of his obligations under the Contract.
4.6
Markings of Pipes and Fittings

Each standard length of pipe, pipe specials and truly circular pipes shall have the
following information painted outside:
The word SYABAS (50mm high) in capital letter

The diameter, length and consecutive number and Bill of Quantities item
number.
The weight in kilogram.
The item number and its consecutive number if more than one in the item
Diameter of branch in the case of tees and angle in the case of bends and
angle branches.
Truly circular pipes shall be marked with two longitudinal parallel bands throughout
their whole length.
The diameter and its consecutive number of standard length pipes shall be repeated
on the lining just inside on both ends of the pipes.
The item number and diameter of branch in the case of tees and the angle in
degrees in case of bends shall similarly be repeated on the lining.
4.7
Measurement
The quantities set out in the Bill of Quantities are provisional only and they are not
to be taken as the actual, limiting and correct quantities of the pipes and fittings to
be supplied by the Contractor in fulfillment of his obligations under the Contract.
For the purpose of this clause, spigot and socket ended pipes shall be measured and
paid in effective length. The effective length shall mean the net length of the pipe as
laid, i.e. after deduction of the length of overlap at any spigot and socket joint to be
made with the pipe. Plain ended pipes shall be measured and paid by the gross
length and pipe specials shall be measured by numbers. All pipes and specials shall
only be measured for payment after they have been laid and incorporated in the
D.10

works. Any excess pipes and specials supplied to the Site shall not be measured for
payment.
The cost of all works testing and all other requirements of the Specification
including lining, coating, wrapping, etc, involved in the manufacture and delivery of
the steel pipes shall be deemed to be included in the Contract Rates.
4.8
Miscellaneous
All flanged pipe ends, flanged branches and plain ends for use with mechanical
couplings or flange adaptors shall have a 6mm steel retaining ring welded into the
bore of the pipe flush with the end of the pipe after which the ring shall be zinc
chromate coated as specified followed by two coats of bituminous paint. The radial
thickness of the rings shall be similar to the thickness of the concrete lining and shall
not be less than 6mm.
4.9
Physical Testing
Unless otherwise specified physical testing of the pipes shall also be in accordance
with Section 4 Std 5L/S.
4.10
External Coating
The pipe shall be coated with bitumen generally in accordance with Clauses 29 of
BS 534 except that the protection shall have a minimum thickness of 6mm for pipes
over 324mm o.d. The bitumen shall be Type 2 of BS 4147 and there shall be not
less than 2mm of bitumen between the inner and outer wraps, and between the pipe
and the inner wrap.
The coating shall be stopped short as shown on the Drawing for ends of all spigot
and socket pipes, and 250mm from the ends of all plain ended pipes for use with
mechanical couplings or flange adaptors. The edge of the wrapping shall be
chamfered at 25 degrees.
4.11
Wrapping
The wrapping materials shall be spirally wound onto the pipes and fittings
simultaneously with the bitumen coating. Each wrap shall be from 150-225mm
wide and the edges shall overlap by 12-25mm. Care shall be taken to ensure that
the inner wrap does not come into contact with the pipe metal or with the outer
wrap.
The inner wrap shall be a glass fibre resin-bonded tissue reinforced in the
longitudinal direction with parallel glass threads space 10mm apart. The nominal
thickness shall be 0.5mm and the minimum weight shall 0.046kg/m2.
The outer wrap shall be of glass fibre resin-bonded tissue reinforced in the
longitudinal direction with parallel glass threads spaced 10-25mm apart. It shall be
impregnated with a material fully compatible with the bitumen coating to give a
finished thickness of 0.75mm.
D.11

Peel-Off Test and Holiday Test in accordance to BS 534 shall be carried out at a
frequency of 1 in every 50 completed wrapping joints.
4.12
Inspection of External Pipe Coating

All coated pipes and fittings shall be rigidly inspected for defects. Thickness shall be
determined by a pit gauge, continuity with a holiday detector and coating quality by
cutting out 75mm square samples at the rate of the one sample per 5 lengths of pipe
manufactured.
The whole coated surface area of all pipes and fittings shall be tested for pinholes or
other invisible defects in the coating using an approved holiday detector at a
potential of 14,000 volts.
Any lengths on which the coating is, in the opinion of the S.O. poorly applied shall
be cleaned to bare metal and re-coated. Minor defects may be repaired by touching
up. All repairs shall be checked for thickness and continuity.
4.13
Painting Coated Pipes and Fittings

All coated pipes and fittings shall be painted as specified below:
a) 75 micron minimum thick primer after surface (at factory) preparation.
b) 150 micron minimum dry finished thickness surface iderant epoxy (after lay)
c) 100 micron minimum dry finished thickness of polyurethane (after laying)
5.0
SPUN CONCRETE LINING AT FACTORY

All pipes and specials shall be lined with concrete. Cement for lining shall be
Ordinary Portland Cement to BS 12. Aggregate shall be well-graded clean fine
aggregate and the maximum particle size shall not exceed 8mm or one-third the
thickness of the lining, whichever is the lesser. All materials used in concrete for
lining shall comply with the requirements for concrete.
The final aggregate grading and concrete mix proportions shall be such that a hard,
durable and dense concrete lining is obtained that satisfied the tests laid down in
Clause 33 of BS 534. Unless otherwise approved, the minimum cement content
shall be 380kg/m3 and the water cement ratio of the mix loaded into the pipe shall
not exceed 0.42. Tests shall be carried out during the lining of pipe to demonstrate
that the concrete lining has a strength equal to or greater than the minimum figures
stated in Clause 33.5 of BS 534. The frequency of these tests shall be at least once
every 250m length of pipe lined or during each working shift, whichever is the
greater.
The testing of concrete cubes shall be conducted at the factory of manufacture.
D.12

All straight pipes shall be concrete lined by the use of a lining machine designed
and built for the purpose of rotating the pipe and centrifugally applying the lining at
sufficient speeds to meet the requirements set out below. The support or holding
device for the pipe shall be such as to avoid damage to the pipe coating during the
spinning operation. If the pipe is rotated by direct contact drive from the machine it
shall be supported over at least 90 degrees of its circumference and driven by nonmetallic surfaced belts of sufficient width to avoid coating damage. The speed of
rotation of the pipe during the lining compaction stage shall be such as to provide a
radial acceleration of at least 250m/s2. The rotational drive shall be capable of close
control and provide smooth acceleration and deceleration when working up to and
down from the compaction spinning stage.
Immediately before lining commences, the pipe bore shall be cleaned of all loose
scale, rust, oil, grease or any other foreign matter likely to contaminate or harm the
concrete. Areas where an approved primer coat has bonded to the pipe such that
wire brushing does not cause areas to flake off will be acceptable as a base for
applying the lining.
The entire quantity of concrete required for the lining shall be continue until the
specified thickness is evenly distributed over the inside of the pipe, all surplus water
has been removed and the greatest possible density of concrete has been obtained.
Tolerance on the thickness of lining shall be as follows :
+3mm to -2mm for 25mm and above

+2mm to -1mm for 19mm and above
Temporary or semi-permanent end restraints shall be fixed to the pipe ends on

completion of lining and before removal of the pipe from the lining machine. The
pipe shall not be rotated about its longitudinal axis after the fixing of the storage
yard and subsequently to the site.
Fittings shall be concrete lined at the factory in such a manner that the lining shall
be of the specified thickness and comparable in density and smoothness to the spun
lining in straight pipes and generally applied in accordance with Clause 33.2 of BS
534. During the lining process, all rebound materials, dribbles, etc. shall be
removed so that the lining is applied in a homogeneous mass to a clean surface.
Inspection of the lining shall be carried out any time prior to and after installation of
the pipes. Any pipe with lining that is broken, defective or otherwise not in
accordance with the Specification may be rejected. The Standard of the remedial
lining shall satisfy the requirements of this Specification.
Surface crazing of the lining will be acceptable unless cracks are severe enough that
they can be penetrated to a depth of 2mm by a 250 microns feeler gauge at 10
points or more over a length of 300mm when measured with the lining in a
saturated condition. These cracks shall be cut back to full depth and sealed with
approved epoxy resin filler.
D.13

Linings applied to pipes shall be cured in such a manner as will enable concrete to
obtain and subsequently retain optimum strength, density and durability.
Linings shall be kept moist by continuous water spraying for a period of at least 3
days. They shall then be protected from sunlight and kept damp by spraying with
water or other means approved by the S.O. for a further period of 7 days. Pipes
shall not be removed from the factory until at least 14 days have elapsed from the
date of lining.
6.0
INTERNAL PROTECTION AT PIPE ENDS

Concrete shall be omitted at the following location:
Spigot and socket ends
-
The edge of the lining shall be angled back at 3mm to the pipe axis in order to
provide a positive key for in-situ joint protection
Plain ends
-
For butt straps or collar joints the lining shall terminate 90mm back from the
pipe end. The edge of the lining shall be angled back at 3mm.
For mechanical coupling and flange adaptor joints, the lining shall be brought
right against the retaining rings.
D.14

E: DUCTILE IRON PIPES AND FITTINGS

1.0
GENERAL
This specification is applicable to Ductile Iron Pipes for water supply systems and
shall conform to BS EN 545:2002.
These specifications will provide necessary information on the product dimension
and requirements for the supply of pipes only.
2.0
PIPES
The pipe shall be manufactured with socket and spigot, plain-ends and flanged-ends
of Class 40 or Class K9.
For all specials/fittings, the products shall be of minimum Class K12.
All Ductile Iron Pipes and accessories shall be designed to withstand hydraulic
working pressure of PN 16.
All flanges shall be of ductile iron complying with BS EN 545 : 2002 or equivalent
standards.
3.0
MANUFACTURING PROCESS
Pipes and the accessories of Ductile Iron may subjected to suitable heat treatment in
order to give them the required mechanical characteristics or tensile properties as
shown below:-
CHARACTERISTICS
CENTRIFUGALLY CAST
PIPES
DN 100 to 800
TENSILE STRENGTH
( N/mm )
420 (Min)
ELONGATION
(%)
10 (Min)
HARDNESS
( HB )
230 (Max)
Table 1
P:\zRAZMANN\SPEC\E-Ductile Iron1.doc
E.1
FITTINGS
DN 100 to 800
420 (Min)
5 (Min)
250 (Max)

4.0
DIAMETER AND SHELL THICKNESS

All straight pipes shall have an effective length of 6.0 meter.
The diameter and shell thickness of standard pipes shall be as shown below:PIPE DIAMETER (mm)
NOMINAL
OUTSIDE
DIAMETER
DIAMETER
(DN)
(OD)
100
118
150
170
200
222
250
274
300
326
350
378
400
429
450
480
500
532
600
635
5.0
PIPE CLASS
(CLASS 40)
4.8
5.0
5.4
5.8
6.2
7.0
7.8
-
SHELL THICKNESS (mm)

PIPE CLASS
SPECIALS /
(K 9)
FITTINGS CLASS
(K 12)
6.0
7.2
6.0
7.8
6.3
8.4
6.8
9.0
7.2
9.6
7.7
10.2
8.1
10.8
8.6
11.4
9.0
12.0
9.9
13.2
COATING AND LINING FOR PIPES

The external coating of D.I. Pipes and specials/fittings shall consist of a layer of
Metallic zinc covered by a layer of a bitumen coating and loose polyethylene
sleeving.
The mean mass of zinc per unit area shall not be less than 130g / m.
The metallic zinc coating shall cover the external surface of the pipe and provide a
dense continuous, uniform layer. It shall be free from such defects as bare patches or
lack adhesion. The uniformity of the coating shall be checked by visual inspection.
Damage to coating where the area of total removal of metallic zinc has a width
exceeding 5 mm and areas left uncoated shall be repaired. Repaired shall be carried
out either by:
Metallic zinc spray, or
Application of zinc rich paint containing at least 90% of zinc by mass of dry
film; the mean mass of applied paint shall not less than 150g / m.
Bitumen coating shall not be less than 70m. It shall uniformly cover the whole
surface of metallic zinc layer and free from such defects as bare patches or lack of
adhesion. The uniformity of the finishing layer shall be checked by visual
inspection. Unless otherwise specified, the finishing layer of bituminous product
shall be coated externally with either one of the following :
Coal tar epoxy (epoxy content approximately 12%)
E.2

Standard coating materials as specified in BS 4147:1980 Type I (bitumen based,

hot applied), or
Standard coating materials as specified in BS 3416:1976 Type II (bitumen

based, cold applied)
Loose Polyethylene Sleeving shall be as specified in ISO 8180 : 1985 Ductile Iron
Pipes Polyethylene sleeving and ISO/DIS 8180 Ductile Iron Pipes for site
application.
The sleeving shall be fitted to effect a smooth, closely contoured envelope with
minimum barrels and socket gaps. There shall be sufficient slack in contouring to
allow the sleeving to follow the profile to the spigot socket interface to prevent
damage during backfill.
Adhesives tape shall be used to seal the free edges of sleeving. The function of the
tape is to inhibit ingress, circulation or passage of ground water inside the
encasement adjacent to the pipe.
The seal is recognized as not only being watertight but still effective in severely
limiting ground water flow.
To assist handling during application and installation, the free edge of the fold shall
be circumference taped at one meter intervals along the barrel of the pipe.
Any damage to the sleeving shall be repaired using tape and cut sections of sleeving
before back filling.
6.0
INTERNAL LINING OF CEMENT MORTAR

All D.I. Pipes and specials/fittings shall be mortar-lined internally.
The lining shall be applied by a centrifugal spinning process or a centrifugal spray
head or a combination of those methods.
The cement mortar mix shall comprise of cement, sand and water. Chloride free
admixture may be used if necessary.
The ratio by mass of sand to cement shall not exceed 3.5.
The compressive strength of the cement mortar after 28 days of curing shall be not
less than 50 Mpa.
E.3

The required thickness of the cement mortar lining and its tolerance shall be as
stipulated in Table 2.
NOMINAL DIAMETER
(DN)
THICKNESS OF CEMENT LINING

(MM)
MAXIMUM CRACK
WIDTH AND RADIAL
DISPLACEMENT
NOMINAL
VALUE
LIMIT
DEVIATION*
40 to 300
- 1.5
0.4
350 to 600
- 2.0
0.5
* Only the lower limits are given
7.0
RUBBER RING / GASKETS

Rubber rings/ gaskets for ductile iron pipes and accessories shall be such size and
shape of manufacturers designs as to provide a pressure tight seal for the life
expectancy of the pipeline under specified working, transient and test pressure
conditions.
Rubber gasket materials shall be of EPDM complying with the requirements of MS
672 :1999, AS 1646 :1992 or BS EN 681 with of 55 85 IHRD with a minimum
volume of 40% of polymer in rubber compound.
8.0
TESTING AND INSPECTION

All ductile iron pipe and accessories shall comply to sampling frequencies and tests
in accordance with the Standards referred.
9.0
PACKING
All ductile iron pipes shall be individually packed with proper methods and
protected from damage during transit.
10.0
MARKING ON DUCTILE IRON PIPES

The following cast-on or cold-stamped marks shall appear on the socket end of each
pipe :
The manufacturers identification mark.
The year of manufacture (the last two digits).
The indicators that the pipe is ductile iron, D.I. .
The nominal diameter (i.e. DN .).
The rating of flanges where applicable (i.e. PN ).
E.4

11.0
Standard Reference BS EN 545:2002.
The word SYABAS (50mm high) in capital letters.
Class designation (Class 40 or K9)
Serial Number
PRE- DELIVERY INSPECTION AND EVALUATION

It is the responsibility of the Tenderer to inform SYABAS for inspection purposes
during manufacturing before delivery.
SYABAS reserved the right to inspect and witness the testing of product offered.
At any time, when requested, the supplier is to provide SYABAS a sample of the
product for evaluation purposes. All costs shall be borne by the Supplier.
If at any time the Supplier failed to deliver the required sample, the product is
deemed to have failed to comply with the Specification.
12.0
CERTIFICATION
Manufacturers or Suppliers are required to provide a copy of the certificate and test
reports either from SIRIM, IKRAM or other recognized certification bodies.
Test reports required shall be those tests conducted within a period of a year.
SYABAS reserved the right to refuse offer or reject supply if the relevant documents
are not enclosed.
13.0
JOINTING AND ASSEMBLY
13.1
Jointing Instruction
Before assembling the joint, the spigot of the pipe and interior of socket of the
adjacent pipe shall both be thoroughly cleaned.
Insertion of Gasket
The gasket shall be wiped clean and flexed and then placed in the socket with bulb
leading. The groove in the gasket must be located on the retaining bead in the
socket, and the retaining heel of the gasket firmly bedded in its seat so that the heel
of the gasket is not proud of the mouth of the pipe. The Contractor shall ensure the
gasket fits evenly around the whole circumference, removing any bugles that
prevent the proper entry of the spigot end.
E.5

Lubrication
A thin film of lubricant is then applied to the inside surface of the gasket which will
be in contact with the entering spigot. In addition, a thin film of lubricant should be
applied to the outside surface of the spigot end.
Initial Entry of Spigot
The spigot of the pipe jointed must be aligned and entered carefully into the
adjacent socket until it makes contact with the gasket. Final assembly of the joint is
completed from this position.
Completely Assembled Joint
Joint assembly is completed by forcing the spigot end of the entering pipe past the
gasket, which is this compressed, until the first painted strip on the end of the pipe
disappear and the second painted strip is approximately flushed with the socket
face. If joint is difficult to assemble, the spigot should be removed and rotated 90
degree before attempting to assemble a second time. If the joint is still difficult to
assemble, the spigot should be removed and the gasket examined.
Deflection
The joints can be deflected in any directions up to 5 degree for pipes up to 300mm
diameter nominal size, up to 4 degree for 350mm and 400mm size and up to 3
degree for 450mm to 700mm.
All spigot must be chamfered.
When making a joint, pipes should always be in line and if required, deflection
made after jonting.
13.2
Method of Assembly
Assembly of the joint shall simple, and may accordingly be carried out by any of the
following methods:Crowbar Method
Complete entry of the spigot into the socket may be obtained by pushing with a
crowbar or a suitable lever against the face of the socket of the entering pipe.
Fork Tool Method
This method may be used for 100mm and 150mm pipe. The fork is placed over and
behind the socket of the last pipe laid. A wire rope with eye at one end and a hood
at the other is connected to the socket of the pipe to be jointed. The fork is now
pulled in direction of arrow and the spigot enters the socket. Reasonable force shall
only be used.
E.6

Trifor or Come along Method

For joint above 150mm a wire rope or chain can be used.
Trench Excavator Method
When the trench is being prepared by using a back hoe or excavator, either machine
may also be used to push the spigot home. This system is mainly used on large
diameter pipe and a timber header should be placed between the pipe and the
bucket to prevent damage to the pipe.
14.0
CUTTING
Ductile iron pipes can be cut by a number of methods.
Where flexible joints are to be made, the cut ends must be trimmed with a file or
grinder to remove the burr formed during cutting and a chamfer must be provided.
A Power Driven Abrasive Disc can be used and is suitable for all sizes. There is no
need for adjustment to suit pipe size or to attach machinery to the pipe. The
abrasive discs are fitted to suitable hand held power tools usually driven by
compressed air or small internal combustion engines.
Semi-Rotary Wheel Type Cutters are available, ranging from the standard chain link
cutters to more sophisticated tools employing a rigid hinged frame. This type of
cutter is normally used on smaller diameter pipe.
It is important when ordering abrasive disc cutting equipment to state that it is for
use with ductile iron pipe and to ensure that the disc type, size and the spindle
speed of the equipment are compatible.
Rotary and Orbital Pipe Cutters, using cutting tools of the simple lathe or milling
saw type respectively, are available throughout the diameter range. Whichever type
of cutter is employed the basic machine is attached to the pipe and the cutting tool
is driven around the pipe by means of gears on a chain link track. The orbital type
cutters have the advantage on the larger sizes of ductile iron pipe in that they a
capable of accommodating the avolities which are sometimes present. Some are
also capable of forming the chamfer in the same operation. These types of machine
are usually driven mechanically, e.g. by compressed air motor although for pipes in
the smaller diameter a hand-operated windlass may be employed. In machines
using lathe type cutting tools, the cutter heads must have a 7 front rake.
Reciprocating Power Saws may also be used for cutting ductile iron pipe. These
tools are usually electrically driven and for this reason they are principally used in
depots or workshop where power supply is available.
The pipe DN<300 the external diameter (measured circumferentially) enable
assembly of the joint over a minimum of two thirds of pipe length from the spigot
end when the pipes need to be cut on site. For pipes DN>350 the same applies to
a percentage of the pipes.
E.7

a)
Procedure for pipe cut on site DN>350

Check the average external diameter of the pipe at the proposed point of the
cut. The dimension must comply with the limits specified in the next table.
Average external diameter of pipe
Measured circumferentially
with standard tape
Maximum
Maximum
mm
mm
1191
1177
1351
1337
1511
1297
1674
1660
1998
1983
Nominal
size DN
350
400
450
500
600
Measured circumferentially
with standard tape
Maximum
Maximum
mm
mm
379
374.5
430
425.5
481
425.5
533
528.5
636
631.0
A diameter tape is calibrated to enable diameters to be read off directly when the
pipe is measured circumferentially.
After cutting the pipe check the cut end and where is found to be oval, locate
and mark the major axis. Measure the length of the major axis. Only where
this exceed the dimensions specified in the table, will ovality correction be
required prior to jointing.
Note : Cut spigot joint must be chamfered
Maximum major axis of spigot ends
Nominal size
DN
350
400
450
500
600
700
b)
For jointing into

T-TYPE SOCKET
mm
379
430
481
533
636
748
For jointing into

K-TYPE SOCKET
mm
379
430
481
533
636
739
Procedure for full length pipe jointed into K type socket

The major axis of the spigot end of a K type joint pipe is indicated by the short
white line painted on the spigot at works.
Measure the length of the major axis, only where this exceeds the appropriate
dimension specified in the above table will ovality correction be required
prior to jointing.
E.8

15.0
OVALITY CORRECTION
Two methods are recommended for ovality correction.
Method A
The use of this method is recommended where it is possible to remove the tackle
after ovality correction and subsequent jointing.
Position the timber strut and jack (approximately 5 tons capacity) inside the spigot
end of 90 degree to the major axis. Rubber pads should be placed in position to
prevent possible damage to the pipe lining. Extend the jack until the major axis has
been reduced to the appropriate limit specified in the table. Complete the jointing
operation with the major axis of the spigot vertical.
Note : In some instances, e.g. jointing into couplings, it may be necessary to use
two jacks in order to obtain a `round profile.
Method B
The use of this method is recommended where it is not possible to remove the
tackle described in Method A. After ovality correction and subsequent jointing,
place the tackle around the spigot end of the pipe at a position approximately
450mm from the pipe end and with major axis of the spigot the re-rounding tackle
and protection system to prevent damage.
Tighten the two nuts evenly until the major axis has been reduced to the appropriate
limits specified. Complete the jointing operation with the major axis of the spigot
vertical. After jointing, remove the tackle.
Note : Where the pipes are to be concreted into a structure they should, if
necessary be re-round before this is done and left until the concrete has set, before
the re-rounding tackle.
E.9

F: HIGH DENSITY POLYETHYLENE (HDPE) PIPES AND FITTINGS

1.0
GENERAL
This specification is applicable to High Density Polyethylene (HDPE) Pipe for water
supply systems and shall conform to JKR Standard Specification JKR 202000-0053-99
and MS 1058:2002.
Relevant standards are:BS 4505
Specification for flanges and bolting for pipes, valves & fittings.
Metric series.
BS EN 545
DI pipes, fittings, accessories & their joints for water pipelines

Requirements & test methods
BS 970 Pt. 1
General Inspection and Testing Procedures and Specified

requirements for Stainless Steel.
AS 1646
Standard Specification for Elastomeric joint rings for Waterworks

purposes.
MS 672:99
Specification for rubber seals in water supply, drainage, &

sewerage pipelines.
BS 5292
Jointing materials & components for installation using water, low

pressure steam.
BS 2789
Specification for Iron castings with spheroidal nodular graphite.
BS EN 1563
Specification for Founding Spheriodal graphite cast iron.
BS EN 10025
Hot rolled products of non-alloy structural steels and their

Technical delivery conditions.
BS 3643
ISO metric screw threads.
BS 4190
ISO metric black hexagon bolts, screws and nuts.
BS 6681
Specification for Malleable cast iron.
BS 6920
Specification for Suitability of non-metallic products for use in

contact with water intended for human consumption w.r.t to their
effect on the quality of the water.
AS/NZS 4158
Thermal-bonded polymeric coatings on values and fitting for

water industry purposes Liquid Epoxy Coating Systems For The
Interior And Exterior Of Steel Water Pipelines.
WIS 4-52-03
Water Industry Specification for anti-corrosion coatings on

threaded fasteners
D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\F- High Density1.doc
F.1

2.0
ISO 12162
Thermoplastics materials for pipes and fitting for pressure

applications Classification and designation overall service (
design ) coefficient.
ISO 12176-1:98
Plastics pipes and fittings Equipment for fusion jointing

polyethylene systems Part 1 : Butt Fusion.
EN 712
Thermoplastics piping system End load bearing mechanical

joints between pressure pipes and fittings Test method for
resistance to pull out under constant longitudinal force.
EN 713
Plastics piping system Mechanical joints between fittings and

polyolefin pressure pipes Test method for leak tightness under
internal pressure whilst subjected to bending.
EN 715
Thermoplastics piping systems Mechanical and cemented joints

between pressure pipes and fittings Test method for leak
tightness under internal pressure, including end thrust.
EN 921
Thermoplastics pipes Determination of resistance to internal

pressure at constant temperature.
ISO 13953:1995
Polyethylene pipes and fittings Determination of tensile

strength of test piece from butt fused joint.
ISO 13954:1997
Plastics pipes and fittings Peel de-cohesion test for polyethylene

(PE) electro-fusion assemblies of nominal outside diameter greater
than or equal to 90mm.
ISO 13955:1997
Plastics pipes and fittings Crushing de-cohesion test for

polyethylene (PE) electro-fusion assemblies.
ISO 13956:1995
Plastics pipes and fittings Pull out de-cohesion test for

polyethylene electro-fusion assemblies.
MATERIAL
The High Density Polyethylene (HDPE) Pipe shall be made from base polymer and shall
conform to the requirements as specified in MS 1058 Part 1:2002.
The base polymer shall be a single grade of polyethylene, PE 80 with a derived density
greater than 0.93g/cm tested at 20 C.
No rework material is allowable for the manufacture of the pipes.
No additives that may contribute to toxic hazard, impair the fabrication of properties
and chemical and physical properties in particular to long term mechanical and strength
is allowed.
3.0
COLOUR
F.2

The colour of the pipes shall be black with blue stripes. The material for stripes shall be
of the same type of resin as used in the compound for the pipe.
4.0
PIPE CLASSIFICATION AND DIMENSION

All HDPE Pipes must be from Class PE 80 with Nominal Pressure (PN) 12.5 and
Standard Dimensions Ratio (SDR) 11 with the minimum strength at 20 C.
Wall thickness and nominal diameter of PE 80 pipes are given below.
NOM. DIAMETER
FOR OTHER PIPES
(mm)
20
25
32
40
50
63
75
90
110
125
140
160
180
200
225
250
280
315
355
400
450
500
560
630
WALL
THICKNESS
(mm)
2.0
2.3
3.0
3.7
4.6
5.8
6.8
8.2
10.0
11.4
12.7
14.6
16.4
18.2
20.5
22.7
25.4
28.6
32.2
36.3
40.9
45.4
50.8
57.2
INTERNAL
DIAMETER
(mm)
18
22.7
29
36.3
45.4
57.2
68.2
81.8
100
113.6
127.3
145.4
163.6
181.8
204.5
227.3
254.6
286.4
322.8
363.7
409.1
454.6
F.3
OUTSIDE
DIAMETER
(mm)
20
25
32
40
50
63
75
90
110
125
140
160
180
200
225
250
280
315
355
400
450
500

5.0
TOLERANCE
The tolerance for wall thickness is determined by the difference between the wall
thickness and the nominal wall thickness as follow:
PN 12.5
NOM. DIAMETER
FOR OTHER PIPES
(mm)
WALL
THICKNESS
(mm)
Min
WALL
THICKNESS
(mm)
Max
WALL
THICKNESS
(mm)
Min
WALL
THICKNESS
(mm)
Max
2.0
2.3
3.0
3.7
4.6
5.8
6.8
8.2
10.0
11.4
12.7
14.6
16.4
18.2
20.5
22.7
25.4
28.6
32.2
36.3
40.9
45.4
50.8
57.2
2.3
2.7
3.4
4.2
5.2
6.5
7.6
9.2
11.1
12.7
14.1
16.2
18.2
20.2
22.7
25.1
28.1
31.6
35.6
40.4
45.1
50.1
56
63.1
2.0
2.3
3.0
3.6
4.5
5.6
8.4
10.1
12.3
14.0
15.7
17.9
20.1
22.4
25.2
27.9
31.3
35.2
39.7
44.7
50.3
55.8
2.3
2.7
3.4
4.1
5.1
6.3
9.4
11.3
13.7
15.7
17.4
19.8
22.3
26.0
27.9
30.8
34.6
38.9
43.8
49.3
55.5
61.5
20
25
32
40
50
63
75
90
110
125
140
160
180
200
225
250
280
315
355
400
450
500
560
630
6.0
PN 16
LENGTH
The required length of HDPE pipes in coil for nominal diameter 63 mm and below will
be100 meter.
The standard length of HDPE pipes for nominal diameter 125 mm and above shall be
9m or 12m.
7.0
APPEARANCE
The internal and external surfaces of pipes must smooth, clean and free from scoring,
cavities and other surface defects which may affect pipe performance.
The ends of pipe shall cut cleanly and square to the axis of the pipe. Appearance shall
be checked at the point of manufacture.
F.4

8.0
ROUTINE TESTS
The pipe suppliers shall, as and when requested by the S.O., furnish results of the
routine tests carried out in accordance with the requirements as stipulated in MS 1058:
Part 1 : 2002.
The minimum Oxidation Induction Time (OIT) for pipes fitting shall be 80 min. The
manufacturer must have their own differential Thermal Analyzer or Differential
Scanning Calorimeter available for SYABAS representatives to carry out the OIT.
9.0
PIPE MARKINGS
All pipes must have the following markings:
Manufacturers name or trade mark

Dimensions
Material supplier and material class (PE 80)
Pipe Class (PN)
The word SYABAS (50mm high) in capital letter
SIRIM/IKRAM and QAS Number.
Year of manufacture (last two digits)
Batch production number
10.0
PIPE FITTINGS
10.1
Types of pipe fittings

The following types fittings shall comply to MS 1058 or EN 12201 3
a)
b)
c)
10.2
Spigot fittings
Electro-fusion fittings and
Mechanical fittings and joints
Spigot Fittings
Spigot fittings fall under three classes as shown below.
Class
Description
Moulded
Injection moulded fittings
Fabricated
o PE 80 min. (PN 12.5 pressure rating)
Fitting which are assembled using butt

fusion joints
Fittings shaped from moulded fittings or
pipes without fusion
The dimensions of spigots up to and including nominal size 63 shall conform to the
requirements of standards.
F.5

10.3
Electro-fusion Fittings
Electro-fusion fittings shall be injection moulded fittings made of PE but incorporating
integral heating element(s) to enable fusion jointing with PE pipes. All PE100 fittings shall be
jointed by couplers only.
10.4
Mechanical Joints and Fittings

i)
General
Metal and plastic fittings available for use with PE pipe are:
Polymeric coated Flanged and other adaptors,
Mechanical type couplers c/w restrainer,
The materials and constituent elements used in making the fitting (including elastomers,
greases and any metal parts) shall be as resistant to the external and internal environments
as the other elements of the piping system and shall have a life expectancy under the
following conditions as least equal to that of the PE pipe conforming to MS 1058 or EN
12201-3 with which they are intended to be used :
a)
During storage;
b)
Under the effect of the fluids being conveyed;
c)
Taking account of the service environment and operating conditions.
The requirements for the level of material performance for non-polyethylene parts shall be
at least as stringent as that of the PE pipe systems.
All mechanical joints and fittings shall be of approved types designed specifically for PE
pipe system. They shall be supplied with all necessary coupling rings, nuts, bolts, washers,
rubber rings/sealing gaskets and restrainers/stiffeners.
All mechanical joints, fittings and systems shall conform to the requirements specified in MS
1058 or BS EN 12201-5 of Table below as applicable.
Characteristics for fitness for purpose of the joint, fitting of system
Test Method
Characteristics
o
Hydrostatic strength at 80
EN 921
Cohesive resistance for
ISO 13954
Electro fusion
ISO 13955
Socket fittings
ISO 13956
For electrofusion saddle fittings
Resistance to tensile force
ISO 13953
Mechanical joints
Leak tightness under internal pressure
EN 715
Leak tightness under internal pressure when
EN 713
Subjected to bending (up to and
including 63mm)
External pressure text
EN 911
Resistance to pull out under constant
EN 712
longitudinal force
F.6

ii)
Plastic Parts
All fittings/components shall conform to the relevant EN standards. Alternative
standards may be utilized in cases where suitable EN standards do not exist provided
a fitness for purpose can be demonstrated.
iii)
Metal Parts
All metal parts shall be made of ductile iron (BS 2789) of Grade 420/12) or carbon
steel (BS EN 10025 Grade S275, S355JR or BS 4360 43A) or stainless steel (BS970
Part1). No gray cast iron shall be used.
All metal components (except parts made of stainless steel BS 970) of the mechanical
joints and fittings shall undergo the necessary surface preparation for polyamide
coating purposes. Bituminous coating is not allowed. Either one of the following
polymeric coating is acceptable:
For coating using either fusion-bonded epoxy powder or polyamide 11

(RISLAN) Bonded Polyamide 11 or not less than 350 m for Fusion Bonded
Epoxy as specified in AS/NZ 4158:1:1994.
For coating using cold applied high solid liquid epoxy (solvent or solventless)
which meet the requirement of AWWA C210-84, the coating thickness shall not
be less than 356 m.
The metal flanges shall be in accordance with PN 16 in BS 4504 or BS En 1092.

iv)
Elastomers
The rubber wedge joint rings shall have a hardness range of 66-75 IRHD and shall
meet the requirements as detailed in MS 672-1999 or AS 1646 : 1992
Flange gaskets shall be of flat section minimum 5mm thick (medium grade) (Hardness
60 5 RHD) rubber reinforced with two-ply flexible fabric and complying with BS
5292.
v)
Bolts, Nuts and Washers

The bolts and nuts shall be hexagonal and shall be in accordance with BS 4190. The
bolts, studs, nuts and washers used shall be made of stainless steel or hot-dipped
galvanized carbon steel coated with fusion bonded epoxy powder or polyamide 11 to
the finished thickness of coating between 75m and 125m according to WIS 4 52
03 1994. Cold applied high solid epoxy shall be used to repair the damaged
coatings on the bolts and nuts after fastening.
vi)
Effect on water quality

When used under condition for which they are designed, materials used for fittings
intended for the conveyance of water for human consumption shall comply with BS
6920.
F.7

10.5
Backing Ring (Slip On Flange) to suit HDPE Pipe

i)
Material
Materials used shall not to be inferior to:-
ii)
a)
Ductile Iron
BS 2789 Grade 420/12 or 500/7

BS EN 1563 Grade 400/15 or 500/7
b)
Carbon Steel
BS 4360 grade 43A

BS EN 10025 Grade S275, S355JR
Drilling Detail
Flanges shall be machined and still to BS 4504/BS EN 545 Table 16 and shall be
protected from corrosion as in clause Metal Parts
iii)
Dimension
Dimension of backing Ring made of ductile iron or carbon steel shall be shown below
Dimension of Backing Ring (Slip on Flange ) to suit PE Pipe
Pipe
O.D
Nominal
Bore
Flange
O.D.
D
Flange
I.D.
C
Pitch
Circle
Diameter
K
Diameter
of Bolt
Hole
H
50
63
75
90
40
50
65
80
150
165
185
200
62
78
92
108
110
125
145
160
110
125
160
180
100
100
150
150
220
220
285
285
128
135
178
188
200
225
250
280
200
200
250
250
340
340
405
405
315
355
400
450
300
350
400
450
500
560
630
500
600
600
Bolt
Flange Thickness
T
Carbon
Ductile
Steel
Iron
Size
Nos
18
18
18
18
16
16
16
16
4
4
4
8
16.0
18.0
18.0
20.0
19.0
19.0
19.0
19.0
180
180
240
240
18
18
22
22
16
16
20
20
8
8
8
8
20.0
20.0
22.0
22.0
19.0
19.0
19.0
19.0
235
238
288
294
295
295
355
355
22
22
26
26
20
20
24
24
12
12
12
12
24.0
24.0
26.0
26.0
20.0
20.0
22.0
22.0
460
520
580
640
338
376
430
517
410
470
525
585
26
26
30
30
24
24
27
27
12
16
16
20
28.0
32.0
36.0
40.0
24.5
26.5
28.0
30.0
715
840
840
533
618
645
650
770
770
33
36
36
30
33
33
20
20
20
44.0
52.0
52.0
31.5
36.0
36.0
All dimension in millimeter (mm)
F.8

iv)
Workmanship
a)
All casting shall be homogenous, smooth and shall be free from flaws, cracks,
blowholes, cuts or other harmful defects. All surfaces in close proximity to the
pipe shall be smooth and free from sharp edges.
b)
All steel flanges cut from plate shall have their surfaces machine finished and
shall be free from surface defects.
10.6
Storage
10.6.1
Storage at Depot
All materials should be carefully inspected at the time of delivery and any defective material
set-aside before accepting the delivery into stores. The defective materials should be return
to the suppliers immediately.
Pipes and fittings should be used in the order of delivery to ensure the correct rotation of
stock.
All pipe stacks should be made on sufficiently firm, flat ground to support the weight of the
pipes and any necessary lifting equipment. Stacking heights should generally be kept to a
minimum and adequate space allocated for lifting machinery to manoeuvre without causing
accidental damage.
For safety and convenience of handling the stacking height of bundles should not be more
than 3m. To prevent possible deformation of the pipes, bundles must be stored timber to
timber.
For similar reasons, pipe coils should be stored flat and the number of coils per stack should
be limited to:
7 coils for 20mm pipe

1 coils for 110, 125 and 180 pipes.
Where individual pipe lengths are stacked in pyramidal fashion, deformation may occur in
the lower layers. Such stacks should therefore be not greater than 1m high.
Electro-fusion and compression fittings should be stored under cover, preferably on racking
and in the manufacturers protective wrapping or cartons which should be kept intact until
the fitting is required for use except spigot fittings.
At all times pipes and fittings should be stored away from exhaust outlets and all other high
temperature sources. Care should also be taken to avoid contact with lubricating or
hydraulic oils, gasoline, solvents and other aggressive chemicals.
All special tool and equipment associated with the jointing of pipes and fittings should be
stored separately and securely until they are required for use.
F.9

10.6.2
Storage on Site
All pipe store locations should be on suitably firm, level ground, free from damaging
material with adequate access for construction vehicles and/or lifting equipment.
In all storage sites, careful consideration should be given to the following aspects:
Security of all materials and equipment from theft, vandalism, accidental damage or
contamination.
Safety of pedestrians.
The movement of traffic and construction equipment
When stringing is adopted, pipes should be placed well clear of the excavators and away
from excavated material area. They should be wedged to prevent accidental movement.
Where necessary protective barriers complete with adequate warning signs and lights
should be erected.
11.0
PRE DELIVERY INSPECTION AND EVALUATION

It is the responsibility of the supplier to inform SYABAS for inspection purposes during
manufacturing and before delivery.
SYABAS reserved the right to inspect and witness the testing of product offered. If the
product fails the mandatory test, the manufacturer will be notified and a second cut
section will be tested. If the second cut section fails, the product will be rejected from
use in the state.
At any time, when requested, the supplier is to provide SYABAS a sample of the product
offered for evaluation purposes. All costs shall be borne by the supplier.
If at any time the supplier fails to deliver the required sample, the product is deemed to
have failed to meet the specifications and the product will not be further used in the
project..
12.0
HANDLING, TRANSPORT AND STORAGE
12.1
General
Polyethylene pipes are characterized by being tough and resilient and are relatively light.
Though it is easy to handle, they are prone to damage by scoring by sharp objects.
Therefore, careful handling is always required and the dragging of straight pipes and coils
should be avoided whenever possible.
The maximum allowance depth of scoring of the external surface of the pipe is 5% of the
wall thickness. Pipes and fittings showing obvious defects, excessive scoring or sharp deep
cut even if less than 5% of the wall thickness should be withdrawn and returned to the
suppliers.
Pipes up to 125mm are usually supplied and delivered loose or strapped into convenient
bundles or banded coils. Fittings are normally supplied in separate bags or cartons/pallets.
F.10

12.2
Transport and Delivery

For transporting bulk loads the vehicles should be provided with a clean flat bed, free from
nails or other projections which may cause damage.
Care should be taken to avoid positioning pipes and fittings near or adjacent to exhaust
systems or other heat sources as after as possible, avoid contamination from materials such
as diesel oil.
Straight pipes should be fully supported or bound together.
Metal chains or slings should not be brought into direct contact with the pipe. Webbed sling
of polyethylene or nylon are recommended.
When transporting pipes of different sizes, pipes of higher-pressure class shall be loaded
underneath. If the pipes are transported one inside another, the smaller pipes shall be
removed first and piled separately.
Both vertical and horizontal deliveries of coiled pipes are permissible.
12.3
Off Loading
12.3.1
Bundled Pipes
When lifting by crane, non-metallic wide band slings or ropes should be used. For pipe
length greater than 6m, load spreading bars of a length at least equivalent to one quarter of
the length of the pipe or bundlepack should be employed.
Chains or end hooks should not be used. Care should be taken to avoid damage to pipes
and pipe ends during lifting.
Some bending should be allowed for in the middle of the lift when loading and unloading
pipes. However to avoid excess bending, lifting points should always be well and evenly
spaced.
Six meters long bundlepacks may be handled by fork lift trucks but the positioning of the
forks shall cause minimum bending of the pipes.
Bundlepacks longer than 6m long should be handled either by side loader with a minimum
of four supporting forks, or by a crane using a spreader beam and suitable slings. Off
loading on site may be made easier by using skid timbers and rope slings.
12.3.2
Coiled Pipes
Coils of pipes can be handled by fork lift truck. Where individual coils are too heavy for
manual lifting, a fork lift truck with suitable protected boom attachments should be used.
They should NOT be rolled off the edge of loading platforms or trailers.
Complete coils are secured by outer and intermediate bands and individual layers are also
independently secures. Plastic tape at least 10mm wide should be used for banding.
F.11

The bands should not be removed until the pipe is required for use. The bands securing the
outer end of the pipe should be removed first and the movement of the free end carefully
controlled. This should be followed by those securing successive layers, and only those
bands necessary to release the length of pipe immediately required should be cut and
removed.
When removed from the coil or drum, the pipe will be oval and curved. Although both
ovality and curvature will reduce with time, special tools are available a facilitate handing
and jointing.
12.3.3
Fittings
Hocks should not be used to lift fittings which are generally supplied with cardboard boxes.
Special care should be taken in the handing of pup fittings to ensure that the weight of the
fittings is not transferred to the fabricated joint.
13.0
CERTIFICATION
Manufacturer or supplier is requirement to provide a copy of the certificate and test
report either from SIRIM, IKRAM or other recognised certification body.
Test reports should be those tests conducted within a year period.
SYABAS reserved the right to refuse offer or reject supply if the necessary documents are
not enclosed.
14.0
HDPE PIPE JOINTING

Pipe joining for pipes buried underground, below pavement or slab or concealed in slab
shall use electro-fusion or fully automatic butt fusion jointing unless instructed
otherwise by S.O.
15.0
JOINTING BY BUTT FUSION
15.1
General
Butt fusion is process of welding HDPE pipes and fittings using an electrically heated
plate. It is suitable for jointing HDPE pipes and fittings of size from 110 : OD and
above. However, only pipes and fittings of the same material type, size and rating shall
be butt welded, e.g. PE 100 pipes should not currently be welded to PE 80 pipes. PN 10
pipe should not be welded to PN 6 pipe or fitting.
The following table shows the recommended conditions.
F.12

Single pressure butt fusion jointing conditions for PE80 and PE100
Heater Plate Surface Temperature 210(+10/-5) o C
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
90
90
90
90
90
21
17.6
13.6
11
9
(mm)
4.3
5.1
6.6
8.2
10
(MPa)
0.150
0.150
0.150
0.150
0.150
(mm)
2
2
2
2
2
(seconds)
105
110
125
140
160
(MPa)
0
0
0
0
0
(seconds)
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
110
110
110
110
110
110
21
17.6
17
13.6
11
9
5.2
6.3
6.5
8.1
10.0
12.2
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
115
125
126
141
160
185
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
15.0
15.0
15.0
15.0
15.0
20.0
8
9
9
9
10
10
15
16
16
16
17
17
125
125
125
125
125
125
21
17.6
17
13.6
11
9
6.0
7.1
7.4
9.2
11.4
13.9
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
120
130
145
150
175
199
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
15.0
15.0
15.0
15.0
15.0
20.0
8
9
9
9
10
11
16
16
16
16
18
18
21
140
17.6
140
17
140
13.6
140
11
140
9
140
Tolerance
6.7
8.0
8.2
10.3
12.7
15.6
0.150
0.150
0.150
0.150
0.150
0.150
0.02
2
2
2
2
2
2
125
140
145
165
185
215
3
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
0.02
15.0
15.0
15.0
20.0
20.0
20.0
9
9
9
11
10
11
16
16
16
18
17
18
Outside
diameter
SDR
Soak Time
F.13
Cooling
Time in
Clamps
Min
Max
(Minutes)
15.0
15.0
15.0
15.0
20.0
(mm)
8
8
9
9
9
(mm)
15
15
15
16
16

Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
160
160
160
160
160
160
21
17.6
17
13.6
11
9
(mm)
7.6
9.1
9.4
11.8
14.8
17.8
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
(mm)
2
2
2
2
2
2
(seconds)
135
150
154
180
205
240
(MPa)
0
0
0
0
0
0
(seconds)
10
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
180
180
180
180
180
180
21
17.6
17
13.6
11
9
8.6
10.2
10.6
13.2
16.4
20.0
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
145
160
165
195
225
260
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
10.0
20.0
20.0
20.0
20.0
35.0
9
10
10
10
11
12
16
17
17
17
18
19
200
200
200
200
200
200
21
17.6
17
13.6
11
9
9.5
11.4
11.8
14.7
18.2
22.2
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
155
175
180
205
240
285
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
15.0
20.0
20.0
20.0
20.0
35.0
9
10
10
11
11
12
16
17
17
18
19
19
225
225
225
225
225
225
21
17.6
17
13.6
11
9
10.7
12.8
13.2
16.5
20.5
25
0.150
0.150
0.150
0.150
0.150
0.150
2
2
2
2
2
2
170
190
195
225
265
310
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
20.0
20.0
20.0
20.0
35.0
35.0
9
10
10
11
12
15
16
17
17
18
19
24
21
250
17.6
250
17
250
13.6
250
11
250
9
250
Tolerance
11.9
14.2
14.7
18.4
22.7
27.8
0.150
0.150
0.150
0.150
0.150
0.150
0.02
2
2
2
2
2
2
180
200
210
245
285
340
3
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
0.02
20.0
20.0
20.0
20.0
35.0
35.0
10
11
11
11
15
16
17
18
18
19
24
25
Outside
diameter
SDR
Soak Time
F.14
Cooling
Time in
Clamps
Min
Max
(Minutes)
15.0
15.0
15.0
20.0
20.0
20.0
(mm)
9
10
10
10
11
11
(mm)
16
17
17
18
18
19

Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
315
315
315
315
315
315
21
17.6
17
13.6
11
9
(mm)
15.0
17.9
18.5
23.2
28.6
35.0
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
(mm)
3
3
3
3
3
3
(seconds)
210
240
245
290
345
410
(MPa)
0
0
0
0
0
0
(seconds)
10
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
0.150
355
355
355
355
355
355
21
17.6
17
13.6
11
9
16.9
20.2
20.9
26.1
32.3
39.4
0.150
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
3
230
260
270
320
380
455
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
20.0
35.0
35.0
35.0
45.0
45.0
14
15
15
16
18
19
23
24
24
25
27
28
400
400
400
400
400
400
21
17.6
17
13.6
11
9
19.0
22.7
23.5
29.4
36.4
44.4
0.150
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
3
250
285
295
355
425
505
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
20.0
35.0
35.0
35.0
45.0
55.0
14
15
15
16
18
20
23
24
24
25
27
29
450
450
450
450
450
450
21
17.6
17
13.6
11
9
21.4
25.6
26.5
33.1
40.9
50.0
0.150
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
3
274
316
325
390
470
565
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
35.0
35.0
35.0
45.0
55.0
65.0
15
16
16
18
19
22
24
25
25
27
28
31
21
500
17.6
500
17
500
13.6
500
11
500
9
500
Tolerance
23.8
28.4
29.4
36.8
45.5
55.6
0.150
0.150
0.150
0.150
0.150
0.150
0.02
3
3
3
3
3
3
300
345
355
430
515
620
3
0
0
0
0
0
0
10
10
10
10
10
10
0.150
0.150
0.150
0.150
0.150
0.150
0.02
35.0
35.0
35.0
45.0
55.0
65.0
15
17
17
18
20
22
24
26
26
27
29
31
Outside
diameter
SDR
Soak Time
F.15
Cooling
Time in
Clamps
Min
Max
(Minutes)
20.0
20.0
20.0
35.0
35.0
45.0
(mm)
13
14
14
15
17
18
(mm)
22
23
23
24
26
27

Wall
Thickness
(minimum)
Bead-up
Interface
Stress
Initial
Bead
Size
(approx.)
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
Typical Final
Overall Bead
Width
(mm)
560
560
560
560
560
21
17.6
17
13.6
11
(mm)
26.7
31.8
32.9
41.2
50.9
(MPa)
0.150
0.150
0.150
0.150
0.150
(mm)
3
3
3
3
3
(seconds)
325
375
390
470
570
(MPa)
0
0
0
0
0
(seconds)
10
10
10
10
10
Fusion
and
Cooling
Interface
Stress
(MPa)
0.150
0.150
0.150
0.150
0.150
630
630
630
630
630
21
17.6
17
13.6
11
30.0
35.8
37.1
46.3
57.3
0.150
0.150
0.150
0.150
0.150
3
3
3
3
3
360
415
435
525
630
0
0
0
0
0
15
15
15
15
15
0.150
0.150
0.150
0.150
0.150
35.0
45.0
45.0
55.0
65.0
17
18
18
20
23
26
27
27
29
32
710
710
710
710
21
17.6
17
13.6
33.8
40.3
41.8
52.2
0.150
0.150
0.150
0.150
3
3
3
3
400
460
480
580
0
0
0
0
15
15
15
15
0.150
0.150
0.150
0.150
45.0
55.0
55.0
65.0
17
19
19
22
26
28
28
31
800
800
800
800
21
17.6
17
13.6
38.1
45.5
47.1
58.8
0.150
0.150
0.150
0.150
3
3
3
3
440
510
535
650
0
0
0
0
15
15
15
15
0.150
0.150
0.150
0.150
45.0
55.0
55.0
65.0
18
20
20
23
27
29
29
32
900
900
900
21
17.6
17
42.9
51.1
52.9
0.150
0.150
0.150
3
3
3
490
570
595
0
0
0
15
15
15
0.150
0.150
0.150
55.0
65.0
65.0
19
22
22
28
31
31
21
1000
17.6
1000
17
1000
Tolerance
47.6
56.8
58.8
0.150
0.150
0.150
0.02
3
3
3
535
625
655
3
0
0
0
15
15
15
0.150
0.150
0.150
0.02
55.0
65.0
65.0
20
23
23
29
32
32
Outside
diameter
SDR
Soak Time
F.16
Cooling
Time in
Clamps
Min
Max
(Minutes)
35.0
45.0
45.0
55.0
65.0
(mm)
16
17
17
19
22
(mm)
25
26
26
28
31

Dual pressure butt fusion jointing conditions for PE80 and PE100
Outside
diameter
SDR
(mm)
Cooling
Interface
Stress
(after 10s)
Cooling
Time in
Clamps
(seconds)
Fusion
and
Cooling
Interface
Stress
(MPa)
(MPa)
Initial
Bead Size
(approx.)
Soak
Time
Minimum
Soak
Interface
Stress
Maximum
Plate
Removal
Time
(MPa)
(mm)
(seconds)
(MPa)
Wall
Thickness
(minimum)
Bead-up
Interface
Stress
(mm)
Typical Final
Overall Bead
Width
Min
(mm)
Max
(mm)
15
16
17
24
25
25
0
280
315
11
11
11
22.7
25.5
28.6
0.150
0.150
0.150
3
3
3
285
315
345
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
(Minute
s)
35.0
35.0
35.0
355
355
355
26
17.6
11
13.7
20.2
32.3
0.150
0.150
0.150
3
3
3
195
260
385
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
20.0
35.0
45.0
13
15
18
22
24
27
400
400
400
26
17.6
11
15.4
22.7
36.4
0.150
0.150
0.150
3
3
3
215
285
425
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
20.0
35.0
45.0
14
15
18
23
24
27
450
450
450
26
17.6
11
17.3
25.6
40.9
0.150
0.150
0.150
3
3
3
235
315
470
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
20.0
35.0
45.0
14
16
19
23
25
28
500
500
500
26
17.6
11
19.2
28.4
45.5
0.150
0.150
0.150
3
3
3
250
345
515
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
29.0
35.0
55.0
15
17
20
21
26
29
560
560
560
26
17.6
11
21.5
31.8
50.9
0.150
0.150
0.150
3
3
3
275
380
570
0
0
0
10
10
10
0.150
0.150
0.150
0.025
0.025
0.025
35.0
45.0
65.0
15
17
22
24
26
31
630
630
630
26
17.6
11
24.2
35.8
57.3
0.150
0.150
0.150
3
3
3
300
420
635
0
0
0
15
15
15
0.150
0.150
0.150
0.025
0.025
0.025
35.0
45.0
65.0
16
18
23
25
27
32
710
710
26
17.6
27.3
40.3
0.150
0.150
3
3
335
465
0
0
15
15
0.150
0.150
0.025
0.025
35.0
55.0
16
19
25
28
900
900
26
17.6
34.6
51.1
0.150
0.150
3
3
405
570
0
0
15
15
0.150
0.150
0.025
0.025
45.0
65.0
18
22
27
31
26
1000
17.6
1000
Tolerance
38.5
56.8
0.150
0.150
0.02
3
3
445
630
3
0
0
15
15
0.150
0.150
0.02
0.025
0.025
0.01
45.0
65.0
18
23
28
32
F.17

15.2
Butt Fusion Jointing Equipment

Butt fusion jointing equipment shall be certified in accordance with MS 1058 or ISO
12176-1. Only fully automatic Computerized Numerical Control (CNC) machines or
computerized microprocessor based machines shall be used. Manual or Semi
Automatic CNC machines are NOT allowed.
a)
Chassis and Clamps

The machine shall have a frame containing clamps which are sufficiently robust to
re-round and accurately align the pipes to be jointed.
The machine shall have a minimum of two rams mounted on the pie center-line
axis. The ram shall move freely and control the movement of any sliding clamps.
All slides shall be kept free from rust and lubricated at all times.
b)
Hydraulic/pneumatic unit
The unit shall be capable of actuating the clamp unit to provide adequate force
and speed of operation. A pressure monitoring device shall be provided to
monitor ram pressure.
Unless an automatic machine is used, a data plate permanently attached to the unit
setting out jointing and cooling pressures and times for specified sizes of pipe.
Note : It is very important that welding machine can control the secondary pressures
accurately as these will sometimes be only slightly greater than the drag pressure.
(c)
Trimming tool
The trimming tool shall be capable of being mounted securely within the frame of
the jointing machine, so that this equipment can produce accurately matched
planed faces.
Trimming blades of the planer shall be sharp and have defect free cutting edges to
provide continuous swarf of uniform thickness.
(d)
Heater Plate
The plate shall be electrically heated and shall be provided with a suitable
temperature controller to give a uniform surface temperature of 210 (+10 / 5)
o
C.
The plate surface shall have a permanent coat of anti-stick material. ADDITIONAL
SPRAY-ON RELEASE AGENTS SHALL NOT BE USED. The surface shall be free
from any contaminants.
The plate shall be fitted with an accurate temperature probe or indicator, accurate
to within 2 oC in the range of 200o 240oC. The temperature on both sides of
the circumference shall be measured using a digital thermometer with an
appropriate surface probe.
(e)
Control system
F.18

The control system shall be designed to carry out the operations as far as possible
automatically at the temperature, time and pressures indicated as required.
bead roll
over
bead roll
over
Interface
stress
(MP a)
Interface
stress
(MP a)
Initial
bead-up
COOLINGTIME
Initial
bead-up
COOLINGTIME
0.15
MP a
0.15
MP a
0.025
MP a
Heat Soak
Heat Soak
Time
Time
Heater plate
removal
Heater plate
removal
Single pressure butt fusion

Jointing cycle (not to scale)
Dual pressure butt fusion

Jointing cycle (not to scale)
In automatic butt-fusion welding machines, the control system shall be capable

of being programmed according to the size and rating of the pipe and fitting.
(f)
Shelter
A shelter shall be used to provide adequate protection for pipe, fittings and
equipment against adverse weather conditions and contamination.
(g)
External and internal bead removal if required

External and internal debeaders shall be capable of removing the cold bead
cleanly in a continuous strip without damage to either joint or bead after the
cooling time.
(h)
Generator
The generator shall be selected to suit the butt fusion machine capacity and heater
plate rating. The specification of the generator shall be supplied by the machine
manufacturer
(i)
Ancillary equipment
The following equipment shall be made available on site :
(a) Pipe support rollers
(b) Pipe cutters
(c) Digital thermometer with probe
(d) Timer
(e) Indelible Marker pen for marking beads
(f)
Bead gauge
(g) Saw and saw guide
(h) Pipe end cover
(i)
Spirit level to ensure machine is level
(j)
Ground sheets or base boards
(k)
Clean clothes to wipe the pipes before trimming
F.19

15.2.1
Butt Fusion Jointing Method

(a)
Definitions
Fusion pressure and cooling pressure : the pressure ( in bar ) required to provide,
on a given machine and for a given size and rating of pipe, an interface stress of
0.15MPa or 0.025MPa as appropriate. This pressure is a function of the ram
dimensions and the efficiency of the machine.
Butt-fusion welding machine shall capable of being programmed according to the
size and rating of the pipe and /or fitting.
Drag pressure : the minimum pressure ( in bar ) required to overcome the sliding
frictional drag of the pipe and the machine. This must be assessed accurately prior
to making each fusion joint and must be added to the ram pressure.
This operation is normally carried out automatically when fully automatic fusion
machines are used.
Bead-up pressure : the sum of fusion and drag pressures required to provide, on a
given machine and for a given size and rating of pipe, an interface stress of
0.15MPa to form the initial bead on the end of the pipe against the heater plate.
Heat soak pressure : the pressure required to maintain the pipe in contact with
the heater plate. This is normally the drag pressure.
Bead roll over pressure : the pressure required to provided, on a given machine
and for a given size and rating of pipe, an interface stress of 0.15MPa. This has the
same value as the initial bead-up pressure.
Plate removal time : the maximum time permitted for the opening of the carriage,
removal of the heating plate and closure of the carriage to bring the two hot pipe
ends together.
(b)
Preparation
(1)
Cleaning the trimming tool

The trimming tool surface shall be visually inspected for grease and dirt and
cleaned where necessary using clean water and lint-free materials. Particular
attention shall be paid to the blade. Blunt or damaged blade shall be
replaced.
(2)
Cleansing / washing the heater plate

The heater plate shall be thoroughly washed with copious quantities of
clean water at the start of a jointing session. It shall also be cold when
washed.
Only clean, disposable lint-free materials shall be used to clean the plate.
F.20

Grease and oily films may be wipe with a clean, disposable lint-free cloth or
cleaning material dampened by a suitable solvent when necessary.
(3)
Sitting the equipment

The butt jointing machine shall be placed on a suitable level baseboard
inside a shelter.
To aid alignment of pipes into the machine and for easy of movement, pipes
to be jointed shall always be supported on rollers. Pipe strings should be
laid out on a level surface where possible.
(4)
Dummy welds
In order to remove dust from the heater plate, a dummy weld should be
carried out at the start of each continuous jointing session, or at a change of
pipe size.
A dummy weld can be made using pipe cut-offs of the same size and
pressure rating and the pipe to be welded. It is not necessary to actually
make a joint, The procedure can be stopped after the full heat soak cycle as
specified in Tables.
(c)
Setting up
Operate the machine to open clamps and position the planer in its position.
Position pipes in the clamps with ends adjacent to planning tool and with pipe
markings aligned. This will assist in obtaining the best match in diameter. Pipes
should be jointed so that the pipe markings are uppermost when the pipes are in
trench.
Tighten pipe clamps to grip and re-round the pipes.
(d)
Trimming
Switch on the trimming tool. The pipe ends shall be moved against the trimming
tool until continuous shavings are produced from each pipe end.
Keep the trimming tool turning, whilst separating the pipe ends to avoid steps on
the trimmed surfaces. Switch off the planning tool and remove after it has come to
rest.
Remove loose shaving from the machine and inside the pipes. Do not touch pipe
or fitting ends, to prevent contamination of the clean surfaces.
Visually check that the pipe or pipe and fitting ends are completely planed and
repeat planning if necessary.
Bring pipe or pipe and fitting ends together and check there is no visible gap
between trimmed surfaces. The maximum permitted outside diameter mismatch
shall not exceed 10% of thickness of pipe / fitting.
F.21

If the mismatch is greater than that given above then the pipe or pipe and fitting
shall be realigned and re-planed.
(e)
Bead-up
Check that the heater plate has attained the operating temperature.
Insert and secure the heater plate into position in the machine.
Bring the pipe or pipe and fitting ends into contact with the heater plate using the
initial bead-up pressure equivalent to 0.15MPa interface stress.
The typical initial bead size is given in Tables.
(f)
Heat soak
After the initial bead-up, the pressure in the system shall be released so that the
pressure gauge registers between zero and the drag pressure to control bead
growth during heat soak time. Check that the clamps do no move. The pipe or
pipe and fitting ends shall be in contact with the heater plate.
(g)
Plate removal
During removal of the heater plate, no molten polymer should stick to the heater
plate. If it does, then the joint shall be aborted, the plate cleaned and the surface
quality of the plate examined. If the plate surface is damaged, the manufacturers
advice should be obtained on cleaning and / or replacement.
The maximum plate removal time, including the time to bring the hot ends
together, shall not exceed 10 seconds for pipe not exceeding 630 mm and 15
seconds for pipes exceeding 630mm.
(h)
Fusion jointing
Immediately after plate removal the hot pipe and fitting ends shall be brought
together in a smooth manner and the pressure raised in accordance to the Tables.
The fused material should roll back in a uniform manner and there should be no
sign of bubbles or contamination present.
The overall width of the bead is not critical and therefore the bead sizes quoted in
Tables are typical only. The uniformity of the bead size around the circumference
of the pipe is important as this indicates that the equipment is set up correctly,
therefore deviations beyond the limits detailed in Section Debeading should be
investigated in order to reduce the variation to within the recommended values.
(i)
Cooling
The joint should be allowed to cool in the clamps, whilst maintaining the joints at
the cooling pressure for at least the time given in Tables for the appropriate pipe.
At the end of the cooling time, the clamps may be released and the jointed pipe
or pipe and fitting removed. No handling of the pipe shall take place until the
F.22

surface temperature of the bead is below 50 deg. C as measured by a digital

thermometer.
(j)
Debeading
All external beads, and internal beads if required, shall be removed after the
cooling time using a suitable debeading tool. The bead removal tool shall not
induce any slits, gouges or defects in the pipe wall.
Butt fusion beads shall be uniform on both sides of the joint i.e. no wrinkles or
discontinuities.
The beads shall be bent back at several positions. No evidence of the bead
splitting shall be seen. If the bead is seen to split at any point then the joint shall
be cut from the pipeline and remade. If a similar defect recurs, all further
production jointing shall cease until the equipment has been thoroughly cleaned
and examined. New trial joints shall be made and shown to be satisfactory.
(k)
Records
Electronic or written records of appropriate joint procedure details shall be kept.
The minimum information to be recorded is given in Table below.
Butt Fusion Joint Record
Machine type :
Serial No. :
Time
:
Joint number :
Job No. :
Pipe or pipe and fitting size :
Joint cycle :
Parameter
Bead pressure ( no drag )
Joint pressure ( no drag )
Drag
Heater temperature
Bead-up pressure
Initial bead size
Heat soak time
Heat soak pressure
Dwell time (change-over
time)
Fusion pressure
(l)
Date :
Operator code :
Units
Actual Value
Permissible
Values
bar
bar
deg. C
bar
Mm
sec.
Bar
sec.
bar
Maintenance, service and calibration

All equipment shall be well maintained and kept in a clean condition at all time,
both in stores and on site.
F.23

The equipment shall be serviced and calibrated regularly. The frequency at which
this is carried out will be different for individual items of equipment and will also
depend on usage but should be at least once every 6 months.
15.3
Electro-fusion Socket Jointing
15.3.1
General
With electro-fusion socket fusion, an electrical resistance element is incorporated in the
socket of the fitting which, when connected to appropriate power supply, melts and
fuses the material of the pipe and fitting together.
The effectiveness of this technique depends on the attention to cleanliness, in particular
the removal of the contaminated surface of the pipe over the socket depth.
Electro-fusion fittings are available in the range 20mm to 315mm although larger sizes
are now under development.
There are 2 control systems specified manual time selection and automatic time
selection. Both are described in this section.
15.3.2
Equipment
The control box input supply shall be from a nominal 220 volt generator.
NO EXTENSION LEADS SHALL BE USED ON THE CONTROL BOX OUTLET
CONNECTORS
WARNING : Control boxes are not intrinsically safe and shall not therefore be taken
into the trench.
Pipe surface preparation tool capable of removing the contaminated surface of the pipe
in excess of the insertion depth before welding is attempted. The tool shall remove a
layer 0.2 0.4mm thick from the outer surface of the pipe preferably as a continuous
strip of swarf over that length and round the pipe.
NOTE : Hand scrapers can be difficult to use effectively in trench conditions.
Pipe clamps or other approved method for restraining, aligning and re-rounding the
pipes during the weld cycle shall be used.
Pipe cutters including saw and saw guide.
15.3.3
Electro-fusion Jointing Method

(a)
Preparation
Check that the pipe ends to be jointed are cut square to the axis and any burrs
removed.
Wipe pipe ends using clean, disposable, lint-free material to remove traces of dirt
or mud, etc.
F.24

Mark the area over which the contaminated surface is to be removed, i.e. in
excess of the penetration depth, on each pipe to be jointed by placing the socket
of the bagged fitting alongside the pipe and. Trace a line round the circumference
at the appropriate distance from the pipe end using a suitable marker.
DO NOT REMOVE THE FITTING FROM ITS PACKING AT THIS STAGE
Connect the electro-fusion control box input leads to the generator.
Check that there is sufficient fuel for the generator to complete the joint.
Check that reset stop button, if fitted on the control box, is in the correct mode.
Using the pipe end preparation tool, remove the entire surface of the pipe
uniformly, preferably as a continuous swarf over the area identified, i.e. in excess
of penetration depth.
(b)
Electro-fusion Jointing Procedure

Remove the fitting from its packaging and check that the bore of the fitting is
clean and dry. If necessary, dry it with clean, disposable, lint-free material and
degrease with a clean cloth dampened by a suitable solvent like aceton liquid.
NOTE 1 : Isopropanol is a suitable cleaner for the material if permitted by the site
health and safety regulations.
Insert the pipe ends into the fitting.
NOTE 2 : It is recommended to mark pipe ends with an indelible pen to ensure
pipe depth of entry is maintained and a visible record retained when fusion is
complete.
Using the pipe clamps, secure the pipes so that they cannot move during the
fusion cycle. Check that the pipe ends and the fitting are correctly aligned.
If applicable, remove the terminal caps from the fitting.
Start the generator and check that it is functioning correctly.
Connect the control box output leads to the fitting terminal and check that they
have been fully inserted.
Switch on the control box where applicable.
Commence the fusion joining procedure in accordance with the control box
instruction and check indicated jointing time with time shown on fitting.
Scan the bar code magnetic card which is provided together with the fusion
socket. Details of the fusion socket will be displayed on the welding set.
Press the start button on the control box and check that the heating cycle is
proceeding as indicated by the display countdown.
F.25

On completion of the heating cycle, the melt indicators should have risen. If there
is no apparent movement of the melt indicators, the joint should be cut out and a
new joint made.
If a satisfactory joint has been made, the joint shall be left in the clamps for the
cooling time specified on the fitting.
NOTE : If the fusion cycle terminates before completion of the countdown, check
for faults as indicated by the control box warning lights. Do not attempts a second
fusion cycle if countdown of the first cycle reached more than half of the total
time require and for at least one hour after the first attempt.
(c)
Maintenance , Servicing and Calibration

(d)
this is carried out will be different for individual items of equipment and will also
depend on usage, but should be at least once every 6 months. Guidance shall be
sought from the equipment manufacturer and a scheme of calibration and
servicing implemented. Particular attention shall be given to the control box and
generator.
Records
Written records of appropriate fusion procedure details shall be kept as required
using the format approved by the S.O.
15.4
Electro-fusion Saddle Jointing
15.4.1
General
With electro-fusion saddle jointing, an electrical resistance element is incorporate in the
base of the saddle which, when connected to an appropriate power supply, melts and
fuses the material of the pipe and fitting together.
The effectiveness of this technique depends on attention to cleanliness, in particular the
removal of the contaminated surface of the pipe over an area equivalent to the saddle
base.
Electro-fusion saddles are available to fit all commonly used main sizes with sizes 20,
25 or 32mm service connections. Outlet connections are also available up to nominal
size 180mm.
Two methods of holding the tapping tee saddle during the fusion cycle are used, top
loading and under clamping systems. However, because of the variations of equipment
used for each method, common procedures for holding the saddle during the fusion
cycle cannot be specified. For each type of fitting used, the manufacturers procedure
for holding the fitting during the fusion cycle should be followed.
F.26

15.4.2
Equipment
The control box input supply shall be from a nominal 220 volts.
NO EXTENSION LEADS SHALL BE USED ON THE CONTROL BOX OUTLET
CONNECTORS.
WARNING : Control boxes are not intrinsically safe and shall not be taken into the
trench.
Pipe surface preparation tool capable of removing the contaminated surface of the pipe
over the full area of the saddle base. The tool shall remove a surface layer 0.2 0.4mm
thick.
Pipe-clamp with suitable dimension for making service or branch connections.
15.4.3
Electrofusion Saddle Jointing Method

(a)
Preparation
Expose the pipe onto which the tapping tee saddle is to be assembled.
Clean the pipe over the general area on which the saddle is to be assembled using
clean, disposable, lint-free material and use clean water only.
Without removing the fitting from its packaging, place it over the required
position on the main. Mark the pipe surface all round and clear of the saddle base
area.
Remove the surface of the pipe to a depth of 0.2 to 0.4mm over the full area
marked using a suitable tool. Remove the swarf.
Check that reset stop button on the control box, if fitted, is in the correct mode.
(b)
Electro-fusion Saddle Jointing Procedure

Position the fitting base onto the prepared pipe surface and install the saddle
clamp to the saddle tee.
Remove the terminal caps from the fitting.
Check that there is sufficient fuel for the generator to complete the joint. Start the
generator and check that it is functioning correctly.
Connect the electro-fusion control box input leads to the generator.
Connect the control box output leads to the fitting terminals and check that they
have been fully inserted.
Switch on the control box if applicable.
Commence the fusion jointing procedure in accordance with the control box
instructions and check indicated joint time shown on fitting.
F.27

Press the start button on the control box and check that the heating cycle is
proceeding as indicated by the display count-down.
On completion of the heating cycle, the melt indicator should have risen. If there
is no apparent movement of the melt indicator, where incorporate, a new saddle
joint should be made. Cut the tee of the faulty joint from its base.
If a satisfactory joint has been made, the joint shall be left in the clamps for the
cooling time specified on the fitting label.
NOTE : If the fusion cycle terminates before completion of the count-down, check
for faults as indicated by the control box warning lights. DO NOT attempt a
second fusion cycle.
NOTE : DO NOT attempt to tap the pipe with the integral cutter for at least 10
minutes after completion of the fusion cycle.
(c)
Maintenance, Servicing and Calibration

this is carried out will be different for individual items of equipments and will also
depend on usage but should be at least once 6 months. Guidance shall be sought
from the equipment manufacturer and a scheme of calibration and servicing
implemented. Particular attention shall be given to the control box and generator.
(d)
Records
Written records of appropriate fusion procedure details shall be kept as required
using the format illustrated below.
ELECTROFUSION JOINT RECORD
Control Box Serial No. :
Operator Code
:
Time
:
Date :
Ambient Temperature :
Joint Number
:
Type of Fitting
:
Target Fusion Time
:
Achieved Fusion Time :
Joint Status
:
Power profile
:
Units
sec.
o
C
sec
sec
A well-made electrofusion saddle joint should have the following features:

The melt indicator should have operated where:
There should be no melt flowing from round the saddle base;

There should be evidence of pipe surface preparation round the saddle base.
The following features indicate faults during the assembly / fusion operation:
F.28

(1) Fusion indicator fails to operate

Causes : (a) incorrect fusion time selected too short ;
(b) control box out of specification under voltage;
(c) fitting heating coil failure;
(d) incorrect fitting for size of main;
(e) top load too low on loading tool.
(2) Excess melt indicator or from saddle base
Causes : (a) incorrect fusion time selected too long;
(b) control box out of specification over voltage;
(c) insufficient pressure from top loading assembly tool;
(d) time failure too long;
(e) incorrect fitting for size of main;
(f)
top load too high on loading tool.
(3) Inadequate fusion of saddle base on main
Causes : (a) lack of pipe preparation;
(b) fitting heating coil failure.
15.5
Mechanical Joints
(a)
General
All mechanical fittings used shall be assembled in accordance with the
manufacturers instructions and all metal fittings should be suitably protected from
corrosion as stipulated in clause Metal Parts.
(b)
Transition joint from HDPE pipe to flanged metal fittings

For transaction from HDPE pipe to flanged metal fittings, either HDPE stub flanges
with metal backing rings or mechanical flanged adaptors of approved types
complied with MS 1058 or EN 12201 shall be used. The flanged joint gasket and
bolt length used shall be appropriate to the particular adaptor.
When tightening bolts and nuts for the flanges, care should be taken to produce
an even torque load ( torque wrench ) to the limits as follows. The use of a torque
wrench is strongly recommended. Typical bolt torques shall be as shown in Table
below.
F.29

Typical bolt torques

Nominal PE
Size (mm)
63
90
125
180
225
250
280
315
355
400
450
500
(c)
Nominal iron
Size (mm)
50
80
100
150
200
250
250
300
350
400
450
500
Standard Flanges
Bolts
No.
4
8
8
8
12
12
12
12
16
16
20
20
Torque Nm
( +/- 10% )
35
35
35
60
80
100
100
120
150
200
250
300
Branch connection
Normally, branch connections on the main are achieved by introducing fusion
tees during installation of the main.
A subsequent branch connection into an existing HDPE main can be achieved by
using :
Standard fusion tee with electro-fusion couplers,

Standard electro-fusion branch connections,
Branch saddle electro-fusion fittings,
Mechanical couplers with restrainers / stiffeners can be used.
16.0
MAIN HDPE PIPE LAYING
16.1
Preparation Of Pipes
Generally HDPE pipes are joined to form a string above ground prior to snaking into the
trench. To prevent scoring, pipe rollers should be used.
Before lowering HDPE pipelines into the trench, a check should be made for cuts, deep
scratches or other pipe damage and in fusion jointed systems that the system has cooled
sufficient before stress is imposed upon any pre-made joints.
When lowering pipe into the trench, care should again be taken to avoid scoring of the
pipe by contact with the sides and bottom of the trench. Use should be made of planks
and ropes where appropriate but wire ropes or chains should not be used.
16.2
Laying Of Pipes
Gradual changes in direction of HDPE pipelines can be accommodated by pipe
deflection but every effort should be made to keep the pipe as central as possible within
the trench to enable adequate compaction of side-fill.
F.30

The bending of HDPE pipelines is permissible and the properties of fusion jointed
systems enable changes of direction without recourse to the provision of special bends
or anchor blocks. However, the pipe should not normally be cold bent to a radius less
than 25 times the outside diameter of the pipe. For push-fit or mechanical non end-load
resistant jointing systems, anchor blocks to withstand the resultant thrusts must be
provided. Under no circumstances should hot bending be attempted on site.
For installation of heavy flanged fittings, provision should be made for concrete support
both for the weight and to resist the turning moments associated with valves and
hydrants.
HDPE pipes and fitting may be partially or completely surrounded by concrete but they
should be protected by 3mm rubber membrane to avoid possible damage during
pouring or compaction to prevent high localized stresses.
After completion of an installation, pipe work and fittings should be inspected and
made ready for testing to ensure the safety and efficiency of the systems. The trench
may be backfilled prior to testing; but it is advisable to leave at least the joints exposed
throughout the test.
Complete and accurate records should be taken of the installation. It is useful for
records to be taken before the pipes are buried.
To assist the future location of the pipelines, a marker tape shall be laid along the line
of the main and connect at each end to either a sluice valve or hydrant. The
recommended position of the tape is 350mm below the surface directly above the
crown of the pipe.
17.0
INSTALLATION OF SERVICE PIPES
17.1
General
This section gives details of installation of HDPE service pipes. A service pipe is that
part of the water supply system which conveys water from the distribution main to the
consumers premises and is subjected to water pressure from that main. It is considered
to comprise two sections:
17.2
The COMMUNICATION PIPE is that part of the service pipes from the main up to
the and including the consumers meter situated at the boundary of the
consumers property. The water supply authority is responsible for the installation
and maintenance of the communication pipe.
The SUPPLY PIPE is that part of the service pipe from the consumers meter into
the premises up to the storage cistern. The customer is responsible for the
installation and maintenance of the supply pipe.
Laying of Communication Pipe

Wherever practicable the whole communication pipe should be laid in a straight line at
right angles to the main when viewed on plan. This assists future location and
identification of these pipes.
F.31

Slight snaking of the communication pipe in the vertical plane is permitted without
overstressing the connection to the main. However, care must be taken not to kink the
pipe and/or impart excess bending moment to the saddle tapping.
The preferred method would seem to be the simple straight connection at right angles
to the main with changes in direction or level achieved by installation electrofusion
elbows to avoid overstressing of the communication pipe.
Where road and / or drain crossing is required, suitable GI ducting should be provided
to accommodate the communication pipe.
18.0
CONNECTION TO HDPE PIPE
18.1
Connection to HDPE Pipe

Connections to HDPE pipe shall vary according to size. Large branch connections are
usually effected by standard tees, while medium sizes are effected by branch saddles.
Other communication pipe connections (< 63mm) are usually affected by electrofusion
saddles.
Electro-fusion saddles have a self-tapping ferrule system whereby the cutter forms an
integral part of the ferrule connection and after withdrawal remains within the ferrule
head.
Self-tapping ferrules may be electro-fusion jointed on to live mains.
18.2
Connection to Pipes of Other Materials

HDPE communication pipes may be connected to pipes of other materials such as AC,
UPVC, MS etc. The use of standard under pressure tapping machine are necessary for
connection to live mains.
Saddle straps are usually required for tapping to AC and uPVC pipes, while traps may
also be required for MS pipes.
19.0
JOINTING OF SERVICE PIPES
19.1
Jointing of HDPE Service Pipes

Butt fusion is not normally considered appropriate for the smaller sizes of pipes i.e.
<63mm. The usual method of jointing service pipes is by using electro-fusion couplers
19.2
Jointing of Dissimilar Service Pipes

Where dissimilar service pipe material are to be joined (e.g. when replacing a section of
metallic pipe with HDPE), special joint adapters are necessary. Two (2) types of
adapters commonly used are:
Transition electro-fusion couplers
Care should be taken to ensure that all pipe jointing is adopted in accordance with the
manufacturers recommendations.
F.32

19.3
Testing and Commissioning of Service Pipes

These requirements will be in accordance with the standard procedure laid down by
the water authorities. These standards will normally require, as a minimum, the
adequate flushing of the service pipes and the testing of all pipes and joints to the
maximum head to which the system is to be subjected.
20.0
REPAIR METHODS
Whilst repairs to burst mains and services are usually carried out in difficult and dirty
conditions, every effort should be made to keep all pipe and joint surfaces clean and the
working area as dry and uncontaminated as possible through the operation.
The completed repair should be examined and approved under working conditions
before re-bedding, side filling and backfilling take placed. Special attention should be
given to the replacement and compaction of suitable material under and around the
repair.
20.1
Repairs to HDPE Pipe
20.1.1
General
The extent of the pipe defect or fracture should be determined to ensure that the
remainder of the pipe has not been weakened or damaged in any way. The inspection
should also ascertain the extent to which the bed and surround may have been
disturbed in the vicinity.
When repairing a burst it is recommended that a short length of pipe ( say 1 meter ) on
each side of the damaged, since the defect may extend on the inner surface of the pipe.
20.1.2
Emergency Repairs
The emergency temporary repair of a HDPE pipe may be carried out by using a split
collar in the normal way but a more permanent repair should be undertaken as soon as
possible.
20.1.3
Permanent Repairs Using Fusion Joints

Butt fusion jointing is not usually a practical approach in repairing a burst pipe in
trench. However, electro-fusion couplers are more commonly used for repair of HDPE
pipes.
The repair of a HDPE pipe requires the defective length to be carefully cut out and
replaced by a measured length of HDPE pipe. It is important that the replacement pipe
is of the same pressure class.
The electro-fusion couplers, after removing the central stopper, may be slipped over the
existing pipe ends and fusion joints made. Care must be taken to ensure all ends are cut
square and dry and clean prior to jointing. Marking of the pipe will ensure that the
coupler is placed centrally over the joint.
Small leaks on HDPE pipe may be repaired by attaching an undrilled electrofusion
saddle over the hole of the pipe.
F.33

20.1.4
Permanent Repairs Using Mechanical Joints

Another alternative means of jointing the replacement pipe is by means of a special
mechanical type repair clamps in accordance with the manufacturers
recommendations.
Mechanical fittings are encouraged for site repair.
20.1.5
Repairs to HDPE Service Pipe

The repair of a HDPE service pipe requires the defective length to be carefully cut out
and replaced by a measured length of pipe of the same pressure class using electrofusion or mechanical end-load resistance couplers.
Small breaks may be repaired using electro-fusion saddle.
There is a wide range of mechanical repair couplers for service pipes. In all cases the
manufacturers recommendations should be followed.
20.1.6
Squeeze-Off Closure Technique

Isolating HDPE pipelines by forcibly pinching or squeezing the walls together is an
effective method used in many repair situations where it may be inconvenient and / or
expensive to close down and empty pipelines.
The squeeze-off technique involves applying pressure to the outside walls of the pipe
across a diameter using two tangential bars. The bars are forced together, collapsing the
pipe until a seal is formed by the upper and lower walls meeting.
Squeeze clamps are available for pipe up to 180mm. The following recommendations
are given for the use of the squeeze-off technique:
Only specially designed equipment should be used with correct stops to avoid over
compression of the pipe.
Do not use within 5 pipe diameters of a fitting, fusion joint or a previous squeezeoff operation.
On release of the squeeze the pipe should be:
Inspected and re-rounded if necessary
Renewed if there is any indication of damage
Adequately marked and recorded.
F.34

G ACRYLONITRILE, BUTADIENCE, STYRENE (ABS) PIPES AND

SPECIALS
1.0
General
1.1
ABS (Acrylonitrile Butadiene Styrene) pressure pipes and fittings must be

manufactured in accordance with Malaysian Standard MS 1419 for size range
from 15mm up to 200mm and must be branded accordingly. The manufacturer
must provide documentary evidence to support its claim to MS 1419 for all
pipes and fittings sizes and classes intended to be used in this tender.
1.2
ABS pipe size above 200mm must be manufactured in accordance with ISO
161.1 and must be tested in accordance to AS 3518: 1988 Part 1 Appendix E.
Manufacturer must provide detailed dimensional specification on all the pipes
and fittings to be supplied.
1.3
The ABS pipes and fittings manufacturer must provide documentary evidence
that it has the facility in its manufacturing site to carry out the relevant tests as
stated MS 1419.
1.4
ABS pressure pipes and fittings compounds shall have a MRS (Minimum
Required Strength) value of 16 Mpa and shall comply with the scope,
designation of properties and test methods defined in ISO 7245. The resin
supplier shall submit data and test reports from independent and reputable test
bodies such as CSIRO Australia, Body Cote Germany or PSB Singapore on the
creep rupture regression curve on the material to show the pipes are conformed
to MRS 16 for 50 years service life. Test must be in accordance to ISO 9080 to
1,000 and 10,000 hours at 3 different temperatures, 20 0C, 40 0C and 60 0C. The
manufacturers shall submit invoices to SYABAS to substantiate that their resin
are sourced from the supplier whom resin has conformed to MRS 16 for 50
years.
1.5 The manufacturers shall NOT use recycle or their own re-processable material.
________________________________________________________________________
E:\_backup g\specification pipe replacement works\WORDs\G-Acrylonitrile.doc
G.1

1.6
The physical properties of ABS material to manufacture the pipe and fitting shall
be as follow:
PROPERTY
S.I. UNIT
OTHER UNIT
Ultimate Tensile Strength at 20 0C
30 Mpa
4,350 lbf/in2
Water Absorption (24 hrs at 20 0C)
0.4% by Weight Gain
0.4% by Weight Gain
25%
25%
2,000 Mpa
290,000 lbf/in2
Compressive Strength at 20 0C
42 Mpa
6,100 lbf/in2
Izod Impact Strength (notched at 20 0C)
340 J/m
6.4 lbf/in2
1.05
1.05
104 0C
219 0F
10.1 x 10-5 m/m0C
5.6 x 10 ft/ft 0F
Maximum Operating Temperature
80 0C
176 0F
Poissons Ratio
0.35
0.35
Thermal Conductivity
0.25 W/m 0K
1.7 BTU/ft2/in/ 0F
Specific Heat
1.47 kJ/kg 0K
0.38 BTU/lbm/ 0F
3.5 x 1016 cm
3.5 x 1016 cm
Elongation at Break at 20 0C
Instantaneous Flexural Modulus at 20
0
C
Specific Gravity
Vicat Softening Point ASTM D1525
Coefficient of Linear Expansion
Volume Resistivity
1.7
ABS resin compounds will absorb moisture during storage in the factory and
caused an increase in moisture content. Since resin compounds with moisture
content higher than the permissible level will affect the quality of the end
products. As such, the manufacturer MUST reduce the moisture content of the
resin with dehumidifier machines.
1.8
All ABS pipes and fittings must pass the test of Effect of the Quality of the
Water under BS 6920. Manufacturer must provide documentary evidence from
the relevant standard testing authority confirming this conformance.
1.9
All ABS pipes, fittings and ABS Solvent Cement used for joining must be
manufactured and supplied by the SAME manufacturer to ensure material
compatibility, dimension accuracy and quality.
________________________________________________________________________
G.2

1.10 ABS pipes and fittings manufacturer must provide documentary evidence to
demonstrate its expertise in the manufacturing and supply of ABS pipes, fittings
and ABS solvent cement. The ABS pipes and fittings manufacturer must arrange
for factory site audit by the owner/consultant prior to letter of award to confirm
product quality conformance.
1.11 All ABS fittings MUST be either injection mould or machine fabricated from
pressure pipes extruded by the same manufacturer. Rotor moulding or other
butt-welded low-pressure fittings are strictly NOT accepted. A factory audit is to
be conducted to ascertain capability of the manufacturer. All fittings supplied
using fabrication method must be fabricated using a single piece of Class 15
ABS pressure pipes extruded by the same manufacturer. All such fittings MUST
be subjected to 100% sample test at rated pressure conducted at the
manufacturers premises prior to acceptance for delivery. Test certificates MUST
be provided.
All pipes and fittings supplied must be accompanied by inspection and quality
reports issued by the manufacturer.
1.12 The manufacturer must provide a company profile among other information
indicating the relevant management personnels capability within the
organization in the manufacturing of ABS pipes and fittings.
2.0
Colour
The colour of ABS pipe shall be either dark blue or dark blue with navy blue stripes.
The minimum number of stripes shall be 4 spaced at 90 0 intervals and shall be of the
same type of resin as used in the compound for the pipe. The stripes shall not exceed
10% of wall thickness.
3.0
Scope of Supply
3.1
The Contractor shall manufacture, test, supply and transport to site as per
attached Bill of Quantities. All pipes shall be supplied with spigot on both ends
or socket on one end and plain on the other. Sockets shall be supplied loose for
site installation. All pipes supplied shall conform to the data in the following
Table 1.
Contractors shall submit a complete work programme on the schedule of
production and delivery.
3.2 SYABAS representatives reserve the right to visit the manufacturers pipe and
fittings manufacturing plant to witness Contractors capability in manufacturing the
pipes and specials. These visits will be notified earlier and will be done
________________________________________________________________________
G.3

during tendering and/or after tendering period is over. They can also request to visit
the plant anytime during the manufacturing period. All costs shall be borne by the
Contractor.
3.3
Contractor shall provide all necessary training and supervision to the pipe-laying
plumber at all time. These costs shall be included in the tender price.
TABLE 1 : ABS PIPE DIMENSION
PIPE SIZE
(DN/OD)
(DN15)
(DN20)
1 (DN25)
1 (DN25)
1 (DN25)
1 (DN32)
1 (DN32)
1 (DN32)
1 (DN40)
1 (DN40)
1 (DN40)
2 (DN50)
2 (DN50)
2 (DN50)
2 (OD75)
2 (OD75)
2 (OD75)
2 (OD75)
3 (DN80)
3 (DN80)
3 (DN80)
3 (DN80)
4 (DN100)
4 (DN100)
4 (DN100)
4 (DN100)
6 (DN150)
6 (DN150)
6 (DN150)
6 (DN150)
6 (DN150)
PIPE
CLASS
MAXIMUM
OPERATING
PRESSURE
(kPa)
OUTSIDE
DIAMETER
INSIDE
DIAMETER
WALL
THICKNESS
MASS
(mm)
(mm)
(mm)
(kg/m)
1500
1500
900
1200
1500
900
1200
1500
900
1200
1500
900
1200
1500
600
900
1200
1500
600
900
1200
1500
600
900
1200
1500
450
600
900
1200
1500
21.4
26.8
33.6
33.6
33.6
42.3
42.3
42.3
48.3
48.3
48.3
60.4
60.4
60.4
75.1
75.1
75.1
75.1
88.9
88.9
88.9
88.9
114.3
114.3
114.3
114.3
168.3
168.3
168.3
168.3
168.3
17.0
21.4
29.3
28.1
26.9
37.0
35.5
34.0
42.3
40.5
38.8
53.0
50.7
48.6
68.8
65.9
63.1
60.5
81.5
78.1
74.8
71.7
104.9
100.5
96.3
92.2
157.7
154.4
148.0
141.8
135.9
2.2
2.7
2.1
2.7
3.3
2.6
3.4
4.1
3.0
3.9
4.7
3.7
4.8
5.9
3.1
5.1
6.0
7.3
3.7
5.4
7.0
8.6
4.7
6.9
9.0
11.0
5.3
6.9
10.1
13.2
16.2
0.14
0.21
0.22
0.28
0.33
0.34
0.44
0.52
0.44
0.57
0.68
0.69
0.88
1.06
0.75
1.17
1.36
1.63
1.04
1.49
1.90
2.28
1.71
2.45
3.13
3.76
2.82
3.68
5.28
6.75
8.12
15
15
9
12
15
9
12
15
9
12
15
9
12
15
6
9
12
15
6
9
12
15
6
9
12
15
4.5
6
9
12
15
________________________________________________________________________
G.4

OD225mm
OD225mm
OD225mm
OD225mm
OD225mm
OD250mm
OD250mm
OD250mm
OD250mm
OD250mm
OD315mm
OD315mm
OD315mm
OD315mm
OD315mm
OD355mm
OD355mm
OD355mm
OD355mm
OD355mm
OD400mm
OD400mm
OD400mm
OD400mm
OD400mm
OD450mm
OD450mm
OD450mm
OD450mm
OD450mm
OD500mm
OD500mm
OD500mm
OD500mm
OD560mm
OD560mm
OD560mm
OD560mm
OD630mm
OD630mm
OD630mm
OD630mm
4.0
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
15
4.5
6
10
12
4.5
6
10
12
4.5
6
10
12
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
1500
450
600
1000
1200
450
600
1000
1200
450
600
1000
1200
225.3
225.3
225.3
225.3
225.3
250.4
250.4
250.4
250.4
250.4
315.4
315.4
315.4
315.4
315.4
355.4
355.4
355.4
355.4
355.4
400.5
400.5
400.5
400.5
400.5
450.6
450.6
450.6
450.6
450.6
500.5
500.5
500.5
5005
560.6
560.6
560.6
560.6
630.7
630.7
630.7
630.7
214.6
211.4
202.8
198.6
192.6
238.6
234.9
225.3
220.8
214.1
300.6
295.9
283.9
278.1
269.7
338.8
333.5
320.0
313.5
304.0
381.8
375.9
360.6
353.3
342.6
429.5
422.9
405.7
397.4
385.4
477.2
469.8
450.7
441.9
534.5
526.2
504.9
494.9
601.3
592.0
564.7
556.8
5.3
6.9
11.2
13.3
16.3
5.9
7.7
12.5
14.7
18.1
7.4
9.7
15.7
18.6
22.7
8.3
10.9
17.6
20.9
25.6
9.3
12.3
19.9
23.5
28.9
10.5
13.8
22.3
26.5
32.4
11.6
15.3
24.8
29.4
13.0
17.1
27.8
32.9
14.6
19.3
31.2
37.0
3.85
5.00
7.92
9.29
11.22
4.72
6.16
9.77
11.45
13.84
7.47
9.76
15.49
18.17
21.96
9.48
12.39
19.66
23.06
27.87
12.02
15.71
24.95
29.26
35.37
15.19
19.86
31.55
37.01
44.75
18.74
24.51
38.95
45.69
23.48
30.72
48.83
57.28
29.70
38.86
61.78
72.48
Solvent Cement
The solvent cement designed for the bonding of ABS pipes and fitting shall have a
viscosity in the range of 0.6 Pa.s to 1.9 Pa.s when tested in accordance with Appendix
B of MS 1419 : Part 3 : 1997. The manufacturers shall provide recognised
documentary evidence that the solvent cement manufactured by them complied with
________________________________________________________________________
G.5

such requirement. The manufacturers should have a Rotational Torsion Viscometer in

their factories for SYABAS representatives to carry out the test.
5.0
Jointing
5.1
All ABS joints shall be of cold solvent cement welded. The Contractor shall
provide sufficient ABS solvent cement for all pipe and socket joints under this
Contract. The Contractor shall ensure that the correct ABS solvent cement is
supplied for ABS pipes and fittings in accordance to the MS 1419. ABS solvent
cement and MEK Cleaner (Primary) fluids used in the jointing of ABS pipe,
fitting and in the fabrication of ABS fitting shall be in accordance with MS 1419.
uPVC cement or glue are strictly NOT allowed for use with ABS pipe and
fittings. Jointing techniques proposed by the Contractor shall be submitted to the
S.O. for approval at least two (2) weeks before the works commenced. Only
purpose-made ABS solvent cement and MEK cleaner manufactured and supplied
by the same pipes and fittings manufacturer are approved for used.
5.2
All pipes shall be cut square and swarf, etc. removed prior to jointing. Pipe
shall be inserted to full depth of fitting socket. Installed fittings which do not
have pipe inserted to full depth shall be considered below required standard
and shall be rectified at the Contractors expense. Backing ring shall be used in
all flanged joints.
5.3
The use of solvent cemented sockets; flange and shoulder style couplings are
permitted to join pipe and fittings as required. Equipment connections 50mm
and less may be threaded.
5.4
ABS pipe connections to other materials must not be made by cementing or

glued joints.
5.5
The use of hand operated lever winch or other suitable means of supplying a
steady effort sufficient to join fittings to pipes shall be made available when
jointing pipe sizes above 100mm. The used of hammers etc. to join fitting is
NOT permitted at anytime.
6.0 Support
6.1
The maximum distance between pipe supports shall be in accordance with the
manufacturer recommendation. The width of pipe supports shall be in
accordance with the manufacturer recommendations. Pipe support shall not
exert undue pressure on the pipe wall or deform the pipe wall against the clamp
or support. All clamps on horizontal pipe shall allow axial movement of the
pipe.
________________________________________________________________________
G.6

6.2
Large valve, filter or other heavy items should always be independently

supported or anchored to prevent undue loading and stress being transmitted to
the pipe. Valve support plates can be used in place of flange backing ring to
provide necessary support.
6.3
ABS pipe may be connected directly to other pipe or equivalent using flange or
threaded connection. Flanges are the recommended method for all sizes,
however threaded connections may be used for size 50mm and below.
6.4
Horizontal pipe support centers for ABS pipe at various temperatures is given in
the Table 2. For vertical pipes, support centers may be increased by 50%. The
adjacent correction factor shown in Table 3 should be applied for other pipe
classes. Pipe at 80C must be continuously supported.
Table 2 : Horizontal Pipe Support Centre
PIPE SIZE
CLASS 15 (PN15) PIPE SUPPORT CENTRE (m)

AVERAGE PIPE WALL TEMPERATURE (0C)
20 0C
50 0C
70 0C
1.00
0.80
0.60
1.10
0.80
0.70
1.20
0.90
0.80
1.30
1.00
0.80
1.40
1.10
0.90
1.60
1.20
0.90
1.80
1.56
1.00
2.20
1.80
1.10
2.50
2.00
1.30
2.80
2.20
1.40
3.10
2.70
1.80
3.40
2.70
1.80
3.70
2.90
2.00
4.10
3.20
2.20
4.70
3.60
2.40
4.70
3.60
2.40
5.10
3.90
2.60
(mm)
15
20
25
32
40
50
80
100
150
225
250
315
355
400
450
500
630
Table 3 : Correction Factor

PIPE CLASS (PN)
9
12
15
CORRECTION FACTOR
0.88
0.92
1.00
________________________________________________________________________
G.7

7.0
Safety Precautions
The following requirements are in addition to any government safety legislation or
established company work practices.
Read safety precautions available on ABS solvent cement and MEK cleaner
containers.
Work area must be well ventilated
As solvent cement and cleaner are flammable liquids, ensure work area is
clear of falling sparks or other sources of ignition e.g. smoking
To wear safety glass and protection glove at all times when using ABS
solvent cement and MEK cleaner
The contractor shall submit safety data sheets in their tender.
8.0
Jointing Procedure
The following procedure shall be observed and obliged at all times during pipeline
installation works.
Measure and cut pipe squared.
Remove internal and external swarf and file a 2 10mm; 30

outer edge of the pipe.
Lightly abrade the gloss from the outer surface of the pipe and the inner surface of
the fitting using emery paper.
Clean the surface with clean rag moistened with MEK cleaner.
Mark the pipe distance back from the end equal to the depth of the socket plus
10mm. This is to allow you to ensure that the joint is fully home.
For sizes above 100mm, position the winch to pull the joint together after solvent
cement is applied.
Apply the solvent cement as quickly as possible first to the socket and to the pipe
using longitudinal brush strokes. For size 100mm and above, two coats will be
required on both the pipe and the fitting.
chamfer on the
________________________________________________________________________
G.8

9.0
Immediately after application of the solvent cement, push pipe fully home using
the mark on the pipe as a guide. Do not twist fitting on the pipe. If using a winch,
do not exert additional force once the pipe is fully home.
As all Malaysian Standard ABS fittings are a tapered interference fit, it is essential
the fitting be held in position for a time intervals of between 10 seconds to one
minute to prevent any movement. When using the winch on larger fittings, leave
the winch in position until winching is required for the next consecutive joint.
Wipe excess solvent cement from the joint. Care should be taken to avoid excess
deposits of solvent cement inside small diameter fittings as this can weaken the
wall of the pipe or fittings.
Notes on Jointing
The following precautions and notes shall always be observed by the Contractor.
Work in a shaded well-ventilated area clear of hazards.
Treat ABS solvent cement and MEK cleaner with care, as they are volatile
flammable liquids. Replace lids after use.
ABS solvent cement should be stirred before use.

cement with MEK.
Double check dimensions before cementing fittings to pipe. It is impossible to

remove fitting intact once jointed to pipe.
Solvent cement jointing must be completed quickly, typically within 2 minutes

of applying the first coat of cement. A 2-person team for sizes 200mm and
above is recommended.
ABS pipe cannot be successfully cemented under wet conditions. Pipe must be
dry for effective jointing.
In preparation for jointing, pipe should be stored in a shaded area as the

working life of the solvent cement is reduced when applied to hot pipe and
fitting.
Use only clean rags and brushes. Brushed must be cleaned in MEK cleaner after
used.
Do NOT dilute solvent
________________________________________________________________________
G.9

10.0
Cement may be removed from your hands with soap and water or industrial
hand cleaning soap. Do not use MEK cleaner to remove ABS solvent cement
from your skin.
Use only purpose-made ABS solvent cement and MEK cleaner from the same
manufacturer.
The key to fast efficient jointing particularly with large pipe diameter is
preparation. When using a lever winch, have everything ready before applying
cement. A canopy over the jointing area is desirable when working in full sun.
Usage of Solvent Cement

An indication on the number of joints likely to be made with ABS solvent cement
following the recommended procedure is as stipulated in Table 4
A socket counts as 2 joints, a tee as 3 joints etc. The usage of MEK is approximately
2/3 times that of ABS cement.
Table 4 : Number of Solvent Weld Per Litre of Solvent Cement
PIPE DIAMETER (mm)
Up to 50
80
100
150
225
250
315
355
400
450
500
11.0
SOLVENT WELD / LITRE

135
45
35
20
10
4
4
3
2
1
1
Solvent Cement Welding Drying Times

The drying time for joints varies depending on:
The amount of ABS solvent cement and MEK cleaner applied.
The diameter of the pipe or fitting.
Ambient temperature.
________________________________________________________________________
G.10

The fit between the pipe and fitting.
Class of the pipe.
Whilst full rated pressure may not be applied for 24 hours, joints in smaller
diameters can often be put back into service within minutes of being made. An
approximate guide is to allow 1 (one) hour per 100kPa working pressure for size up
to 80mm. For size 100mm and above, the time should be increased to 1.5 hours
per 1 bar.
12.0
Sockets
Socket joints are permitted to be used for pipe and plains ended fittings.
Socket joints are permanent and cannot be disassembled.
13.0
Pipe Markings
All pipes must have the following markings:
14.0
Manufacturers name or trade mark

Pipe Diameter, SDR
Material Supplier and MRS
Pressure Class (PN)
The word SYABAS (50mm high)in capital letter
Production Date
Batch Production Code
SIRIM QAS License Number
Specification
Minimum Wall Thickness
Installation of Saddles
14.1 Drill the hole in the pipe wall with a small clearance to suit the spigot size
of the saddle. A hole-saw is useful for pipe size up to 100mm whereas a
jigsaw may be more effective for larger sizes.
14.2 Mark out the area on the pipe to be covered by the saddle.
14.3 Lightly abrade the area to be covered on the saddle and pipe to remove any
gloss.
________________________________________________________________________
G.11

14.4 Feed into the pipe a minimum two worm drive (jubilee) style stainless steel
clips placing one either side of the saddle position. On the larger saddle
sizes (225-630mm) two or more clamps per side may be required.
14.5 Clean the abraded surfaces of the pipe and saddle using MEK cleaner.
14.6 Apply minimum of two coats of ABS solvent cement to pipe and saddle.
14.7 Immediately place the saddle in position, secure with the saddle in position,
and secure with the stainless steel clamps. The saddle must be pulled down
onto the pipe to ensure there is no gap between the pipe and the saddle.
This may require the use of a clamp. Leave worms drive clips in place for a
minimum of 48 hours. It is recommended to leave the stainless steel clamp
on at all times. Wipe off excess cement.
14.8 A minimum of 24 hours drying time must be allowed before applying full
pressure. On sizes 250mm and above a drying time up to 48 hours is
recommended.
15.0
Connections ABS to Other Pipe Systems

There are several methods of connecting other pipe systems directly to ABS pipe.
16.0
Composite Unions
Flanges
Threaded adaptors
Shoulders end style couplings
Milnes style clamps
Flanged Joints
Two styles of flange jointing systems shall be used:
Full face flange for size to 6 and stub flange for size 2 to 630mm
Stub flange assemblies shall have the same pressure rating as full face
flanges assemblies
________________________________________________________________________
G.12

Backing rings must be used with both full face and stubs flanges available in
all standard-drilling configurations. Gaskets must be used with flanges.
ABS stub or full-face flange assemblies may be bolted directly to other pipe
systems of the same flange-drilling standard. Gaskets and backing rings must
be used at the joints. Torque values for flange face are as stipulated in Table
5.
Table 5 : Recommended Bolt Torques and Bolt Sizes

Pipe size
(mm)
15
20
25
32
40
50
80
100
150
225
250
315
355
400
450
500
560
630
Bolt Sizes
(mm)
M12 x 50
M12 x 50
M12 x 50
M12 x 50
M16 x 60
M16 x 65
M16 x 70
M16 x 80
M20 x 90
M20 x 100
M20 x 130
M20 x 150
M24 x 160
M24 x 170
M24 x 180
M24 x 190
M27 x 230
M27 x 240
Recommended
Torque (NM)
7
10
14
13
20
22
33
25
42
63
80
74
133
163
157
185
190
190
Hole per Flange

4
4
4
4
4
4
4
8
8
8
12
12
12
16
16
20
20
20
Standard butterfly valves shall be placed between ABS stubs or full-face flange
assemblies without modification. Valve should be checked for full and free movement
prior to final tightening of flange bolts.
17.0
Threaded Connection
The following table shows the class of pipe which shall be used for BSP treading.
When threading, sharp die shall be used and cut full thread depths, without
lubricant in one operation.
All threaded fitting shall be rated at 12 bar at 20C.
________________________________________________________________________
G.13

For high-pressure installations it is preferable to use adaptors or fitting with male ABS
threads in preference to female threaded fittings.
Composite unions, available in male and female threaded configurations to 50mm are
recommended for joining ABS pipe to metal threads particularly in systems subject to
thermal cycling.
Tightening should only be done by hand with a maximum of an extra quarters turn
with a pipe wrench. There is often a tendency to over tighten threads however this
only causes distortion and leaks.
If leakage occurred at the threaded joint, disassemble the joint. If there is no damaged
at the thread, remake the joint and care shall be taken not to over tighten.
PTFE tape is the recommended thread sealant.
Do not use liquid thread sealant, e.g. Loctite or PTFE, as they contain chemicals,
which attack most plastic materials.
BSP Size (in.)
1
1
1
2
3
4
18.0
BSP Size (mm)

15
20
25
32
40
50
80
100
Pipe Class
T
T
T
T
T
T
T
T
Instrumentation Connections
Instrument connections may be made a combination of saddle and threaded reducing
bushes. In addition, for 80mm and larger pipe sizes, drilling and tapping directly in
the pipe at a fitting may be from these combinations. Maximum size tapping as
follows:
Pipe Size
(mm)
80
100 - 150
200
250
315
400 - 500
Maximum Instrument
Tapping Point Size
3/8
1
2
________________________________________________________________________
G.14

19. 0
Buried Pipes
19.1
Pipe Trench
Trenches should
requirements.
In general, trenches should be as narrow as possible having regards to the

practicalities of handling the pipes in the trench and the stability of the
ground conditions.
A minimum bottom of trench width equal to the outside diameter of the

pipe plus 200 300mm should be sufficient. Depth of the trench, as per
following table, should allow for the required top cover plus diameter of
the pipe and the depth of the bedding.
Where very heavy vehicle loads are anticipated, trench depths should be
calculated in accordance with SYABAS requirements.
19.2
be
constructed
in
accordance
with
SYABAS
Recommended Minimum Pipe Bedding

Trench bottom should be as even as possible to support the pipe. Trenches
constructed in ground containing sharp stones or rock must have a
minimum 75mm cover of bedding layer of coarse sand or fine gravel
above and below pipe.
19.3
Thrust Blocks
Thrust blocks may be installed for solvent cement jointed buried pipelines
at changes of direction, termination, changes in pipe diameter or tees.
Thrust blocks may be required where valve or other equipment is
positioned in the pipeline and are not independently supported.
19.4
Installing Pipe
Pipe length up to 12 meters is available and is recommended to minimize

the number of joints and to speed up handling and installation time.
Pipes joined above ground should remain undisturbed for a minimum of 2

hours before being snaked into the trench.
Pipe sizes 250mm and above should be joined in the trench.
________________________________________________________________________
G.15

19.5
Particular care must be taken to ensure pipes and jointing material are
clean and dry when making a joint.
Final Connections
Final connection, backfilling and tamping should be completed in the
coolest part of the day, i.e. early morning. This is to prevent undue tensile
loads being imposed on the pipe joints. If final joints or backfilling is
completed in the hotter part of the day, the pipe contracts during the
cooler hours of the night, excessive tensile loads may be placed on the
joints.
19.6
20.0
Backfilling and Tamping

Screened excavated material or bedding sand/gravel should be used to
back fill trench to a minimum cover of 75mm above the top of the pipe.
Backfill must be effectively tamped under both sides of the pipe to provide
proper support. Joints should be left uncover until pressure testing has
been completed. Excavation material may be used for final backfilling.
For installation of pipelines operating at above or below ambient
temperatures, a complete method of installation shall be submitted to S.
O. for approval.
Hydrostatic Pressure Testing

The following test procedure should be followed where installations must be
pressure tested.
The test pressure to be applied shall be equivalent to 1.5 times the static head.
Testing must not be carried out until the following times have elapsed since
completion of the last joints.
Pipe Size
(mm)
10 200
250 355
400 630
Times
(Hours)
24
36
48
For large installation split the system into several sections for testing.
Fill section with clean ambient temperature water (20C is ideal). Do not
pressurize.
________________________________________________________________________
G.16

Ensure no air trapped in the system.
Inspect system for gas leaks.
Allow the system to stand for one hour to allow temperature to stabilize and
equilibrium reached.
If there are no leaks remove any remaining air and increase pressure to 3 bar.
Leave at this pressure for 15 minutes and inspect for leaks.
If pressure remains constant, increase pressure to recommended test pressure.

Leave pressurized for a period not exceeding one hour. During this time
pressure should hold almost constant.
All pipes shall be tested at a test pressure 1.5 times higher than the system
operating pressure less the allowance for temperature / pressure de-rating at the
current test temperature.
NOTE :
CAUTION :
If extended times are required to achieve the test pressure either leakage is
occurring or there is air trapped in the system. Inspects for leakage and if
apparent reduce the pressure and check for trapped air which must be
removed before the test and continue.
Under no circumstances should pressure tests be carried out using
pressurized gases. Such test could be extremely dangerous should a failure
occur.
________________________________________________________________________
G.17

H : DUCTILE IRON FERROUS SADDLES

1.0
GENERAL
1.1
Scope
This Standard specifies the requirements for the design, materials, manufacturer and
testing of standard ductile iron ferrous saddles for uPVC, Ductile iron and Asbestos
cement pipes.
1.2
Referenced Documents
The following referenced documents contain provisions, which, through reference
in this text, constitute provisions of this Standard. For dated references, where there
are subsequent amendments to, or revisions of, any of these publications, the
Standard shall be amended or revised accordingly. For undated references, the latest
edition of publication referred to applies.
The titles of publications referred to in this Standard are listed below:Spesifikasi JKR
JKR Standard Specification for Ferrous Saddles (revised edition

1999) 20200-0044-99
MS 628 :Part 1
Specification for unplasticised PVC (uPVC) pipes for water

supply: Part 1: Pipes (First Revision)
MS 712
Specification for asbestos cement pressure pipes
N1S 740
Specification for hot-dip galvanized coatings on iron and steel

articles
BS 21
Specification for pipe threads for tubes and fittings where

pressure-tight joints are made on the threads (Metric
dimensions)
BS 6681
Specification for malleable cast iron
BS 4190
Specification for ISO metric black hexagon bolts, screws and

nuts
BS 970 : Part 1
Specification for general inspection and testing procedures and

specific requirements for stainless steel
BS 3505
Specification for unplasticised PVC pipe for Cold water services
BS 4772
Specification for ductile iron pipes and fittings
BS 2789
Specification for spheroidal graphite or nodular graphite cast

iron
P:\zRAZMANN\SPEC\H-DI Ferrous Saddle1.doc
H.1

BS EN 1563
Specification for Founding - Spheriodal graphite cast iron
BS 1706
Method for specifying electroplated coatings of zinc and

cadmium on iron and steel
BS 2779
Specification for pipe threads for tubes and fittings where

pressure tight joints are not made on the threads (Metric
dimensions)
MS 672 : 99
Specification for rubber sap-is in water supply, drainage &

sewerage pipelines
BS 6920 : Part 1
Specification for suitability of non-metallic products for use in

contact with water intended for human-consumption with
regard to their effect on water quality of the water. Part 1:
Specification
BS 3643 : Part 2
ISO metric screw threads . Specification for selected limits of

size
BS 7079
Preparation of steel substrates before application of paints and

related products
BS 3900
Methods of tests for paints.

Part F4 : Resistance to continuous salt spray
Part F11: Durability tests on paint films. Determination of
resistance to cathodic disbanding of coatings for use on landbased buried structure
BS EN 512
Fibre-cement products. Pressure pipes and joints
BS EN 10083-1
Technical delivery conditions for special steels
AS 1646
Specification for elastomeric seals for waterworks purposes
AS 4020
Product for use in contact with water intended for human

consumption with regard to their effect on the quality of water
AS/NZS 4158
Thermal-bonded polymeric coatings on values and fitting for

water industry purposes
ISO 2531
Specification for ductile iron pipes, fittings and accessories for

pressure pipelines
ISO 8501: Part 1
Preparation of steel substrates before application of paints and

related products - visual assessment of surface cleanliness
H.2

Part 1: Rust grades and preparation grades of uncoated steel

substrates and of steel substrates after overall removal of
previous coatings
1.3
SS 05 5900
Pictorial surface preparation standard for painting steel surfaces
AWWA C210
Liquid epoxy coating systems for the interior and exterior of

steel water pipelines
ASTM D570
Water absorption test
ASTM D 4066
Specification for nylon injection and extrusion materials (PA)
Definitions
For the purpose of this standard, the following definition applies.
1.3.1
Ferrous Saddle
Ferrous saddle is a device used in water works for making service connections and
tapping. It is used as a services clamp, which is, attached directly 360 around the
pipe or for pipe's wall which is too thin or too soft. The use of the ferrous saddle is
to provide support for the pipe without deforming it and distributes stresses away
from tapping hole as well as purchase for the threads of the ferrule.
1.3.2
Polyamide Adaptor
Polyamide (high strength plastic) adaptor provided with the tapping thread, is
integral with the boss of the saddle. The design of polyamide adaptor is to have
protection against corrosion. It replaces threading onto the ductile iron-boss/body of
the saddle that will also prevent galvanic effect (that will cause severe corrosion)
between ductile iron ferrous saddle and the brass ferrule.
1.4
Types of Ferrous Saddle

Ferrous saddles shall be one of the following types :
1.4.1
Saddle Type A
Type A ferrous saddle is suitable for tapping Asbestos Cement Pipe complying with
MS 712 and BS EN 512 and Ductile Iron pipes complying with BS EN 545 : 2002
(previously known as BS4772 : 1933) and ISO 2531. (see Figure 1)
1.4.2
Saddle Type B
Type B ferrous saddle is suitable for tapping uPVC pipe complying with MS 628:
Part 1 and BS 3505 (see Figure 2)
NOTE : Both are designed to withstand same torque loads and bending moments,
H.3

1.5
Illustration
Ferrous saddle shall be of general form shown in Drawing.
1.6
Materials
The clamp ferrous saddle should be manufactured from compounded material
meeting the followings specification as below.
Table 1: Material for Ferrous Saddle
Components
Material
Symbol
Reference
Grade or
Designation
Ferrous saddle
body
Ductile Iron
DI
BS 2789
BS EN 1563 : 97
420/10, 500/7
400/15, 500/7
Bolts, Nuts,
Washer
Stainless Steel*
Carbon Steel
(Polymeric Coated)
SS
BS 970 Part 1
BS EN 10083-1
304 S31, 16S13,

321 S13
2C22
Sealing Gasket
(TOP)
Synthetic Rubber
EPDM
MS 672: 99/
AS 1646/BS EN 681
66-75 IRHD
Sealing Gasket
(Bottom)
Synthetic Rubber
EPDM
MS 672: 99/
AS 1646/BS EN 681
66-75 IRHD
Polyamide
Adaptor
Polyamide -11
PA
ASTM D 4066
PA321
NOTE : All casting shall have smooth, homogeneous and free from flaws, cracks blow
outs or other harmful defects. Grey cast iron, of BS 1457 Grade 220 and Malleable cast
iron BS 6681 Grade B30-06/W35-04 are not allowed to be used for this product.
* For coating refer Section Two - Protection against corrosion
All materials likely to contact with potable water should be incapable of permitting
bacterial growth. Non-metallic materials should comply with the requirement of the
effect of non-metallic materials on water quality as mentioned in specification.
H.4

1.6.1
Body
Body material shall be manufactured from the materials given as appropriate in
Table : Material For Ferrous Saddle.
NOTE : Body materials may be specified by the purchaser in his enquiry or order
1.6.2
Bolt, Nut and Washer

Bolt, nut and washer materials should be selected from Table : Material For Ferrous
Saddle. The length of the bolts shall be as shown in the drawing.
1.6.3
Sealing Gasket
Gaskets shall be vulcanised, moulded or extruded elastomer and shall be free from
porous areas, foreign materials and visible defects. Reclaimed rubber shall not be
used
Sealing Gasket shall be made of EPDM complying with MS672 : 99, AS 1646:92 or
BS EN 681 for potable water applications, sealing gasket made of natural rubber is
not allowed. Materials complying with this standard shall meet the requirements of
BS 6920, which specifies the requirements for non-metallic materials in contact with
portable water.
Gaskets shall be manufactured from elastomeric compound of hardness (measured
in IRHD) such that the ferrous saddle shall perform satisfactorily in both short and
long term tests as specified. To meet this requirement gaskets shall fall within the
nominal hardness range of 66 -75 IRHD)
1.6.4
Polyamide Adaptor
The adaptor shall be made of injection moulded Polyamide 11 and shall comply
with ASTM D 4066 and shall follow the dimension and illustration in drawing.
1.7
Effect of Non-Metallic Products on Water Quality

When used under the conditions for which they are designed, non-metallic
products in contact with or likely to come into contact with potable water
shall comply with BS 6920 : Part 1.
1.8
Workmanship
1.8.1
Casting
All casting shall be homogeneous, smooth and shall be free from flaws, cracks,
blowholes, cuts or other harmful defects. All surfaces in close proximity to the pipe
and gaskets shall be smooth and free from sharp edges.
H.5

1.9
Nominal Sizes
Ferrous saddle shall be one of the following nominal sizes (DN) DN 80, DN 100,
DN 150, DN 200, DN 250, DN 300, DN 350 and shall be designated by the
nominal diameter of the pipes.
1.10
Dimension and Tolerances

The ranges of nominal sizes from DN 80 to DN 350 applicable to each materials,
tapping sizes dimensions of each tape materials shall be as shown in drawing.
The tolerances for these dimensions shall be as shown in drawing.
NOTE. The details of ferrous saddle shown in drawing may differ from one
manufacturer to another provided the dimensions identified are maintained.
1.10.1
Boss Dimensions
The boss dimensions shall comply with table as appropriate. The boss shall permit
tapping within the size range " to 1" BSP.
1.10.2
Tapping Dimensions
The tapping hole shall be threaded in accordance with BS 21 with positive tolerance
deviation accordance with the requirements of BS 2779.
1.10.3
Bolts, Nuts and Washer Dimensions

Bolt, nut and washer dimensions shall comply with BS 4190. Bolts shall be provided
with a track-head, or similar neck which locates in a similarly shaped hole in the
ferrous saddle body, thus preventing rotation of the bolt and permitting tightening of
the bolts using only one spanner. The threads on bolts, studs and nuts shall comply
with ISO metric series of BS 3643 : Part 2. Thread lengths shall in every case be of
sufficient length to permit proper tightening of the ferrous saddle to create the
designed pressure seal without the nut reaching the end of the threaded section.
All bolts holes shall be drilled or accurately moulded and shall be equally spaced on
the pitch circle diameter and shall be located off-centre.
1.10.4
Sealing Gasket Dimensions

Gaskets shall be such size and shape as to provide a pressure tight seal for the life
expectancy of the pipeline under the specified working, transient and test pressure
conditions.
H.6

Saddle Type A
Sealing Gasket shall be contained within the recess between the boss and the pip.
The thickness of the rubber sealing gasket shall be not less than 4 mm while the
outside diameter shall be not less than 75mm.
Saddle Type B
The thickness of sealing gasket contained within the recess between the boss and
the pipes shall be not less than 4 mm while the rubber gasket contained under the
ferrous saddle body shall be not less than 1.5 mm.
2.0
PROTECTION AGAINST CORROSION
2.1
Surface Preparation
This section specifies methods of protecting ferrous saddles against corrosion. It
covers internal and external protection by Fusion Bonded Epoxy powder (FBE) and
by Polyamide 11.
The surface to be protected shall be clean and free from porosity, cracks, scale,
loose rust, oil, grease or other foreign matter. Surface preparations shall be effected
by abrasive blast cleaning cold applied surface tolerant high solid epoxy with
AWWA C210 can be used as an alternative polymeric coating system. The surface
preparation, coating requirements and test methods for this coating system are
separately dealt with in Appendix : Surface Preparation, Coating Requirements and
Test Methods for Cold Applied Surface Tolerant High Solid Liquid Epoxy.
2.2
Degreasing
All items intended for coating shall be decreased to remove all oil, grease and
residual surface solids.
2.3
Abrasive Cleaning
Iron and steel surfaces of ferrous saddles shall be prepared by abrasive blast cleaning
to SA 2 quality of BS 7079.
NOTE : If a SA 3 surface quality is required, the purchaser shall specify this at
time of placing an order.
2.4
Pre-Treatment
After blast cleaning the resultant surface shall be free of loose dust, oil, grease,
soluble salts and other materials that may be deleterious to the final performance of
the coating. Water washing, degreasing and oil-free air blast shall be used as
necessary to ensure these contaminants are removed prior to proceeding with the
coating process.
H.7

If recommended by the coating materials manufacturer, chemical pre-treatments

such as phosphate conversion coatings may be applied. The final coating process
shall be carried out within 24 h of such pre-treatment, and within 3 h if no chemical
pre-treatment coating is applied.
All metal surfaces that are to receive a coating of Polyamide 11 shall be coated with
a primer, supplied by the coating material manufacturer for use with the nylon
powder and allowed to dry before the final coating process proceeds. This operation
of primering shall take place within 8 hours after blast cleaning, onto clean, dedusted surfaces. Threaded fasteners that are to be coated with a self-adhesive grade
of Polyamide 11 do not require primering. The final coating shall take place within
8 hours after blast cleaning.
2.5.
Coating
2.5.1
General
Coating shall be carried out using either fusion bonded epoxy powder or nylon 11
materials. The coating shall be applied using either the fluidised bed dipping process
or the electrostatic spray process and shall produce a finished coating which fully
complies with the thickness recommendations of the coating materials
manufacturer, though subject to the thickness limitation specified.
2.5.2
Body
The coatings on ferrous saddle body shall be not less than 250 m for Polyamide 11
or not less than 350 m thick for Fusion Bonded Epoxy as specified in AS/NZ 4158.
Particular attention shall be paid to either thinning or excessive build-up of coatings
at sharp edges especially at bolt - holes. Clearance between the pipe outside
diameter and the internal diameter of coated ferrous saddles shall be sufficient to
ensure satisfactory assembly of the ferrous saddle onto the pipe, without damage to
the coating.
2.5.3
Fasteners
Bolt, studs and nuts which are to be coated with epoxy or materials shall first be
zinc plated on all surfaces to BS 1706 Grade Fe/Zn 12 Threaded fasteners which are
to be Polyamide 11 coated shall use a self-adhesive grade of Polyamide 11.
The finished thickness of coating on threaded fasteners shall be between 75 m and
125 m. All surfaces of bolts, studs and nuts shall be coated, except that it is
permissible to leave uncoated the internal surface of coated nuts and the extreme
tips of coated bolts, provided that the resultant uncoated sections of bolts do not
form part of the tensile section of the bolt after tightening.
Fasteners shall be provided with washers under each nut. Washers shall be spun
galvanised to MS 740 and may in addition be further coated with either epoxy or
Polyamide 11.
H.8

2.6
Coating Application
The method of coating application shall comply fully with the recommendations of
the coating materials manufacturer and if required by the purchaser, the coupling
manufacturer shall submit full detail of the method of application for approval by the
purchaser. In case of epoxy coatings, which have limited shelf life, particular
attention shall be taken on products tracing.
The resultant coating shall be uniform in colour and texture and shall not exhibit
blisters, bubbles, crazed areas or contaminant inclusions. The coating shall be
completely fused to a smooth continuous film. No bare metal shall be visible except
for areas left deliberately uncoated No pinholes, tears, runs, sags or excessive
coating build-up shall be evident. All support points shall be touched up with a
compatible coating material recommended by the coating supplier
2.7.
Tests on Applied Protections
2.7.1
Holiday Test
Ferrous saddle shall be tested for continuity of the applied coating protection using a
high voltage holiday detector set at a minimum 1,500 V or 5 m. Discontinuities
and pinholes indicated by the test shall be made good with an approved repair
material and the component re-tested satisfactorily.
2.7.2
Cure Test
Fusion bonded epoxy coatings shall be tested for proper cure of the coition by
rubbing the coating with MEK (methyl ethel ketone). If the coating becomes soft or
tacky, insufficient cure is indicated. In such case, post curing of the coating shall be
carried out by further heating in an oven until the necessary degree of cure is
achieved. Polyamide 11 coatings which are thermoplastic do not require this test.
NOTE. When working with MEK appropriate safety precautions must be taken. MEK
is flammable and must be kept away from open flames or other sources of ignition.
2.8
Repair
Any defective coatings shall be made good using methods approved by the coating
materials manufacturer.
2.9
Sampling
Two percent of each particular size and type of the ferrous saddles to be supplied
shall be tested. Any test piece, which fails to comply with dimensions, tests, or
showing signs of defect will render the whole batch to be rejected.
H.9

2.10
Protection Against Damage in Storage; Transport and Handling

Coated ferrous saddle shall be protected against damage in storage, transport and
handling by means of plastic sheeting, corrugated paper, rubber pads, wood wool
pads, etc.
3.0
TESTING
3.1
Testing
3.1.1
Test Requirement
The manufacturer shall conduct a type test on each type and size of ferrous saddle
before dispatch to the site.
Type testing shall consist of the following tests in the sequence specified:
Strength Testing
Functional Testing
Corrosion Testing
Water Testing Test
Cathodic Disbondment Test
Adhesion Test
Chemical resistance test
Test results shall be recorded and retained by the manufacturer and shall include the
results of a visual examination of the ferrous saddle components after type testing.
3.1.2
Strength Testing
The ferrous saddle should be attached directly 360 around the test apparatus with
corresponding pipe OD in normal manner and gradually tightened the bolts with a
torque as specified in Table 2, in order to test the strength of the ferrous saddle body
There shall be no visible evidence of structural damage to the ferrous saddle body.
3.1.3
Functional Testing
The same ferrous saddle be attached directly 360 around the corresponding type
size of pipe with the insertion of sealing gasket under the boss (with tapping hole
c/w stop plug) and around a hole drilled in the pipe with a torque which shall not at
any point exceed the maximum functional test torque specified in Table 2 as
applicable. There shall be no visible evidence of structural damage to the boss and
ferrous saddle body and of leakage when subjected to an internal pressure of 16 bar
during the test duration as shown below.
H.10

Table 2: Test Torque

Nominal Size
(DN)
Minimum Strength Maximum Functional

Test Torque
Test Torque
(Nm)
(Nm)
80 up to & including 350
3.1.4
220
120
Test Duration
(minimum)
(Min)
1
Corrosion Testing
The ferrous saddle should be coated in accordance with Clause 2.5 and shall
conduct a salt spray test complying requirement specified in BS 3900 : F4.
3.1.5
Water Absorption Test

Samples shall be tested according to ASTM D570 for water absorption. The test
consists of an immersion in water at 20 C during 90 days. Samples shall display
water absorption of not more than 3 % by weight of coating.
3.1.6
Cathodic Disbondment test
3.1.7
Coated pieces shall be tested according to Sections 5, 6, 7, 8 and 9 of BS 3900 :

F11. The coating, when subjected to an impressed current at a negative voltage of
1.5 V, shall not disbond more than 5 mm radially from the end of the damaged
coating after 28 days.
Adhesion Test
Adhesion testing shall be carried out to determine the adhesive strength of the
coating to the substrate. It does not prove cohesive strength of the coating. Testing
shall be by means of a 'V'-cut test. Toughness of the film and visual evidence of
coating in the anchor pattern valleys will give good indication of satisfactory
adhesion.
The test shall be carried out using a sharp knife. Two cuts are made in the coating at
an included angle of approximately 30. Using the sharp point of a craft knife or
similar, the knife shall be used to attempt to lift the point of the 'V' in a single action
by levering against a fulcrum. No more than 2 mm of the 'V' shall be removed by
this method by adhesive failure to the substrate or the adhesion shall be considered
to be unsatisfactory.
The purchaser shall state his requirement for an adhesion test at time of order and
shall agree with the coupling manufacturer the frequency of testing to be carried out
and any variation on the acceptance criteria.
3.1.8
Chemical Resistance Test

The ferrous saddle shall be immersed in a saturated solution of zinc chloride under
room temperature for 10 hours. There shall be no visible evidence of damage and of
leakage when subjected to an internal pressure of 16 bar.
H.11

3.1.9
Visual Inspection
Ferrous saddles shall be clean and free from such defects as can be established by
visual inspection in accordance with this standard.
Ferrous saddles shall not deviate from roundness by more than +1mm. Ferrous
saddle body shall be smoothed and free from excessive burrs that might cause
damage to the gasket or might impair the pressure tightness of the joint.
Gaskets shall be moulded as specified in Sealing Gasket Dimensions.
3.1.10
Short Term Pressure Testing

The ferrous saddle body shall be subjected to a hydrostatic pressure test of 1.5 times
the maximum permissible installed working pressure for a period of at least 1 hour
without leakage.
3.2.
Production Testing
Steel saddles which are flash welded and expanded beyond the yield point of the
steel, need not be further mechanically or hydrostatically tested.
Steel saddles that are manufactured from previously pressure tested pipe or tubing
need not be further hydrostatically tested.
Ferrous saddles made from malleable or ductile iron shall be 100 % air tested under
water, either at the foundry or by the coupling manufacturer, to a pressure of at least
6 bar for a period of at least 5 seconds after static conditions have been obtained
after immersion in the water, without visible leakage. Castings which fail this test
shall be rejected.
4.0
MARKING
4.1
Marking
Each ferrous saddle shall be legibly marked (not on top of the boss of the saddle) in
accordance with the following requirements.
o
o
o
o
o
o
Manufacturer's name or trade mark;

The designation of size
Body material designation
Year of manufacture (last two digits)
Standard of manufacture
Ferrous saddle type
NOTE. Additional markings may be used at the option of the manufacturer and
purchaser provided that they do not conflict with any of the markings specified.
H.12

I : VALVES
1.0
General
1.1
Approved makes and brand of valves

The Contractor shall only use approved makes and brand of valves. He shall submit the
list of proposed valve(s) within two (2) weeks of the issuance of the Letter of Award,
complete with the detailed Schedule of Particulars. He shall be responsible to test and
commission all valves, fittings, etc. supplied and installed by them.
1.2
Drawings
Typical Drawings are presented in the Schedule of Particulars.
Detailed engineering shop drawings MUST BE issued by the Contractor before
manufacture/fabrication. The Contractor shall prepare any additional drawings, which
the Contractor requires to interpret the Drawings for the use of his employee.
The Contractor shall be responsible for any discrepancies, errors or omissions in the
Drawings or other particulars supplied by him, whether such Drawings or particulars
have been approved by the S.O. or not.
1.2.1
Drawings to be provided by the Contractor.
1.2.1.1 Tender Drawings

The Contractor shall submit with his tender two (2) copies of typical cross-section
drawings showing the salient features of the valves and fittings offered together with
sufficient details to enable the general arrangement of the valves to be determined.
All drawings submitted by the Contractor with his tender shall be listed in the Schedule C
of the Schedule of Particulars.
1.2.1.2 Approved Drawings
Within four (4) weeks of the Contract being awarded, the Contractor shall submit for
approval to the S.O. the following shop drawings with the manufacturers endorsement in
triplicate:
(i)
Dimensioned drawings of each valve, which shall include details of each
component, and shall show the grade and materials of construction of each
component;
(ii)
Diagrams of connections for each type of electrical equipment together with a
comprehensive wiring diagram showing all connections between the various
items of equipment. The terminal lettering on the diagrams shall correspond to
the terminal makings to be used on the equipment;
(iii)
All details drawings necessary to enable the S.O. to provide to other Contractor
with details such as interconnecting cables, cable terminations, foundations and
bolt holes.
D:\TECHNICAL DEPARTMENT\SPEC YHH\New Folder\I-Valves.doc
I.1

(iv)
All detail drawings showing the installation of the valves and actuators where the
installation works is being carried out the Contractor.
The Contractor shall make such changes to the drawings as the S.O. may require and shall
resubmit the amended drawings to the S.O. for approval. These drawings and any
additional detailed drawing as the S.O. may require from time to time shall become the
Approved Drawings to be used for the manufacture and supply of the Goods. The
Contractor shall provide additional set(s) of the Approved Drawings as the S.O. may
require, without additional charge.
Unless specific instructions are given by the S.O. in writing, no drawings other than
Approved Drawings or drawings issued by the S.O. shall be used for the performance of
the Contractors obligations under the Contract.
Within 1 month of the despatch of any item of the Goods, the Contractor shall supply for
record purposes six (6) bound complete sets of the Manufactured Drawings amended as
necessary to show the Goods as manufactured.
After completion of installation, As-Built Drawings for installation works shall be
submitted within one (1) month of the completion of the Works.
Drawing format:
All drawings at each stage shall be submitted in the following formats:Approved Drawings: Five (5) sets in paper prints (A3 size);
Manufactured Drawings: Six (6) sets in paper prints (A3 size);
As-Built Drawings: Six (6) sets in paper prints (A3 size); and three (3) sets in CDROM.
All drawings must be signed and duly endorsed.
1.3
Manufacturing Report and Instruction Manuals

The Contractor shall supply six (6) bound copies of the Manufacturing Report and
Instruction Manuals to the S.O. on or before delivery of the Goods.
The Manufacturing Report shall provide a detailed description of the manufacturing
process, the raw materials used, test on raw materials, the standard and method of
manufacture, the tests employed at every stage of the manufacturing process in particular
ISO Quality Assurance, Internal Quality Control, type of paint, test on completed
paintwork, etc. The quality of the product shall not be less that the minimum quality as
approved by the S.O. In case of non-compliance, the Goods shall be rejected without
payment and the S.O. will not entertain any further requests.
The Instruction Manuals shall include the full description of the Goods supplied, state
requirements for the handling and storage of the Goods from the date of acceptance to
installation and give step by step procedures to assemble and erect the Goods and the
S.O. to carry out any operations likely to be required during the life of the Goods,
including installation, commissioning, testing, operation, maintenance, dismantling and
repairs. The Instruction Manuals shall be approved in draft form by the S.O. before
printed in its final form.
I.2

Maintenance instructions shall include charts showing lubrication, checking, testing and
replacement procedures to be carried out weekly, monthly and at longer intervals to
ensure trouble-free operations. Where applicable, fault location charts shall be included
to facilitate finding the cause of imperfect operation or breakdown.
The manuals shall contain detailed descriptions of the construction and operation of the
Goods with enlarged diagrams, lists of parts and procedures for ordering spares.
If in the opinion of the S.O. the information supplied is insufficient, the Contractor shall
supply further information as required. The manuals shall be printed in A4 size sheets
and suitably indexed and bound. A collection of manufacturers descriptive leaflets alone
will not be acceptable.
1.4
Quality Assurance
Within fourteen (14) days of the Letter of Acceptance, the Contractor shall produce and
submit to the S.O. for comment an outline Quality Assurance Plan. Within fourteen (14)
days thereafter, the Contractor shall submit to the S.O. for approval a detailed Quality
Assurance Plan that shall take proper account of the S.O.s comments on the outline
Quality Assurance Plan.
The approval by the S.O. of such Plan shall not relieve the Contractor of any of his duties
or responsibilities under the Contract. The Contractor shall implement the quality
assurance procedures in the Approved Quality Assurance Plan. The Quality Assurance
Plan shall set out the specific quality procedures, practices, resources and sequence of
activities to meet the requirements of the Conditions of Contract and Specifications and
shall include but not limited to:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.
ix.
x.
xi.
xii.
xiii.
xiv.
xv.
xvi.
Contractors quality statement

Contractors organisation structures including quality control organisation
Contractors quality procedures
Principal staff
Contractors plant
Manufacturing and delivery programme
Progress reports
Contractors design procedures
Contractors method statement, including transportation and handling of
materials
Contractors method statement during installation
Verification, testing, and reporting procedures for design, equipment,
materials and workmanship in the office, factory or on site
Document Control
Health, safety and security
Internal quality control
Interim measurements and payment
Final measurement
The Plan shall include organisation charts illustrating the main tasks and their sub-division,
the reporting structure and;
i.
Interface between the Contractor and the S.O.
I.3

ii.
iii.
interface within the Contractors internal project team

Contractors internal quality management arrangement including quality
assurance and auditing personnel.
The Contractor shall submit and receive approval of the Quality Assurance Plan before
starting manufacture of the Goods. The S.O. shall audit the Contractors quality plan and
its implementation. The Contractor shall submit a partial Quality Assurance Plan to the
S.O. to cover any work the Contractor will carry out within fourteen (14) days from the
date of the Letter of Acceptance. The Contractor shall not be entitled to commence the
manufacturing of the Goods prior to receipt of the S.O. approval of the Quality Assurance
Plan for that part. The S.O. may at his sole discretion, reject any of the works which in his
opinion have not been executed in accordance with the Quality Assurance Plan and the
Contractor shall re-execute at his own cost and without any entitlement to any extension
of time all such parts of the Works so rejected.
The Contractor shall adhere to the principles and procedures contained in the Approved
Quality Assurance Plan and any amendment or supplement thereof.
The Contractor shall deliver the goods by the dates and in the order of priority as he shall
have ascertained from the S.O. and included in the programme of delivery.
1.5
Notice of Deliveries
The Contractor shall notify the S.O. of the delivery date of each consignment at least
two (2) weeks in advance, and seek his instruction as to the point(s) of unloading. Every
consignment shall be accompanied by a detailed delivery note including the numbers of
each valve, fitting and/or actuator itemised as in the Bill of Quantities.
1.6
Marking
All valves shall bear the following marks on the outside of the valves:
(a)
The Manufacturer's distinguishing mark, manufacturing standard
(b)
The diameter (mm) and weight (kg).
(c)
The serial number and/on item number associated with the Bill of Quantities.
(d)
The pressure rating (PN)
(e)
Loading and duty at, which the valve has been designed to operate
Apart from all these markings, a bronze plate engraved with the word SYABAS (50mm
high) shall also be tied to each valve.
1.7
Inspection
All Goods to be supplied under the Contract shall be inspected by the S.O., the Engineer
or their appointed representative at the Contractor's premises or at the places of
manufacture, if manufactured at other premises.
The Contractor shall provide such office facilities, assistance, labour, materials, electricity
supply, fuel, stores, apparatus and instruments including X-ray or gamma ray equipment,
as may be necessary to allow a thorough and extensive inspection to be carried out.
I.4

The S.O., the Engineer or their appointed representative shall be entitled at all times
during manufacture to inspect, examine and test on the Contractors premises or at the
places of manufacture if manufactured at other premises, the materials and workmanship
of the Goods. Such inspection, examination or testing shall not relieve the Contractor
from any of his obligations under the Contract.
1.8
Delivery, Install and Commission

The Contractor shall deliver to and unload all the Goods at the site or at a designated
storage yard as instructed by the S.O., where the Goods will be examined, inspected and
re-tested by the S.O., the Engineer or their appointed representative. Any endorsement by
the S.O.'s Representative on any delivery order issued by the Contractors transporting
agent shall not be taken to mean acceptance of the Goods.
The Contractor shall provide and be responsible for all labour, plant and equipment and
packing necessary including the provision of padded timber support, wedges, hessians or
straw for off loading the goods from the transport lorries and stacking them in an orderly
and safe manner along with sufficient protection of the Goods from the time of storage up
to the time of the installation to the satisfaction of the S.O. and/or the Engineer.
Any of the Goods found on delivery at the Site to be faulty or damaged will not be taken
over and shall be repaired or replaced by the Contractor at his own cost, as directed by
the S.O.. In this respect, the Contractor, or his authorised representative shall be present
on Site and storage yard during the deliveries and subsequent inspection, if necessary.
The Contractor shall plan, make all necessary arrangement(s), provide manpower, specials
and fittings, lighting for night work, barricades and blinking lights for work along busy
roads, apply for work permits with the Local Authorities, pay for such permits, remove
and dismantle the old valve, make preparations of pipe ends and join with the new valve,
commission the works to the satisfaction of the S.O.. The rates quoted shall include the
Contractors profit, derived from the sale of the damaged or old valve.
The acceptance and/or taking over the Goods by the S.O. shall be subject to the testing
and commissioning specified in the Specification.
1.9
Site Conditions
The climatic conditions in Malaysia are generally hot, humid and tropical with maximum
air temperature in the shade exceeding 35C and relative humidity frequently reaching
98%. The Contractor shall take due considerations of the climatic conditions in the
design, transportation and storage of the Goods during the entire course of the works and
working life of the Goods.
1.10
Valve Agent
The Contractor shall assign a competent Valve Agent and such assistants as may be
necessary who must be capable of receiving instructions in Bahasa Malaysia and English.
The Valve Agent shall co-ordinate all submission until approval; co-ordinate the whole
stage of design, manufacture, shipping, delivery, installation, testing, commissioning,
I.5

prepare payment claims, settle any claims with regards to the Work, until issuance of the
Certificate of Making Good Defects and Final Accounts.
Any directions, explanations or instructions given to such Valve Agent by the S.O. shall be
deemed to have been given to the Contractor. Should the Contractor fail to provide such
Valve Agent, the S.O. shall appoint others as Valve Agent and all wages and other
expenses in connection with such employment shall be deducted from any monies due to
the Contractor.
2.0
Material and workmanship
2.1

The following Standards and Codes of Practice are referred to in this Specification. The
Standards or Codes shall be the latest edition current at the time of the preparation
unless otherwise specified for particular application.
JKR Specification
(1) 20200-0043-99
JKR Standard Specification for Ductile Iron Air Valves
(2) 20200-0050-99
JKR Standard Specification for Butterfly Valves
(3) 20200-0083-00
JKR Standard Specification for Ductile Iron Type B Gate (Sluice) Valves
for Waterworks Purposes (DN 50 to DN 600
(4) BS 5163:1986
Predominantly key-operated cast iron gate valves for water works
purposes (part superseded by JKR specification)
(5) BS 5150:1990
Cast iron gate valves (part superseded by JKR specification)
(6) BS 4504:1989
Circular flanges for pipes, valves and fittings (PN designated)
(7) BS5155:1984 (1991) Specification for butterfly valves (part superseded by JKR specification)
(8) BS 5840:Part 1
Valve mating details for actuator operation.

Specification for flange dimensions and characteristics testing of valves
(9) BS 6755:Part 1:1986 Specification for production pressure testing requirements

(10) BS 1452:1990
Specification for flake graphite cast iron
(11) BS 2789:1985
Specification for spheroidal graphite or nodular graphite cast iron
(12) BS 970
Specification for wrought steels for mechanical and allied employering

purposes
BS970:Part 1(1991) General inspection and testing procedures and specific requirements for
carbon, carbon manganese, alloy and stainless steels
(13) BS 1504:1984
Specification for steel castings for pressure purposes
(14) BS 3100:1991
Specification for steel castings for general employering purposes
(15) BS 1400:1985
Specification for copper alloy ingots and copper alloy and high
conductivity copper castings
I.6

(16) BS 2872:1989
Specification for copper and copper alloy forging stock and forgings
(17) BS 2874:1986
Specification for copper and copper alloy rods and sections (other than
forging stock)
(18) BS 4164:1967
Specification for coal tar based hot applied coating materials for
protecting iron and steel including suitable primers where required
(19) BS 2494:1990
Specification for elastomeric joint rings for pipe work and pipelines
(20) BS 6920:1988
Suitability of non-metallic products for use in contact with water intended

for human consumption with regard to their effect on the quality of water;
Specification
Method of test
Part 1
Part 2
(21) MS 672 : 1999
2.2
Specification of Rubber Seals in Water Supply, Drainage and Sewerage

Pipelines (1st revision)
Materials
The term materials shall mean all materials and articles of every kind whether raw,
processed or manufactured to be supplied by the Contractor for the manufacture of the
Goods. Except as may be otherwise specified for particular parts of the Goods, the
provisions in this section of the Specification shall apply to materials and workmanship
for any part of the Goods.
All materials other than natural or pre-treated materials shall be new and of the kinds
and qualities described in the Contract and shall at least be equal to approved samples.
As soon as practicable after receiving the order to commence the manufacture of the
Goods, the Contractor shall inform the S.O. of the names of the suppliers from whom he
proposes to obtain any materials, but he shall not place any order, without the approval
of the S.O. which may be withheld until samples have been submitted and satisfactorily
tested. The Contractor shall thereafter keep the S.O. informed of orders for and delivery
dates of all materials.
Materials shall be transported, handled and stored in such a manner as to prevent
deterioration, distortion, damage or contamination.
2.3
Samples and Test on Samples

Pursuant to the Conditions of Contract, the Contractor shall submit samples of such
Goods as may be required by the S.O. and shall carry out the specified tests directed by
the S.O. at the place of manufacture of the Goods or at a laboratory approved by the S.O..
Samples shall be submitted and test be carried out sufficiently early to enable further
samples to be submitted and tested if required by the S.O.. The Contractor shall prepare
the necessary test pieces and supply all labour, appliance, testing apparatus and
everything necessary for the carrying out of all the specified tests.
The cost of the samples and of conducting all specified tests on the samples shall be
included in the Contract Rates.
I.7

Approval by the S.O. as to the placing of orders for materials, Goods or as to samples or
tests shall not prejudice any of the S.O.s power under the Contract nor relieve the
Contractor of any of his obligations under the Contract.
The S.O., the Engineer or their representatives will inspect and examine the Goods and
witness the test on the Goods at the Contractors premises in accordance with the
requirements of the Specification and the relevant standards.
2.4
Test Certificates
Certificates in duplicate shall be provided by the Contractor giving the process of
manufacture and the results of the specified tests as and when requested by the S.O.
Similar certificates in duplicate shall be provided by the Contractor in respect of materials
to be used in the manufacture of the Goods giving the process of manufacture, chemical
analysis (where relevant) and the results of the specified tests. The material shall be
suitably marked to enable it to be identified from reference on the certificates.
No materials subject to test shall be incorporated in the manufacture of the Goods until a
satisfactory test certificate has been received and approved by the S.O.
In case of any items which have not been inspected at the manufacturers works, the
Contractor shall obtain from the Manufacturer and supply to the S.O. certificates signed
by the Manufacturer giving the results of the tests as carried out and certifying that the
items have been manufactured in accordance with this Specification.
2.5
Independent and Local Tests

The S.O. reserves the right to carry out any independent tests he may deem fit on the
completed goods or any material supplied under the Contract, at any state of manufacture
or delivery.
Any samples of materials which may be required for such tests shall be provided by the
Contractor at no extra cost to the Contract.
Inspection may be undertaken at the manufacturers works or at such other locations as
specified/required by the S.O.
All facilities and test equipment, which may be required by the S.O., shall be provided at
the Contractors expense.
Any materials, workmanship or completed Goods, which are shown to be not in
accordance with the Specification by such independent test shall be rejected,
notwithstanding any previous certificate which may have been provided in accordance
with Clause 2.5 of the Specifications.
I.8

2.6
Testing Facilities
The Contractor shall at his own expense arrange with the suppliers or manufacturers to
supply the necessary gauges and prepare all test pieces and supply all labour and
apparatus for testing which may be required by the S.O., the Engineer or their
representatives for carrying out the tests to requirements of this Specification at the
Contractors premises or at the place of manufacture, and shall also provide all test pieces
required.
If the Contractor shall fail to perform any of the foregoing obligations, the S.O. shall be at
liberty to perform the said obligations or any of them, which the Contractor has failed to
perform, either at the Contractors premises, places of manufacture or elsewhere and
charge the costs and expenses thereof to the Contractor.
2.7
Certificate of Quality and Warranty

With every consignment of Goods delivered under this Contract, the Contractor shall
furnish a signed certificate in each case and worded as follows.
The manufacturer shall provide a 10-years written warranty in a form to be acceptable by
the S.O.
This is to certify that the quality of the Goods delivered in the consignment is not
inferior to the quality laid down in the Specification. It is warranted that all Goods
supplied are new and unused.
The installing Contractor shall provide a 5-years written warranty as follows:We warranty that we have taken the utmost care in installing the valve, fittings, etc.
equivalent to or higher than the standard required in this Specification. We shall
provide FREE inspection, advise, maintenance and repairs should the installed Goods fail
in any way.
No payment will be made in respect of any consignment not accompanied by such
certificate.
2.8
Rejected Materials
Any materials delivered to the Site, which have been rejected by the S.O., the Engineer or
their representatives shall IMMEDIATELY be removed from the Site.
Any Goods or materials, which have been rejected shall be marked in a distinctive
manner which will preclude any possibility of their use for the purposes of the Contract.
Such Goods may be submitted for re-test following the correction of any defects, where
such correction is permitted, subject to the approval of the S.O.
I.9

3.0
REQUIREMENT
3.1
3.1.1
Materials
The valves, fittings and actuators (`Goods) shall be manufactured from materials
specified in the clauses appropriate to the particular item. Where the material to be
used has not been laid down in this Specification, the Contractor shall use only those
materials in such compositions as have been proved in actual service to be the most
suitable for the particular purpose.
All castings shall be reasonably smooth and free from flaws and defects. The valve trims
including pins, spindles and face rings, etc, shall be of corrosion resistant metals and
such parts that may show signs of corrosion or wear at the end of the Defects Liability
Period shall be replaced at no extra cost to the Contract or where allowed by the S.O.,
replaced by non-corrodible material of special quality at the Contractors expense. Care
shall be exercised in the selection of various types of metals for use in the valves to
reduce the effects of bi-metallic corrosion to the minimum.
Clauses on materials, standards, samples, tests and testing facilities under Section 3.2 of
the Specification shall be applicable where appropriate.
3.1.2
Grade of Materials
Materials used shall be of a quality not inferior to the following :-
3.1.3
Ductile Iron
BS 2789/BS EN1563 (Grade 500/7)
Stainless
BS 970 Grade 316S16 and Grade 304S31 (in some cases only)
Cast Steel
Plain carbon steel to BS 1504-161; Grade 430 BS 3100 Steel A1
Gunmetal
BS 1400 Designation LG2
High Tensile Brass -
BS 2872 CP114; Grade CZ114/CZ116
Phosphor Bronze -
BS 2870
Design
The Contractor shall design the valves to the S.O.s satisfaction and in accordance with
the Specification. The design shall be in accordance with the best modern practice and
shall be such as will facilitate inspection, cleaning, lubrication and repair to ensure
satisfactory operation under all service conditions.
The Goods may be of the Contractors standard design provided that such design is
generally in accordance with the Specification.
I.10

Approval by the S.O. of the Contractors design or drawings shall not relieve the
Contractor or any of his obligations or liabilities under the Contract except in so far as is
provided for by the Conditions of Contract.
3.1.4
Castings
The structure of castings shall be homogeneous and free from non-metallic inclusions and
other injurious defects. All castings shall be close-grained, sound, smooth, symmetrical
and shall be carefully cleaned and dressed off. No stopping or plugging will be permitted
in the case of holes or flaws appearing therein, and casting shall be made from first
running.
If any casting should prove defective, the S.O. shall have the power to reject it and the
Contractor shall replace it at no extra expense to the Contract.
3.1.5
Forgings
All major stress bearing forgings shall be made to a standard specification, which shall be
submitted if required to the S.O. for approval before work is commenced. Forgings shall
be subjected to non-destructive tests to detect flaws if any. Forgings shall be heat treated
for the relief of residual stresses. The name of the maker and particulars of the heat
treatment proposed for each such forging shall be submitted to the S.O.. The S.O., the
Engineer or their representatives may inspect such forgings at the place of manufacture
with a representative of the Contractor.
3.1.6
Workmanship and finish

Workmanship and general finish shall be of first class commercial quality and in
accordance with best workshop practice.
All parts, which can be worn or damaged by dust shall be totally enclosed in dust proof
housings.
3.1.7
Lubrication
The Contractor shall submit full details of the method of lubrication to be employed for
Goods to be supplied under the Contract. The Contractor shall supply all necessary
lubricating equipment, including sufficient grease and other lubricants of each required
grade for setting valves to work and the cost of this shall be deemed to have been
included by the Contractor in the Contract rates.
3.1.8
Protection against climatic conditions

The valves supplied shall be of the appropriate grade and quality and shall be adequately
protected against the climatic conditions at the Site. The Contractor shall take these
conditions into account in deciding what grade, quality and protection is required. Any
valves which are found to be unsuitable for use under these conditions shall be removed
and replaced by a suitable one by the Contractor at no extra expense to the S.O..
I.11

Valve bodies, surface boxes and all other castings shall be coated in accordance with
Section 3.2.4 for tropical conditions. Machined surfaces shall be covered by a suitable
rust inhibitor, such as a high melting point grease of approved quality.
All submerged moving parts, or the pins, spindles and faces, etc in contact with them,
shall be of non-corrodible materials. Any parts that show signs of corrosion or wear
during the Period of Defects Liability shall be replaced by non-corrodible material of
special quality for the purpose at no extra expense to the S.O.. Care shall be exercised in
the choice of metals for use in the Goods to reduce the effects of bi-metallic corrosion to a
minimum. The foregoing shall apply also to the moving parts exposed to the weather.
3.1.9
Inspection
All Goods shall be inspected by the S.O., the Engineer or their representatives at the
Contractors premises or at the place of manufacture. The Contractor shall provide such
office facilities, assistance, labour, materials, apparatus and instruments as may be
necessary to allow a thorough and extensive inspection to be carried out.
The S.O. shall have free access to the Contractors plant or the manufacturers works at all
reasonable times, and shall be at liberty to inspect the manufacture of the Goods and
component parts at all stages. The charging of cupolas, melting, drawing off, conveying
and pouring of all metals shall be carried out in such a manner and at such time or times
that the S.O. desire to see that the work is carried out in accordance with this
Specifications, particularly but not limiting the following requirements/ conditions:
(a)
The manufacture of the Goods and component parts at all stages shall be
inspected and if found defective or inferior in quality to, or differing in form or
material, from the requirements of the Contract, may be rejected. The whole of
any consignment may be rejected if any of the Goods, or component part is found
not to conform in every respect to the requirements of the Contract.
(b)
The Contractor shall, if called upon to do so, obtain the S.O.s approval of the
manner in which the Contractor proposes to supply the Goods shall furnish such
drawings and information as the S.O. may require.
(c)
The Contractor shall notify the S.O. in advance of the date on which any of the
component parts, or Goods are ready for inspection.
(d)
The S.O. shall not be required to sign any form of waiver or indemnity concerning
his presence or actions at the place of inspection.
(e)
If any of the items, whether completed or in course of production, are rejected by

the S.O., they shall be marked or segregated in such manner satisfactory to the
S.O. as to ensure their subsequent identification as rejected work.
(f)
When independent tests and analyses, in addition to those made by the S.O. at
the Contractors or manufacturers premises, are considered necessary by the S.O.,
such tests, or analyses will be made by persons appointed by the S.O.. The
Contractor shall bear the cost of supply and carriage of samples and in addition
where the results of such tests or analyses show that the items are not in
accordance with the Specification, the cost of such tests or analyses.
I.12

(g)
The Contractor shall not deliver any of the Goods or report them as ready for
delivery until the S.O. shall have given his consent.
(h)
The inspection, examination or testing including the approval of the Goods by the
S.O. shall not release the Contractor from any of his obligations and liabilities
under the Contract.
The Contractor shall allow in his rates, where applicable and related expenses for
inspection of valves by the S.O..
3.1.10 Protection against damage during transit
All Goods shall be securely packed in crates or boxes for protection against damage
during transit. Valves of 450mm diameter and above shall be individually crated, battened
and bound with steel strip.
Flanges of valves shall be protected by wooden discs temporarily bolted on or secured by
steel strapping. Spindle caps of sluice valves shall be removed and secured to the inner
side of one of the wooden discs by means of a steel strip. Otherwise they shall be packed
in a case. The projecting end of the spindle shall be well wrapped with straw rope
covered by hessian cloth and secured in place by binding wire, which shall be carried
under the flange of the gland.
All plain ends shall be adequately protected by straw rope secured in place by binding
wire or strap. None of the packing will be returnable. The cost of packing shall be
included in the Contract rates.
3.1.11 Identification plates and labels
Each main and auxiliary item of the Goods shall, unless otherwise, specified, have
permanently attached to it in a conspicuous position an identification plate of weatherresistant material on which are engraved or stamped the Manufacturers name, service
rating, loading and duty at which the item of valves has been designed to operate, serial
number, weight and reference number as specified.
Additionally, each item shall have marked upon its body in raised letters the
manufacturers name, service rating, year of manufacturer and size of the Goods.
Details of proposed inscriptions shall be submitted to S.O. for approval before any labels
are manufactured.
3.2
Valves, Fitting and Actuators
3.2.1
General
All valves shall be designed to avoid cavitation and vibration in all positions, to minimize
head loss in the open position and to seal the water passage completely when shut. All
operating spindles and gears shall be provided with adequate points for lubrication.
Unless otherwise specified, all valves shall be closed in a clockwise direction. Lifting lugs
shall be provided for valves of sizes 600mm and above.
I.13

Head loss curves through the valves for throttled flow conditions shall be provided for
all valve sizes.
All protective coatings shall be non-toxic and shall not foster microbiological growth nor
impart any odour, taste, cloudiness or discoloration to the water.
After installation, the external surfaces shall be painted with two coats of cold applied
high solid liquid epoxy to AWWA C210-84. The minimum dry finished thickness shall
not be less than 350 micron.
The Contractor shall take note that all valves will normally be installed with one end fixed
and the other end to a flexible joints either a flange adaptor or mechanical coupling joint.
Unless otherwise stated, all valves shall be double flanged.
Unless otherwise specified, the bodies and discs of sluice valves, butterfly valves, and
non-return valves shall be manufactured from ductile iron to BS 2789/BS EN 1563 Grade
Grade 500/7.
3.2.2
Flanges
All valves are to be installed on steel pipes with flange details as per BS 4504. All flanges
shall be cast integral with the valve, add-on flanges by other means is not acceptable.
All valve flanges shall be designed to withstand the stresses of the valve ratings. They
shall be at right angles to and concentric with the bore axes. They shall be of the raised
face type, truly faced over their whole width and drilled in accordance with BS 4504 to
match with the flanges for the steel pipes. Bolthole shall be drilled off centre lines and
shall be truly in line end to end with the longitudinal axis.
3.2.3
Works Test
After completion of assembly each valve shall be shop operated from the fully open
position to the fully closed position and return to fully open under no flow condition to
demonstrate that the assembly is working smoothly. The torque required on each valve
shall be ascertained. Where electric motor actuators are provided, the complete assembly
of valve and actuator shall be tested.
All valves shall be hydrostatically tested at the place of manufacture to the pressures
specified and shall satisfactorily pass the specified tests before they are packed for
delivery.
All valves shall be body tested to one and a half (1 ) times the valve rating pressure.
Seat tests to 1.1 times the valve rating pressure and shall be carried out on all valves.
All valves shall be subjected to open end test in accordance with B.S. 5163 and each
valve shall be subjected to separate hydrostatic tests as follows:(a)
Seat tests
The tightness of seats shall be tested as follows:-
I.14

(b)
(i)
with the wedge or disc closed and with the valve fixed at one end only
and the other end free, the test pressure shall be applied to that face of
the wedge or disc, the other face being at atmospheric pressure. There
shall be no visible leakage past the wedge or disc at the hydrostatic test
pressure (gauge) specified;
(ii)
The above procedure shall be repeated but with the valve fixed at the
other end and with the pressure applied to that end of the valve.
Body test
With the wedge or disc open the test pressure (gauge) specified shall be applied to
the whole body of the valve. There shall be no visible leakage through the body,
the flanged joint or the valve packing gland nor shall any part be permanently
deformed.
The test durations for all tests shall be as in the table below:Minimum test duration (minutes) for
Nominal Diameter
(mm)
(c)
Body
Seat
Up to and including 150
200 to 300
350 and above
The S.O. requires the Contractor to comply with the following additional tests, as
per JKR Standard Specification (JKR 20200-0083-00):
Strength Test (Type B gate valve)

The valve shall be arranged that one end is pressurised to produce a
differential pressure on the disc equivalent to the maximum permissible
working pressure of the valve. The minimum strength test torque as
specified in Table 8 JKR 20200-0083-00 shall then be applied gradually to
the top end of the valve stem in the fully closed position, in order to test
the strength of the valve component.
The test shall be repeated with the valve in the open position. During the
strength test, the test pressure shall be maintained.
I.15

Functional Test
The valve shall be fully opened and then closed, using the same number
of turns, as specified in the Schedule of Particulars, with a torque not
exceeding the maximum functional test torque during any time in its
travel.
Then the test shall be repeated in the closed position.
Durability test (for elastomer on the wedge or for resilient seated valve)
The valve shall be fully closed and subjected to the working pressure of
the valve. Then, it is opened to 1/3 of the fully open position and fully
closed again. Each closure is considered as one cycle.
Each valve shall be subjected to 50 cycles whilst the working pressure of
the valve is maintained.
After the durability test, the elastomer shall be inspected to ensure no
visual cracks, tear or chipping off.
(d)
A test certificate must be supplied with each valve. It shall contain a statement by
the manufacturer confirming that the valve has been tested, the test results, the
standard adopted, pressures used, test medium and duly signed by an authorized
personnel. The serial number on the certificate shall be the same as on the valve.
The cost of these additional tests shall be included in the Contract rates for factory
testing.
3.2.4
Surface Preparation/Protective Coating

All protective coatings shall be non-toxic, potable water compatible and shall not foster
micro biological growth nor impart any odour taste, cloudiness or discoloration to the
water.
All internal and external parts of the ductile iron valves shall undergo the necessary
surface preparation for polymeric coating purposes. Bituminous coating is not allowed.
Either one of the following polymeric coatings is acceptable:
for coating using either fusion-bonded epoxy powder or polyamide 11 (RISLAN)

materials, the coating thickness shall not be less than 250m for fusion bonded
polyamide 11 or not less than 350m for fusion bonded epoxy as specified in AS/NZ
4158.1 Part 1.
for coating using cold applied high solid liquid epoxy (solvent or solventless) which
meet the requirement of AWWA C210-84, the coating thickness shall not less than
350m.
I.16

3.2.5
Sluice Valves (Gate Valves) Type B
3.2.5.1 General Description

(a)
All gate valves shall be of resilient seat (50mm to 300mm); metal seat (350mm to
600mm), Type B, PN 16(bar) rating (unless otherwise specified), cap operation
with non-rising spindle/stem, conforming to JKR Specification 20200-0083-00: JKR
Standard Specification for Double Flanged Ductile Iron Type B Gate Valve for
Waterworks Purposes and BS 5163:1986 or better. The range of valve sizes
covered is DN50 to DN600.
(b)
All gate valves of 300mm dia. and up to 600mm dia. shall be supplied complete
with spur gearing. Where gear box is specified, the status of the valve open/close
position shall be provided.
(c)
It shall be closed by turning the key or hand wheel in a clockwise direction

when facing the top of the valve.
(d)
All flanges and boltings shall comply with BS4504 or BS EN 1092-2: 1997.
(e)
A schedule of component and material are attached in Table 1.
3.2.5.2 Materials and Designs

(a)
Ductile iron conforming to BS 2789/BS EN 1563 with Grade 500/7 for the
following:
(i)
(ii)
(iii)
(iv)
Body
Bonnet
Stuffing Box
Grand/Seal housing
(v)
(vi)
Wedge
Cap/Handwheel/ torque limiting/stem cap
(b)
Spindle shall be of stainless steel 431S29 conforming to BS 970. The spindle

shall be of the inside screw non-rising type and shall have machined square or
ACME threads. It shall be truly circular throughout and be of such length that
when the valve is closed, the bottom end of the spindle engages fully in the
spindle nut. The spindle collar or thrust plate shall be concentric and machined,
suitable for the specified test pressure to provide stem guidance and low friction
bearing on opening and closing torque.
( c)
Stem nut and wedge ring/body (not applicable for resilient seat) shall be of
gunmetal LG2 conforming to BS 1400 or stainless steel 431S29 or 304S31
conforming to BS 970.
(d)
Dust seal/excluder and spindle seal shall be of rubber O-ring made of EPDM or
Nitrile conforming to MS 672:99 or AS1646:92. Stuffing box and bonnet gasket
shall be not less 3mm thick gasket made of EPDM or Nitrile conforming to MS
672:99 or AS1646:92 with 66-75 IRHD. Gland Packing shall be of asbestos free
teflon braided packing or rubber O-ring made of EPDM or Nitrile conforming to
MS 672:99 or AS 1646.
I.17

(e)
The wedge for resilient seat shall be vulcanised with rubber made of EPDM or
Nitrile conforming to MS 672:99 or AS 1646:92. The entire wedge gate shall
form an axial and butt seal against the valve body, giving a tight shut-off at all
pressures up to the full rating or the required test pressure. The method of butt
sealing at the bottom of the wedge shall give smooth straight-through bore in the
body without seating recess.
The valve shall be designed so that the gate may be removed without removing
the body from the connecting pipe work. The gate guides shall be cast integrally
with the valve body and be of adequate strength and of sufficient length to guide
the gate throughout their full travel. In the fully open position, the gate shall be
withdrawn well clear of the flow stream and the spindle shall not protrude into
the bore of the valve.
(f)
Seal cartridge shall be of gunmetal LG2 of BS 2872 or acetal resin.
(g)
Bolts, nuts, washers and setscrews shall be of stainless steel 316S16 for
corrosion resistance for the following:
(i)
(iii)
Hand wheel setscrew & washer

Gland bolts & nuts
(ii) spindle cap setscrew

(iv) Bonnet bolts & nuts
(h)
The valves will normally be installed in concrete chambers approximately 3 to 4

metres below the ground level and as such the gears and bearings shall be
protected by suitable water-tight enclosures permanently packed with grease.
The gearing assemblies shall be enclosed in boxes of corrosion resistant
material.
(i)
Ductile iron caps shall be supplied to fit the spindles or operating gears for all
the valves and these shall be secured by brass set screws with the direction of
closing indicated on the caps.
(j)
Opening closing indicators shall be provided and mounted on all valves.
(k)
An identification plate marking the serial no. of the valve, dimension, type of
valve, etc. shall be permanently attached to the valve body.
I.18

ITEM
COMPONENTS
MATERIAL
GRADE
STANDARD
1
2
3
4
5
6
7
Handwheel setscrew & washer

(Stem cap setscrew)
Handwheel
(Stem cap)
Gland
Gland bolts & nuts
Gland packing
Stainless steel
Stainless steel
Ductile iron
Ductile iron
Ductile iron
Stainless steel
Asbestos free teflon braided packing
Or
Rubber O-Ring
304S31
304S31
500/7
500/7
500/7
304S31
-
BS 970
BS 970
BS 2789 or BS EN1563
BS 970
-
Nitrile or EPDM
8
9
10
Stuffing box
Stuffing box gasket (3mm thick) (min)
Stem/Spindle
11
12
13
14
Bonnet
Bonnet bolts & nuts
Bonnet gasket (3mm thick) (min)
Stem nut/Spindle nut
15
Wedge ring/Body ring (not applicable for

resilient seating)
16
Wedge
17
18
19
20
Body
Dust seal/excluder
Seal cartridge
Stem seal/Spindle seal
Ductile iron
Rubber
High tensile brass
Or
Stainless steel
Ductile iron
Stainless steel
Rubber
Gunmetal
Or
Stainless steel
Gunmetal
Or
Stainless steel
Ductile iron (400mm dia. only)
Or
Ductile iron vulcanized with rubber
500/7
Nitrile or EPDM (66-75 IRHD hardness)
CZ116, CZ114
MS 672 : 1999 or
AS 1646 : 1992
BS 2789
MS 672
BS 2872/BS 2874
431S29
500/7
304S31
Nitrile or EPDM (66-75 IRHD hardness)
LG2
BS 970
BS 2789
BS 970 : Part 4
MS 672
BS 1400
431S29 or 304S31
LG2
BS 970
BS 1400
316
500/7
BS 970 : Part 4
BS 2789
Nitrile or EPDM
Ductile iron
Rubber O-ring
Gunmetal/acetal resin
Rubber O-ring
500/7
Nitrile or EPDM
LG2
Nitrile or EPDM
MS 672 : 1999 or
AS 1646 : 1992
BS 2789
MS 672 : 1999
BS 2872
MS 672 : 1999
Table 1 : Components and materials for sluice valve
S3-19
24 July 2007

3.2.5.3 Test and Inspection

(a)
All sluice valves shall be Works Tested in accordance to Clause 3.2.3 and site
tested where deemed necessary.
(b)
Durability test for elastomer on the wedge of the resilient seated valves shall be
tested in accordance to JKR Specification 20200-0083-00.
(c )
A test certificate shall be issued for each valve tested with details of the standard,
pressures used, type of tests conducted, medium used, duration of tests, serial
number of valve, date of tests, certified by a qualified tester, etc.
3.2.5.4 Mandatory Marking

Each valve shall be clearly marked on the body (this marking shall be integral with the
body of the valve) with the following information:(a)
Nominal diameter (i.e. DN.)
(b)
Pressure rating (i.e. PN.).
(c)
Manufacturers name or trade mark.
(d)
The relevant Standard (i.e. Specification JKR/20200-0083-00 or BS 5163)
(e)
Body material designation (i.e. DI for Ductile Iron)
(f)
Designation of the valve type (i.e. Type `B).
(g)
Year of manufacture.
(h)
Direction of valve closing (i.e. arrow indicating clockwise).
(i)
Seat material identification (i.e. RES for Resilient Seated).
3.2.6
Butterfly Valves
3.2.6.1 General
(a)
The butterfly valves shall conform generally to JKR Specification 202000050-99 or BS 5155 or better. The valve shall be selected as follow:CONCENTRIC DISC DESIGN is suitable for dual flow operation;
SINGLE or DOUBLE ECCENTRIC DISC DESIGN WITH RESILIENT
SEAT, TIGHT SHUT-OFF TYPE is suitable for single way operation.
I.20

All valves shall be suitable for waterworks purposes in a tropical country. All
butterfly valve shall be rated at PN16 (bar) unless otherwise specified. The
range of valve sizes covered is DN50 to DN2000.
(b)
It shall be closed by turning the lever or hand-wheel in a clockwise direction

when facing the top of the valve. Opening/closing indicators shall be provided
and mounted on all valves. These indicators shall be visible from the top of
deep chambers (especially when the valve is installed in a chamber).
(c )
All flanges (and boltings when required) shall comply to BS 4504:1989 or BS

EN1092-2:1997.
A schedule of components and materials are attached in Table 2.

3.2.6.2 Materials
(a)
Ductile Iron conforming to BS 2789/BS EN1563; minimum Grade of 500/7 shall

be used for:
(i)
Body
(ii)
Disc
The disc shall be concentric for hydrodynamic flow, reduced turbulence, to
minimize pressure drop across the valve and to ensure stable hydraulic flow
characteristics.
For the internal body resilient lining type, the lining may be of the replaceable or
non-replaceable type. The body lining shall isolate the complete body interior
surface from the water conveyed by ensuring leak tightness around the pipe
flanges and at the shaft.
Liner shall be EPDM, foodstuff approved conforming to MS 672:1999 or
AS1646:1992.
Disc shall be polyurethane coated; foodstuff compatible.
For the eccentric disc design resilient seated type, the seat facing shall be of full
peripheral seating with one face of a resilient material [EPDM to MS 672:1999]
and the other face of stainless steel ring secured to the body or disc by stainless
steel screws. The seat shall be fully adjustable and replaceable without
removing the valve from the line [applicable for valves larger than 700mm dia.
only].
(b)
Shaft shall be in 13% Cr Stainless Steel to EN 10088-3 A35-574 with a minimum

thickness of 250 microns, if it is fully isolated from the fluid, or 18-12 type
stainless steel to BS 1504 315L16 if the shaft is in contact with the fluid.
The shaft and the disc shall be on the same axis and the valve shall be fully bidirectional i.e. capable of being completely tight shut off under the full
differential pressure (valve rating) in both directions.
The shaft shall be of solid, one-piece construction and secured to the valve disc
by stainless steel pins or spline key of adequate strength. All shafts shall have
I.21

phosphor-bronze graphite-filled self-lubricating or similar approved bushes with

approved seals designed to allow valve placement with the shaft horizontal or
vertical. The shaft seal of the gland packing type shall be fully adjustable to
eliminate line leakage and shall be accessible and replaceable without removing
the valve actuator.
(c )
Valves will be installed with the disc shafts horizontal. Valves of 450mm
diameter and above shall be provided with suitable reducing gears. Quadrant
worm reducing gear totally enclosed in a ductile iron gear box and secured to
the valve body shall be provided for the smooth operation of the valves.
The worm shaft shall be vertical and square at the top for operation with a mild
steel/stainless steel key held in a vertical position. The gearing shall be suitable
for operation of the respectively valves by a mild steel/stainless steel tee key and
bar with a force of 270 Newtons applied on each side simultaneously from a
distance 750mm from the centre of the key against the full unbalanced pressure
of the valve rating. Suitable means shall be provided to prevent overstressing of
the valve seat in the close position.
The gearing and bearings shall be protected by suitable water-tight enclosures
permanently packed with grease. The Contractor shall provide details of the
type of gearings in the Schedule of Particulars and shall state in his Tender the
type of test to be carried out to demonstrate the water tightness of the assembly
under a head of 3.5 metres of water column.
(d)
Ductile iron caps shall be supplied to fit the spindles or operating gears of all the
valves and these shall be secured by brass set screws with the direction of
closing indicated on the caps.
(e)
Opening/closing indicators shall be provided and mounted on all valves.
3.2.6.3 Tests and Inspection

(a)
All butterfly valves shall be Works tested in accordance to Clause 3.2.3 and site
tested where deemed necessary.
(b)
Durability test for elastomer on the wedge of the resilient seated valves shall be
tested in accordance to JKR Specification 20200-0050-99.
(c )
A test certificate shall be issued for each valve tested with details of the standard,
pressures used, type of tests conducted, medium used, duration of tests, serial
number of valve, date of tests, certified by a qualified tester, etc.
3.2.6.4 Mandatory Markings

Each valve shall be clearly marked on the body (this marking shall be integral with the
body of the valve with the following information :(a)
Nominal diameter (i.e. DN.)
(b)
Pressure rating (i.e. PN10)
I.22

(c)
Manufacturers make or trade mark
(d)
The relevant Standard (i.e. JKR/20 2000-0050-99 or BS 5155)
(e)
Body material designation (i.e. DI for Ductile Iron)
(f)
Designation of the valve type (i.e. Type : rubber-lined)
(g)
Year of manufacture
(h)
Direction of valve opening (i.e. arrow indicating clockwise)
(j)
Seat materials identification (i.e. EPDM)
Table 2 : Components and materials for butterfly valve
Component
Body
Body with integral seat
Disk
Handwheel
Shaft/Spindle
Material
Ductile Iron
Ductile Iron
Stainless steel
BS Reference
BS 2789
BS EN 1563
BS 2789
BS EN 1563
BS 970
Grade or
designation
500/7
420/12
431S29
Carbon steel
Internal fastenings
Stainless steel
3.2.7
Specific grades are outside the scope

of this standard
Phosphor bronze
Aluminium bronze
BS 2870, BS 2873
BS 2872, BS 2874,
BS 2875
PB102
CA103,
CA104, CA106
Nickel copper alloy
BS 3076
NA13
Non-return Valves
Non-return valves shall be of an approved non-slamming, tilted disc or recoil type to
PN 16 (unless otherwise specified), capable of withstanding severe transient surge shall
be mechanically and hydraulically designed to ensure rapid closure before reversal of
flow under high velocities and surge conditions especially when an air surge vessel is
incorporated and/or when two or more pumps are running in parallel. The valves shall
be adequately sized so that under normal flow conditions the velocity shall not exceed
2.0m per second and the friction losses not greater than 0.5m. Valves of diameter
greater than 460mm shall be of the multi-door type. Friction curves and dynamic
performance test for non-slam features MUST be submitted with the tender. These
curves must be endorsed and signed by both the manufacturer and agent/sole
I.23

distributor, without which their tender will not be accepted. In this instance, an
endorsement means that the manufacturer and agent/sole distributor warranties the
results of the tests and that each of the valves manufactured will meet these minimum
standard.
The body, door and cover shall be of spheroidal graphite iron to BS 2789/BS EN1563;
minimum Grade of 500/7.
The door shall be hinged on an aluminium bronze or stainless steel pin and supported
in gun metal bearing blocks. The body seat and door facing rings shall be gun metal or
aluminium bronze. For horizontal valve, the seating shall be inclined at an angle of not
greater than 50 degrees from the flow axis. All internal parts shall be renewable. All
non-return valves exceeding 450 mm diameter shall incorporate a by-pass complete
with isolating valves.
The flow are through the valve body, inlet and outlet, shall be equal to the pipe size and
gradually increased to as area 40% greater that pipe size through the valve seat.
Non-return valves for installation in vertical pipes delivering upward flows shall be
suitably modified where necessary to achieve the above design criteria.
Conventional check-valves are unsuitable for the above duties and will not be
acceptable for use in delivery mains of the pumps.
During normally open position, headloss must be at the minimum possible and in the
close position, there shall be NO LEAK. Certified test reports must be submitted.
The Contractor shall guarantee that the valve supplied complies with the NON-SLAM
Characteristics. This feature shall be specified in the test certificate and verified on site.
Should the valve fail to prove this, the Contractor shall provide a replacement and/or
alternative, at no additional cost to the Contract.
All check valve shall be provided with a position indicator of the disc, visible from all
positions. All check valve shall be surface prepared in accordance to Clause 3.2.4 and
BS 6920.
I.24

Air Valves
3.2.8.1 General
All air valves shall generally conform to JKR Specification 20200-0043-99 (or better) for
ductile iron air valves.
Double orifice air valves shall be of the `Aerokinetic type incorporating hydrodynamic
principles suitable for air exhausting during charging or venting when emptying of the
main. The ball-sealed orifice shall always remain open while air is discharged and shall
be immediately closed when the water rises in the valve to lift the ball and seal the
orifice.
The escaping turbulent air or a mixture of air and water spray (even at the critical
velocity of 300 m/sec) shall not cause the ball to be thrown into the discharging air
stream and be blown shut prematurely during the filling of the water main a high rate.
Under no circumstances shall the large orifice ball blow shut prematurely.
Standard double orifice air valves shall have a minimum pressure rating of 16 bars
(unless otherwise specified) and in all cases shall be supplied with PN 16 flanges to BS
4504:1989.
The ball of the large orifice shall bear a calculated mathematical relation with the inlet
diameter of the valve i.e. average cross-sectional area of escaping air stream, so that the
ball will be blown shut by a stream of water but held down by a stream of air. The
buoyancy of the ball shall be such that it will ensure effective sealing of the large orifice
even at low pressure. The weights of each ball of the same size and type shall be not
differ by more than 2%.
Single small orifice air valves shall be reliable in action and shall operate such that the
ball cannot be held against orifice by air pressure alone.
The design of the valve shall be such as to allow maximum free air discharge and inflow
at pressure differentials of plus 0.5 bar and minus 0.2 bar respectively. The Contractor
MUST submit with his tender, curves for free air discharges and inflow against various
air pressures at valve inlet. These curves must be endorsed and signed by both the
manufacturer and agent/sole distributor, without which their tender will not be
accepted. In this instance, an endorsement means that the manufacturer and
agent/sole distributor warranties the results of the tests and that each of the valves
manufactured will meet these minimum standard.
Each air valve shall be supplied with horizontally positioned isolating sluice valve of the
same size with bevel gearing arrangement for vertical operation and a set of flange
jointing materials including nuts, bolts, washers and joint gaskets for insertion between
the air valve and sluice valve. The gear box shall be greased pack, concealed
permanently and water-tight. The isolating sluice valve is specified in Clause 3.2.5. The
bevel gear pinion shall be of corrosion resistant steel. A pressure tapping insertion into
a suitably designed short piece as shown in the Drawings shall be supplied with each air
valve tee. The flange diameter of the insertion short piece shall be the same to suit the
air valve.
I.25

All air valves shall be made insect proof by providing stainless steel screens at the vents
leading into the atmosphere. The floats shall be ABS plastic balls or stainless steel
Grade 316.
The orifice shall be either gunmetal or stainless steel, not less than 3mm and tapering to
10mm suitable to release accumulated air within the pipe. The profile of the orifice
shall be such as to avoid damage to the ball surface. The orifice shall be protected by a
suitable plug of stainless steel.
The low pressure cover shall be massive and designed to withstand full operating thrust
in working condition. The neoprene seat ring shall be held securely in place under the
low pressure cover by a joint support ring to prevent it from sagging when the ball is not
sealing the orifice.
After completion of machining but before assembly the valve body shall be
hydraulically tested to one and a half (1.5) times the valve rating pressure for a period a
5 minutes and thereafter compressed air at a slightly higher pressure shall be released
through the valve inlet to check the function of the ball.
Subsequently, the hydraulic pressure shall be reduced to 0.5 bar and there shall be no
leakage through any of the orifices.
Materials used shall not be inferior to the following:
(a)
Ductile Iron
BS 2789/BS EN 1563:1997; Grade 500/7
(b)
Gunmetal for valve seats
BS 1400 LG2
(c)
Brass/Gunmetal for
plugs and spindles
BS 2872/2874 CZ114, CZ116/BS 1400

LG2
(d)
Rubber for Gasket or seal ring :
MS 672:99/AS (Grade 66-75 IRHD)
(e)
ABS Plastic *
ISO 2580
(f)
Stainless Steel
BS 970 Grade 316S16
Note :* ABS plastic float shall be counter weighed such that the seam/joint of the ABS ball will always
remain horizontal, it will seal against the seat of the air valve in one position only.
3.2.8.2 Test and Inspection

(a)
All air valves shall be tested in accordance to JKR Specification 20200-0043-99 :

Section 3.
(b)
A test certificate shall be issued for each valve tested as follows: Type tests
Performance test
The certificate shall be complete with details on pressure used, type of test conducted,
medium used, serial number of valves, date of test, certified by a qualified tester.
I.26

3.2.8.3 Mandatory Marking

All air valves shall have the following cast on the body:
a)
Manufacturers name or distinguished trade mark;
b)
The designation of size.
c)
Nominal pressure designation
d)
Year of manufacture
e)
Air valve type
3.2.9
Control Valves
3.2.9.1 Altitude Control Valves

The altitude valve supplied shall be of the full bore, one way flow, pilot controlled,
diaphragm or piston actuated, hydraulically operated Globe type valve, which closes
to prevent overflow when top water level is reached and opens for refilling when the
tank or reservoir water level lowers to a present limit. Wherever specified, the altitude
valve shall be equipped with stop-starter switch to stop the pump(s) at top water level
and restart the pump(s) when the water level lowers to a present level. Throttling action
is required for gradual closure of the valve as the top water level is approached.
All altitude valves supplied shall also function as a check valve designed to close
anytime the upstream or supply pressure drops below the reservoir head regardless of
the elevation of water in the reservoir.
The valve body shall be of the cast on double-flanged type, fabricated from cast iron of
grade not inferior to BS 1452 Gr 250 or ASTM A-126. Flanges shall be dimensioned
and drilled in accordance with BS 4504 to PN 16 (unless otherwise specified). The valve
shall be of extra heavy construction throughout with an interior trim of bronze to ASTM
B-62.
The valve seats and seals shall be easily serviceable/renewable. All controls and piping
shall be of non-corrosive material.
The main valve shall be external pilot operated, with free floating piston operated
without springs, diaphragms or levers. The piston shall be guided on its outside
diameter by long stroke stationary cage.
The pilot shall be direct acting, 3-way, spring and diaphragm operated valves. The
sensing control line shall be 25mm nominal outer diameter PE or copper pipe with
compatible and suitable fittings for connection to the pilot and the reservoir. The
sensing tubing through the reservoir wall shall be stainless steel SS316.
I.27

A visual valve position indicator shall be provided to indicate the valve piston position.
The visual shall be capable of operating in any position and shall incorporate a single
flanged cover at the top of the valve. All parts shall be accessible and serviceable
without removing the valve from the pipeline.
3.2.9.2 Float Control Valves
The float/level controlled valve supplied shall be of the full bore, one way flow, pilot
controlled, diaphragm or piston actuated, hydraulically operated globe type valve.
The main valve modulates to maintain a constant tank level.
The valve supplied shall be suitable for side mounting and/or at ground level. It may or
may not operate together with another external float, plunger, level, etc.
The control shall be a modulating, remote mounted type of simple but sensitive design,
requiring minimum head to open the valve and responsive to water level variation.
The construction material of this valve is similar to the Altitude Control valve in Section
3.2.9.1.
3.2.10 Fittings
Extension spindles of galvanised mild steel/stainless steel shall be provided for operating
of valves. The bottom end of the spindle shall be in the form of a socket to fit the cast
iron cap and the top end squared to suit the valve key.
Extension spindles shall be of suitable cross section to prevent buckling or permanent
distortion under all operating conditions and shall be capable of withstanding at least
twice the rated output torque of the electric motor actuator or at least twice the torque
developed at the stem created by a maximum force of 340 N at the rim of the hand
wheel.
The length of the spindle required between the top of the valve and the horizontal axis
of the hand wheel, both in the case of hand wheel operated valves and electric motor
actuated valves, shall be as shown on the Drawings. The spindle shall be supported
such that the L/R (L= length or span between supports, R = radius of gyration) for the
unsupported part of the spindle shall not exceed 200.
Where spindles are furnished in more than one piece, the different sections shall be
joined together by rigid couplings. The couplings shall be threaded and keyed or
threaded and bolted, and shall be of greater strength than the spindle.
The threads of the spindle shall be machine cut and of the square or ACME type. The
number of threads per decimetre shall be such as to work most effectively with the
actuator.
Rising spindles shall be provided with adjustable limit nuts or stop collars above and
below the pedestal lift nut to prevent over-travel of the sluice or disc gate in either
direction.
I.28

Bracket-mounted and floor-mounted spindle guides, including both the guide housing
and the bracket, shall be constructed so that when properly spaced they will hold the
stem in alignment and yet allow it enough play to permit easy operation. The inside
diameter of the guide shall not be more than 3mm larger than the outside diameter of
the spindle. The guides shall be spaced in accordance with the manufacturers
recommendations for each spindle size.
The guide shall be adjustable with regard to the bracket to provide concentric alignment
with the spindles and shall be lined, and provisions shall be made to hold the lining
rigidly in place so as to prevent loosening while in service.
Brackets shall be fixed to the concrete walls with sufficient anchor bolts to prevent
twisting or sagging under load. Valve keys shall be of galvanized mild steel/stainless
steel suitable to operate the extension spindles.
Cast iron surface boxes shall have square openings with top supporting flanges and be
100mm deep suitable for heavy traffic. The covers shall be of the chained type.
The Contractor shall obtain from the S.O. confirmation of the exact length of extension
spindles required before manufacturing them.
3.2.11 Electric Actuators
Electrically operated actuators for valves shall be sized to guarantee closure at the
maximum possible differential pressure across the disc. The safety margin of motor
power available for unseating the door shall be at least 50 percent in excess of
maximum closing torque at the nominal supply voltage. For valve sizes 300mm or
greater, the closing and opening shall take approximately 2 minutes for each operation
unless otherwise specified. For valve sizes less than 300mm, the operating speed for
closing and opening shall be 300mm per minute.
The electric motors shall be Class F insulated and tropicalised and with a time rating of
15 minutes or twice the valve stroking time, whichever is longer. Duty rating shall be S2
or S4.
Motor burn-out protection shall be provided by direct sensing of motor temperature by a
thermostat embedded in the motor winding. A changeover volt-free contact (monitor
relay) for remote indication of motor tripped shall be provided.
A space heater shall be provided in the electric actuator. The heater shall be suitable for
use on a single phase A.C. supply and wired to the terminals compartment. The heater
shall be sufficiently rated to maintain the temperature above dew point when the
actuator motor is stationary.
The actuators gearbox shall be of totally enclosed grease lubricated type, suitable for
operation at any angle. The gearbox shall be designed to be leak proof and without
further re-greasing throughout its operating life. The drive shall incorporate a lost
motion hammer blow feature. The output shaft shall be hollow to accept a rising stem.
Thrust bearings of the ball or roller type shall be provided in such a way that the gear
case can be opened for inspection or disassembled without releasing the stem thrust or
taking the valve out of service.
I.29

A hand wheel shall be provided for emergency operation and shall be arranged such
that when engaged the motor shall be automatically disconnected mechanically and
electrically and the drive being restores to power only after disengaging the hand wheel
and by starting the motor. The hand wheel and any gearing shall be such as to permit
emergency manual operation in a reasonable time and in any case shall not exceed one
hour. Clockwise operation of the hand wheel shall give closing movement of the valve
unless otherwise stated.
The actuator shall be furnished with a drive bushing easily detachable for machining to
suit the spindle or gearbox input shaft. The drive bushing shall preferably be positioned
to enable standard length stems to be used. The valve manufacturer shall furnish stem
details so that the actuator manufacturer can machine the drive bushings to suit the
valve extended spindles. Unless otherwise specified, extended spindles, wherever
required, shall be of hot dipped galvanised mild steel construction coated with coal tar
epoxy paint. Where the length of the extended spindle exceeds 1.5m length, universal
couplings shall be incorporated.
Electric actuators shall be provided with open and close torque and position limit
switches with separate changeover volt-free contacts at each end of travel for remote
indication and inter-locking. Means shall be provided to prevent the open torque switch
tripping while the initial unseating hammer blow effect is applies. Two extra sets of
limit switches shall be provided, as required, with at least three switches per set, each
set independently adjustable to any valve opening or closing position.
A mechanical dial indicator (indicating 0-100 percent marking) shall be provided to
show continuous valve movement. In addition, a 4 20 mA analogue signal output
shall be provided for continuos remote position transmission.
The reversing contactor starter and local controls shall be integral with the actuator,
suitably housed to prevent breathing and condensation build-up.
Static or solid state controls will not be accepted.
The starter shall be suitable for 60 starts per hour, and shall comprise mechanically and
electrically interlocked reversing contactors of appropriate rating to the motor size with
coils fed from a 110 volt control transformer of 40 VA minimum rating. The common
connection of the contactor coils at the transformer shall be earthed so that the
contactors drop out in the event of leakage to earth. The primary winding shall be
separated from the secondary by an earthed screen and the secondary output shall be
protected by an easily replaceable cartridge type fuse.
When the distance between the actuator and the remote control point exceeds 500
metres, the remote control voltage shall be 24V DC, derived from a rectified supply
from the remote control point. The required DC interposing relays shall be incorporated
in the actuator and shall be suitable for satisfactory operation within 80-110% of the
nominal DC voltage.
A phase discriminator shall be incorporated to ensure correct rotations.
Local controls shall comprise pushbutton switches to Open, Close and Stop and a
Local/Off/Remote selector switch pad lockable in any one of three positions:Local control only.
I.30

Off-On electrical operation.

Remote control plus local stop only.
Padlocks shall be provided.

A monitoring relay with a normally open contact to indicate that the actuator is
available for remote operation shall be provided with the relay being energised from the
control transformer only when :Local/Off/Remote selector switch is in Remote position
3 phase power supply available
Control supply available
Phase rotation correct
Thermostat not tripped
Local stop button not locked off
Internal wiring shall be of tropical grade PVC insulated stranded cable of 5A minimum
rating for control circuits and of appropriate size for the control and 3-phase power.
Each wire shall be clearly numbered and identified at each end. The terminals shall be
of the stud type. Cable entries shall be suitable for PVC/SWA/PVC cables and armoured
screened signal cables.
The terminal compartment shall be separated from the inner electrical components of
the actuator by means of a watertight seal and the compartment shall be provided with a
minimum of three threaded cable entries. All wiring supplies as part of the actuator
shall be contained within the main enclosure for physical and environmental protection.
External conduit connections between components are not acceptable. A durable
terminal identification card showing plan of terminals shall be provided attached to the
inside of the terminal box cover indicating serial number, external voltage values, wiring
diagram number and terminal layout.
The actuator enclosure shall be weatherproof, hose-proof and water-tight to IP 68 (3
metre water head) of BS 5490 with sealing O-rings. The terminal compartment shall be
separately sealed from the rest of the enclosure so that wiring and integral controls are
not adversely affected by water, while the cover is removed for site cabling or
maintenance.
Each actuator shall be supplied complete with installation instructions and wiring
diagram and sufficient spare cover screws and seals to make good site losses.
Where power supply is not available at site, a socket and plug arrangement shall be
provided to receive power supply from a portable/mobile generator set. The sockets
shall be bulk head mounted on to the actuator and shall be provided with a hood. The
protection afforded by the socket shall be IP 67 even with the plugs disconnected.
The sockets mounted on the actuators shall be provided with male pins (8 pins rated at
35 Amps to suit 415V power supply). Plugs complete with hood cover to match the
sockets fitted on the actuators shall be provided. Plug/socket connectors fitted on the
end of flying leads will not be accepted.
I.31

3.2.12 Head Stocks

Headstocks for valves shall be the non-rising spindle and direct manual type with open
and shut indicator. The headstock supplied shall be suitable for mounting of actuators
for valves. The components used shall be cast iron which comprises of a handwheel, a
yoke cap housing gunmetal and a headstock.
After completion of installation and site tests, all headstocks shall be painted with two
coats of cold applied polyurethane topcoat minimum 100 micron dry film thickness and
to a colour approved by the S.O. and these costs are deemed included in the Contract
rates.
3.2.13 Spares
All spare parts shall be new, unused and strictly interchangeable with the parts for
which they are intended to be replaced and shall be treated and packed for long storage
under the climatic conditions prevailing at the Site. Each spare part shall be clearly
marked or labelled on the outside of its packing with its description, number and
purpose and, when more than one spare is packed in a single case or other container, a
general description of its contents shall be shown on the outside of such case or
container and a detailed list enclosed. All cases, containers and other packages shall be
marked and numbered in an approved manner for purposes of identification.
All cases, containers or other packages are liable to be opened for such examination as
the S.O. may require and the packing shall be designed to facilitate opening and
thereafter repacking.
3.2.14 Measurement and Payment
The Goods and all work in connection therewith as specified shall be valued by remeasurement. Items in the Bills of Quantities are provisional and only such items as are
installed in the system shall be paid, unless otherwise specified.
The Goods supplied under this Contract shall include design, manufacture, shipping, tax
and duties, etc. transport, temporary storage at store yard, haul, guard, handle and place
in position ready for jointing and painting of valve, etc. after installations.
The Contractor shall take note that valves shall be installed under the supervision and/or
direction of the valve manufacturer/supplier and the Contractor shall accord all
necessary assistance and coordination for the successful and complete installation. The
cost of such provision shall be deemed to be included in Contract rates.
All the Goods other than spares shall only be measured for payment after they have
been installed, incorporated and accepted in the Works.
All Goods shall only be measured for payment after they have been delivered to the site
and accepted by the S.O.. Notwithstanding what is provided elsewhere, the terms and
conditions of payment of the Goods shall be as follows:
75% on delivery and successful testing of the valves at Site
15% on successful installation and commissioning
10% on satisfactory completion of Defects Liability Period
I.32

3.2.15 Site Testing and Commissioning

After the valves have been delivered to the Site, the Contractor will repeat the
hydrostatic pressure tests as specified for the works tests. The Contractor will give the
S.O. in writing (2) weeks notice of the date on which the valves will be tested and the
S.O. or his representatives will attend the tests. Whether the S.O. or his representatives
witness the tests or not, the Contractor will provide a copy of the test results to the S.O..
Should any leakage occur in the valves during these tests, the Contractor shall remedy
the defects at his own expense failing which the S.O. will remedy the said defects and
charge all expenses incurred to the Contractor. Notwithstanding what are stated
elsewhere no valve shall be considered accepted for installation until the valve has
passed the specified tests at the manufacturers works and at the site.
Upon completion of the installation works (whether by the Contractor or by others), the
operation of all the valves in particular those that are electrically actuated shall be tested.
When all the valves have been successfully tested, the Contractor shall apply in writing to
the S.O. to install and to commission the Works.
The commissioning of the Works shall be carried out over a period of one (1) week
wherein all the valves shall be checked for operation. The frequency of checks during the
one (1) week commissioning shall be at the direction of the S.O.
I.33

First Edition: May 2007
J - DUCTILE IRON PILLAR HYDRANTS

1.0
General
1.1
This specification briefly specifies the requirement for the standard 100mm and 150mm
pillar hydrants.
1.2.
Pillar hydrants will be of ductile iron material conforming to BS 750 : 1984 or JKR
Specification 202000-0042-99.
2.0
Type of Pillar Hydrants
2.1
100 mm diameter Pillar Hydrant
2.2
The 100 mm pillar hydrant shall be designed with 65 mm diameter outlets as shown
in Appendix 1 & 2.
The pressurized 100 mm pillar hydrant shall be equipped with landing valves as in
Appendix 3.
150 mm diameter Pillar Hydrant
The 150 mm pillar hydrants is provided with two 65 mm diameter outlets and one
100 mm diameter outlet as in Appendix 4.
The pressurized 150 mm pillar hydrant is equipped with two 65 mm diameter

landing valve and one 100 mm diameter outlet in Appendix 5 & 6.
3.0
Materials
3.1
Body and Cap: -
The body and cap of the pillar hydrants shall be made of ductile (spheroidal graphite) iron at least
of quality conforming in all respect to the requirements specified in BS 2789:1985 of Grade
421/12.
3.2
Outlets
The material for outlets shall be made of die-cast brass which must comply with the
standard BS 1400 Grade DCB1 with minimum tensile strength of 210 N/mm.
The screwed outlets shall be provided with caps to cover the outlet thread.
_____________________________________________________________________________________________
J.1

3.3
The caps shall be securely attached to the hydrant by galvanized steel chain.
A minimum 3 mm thick rubber gasket conforming to BS 3457 shall be provided.
The screwed outlets shall be locked to prevent theft by using pins as shown.
Landing Valve: -
The materials used for all the components of the landing valve are as shown and must comply with
BS 5041 Part :1987.
4.0
Dimensions
4.1
Body
4.1.1
100 mm Pillar Hydrant
4.1.2
Overall height 827 mm 10 mm
External diameter of hydrant 130 mm 5 mm
Internal diameter of hydrant 102 mm 2.0 mm
Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron.
150mm Pillar Hydrants
Overall height
875 mm 10 mm
External diameter of hydrant
213 mm 3 mm
Internal diameter
Flange at inlet as specified in Table 11 BS 4504 1989 Section 3.2 for Ductile Iron.
4.2
Outlet
4.2.1
65 mm diameter Outlet
150 mm 3 mm
This outlet is used as the standard outlets for the 100 mm diameter pillar hydrant and as the
side outlets of the 150 mm diameter pillar hydrant.
_____________________________________________________________________________________________
J.2

4.2.2
4.2.3
Outlet diameter
Internal 64mm
+ 0.0 mm
- 1.5 mm
External 75 mm
+ 0.8 mm
- 0.0 mm
Length of outlet
122 mm 1.0 mm
Thickness of flange 10 mm 1.5 mm
Diameter of flange
96 mm 1.0 mm
Length of thread
35 mm 1.0 mm
Diameter of thread
(External)
35 mm 0.4 mm
Type of threads
V - Threads
Threads per 25.4 mm
5 1/3 Nos
100 mm diameter Outlet

For the front outlet for all 150 mm diameter pillar hydrants required dimensions are
as follows: (i)
Outlet Diameter
Internal
95 mm + 0 mm
- 1.5 mm
External
112 mm + 0.8 mm
- 0 mm
(ii)
Length of Outlet
126 mm 1.0 mm
(iii)
Thickness of Flange
12 mm 1.5 mm
(iv)
Diameter of Flange
140 mm 1.0 mm
(v)
Length of thread
50 mm 1.0 mm
(vi)
(vii)
Type of threads
Threads per 25.4 mm
Round Threads
3 Nos.
_____________________________________________________________________________________________
J.3

4.2.4
Landing Valves
All landing valves shall comply with BS 5041 Pt 1:1987 to be used for the pressurized
100mm pillar hydrant as well as the side outlets of the pressurized 150 mm pillar hydrant.
4.3
Caps
Cap dimension are as follows:
4.4
4.3.1
Cap for 65 mm diameter Outlets
Width of cap
External diameter of cap
Internal diameter
Rubber gasket
4.3.2
Cap for 100 mm diameter Outlet
Width of Cap
51 mm 1.0 mm
External diameter
210 mm 3 mm
Internal diameter
112 mm 0.5 mm
Rubber gasket
42 mm 1.0 mm
100 mm 2.0 mm
81 mm 0.5 mm
Min. 3 mm thick
Min. 3 mm thick
Chain
Material to be of galvanized steel.
Minimum diameter for the link of the chain shall be 5 mm.
The total minimum length of chain used for 100 mm pillar hydrant.
150 mm pillar hydrant shall be 660 mm and 1160 mm respectively.
Link of galvanized steel chain can be fixed either by attaching to the ear with a 100
mm drill hole or embedding in lug formed in casting.
5.0
Coating
5.1
All machined surfaces shall be thoroughly cleaned and shall be treated with a protective
composition before they become affected by rust.
_____________________________________________________________________________________________
J.4

5.2
The outer surface of the body shall be coated of either fusion bounded epoxy powder or
approved fire hydrant yellow with minimum thickness 250 m conforming to AS / NZ
4158.
6.0
Testing
6.1
Hydrostatic Test
7.0
The hydrant is subjected to a hydraulic pressure of not less than 24 bar for a period of not
less than 24 bar of a period of not less than 1 minute.
Overall Flow Test
The hydrant shall deliver not less than 210 liters / min at a constant pressure of 1.7 bar at
the inlet to the hydrant (Results may be obtained by interpolation by referring to the
pressure versus flow curve as in Appendix 7).
Markings
Each hydrant shall have the following markings in raised letters of minimum 50 mm high cast on
the body.
The Manufacturers name and trade mark
The size of the hydrant
The year of manufacture (last two digits)
The word SYABAS
The body material identification DI
Made in Malaysia
8.0
Accessories
8.1
Accessories and fittings associated to pillar hydrants are:
Double-flanged duck-foot 90 () bends
Pipes with cast-on flanges, Class K12
Valves
_____________________________________________________________________________________________
J.5

8.2
All fittings such as double-flanged duck-foot 90 () bends and pipes with cast-on flanges,
Class K 12 connecting to the pillar hydrants shall be made of ductile iron.
8.3
All ductile iron fittings shall have the tensile strength of 421 Mpa and minimum elongation
of 5%.
8.4
Coating for fittings (both internally and externally)
All fitting shall be coated with fusion bonded epoxy powder of not less than 350 m
thickness.
All bolts, nuts and washers made of hot dipped galvanize zinc plated carbon steel
coated with Rislan Nylon with the finished thickness of coating between 75 m and
125 m.
9.0
Flanged joints
9.1
The dimensions and tolerances of the flanges of pipes and fittings shall comply with PN 16
requirement for ductile iron.
9.2
Each fitting shall be supplied with a set of flange jointing materials, which shall be
completed with nuts, bolts, washers and joint rings.
9.3
Joint rings shall be of flat section 5 mm thick, medium rubber reinforced with two-ply
flexible fabric and shall not extend beyond the bolt circle.
10.0
Pre- Delivery Inspection and Evaluation
10.1
It is the responsibility of the Contractor to inform SYABAS Sdn. Bhd. for inspection purposes
during manufacturing and before delivery.
10.2
SYABAS reserved the rights to inspect and witness the testing of product offered.
10.3
At any time, when requested, the Contractor is to provide SYABAS a sample of the product
offered for evaluation purposes. All costs shall be borne by the Contractor.
10.4
If at any time the Contractor fails to deliver the required sample, the product is deemed fail
to meet the specifications.
11.0
Certification
11.1
The Contractor is required to provide a copy of the certificate and testing report from SIRIM,
IKRAM or other recognised certification body.
11.2
Tests report required should be those tests conducted within a year period.
_____________________________________________________________________________________________
J.6

11.3
SYABAS reserved the rights to refuse offer or reject supply if the documents required are not
enclosed.
12.0
Packaging
All pillar hydrants shall be individually packed with proper methods and protected from
damage during transit.
_____________________________________________________________________________________________
J.7

_____________________________________________________________________________________________
J.8

_____________________________________________________________________________________________
J.9

_____________________________________________________________________________________________
J.10

_____________________________________________________________________________________________
J.11

_____________________________________________________________________________________________
J.12

_____________________________________________________________________________________________
J.13

Appendix 5
Cold Applied High Solid Liquid Epoxy Coatings
On Casting Surfaces (Both Internally and Externally)
1.
Surface Preparation
All surfaces to be coated shall be clean and dry and free from porosity, crack, sand, rust,
oil, grease and other foreign matter. They shall be prepared by abrasive blast cleaning to Sa
2 Standard (ISO 85011). Only dry abrasive blasting procedures shall be used.
Any clean surface left overnight without coating shall be reblasted before application of
coating. In the event rusting occurs after completion of surface preparation due to bad
weather, the surface shall again be cleaned in accordance with the specified standard.
Cleaning shall be discontinued each day in sufficient time to permit the surfaces cleaned to
be coated before rust booming.
2.
Coating Application
Coatings shall be applied in accordance with Section 3.3 of AWWA C210-84. Application
of coating shall be by spraying to a total dry film thickness of more than 356 microns but
less than 635 microns.
The coating shall not have coating imperfections such as blisters, cracks, bubbles,
underfilm voids, mechanical damages, holidays, pinholes or discontinuities.
3.
Coating Repair
Areas requiring coating repairs due to coating imperfections shall be cleaned using hand
and power tool to minimum St 2 Standard (ISO 8501-1). The adjacent coating shall be
roughened. All dust shall be wiped off.
Same coating material shall be applied to the prepared repair areas immediately to the
required thickness. Repairs shall be electrically inspected using a holiday detector.
4.
Coating Procedure
a.
Coating System 1 (one) coat system
b.
Application Condition :
_____________________________________________________________________________________________
J.14

Surfaces shall not be coated in rain, wind, fog, mist or in areas where airborne elements
exist; when the steel surface temperature is less than 30C above dewpoint; when the
relative humidity is greater than 85%. Blast-cleaned surfaces shall be coated as soon as
practical, not later than rust booming.
c.
Paint Application Procedure :
Mixing, pot life, thinner shall be as per paint manufacture recommendation.
Apply a wet coat in even parallel passes. Overlap each pass 50% to avoid bare
areas pinholes or holidays.
Thinning normally not required. Thin only for workability with not more than 10%
by volume of thinner.
Check thickness of dry coating with non-destructive dry film thickness gauge.
In confined areas, observe safety rules provided by paint manufacturer.
Uncured paint should not be exposed to water, chemicals or mechanical stress

before the paint is fully cured.
It is recoatable provided that the existing surface is cleaned from oil or other foreign
contamination. Prior to recoating all irregular surfaces are to be sand paper abraded.
For multicoat system,

recommendation.
Prior to recoating, all irregular surfaces are to be sand paper abraded.
5.
Inspection
a.
Surface Preparation :
recoating
time
shall
follow
paint
manufacturer
Visually (From ST2 to SA 2.5)

b.
Surface Profile :
The profile height shall be spot checked with Elcometer Profile Gauge or KeaneTator Comparator with reference to5a. above.
c.
Paint Material
_____________________________________________________________________________________________
J.15

Record batch number

d.
Metal Temperature
The magnetic metal temperature gauge should be used. Metal temperature must be
30C above the dew point.
e.
Wet Film Thickness (WFT)

The comb-type gauge shall be used.
f.
Dry Film Thickness (DFT)

The Elcometer DFT Gauge shall be used.
g.
Visual Inspection
Coats shall be smooth, free from dry spray, pinholes, blisters, craters and excessive
sagging.
6.
Testing on Applied External and Internal Coating
6.1
Holiday Test ASTM G62-87
All pipes shall be checked for continuity of the applied protection in accordance with
ASTM G62-87. Discontinuities and pinholes indicated by the test shall be made good as
per the manufacturer recommendation.
6.2
Adhesion Test
When an adhesion test is carried out, it shall comprised one of the following methods :
a.
The Ring Test

A ring 75mm wide shall be cut cold from one end of finished pipes. The ring shall
be flattened at a temperature between 100C and 210C to 50% of the original
diameter. The lining and / or coating shall not part from the metal under this test.
b.
The Strip Test

Using a tool with a thin sharp blade, two cuts approximately 50mm apart shall be
_____________________________________________________________________________________________
J.16

made through the protection on the metal pipe. Sudden impact that would cause
ultimately separation shall be avoided. The blades shall be worked under the
protection and an attempt made to peel it from the metal. The adhesion shall be
considered satisfactory if removal of the protection causes cohesive failure and the
protection does not peel cleanly from the primer or the pipe surface.
c.
Measuring Adhesion by Tape Test ASTM D 3359-93

Test method A is primarily intended for use at job sites. An X cut is made in the
film to the substrate, pressure sensitive tape is applied over the cut and then
removed, and adhesion is assessed qualitatively on the 0 to 5 scale. The acceptance
should be 4A-Trace peeling or removal along incision or at their intersection.
d.
Pull-Off Strength of Coating Using Portable Adhesion Testers ASTM D 4541-93

This test method is for the determination of perpendicular force of the coating can
bear a plug of material is detached. It has to be carried on a flat surface. The general
pull-off test is performed by securing a loading fixture (dolly) normal (perpendicular)
to the surface of the coating with an adhesive. After the adhesive is cured, a testing
apparatus is attached to the loading fixture and aligned to apply tension normal
(perpendicular) to the test surface. The force applied to the loading fixture is then
gradually increased and monitored until either a plug of coating material is
detached or a specified value is reached. The acceptance criterion is a minimum
strength of 20 kg/cm2.
The tests shall be performed when the protection has been allowed to cure at a
temperature not less than 100C or more than 350C for a minimum of 48 hours after
application. However for pull-off adhesion test, a proper curing period of 7 days is
required before the test.
Note : When an adhesion test is required, this should be stated by the purchaser
during enquiring or ordering.
_____________________________________________________________________________________________
J.17

STANDARD INSPECTION PROCEDURE (BLASTING)

A.
BEFORE BLASTING
1. Condition of Rust
- Grade A, B, C, D
INSPECTION OF
CASTINGS
To check
2. Oil or grease solvent wipe in
accordance with SSPC-SP1
3. Sharp edges, wedge slag
- grind off
1. Grade / Mesh size
INSPECTION OF
ABRASIVE
To check
2. Salt free and general utility
1. Test run for equipment

INSPECTION OF
BLASTING
EQUIPMENT
To check
2. Compressed air free from oil

and moisture trap and separator
3. Pressure at blast hose nozzle
- hyperdermix needles (85
100psi)
4. No defective on blasting
nozzle
_____________________________________________________________________________________________
J.18

B.
DURING BLASTING
MEASURE AND
RECORD WEATHER
CONDITION
INSPECTION OF
CASTINGS
To check
1. Measure and record weather
condition dew point, relative
humidity, steel surface
temperature. No blasting shall be
allowed if steel temperature is not
at least 30C above dew point
To check
1. Standards achieved visual

comparison using Pictorial
Standard ISO 8504
2. Surface roughness of minimum
30 as measured by KeaneTator surface comparator
Note :
1.
No blasting to be allowed if relative humidity is above 85% (Whitling Hygrometer

to be used). Casting surface temperature (using Magnetic Contact Thermometer) is
not more than 30C above dew point (using Dew Point Calculator)
2.
Blasted casting surfaces should be primed within 4 hours at normal weather

condition provided that no abrupt change in weather condition, and surface (rust
blooming).
3.
Blasted surfaces left uncoated overnight shall receives a complete light blasting the
next day before priming.
_____________________________________________________________________________________________
J.19

C.
AFTER BLASTING
CHECK WEATHER
CONDITION
INSPECTION OF
CASTINGS
To check
No coating to be applied if casting
temperature is less than30C above
dew point
To check
1. Sharp edges to be removed by
sanding down
2. Dust free surface to blow off
dust
Within 4 hours
3. Dust/pollution free environment

to be applied when blasting
work is being carried out nearby
PAINT APPLICATION
_____________________________________________________________________________________________
J.20

References of Cold-Applied High Solids (solvent or solventless) Epoxy
as Internal and External Coating System For Metal Surfaces Suitable For Portable Water
(Using High Solids (solvent or solventless) Epoxy-Based Primer/Topcoat)
Jotun
Dimet
Manufacture Description
Courtaulds Coatings
(International Paint)
Intergard Potable
Interline 925
Water Tank
Coating
Nippon Paint
Coppon EA-9
Finish HB
Jotamastic 87
Naviguard
Amerlock 400
Amercoat 395
Coating System
AWWA C210 84
by COT
10 Dec 92
1 or 2 coats
AWWA C210
84/92 by COT
27 Sep 94
1 or 2 coats
1 or 2 coats
2 coats
Multicoat System
Multicoat System
2 coats
Colour
Varieties
Varieties
Varieties
White, Pink
Cream, White
Varieties
Solids Volume
DFT per Coat
Recommended Total DFT
82% 2%
150 - 400
400
Airless or
Conventional
Spray
100%
150 - 400
400
Airless or
Conventional
Spray
83% 3%
100 - 210
400
Airless or
Conventional
Spray
White. OffWhite Orange

91% 3%
75 - 125
400
Airless or
Conventional
Spray
56%
125
400
100%
300 - 600
400
Airless Spray
Airless Spray
55%
150
400
Airless or
Conventional
Spray
BS 3900 C2 & C3
(350C)
BS 3900 C2 & C3
(350C)
ASTM D1640
(320C)
ASTM 1640
(210C)
(350C)
(350C)
2.5 hrs
5 hrs
3 days
2.5 hrs
4 hrs
3 days
4.5 hrs
12 hrs
4 days
6 hrs
24 hrs
7 days
1 hrs
3 hrs
-
4 hrs
8 hrs
-
Certification
Application Method
Drying Period
Touch Dry
Hard Dry
Curing
_____________________________________________________________________________________________
J.21
(250C - 350C)
2 hrs
16 hrs
9 days

Appendix 6
Polymeric Coating
1.
Materials and Thickness
Pipes and fittings shall be coated with either a thermoset or thermoplastic polymeric
coating material. The coating shall be applied using either the fluidized bed dipping
process or the electrostatic spray process. The minimum thickness of polymeric coating
material shall be not less than those specified below :
Coating Type
Coating Thickness (m)
Thermoplastic
200 450
Thermoset
350 650
Note : A coating manufacturer may specify higher minimum coating thickness than those
specified above
2.
Performance Testing
Water Quality
All coating material in contact with or likely to come in contact with potable water
shall meet the requirements of BS 6920 Part 1.
3.
Physical Characteristics and Performance
a.
Holidays
Coating shall be tested in accordance with AS 3894.2. Only pinhole-free coated test
piece shall be used in subsequent performance test.
b.
Hot Water Immersion

Test in accordance with AS 3862 at 600C 21C for 100 days. The coating shall have
a rating of equal to or greater than four when tested in accordance with method
408.2 of AS 1580, immediately after exposure.
_____________________________________________________________________________________________
J.22

c.
Water Absorption
d.
Flexibility
When tested in accordance with AS 3682 at 00C, the coating shall not crack when
strained at 1.0% as calculated in the following equation :
Strain
where
e.
Sc
R
100 Sc
2R Sc
Sample Thickness
Radius of Mandrel
Impact Resistant
When tested in accordance with ASTM G14 at 230C, the impact resistant shall be
equal to or greater than 2.0 J. The test may either be conducted on pipe with an
outside diameter of 110mm to 125mm and wall thickness from 5mm to 7mm (6mm
for flat plate). If cast plate is used, the side in contact with the anvil shall be
machined flat prior to testing.
f.
Abrasion Resistance
The abrasion resistance test shall be undertaken according to ASTM D4060 with
CS18 wheel, 1000 cycles at 230C 21C. The weight loss shall be equal to or less
than 40mg.
g.
Cathodic Disbondment
Coated test piece shall be tested according to sections 5, 6, 7, 8 and 9 of BS 3900 :
F 11. The coating when subjected to an impressed current at a negative voltage of
1.5V, shall not disbond more than 5mm radially from the end of the damaged
coating after 28 days.
h.
Cure Test
This test applied only to thermosetting coatings, including liquid thermosets. After
an appropriate combination of time and conditions (both to be defined prior to the
test by the manufacturer) from the point of coating application, thermosetting
coating on coated test pieces shall be demonstrated to have been cured within
_____________________________________________________________________________________________
J.23

declared limits. The method used shall also be declared. Whenever practicable, the
method chosen should produce quantitative results.
Thermoplastic coating do not required this test.
i.
Adhesion Test
Adhesion testing shall be carried out to determine the adhesive strength of the
coating to the substrate. It does not prove cohesive strength of the coating. Testing
shall be by means of a V-cut test. Toughness of the film and visual evidence of
coating in the anchor pattern valleys will give good indication of satisfactory
adhesion.
The test shall be carried out using a sharp knife. Two cuts are made in the coating at
an included angle of approximately 300. Using the sharp point craft knife or similar,
the knife shall be used to attempt to lift the point of V in a single action levering
against a fulcrum. Not more than 2mm of the V shall be removed by this method
by adhesive failure to the substrate or the adhesion shall be considered to be
unsatisfactory.
The purchaser shall state his requirement for an adhesion test and the frequency of
testing at the time of enquiry and order.
j.
Salt Spray Test

Prior to exposure, each test piece shall have a V cut made through the coating in
accordance with D.3.10. Coated test pieces shall undergo 2100 hours exposure to
salt spray in accordance with BS 3900 : F4. After exposure, the underfilm corrosion
must not extend more than 1mm from the cut edge of the coating. There shall be no
blistering in this area.
Addition, a V cut test shall be carried out in accordance with D.3.10 on the
undamaged side of the sample after exposure. On this side, there shall be not more
than 1mm disbondment, no underfilm corrosion and no blistering.
_____________________________________________________________________________________________
J.24

_____________________________________________________________________________________________
J.25

J.26

J.27

K : STAINLESS STEEL PIPE AND WATER METER STANDS

1.0
GENERAL
This section of this specification covers necessary information on the
dimensions and various material requirements for Stainless Steel Water Meter
(15mm) Positions connected to public mains.
Specifications and material requirements for commonly used plumbing
materials are also covered in this section.
They are made up of the following components:
Stainless steel pipes
All outgoing pipes are 20mm I.D.
For one-meter position, the incoming pipe is 20mm I.D.
For two-meter position, the incoming pipes are 25mm I.D.
For three to five meter stands, the incoming pipes are 50mm I.D.
Brass lockable valves;
Brass gate valve or ball valve (full bore) for two to f i v e meter positions
(optional, depending on the respective State Water Authority) - ,
Brass or stainless steel fittings (e.g. nipple, coupling, elbow, jam nut, tee
etc);
Sub-main, communication pipes and associated fittings;
Saddle anti ferrule for tapping from public main;
For single meter position, concrete slab (600mm x 600mm x 50mm

thick)
Other jointing combinations for single and multi meter stands are as shown in
Drawing (Please refer to Standard Drawing).
Typical details of standpipe taps and kitchen sink tap are shown in Standard
Drawing
D:\TECHNICAL DEPARTMENT\SPECIFICATION\SPEC FINAL PDF\PDF New Folder Final\K-Stain Steel1.doc
K.1

2.0
MATERIAL
2.1
Pipework for Stainless Steel Meter Position

Pipework for stainless steel meter stands shall be to the dimensions shown or
as specified and shall be complete with all elbows, tees, couplings., sockets,
plugs, reducers, brackets, supports and everything else necessary to complete
the installation.
All stainless steel pipes used, shall be grade TP 304/TP316 conforming to
ASTM A312 Welded Stainless Steel pipes (Schedule 40S).
All fittings shall be stainless steel pipe fittings conforming to ASTM A351 GR CF
8/CF 8M or brass threaded fittings conforming to BS 143 & 1256 respectively. Brass
threaded fittings made to EN l254-2 can also be used.
Brass gate valve (full bore) shall confirm to BS 5154. Brass ball valve (full
bore) shall conform to BS 6675:1986 or BS 1552 - .1995.
Figure 1: Standard Meter Stand for Pipe Size 15mm to 50mm

All polyethylene (PE) pipes and fittings used as communication pipes, unless
otherwise stated or shown in the drawing, shall have a minimum wall
thickness and pressure rating of PN 12.5 at 20 0 C (equivalent to 10 Bar derated
working pressure at 30 0 C) and manufactured to MS 1058 or EN 12201. All PE
pipes used shall be marked with SIRIM certification numbers. If PE pipes and
fittings were to be used for drain crossing or in the exposed situation, metal
sleeves made of stainless steel or galvanised iron (G.I.) pipes to protect the PE
pipes shall be provided.
K.2

(Note : G.I. pipes and fittings are not allowed to be used in contact with
potable water supply.)
2.2
Pipework for Plumbing

Pipework for water supply plumbing shall he to the dimensions shown or as
specified and shall be complete with all bends, tees, sockets, plugs, reducers,
brackets, supports and everything else necessary to complete tire installation.
Typical details of standpipe taps and kitchen sink tap shown in Drawing MPE
shall cover ABS pipes and fittings and all other types of pipes mentioned
below for internal plumbing. Only ASTM A312 Schedule 40S stainless steel
pipes and ASTM A.351 stainless steel pipe fittings or BS 143 & 1256 brass
threaded fittings for external pipework are allowed.
Where polyethylene PE pipe is stated or shown, the PE pipes and fittings used
in cold water supply pipe work in distribution pipes above ground, below
ground or concealed, unless otherwise stated or shown in the drawing, shall
have a minimum wall thickness and pressure rating of PN 12.5 at 20 0 C
(equivalent to 10 Bar de-rated working pressure at 30 0 C) and manufactured to
MS 1058 or EN 12201). All PE pipes used shall be marked with SIRIM
certification numbers. All metal fittings moulded integrally shall be dezincified brass with BSP threads to CZ132 or BS 2872 or BS 2874 and Nickel
& Chromium plated to BS 1224: 1970, service condition No. 2, classification
number Cu/Ni 10b Cr r.
Where Acrylonitrile Butadiene Styrene (AF3S) pipe (for cold water
applications only) is stated or shown, ABS pipes and fittings used in the
water supply pipework in distribution pipes above ground, below ground or
concealed, unless otherwise stated or shown in the drawing, shall have a
minimum wall thickness and pressure rating of class 12 to MS 1419.
Where polybutylene (PB) pipe (for cold and hot water applications) is stated
or shown, PB pipes and fittings used in the water supply pipework in
distribution pipes above ground, below ground or concealed, unless
otherwise stated or shown in the drawing, shall have a minimum wall
thickness and pressure rating of PN 12.5 at 21C (equivalent to 10 Bar derated working pressure at 30C) and manufactured to EN l2321 or AS/NZS
2642. All metal fittings (in contact with water ) moulded integrally shall be
de-zincified brass with BSP threads to CZ132 of BS 2872 or BS 2874 and
Nickel & Chromium plated to BS 1224 : 1970, service condition No. 2,
classification number Cu/Ni 10b Cr r.
Where polypropylene Random Co-Polymer (PP-R) Type 3 Pipe and Fitting
(for hot and cold water applications) is stated or shown, PP-R type 3 pipes
and fittings used in the water supply pipework in distribution pipes above
ground, below ground or concealed, unless otherwise stated or shown in the
drawing, shall have a minimum wall thickness and pressure rating of PN 16
or SDR 7.4 at 24C, designed for 10 bar working pressure at 60C for a
minimum operation life of 50 years and manufactured to DIN 8077, DIN
K.3

8078 and DIN 16962 Part 5-8. All metal fittings moulded integrally shall be
dezincification resistant brass with BSP threads to CZ 132 of BS 2872 or BS
2874 and Nickel & Chromium plated to BS 1224, service condition no.3
classification number Cu/Ni 10b Cr r. The minimum wall thickness and
pressure rating for cold water system, unless otherwise stated or shown in
the drawing is PN 10 or SDR 11 according to DIN 8077.
Where stainless steel pipe (suitable for cold and hot water) is stated or
shown, all service pipes, pump delivery pipe works, plumbing works at
below and above ground level shall be welded austenitic stainless steel
pipes (using Schedule 40S pipes for sizes ranging f/2" to 2" Diameter and
threaded, and Schedule 10S pipes for 2" to 8" Diameter pipes by way of
welding) manufactured according lo ASTM A.312/A312M together with
stainless steel butt welding fittings manufactured according to ASTM
A403/A403M or stainless steel screwed fittings manufactured according to
ASTM A351/A351M.
However for pipe work in plumbing above ground level (which include
service pipes, pump delivery pipe works ), as an option, stainless steel tubes
manufactured according to BS 4127 : 1994 specification for light gauge
stainless steel tube, primarily for water application, may be used. It shall be
made of stainless steel material grade 304 S15 of BS 1449 Part 2 : 1983
Compression fittings and capillary fittings to be used for joining the stainless
steel tubes shall be made of copper and shall comply with BS 864.
Where copper pipe is shown, it shall be to B.S. EN 1057:1996. Fittings to be
used for joining copper pipe shall be to B.S. 864 :Pt. 2.
Unless shown or stated otherwise, service pipes and distribution pipes
except those buried under ground level, shall be concealed or protected
with metal sleeve made of stainless steel or G.I. pipes. The contractor shall
execute the work In such a manner so as to avoid cutting into finished work
in walls, aprons, beams, etc. where practicable as the work proceeds.
Pipework to be buried or concealed shall not be covered or plastered before they
are examined, tested and approved by the State Water Authority,
notwithstanding any approval given by the S.O.
Saddles used for tapping to public main shall conform to one of the following
standards;
JKR Standard Specification for Ferrous Saddles (revised edition 1999) Spesifikasi JKR 20200-0044-99.
JKR Standard Specification for Polyamide/polypropylene Alloy (PA/PP)
Clamp Saddles to Be Used with uPVC; Ductile Iron, CIOD and AC Pipes
(revised edition 1999) - Spesifikasi JKR 20200-0046-99.
Tapping ferrules used shall conform to one of the following standards:
Malaysian Standard Specification for Brass Ferrules - MS 1396: 1991,
K.4

2.3
MR Standard Specification for Polypropylene (PP) Tapping Ferrules To Be

Used with Polyethylene (PE) and uPVC Pipes - Spesifikasi JKR 20200-005599.
Concreting
As shown in Drawing, 1:2:4 concrete slab casted with BRC 10 of minimum
dimensions 640mm x 600mm x 50mm shall be provided for single or multi
meter stands if they are placed in the open ground.
3.0
DIMENSIONS & THREADING REQUIREMENTS

The design and pipework layouts of the single and multi meter stands shall
comply with the dimensions shown in Diagrams MPA and MPB.
All stainless steel screwed ends and fittings shall be as follow:
o
Wall thickness
ANSI Class 1 5 0 / A N S I B 1 6 3 4
Threaded ends
BS 21 ( BSPT )
All stainless steel pipes and fittings (including brass) shall be threaded to BS21.
4.0
TESTS AND INSPECTION

Meter stands to be buried or concealed shall not be covered before they are
examined, tested to the required working pressure (e.g. PN 10) and approved
by the State Water Authority, notwithstanding any approval given by the S.O.
The whole pipe work shall be accepted as satisfactory if there are no sign of
leakages. The Contractor shall make good all leakages and replace any defective
parts to the approval of the State Water Authority all at his own expense
5.0
MARKING FOR METER POSITION

Single and two meter positions do not require any marking. For three or more
meter stands, identification markings engraved on to the bronze plates shall be
provided and nailed to the floor or the wall adjacent to it.
K.5

L CONCRETE WORK
1.0
CONCRETE
1.1
Scope
This section covers the supply of materials for concrete, design of concrete mixes,
quality control of concrete, mixing, transporting, placing and curing of concrete,
and testing of concrete.
The standard of materials and workmanship shall not be inferior to the
recommendations of the current:
British Standard 8110 : Structural Use of Concrete
British Standard Code of Practice BS 8007 1987: Design of Concrete
Structures for Retaining Aqueous liquids.
Appropriate Malaysian Standards approved by the S.O.
Unless otherwise specified, all reinforced concrete for retaining aqueous liquids
shall comply with BS 8007 and shall be of Grade C35A designed to resist Class 2
Sulphate Conditions as defined in BS 5238: Part 1 Table 7.
1.2
Concrete Production at the Site

At the commencement of the Contract the Contractor shall submit for the approval
of the S.O. a method statement detailing with regard to the requirements of this
Specification his proposal for the organization of concreting activities at the site.
The method statement shall include the following items :-
1.3
(a)
Plant proposed;
(b)
Laying of concrete production facility;
(c)
Proposed method of organisation of the concrete production facility;
(d)
Quality control procedures for concrete and concrete materials;
(e)
Method of transport and placing of concrete;
(f)
Striking times for formwork and procedure for temporary support of beams
and slabs.
Test Certificates
Unless otherwise directed by the S.O., manufacturer's test sheets shall be supplied
with each consignment of cement and admixture certifying compliance with the
relevant standard.
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L.1

The Contractor shall also submit to the S.O. certificates of calibration for the
weighing and dispensing equipment on the concrete batch mixing plant, certified
test results for all tests carried out on aggregate, water, fresh concrete and hardened
concrete, all as specified.
1.4
Aggregate Samples
Prior to the commencement of the trial mixes of concrete the Contractor shall
submit for approval samples 50 kg in weight of each aggregate which he proposes
to use.
The source of each aggregate shall be clearly marked on the container of each
sample.
Certified test results demonstrating compliance with the relevant quality standard
shall be submitted at the same time. Samples approved by the S.O. shall remain
preserved at site for reference.
1.5
Records of Concreting
An accurate and up to date record showing dates, times, weather and temperature
conditions when various sections of the works are concreted shall be kept by the
Contractor and shall be available for inspection by the S.O. The Contractor shall
also record the results of all tests of concrete and shall identify these results with the
parts of the works of which the samples material is representative.
For each grade of concrete, the Contractor shall submit to the S.O., not later than
twenty-four hours after concreting, a daily return of the number of batches mixed,
the number of batches and total volume of concrete placed, the number of batches
wasted or rejected and the weight of cement used.
The return shall also include specific details of each location in the works where
concrete is placed, together with the grade of concrete, total volume of concrete
placed and the number of batches used for each location.
1.6
Concrete Mixes
At the commencement of the works the Contractor shall design a mix for each grade
of concrete which will be required for use in the works and shall submit full details
of the mix designs to the S.O. for his approval. Each mix design shall be according
to the requirements of BS 5328.
1.7
Construction Joints and Lifts

The Contractor shall submit to the S.O. for his approval, as soon as is practicable
after the acceptance of his tender and not less than three weeks before the
commencement of concreting, drawings showing his proposals for placing concrete
on which the position of all construction joints and lifts shall be shown. No
concreting shall be started until the S.O. has approved the method of placing, the
positions and form of the construction joints and the lifts. The construction joints
shall be located so as to impair the strength of the structure.
L.2

Rebates, keys or notches shall be formed and waterstops inserted as the S.O. may
require. The position of construction joints and the size of formwork panels shall be
so coordinated that where possible the line of any construction joint coincides with
the line of a formwork joint and that in any case all construction joint lines and
formwork joint lines appear as a regular and uniform series.
For all exposed horizontal joints and purposely inclined joints, a uniform joint shall
be formed with a batten of approved dimensions to give a straight and neat joint
line.
1.8
Cement
The cement used for any particular mix shall comply with whichever of the
following standards is relevant :Ordinary Portland cement
BS 12
Sulphate-resisting Portland cement
BS 4027
Portland Pulverised-Fuel Ash cement
MS 1227
Portland Blastfurnace Cement
MS 1389
For water retaining structures, the cement used shall be a blended cement
comprising ordinary portland cement from an approved source and conforming to
BS12 and containing 25%, by mass, of pulverised fly ash (PFA) to the requirement of
MS 1227, or containing 50%, by mass, of ground granulated blast furnaced slag
(GGBS) to the requirement of MS 1389. The cement used shall be an approved
brand of Malaysian manufacture unless otherwise approved.
In addition to the requirements for soundness of cement given in the relevant British
Standard for the type of cement being used, the cement shall also be tested for
soundness in accordance with ASTM C151-77 `Standard Test Method for Autoclave
Expansion of Portland Cement'. The expansion of the cement bar resulting from this
test shall not exceed 0.8 percent.
The Contractor shall provide from each consignment of cement delivered to the site
such samples as the S.O. may require for testing. Any cement which is, in the
opinion of the S.O., lumpy and partially set shall be rejected and the contractor
shall promptly remove such cement from the site. Cement which has been stored
on the site for more than forth days and cement which in the opinion of the S.O. is
of doubtful quality shall not be used in the works unless it is retested and the test
results show that it complies in all respects with the relevant standard.
1.9
Storage of Cement
Immediately upon arrival at the site, cement shall be stored in silos designed for the
purpose or in dry weather-tight and properly ventilated structures with floors raised
500 mm above ground level with adequate provision to prevent absorption of
moisture. All storage facilities shall be subject to approval by the S.O. and shall be
such as to permit each access for inspection and identification. Each consignment of
L.3

cement shall be kept separately and the Contractor shall use the consignments in the
order in which they are received.
Cement of different types and from different sources shall be kept in clearly marked
separate storage facilities. Cement delivered to the site in drums or bags provided
by the supplier or manufacturer shall be stored in the unopened drums or bags until
used in the works.
Any cement in drums or bags which have been opened on the site shall be used
immediately or shall be disposed of.
1.10
Aggregates
Aggregates for concrete shall be obtained from an approved source and shall
conform with the requirements of BS 882.
Sampling and testing of aggregates shall be carried out as required by S.O in
accordance with the requirements of the appropriate clauses of BS 812. Water
absorption of aggregates when tested in accordance with the standard procedure
prescribed in Part 2 of BS 812, shall not exceed 3%.
The aggregates to be supplied shall not give rise to any alkali reaction with the
cement, whether silica or carbonate. Potential reactivity or otherwise of aggregates
shall be determined in accordance with ASTM C 289.
In addition, the soluble chlorides and sulphates content of the aggregates shall be
such that the concrete mix as a whole complies with the specified limits of salt
content.
Tests for chlorides and sulphates and for potential alkali reaction shall be carried out
when required by the S.O.
Notwithstanding any provisions contained herein, limestone aggregates shall not be
used in underground and water retaining structures.
1.11
Storage of Aggregates
The Contractor shall provide means of storing the aggregates at each point where
concrete is made such that :
(i)
Each nominal size of coarse aggregate and fine aggregate shall be kept
separated at all times;
(ii)
Contamination of the aggregates by the ground or other foreign matter shall be

effectively prevented at all times;
(iii)
Each heap of aggregate shall be capable of draining freely.
L.4

The Contractor shall ensure that graded coarse aggregates are tipped, stored and
removed from store in a manner that does not cause segregation.
Wet fine aggregate shall not be used until, in the opinion of the S.O., it has drained
to a constant and uniform moisture content of the fine aggregate continuously and
adjusts the amounts of fine aggregate and added water in each batch of concrete
mixed to allow for the water contained in the fine aggregate. If necessary to meet
the requirements of this clause, the Contractor shall protect the heaps of fine
aggregate against inclement weather.
1.12
Water
Water for washing aggregates and for mixing concrete and curing shall be clean and
free from harmful matter and shall satisfy the recommendations in the Appendix to
BS 3148. When required by the S.O. the Contractor shall take samples of the water
being used for which it is proposed to use for mixing concrete and test them for
quality, including determining the concentration of sulphates and chlorides, which
shall be such that the concrete mix as a whole complies with the specified limit for
salt content.
1.13
Admixtures
Admixtures shall mean material added to the concrete materials during mixing for
the purpose of altering the properties of the concrete mix.
Admixture containing calcium chloride shall not be used.
Admixtures shall not be used unless the S.O. has given his prior approval in writing
for each instance. Both the amount added and the method of use shall be to the
approval of the S.O. who shall also be provided with the following information :(i)
The typical amount added and the detrimental effects if any, due to an
increase or decrease in this amount;
(ii)
The chemical name(s) of the main active ingredient(s) in the admixture;
(iii)
Whether or not the admixture leads to the entrainment of air when used at the
amount the manufacturer recommends.
Any approved admixture shall conform to whichever of the following standards is

appropriate :-
Air entraining admixtures
BS 5075 Part 2
Water reducing admixtures
BS 5075 Part 1
Retarding admixtures
BS 5075 Part 1
Fly ash and raw or calcined natural

pozzolans for use as a mineral admixture
ASTM C 618
L.5

1.14
Test Equipment
The contractor shall furnish all equipment and materials necessary for collecting
samples and carrying out field laboratory tests on materials for concrete and on fresh
and hardened concrete. Laboratory equipment shall be housed in a suitable
laboratory building on the site, which shall also incorporate space for storage of
field test equipment, and for curing of concrete test cubes in an orderly manner so
that they are readily accessible for testing on the due date. The contractor shall also
furnish all weights, containers and other equipment necessary for testing the weightbatching equipment for concrete materials and the dispensers for admixtures.
1.15
Grades of Concrete
Grades of concrete for use in the work shall be as shown in the table below:Maximum
Cement
content
(kg/cu.m)
Maximum
free
water/cement
ratio
325
550
0.55
35
325
400*
0.55**
40
35
300
550
0.60
C30
20
30
275
550
0.65
C25
20
25
250
550
0.70
C20
20
20
225
550
C15
20
15
205
550
Characteristic
Minimum
strength at 28 days
cement
(N/sq.mm)
content (kg/cu.m)
Concrete
grade
Maximum
aggregate
size (mm)
C40
20
40
C35A**
20
C35A**
Maximum cement content 400 kg/m3 where OPC or cement containing

GGBS is used. Maximum cement content 450 kg/m3 where cement
containing PFA is used.
**
Maximum free water cement ratio is 0.55 where OPC or cement containing
GGBS is used. Maximum free water cement ratio is 0.50 where cement
containing PFA is used.
***
Blended cement comprising Portland cement and PFA or PFA as specified
Concrete grade is that number which represents its 28 day characteristic strength
expressed in N/sq.mm.
Characteristic strength is that value of cube crushing strength below which none of
all test results fail. This condition shall be deemed to be satisfied when test results
comply with the specified test requirements.
L.6

Maximum free water/cement ratios shall be based on aggregates being in a surfacedry condition.
1.16
Free Water/Cement Ratio

In designing and establishing approved mixes of concrete for any part of the works
the contractor shall keep strictly within the limitations on free water/cement ratios
which may be shown on the drawings or expressly stated elsewhere as applying to
concrete for particular parts of the works.
1.17
Limits of Salt Content

No concrete shall contain more than the following total quantities of substances
expressed as percentages by weight of cement :(a)
For mixes containing ordinary Portland cement to BS 12 :

Total water soluble chlorides
b)
0.4% (as chloride ions)
For mixes containing cements complying with BS 4027 :

Total chlorides
c)
For mixes used for pre-stressed concrete (all cement types) :

Total chlorides
d)
For all mixes :

Total acid soluble sulphates
4.0% (as SO3 ions)
Tests shall be carried out in accordance with the following standards :-
1.18
Chlorides in aggregates
ASTM D 1411
Sulphates in aggregates
BS 1377 Test 9
Chloride ion in mixing water
ASTM D 512
Sulphates in mixing water
ASTM D 516
Workability
The workability of each grade of concrete shall be such that satisfactory compaction
can be obtained when the concrete is placed and vibrated and that there is no
tendency to segregate when it is handled, transported and compacted by the
methods which the contractor proposes to use in the works.
For reinforced concrete, the compacting factor, determined by the method
described in BS 1881, shall not be less than 0.85 nor greater than 0.92. For
unreinforced concrete the compacting factor shall be not greater than 0.85. Where
L.7

pumping of concrete is permitted, the compacting factor may be increased to 0.95,

provided that the conditions are not varied. In any case no pumped concrete shall
be used for all water retaining structures.
1.19
Design of Concrete Mixes

Each mix design shall be such that :
(i)
The aggregate shall comprise both fine aggregate and coarse aggregate. The
maximum size of coarse aggregate shall be 20 mm or 40 mm as approved by
the S.O.
(ii)
The cement content shall not be below the minimum specified for the grade of
concrete.
(iii)
The maximum free water/cement ratio shall be the maximum water/cement

ratio when the aggregate is saturated but surface dry.
(iv)
The mixes shall be designed to produce a targeted mean concrete cube

strength at 28 days after manufacture and shall be greater than the
characteristic strength at 28 days by a margin of at least 10 N/sq.mm for Grade
15 and 15 N/sq.mm for Grade 20, 25, 30, 35A and 40.
(v)
Where sufficient data can be produced by the contractor to show that the
standard of acceptance for characteristic strength can be maintained using a
lower margin, the mix may be redesigned to have such reduced margin.
Sufficient data shall consist of cube test results from at least 40 separate
batches of concrete produced over a same plant under similar supervision.
The reduced margin shall be 1.64 times the standard deviation of the test
results considered, but not less than 5 N/sq.mm for Grade 15 and 7.5
M/sq.mm for Grades 20, 25, 30, 35A and 40.
For any concrete containing admixtures, the strengths shall not be less than those
specified but the mixes for the grade of concrete shall be separately designed to take
account of the effects of the admixtures, and shall have separate trial mixes made
and tested.
1.20
Trial Mixes
As soon as the S.O. has approved each of the concrete mix designs, two batches
from a trial mix for each grade shall be produced in laboratory using cement and
surface dry aggregates known to be typical of the proposed source of supply. The
proposed mix proportions of each grade shall be approved only if both batches have
the correct cement content and free water cement ratio at or below the maximum
value for the proposed degree of workability.
When mix proportions have been approved by the S.O., three further batches of
concrete for each grade shall be made at site under full scale production conditions
using the same mixing time and handles by means of the same plant which the
Contractor proposes to use in the works.
L.8

The proportions of cement, aggregates and water, shall be carefully determined by

weight in accordance with the contractor's approved mix design, and sieve analyses
shall be made, by the method described in BS 812, of fine aggregate and each
nominal size of coarse aggregate used.
The compacting factor of each batch of each trial mix shall be determined
immediately after mixing by the method described in BS 1881 and shall not be
outside the limits specified in clause 2.3.18.
Three 150 mm compression test cubes from each of the three batches shall be made
by the Contractor in the presence of the S.O. from each trial mix. The cubes shall be
made, cured, stored and tested at 28 days after manufacture in accordance with the
method described in BS 1881. If the average value of the compressive strength of
the nine cubes taken from any trial mix is less than the target mean strength used in
the mix design or if any individual cube test result falls below 85% of the target
mean strength, the Contractor shall redesign that mix and make a further trial mix
and set of test cubes.
A full scale test of the workability of each trial mix of each grade of concrete shall
be made by the contractor in the presence of the S.O. The trial mix of each grade of
concrete shall be batched, mixed and then transported a representative distance in
the manner that the contractor proposes to batch, mix and transport the concrete to
be placed in the works. After discarding the first batch so made, the concrete from
later batches shall be placed and compacted in trial moulds both for reinforced and
mass concrete with dimensions typical of the works in accordance with the
procedures described in later clauses, the sided of the moulds being capable of
being stripped without undue disturbance of the concrete placed therein. The sides
of the moulds shall be stripped after the concrete has set and the workability judged
by the surface appearance and compaction obtained. If the workability test shows
that the workability required is not attained for any trial mix for any grade of
concrete, the trial mix shall be re-designed by the Contractor and a further full scale
workability test undertaken for that trial mix.
The re-design of the concrete mixes and the making and testing of trial mixes of
concrete shall be repeated for each grade of concrete until trial mixes of concrete
have been established which meet the specified requirements and have the required
workability as demonstrated in the full scale workability test described above.
If at any time during the construction of the works the S.O. approves a change in the
source of cement or aggregate or if the grading of the aggregate alters to such an
extent that the fraction of aggregate retained on any sieve cannot be maintained
within two percent of the total quantity of fine and coarse aggregate when adjusted
as specified for sampling and testing of aggregates, then further trial mixes of
concrete shall be made, tested and approved for use.
1.21
Material Batching
All cement used in the manufacture of concrete shall be measured by weight either
with an approved weighing machine or by making the size of each batch of
concrete such as to require an integral number of complete bags or drums of
cement.
L.9

For concrete of Grades 20, 25, 30, 35A and 40, the fine aggregate and the several
nominal sizes of coarse aggregates shall be measured singly or cumulatively by
weight using weight-batching machines.
For concrete of Grade 15, the fine and coarse aggregate shall be measured
separately either by weight using weight-batching machines or by volume in gauge
boxes.
Weight-batching machines shall provide facilities for the accurate control and
measurement of the aggregates either singly or cumulatively and shall be capable of
immediate adjustment by semi-skilled operators in order to permit variations to be
made to the mix. All weigh dials shall be easily visible from the place at which
filling and emptying of the hoppers is controlled.
Every concrete mixing machine shall be fitted with a device to measure added water
by weight and shall be so constructed that the water inlet and outlet valves are
interlocked so that either one of them cannot be opened unless the other is fully
closed. The weighing device shall be provided with an overflow with a crosssectional area at least four times that of the inlet pipe and with its discharge point
clear of the mixing plant. The entire water system shall be maintained free of leaks
at all times and the measuring device shall be fitted with a drain pipe which allows
the full quantity of water being measured to be drained off for checking the
measurement. The outlet arrangement of the measuring device shall be such that
between five and ten percent of the water enters the mixer before the other
materials and further five to ten percent of the water enters the mixer after the other
materials. The remainder of the water shall be added at a uniform rate with the
other materials. The water measuring device shall be readily adjustable so that the
quantity of water added to the mixer can, if necessary, be varied for each batch.
Where volume batching is permitted by the Specification, gauge boxes shall be
soundly constructed of timber or steel to contain exactly the volume of the various
aggregates required for one batch of each mix. They shall have closed bottoms and
shall be clearly marked with the mix and aggregate for which they are intended.
When calculating the size of the gauge box for fine aggregate, an allowance shall be
made for the bulking of the fine aggregate due to the average amount of moisture
contained in the stockpiles on the site. Before the contractor puts any gauge box
into use on the site he shall obtain the approval of the S.O. of the size and
construction of such gauge box.
Any admixtures which may be used shall be measured separately in calibrated
dispensers.
All mixing and batching plants shall be maintained free of set concrete or cement
and shall be clean before commencing mixing. The accuracy of calibration of any
weighing plant, water measuring plant and admixture dispenser, shall be checked
before carrying out trial mixes, before mixing concrete for inclusion in the work,
after each service or adjustment to the mixing plant, and in any case at least once
per month.
L.10

1.22
Mixing Concrete
Concrete shall be mixed in batches in plant capable of combining the aggregates,
cement and water (including admixtures, if any) into a mixture uniform in colour
and consistency, and of discharging the mixture without segregation.
On commencing work with a clean mixer, the first batch shall contain only half the
normal quantity of coarse aggregate to compensate for the adhesion of the other
materials to the drum.
The moisture contents of the aggregates shall be determined before the
commencement of each day's concreting and at such intervals during each day as
may be necessary. The Contractor shall make due allowance for the water
contained in the aggregates when determining the quantity of water to be added to
each mix, and shall adjust the amount of water added to each mix to maintain
constant the approved free water/cement ratio of the mixed concrete.
1.23
Ready-Mixed Concrete
Ready-mixed concrete shall not be used in any part of the works without the S.O.'s
written approval, which may be withdrawn at any time.
The Contractor shall satisfy the S.O. that ready-mixed concrete complies with the
Specification in all respects, add that the manufacturing and delivery resources of
the proposed supplier are adequate to ensure proper and timely completion of each
concreting operation.
The specified requirements as to the sampling, trial-mixing, testing and quality of
concrete of various grades shall apply equally to ready-mixed concrete which shall
furthermore be made and delivered in accordance with BS 5328 : 1981.
Any additional facility, which the S.O. may require for the supervision and
inspection of the batching, mixing and transporting of ready-mixed concrete shall be
allowed to be used after 45 minutes of initial mixing.
1.24
High Alumina Cement

The composition of high alumina cement shall comply with B.S. 915 Part Two. It
shall consist of a minimum of 32% of alumina and the minimum compressive
strengths of mortar cubes at one and three days shall be 42 N/sq.mm and 48
N/sq.mm respectively.
High alumina cement shall be refrained from being used in structural concrete
including foundations as a substantial reductions in strengths is observed under the
vulnerable tropical conditions.
L.11

1.25
Preparing for Concreting

Before placing concrete the contractor shall remove from the surface of the
foundations or previously placed concrete, all oil, loose fragments of rock, earth,
mud, timber and other debris, and standing water, to the satisfaction of the S.O.
Where specified and elsewhere as ordered by the S.O., the excavated surfaces shall
be prepared as specified under concrete protection.
1.26
Transporting Concrete
Concrete shall be conveyed from the mixer to its place in the works as rapidly as
possible by methods which will prevent segregation or drying out and ensure that
the concrete is of the required workability at the time of placing. If segregation has
nevertheless occurred in any instance, the materials shall be remixed or rejected.
1.27
Placing Concrete
Concrete shall be placed and compacted before the initial set has occurred and, in
any event, not later than 45 minutes from the time of mixing.
When pneumatic placers are used, if the end of the placer pipe is not equipped with
an energy absorbing device, it shall be kept as close to the work as practicable.
Mortar or water used at the beginning or end of a run shall be discharged outside
the formwork..
When pumps are used, the end of the supply pipe shall be kept immersed in the
concrete during placing to assist compaction. Mortar and water used at the
beginning or end or a run shall be discharged outside the formwork.
1.28
Concreting in Hot Weather

In hot weather, the contractor shall take steps to ensure that the temperature of the
concrete as placed shall not exceed 32 deg. C and that the maximum internal
temperature attained during setting does not exceed 70 deg. C.
To achieve this, the contractor shall provide sun shades over stockpiles of aggregate,
cement silos, mixing water tanks and pipelines and in addition shall carry out the
first and as necessary other of the following procedures which shall be submitted to
the S.O. for approval :
(i)
Cool the mixing water and replace part of the water by chipped ice. The ice
shall be completely melted by the time mixing is completed.
(ii)
Spray clean cool water over the aggregate stockpiles. The Contractor shall
carry out regular tests on the aggregates to ensure that concentrations of
sulphates or chlorides do not rise to unacceptable levels, and to ensure that
moisture content determinations allow for such spraying.
(iii)
Shade or wet outside of the formwork.
L.12

1.29
(iv)
Apply a fine moisture (fog) spray of clean cool water to shaded areas
immediately prior to placing concrete.
(v)
Pour concrete at night.
Compaction
All concrete placed in-situ shall be compacted with power driven internal type
vibrators supplemented by hand spading and tamping except as otherwise approved
by the S.O. The vibrators shall at all times be adequate in number, amplitude and
power to compact the concrete properly and quickly throughout the whole of the
volume being compacted. Spare vibrators shall be readily on hand in case of
breakdown.
Vibrators shall be inserted into the uncompacted concrete vertically and at regular
intervals. Where the uncompacted concrete is in a layer above freshly compacted
concrete the vibrator shall be allowed to penetrate vertically for about 100 mm into
the previous layer. In no circumstances shall vibrators be allowed to come into
contact with the reinforcement or formwork nor shall they be withdrawn quickly
from the mass of concrete but shall be drawn back slowly so as not to leave voids.
Internal type vibrators shall not be placed in the concrete in a random or haphazard
manner nor shall concrete be moved from part of the work to another by means of
the vibrators.
The duration of vibration shall be limited to that required to produce satisfactory
compaction without causing segregation. Vibration shall on no account be
continued after water or excess grout has appeared on the surface.
1.30
Attendance of Steel Fixer and Carpenter

During the concreting of all reinforced concrete, including prestressed concrete, a
competent steel fixer and carpenter shall be in attendance on each concreting gang,
to ensure that the reinforcement, formwork and embedded fittings are kept in
position as work proceeds.
1.31
Curing of Concrete
Concrete shall be cured by protecting the surface from the effects of sunshine,
drying winds, frost, rain, running water or mechanical damage for a continuous
period of four days when the cement used in the concrete is sulphate-resisting
Portland cement, Portland Pulverised-Fuel Ash cement or Portland Blastfurnace
Cement. The protection shall be applied as soon as practicable after completion of
placing by one or more of the following methods as approved by the S.O.:
(a)
By water sprays in continuous operation;
(b)
By covering with hessian or similar absorbent material, or sand, kept

constantly wet;
(c)
After thorough wetting, by covering with a layer of waterproof fabric kept in

contact with the concrete surface.
L.13

(d)
By the application of an approved non-staining liquid curing membrane which

is either self-removing or easily removed following curing period and which
has a 75% moisture retention standard. The liquid shall be applied to formed
surfaces immediately after stripping the formwork.
Liquid curing membrane (d) shall not be used on Class U1 surfaces where laitance is
to be removed and aggregate exposed to provide a satisfactory bond for placing
further concrete or mortar screeds or on surfaces where the S.O. is of the opinion
that the appearance of the concrete surface will be affected.
1.32
Construction Joints
A construction joint is defined as a joint in the concrete introduced for convenience
in construction at which special measures are taken to achieve subsequent
continuity without provision for further relative movement.
Concrete placed to form the face of a construction joint shall have all laitance
removed and the large aggregate exposed prior to the placing of fresh concrete.
The laitance shall wherever practicable be removed when the concrete has set but
not hardened by spraying the concrete surface with water under pressure or
brushing with a wire brush sufficient to remove the outer mortar skin and expose
the large aggregate without being disturbed. Where the laitance cannot be removed
due to hardening of the concrete, the whole of the concrete surface forming the
joint shall be treated by high pressure water jet, sand blasting, use of a needle gun
or a scaling hammer to remove the surface laitance.
Before concreting is resumed, all loose matter on the existing concrete surface shall
be removed and the surface slightly wetted.
1.33
Dimensions and Surfaces of Finished Concrete

Workmanship in formwork and concreting shall be such that concrete shall require
no making good, surfaces being perfectly compacted, smooth and with no
irregularities. Concrete surfaces for the various classes of unformed and formed
finishes shall in any event not exceed the maximum permitted tolerance which shall
be as shown in the table below except where expressly stated otherwise in the
Specification or Drawings.
In the table "line and level" and "dimension" shall mean the lines, levels and crosssectional dimensions shown on the Drawings.
Surface irregularities shall be classified as "abrupt" or "gradual".
Abrupt
irregularities include, but shall not be limited to offsets and fins caused by displaced
or misplaced formwork, loose knots and other defects in formwork materials, and
shall be tested by direct measurement. Gradual irregularities shall be tested by
means of a straight, template for plane surfaces or its suitable equivalent for curved
surfaces, the template being 3.0 m long for unformed surfaces and 1.5 m long for
formed surfaces.
L.14

Maximum tolerance (mm) in :
1.34
Class of
finish
Line and
level
Abrupt
irregularity
Gradual
irregularity
Dimension
U1
+/-12
+/ -6
U2
+/ -6
+/ -3
U3
+/ -6
+/ -3
F1
+/-12
+/ -6
+12, -6
F2
+/ -6
+/ -6
+12, -6
F3
+/ -3
+/ -3
+6/ -6
Unformed Surfaces
Finishes to unformed surfaces of concrete shall be classified as U1, U2, U3, spaded'
or `bonded concrete' or such other special finish as may be particularly specified.
Where the class of finish is not specified, the concrete shall be finished to Class U1.
Class U1 finish is the first stage for Class U2 and U3 finishes and for a bonded
concrete surface. Class U2 finish shall be a leveled and screeded, uniform plain or
ridged finish, which (unless it is being converted to Class U2, U3 or bonded
concrete) shall not be disturbed in any way after the initial set and during the period
of curing, surplus concrete being struck off immediately after compaction.
Where a bonded concrete surface is specified, the laitance shall be removed from
the Class U1 finish surface and the aggregate exposed while the concrete is still
green.
A spaded finish shall be a surface free from voids and brought to a reasonably
uniform appearance by the use of shovels as it is placed in the works.
Class U2 finish shall be produced by manual or mechanical floating of the concrete
surface after the initial set has taken place and the surface has hardened sufficiently.
The concrete shall be worked no more than is necessary to produce a uniform
`sandpaper' finish free from screedmarks.
Class U3 finish shall be a hard smooth steel-trowelled finish. Trowelling shall not
commence until the moisture film has disappeared and the concrete has hardened
sufficiently to prevent excess laitance from being worked into the surface. The
surface shall be trowelled under firm pressure and left free from trowel marks.
The addition of dry cement, mortar or water will not be permitted during any of the
above operations.
L.15

Exposed aggregate finish shall be achieved by exposure of the coarse aggregate

using a method approved by S.O. The average depth of exposure shall be 6 mm for
concrete with a maximum aggregate size of 20 mm and between 6 mm and 12 mm
for concrete with a maximum aggregate size of 40 mm.
The Contractor shall prepare sample panels 1000 mm x 500 mm of concrete with
an exposed aggregate finish for inspection and approval by the S.O. at the site.
1.35
Building in Plant and Grouting- in

Wherever possible, pipes and other items of plant passing through concrete
structures shall be installed and connected to the remainder of the pipework system
to ensure proper fit, and shall be built into the structure as work proceeds.
Where this procedure is impracticable due to programme or other requirements,
holes shall be formed for the items of plant to allow them to be built in later after
complete installation of the plant.
In no case shall individual pipes of a complicated pipework system including
flanged joints be built into concrete structures before accurate fit of the whole
system can be checked after the complete installation.
Where holes are formed these shall be of size and shape sufficient to permit proper
placing and compaction of concrete or grout. The surfaces of the holes shall be
treated to produce a `bonded' surface before installation of plant.
Before grouting-in commences the plant shall be adequately supported in position
to prevent movement or damage during grouting-in.
Concrete used for building-in shall be of the same grade as concrete of the member
into which the plant is being built, except that the mix shall also incorporate an
approved expanding additive used in accordance with the manufacturer's
instructions. Concrete used for water retaining structures shall be non shrink in
nature to ensure water tightness. Concrete, mortar and grout shall be carefully
placed and compacted around the plant to avoid damaging or moving the plant.
1.36
Structural Pre-Cast Concrete

Structural units of pre-cast concrete shall be manufactured in the grade of concrete
and to the sizes and details shown on the Drawings. The concrete shall comply in
every aspect with the provisions of the Contract whether such units are
manufactured on the site or obtained from other manufacturers.
All cement, aggregate and other materials for pre-cast concrete units with faces
which are exposed either internally or externally shall be from the same sources
throughout. Exposed surfaces of the units shall be uniform in colour and in texture.
Formwork and unformed surfaces for pre-cast concrete units shall comply with the
requirements for F3 formed surfaces and U3 unformed surfaces except that the
dimensional variations shall not exceed the values listed below, unless otherwise
detailed on the Drawings.
L.16

Length
+/-6 mm
Cross-section
+/6 mm each direction
Straightness
6 mm (deviation from intended line)
Flatness 3 mm (deviation from a 1.5 m straight edge placed in any position on a

nominally plane surface)
Squareness when considering the squareness of a corner, the longer of the two
adjacent sides being checked shall be taken as the baseline, and the shorter side
shall not vary in its distance from the normal so that the differences between the
greatest and the shortest dimension exceeds 6 mm. When the nominal angle is
other than 90 degrees, the included angle between the check line shall be varied
accordingly.
Twist any corner on any nominally plane surface shall not be more than 6 mm from
the plane containing the other three corners.
The positions of individual connecting bolts, bolt holes, projecting steel and other
devices in any associated group (eg. the joint of two pre-cast units) shall be within 3
mm of their true position in the group in which they are cast. The location of any
such group shall be within 6 mm of its true position in the unit in which it is cast,
provided that such deviation does not adversely affect the proper assembly of the
whole structure.
The Contractor shall submit to the S.O. for approval, full details of his proposed
method of carrying out all operations connected with the manufacture and assembly
of precast concrete structural members, including :
A description of the types of casting bed, mould and formwork for the various
types of members;
The procedure for concrete casting and the method of curing the concrete;
The procedure for transporting, handling, hoisting and placing of each type of
pre-cast structural member;
Full details of temporary supports necessary to ensure adequate stability
during erection, due account be taken of construction loads, including wind.
1.37
Installation of Pre-Cast Concrete Units

At all stages and until completion of the work, pre-cast members shall be adequately
protected to preserve all permanently exposed surfaces, arises and architectural
features. The protection shall not mark or otherwise disfigure the concrete.
All units shall be laid, bedded, jointed and fixed in accordance with the lines, levels
and other details shown on the Drawings.
L.17

Dry-pack mortar jointing for packing shall consist of one part of volume ordinary
Portland cement and two and half parts by volume of fine aggregate passing a 1 mm
sieve. The mortar shall be mixed with only sufficient water to make the materials
stick together when being moulded in the hands. The mortar is thoroughly
compacted.
Any pre-cast concrete structural member which is found to be cracked, damaged or
otherwise inferior in quality either before or after erection shall be rejected and
replaced by the Contractor.
1.38
Pr-Sstressed Concrete
The Contractor shall submit to the S.O. for approval his proposed method of carrying
out all operations connected with pre-stressed concrete work and his proposals for
handling, hoisting and placing a position any pre-cast pre-stressed concrete units.
Pre-stressed concrete work whether pre-cast or cast in-situ shall be as detailed on the
Drawings and the Contractor shall provide full details of his proposed method of
carrying out all operations connected with pre-stressing including :(a)
Design of concrete mix
(b)
Description of concrete casting and curing operations
(c)
Procedure for pre-stressing and method of checking and recording the prestress, wire extension and anchorage slip.
(d)
Procedure for handling, hoisting and placing of any pre-cast units.
(e)
Grouting of ducts
All tendons, duct forming devices, anchorages and other components shall be kept
free of mud, oil (except water soluble oil applied for protection), paint, retarders,
loose rust, or other foreign matter. They shall be placed with a tolerance of +/-3
mm in concrete dimensions of 300 mm of less or 6 mm in concrete dimensions
over 300 mm.
1.39
No-Fines Concrete
No-fines concrete shall be made using a coarse natural aggregate conforming with
BS 882 and cement to BS 4027. No fine aggregate shall be used. The grading of
the coarse aggregate shall be;
Not less than 95% by weight passing a 19 mm BS sieve;
Not more than 5% by weight passing a 10 mm BS sieve.
The proportion of aggregate, cement and water shall be determined by trial mixes
by the Contractor starting with a cement : aggregate particles ratio of one to eight by
volume.
L.18

The trial mix shall be considered suitable when all the aggregate particles are coated
with a film of cement grout. The water content shall be just adequate. The concrete
when placed shall contain no layers of laitance.
No-fines concrete shall not be mixed by hand.
Vibration shall not be used to compact the concrete. Three test cubes of no-fines
concrete shall be made of each trial mix. The minimum crushing strength of the
chosen mix shall be 3 N/sq,mm at 28 days.
1.40
Pre-Cast Concrete Products

(a)
Pre-cast concrete products shall where appropriate be constructed in

accordance with British Standards as follows, being hydraulically pressed
where possible :
Type of Unit
Standard
Concrete blocks
BS 6073 : Pt 1 : 1981
Concrete kerbs, etc.
BS 7261 : Part 1 : 1990
Concrete flags
BS 7263 : Pt 1 : 1990
Concrete sills
BS 5642
Concrete lintels
BS 5977
The concrete shall comply in every aspect with the provisions of the
Specification whether such products are manufactured on the site or
obtained from other manufacturers.
(b)
Interlocking concrete paving shall include supply and laying of pavers,

preparation of surface, supply of sand and casting of edge restraint beams.
The pavers shall comply with the requirement of MA 20, Specification for
concrete segmental Paving Units, published by the Concrete Masonry
Association of Australia.
1.41
Sampling and Testing of Aggregate

The Contractor shall sample and carry out a mechanical analysis of the fine
aggregate and each nominal size of coarse aggregate in use employing the methods
described in BS 1881 at least once in each week when concreting is in progress and
at such more frequent intervals as the S.O. may require.
The grading of all aggregates shall be within specified limits and should the fraction
of aggregate retained on any sieve differ from the corresponding fraction of
aggregate in the approved mix by more than 2% of the total quantity of fine and
coarse aggregate, S.O may instruct the contractor to alter the relative proportions of
the aggregates in the mix to allow for such difference.
L.19

1.42
Sampling and Testing of Concrete

The Contractor shall provide the equipment necessary to determine the compacting
factor of freshly mixed concrete at each place where concrete is being made and
shall determine the compacting factor of the freshly mixed concrete by the method
described in BS 1881 on each day or as the S.O. may direct.
For each grade concrete, works test cubes shall be made whenever required by the
S.O. but not less frequently than as follows unless otherwise particularly specified :for concrete of
Grades 25, 30, 35A, 40
for concrete of
Grades 15 or 20
one set of cubes per 25 cu.m

or part thereof concreted per day;
one set of cubes per 50 cu.m
or part thereof concreted per day
Each set of cubes (six cubes per set) shall be made from a single sample taken from
a randomly selected batch of concrete. Three cubes shall be tested 7 days after
manufacture and three cubes 28 days after manufacture.
1.43
Compliance with Specified Requirements

The concrete shall be deemed satisfactory provided that :
(i)
The average 28 days strength determined from any group of four consecutive
sets of three test cubes exceeds the specified characteristic strength by not less
than 7.5 N/sq.mm for Grade 15 concrete and 10 N/sq.mm for Grades 20, 25,
30, 35A and 40.
(ii)
The average of each set of three test cube results is greater than 100% of the
specified characteristic strength.
If only one set of three cube results fails to meet the second requirement, those
results may be considered to represent only the particular batch of concrete from
which the cubes were taken, provided that the average strength of the group satisfies
the first requirement.
If more than one set of three cube results in a group fails to meet the second
requirement or if the average strength of any group of four consecutive sets of three
test cubes fails to meet the first requirement then all the concrete in all the batches
represented by all such cubes shall be deemed not to comply with the strength
requirements.
1.44
Non-Compliance
When the average strength of four sets of three consecutive test cubes fails to meet
the first requirement, no further concrete from that mix shall be placed in the work
and the contractor shall establish the cause of the failure and apply such remedies as
are necessary. The Contractor shall demonstrate by trial mixes and test cube results
that the revised mix is in accordance with the specified requirements.
L.20

The Contractor shall within 24 hours of the date of test make proposals for
agreement with the S.O. about action to be taken in respect of any concrete
represented by test cubes which fail to meet either of the requirements. These
proposals may include, but shall not be limited to, cutting and testing cores.
Concrete which is ultimately found not be comply with any of the requirements of
the Specification shall be rejected and shall be broken out and replaced or
otherwise dealt with as agreed with the S.O.
1.45
Cutting and Testing of Core Samples

As and where discussed by the S.O. cylindrical core specimens of 150 mm nominal
diameter shall be cut normal to the face of the hardened concrete for the purpose of
examination and testing. The procedure for drilling, examination, measurement and
testing for comprehensive strength shall be in accordance with BS 1881. Prior to
preparation for testing, the specimen shall be made available for examination by the
S.O. If the crushing strength of the specimen determined in accordance with
paragraph 114 of BS 1881 is less than the characteristic strength at 28 days for the
grade requirements in other respect, the concrete in that part of the works of which
it is a sample shall be considered not to comply with the specified requirements.
1.46
Inspection Procedures
Before any concrete is placed, the Contractor shall carry out an inspection to ensure
that all preparations are complete, including the provision of the necessary
equipment and personnel, and shall ensure that sufficient materials are available to
complete the work proposed.
After completion of this inspection the work shall be offered for inspection by the
S.O., sufficient time being allowed for inspection and correction of any defects. no
concrete shall be placed until the S.O. has inspected and approved the surfaces
upon which the concrete is to be placed the formwork and the reinforcing steel.
Where required by the S.O. the Contractor shall institute a `pour card' system in
which a card is made out for each lift of concrete and is initialed by the Contractor
and S.O. indicating that the inspections have been carried out.
The `pour card' shall include spaces to identify the concrete being placed and to
signify completion of the inspections by the Contractor and S.O. of the following
items:
Preparation of surface on which concrete is to be placed;
Formwork;
Reinforcement;
Ready for concrete placing;
Inspection after removal of formwork (any remedial work shall be agreed and
noted);
L.21

Curing procedures;
Completion of remedial work (if any)
1.47
Concrete Protection Systems

Where required all structural concrete in contact with the ground shall be protected
by one of the methods specified below. Unless otherwise specified or detailed on
the Drawing, in-situ concrete surfaces which are to be protected shall have either
U2 or F2 finish as appropriate.
(a)
Prefabricated membrane tanking :

The membrane shall be preformed consisting of 1.5 mm thick rubber/bitumen
compound formulated for use in hot climates, backed with 0.3 mm thick PVC
sheet. The membrane shall adhere with watertight joints to itself at overlaps
and to concrete surfaces prepared with suitable priming compound.
The membrane and primer shall be applied in accordance with the
manufacturer's instructions to horizontal, inclined and vertical surfaces.
After the blinding concrete has hardened, the membrane shall be applied,
bitumen face downwards, and shall extend at least 150 mm beyond the outer
limits of the structure. As soon as the membrane has been applied and before
any reinforcement or structural concrete is placed, the membrane shall be
covered by a sand/cement screed 50 mm thick, extending over the whole area
of the base of the structure. The membrane projection of 150 mm shall be
temporarily protected with a layer of board as specified below to prevent
mechanical damage.
After the concrete structure has been constructed up to ground level and
curing is completed, the surfaces which will be in contact with the ground, or
as detailed otherwise on the Drawings, shall be primed with the material
supplied by the membrane manufacturer. The vertical membrane shall be
bonded onto the projection of the base membrane and terminated in a chase
at the top. Fillets and reinforcing strips shall be used.
Completed areas of vertical membrane shall be protected from mechanical
damage during backfill operations by 12 mm thick cardboard, fibre-board or
chipboard secured with suitable adhesive or by concrete block-work.
(b)
Made-in-place membrane tanking :

As an alternative to prefabricated membrane taking on horizontal surfaces, the
contractor may propose to design, supply and install a made-in-place
membrane of bitumen asphalt concrete laid on a tack coat placed on clean
original ground.
The bitumen asphalt concrete shall comprise bitumen or asphalt and coarse
and fine aggregates.
L.22

The Contractor shall demonstrate to the S.O. by testing, by trial and by

experience that made-in-place membrane tanking exhibits characteristics
which are in all respect equal to or better than prefabricated membrane
tanking. The system shall be :Waterproof during life of protected structure;
Robust during preparation for concreting;
Durable during life of structure;
Flexible in differential settlement;
Incompressible under weight of structure.
Made-in-place membrane tanking may be used in place of blinding concrete
provided that the contractor shall also have demonstrated to the S.O. the
practicability of this system by testing, by trial and by experience.
Vertical or sloping concrete surfaces shall be protected by prefabricated
membrane ranking as specified which shall overlap and adhere to made-inplace membrane tanking over a width of 150mm.
The emulsion shall be a rubber-rich bituminous emulsion suitable for use in
hot climates and capable of building up a film with minimum dry thickness of
1.0 mm, which is impermeable to water penetration and possessing a high
degree of flexibility.
A priming mixture shall be made by thoroughly mixing 1 part emulsion with 6
parts fresh water. Coats other than priming coat shall not be diluted.
Application rates shall be as follows or as necessary to build up a minimum
dry film thickness of 1.0mm.:
Surface
Coat
Application rate
(sq.mm/litre)
Horizontal
1st (priming)
2nd
3rd
7
1
1.5
Vertical
1st (priming)
2nd
3rd
4th
7
2
2
2
Over-coating shall take place as soon as the previous coat has dried.
Immediately the final coat has been applied to vertical surfaces, bitumenized
building paper shall be applied to the fresh emulsion and pressed into close
contact over the whole area of the protection.
L.23

Horizontal and vertical surfaces shall be protected from mechanical damage

during subsequent construction work by screed or boarding as specified for
membrane tanking.
(d)
Polyethylene sheet
250 micron polyethylene sheet shall be placed against vertical or sloping
surfaces of excavated ground before placing concrete directly against such
surfaces.
Backfilling with sand against protected surfaces shall be carried out in such a
manner that the protection is not damaged. Nevertheless, if such damage
occurs, the damage shall be made good to the satisfaction of the S.O.
1.48
Concrete Protection Procedures

Details of concrete protection shall be shown by the contractor on the preliminary
working drawings. Such details shall include corners overlaps, brick or board
protection and details for curves faces, etc. Concrete protection systems proposed
for use in the works shall be demonstrated by the Contractor to the S.O. for
approval before submission of preliminary working drawings showing use of such
systems in the works.
1.49
Machinery Bases and Closure of pocket

Bases to take machinery and associated pipework shall be constructed in fair faced
concrete to the dimensions shown on the approved machinery drawings or as
ordered by the S.O. The mounting surface of the base shall be steel floated to true
and level planes.
The structural concrete on which the bases are to be erected shall be prepared by
hacking and cleaning off.
Bases shall be tied to the structural concrete with vertical reinforcement. Horizontal
reinforcement shall also normally be provided at the level of the pockets for the
holding down bolts.
Bolt pockets and lead-ins for grout shall be formed by a means which shall have the
approval of the S.O. Polystyrene formers will not be permitted. Where expanded
metal is used as a former it shall be left in.
When the machinery has been erected the bolt pockets shall on approval of the S.O.
be completely filled using a mixture of 2 parts of cement to 3 parts sharp sand by
volume with sufficient water to form a thick creamy consistency.
The machinery shall be run under the supervision of the contractor and witnessed
by the S.O. after the grout has hardened. When so directed the Contractor shall
complete the grouting operation by filling the space between the top of the concrete
and the underside of the machinery base plate.
L.24

No separate payment will be made for complying with the provision of this clause
and all cost shall be deemed to be included elsewhere in the Bill of Quantities.
1.50
Measurement of In-Site Concrete

For concrete placed in-site separate measurements shall be made of plain or mass
(i.. unreinforced) concrete and of reinforced concrete for each of the specified
grades of concrete.
In-situ concrete and all work in connection therewith as specified shall be valued by
the measurement of only such items as are set forth in the Bill of Quantities. Except
where expressly shown to the contrary, formwork (excluding formwork for
horizontal construction joints) and steel reinforcement shall be measured separately
from and in addition to, measurement of concrete placed in-situ. Measurement of
formwork and of steel reinforcement shall be as provided in clauses 2.4.14 and
2.5.12 respectively. Unformed surface finishes class U1, U2 and U3 and spaded
finish shall not be measured for payment.
In-situ concrete shall be measured to the limits shown on the Drawings and any
concrete placed outside such limits by reason of the Contractor's method of working
or due to his carelessness or error and whether it has been permitted by the S.O. or
not shall not be measured for payment. In concrete surround to pipes, thrust and
anchor blocks and valve chambers a deduction from the measurement shall be
made for the volume occupied by the pipes. No deduction from the measurement
shall be made in respect of:(i)
Any purpose made hole or opening which has an average cross-sectional area
less than 1600 sq cm or which has a volume of 0.1 cu metre of less;
(ii)
Any portion of chases, rebates, channels, pipes, ducts or the like whose crosssectional area in 1000 sq mm or less;
(iii)
Any chamfer 100 mm wide or less on the splay;
(iv)
The space occupied by any steel reinforcement, rails, joints or the like
embedded in the concrete.
Building paper or other protection of foundation surfaces, where ordered by the

S.O. shall be measured as the net area so protected and no measurement shall be
made of laps or joints.
Concrete testing shall be separately measurement only if and to the extent that items
for tests are provided in the Bill of Quantities.
1.51
Measurement of Form Opening of Build in Plant

Payment for form opening or build in plant shall be made at the rate per opening
tendered. The rate shall include the cost of handling, provision of false work and
labour necessary to forming opening or building in at the required position. The
rate shall be measured according to the opening size.
L.25

1.52
Measurement of Grouting Back The Opening

Payment for grouting back the opening shall be made at the rate per opening
tendered. The rate shall include the cost of handling, provision of falsework,
labour, material and equipment necessary to complete grout the gap. The grout
shall be either ordinary Portland Cement or Non-shrink grout. The rate shall be
measured according to the opening size. The work could only be considered
complete after it has passes the water tightness test.
1.53
Measurement of Pre-Cast Concrete

Items for pre-cast concrete shall include the manufacture and fixing in the works of
the pre-cast units and all works in connection therewith as specified.
Pre-cast concrete shall be measured as fixed in the works by numbers of units, by
volume, by area or by length as indicated in the Bill of Quantities. Measurement
(except where by numbers) shall include the space occupied by joints between units
but not by bedding. Otherwise all measurement shall be net except that no
deduction shall be made in respect of any purpose formed hole, duct or the like
which has an average cross-sectional area less than 2500 sq.mm.
No separate measurement for payment shall be made in respect of formwork,
surface finishes, reinforcement, joggles, dowels, jointing, bedding or the like for precast concrete unless separate items are expressly provided in the Bill of Quantities.
Pre-cast pre-stressed concrete and all work in connection therewith as specified shall
be valued by the measurement of only such items as are provided in the Bill of
Quantities.
1.54
Sizes and Sequence of Concrete Pours

Before commencing concreting the Contractor shall submit for approval his detailed
proposals for the sequence of placing concrete and the positions of vertical and
horizontal construction joints. The proposals shall comply with the following :Where limitations in lengths of floor or roof slabs that may be cast without joints in
any direction are stated on the Drawings, the slabs shall be subdivided by
construction joints into panels of dimensions not exceeding the stated limit on
length. The panels shall be separately concreted in one continuous operation and
no panels shall be concreted until the concrete in adjacent panels is at least 7 days
old.
Where limitations in lengths of wall that may be cast without joints are stated on the
Drawings they shall be divided into segments not exceeding the stated maximum
length by vertical joints which are continuous with the floor joints and extend the
full height of the walls in an unbroken alignment. Each segment above the top of
the wall haunch and the top of the wall shall be cast in a series of lifts each of a
length and height to be approved by the S.O.
Alternate segments in a lift shall be concreted and an interval of 7 days shall elapse
before the intervening segments in the same lift are concreted.
L.26

At each joint rebates shall be formed to receive sealing compounds as shown on the
Drawings.
Each segment of the wall footing and haunch defined by the floor and wall joints
shall be concreted in one continuous operation. Segments shall be concreted
alternately and an interval of at least 7 days shall elapse before intervening segments
are concreted.
1.55
Cleaning to Water Retaining Structures

All water retaining structures shall on completion, be carefully cleaned as follows:-
1.56
(a)
The structure shall be cleared of all debris and shall be brushed down on all
internal faces with a stiff broom while still dry, and all resulting debris
removed; all associated reservoir pipework shall be cleaned in accordance
with the specification requirements.
(b)
The structure shall then be flooded with approximately 75 mm of clean water

and the whole of the internal faces shall be carefully brushed down with stiff
brooms, using the water continuously until all faces are clean; the water shall
then be drained off, and the walls and floors hosed and flushed with clean
water until perfectly clean.
Testing of Water Retaining Structures

As soon as possible after completion of water retaining structures but not before the
concrete has attained its specified 28 day strength they shall be tested for water
tightness by filling with water up to the designed top water level. The rate of filling
shall be reasonably constant and shall not exceed 2 m of depth in 24 hours except
in the case of small structures where a higher rate may be allowed by the
Contractor. After filling the structure shall be allowed to stand full (being topped up
as necessary) for at least 72 hours, for absorption of water by the concrete to take
place, at the end of which period the level shall be accurately noted. The structure
shall then be tested for a further period of at least 72 hours (48 hours in the case of
channels and smaller structures as agreed) and shall be accepted as watertight if :(i)
No leaks or damp patches on the backs of walls are discernible during period
of the test (if the backs of walls are wetted by rainfall or any other cause the
test must be delayed until they are dry for at least 72 hours). In the case of
individual parts of a structure being tested independently, the division walls
also must be watertight.
(ii)
The floor under drainage system of the structure (if any) remains dry, or the
flow in it before the test is not increased as a result of filling the structure with
water;
(iii)
The recorded change in level of the water in the structure minus the loss of
water by evaporation gives a figure which does not exceed 1/2000 of the
depth of water originally in the structure.
L.27

During the 72 hour test period referred to above the loss of water by evaporation
shall be determined by measurement of the loss of water from a shallow watertight
tray of 0.4 sq.m in area containing not less than 75 mm depth of water and
positioned to float on the surface of the water in the structure.
The roofs and manhole covers of the closed reservoirs shall be tested for watertightness before the laying of any roof membrane by general observation from
within the reservoir for damp patches or leaks over a period of heavy and prolonged
rain but should such a suitable occurrence fail to happen, the roof and fittings shall
be hosed down vigorously and this shall be repeated in such a way as to keep the
roof wet for 3 successive days.
The roof and fittings shall be deemed satisfactory for water-tightness if there are no
discernible leaks or damp patches from inside the reservoir. Remedial measures
and retesting shall be carried out at the Contractor's expense until satisfactory.
Should any parts of the structure fail the above tests in any respect, the Contractor
shall immediately take steps to ascertain the nature and positions of any defects or
leakages, shall empty the structure, and remedy the defects in an approved manner.
Note that a damp patch appearing on the outside of the wall must be rectified from
the water face, a repair making the outer face only watertight shall not be approved;
this applies to bobbin holes also.
When the remedial work has been completed in an approved manner, the testing
and if necessary rectification shall be repeated until a satisfactory test is achieved.
If necessary, in extreme cases of lack of water-tightness, the structure or any member
or section of a member thereof may be rejected.
Any expense in materials (including the supply of water), plant labour and all other
costs including overheads and profit involved in the satisfactory water-tightness
testing of all the water retaining structures in the works shall be included in the rates
entered by the Contractor in the Bill of Quantities.
Any costs, incurred by the Contractor in remedial or replacement work necessary to
achieve the satisfactory testing shall be entirely at the expense of the Contractor.
1.57
Disinfection of Water Retaining Structures

Disinfection of water retaining structures shall be carried out by the Contractor after
these structures have passed the water-tightness test.
The structure shall be emptied. The internal surfaces of the walls, the internal
surface of the roof, the internal and external surfaces of all pipes and specials inside
the structure, and all other surfaces inside the structure shall be vigorously brushed
and flushed with jets of clear, clean water until all foreign materials, dirt and grit
which may have accumulated thereon are removed. All water and material
accumulated in the cleaning operation shall be discharged or otherwise removed
from the structure.
L.28

The Contractor shall provide evidence to the satisfaction of the S.O. that the
chlorine dosage proposed for sterilisation will not adversely affect joint sealant
materials.
Chlorination shall be carried out by Method 1 or Method 2 as set out below. The
Contractor shall submit details of his proposed method of working to the S.O. for
approval before commencing disinfection of any structure.
Method 1
The structure shall then be filled to the overflow level with potable water to which
enough chlorine is added to provide a free chlorine residual throughout the
structure of not less than 10 mg/l at the end of the appropriate retention period.
This shall be not less than 6 hours when the water entering the structure has been
chlorinated uniformly by gas-feed equipment or chemical pump or not less than 24
hours when the structure has been filled with water which has been mixed with
calcium hypochlorite or sodium hypochlorite within the structure. The procedure
set out in AWWA C652 shall be followed.
At the end of the retention period the free chlorine residual shall be reduced to not
more than 2 mg/l by draining and refilling or blending with potable water having a
low chlorine concentration, after which the water within the structure shall be
sampled to determine the free chlorine residual and for bacteriological analysis to
check for the absence of coliform organisms of faecal origin. If the results are
unsatisfactory the structure shall be drained and the disinfection procedure shall be
repeated. The costs of any re-testing shall be borne by the Contractor.
Method 2
A solution of 200 mg/l available chlorine shall be applied directly to all surfaces of
the structure which would come into contact with water by suitable brushes or
spray equipment. The disinfected surfaces shall remain in contact with the strong
chlorine solution for at least 30 minutes after which potable water shall be admitted
and the structure shall be filled and tested for bacteriological quality as in Method 1.
1.58
Chlorine Bearing Solution/Mixture for Disinfection

The chlorine bearing solution/mixture shall be prepared using clear, clean water and
chlorine, either as liquid chlorine, calcium hypochlorite or sodium hypochlorite.
Liquid chlorine shall be introduced into the water filling the structure to give a
uniform concentration during the entire filling operation. Portable chlorination
equipment shall be carefully operated and shall include a liquid chlorine cylinder,
gas flow chlorinator, chlorine ejector, safety equipment and an appropriate solution
tube to inject the high concentration chlorine solution into the filling water. The
solution tube shall be inserted through an appropriate valve located on the inlet
pipe and near the structure so that the chlorine solution will mix readily with the
inflowing water.
L.29

Calcium hypochlorite granules, broken to a size not exceeding 0.6 mm maximum

dimension, may be poured into the structure from an opening or placed inside on
dry surfaces prior to the introduction of flowing water. They shall be so positioned
that a current of water circulating around the structure shall dissolve them during
the filling operation.
Sodium hypochlorite shall be applied to the water entering the structure by means
of a chemical feed pump, or shall be applied by hand-pouring into the structure and
allowing the inflowing water to provide the desired mixing.
1.59
Sealing Compounds
Sealing compounds for horizontal construction joints shall be hot applied
bituminous sealants complying with the requirements of BS 6213. Sealing
compounds for vertical and inclined construction joints shall be bituminous putty of
a quality approved by the S.O.'s Representative. Both sealing compounds shall be
capable of expanding to 110% of their original thickness between parallel faces
without separation.
Horizontal floor joints and vertical and inclined joints to be filled with the sealing
compound shall first be thoroughly cleaned and dried and an approved primer
compatible with the sealing compound shall be applied. Each primer and sealing
compound shall be applied in accordance with the manufacturer's
recommendations for tropical climates.
Sealing compounds for expansion and contraction joints shall be polyuretane or
polysulphide liquid polymer sealants complying with BS 6213 obtained from
approved manufacturers. The sealing compound shall be capable of expanding to
133% of its original thickness between parallel faces without extruding and of
contracting to 67% of its original thickness without separation.
Expansion and contraction joints to be filled with the sealing compound shall first
be thoroughly cleaned and dried and an approved primer compatible with the
sealing compound shall be applied. Both primer and sealing compound shall be
applied in accordance with the manufacturer's recommendations for tropical
climates.
1.60
Joint Fillers
Joint filler shall either cork joint filler or cellular joint filler.
Cork joint filler shall be waterproof and rotproof and shall not extrude as a result of
compression. Cork joint filler shall compress to less than 50% of its original
thickness with immediate recovery to 80% or more of its original thickness.
Cellular joint filler shall be preformed low-compression joint filler made from foam
rubber. Cellular joint filler shall recover to its original thickness after each loading
and unloading.
L.30

1.61
Waterstops
Waterstops shall be of rubber or PVC and shall be of a type and manufacture
approved by the S.O. The Contractor shall carefully follow the manufacturer's
instructions in any work involving the incorporation of waterstops into structures.
Waterstops shall be fully continuous when laid and site joints shall be limited to
simple butt joints which are to be made with the manufacturer's fusing jig. A
careful check shall be made on all joints after completion to ensure that no
imperfections exist.
Waterstops shall be securely held in position by the formwork or by means to be
approved by the S.O. and the concrete shall be carefully worked around the
waterstops to ensure that they are completely embedded and that no air pockets will
exist.
1.62
Movement Joints
Movement joints are defined as all joints intended to accommodate relative
movement between adjoining parts of a structure, special provision being made
where necessary for maintaining the water tightness of the joint. The Contractor
shall comply with the instructions of manufacturers of proprietary jointing materials
and shall, if required by the S.O., demonstrate that the jointing materials can be
applied satisfactorily.
The Contractor shall submit to the S.O. for his approval, as soon as practicable after
the acceptance of his Tender and not less than three weeks before the
commencement of concreting, details of his proposals for the installation of
waterstops. These shall show where joints are to be located and details of the
intersections and changes of direction to a scale that shows the position of any joint
or shape of any moulded section.
As far as possible jointing on Site shall be confined to the making of butt joints in
straight runs of waterstops. Where it is agreed with the S.O. that it is necessary to
make an intersection or change of direction or any joint. Other than a butt joint in a
straight run, on Site, a prefabricated joint intersection or change of direction piece
shall be made and submitted to such tests as the S.O. may require.
Flexible waterstops shall be fully supported in the formwork, free of nails and clear
of reinforcement and other fixtures. Damaged waterstops shall be replaced and
during concreting care shall be taken to place the concrete so that waterstops do not
bend or distort.
The surface of set concrete in a movement joint shall, where specified on the
Drawings, be painted with two costs of bituminous paint and fresh concrete shall be
placed against it only when the paint is dry. Expansion joints shall be formed by a
separating strip of approved preformed joint filler.
L.31

Caulking grooves shall be provided as shown on the Drawings. At all joints where a
caulking groove is formed, immediately prior to caulking, the groove shall be wire
brushed and loose material removed and blown out by compressed air. After the
groove has dried it shall be primed and caulked with approved jointing compound
applied in accordance with the manufacturer's instructions. At all caulked joints,
the face of the caulking strip and 25 mm width of concrete on either side shall be
painted with two coats of paint having the same base as the caulking compound.
1.63
Structural Tests
The S.O. may, if required, call for loading test on the structure, and for floors, roofs
and similar structures. The test load shall be up to 1 times the design
superimposed load for the areas to be tested. The test load shall not be applied
within 84 days of the casting of the appropriate concrete, and temporary timber
supports, in case of failing, must be immediately available. The test shall be
satisfactory if upon removal of that load the residual deflection does not exceed one
quarter of the maximum deflection after 24 hours loading. If the residual deflection
exceeds this amount, the test is to be repeated and if residual deflection is as above,
this may be considered satisfactory. All measurements and levels of the second test
are to be entirely independent of the first test.
The S.O. may deem tests necessary because :(a)
Site made test cubes failed to attain specified strengths.
(b)
Shuttering was prematurely removed.
(c)
Overloading occurred during stages of construction or while concrete was

immature.
(d)
Concrete was improperly cured.
(e)
Any other circumstances attributed to alleged negligence by the Contractor.
(f)
Any other reason.
If the loading test be made wholly or in part for reason (a), the test shall be at
Contractor's own cost; if for reason (b) to (e) inclusive, then if the test be satisfactory
the Contractor shall be reimbursed for the cost of the test; if for reason (f) Contractor
shall make the test and be reimbursed for the cost of same, whatever the test result.
If the result of the loading test be unsatisfactory the S.O. may instruct that the part of
the works concerned be taken down or removed and reconstructed to comply with
this Specification, or that such remedial measures shall be taken as to make the
works secure. If the test was made for one or more of the reasons (a) to (e)
inclusive, as detailed above, the Contractor shall take down or remove and
reconstruct the works or take such remedial measures as the S.O. may instruct, all at
his own cost.
L.32

First Editon : May 2007
M FORMWORK
1.1
FORMWORK
1.1
Scope
This section covers the supply, erection and removal of formwork, the finishes
to be attained and the remedial action to be taken to the finished concrete after
removal of formwork.
1.2
Submissions
When required by the S.O., the contractor shall submit calculations and designs
for formwork including of layout of panels, before fabrication commence.
1.3
Materials
Formwork shall be constructed of timber, sheet metal or other approved
materials. The Contractor shall also furnish all struts, braces and ties to
withstand the placing and vibrating of concrete, all construction loads and the
effects of weather.
Form ties shall be rod and cone or other approved proprietary type. They shall
be designed so that no part remaining embedded in the concrete after formwork
has been removed shall be nearer than 50 mm from the surface in the case of
reinforced concrete and 150 mm in the case of unreinforced concrete.
Form ties for use in water-retaining structures shall incorporate a diaphragm not
less than 50 mm diameter welded to the mid point of the tie, designed to
prevent water passing along the tie.
1.4
Design and Detailing

The Contractor shall be responsible for the adequacy and safety of formwork.
On formwork to external faces which will be permanently exposed, all
horizontal and vertical formwork joints shall be so arranged that joint lines shall
form a uniform pattern on the face of the concrete. Where the contractor
proposes to make up the formwork from standard sized manufactured formwork
panels, the size of such panels shall be approved by the S.O. before they are
used in the construction of the work. The finished appearance of the entire
elevation of the structure and adjoining structures shall be considered when
planning the pattern of joint lines caused by formwork and by construction
joints to ensure continuity of horizontal and vertical lines.
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M.1

1.5
Formed Surfaces - Class of Finish

Finishes to formed surfaces of concrete shall be classified as F1, F2 or F3 as
specified in Section 2.3. Where the class of finish is not specified the concrete
shall be finished to Class F1.
Formwork for class F3 finish shall be lined with panels of non-staining material
with a smooth unblemished surface such as sanded plywood or hard
compressed fibre board. The panels shall be as large as possible and shall be
arranged in a uniform approved pattern and fixed to back formwork by oval
nails. Unfaced wrought boarding or standard steel panels will not be permitted.
Ribbed finishes shall be formed by a backing of sanded plywood or hard
compressed fibre board, as described for a Class F3 finish, against which timber
battens are fixed. Battens shall have clean, sharp arises at base and be stopped
with a waterproof filler and sanded to give a smooth surface. Battens shall be
securely fixed to the backing by adhesive and screws to prevent the penetration
of grout behind them.
Formwork for Class F2 finish shall be faced with wrought tongued and grooved
boards or plywood or metal panels arranged in a uniform approved pattern free
from defects likely to detract from the appearance of the surface.
Formwork for Class F1 finish shall be constructed of timber, sheet metal or any
suitable materials which will prevent loss of grout when the concrete is
vibrated. Surfaces subsequently to be rendered, plastered or tiled shall be
adequately scabbled or roughened as soon as the formwork is removed to
reduce the irregularities to not more than half the thickness of such rendering,
plastering or bedding for tiles and to provide a satisfactory key.
1.6
Erection of Formwork
All formwork shall be soundly constructed, firmly supported, adequately
strutted, braced and tied to withstand the placing and vibrating of concrete,
construction loads and the effects of weather. Formwork shall not be tied to or
supported by reinforcement.
Faces of formwork in contact with concrete shall be free from adhering foreign
matter, projecting nails and the like, splits or other defects, and all formwork
shall be clean and free from standing water, dirt, shavings, chippings or other
foreign matter. Joints shall be sufficiently watertight to prevent the escape of
mortar or the formation of fins or other blemishes on the face of the concrete.
All exposed exterior angles on the finished concrete of 90 deg. or less shall be
given 20 mm by 20 mm chamfers.
M.2

Formwork shall be provided for the top surfaces of sloping work where the
slope exceeds 15 deg. from the horizontal (except where such top surface is
specified as spaded finish) and shall be anchored to enable the concrete to be
properly compacted and to prevent air being trapped.
Formwork in contact with the concrete shall be treated with a suitable nonstaining mould oil prior to reinforcement and concrete placement to prevent
adherence of the concrete. Care shall be taken to prevent the oil from coming
in contact with reinforcement or with concrete at construction joints. Surface
retarding agents shall not be used unless specified.
Where ties are built into the concrete for the purpose of supporting formwork,
the whole or part of any such supports shall be capable of removal so that no
part remaining embedded in the concrete shall be nearer than 50 mm in the
case of unreinforced concrete. Holes left after removal of such supports shall be
neatly filled with well rammed dry-pack mortar.
Openings for inspection of the inside of the formwork, for the removal of water
used for washing down and for placing concrete shall be provided and so
formed as to be easily closed before or during placing concrete. Before placing
concrete all bolts, pipes or conduits or any other fixture which are to be built in
shall be held fast by fixing to the formwork or otherwise. Holes shall not be cut
in any concrete without prior approval of the S.O.
1.7
Removal of Formwork
Formwork shall be so designed as to permit easy removal without resorting to
hammering or levering against the surface of the concrete.
The periods of time elapsing between the placing of the concrete and the
striking of the formwork shall be as approved by S.O after consideration of the
loads likely to be imposed on the concrete and shall in any case be not less than
the periods shown in the following table. Where soffit formwork is constructed
in a manner that allows the removal of the majority of the formwork and the
retention during and after such removal of a sufficient number of adequate
supporting props in an undisturbed condition, the Contractor may with the
agreement of the S.O. remove the formwork at the earlier times listed below
provided that the props are left in position and are not disturbed during removal
of the majority of the formwork.
M.3

Position
Time for striking using ordinary

Portland cement under normal
weather days
Beam sides, walls and columns
Slabs (props left under)
Props to slabs
14
Beams soffits (props left under)
10
Props to beams
21
Notwithstanding the foregoing, the Contractor shall be held responsible for any
damage arising from removal of formwork before the structure is capable of
carrying its own weight and any incidental loading.
1.8
Building in Plant
The Contractor shall erect all formwork, struts and other temporary work to
enable plant to be built in, and such formwork shall be designed to allow
placing of the concrete, mortar or grout so as to fill the voids completely, and to
enable air to escape from any cavities during filling.
The formwork shall be sealed against pipework and other items of plant to
prevent leakage of grout.
Formwork shall be supported independently of all plant and pipework. The
Contractor shall use such templates and moulds as are necessary to achieve the
accurate positioning of such items.
1.9
Dry-Pack Mortar
Dry-pack mortar for filling holes and repairing surface blemishes shall be made
from one part by weight of cement and three parts fine aggregate passing a 1
mm sieve. The colour of the mortar shall match that of the surrounding
concrete. The mortar shall be mixed with only sufficient water to make the
materials stick together when being moulded in the hands.
The dry-pack material shall then be placed and packed in layers having a
thickness not greater than 15 mm. The compaction shall be carried out by use
of hardwood stick and hammer and shall extend over the full area of the layer,
particular care being taken to compact the dry-pack against the sides of the hole.
After compaction the surface of each layer shall be scratched before further
loose material is added. Holes shall not be over filled and the surface shall be
M.4

finished by laying the hardwood block against the dry-pock fill and striking the
block several times. Steel finishing tools shall not be used and water shall not
be added to facilitate finishing.
1.10
Defects in Formed Surfaces

Workmanship in formwork and concreting shall be such that concrete shall
require no making good, surfaces being perfectly compacted and smooth.
Any surface blemishes shall be repaired by the Contractor, at his expense, to the
satisfaction of the S.O. immediately after removal of formwork. Any remedial
treatment to concrete surfaces shall be agreed with the S.O.
No rendering of finished surfaces to make good shall be allowed.
Any concrete the surface of which is found to have been treated before
inspection by the S.O. shall be rejected.
Remedial measures may include, but shall not be limited to, the following:
Holes left by the formwork supports shall be thoroughly cleaned out to
remove all loose material and the sides shall be roughened, if necessary,
to ensure a satisfactory bond : they shall then be filled with an approved
proprietary epoxy resin mortar or with dry-pack mortar if agreed by S.O;
Fins, pinhole bubbles, surface discolouration and minor defects may be
rubbed down with sacking and cement immediately the formwork is
removed;
Abrupt and gradual irregularities may be rubbed down with carborundum
and water after the concrete has been fully cured;
Small defects and minor honeycombing shall be chipped out normal to
the face of the concrete to a depth of at least 25 mm and filled with an
approved proprietary epoxy resin mortar or with dry-pack mortar if agreed
by the S.O.
Where deeper or more extensive defects occur, the Contractor shall obtain the
approval of the S.O. to the methods of repair proposed which may include, but
shall not be limited to, cutting out to a depth of 25 mm with a diamond saw to
give a regular edge to the repair and further chipping to form a hole with
dovetail shape to sound concrete or to a total depth of 75 mm whichever is the
greater. If reinforcing steel is exposed, the concrete shall be removed to a depth
of 25 mm beyond the back side of the reinforcement. Steel mesh reinforcement
shall then be sprung into the dovetail. The void shall be refilled with concrete
or suitable approved epoxy resin mortar.
M.5

The Contractor shall thoroughly clean up any hole or defective area that is to be
filled and where the surface has been damaged the Contractor shall break out
any loose, broken or cracked concrete or aggregate.
Where the remedial work is to be carried out using dry-pack mortar or concrete,
the concrete surrounding the hole shall be thoroughly soaked after which the
surface shall be dried so as to leave a small amount of free water on the surface.
The surface shall then be dusted lightly with cement by means of a small dry
brush until the whole surface that will come into contact with the dry-pack
mortar has been covered and darkened by absorption of the free water by the
cement. Any dry cement in the hole shall be removed.
Dry-pack mortar shall be mixed and placed as specified.
Where concrete is to be used, the concrete mix shall be approved by S.O and
shall be placed and compacted into the hole, using formwork as necessary.
Where the remedial work is to be carried out using epoxy resin mortar or other
specialist material, the surface of the cleaned hole shall be prepared and primed
and the repair material placed, compacted and finished in accordance with the
manufacturer's instructions.
Where in the opinion of the S.O., the defect is too extensive to permit
satisfactory repair, either from the point of view of structural integrity or
appearance, the concrete containing the defect shall be broken out and
replaced.
1.11
Movement Joints
Movement joints for expansion and contraction shall be constructed in
accordance with the details and to the dimensions shown on the Drawings or
where otherwise ordered by the S.O. and shall be formed of the elements
specified.
The Contractor shall pay particular attention to the effects of climatic extremes
about the works on any material which he may desire to use in any movement
joint and shall submit for approval by the S.O. his proposals for the proper
storage handling and use of the said materials having due regard for any
recommendations in this connection made by manufacturers.
Waterstops shall be incorporated into all expansion and contraction joints in
units which retain or exclude liquids.
Different types of waterstop material shall not be used together in any complete
installation. Waterstops shall be fabricated into the longest practical units at the
supplier's works and shall be continuous throughout the structure below highest
water level. Intersections and joints shall be factory made where possible.
M.6

Horizontally placed surface type waterstops shall have an interposing sliding

plane.
Waterstops shall be carefully maintained in the position shown on the Drawings
supported on accurately profiled stop boards to create rigid conditions.
Joint filler shall be either cork joint filler or cellular joint filler. Cork joint filler
shall be waterproof and rotproof and shall not extrude as a result of
compression. Cork joint filler shall compress to less than 50% of its original
thickness with immediate recovery to 80% or more of its original thickness.
Cellular joint filler shall be of preformed low-compression joint filler made from
foam rubber. Cellular joint filler shall recover to its original thickness after each
loading and unloading.
The joint filler shall be fixed to the required dimensions of the joint cross
section and shall provide a firm base for the joint sealer. Where the depth of
joint between the concrete surface and the water stop does not exceed 500 mm
a filler shall be placed in single depth sections.
Sealing of movement joints shall be carried out only when adjacent concrete
surfaces are perfectly dry.
Immediately before the application of the joint sealer the groove protection
batten shall be removed in such lengths as represent a single days work for
sealing the joints.
The joint grooves shall be cleaned, adequately primed and filled with approved
sealer strictly in accordance with the manufacturer's instructions.
On permanently exposed areas of structures joint sealing is to be carried out
with the aid of masking tape to form neatly defined surface limits to the sealer.
1.12
Sliding Planes and Joints

Sliding planes on the concrete blinding layer shall consist of a bitumen sand
mixture 1 to 4 by volume spread evenly 3 mm thick over the carpet coat or of
building paper either of which shall be applied immediately before the
structural floor is concreted and shall be at all times suitably protected. Where
building paper is used the concrete formation carpet shall be finished with a
steel trowel to give a smooth surface.
Sliding joints shall consist of one layer of bituminous felt, as B.S. 747 Type IC of
weight 1.36 kilograms per square metre, to each of the complementary contact
surfaces. Alternatively, and subject to the approval of the S.O. sliding joints
may comprise two layers of purpose made preformed plastic membrane which
M.7

when in contact shall give a coefficient of friction of not more than 0.2 when
subjected to a load of 270 kN/sq.m.
Where formed in concrete structures the lower joint bedding surface shall be
steel float finished to a smooth true surface.
1.13

Before concrete is placed against any formwork, the formwork shall be
inspected and approved by the Contractor and offered for inspection by the S.O.
If a "pour-card" system is in operation, the card shall be signed by the contractor
and submitted to the S.O. with the request for inspection of the formwork.
1.14
Measurement of Formwork
Formwork and all work in connection therewith as specified for each surface
finish of classes F1, F2 and F3 shall be valued by measurement of only such
items as are provided in the Bill of Quantities under the following categories :Vertical formwork
Battered formwork
to faces of concrete which are vertical

: to faces of concrete battered at less than 45 deg. from
the vertical
Soffit formwork
to under-faces of concrete, either horizontal or sloping

at an angle not exceeding 45 deg. from the horizontal,
including for cambering of beams.
Top-face formwork
to top faces of concrete sloping at more than 15 deg.

and not exceeding 45 deg. from the horizontal. Top
face of concrete sloping at 15 deg. or less from the
horizontal shall be classed as unformed surface finish
and shall not measured fro payment for formwork
except where such faces occur in openings, chases,
rebates and other similar features. No top-faces of
concrete surfaces having a spaded finish shall be
measured for payment regardless of its slope.
Curved formwork
to faces of concrete curved to a single radius in one

plane. Formwork to faces of concrete for other curved
surfaces shall be separately measured under items that
are particularly described.
M.8

Main formwork shall be measured as the net area of formwork in contact with
the surface of concrete it is required to support. Formwork for special features
of any kind including fillets, shall not be measured for payment except to the
extent that separate items for such features are provided in the Bill of Quantities.
Provided that in the case of a fillet or chamfer which is being measured under
an item for main formwork and whose width on the splay is less than 150 mm
the measurement shall be calculated from dimensions extending to the point of
the intersection of the concrete faces as if the angle had been formed without
fillet or chamfer.
No deduction from the measurement of formwork shall be made in respect of;
(i)
The area occupied by in-situ pipes or ducts of any size passing through the
formwork.
(ii)
The area occupied by the face of any purpose-formed hole or opening in

the concrete behind the formwork whose area is less than or equal to one
sq metre.
Where the Contractor's methods of construction provide, with the permission of

the S.O. for concrete to be supported by some means other than purpose-made
formwork (e.g. against the face of an excavation) then such alternative support
shall be measured as if it were formwork to the extent that it would otherwise
have been so measured. Provided that such support shall not be measured as
formwork in any case where it is specified that concrete shall be placed against
undisturbed ground or excavated faces.
Notwithstanding anything in this clause, where formwork is stated as being
included in other work (e.g. in-situ or precast concrete or in bedding and
surround to pipes) it shall not be measured for payment.
Formwork for movement joints and for vertical construction joints shall be
measured only to the extent shown on the Drawings or otherwise directed by
the S.O., and shall further include for all work necessary to accommodate any
reinforcement passing through the joint, but unless indicated otherwise any
requirement for water-stops, joint fillers, joint sealing, or painting of joint faces
specified in (movement joints) shall be additionally measured under relevant
items as follows :Water-stops shall be measured as the net length fixed in place, and shall include
for all necessary work in dividing formwork to accommodate the water-stop,
and for the making of any straight butt joints in the water-stop. Other joints,
intersections, or change-of-direction pieces, whether made on site or at factory,
shall be measured extra over items for water-stop.
M.9

Joint filler shall be measured as the net area (or length) fixed in place. Joint
sealing of caulking grooves shall be measured as the net length of joint sealed
and shall include for cleaning, priming and caulking over the joint.
Painting surface of set concrete shall be measured once as the net area painted
with two coats.
M.10

O STEEL REFORCEMENT
1.0
1.1
GENERAL
Scope
This Specification covers detailing, fabricating, supplying and placing of
reinforcing steel and accessories for all cast in place and pre-cast concrete.
The Contractor shall be entirely responsible for the correctness of bar schedules
before arranging for the supply, cutting and bending of steel reinforcement.
1.2
Submission
The following submissions are required to be submitted by the contractor:
(1)
Test Certificates
Manufacturer's test certificates for each delivery of reinforcing steel. Each
certificate shall show the country of origin and test.
(2)
Data
Manufacturer's data on accessories and mechanical couplings.
1.3
Steel Reinforcement
Steel for reinforcement shall be of the following kinds as may be specified or
detailed on the Drawings :
Type R -
hot-rolled plain round mild steel bars conforming to BS4449
Type Y -
either, hot-rolled deformed high yield steel bars conforming to BS

4449 (with geometrical classification Type 2)
or, cold-rolled deformed high yield steel bars conforming to BS

4449 : 1988 (with geometrical classification Type 2)
welded hard drawn steel wire and other cold worked high bond
bar fabric conforming with BS 4483.
Fabric
1.4
Steel Wires and Bars for Prestressing

Prestressing steel wire or bars shall be of the following kinds as specified or
detailed on the Drawings :
(a)
Cold drawn wire or cold drawn and stress relieved wire conforming with
BS 5896.
(b)
Stress relieved seven-wire strand conforming with BS 5896.
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O.1

(c)
1.5
Cold worked high tensile alloy steel bars conforming with BS 4486.
Accessories
The Contractor shall supply all accessories such as reinforcing steel supports,
hold-downs, spreaders, hangers, tie wire and all other incidentals necessary to
complete an acceptable installation of all steel reinforcement. All accessories
shall be of steel with the exception of spacers to maintain concrete cover to
reinforcement against formed or blinded surfaces which shall be of concrete of
same texture, colour and composition as cast-in-place concrete. Concrete
spacers shall be in the form of a truncated cone or pyramid and shall be used
with the larger face towards the reinforcing steel. The smaller face of a
truncated cone or pyramid shall have a maximum dimension of 50 mm.
1.6
Detailing
1.7
Steel reinforcement shall be as shown on the Drawings. The contractor shall be

responsible for checking the Drawings before cutting and bending
reinforcement. When any information relating to reinforcement is missing or
apparently incorrect, the Contractor shall remedy the missing or incorrect
information to the approval of the S.O.
Cutting and Bending of Reinforcement
Bars shall be cut and bent in accordance with the provisions of BS 4449. All
bending shall be done cold with the use of an approved bending machine. Rebending of bars will not be permitted. Cut and bent bars shall be bundled and
labeled for positive identification with the Drawings and bending schedules,
until they are incorporated into the work.
1.8
Storage of Reinforcing Bars and Fabric

The Contractor shall stack separately and label different types of reinforcement
for position identification.
Steel reinforcing bars shall be kept clean and shall be free from pitting, loose
rust, mill scale, oil, grease, earth, paint, or any other material which may impair
the bond between the concrete and the reinforcement.
Reinforcing steel shall be stored and fabricated under cover on wooden or
concrete supports such that the steel is elevated from the ground surface by a
minimum of 150 mm.
1.9
Storage of Pre-Stressing Wire and Bars

In addition to complying with the above storage requirements, the contractor
shall ensure that pre-stressing wire and bars are protected from mechanical
damage by storing on timber supports above a concrete slab, and shall ensure
that during storage the wire and bars are kept properly coated with water
soluble oil inside protective wrappings.
O.2

1.10
Fixing of Reinforcement
All reinforcement shall be securely and accurately fixed in positions shown on
the Drawings using approved spacer blocks or chairs. All intersections of bars
shall be secured with No. 16 gauge (1.60 mm) soft iron wire, the ends being
turned into the body of the concrete. The contractor shall ensure that all
reinforcement is maintained in position at all times, particular care being taken
during placing of concrete.
Concrete cover to reinforcement shall be as specified or detailed on the
Drawings, and shall be maintained in accordance with the tolerance specified in
BS 8110. Correct concrete cover to reinforcement shall be maintained with the
aid of approved spacer pieces. Top reinforcement in slabs shall be maintained
in position by means of chairs, the diameter and quantity being sufficient to
ensure security of the reinforcement in shape and positioO.
No part of the reinforcement shall be used to support formwork, access ways,
working platform, or the placing equipment or for the conducting of an electric
current.
1.11

When required by the S.O., the Contractor shall take samples from
reinforcement delivered to site and shall arrange for the samples to be tested by
an approved testing agency. Test certificates from that agency shall be
submitted to the S.O.
The S.O. or his authorised representative may require to witness such testing
and also routine testing at the manufacturer's works.
The Contractor shall be responsible for all checking and inspection of
reinforcement before preparations for placing concrete are offered for inspection
by S.O.
1.12
Measurement of Steel Reinforcement

Steel reinforcement and all work in connection therewith shall be valued by
measurement of only such items as are provided in the Bill of Quantities.
Bar reinforcement shall be measured as the calculated weight of reinforcement
detailed on the Drawings or otherwise specified and for this purpose the weight
of reinforcement shall be taken as 7.85 kg. per metre per 1000 sq mm of
nominal cross-sectional area. Reinforcement required in compliance with
specified laps of bars shall be included in the weight measured for payment.
Fabric reinforcement shall be measured as the net area of fabric laid and laps
shall not be measured.
In no case shall measurement be made in respect of binding wire, welding,
chairs, spacers, waste in cutting, or any laps introduced by the contractor.
O.3

Notwithstanding anything in this clause, where reinforcement is specified as

being included in other measured work it shall not be measured for payment.
O.4

N - PILING WORK
1.0
1.1
General
Unless otherwise specified, all pilings shall comply in all respects to CP 2004. All
materials and workmanship for piling shall be in accordance with the appropriate
sections of this specification.
1.2
Soil Investigation Reports

Any information and reports on site investigations for the works made available to
Tenderers are intended for guidance only. The S.O. shall not be responsible for the
scope, completeness or accuracy of the information, or for any opinions or
conclusions given in the reports.
1.3
Handling of Piles
All piles shall be handled with great care. Any piles cracked or damaged during
handling shall not be used in the works and shall be replaced by the Contractor at
no extra cost to the Government.
1.4

Piles shall be pitched accurately and driven to the lines and levels as shown on the
drawing. During and after completion of piling, the pile head shall not be more than
75mm off-centre in any one direction from its required position. Piles deflected from
vertical with an eccentricity larger that this shall, where ordered by S.O. be
extracted or re-pitched until the proper line is obtained. No forcible method of
correction will be permitted. The cost of such extraction or re-driving, or any extra
cost in a modified foundation shall be borne by the Contractor if the opinion of the
S.O. such extra works has been occasioned by the negligence of the Contractor.
During driving, the Contractor must ensure that the piles head are properly
protected.
The head of pile shall at all times be central with the hammer and normal to the
length of the pile and the pile shall not run out of position relative to the leaders.
Where cracks or fissures appear in pile while it is being driven, the pile shall be
rejected.
1.5
Pile Driving Plant

The weight of hammer, height of drop and set to be achieved shall be approved by
the S.O. In general, for heavy piles the weight of the hammer shall be at least equal
to the weight of the pile for hard driving conditions and not less than half of the
weight of the pile for easy driving.
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N.1

The plant used for pile driving shall be of such type and capacity with the approval
of the S.O.
1.6
Extension of Piles
As the result of measurements of the driving resistance or load bearing capacity of
piles driven, the S.O. may order the lengths of piles to be modified either by
lengthening in-situ or by providing a longer initial length of pile.
Where piles have to be further extended with extension piles, they shall be brought
up to the required length by addition of an extension pile as shown on the Drawing.
The extension pile shall be placed in alignment and jointed as shown on the
Drawing.
1.7
Piling Programme
The Contractor shall submit to the S.O. his proposed programme for the execution
of the piling work at least seven days before commencement of the work. In
addition, the Contractor shall inform the S.O. daily of the programme of the piling
for the following working day and shall give adequate notice of this intention to
work outside working hours, if this has already been approved by the S.O.
1.8
Records
The Contractor shall maintain a record of driving of all piles giving sets and other
data listed below or as required by the S.O. to whom the records shall be submitted.
All piles shall be driven to such final sets or depths as may be approved by the S.O.
Piling Records shall include the following details:
Contract particulars.
**Pile type.
Pile reference number (location).
Nominal cross-sectional dimensions or diameter.
Length of preformed pile.
Date and time of starting and finishing and redriving.
Ground level at commencement of installation of pile.
Cut - off level
Type, weight, drop and mechanical condition of hammer and equivalent
information for other equipment.
Number of types of packing used and type and condition of dolly used during
driving of the pile.
**Pile driving log.
*Set of pile in mm per blows or number of blows per 25mm of penetration.
*If required, the sets taken at intervals during the driving.
*If required, temporary compression of ground and pile from time of marked
increase in driving resistance until pile reaches its final level.
All information regarding obstructions, delays and other interruptions to be
sequence of work.
N.2

**
e.g. Pre-cast concrete, timber or bakau; vertical or rake;

or tension; friction or and bearing or both.
Not applicable to Bakau piles
compression
Immediately after a pile has been completely driven a record shall be made of the
reduced level of the pile head and further checks shall be made on the level of the
pile head and further checks shall be made on the level of each pile head after the
driving of adjacent piles. Should any pile heave upwards it shall be re-driven to its
original level or, if necessary, until its specified set is again obtained.
Any unexpected driving conditions shall be noted in the records.
1.9
Nuisance and Damage

The Contractor shall take all necessary precaution in carrying out the work to
minimize noise and disturbance during driving.
The Contractor is deemed to have familiarized himself with the risks likely to be
imposed on adjacent structures and all utilities by the proposed method of piling.
Before commencing any piling work, the contractor shall accompany the S.O on a
site inspection in order to consider any circumstances which may indicate the
presence of underground mains at or in the vicinity of the site. If, during execution
of the works damage is, or is likely to be caused to any utilities or adjacent
structures, the Contractor shall submit to the S.O. his proposal for repair or
avoidance of such damage.
1.10
Safety Precaution
The Contractor shall take safety precautions throughout the piling operations in
accordance with the requirements of the relevant laws and by-laws and to the
approval of the S.O.
1.11
Definition
A preliminary pile is a pile installed before the commencement of the main piling
works for the purpose of establishing the driving criteria for subsequent working
piles and for conforming the adequacy of the design, dimensions, and bearing
capacity. The pile shall be treated as a working pile unless otherwise directed by the
S.O.
A working pile is a pile which is installed as part of the permanent foundation
works.
Where a pile test is carried out, the ultimate load is defined as the constant load at
which the pile continue to settle at a steady rate or the load at which the maximum
settlement of the pile test during one continuous loading cycle is one tenth of the
pile base diameter or least dimensions, which ever is the lesser.
N.3

Where a pile test is not carried out, the ultimate load is defined as the calculated
ultimate load, derived from appropriate static bearing capacity calculations.
The design load shall be defined in relation to pile loaded in isolation, without
nearby piles being loaded except those providing test reaction.
Where the ultimate load is measured by means of pile tests, the design load is the
ultimate load divided by the specified factor of safety.
Where the ultimate load is not measured by means of pile tests, the design load is
the lesser of the following:
The calculated ultimate load for the pile divided by the specified factor of
safety.
The calculated load of the pile base together with the calculated shaft
adhesion, as derived from appropriate static bearing capacity calculations
divided by a factor of safety of 3.0
Unless otherwise specified, the factor of safety shall be taken as not less than 2.0 for
piles in compression and not less than 3.0 for piles in tension.
The working load is the design load modified to allow for group effect, pile spacing
or any other factors changing the efficiency of the total foundation from that of a
single isolated pile and is at least equal to the dead plus imposed loads on the pile
together with down drag or up lift loads appropriate.
2.0
PRE-CAST REINFORCED CONCRETE PILES
2.1
General
The materials to be used and workmanship for pre-cast reinforced concrete piles
shall be as specified under concrete works. The type of mix used shall be as those
shown in the Drawings.
2.2
Reinforcement
The main reinforcing bars in piles not exceeding 12m in length shall be in one
continuous length unless otherwise approved by the S.O.
In the piles exceeding 12m long, joints will be permitted in main longitudinal bars
at 12m nominal intervals. Joints in adjacent bars shall be staggered at least 1m apart
along the length of the pile. Joint shall be butt-welded as specified in concrete work.
Other means of jointing reinforcement, such as by means of mechanical couplings
shall be to the approval of the S.O.
2.3
Pile Shoes
The type of pile shoes to be used shall be as shown in the Drawings and shall
comply with the following as relevant :
N.4

Chilled-hardened cast iron shoes as used for making grey iron casting to BS
1452, Grade 10; or
Mild steel to BS 4360, Grade 50B; or
Cast steel to BS 3100, Grade A.
Mild steel straps cast into the shoes shall be as shown in the Drawings. Rock shoes
where required shall consist of wrought iron shoes and mild steel straps cast into
chilled-hardened cast iron blocks, as shown in the Drawings.
2.4
Formwork and Casting of Pile

Pile units shall be cast in one continuous operation on a horizontal platform in
approved moulds to the dimensions as shown in the Drawings. The moulds shall be
thoroughly cleaned before casting and the assembled reinforcement lowered into
the mould and held in position from top. Lifting holes shall be formed during casting
in the positions and in accordance with the details shown in the Drawings.
After casting the piles, shuttering shall be removed in the presence of the S.O.
Failure by the Contractor to observe this requirement may result in rejection of the
pile concerned. Any pile showing signs of honey combing or other defects on
removal of the shuttering shall be repaired to the approval of the S.O. before it is
used in the works.
2.5
Curing, Stripping, Handling and Storage of Piles

Piles shall be kept damp for a period of at least 10 days after casting. Side shuttering
may be stripped after 4 days and bottom boards 14 days after casting, provided the
piles are kept supported on level blocks spaced not more than 2 metres apart. After
14 days the piles may be lifted and removed to a suitable stacking point, but no pile
shall be driven until it is at least 28 days old.
Each pile shall be clearly marked with date of casting and graduated in 300mm by
painting. All stacks shall be arrange to facilitate the removal of piles for driving in
their correct age order.
The method and sequence of lifting, handling, transporting and storing piles shall be
such that piles are not damaged. Only the designed lifting and support points shall
be used. During transport and storage, piles shall be placed on adequate supports
located under the lifting points of the piles.
2.6
Tolerance in Piles Dimension

The cross-sectional dimensions of the pile shall not be less than those shown in the
Drawings and not exceed them by more than 6mm.
Any face of the pile shall not deviate by more than 6mm from a straights edge 3m
long laid on the face, and the centroid of any cross-section of the pile shall not
N.5

deviate by more than 12mm from the straight line connecting the centroids of the
end faces of the pile.
2.7
Length of piles
The length of a pile shall be taken to the mean overall length measured from the tip
of the shoes to the top of the head. The length of the piles to be cast shall be to the
approval of the S.O. Based on the results of piles driving resistance and/or load tests
carried out on piles driven on the site, the S.O. may from time to time order the
lengths of piles to be modified.
2.8.
Pitching and Driving

The equipment to be used shall be of such type and capacity to the approval of the
S.O. If drop hammer is used, it shall be of a free fall type and the weight of the
hammer shall be as specified in of CP 2004.
Piles shall be pitched accurately in the positions as shown on the Drawings. At all
stages during driving and until the pile has set or driven to the required length, all
exposed piles shall be adequately supported and restrained by means of leaders,
trestles, temporary supports or other guide arrangements to maintain position and
alignment and to prevent buckling and damage to the piles.
Each pile shall be driven continuously until the specified set and/or depth has been
reached. However, the S.O. may permit the suspension of driving if he is satisfied
that the rate of penetration prior to the cessation of driving will be substantially reestablished on its resumption or he is satisfied that the suspension of driving is
beyond the control of the Contractor.
A follower (long dolly) shall not be used for driving end bearing piles. It may be
used for driving frictional piles with prior approval of the S.O.
The contractor shall inform the S.O. without delay if an unexpected change in
driving characteristics is encountered.
Where required by the S.O., set shall be taken at approved intervals during the
driving to establish the behavior of the piles. A set shall be taken only in the
presence of the S.O. The Contractor shall provide all facilitate to enable the S.O to
check driving resistances.
Redrive checks, if required, shall be carried out in accordance with an approved
procedure.
A detail record of the driving resistance over the full length of each pile shall be
kept. The log shall record the number of blows for every 300mm of pile penetration.
The final set of a pile other than as friction pile, shall be recorded either as the
penetration in millimetres per 10 blows or as the number of blows required to
produce a penetration of 25mm.
When a final set is being measured, the following requirements shall be met:
N.6

The exposed part of the pile shall be in good condition, without damage or
distortion;
The dolly and packing shall be in sound condition;
The hammer blow shall be in line with the pile axis and the impact surfaces
shall be flat and at right angle to the pile and the hammer axis.
The hammer shall be in good condition and operating correctly;
The temporary compression of the pile shall be recorded if required.
Piles shall be driven in an approved sequence to minimize the detrimental effect of
heave and lateral displacement of the ground. When required, levels and
measurement shall be taken to determine the movement of the ground or any pile
resulting from the driving process. If any pile rise occurs as a result of adjacent piles
being driven, the contractor shall submit to the S.O. his proposal for correcting this
and to avoid the same in subsequent work.
If preboring is specified the pile shall be pitched into a hole prebored to the depth
shown on the Drawings, unless otherwise instructed by the S.O.
Jetting shall be carried out only when the Contractors detailed proposals have been
approved and not for the last 3m of the required depth of penetration.
2.9
Repair and Lengthening of Piles

Any damage pile heads shall be cut of square at sound concrete and all loose
particles shall be removed by wire brushing, followed by washing with water. If the
pile is to be subjected to further driving, the head shall be replaced with concrete of
an approved mix. The new head shall be cast truly in line with the remainder of the
pile, and be properly cured and allowed to harden sufficiently to develop the
strength necessary for further driving.
If a pile has been driven to the required set or depth but sound concrete of the pile
is below cut-off level, the pile shall be made good to the cut-off level with concrete
of a mix not inferior to that of the concrete of the pile.
Where piles have to be lengthened, other that by means of welding of steel plates as
detailed in the Drawing, the reinforcement shall be stripped-off all surrounding
concrete for a distance equal to thirty times the diameter of the main reinforcement
measured from the pile head for spliced joints and 300mm for butt welded joints
and all lateral reinforcement shall be removed. The lengthening bars shall butt on
the exposed bars of the same diameter as the main pile bars, 60 diameters in length
and lapping the main bars for a distance of 30 diameters above and below the joint,
and shall be securely bound with 1.63mm soft annealed iron wire. New binders of
similar size shall be provided and spaced at half the centre of the binders in the
main body of the pile and shall be securely bound with 1.63 mm soft annealed iron
wire and the pile extended by correcting in properly constructed moulds to the
length required. Care shall be taken to form the joint between the old and new
concrete as specified, hereinbefore. The extension shall be truly in line with the
N.7

remainder of the pile, and be properly cured and allowed to harden sufficiently to
develop the strength necessary for further driving.
Pile which has been repaired/lengthened by adding cast-in-situ concrete as
described in 2.9 and shall not be driven until the added concrete has reached the
specified strength of the concrete for the pile.
2.10
Cutting and Stripping Pile Head

When a pile has been driven to the required set of depth and after load test has been
carried out, the head of the pile shall be cut off to the level specified or shown in the
Drawings. The length of the reinforcing bars projecting above this level shall be as
shown or specified in the Drawings.
Care shall be taken to avoid cracking or otherwise damaging the rest of the pile. Any
cracked or defective concrete shall be cut away and made good with new concrete
properly bounded to the old.
3.0
STEEL H-BEARING PILES
3.1
Pile Sections and Dimensions

All steel H-bearing pile shall comply with BS 4 with regards to sectional dimensions
and the steel shall comply with the requirements of BS 4360. The section and grade
to be used are as specified or as shown in the Drawings.
3.2
Straightness of Piles
For standard rolled sections the deviation from straightness in millimetres shall not
exceed 1.04 (L- 4.5) where L is the length of pile in metres.
For proprietary sections made up from rolled sections the deviation from straightness
shall not exceed 1/1000 of the length of the pile.
3.3
Strengthening of Piles
Unless otherwise approved by the S.O. the strengthening of the toe of the pile in
lieu of the shoe or the strengthening of the head of a pile shall be made from
material of the same grade as the pile and to the details as shown in the Drawings.
3.4.
Marking of Piles
Each pile shall be clearly marked with indeletable marking at the flanged head
showing the following:
Reference Number
Overall Length
In addition, each pile shall be marked at interval of 300mm along its length before
being driven.
N.8

3.5
Handling and Storage of Piles

All operations such as handling and transporting of piles shall be carried out in such
a manner that damage of piles and their coatings are minimized. Piles that are
damaged during handling and transporting shall be replaced by the Contractor at his
own expense. All damaged and rejected piles shall be removed from the site
forthwith.
Piles within a stack shall be in groups of the same length and on approved supports.
3.6

Pitching and driving of piles shall in accordance with Clause 2.8 as described herein
before under Pre-cast Reinforced Concrete Piles.
3.7
Where lengthening of piles are required, the piles shall be joined by butt-welding
stiffened with plates fillet-welded on all four sides as detailed in the Drawings. All
welding shall be continuous and complying with BS 4449. The type and size of
welding shall be detailed in the Drawings.
3.8

When a pile has been driven to the required set or depth and before encasing in
concrete, the pile shall be cut to within 21mm of the levels shown in the Drawings,
and protective coatings if any shall be removed from the surface of the pile heads
down to a level 150mm above soffit of the concrete. Pile heads shall be constructed
to the details as shown in the Drawings.
4.0
PRESSURE TREATED TIMBER PILES.
4.1
Species of Timber
Unless otherwise approved by the S.O only Kempas (Keempassla Malaccensis) of
approved manufacture shall be used for the Works.
4.2
Definitions
The timber terms used in this specification shall have the meaning assigned to them
in CP 112:1967 on Malayan Grading Rules for Sawn Hardwood Timber (2168)
whichever is applicable.
4.3
Quality
The timber used for the piles shall not be of a lesser quality than the selected
Structural Grades Specified in section J (Stress Grading) of part III of the Malayan
Grading Rules for Sawn Hardwood Timber. The timber shall be free from rot, fungal
or pest attack and any other defects not permitted for its grade.
N.9

4.4
Sizes
The tolerance allowed for the pile shall be as for U.K Standard of CP 112:1967. The
dimension of sawn timber piles shall be within the range of 2mm less and 6mm
greater than their specified cross sectional dimensions. The centroid of any crosssection of sawn timber pile shall not deviate by more than 25mm from the straight
line connecting the centroids of the end faces of the standard length of pile.
4.5
Workmanship
The standard of workmanship shall comply with CP 112:1967 where applicable.
4.6
Preservative Treatment
The method of treatment shall be the full-cell process as described in MS 3.38. The
composition of preservative shall be Type 2 of MS 3.38. The depth of penetration of
preservative when determined by the method described in Appendix H of MS
3.38, shall be a minimum of 25mm. The net dry salt retention in the treated part of
the timber as determined by the method described in Appendix K of MS 3.38 shall
be a minimum of 16kg/cu.metre.
4.7
Inspecting and Testing

The S.O. may require inspection of treatment plant and control testing described in
MS 3.38. Each pile shall be inspected for compliance with this specification before
installation.
4.8
Marking
The treated timber piles shall be permanently marked with an identification which
indicates that they comply with this specification, manufacturers trade mark, charge
number and date of treatment, and the length of the pile.
4.9
Warranty
Before commencement of work the Contractor shall nominate the supplier who shall
be approved by the S.O.
The supplier of the treated piles shall issue a warranty which provides that for ten
years period the treated piles shall be free from, such fungus and insect attack which
may render the supported structure structurally unsound. If it is established that the
defects in the supported structure are due to wood destroying organisms in the pile,
the supplier shall remedy the defect in the structure and its foundation at his own
cost. Subject to the provision of this clause, the actual form of the warranty shall be
approved by the S.O. before the treated piles are accepted for the incorporation
work.
N.10

4.10
Delivery and Stacking

The Contractor shall notify the S.O. of the delivery of timber piles to the site, and
provide the necessary facilities to enable the S.O. to inspect each pile and take
random sampling for net dry salt retention.
Accepted pile shall be marked and stacked in lengths on paving of drained hard
ground. Each piece of pile shall be stacked clear of the ground and have an air space
around it. The pile shall be separated by sticks or blocks placed horizontally to
avoid sagging of the piles. All rejected piles shall be removed from the site
promptly.
4.11
Pile Head
The pile head shall be adequately protected during driving, so that brooming does
not occur.
The pile head shall be fitted with toothed metal plates as approved by the S.O. for
protection against brooming and splitting during normal driving.
In case of hard driving, unless otherwise approved by the S.O. a metal helmet shall
be fitted to the top of the pile. The top of the pile shall first be trimmed to fit closely
into recess of underside of the helmet. A hardwood dolly and, if necessary, a
packing piece shall be used above the helmet.
If during driving the head of the pile becomes excessively broomed or otherwise
damaged, the damaged part shall be cut off, and the helmet refitted.
4.12

Driving of piles shall in accordance with clauses 2.8 on Section 2.0
4.13
Piles shall be provided in one single length of 6.0m each unless otherwise
approved. Any pile driven to the required set at a depth of 6.0m or less shall be one
continuous length.
If jointing is required, piles joints shall be made by using mild steel welded boxes
450mm long fabricated from 5mm thick plates unless otherwise shown in the
Drawings. The internal dimensions of the box shall be 3mm undersize of the pile
cross-sectional dimensions. The joints and the ends of the piles to be jointed shall be
constructed, so that the necessary strength and stiffness are developed at the joint.
4.14
Defects on Piles while Driving

When fissures appear in a pile during driving, which in opinion of the S.O. will
affect its strength, the pile shall be rejected and replaced at the Contractors own
expense.
N.11

4.15

When a pile has been driven to the required set or depth, the head of the piles shall
be cut off square to sound wood and treated with an approved preservative and
waterproof coating to the approval of the S.O.
The pile head shall be embedded for a depth of not less than 150mm in the concrete
cap which shall be at least 150mm thick round the piles.
5.0
PILE TESTING
5.1
General
5.1.1
Type of Tests Necessary

The Maintained Load Test shall be carried out on a test pile. The Contractor shall,
if required by the S.O. carry out the Constant Rate of Penetration Test on
completion of the Maintained Load Test.
5.1.2
Safety Precautions
When preparing, conducting and dismantling a pile test the Contractor shall carry
out the work in a safe manner and shall in addition make such other provisions as
may be necessary to safeguard against any likely hazards.
5.2
Definitions
5.2.1.
Compression Pile
A pile which is designed to resist an axial force such as would cause it to penetrate
into the ground.
5.2.2
Anchor Pile
A pile which is designed to resist an axial force such as would tend to cause it to be
extracted from the ground.
5.2.3
Test Pile
Compression pile to which a load is applied to determine the load versus settlement
characteristics of the pile and the surrounding ground.
5.2.4
Reaction System
The system of kentledge, piles or anchors that provides a resistance against which
the pile is tested.
5.2.5
Kentledge
The dead weight used in loading test.
N.12

5.2.6

A loading test in which each increment or decrement of load is held constant either
for a defined period of time or until the rate of settlement or rebound falls to a
specified value.
5.2.7
Constant Rate of Penetration Test (CRP)

A loading test in which the pile is made to penetrate the soil from its position at a
constant speed while the force applied at the top of the pile to maintain the rate of
penetration is continuously measured. The force versus penetration relationship
obtain does not represent an equilibrium condition between load and settlement.
5.3
Supervision
All tests shall be carried out only under the direction of an experienced and
competent Contractors Supervisor with approved test equipment and test procedure
as specified hereinafter.
All Contractors personnel operating the test equipment shall have been trained in its
use. Test shall be carried out only in the presence of the S.O.
5.4
Reaction System
5.4.1
General
Compression test shall be carried out using a kentledge, anchor piles or specially
constructed anchorages as reaction system. The reaction system used shall be
designed to transfer safely to the test pile the maximum load required for testing.
Full details of the reaction shall be submitted to the S.O. prior to any work related to
the testing process being carried out on the Site.
5.4.2
Kentledge
Where kentledge is to be used it shall have adequate weight to resist load up to 1.2
times the maximum test load. The kentledge shall be supported on cribwork, beams
or other supporting structures disposed around the test pile so that its centre of
gravity is on the axis of the pile. Kentledge shall not rest directly on the pile head.
The bearing pressure under the supports shall be such as to ensure stability of the
kentledge stacks and shall not impair the efficiency of the testing operations. The
distance from the edge of the test pile to the nearest part of the support to the
kentledge stack in contract with the ground shall not be less than 1.3m.
5.4.3
Anchor Pile and Ground Anchor

Where anchor piles or ground anchors are to be used, they shall be of adequate
strength to resist load up to 1.2 times the maximum test load on the ground in a safe
manner without excessive movement or influence on the test pile. The method
employed in the installation shall be such to prevent damage to any test pile or
working pile.
N.13

The Contractor shall ensure that when the test load is applied, the load is correctly
transmitted to all the bolts and tie rods. The extension of rods by welding shall not
be permitted unless it is known that the steel will not be reduced in strength by
welding. The bond stress of the rod in tension shall not exceed normal permissible
bond stresses of the type of the steel and mix of concrete used.
Where anchor piles are used the centre to centre spacing of the piles from the test
pile shall be not less than three (3) times the diameter of the test pile or the anchor
piles or 2m whichever is the greater. Under-reamed tension piles shall not be used.
Where permanent working piles are approved by the S.O. to be used as anchor
piles, their levels shall be observed during application of the test load to ensure that
there is no residual uplift.
Where ground anchors are used, no part of the section of the anchor transferring
load to the ground shall be closer to the test pile than three (3) times the diameter of
the test pile. Furthermore, no part of the ground anchor shall be closer to a working
pile than one-and-a-half times the diameter of the test pile along the unbounded
length of the anchor, and three (3) times the diameter of the test pile along the
bonded length of the anchor. Under-reams on ground anchors shall not exceed
180mm in diameter.
5.5
Testing Equipment
The Contractor shall ensure that when the hydraulic jack and load measuring device
are mounted on the pile heads, the whole system will be stable up to the maximum
load to be applied.
The test loads shall be applied by means of a hydraulic jack of adequate capacity
fitted with a load measuring device.
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be
operated under hydraulic pressure shall be capable of withstanding and test pressure
equivalent to one an a half times the maximum test load without leakage.
Where the C.R.P test is required the jack pump capacity shall be adequate to
maintain the required rate of penetration. The permissible extension of the jack shall
be such that the pile can be moved continuously and without repacking for distance
of at least 50mm.
The measuring device shall be of the type approved by the S.O. capable of
registering loads in increments not exceeding 21KN.
The hydraulic jack and measuring device shall be calibrated together to the approval
of the S.O. before and after each series of test whenever adjustments are made to
device or at intervals appropriate for the type of equipment used. Certificates of
calibration shall be submitted to the S.O.
The loading equipment shall be capable of adjustment throughout the test to obtain
a smooth increase of load or to maintain each load constant at the required stages of
maintained loading test.
N.14

5.6
Preparation of a Working Pile to be Tested
5.6.1
General
If a test is required on a working pile the Contractor shall prepare the pile for testing
to the approval of the S.O.
5.6.2
Driving Records
For each working pile which is to be tested a detailed records of driving shall be
made and submitted to the S.O. daily not later than noon on the next working day.
5.6.3
Cut-off Level
The pile shall terminate at the normal cut-off level or at a level required by the S.O.
However, where necessary the pile shall be extended above the cut-off level of
working piles so that gauges and other apparatus to be used in the testing process
will not be damaged by water or falling debris. If the cut-off level is below ground
level, the pile is not extend and there is a risk of the borehole collapsing, a sleeve
shall be left in place or inserted above the pile, or other approved action shall be
taken.
Adequate clearance shall be given between the top of the pile and the bottom of the
sleeve to permit unrestricted movement of the pile.
5.6.4
Pile Head of Compression Test

For a pile that is tested in compression, the pile head or cap shall be formed to give
a plane surface which is normal to the axis of the pile. An approved mild steel
bearing plate shall be mounted on top of the pile head or cap to accommodate the
loading and settlement measuring equipment and to prevent damage from the
concentrated application of load from the loading equipment.
5.6.5
Notice of Test
The Contractor shall give the S.O. at least 24 hours notice of the commencement of
test.
5.7
Settlement Measurement
An independent reference frame shall be set up to permit measurement of the
vertical movement of the test pile. The support for the frame shall be located not
closer than 2m from the test pile, and shall be rigidly fixed to the ground to a depth
of not less than 1m of concrete surround. In addition, the elevation of the supports
shall be checked frequently with reference to fixed benchmark.
The entire measuring assembly shall be protected against rain, direct sunlight and
other disturbances that might affect its reliability. Temperature readings shall be
taken when requested by the S.O. The measurement of pile movement shall be
made by four dial gauges rigidly mounted on the reference frame that bear on
machined metal or glass surfaces normal to the pile axis fixed to the pile cap or
head. Alternatively the gauges may be fixed to the pile and bear on surfaces on the
N.15

reference frame. The dial gauges shall be placed in diametrically opposite positions
and be equidistant from the pile axis. The dial gauges shall enable readings to be
made to within an accuracy of 0.1mm and shall have minimum travel of not less
than 50mm.
The Contractor may submit other methods of measuring the movement of pile heads
fro approval.
5.8
Test Procedure
5.8.1
General
Throughout the test period all equipment for measuring load and movement shall be
protected from the effects of weather. Construction equipment and persons who are
not involved in the testing process shall be kept at sufficient distance from the test to
avoid disturbance to the measurement apparatus.
5.8.2

The load shall be applied in increments of 25% of the working load and
appropriately smaller thereafter, until a maximum test load of twice the working
load is reached. Each increment of load shall be applied as smoothly and as
expeditiously as possible. Settlement readings and time observations shall be taken
before and after each new load increment.
A time-settlement graph shall be plotted to indicate when the rate of settlement of
0.05mm in 15 minutes is reached. A further increment of load shall be applied
when this rate of settlement is achieved or until a minimum time of 2 hours has
elapsed, whichever is later. The process shall be repeated until the maximum test
load is reached.
The maximum test load shall then be maintained for a minimum of 24 hours, and
time-settlement readings shall be taken at regular intervals as for the earlier load
stages.
The test load shall then be decreased in four equal stages and time-settlement
reading shall be as described aforesaid until the movement ceases. At least 60
minutes interval shall be allowed between the unloading decrements.
5.8.3
Constant Rate of Penetration Test

The load shall be applied to achieve a constant rate of penetration value varying
between 0.75mm per minute to 1.5mm per minute. The rate chosen shall suit the
jacking equipment used.
Both settlement and time reading shall be recorded at every minute period. Further
loading shall be discontinued when the loading varies indirectly as the penetration
in the case of end bearing piles in sand or gravel, or when the rate of penetration is
constant without further increase in the load in the case of friction piles in clay.
Loading shall then be released gradually and rebound readings taken.
N.16

5.9
Presentation of Results
5.9.1
Submission of Results
Result shall be submitted as a signed summary in duplicate to the S.O. immediately
on completion of the test, which shall give:
For the Maintained Load Test for each stage of loading, the period for which the
load was held, the load and the maximum settlement. These are to be plotted as
time-settlement graphs.
For the CRP test, the maximum load reached and a graph of load against
penetration.
5.9.2
Schedule of Recorded Data

The Contractor shall provide information about the tested pile in accordance with
the following schedule where applicable:
General
Site Location
Contractor Identification
Proposed Structure
Main Contractor
Piling Sub-contractor (if any)
Site Office
Clients Name
Maintained Load or CRP Test
Date of Test
Test Procedure
Weight of Kentledge
Tension of Pile, Group Anchor Details
Plan of Test Arrangement showing position and distance of Kentledge
Supports, Tension Piles and reference frame to Test Piles
Jack Capacity
Method of Load Measurement
Method(s) of Penetration Measurement
Relevant Dates and Times
Test Results
In Tabular Form
In Graphical Form : Load Plotted against Settlement, with Times
Ground Heave (if any)
Effect on Adjacent Structure (if any)
N.17

Site Investigation
5.10
Site investigation Drawing Number

Borehole Reference nearest to Test Pile.
Interpretation of Test Results

The S.Os interpretation and conclusions on the test results shall be final. The pile so
tested shall be deemed to have failed if:
The residual settlement after removal of the test load exceeds 6.50mm: or
The total settlement under the Design Load exceeds 12.50mm;
or
The total settlement under twice the Design Load exceeds 38.0mm, or 10% of
pile diameter/width whichever is the lower value.
5.11
Completion of Test
5.11.1
Measuring Equipment
On completion of a test all equipment and measuring devices shall be dismantled,
checked and either stored so that they are available for use in further tests, or
removed from the Site.
5.11.2
Kentledge
Kentledge and its supporting structure shall be removed forthwith from the Site on
completion of all tests.
5.11.3
Ground Anchors and Temporary Piles

On completion of a pile test, tension piles or ground anchors shall be cut off below
ground level, and the ground made good with approved material.
5.12
Load Testing of Bakau Piles
5.12.1
General
In general, all relevant clauses stated herein before shall apply to the load testing of
bakau piles, except that what is understood as single test pile in these clauses shall
mean a group of test piles for bakau piles.
5.12.2
Arrangement of Test Piles

The load testing of bakau piles shall be carried out on a group of nine bakau piles,
made up of three rows of piles and of three in a row.
N.18

5.12.3
Pile Cap
An approved reinforced concrete pile cap with a column stump shall be cast
centrally over the group of piles to be tested. The column stump shall be short to
ensure stability, and it shall have an approved mild steel bearing plate cast on top.
The loads shall be applied centrally on to the steel plate.
5.12.4
Test Procedure.
The bakau pile shall be tested to failure by the Maintained Load Test as described
herein before. The load on the pile group shall be applied in 6 to 8 equal
increments until failure load is reached. Failure load (i.e. ultimate load) is that load
at which the piles continue to settle at a constant rate without further increase of
load.
For each increment of load, the settlement readings shall be recorded at various time
intervals until the rate of the settlement is less than 0.25mm per hour. The load at
each increment shall be maintained at a constant value throughout the test.
(Note : for a group of 9 (nine) bakau piles, the increment of load is generally about
4 tonnes).
The process of applying the next increment of load and taking the settlement
readings against various times intervals shall be repeated until the ultimate load for
the pile group is reached. The test load shall than be gradually released. No further
settlement readings or rebound readings need to be taken on release of load.
5.12.5
Interpretation of Results
The allowable load on the pile group shall be obtained by applying an appropriate
factor of safety to the ultimate load determined from the load test. The factor of
safety is applied chiefly to offset against the possibility of settlement due to
consolidation. A factor of safety from 3 to 6 shall be applied depending on the
strength of the soil. As a guide, a factor of safety of 6 shall be applied to very soft
soil and a factor of safety of 3 shall be applied to medium strength soil.
N.19

DRAFT
REVISION NO
DATE
:3
: 30 NOVEMBER 2006
P BRICKWORK
1.0
GENERAL
Unless otherwise specified all brickwork shall comply with the requirements of CP
121 : Part 1:1973.
2.0
MORTAR
2.1
General
Mortar to be used for the work shall be in accordance with CP 121: Part 1: 1973 and
consists of either:
o
Cement : sand
Cement : sand with plasticizer
Masonry cement : sand
All mortar shall be used within 45 minutes of mixing and no remarking up of mortar
shall be permitted thereafter.
Mortar for brickwork and plasterwork below ground level shall be in the proportion
of 1 part of cement or masonry cement and 3 parts of sand.
Mortar for brickwork and plasterwork above ground level shall be in the proportion
of 1 part of cement and sand, with the addition of an approved mortar plasticizer or
1 part of masonry cement and 6 parts of sand.
The ingredients for mortar shall be measured in proper gauging boxes and shall be
mixed on a clean boarded platform or in the approved mechanical batch mixer. The
mixture shall be thoroughly mixed dry after which only sufficient water shall be
added with fine roses and the mass thoroughly mixed again to produce a uniform
material of good consistency. No remaking up of partially set mortar shall be
permitted.
2.2
Cement
The cement to be used, unless otherwise specified shall be Ordinary Portland
Cement complying with MS 522:1977 and masonry cement shall comply with MS
794:1982.
2.3
Admixtures
Mortar plasticizers shall comply with the requirements of BS 4887:1973 and used
strictly in accordance with the manufacturers instructions.
D:\TECHNICAL DEPARTMENT\SPECIFICATION\SPEC FINAL PDF\PDF New Folder Final\P-Brickwork1.doc
P.1

DRAFT
REVISION NO
DATE
2.4
:3
: 30 NOVEMBER 2006
Sand
Sand for mortar shall comply with BS 1210:1976 and shall be natural sand obtained
from rivers or approved pits. Sand shall be hard, durable, clean, and free from
adherent coatings such as clay, and from any appreciable amount of clay in pellet
form. It shall not contain harmful materials such as iron pyrites, salts, coal or other
organic impurities, mica, shale or similar laminated materials or flaky or elongated
particles in such a form or sufficient quantity to affect adversely the hardening
strength or durability of the mortar or as might attack the reinforcement in reinforced
brickwork. The S.Os decision as to the suitability of any sand shall be final. The
grading of the sand when determined as described in MS 30:1971 shall be within
the following limits:
BS Sieves
(mm)
2.5
Percentage by mass passing BS Sieves
6.3
5.00
2.36
1.18
Type S
100
98 100
90 100
70 100
Type G
100
98 100
90 100
70 100
m
600
300
150
75
40 100
5 70
0 15
05
40 100
21 90
0 25
08
Water
The water to be used shall be as specified under Concrete Work.
3.0
BRICKS
The bricks to be used for the work shall be solid common fired-clay bricks
complying with MS 76:1972 and of approved manufacture. They shall be regular in
size and shape, with good-faces and clean arises, undamaged, and free from all
defects. Before any bricks are ordered, samples shall be submitted to the S.O for the
approval and all deliveries of bricks shall be up to standard of samples approved and
kept on the site. All rejected bricks shall be removed from the site forthwith at the
Contractors own expense.
4.0
BRICKWALLING
The whole of the brickwork shown upon the drawings unless otherwise specified,
shall be constructed with standard size clay brick in the mortar and leave surface
ready for plastering.
All bricks shall be soaked in a suitable tank or pit to be provided by the Contractor
for at least half an hour before being laid and shall be kept wet whilst being laid.
The top of the walls left off shall be thoroughly wetted before work is resumed. All
P.2

DRAFT
REVISION NO
DATE
:3
: 30 NOVEMBER 2006
constructed walling must be left wet and properly protected from the direct sunlight
during the following day. The Contractor shall provide sufficient means to ensure
that this is done.
All bricks shall be properly bedded in mortar. All joints shall be thoroughly flushed
up and raked out to a depth of 13mm as the work proceeds. No joint shall exceed
10mm in thickness.
Brickwork shall be carried perfectly true and plumb in a uniform manner. No one
portion being raised more than 1m above another at one time. No overhand work
shall be permitted and scaffolding shall be carried up as work proceeds. The vertical
points of every alternate course shall be kept perpendicular over one another, and
all perpends, quoins etc, shall be kept strictly true square.
All intersections and angles of walls shall be properly bonded together, and all walls
and piers of lengths and widths not multiples of brick sizes shall be cut and bonded
in the best approved manner. No broken bricks shall be used except where required
to form bond.
All half brick (113mm) walls shall be reinforced at every fourth course with
approved brick reinforcement commencing two courses above base level.
All brickwork adjacent to reinforced concrete shall be bonded to the concrete
structure properly with wrought iron cramps of approved size and pattern set at
900mm centres.
All arches, cuttings, sinkings, setbacks and projections shall be properly formed.
Chases and holes through walls for the passage of pipes, and the like shall be neatly
cut and formed.
5.0
BOND
All half brick-walls shall be built in stretcher bond.
All other brickwork shall be built in English bond or as shown in the Drawings.
P.3
SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORK

Q PAINTING WORK
1.0
GENERAL
All paints to be used shall be those supplied by the manufacturers approved by
SIRIM. The brand name of the paint to be used shall be as stated by the Contractor
at the time of tendering and agreed upon by the S.O. The quality of paints shall
comply with M.S. 124 : 1989 in respect of emulsion paint and M.S. 125 : 1995 in
respect of oil/enamel paint. The paint manufacturer shall provide SYABAS written
warranty from the date of the certificate of Practical Completion.
Paints shall be delivered to the site in the manufacturers original sealed containers
unopened and shall be used strictly in accordance with the manufacturers
instruction
Paints shall not be adulterated and any paint that has deteriorated shall not be used
and shall be removed from site forthwith.
The colours and tints of paints shall be selected by the S.O. and the priming,
undercoats and finishing coats shall be of differing tints as approved and shall be
obtained from the same manufacturer.
Painting work shall be done by skilled workmen approved by the manufacturer and
appropriate equipment or tools shall be used.
No painting shall be done under conditions which may jeopardize the quality of
finished paintwork.
During painting, care shall be taken to prevent stain or damage to other works.
Surfaces to be painted shall be dry, free from dirt, oil, grease, old loose paint and
other deleterious matter. All cracks shall be raked out and stopped and all holes and
dents shall be filled.
Unless otherwise specified in the manufacturers instructions, each coat of paint
applied on masonry or metal surfaces shall be allowed to dry and subsequently
rubbed down lightly with sand paper before the next coat is applied. Any dirt or
dust shall be removed from preceding coat immediately before proceeding with
application of the next coat.
All priming to shop fabricated components shall be done at the shop.
Finished surfaces shall be uniform in finish and colour and be free from brush marks
or other defects.
Sample areas showing all tints of paints to be used shall be prepared by the
Contractor as and when required by the S.O.
D:\TECHNICAL DEPARTMENT\SPECIFICATION\SPEC FINAL PDF\PDF New Folder Final\Q-Painting1.doc
Q.1

2.0
PAINTING TO METAL WORKS

The areas to be painted shall be wire brushed to obtained a finished surfaces of St. 3
180 8510 1 : 1988 and be free from rust, scale, oil, grease, dirt and dust.
The painting system shall be as stipulated below :
COATING
SEQUENCE
TYPE OF PAINT
NO. OF
COATS
DRY FILM
THICKNESS
(MICRON)
Primer Coat
Copon 8048 Zinc Phosphate

Primer QD or equivalent
75
Intermediate Coat
Copon 8048 or equivalent
100
Finishing Coat
Nippon Polyurethane
Recoatable Finish or
equivalent
150
325
Total minimum dry film thickness
3.0
PAINTING TO MASONRY WORKS

Concrete surfaces shall be allowed to cure until moisture content is below 8% and
pH value below 9.
Loose concrete and oily residues on the concrete surface to be painted should be
removed as completely as possible
The surface should be clean and dry prior to painting.
The painting system shall be as stipulated below :
COATING
SEQUENCE
TYPE OF PAINT
NO. OF
COATS
DRY FILM
THICKNESS
(MICRON)
Primer Coat
Copon EA 9 Finish Hb or
equivalent
50
Intermediate Coat
Copon EA 9 Finish Hb or
equivalent
50
Nippon Polyurethane
Recoatable Finish or
equivalent
50
150
Finishing Coat
Total minimum dry film thickness
Q.2

4.0
COMPLETION OF PAINTING WORK

On completion of paintwork, all paint marks inadvertently left on glass, floor, tiles
and other surfaces shall be removed. Any stain or marking on finished paintwork
shall be removed and touched up to the approval of the S.O.
Q.3

R MISCELLANEOUS
1.0
FENCE AND GATE

Unless otherwise shown in the drawings, fencing shall be of the chain link type
complying with BS 1722.
Unless otherwise stated the height of the fence shall be 2440mm from the ground
up to the full height of the chain link.
The fence shall be erected to the extent and location as shown in the Drawings.
Where fencing is to be located on the boundary of the site, the Contractor shall
ensure that the construction shall not infringe the adjoining properties.
Unless otherwise shown in the Drawings mild steel angle posts shall of size 64mm x
64mm x 6.2mm. All steel members for fencing and gates shall be to the approval of
the S.O. Previously used steel member shall not be used in the construction of new
fencing and gates. Before delivery to site, the steel members for fencing and gates
shall be pre-cut and assembled at Contractors workshop and painted in accordance
to Section Q.
Where 4 strands of barbed wire are required a mild steel angle arm 650mm long of
the same cross sectional dimensions as the post shall be welded at the top of the
post at 45 degrees inclination. Where 8 strands of barbed wire are required, two
pieces of mild steel angle arm are specified herein before shall be welded to the top
of each post forming the shape Y which each arm having 4 strands of barbed wire.
The welding use shall be of continuous fillet weld. Necessary holes shall be made in
the post, arms and bracings for insertions of fixing bolts and clips.
Chain link fencing shall be of 3.25mm (10 gauge) P.V.C. coated wire of core
diameter 2.33mm and overall diameter of 3.25mm and of 64mm mesh size. The
straining wire shall be of 3.71mm (9 gauge) diameter and barbed wire shall be of
2.64mm (12 gauge) diameter.
Unless otherwise shown in the Drawings, the mild steel angle posts shall be erected
at every 3000mm centres commencing from the gate post and the post shall be
embedded plumb in 1 : 3 : 6 mix concrete footings of size 300mm x 300mm x
600mm deep. Mild steel angle struts of size 51mm x 51mm x 6.0mm shall be fix at
all corners, bends, junctions, gates posts and at every 5 bays of straight fencing.
The struts shall be fixed at inclination 60 degrees to the horizontal with the top end
bolted to the post at the middle height of the post and the bottom end encased in
concrete footing as described herein before.
The chain link mesh shall stretch across the posts and secured in place using
approved fencing clips. The end of chain link fencing, abutting mild steel gates posts
shall be fixed by means of 25mm x 5.0mm mild steel flat straps drawn through the
mesh and bolted using 10mm diameter mild steel bolts. Where gate posts are non-
D:\TECHNICAL DEPARTMENT\SPECIFICATION\SPEC FINAL PDF\PDF New Folder Final\R-Miscellaneous1.doc
R.1

metal, the termination of the fencing at the gate shall be by means of another mild
steel of angle post fixed to one side of the gate post and strengthened by struts as
described herein before. The chain mesh shall be strained by 3 strands of 0.71mm
(gauge) diameter galvanized steel straining wire threaded through the mesh and
fixed to the posts.
Where shown in the drawings, the bottom of link mesh shall be buried in
continuous concrete curbs of Grade 25 mix concrete. Unless detailed otherwise in
the drawings, the cross-sectional dimension of curb shall be 100mm wide x 230mm
high with 75mm protruding above the ground.
Gates shall be constructed as detailed in the Drawings.
All the posts, struts and gates shall be painted in accordance to Painting Work
Specification.
2.0
MANHOLES AND VALVES CHAMBERS

Manholes and inspection chamber shall be constructed to the size shown on the
Drawings. Unless otherwise specified, all dimensions on plan shall be inside
measurement.
Unless otherwise shown in the Drawings all manholes and chambers shall be
brickwork in the cement mortar 1:3. The brickwork shall be constructed on 1:2:4
concrete mix foundation unless shown otherwise. The thicknesses and sizes shall be
as shown on the Drawings. The inside of the chambers and manholes shall be lined
with 12mmm thick cement render (1:3). Externally, the exposed concrete or block
brick surfaces shall be rendered with 12mm cement and sand mortar (1:3) and
terminated 150mm below the finished ground level. All internal angles shall be
rounded off. Manholes and chambers shall be provided with pre-cast concrete cover
unless otherwise specified on the Drawings. Approved type wrought iron steps shall
be built into the brick wall of all manholes and chambers of depth 0.5m or more
and they shall be spaced not more than 300mm apart projecting 100mm over face
of wall.
3.0
PRE-CAST CHAMBERS
Pre-cast valve chambers, unless otherwise specified, shall be as shown in the
Drawings and in accordance to Concrete Work Specification.
4.0
WASHOUT
Washout shall be constructed at locations specified in sub-clause 8.5 of section C or
as may be directed by the S.O. The washout branches shall be connected to the
pipeline by special washout tees and sluice valves. From the washout sluice valves,
MS pipe or uPVC pipes Class E shall be laid to the nearest drain or stream. The
discharge point shall be downstream.
R.2

5.0
INDICATOR POST
The Contractor shall provide and fix ABS indicator posts close to the centre line of
pipes, at valves, washout and other points as directed by the S.O. The details of
indicator posts are shown in the Drawings.
R.3

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SYABAS

SYABAS' STANDARD SPECIFICATIO N

FIRST EDITION : M AY 2007

SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

STANDARD SPECIFICATION FOR PIPE LAYING WORK

HANDLING OF PIPE AND SPECIALS

STEEL PIPES AND SPECIALS

DUCTILE IRON PIPES AND FITTINGS

HIGH DENSITY POLYETHYLENE (HDPE) PIPES AND FITTINGS

ARCYLONITRILE, BUTADIENCE, STRYENE (ABS) PIPES AND FITTINGS

DUCTILE IRON FERROUS SADDLES

DUCTILE IRON PILLAR HYDRANTS

STAINLESS STEEL WATER METER STANDS

SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

PROGRAMME AND PROGRESS OF WORKS

PREPARATION OF THE WORK AREA

Detection of Existing Utilities and Services

Trench Excavation / Cutting of Metalled Premix Road

Normal Earth Shoulder

Shoulder with hard standing / tiles

Metalled Premix Road

SETTING OUT AND RE-SURVEY

PROVISION OF SURVEY INSTRUMENTS AND CHAINMEN

MATERIALS AND WORKMANSHIP

SUPPLY OF MATERIALS BY SYABAS

REQUIREMENTS OF OTHER CONTRACTOR

PUBLIC UTILITIES AND OTHER SERVICE

PUBLIC AND PRIVATE ROAD

WORK THROUGH PRIVATE LAND

SAFETY AND SECURITY MEASURES

DAMAGES TO EXISTING WORK

FIRST AID BOX

CLEARING UP AND REINSTATEMENT ON COMPLETION

CLAUSES RELATING TO WORK OR MATERIALS NOT REQUIRED IN THE WORKS

EMPLOYEES SOCIAL SECURITY ACT

DELAYS AND STOPPAGES

SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

EXPLANATION OF THE DOCUMENTS

CO-ORDINATION MEETINGS AND PROGRESS REPORTS

ASSISTANCE TO SUPERINTENDING OFFICER'S REPRESENTATIVE

SUPERINTENDING OFFICER'S APPROVAL

TEMPORARY ACCESS ROAD

WORK OUTSIDE NORMAL HOURS

FORMS FOR MONTHLY STATEMENTS

TEMPORARY CONNECTIONS DURING CONTRACT PERIOD

STATUTORY REGULATIONS AND APPROVAL

DELAYED TAKING OVER

PIPE BALANCE AND EXCESS MATERIALS

RIGHT TO OPERATE UNSATISFACTORY EQUIPMENT

SUPPLY OF CLEAR WATER FOR TESTING AND COMMISSIONING

APPLICATIONS FOR PAYMENT

REQUIREMENT OF CONSTRUCTION INDUSTRY DEVELOPMENT BOARD

Compliance with Environmental Legislation

Survey Plan and Scales

MANUFACTURERS WORKS INSPECTION AND TESTING

SYABAS STANDARD SPECIFICATION FOR PIPE LAYING WORKS

EXCAVATION FOR PIPE TRENCHES

WEATHERED ROCK EXCAVATION

UNAUTHORIZED EXCESSIVE EXCAVATION

ADDITIONAL EXCAVATION ORDERED BY THE S.O.

TIMBER LEFT IN EXCAVATION

CROSSING WATER-COURSES ETC.

BACKFILLING OF EXCAVATIONS OTHER THAN PIPE TRENCHES