Method Statement (DW) Final

DOHA SOUTH SEWAGE TREATMENT WORKS
Phase II Expansion
Civil Project 361/1 Public Works Authority
METHOD STATEMENT
SECTION 1 : GENERAL, CIVIL, MECHANICAL &

ELECTRICAL WORKS
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CONTENTS
1 GENERAL..................................................................................................................5
1.1 OUTLINE NARRATIVE............................................................................................................... 5
1.2 PHASE II EXPANSION UNDER CONTRACT C361/1.....................................................6
1.3 WORK SCOPE FOR PHASE II UNDER CONTRACT C361/1.......................................6
1.4 SEWAGE TREATMENT PLANT EXPANSION WORKS....................................................8
2 TEMPORARY WORKS..........................................................................................13
2.1 MOBILIZATION......................................................................................................................... 13
2.1.1 GENERAL..................................................................................................................................... 13
2.1.2 CONTRACTOR’S MAJOR FACILITIES................................................................................14
2.2 TEMPORARY FACILITIES........................................................................................................ 15
2.2.1 GENERAL..................................................................................................................................... 15
2.2.2 ENGINEER’S TEMPORARY FACILITES...............................................................................15
2.2.3 CONTRACTOR’S TEMPORARY FACILITIES......................................................................16
2.2.4 ACCOMMODATION................................................................................................................ 17
2.2.5 CAMP MANAGEMENT AND SECURITY..........................................................................18
2.2.6 UTILITIES...................................................................................................................................... 18
2.3 WATER SUPPLY......................................................................................................................... 20
2.4 ELECTRIC POWER SUPPLY................................................................................................... 20
2.5 COMMUNICATION SYSTEM............................................................................................... 20
3 PERMANENT WORKS.........................................................................................21
3.1 SITE CLEARANCE..................................................................................................................... 21
3.1.1 SETTING OUT OF BENCHMARKS (“BM”).......................................................................21
3.1.2 WORK PROCEDURE................................................................................................................ 21
3.2 EARTH WORKS......................................................................................................................... 22
3.2.1 GENERAL..................................................................................................................................... 22
3.2.2 MATERIALS................................................................................................................................. 22
3.2.3 GENERAL WORK PROCEDURE FOR EARTHWORKS..................................................22
3.2.4 CONSTRUCTION...................................................................................................................... 24
3.3 ROADWORKS............................................................................................................................ 26
3.3.1 BASE COURSE WORK............................................................................................................ 26
3.3.2 ASPHALT CONCRETE PAVEMENT.....................................................................................28
3.3.3 CONCRETE PAVEMENT WORK........................................................................................... 31
3.4 CONCRETE AND DRAINAGE STRUCTURES..................................................................41
3.4.1 GENERAL..................................................................................................................................... 41
3.4.2 SETTING OUT............................................................................................................................ 42
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3.4.3 EARTHWORKS FOR STRUCTURAL WORKS...................................................................42

3.4.4 BLINDING CONCRETE............................................................................................................ 43
3.4.5 BOTTOM CONCRETE AND WALL CONCRETE.............................................................43
3.4.6 INSTALLATION OF PIPES...................................................................................................... 44
3.4.7 FABRICATION OF SURROUND FORMWORK................................................................44
3.4.8 PLACING OF SURROUND, WINGWALL AND HEADWALL CONCRETE..............44
3.4.9 CURING CONCRETE................................................................................................................ 45
3.4.10 STRIPPING OF FORMS AND DRESSING........................................................................45
3.4.11 BACKFILLING.............................................................................................................................. 45
3.5 PIPELINE WORKS INCLUDING PIPE JACKING.............................................................46
3.5.1 GENERAL..................................................................................................................................... 46
3.5.2 PIPE MATERIALS....................................................................................................................... 46
3.5.3 PIPE PROCUREMENT, LOADING, UNLOADING, STOCKPILING & SHIFTING. .46
3.5.4 SURVEY, SETTING OUT AND PIPELINE ALIGNMENT................................................48
3.5.5 EARTHWORKS FOR SEWERAGE WORK..........................................................................49
3.5.6 LAYING OF PIPES..................................................................................................................... 52
3.5.7 PIPE JACKING METHOD FOR TRENCHLESS EXCAVATION.....................................58
3.5.8 METHOD OF CONNECTING PIPE TO EXISTING SEWER MANHOLE..................64
3.6 APPURTENANT WORKS........................................................................................................ 65
3.6.1 PERMANENT PAVEMENT MARKINGS.............................................................................66
3.7 BUILDINGS................................................................................................................................. 67
3.7.1 CONCRETE WORKS................................................................................................................. 67
3.7.2 THE STEEL REINFORCEMENT WORKS............................................................................86
3.7.3 FORM WORKS.......................................................................................................................... 95
3.7.4 STRUCTURAL STEEL WORKS.............................................................................................. 99
3.7.5 HOLLOW CONCRETE BLOCK MASONRY WORKS...................................................103
3.7.6 WATER PROOFING WORKS..............................................................................................110
3.7.7 TILE WORKS............................................................................................................................ 113
3.7.8 CEILING WORKS.................................................................................................................... 116
3.7.9 OTHER WORKS...................................................................................................................... 119
3.8 BLOCK PAVING....................................................................................................................... 131
3.8.1 MATERIAL................................................................................................................................. 131
3.8.2 TRIALS........................................................................................................................................ 133
3.8.3 LABELLING REQUIREMENTS............................................................................................. 134
3.8.4 DELIVERY.................................................................................................................................. 134
3.8.5 BEDDING SAND..................................................................................................................... 134
3.8.6 JOINTING SAND.................................................................................................................... 135
3.8.7 CONSTRUCTION OF EDGE RESTRAINTS.....................................................................136
3.8.8 LAYING OF SAND BEDDING COURSE..........................................................................136
3.8.9 LAYING OF PAVING UNITS................................................................................................ 136
3.8.10 INITIAL COMPACTION........................................................................................................ 137
3.8.11 JOINT FILLING........................................................................................................................ 138
3.8.12 FINAL COMPACTION........................................................................................................... 139
3.8.13 EXCESS SAND......................................................................................................................... 139
3.9 MAJOR MATERIAL................................................................................................................ 139
3.9.1 CEMENT AND CONCRETE................................................................................................. 139
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3.9.2 AGGREGATE, SAND AND BOULDERS...........................................................................140

3.9.3 REINFORCING STEEL BAR.................................................................................................. 140
4 MECHANICAL AND ELECTRICAL WORKS.....................................................141

4.1 GENERAL.................................................................................................................................. 141
4.1.1 REFERENCES............................................................................................................................ 141
4.1.2 RESPONSIBILITIES................................................................................................................. 141
4.1.3 HANDLING & STORAGE..................................................................................................... 142
4.1.4 TOOLS AND EQUIPMENTS...............................................................................................143
4.1.5 INSTALLATION PROCEDURE............................................................................................. 143
4.2 MECHANICAL WORKS........................................................................................................ 144
4.2.1 MECHANICAL BAR SCREENS...........................................................................................144
4.2.2 DEGRITTER............................................................................................................................... 145
4.2.3 RAS AND SAS PUMPS, FILTER FEED PUMPS, WORKS DRAINAGE PUMPS,
SCUM PUMPS........................................................................................................................ 145
4.2.4 FILTER BACKWASH PUMPS, ULTRAFILTRATION FEED PUMPS,
ULTRAFILTRATION BACKWASH PUMPS, WASHWATER PUMPS, CHLORINE
BOOSTER WATER PUMPS.................................................................................................147
4.2.5 AERATION AIR BLOWERS..................................................................................................149
4.2.6 FILTER BACKWASH BLOWERS, SAS TANK BLOWERS, AEROBIC DIGESTER
BLOWERS, PRE- AND POST-DIGESTION BALANCING TANK BLOWERS.......151
4.2.7 RAPID GRAVITY SAND FILTERS.......................................................................................152
4.2.8 ULTRAFILTRATION SYSTEM...............................................................................................154
4.2.9 ULTRAVIOLET DISINFECTION SYSTEM.........................................................................155
4.2.10 CHLORINATION SYSTEM.................................................................................................... 157
4.2.11 CENTRIFUGE............................................................................................................................ 158
4.2.12 DUCTILE IRON PIPES........................................................................................................... 159
4.2.13 GRP PIPING.............................................................................................................................. 160
4.2.14 uPVC PIPES............................................................................................................................. 161
4.3 ELECTRICAL WORKS............................................................................................................ 163
4.3.1 WORK PROCEDURE FOR CABLE TRAY AND SUPPORT........................................163
4.3.2 WORK PROCEDURE FOR CABLE CONDUIT AND SUPPORT...............................166
4.3.3 WORK PROCEDURE FOR CABLING AND WIRING OF LV CONTROL CABLE
...................................................................................................................................................... 170
4.3.4 WORK PROCEDURE FOR INSTALL TRANSFORMER................................................178
4.3.5 PROCEDURE FOR TERMINATION AND SPLICING LV, CONTROL CABLE.......182
4.3.6 PROCEDURE FOR INSTALL CONTROL LOCAL STATION.......................................185
4.3.7 WORK PROCEDURE FOR UNDERGROUND CABLING IN TRENCH..................195
4.3.8 WORK PROCEDURE FOR INSTALL LIGHTING WORKS..........................................200
4.3.9 WORK PROCEDURE FOR EARTHING WORKS...........................................................208
4.3.10 WORK PROCEDURE FOR INSTALL COMMUNICATION SYSTEM.......................212
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1 GENERAL
1.1 OUTLINE NARRATIVE
This section presents a narrative outline of the proposed construction methodologies for
the major work activities. It should be understood that the method statements stated
herewith, present only preliminary details intended for the successful execution and
completion of the contract. Changes, revisions or modifications of methodologies
presented herewith may be necessary later dependent on the requirements of the detailed
design after award and also after assessing the ground conditions following the results of
further geotechnical investigations.
Please also refer to other sections of the tender submission for more details of the
proposed organization, manpower, equipment and work schedule.
Reporting to the Project Director is the Site Project Manager who will lead the construction
management activities of the site. In conjunction with the concerned discipline managers,
the Site Project Manager will develop and direct the construction teams to ensure
satisfactory performance including the following general functions:
 Ensuring that all materials fully comply with the specifications’ requirements and that
proper procedures are established to cover all aspects related to material receiving,
storage, and issuing, site purchasing, material tracking and maintenance of tools and
plant equipment.
 Technical supervision assured by qualified and experienced superintendents and
supervisors.
 Ensuring that the personnel for all categories of activities are qualified for the relevant
job and have suitable experience.
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 Timely transportation of the Contractor’s personnel and materials.

 Taking all reasonable precautions to protect all the works completed or partially
completed and the supplied materials and equipment from damages by fire, theft,
weather conditions, construction or erection actions for construction activities.
 Providing records of field and/or shop inspection, tests, alignments and calibrations
performed.
 Advising the Engineer when any inspection or test of field installation is required.
 Ensuring full compliance with the Engineer’s/EMPLOYER's environmental, safety and
health procedures by the Contractor’s personnel and those of its sub-contractors.
 Providing all means of access to the work including hoists, ladders, scaffolding, or any
other means acceptable to the EMPLOYER and in accordance with safety
regulations.
 Administrative reporting requirements, including provision of all labour force and
construction equipment reports.
 Protecting the EMPLOYER's benchmarks and monuments from damage by the
Contractor and subcontractors.
 Submission in appropriate time to Engineer for his approval of various method
statements in the format described in the Contract.
 Carrying out complete Quality Control Procedures and tests to fully satisfy the
requirements of the Contract.
1.2 PHASE II EXPANSION UNDER CONTRACT C361/1
The Phase II Expansion is the second stage of the extension works of the existing Doha
South STW purportedly for increasing its capacity. Provision has been made in the Phase
I Works to accommodate some of the Works proposed under Contract C361/1.
1.3 WORK SCOPE FOR PHASE II UNDER CONTRACT C361/1
The Project is comprised of the Design and Construction of Works as described below in
the form of a single turnkey package deliverable.
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In accordance with Section C EMPLOYER’s Requirement Part I Clause 4 “Scope” issued

to the Contractor, the main project scope of works are the following:
 2 No. inlet screens in existing channels at the inlet works.

 2 No. vortex grit removal units in the space provided at the inlet works.
 Modifications to the inlet FTFT flow distribution arrangements and storm overflow.
 Second Sequencing Batch Reactor (SBR) complete with air diffusers and blowers
housed in a building.
 Secondary effluent balancing tank.
 Ultra-filtration (UF) plant. Main Tender is for the UF plant to be sized to treat the flow
from the proposed SBR only. An Alternative Tender is required with the UF plant sized
to treat the full flow from all the treatment streams of the STW.
 UF Feed Pumping Station sized for main Tender and for Alternative Tender
 Improvement to the chlorination system as necessary.
 Storm water/TSE lagoon and associated return pumping station.
 Replacement of existing DAF equipment in Thickener Building A with sludge feed
pumps, 4 No thickening centrifuges, sludge pumps & polymer dosing system as
Thickener Building B.
 2 No SAS balancing tanks.
 Conversion of 3 No. former primary digestion tanks to Aerobic Digesters.
 New blower house and blowers feeding the new aerobic digesters.
 1 No. dewatering centrifuge, polymer dosing system, new sludge feed pumps, and
conveyor; all in the Dewatering Building.
 Inter-process pipework.
 Modifications to the TTP Screw Pumps sump and overflow pipework.
 SCADA/PLC system for new works and Integration with existing SCADA.
 Security system, network and control room.
 Power supplies including HV & MV/LV networks, MCCs, secondary substations,
switchgear, transformers and standby generators.
 Refurbishment of existing Sub-Stations.
 Capsular type using FM-200 fire fighting system in the existing and proposed MCC’s,
see page C4/19 item 3.
 HVAC where necessary.
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 Site services, including electrical network, street lighting and site lighting,
telecommunications, works drainage, washwater and potable water storage facilities
to serve new works.
 Site works, landscaping and irrigation of STW.
 Demolition of redundant buildings and structures and removal from site as instructed
by the Engineer.
 Former primary sludge pumping station modification complete with new pumps and
pipework to accept stormwater drain and other drains in the vicinity and return to the
inlet reception chamber.
 Replacement pre-cast concrete panel site boundary wall with 3 No. motorized sliding
gates to STW.
 Perimeter camel fencing to lagoons area.
 Refurbish the Old Liquor Pumping Station to pump SAS from the Activated Sludge
Plant to the SAS balancing tank.
1.4 SEWAGE TREATMENT PLANT EXPANSION WORKS
Upon contract commencement, all areas of sewerage treatment plant pertaining to

expansion Works will be handed over to the Contractor and the Contractor will take over
these site areas immediately to start the performance of the Works.
Contractor will exert utmost effort in planning and executing the perfect sequence of the
construction activities according to the Program of Works in order not to create any
disturbance or stoppage to the ongoing operations of the existing STW during the
performance of Works save only in the case of tapping, alignment and other interfacing
works that may necessitate the temporary stoppage of operation/s for which approval from
the Engineer is required.
Site land surveying works will be carried out in priority to establish site boundaries,
structures orientation, pipes location, access, landscaping and other installations which
will be set out with appropriate mark-ups initially, and to record existing ground features.
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General topographical surveying works will be carried out for the whole sewage treatment
expansion works under Phase II contractual works scope in due course.
Geotechnical ground boring works will be carried out in the designated locations at
appropriate intervals to ascertain underground geological features of the site of sewerage
treatment additional structures according to the contract.
Surveying report will be forwarded to engineering team for consideration into detailed
design of the sewerage treatment extension works under Phase II contract.
Detailed design will be carried out satisfying over and above all EMPLOYER’s
requirements in a view of ensuring Safety in works at all times, procedural speedy works,
technically sound construction with high performance output under good construction
practices.
In accordance with the proposed site layout and preliminary design of access roads to be
prepared based on PWA’s guideline, a plan of road network in between various sewerage
treatment process structures, service buildings, lagoons and etc will be established in
advance by the Contractor for Engineer’s perusal. Temporary road alignment would be
demarcated on site.
After site survey and layout of boundaries of each respective work areas, site grubbing
and clearing works with approved permission from Engineer will be carried out initially,
which shall be supervised by survey team. Removal of top soil will then be carried out
expeditiously.
Any sand dunes encountered on the work area will be handled with care during
excavation to avoid contamination by soil or reject materials in order for such material to
be used in work once passed the required testing where it is applicable.
Road works would then be carried out up to preliminary levels along routes connecting
major structures of sewerage treatment process extension works. These access roads
are planned to be built with priority based on work program. The works will include roads
to respective Working sites and Contractor’s camp facilities. Such roads will facilitate
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movement of resources between various sites of work disciplines. These roads will be
those of initial stage and readjusted and rerouted in and around the site depending on site
requirements as the works develop progressively.
If blasting is necessary for excavation of underground rocks for foundation of the

structures, steps and procedures to secure all necessary licenses, magazines and
approvals of Authorities concerned, will be taken in due course and expeditious manner.
Deep excavation works that may need blasting operations for major sewerage treatment
process structures with deep invert levels will commence with first priority.
Land for temporary use for stockpiling of backfilling materials coming from various
excavation activities will be built situated common to all working sites for effective material
maneuver and utilization purposes. Temporary access roads to such stockpile areas will
also be constructed and maintained.
To avert accidents or untoward incidences to happen on site, safety precautions and

measures will be taken during the course of whole construction period. Safety signboards
and warning signs shall be disseminated and installed to all working areas and identified
accident prone areas and critical zones in order to remind all working crews of the “Safety
First” motto at works all the time.
After the excavation up to desired formation levels has been established, structural works
of sewerage treatment process will commence.
The construction of the main structures of Sewage Treatment Works shall normally start
from its substructures by laying down of blinding/lean concrete and mattresses of the
foundations. Subsequently, footings, stumps and underground slabs, walls, columns &
beams shall be constructed in sequences. Particular attention should be given to all
underground piping works, electrical groundings and other embedment works of the
structures not to miss out its integration into the works prior to proceeding of concreting
and backfilling works.
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Upon completion of concrete structural works, backfilling works will be carried out in
appropriate thicknesses and layers up to sub-grade level compacted to desired limits as
per construction drawings and technical specifications. The construction of
superstructures shall just follow after the completion of substructure.
Inter-process Pipelines will be carried out on top of the sub-grade and other structural
levels built up between and next sewerage treatment process structures.
Electro-mechanical pumps, motors, penstock and other process components shall

proceed for installation once the structure is ready to accept those items and shall follow
the electro-mechanical schedule.
All underground services lines i.e. sewerage drain, surface drainage, water main, electric
power cable duct, cable ducts for telecommunication including SCADA system, etc. will be
constructed in parallel and in procedural manner.
Emphasis shall be given to the construction of such Inter-process Pipelines and all
underground services lines, which will be planned properly such that smooth interfacing
works with minimum double-handling and disturbances to each and every service line of
various functions, can be ensured.
Bedding and backfilling of the above pipeline works and service line works will be carried
out with due care as per technical specifications so that there would be no unbalance
settlement occurrence after final pavement.
Construction of sub-grade will be completed with all above-mentioned Inter-process

Pipelines and underground services lines built in properly implemented procedures.
Main Pipelines, Gravity Sewer and TSE lines will be undertaken with due expedition in
their respective grids and details in the drawings taking all good construction
considerations, safety and under strict compliance with the technical specifications.
Earthworks for Landscaping and Lagoons formation will be carried out on the sub-grade
constructed and excavation pit respectively as mentioned above.
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Other than ways of roads, the spaces in areas designed for various paving with concrete
or asphalt or interlocking block will be graded and compacted to formation level. Concrete
or asphalt pavement or interlocking block pavement will be carried out properly in
accordance with the construction drawings and specifications.
Demolition of redundant buildings and structures will be carried out separately as per
program in due course.
Major Road Pavement works to final finish level will be carried out on top of sub-grade
after all precedent works are completed.
Planting on Landscaping Areas will be carried out when Treated Sewerage Effluent (TSE)
water becomes available from the sewerage treatment operation.
There are two Lagoons to be constructed separated by cell. The Lagoon No. 1 which is
25% of the total volume will collect storm flow in excess of the storm tank capacity and the
contaminated flow to the STW. Whereas Lagoon No. 2, which is 75% of the total volume,
will collect the overflow from the following:
 Occasional storage of treated sewage effluent that cannot be disposed of (where

demand is insufficient)
 Treated sewage effluent that overspills from the tertiary balancing tank and the
ultrafiltration balancing tank
 Emergency facility to store any flow that overspills from Lagoon No. 1
Both Lagoons are to be constructed with inlet/outlet structures made of reinforced

concrete and pipeworks with interconnecting spillway. These Lagoons are connected to
the Lagoon Pump Station which regulates the in and out flows. The average depth of
Lagoons is 3m. Lagoon embankment will be constructed under minimum height and side
slopes not steeper than 1 in 2.5 and to be compatible with all design criteria incited in the
contract.
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2 TEMPORARY WORKS
2.1 MOBILIZATION
2.1.1 GENERAL
The mobilization of the needed resources to site within the shortest time is one of the
most crucial factors for the timely execution of the project.
Immediately upon receipt of the Notice to Proceed/Award the designated project

management team which is composed of qualified and well experienced personnel will be
assigned to the project and embarked on the mobilization activities. A supporting team in
the Head Office will also be formed to facilitate the resources mobilization to site more
efficiently.
The major tasks to be carried out by the team are as follows:
1 To review the contract documentation and data and establish the detailed
requirements of the project.
2 To prepare the detailed work schedule based on the given preliminary construction
schedule. This work will include a time barred PERT-CPM network and time barred
sub-level networks. These networks will present in detail and in proper sequence all
the principal activities. The PERT-CPM network will show all the restraints and
interfaces of the various job orders of the contract.
3 To provide the general layout of the camp and job site facilities.
4 To establish detailed procedure for administration, supervision, and supporting
activities.
5 To select and nominate the subcontractors, if required.
6 To select and nominate the material suppliers.
7 To prepare requisition orders and purchase orders for the job site facilities,
construction equipment, small tools, consumable and supplies, etc.
8 To finalize the lease agreement with the EMPLOYERs of the land where it is intended
to establish the temporary facilities.
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Mobilization of key personnel to the job site will commence in accordance with the
mobilization plan, together with the arrangements for delivery of the major construction
plant, equipment and tools required for the initial construction schedule.
The site for the temporary facilities such as field office, laboratory will immediately be
cleared and leveled to allow installation of the prefabricated modular camp buildings or
permanent buildings with cement hollow block, material handling facilities and the project
workshops. Adequate measures will be taken to provide adequate drainage for the yard.
The site operation offices will be located in the appropriate area but will be determined
after further investigation.
Primary earthmoving equipment such as dozers, backhoes, wheel loaders and dump
trucks are readily available to site during the early pace of mobilization as these are key
resources in the construction of temporary camp & facilities. The other items of heavy
equipment and tools will also be mobilized as required, such as mobile cranes, concrete
vibrators, air compressors, stand-by power generators, welding machines, bar
cutter/benders, flat bed trucks, etc.
Mobilization activities will be carried out in close consultation with the Engineer based on
construction schedule.
2.1.2 CONTRACTOR’S MAJOR FACILITIES
1 Main Field Office

It is proposed to establish the main field office in job site. The area of the office & camp
site shall be approximately 6 Ha including batch Plant and additional space in size. For
ease of access to the concurrent job sites, whenever needed, the contractor will improve
the access road condition from the office to the job site using grader, roller and water
truck.
2 Workshops
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The Contractor will establish mechanical workshops for servicing and repair of the
construction equipment handled by skilled mechanics. The Contractor is to do their best
endeavour to shorten the maintenance & repair time by ensuring enough stock of spare
parts needed on site. It also is intended to install fuel tanks and filling stations for the
construction equipment nearby workshops.
3 Laboratory
The Contractor will operate their own site laboratory for material testing to control the
quality of the work located at main office compound. Wide arrays of laboratory tools and
equipments with relevance to the Contractor’s work shall be provided. The major tests will
be carried out in the laboratory but some of the field test such as FDT, coring samples and
others requested by Engineer will be performed by qualified technicians and aided with
mobile vehicle at designated areas on site.
4 Staff Dormitory
A dormitory for the expatriate staffs will be provided either by a temporary building in the
Contractor’s Compound or the rented house in town.
5 Storage
The Contractor will establish ample number of storages to keep material, tools, and spare
parts for the equipment inside the site compound.
2.2 TEMPORARY FACILITIES
2.2.1 GENERAL
The temporary on-site facilities will be planned and coordinated with all parties involved to
ensure progressive provision of adequate services and facilities to support the
construction of the Project.
2.2.2 ENGINEER’S TEMPORARY FACILITES
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Temporary facilities for the Engineer and the EMPLOYER will be provided in accordance
with the Section C Part 1 EMPLOYER’s Requirements Clause 18 and will include but not
be limited to:
1 Air-conditioned site office complete with internal partitions and rooms for designated
use, office equipment, furnishing, kitchen and toilets with shower facilities ;
2 Communication facilities such as telephones, facsimiles, internet.
3 Parking facilities ;
4 All required utilities such as cold and hot water, electricity and sanitary drainage.
2.2.3 CONTRACTOR’S TEMPORARY FACILITIES
The Contractor’s site office complex will comprise a main office to house the project
management staffs and separate offices for subcontractors. Portable cabins shall also be
used at appropriate locations within the construction areas, to function as satellite offices
for specific site operational centres.
The temporary facilities will include but are not necessarily limited to the following:
1 Lay-down areas
2 Warehouse
3 Stockyards
4 Concrete Batching Plant and materials storage areas
5 Contractor offices
6 Workshops
7 Fuel Station
8 Temporary roads
9 Parking areas
10 Clinic
These temporary facilities will be sized as shown in proposed layout of camp yard and
operated in a manner consistent with their important function for adequately supporting,
both efficiently and effectively, the construction operations of the project.
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The warehouse facilities will allow indoor storage of sensitive plant and equipment such
as the selected AGL units, motors, pumps, control equipment, instruments, welding
electrodes, expendable tools and supplies, fasteners, etc. Controlled climatic storage will
be installed to provide storage for equipment susceptible to climatic conditions.
Outdoor storage will be categorized as under covered or uncovered storage with

adequate security fencing and lighting.
2.2.4 ACCOMMODATION
Accommodation facilities meeting the requirements stipulated in the contract will be

installed and maintained for the professional personnel of the Contractor, Subcontractors,
and Vendors.
These facilities will be enclosed by perimeter fence with suitably controlled access. The
accommodation will be built and maintained to satisfy both the EMPLOYER’s and Qatar
standards.
The labour camp is proposed to be located at the designated ‘off-site’ area.
 Kitchen / Dining
Meals served in any camp are one of the vital aspects in workers’ daily lives that may
affect the Work if not given importance. Considerable attention will be given to meet the
necessary cuisine standards and to maintain nutritious menu under hygienic condition on
site at all times. A kitchen and dining hall will be built and operated as one large facility
divided into two areas serving both the workmen and management, supervisor personnel.
The camp kitchens will have the cooking paraphernalia found in some large, modern
restaurant such as walk-in freezers, ice makers, ovens, bakery tables, food mixing
machines, etc. Meals need to be of high-quality, nutritionally balanced, and will be
prepared and served pleasantly and with sufficient quantity and variety while maintaining
sanitation.
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The dining hall will also serve packed lunches and midnight food as required for personnel
in remote locations and overtime works.
 Laundry
A laundry, furnished with suitable commercial laundry equipment, will be operated to cater
the laundry services to residents in the camp.
2.2.5 CAMP MANAGEMENT AND SECURITY
The Contractor recognizes the importance of setting up a camp and associated facilities
that can provide shelter conducive for work, meeting all the basic needs for living in and
the relaxation of employees in such a location. To maintain a high quality camp, the
“Camp Manager” will be in a charge of operating the camp and will be responsible to
report the Administration Manager for its operation and maintenance.
Security within the labour camp will be especially emphasized with all residents being
required to be registered and issued with passes in accordance with the Project’s
established procedures.
The labour camp will be adequately fenced with manned main gates to ensure that
entrance is for residents only or for approved special passes for designated guests or
VIPs. The “No Pass or No ID, No Entry” procedural entry shall be imposed and
mandatory.
2.2.6 UTILITIES
1 Water
Water will be brought into the site by water trucks. Sufficient storage capacity tanks with
an adequate water reserve will be provided at the jobsite and campsite for emergency and
operational failure from the source.
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2 Power
The Contractor will provide main power supply to the camp, offices and workshops. The
electric distribution system will be designed and installed according to Qatar standards
and requirements. The source of the power supply may be taken from local/government
electric company or by Contractor’s generator sets.
3 Sanitary Facilities
The Contractor will take all necessary steps to make certain that the work site and all
premises occupied by its personnel are maintained under a clean and sanitary
environment.
These will includes the following ;

 Washroom, latrine and related facilities
 Sufficient covered garbage containers at all necessary places to provide
 Adequate waste storage and to prevent litter.
 Premises cleaned daily, garbage and refuse collected daily.
 Garbage and refuse collection and disposed of in an acceptable manner
 Premises and grounds treated, as necessary, to prevent breeding of insects or
vermin.
 Quarantining of personnel known to be carrying or suffering from a contagious
disease.
 Field toilets provided at the work site.
 Improved water drainage or sewage system.
A sewage collection and treatment system will be sized and installed to meet the total
camp demand including the facilities for medical, laundry, recreation, storage, workshops
etc.
Sewage from closed septic tanks shall be collected and taken offsite by the Contractor
and disposed to treatment plant of septage specified by the EMPLOYER.
4 Transportation
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Buses will be furnished to transport workmen from the camp to the work site. In case that
the camp compound is close enough to walking commute to Site, commute by walk shall
be preferred. A regular time schedule will be established connecting the camp and jobsite
with buses and pick-up trucks. Sedans might be used for staff transportation.
2.3 WATER SUPPLY
Construction and utility water for mixing & curing the concrete and control of moisture
content in the filling materials, sub-base/base course materials will be obtained from
public water sources and be transported by Water Tanker.
Potable water will basically be obtained from commercial water supplier.
Care will be taken to ensure that the quality of water for construction purposes will meet
the related technical specifications in order to achieve the required quality of concrete.
2.4 ELECTRIC POWER SUPPLY
It is proposed to also use various diesel generating sets to ensure uninterrupted supply.
However, the Contractor will purchase electricity from the local electric power supplier for
camp, office, miscellaneous plant, etc., if available.
2.5 COMMUNICATION SYSTEM
Short/Long Distance Radio Telephone System will be installed at the main office,
laboratory and workshops (if necessary).
Telephone and facsimile systems including international lines will be installed at the main
office and the application to the telecommunication corporation will be arranged so as the
lines are operational as soon as the buildings are ready to use.
Internet line, landline or satellite, will be installed to ensure efficient business
communications and transactions.
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3 PERMANENT WORKS
3.1 SITE CLEARANCE
3.1.1 SETTING OUT OF BENCHMARKS (“BM”)
As soon as the Site has been handed over to the Contractor, the Contractor will check
the coordinates and levels of the ground control traverse stations based on the data
supplied by the Engineer.
The Contractor will immediately report to the Engineer any discrepancies between the
measured coordinates and levels of the ground control points and the given data, if there
is any.
The Contractor will establish construction control points (BM) at various locations so that
all setting out can be carried out from them.
These control points, which are used as reference of Permanent Works, should be
located outside the direct area of work, and successive points will be mutually inter-visible.
The Contractor will clearly mark and protect the control points, which are comprised of
steel pins setting on concrete bases, until completion of the Contract.
The Contractor will check all existing ground levels prior to commencing construction of
the permanent works, and will notify the Engineer of the results.
The Contractor if necessary will provide the Engineer with all necessary assistance for
checking the setting out, agreement of levels and any other survey or measurement which
the Engineer may require to carry out in connection with the Contract.
3.1.2 WORK PROCEDURE
From the results of the initial site survey, quantities of crops, trees, plants, and other
structures that may present over the project site will be measured and be reported to
Engineer to get a confirmation for clearing.
General site clearing will only commence after the Engineer has given the approval.
Existing masonry structures will be demolished by the Contractor’s hydraulic
breaker/excavator and be disposed of by the Contractor’s tipper trucks to the designated
disposal areas. All metals, electric wires and scrap materials as a demolition residue with
salvage worth shall be considered refuses if Engineer shall not remove the matter prior to
dumping operations after the report has been made.
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Skillful operators will run the related equipments for the above work and also care will be
taken to avoid any accident and damage to adjacent property by the undertakings in
accordance with HSE procedures.
3.2 EARTH WORKS
3.2.1 GENERAL
Earthworks will generally comprise of excavation and disposal of soil and rock after site
clearance, furnishing, placing and compacting earthen materials on the backfill and
embankment areas in accordance with specified alignments, levels, grades, dimensions
and cross sections indicated on the construction drawings and as required by the
Engineer.
3.2.2 MATERIALS
Embankment and backfill will be suitable materials from approved borrow pits and cut
materials from earthworks that passed the criteria in accordance with the technical
specifications.
Borrow pits development will just commence after the completion of laboratory testing on
samples taken from each borrow pit once passed the criteria of the technical
specifications.
Further laboratory testing will be carried out to materials continuously to ensure for its
suitability in the works.
3.2.3 GENERAL WORK PROCEDURE FOR EARTHWORKS
Earthworks including site clearing and grubbing, topsoil removal, excavation, backfilling
and embankments will basically be carried out in accordance with the procedures in the
following diagram.
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Earthwork Procedure
Inspection
Quality Control/
Work scope of approval
Laboratory Tests
required
- Decide whether OGL will be taken before or after site
Original
Ground clearance
Survey Survey
- Survey Original G.L
- Submit the results to the Engineer
- Removal of all vegetation, debris, timber, trees and
Site
Clearing
roots, etc.
&
grubbing Inspection - Demolition and disposal of structures
- Disposal of debris remaining after removal of houses
and other structures
- Topsoil from the existing embankment within the Site
Removal Boundary shall be removed or stockpiled for re-use
of
topsoil
Inspection
- After removal of the topsoil, the surface shall be
compacted properly as per the Specifications.
- Excavate and compact to the Formation Level if on site
Earthwor
ks material is suitable
Cutting - Where the excavated material is suitable, it will be
Inspection
stockpiled and re-used or directly re-used in
embankment. Otherwise, it will be disposed to spoil
areas.
- Place materials from the excavation and borrow pits in
Embankme
nt the required depth of layers
Inspection
- Spread, water, mix, grade and compact to the required
density.
Slope
Protection Inspection - Provide Slope Protection as necessary
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3.2.4 CONSTRUCTION
 Stripping of top soil
1 Stripping and collection of topsoil will be carried out by Bulldozer and loaded by
Wheel Loader and hauled by Dump Truck to the disposal area where it will be spread
out by Bulldozer.
2 Suitable topsoil will be stocked separately for future use.
 Excavation
1 Mainly Bulldozer will be used in cut and haul operations for common excavation.
2 In the case that hauling distances are greater than 100m, Excavator and Dump trucks
will be used for excavating, loading and hauling operation.
3 Excavator of 0.8~1.2m3 class shall be used for foundation and deep excavation.
4 All excavation materials derived from various excavation works shall be tested for
backfilling qualification, if qualified the materials shall be brought to the stockyard
area, otherwise the same shall be disposed to approved disposal areas.
5 To check the quality and quantity of fill materials in each borrow pit, the QC of the
Contractor shall do the required testing on samples taken from site in accordance
with the technical specifications before the development of borrow pit can commence
to export fill material to site.
 Rock Excavation (if applicable)
1 Whenever possible, excavation by excavator with hydro-breaker or jack hammer or

bulldozer with ripper shall be used for rock excavation to avoid the much dangerous
blasting work.
2 Where massive rocks are encountered during excavation, the blasting method may
be opted for expeditious execution of works under the approval of the Engineer.
3 Special care and precautions will be taken to prevent any damage or danger to the
workers and public during the blasting performance alongside the roadway in
accordance with the safe blasting operation procedure.
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4 Suitable drilling equipment will be used with air compressor 600cfm class to drill holes
of 65-90mm dia. to be charged of ammunition for blasting.
5 Various blasting patterns suited to rock excavations shall be prepared and submitted
to Engineer in advance for reference and approval.
6 Explosive materials will include gelatine dynamite, ammonium nitrate (ANFO) and
detonators with detonating cord.
7 Explosives will only be stored at the magazine room, approved for storing live
ammunitions, and handled under strict supervision by a registered blasting supervisor
with close communication and permission from the relevant Authorities.
8 Special precautions will be taken up by pre-notification of all concerned people on site
30 minutes earlier than firing using flagmen with walkie-talkies, sign boards and
sirens to prevent any accidents involving site personnel, general public, buildings and
other properties during the blasting activities.
9 Bulldozer and Wheel Loader or excavator will carry out the pushing and loading of the
blasted rock/muck materials into dump trucks for disposal to stockyard or refuse
areas to establish the formation level as per the construction drawings.
 Embankment Work
1 Before starting embankment works, the existing ground surface will be prepared free
from unsuitable and perishable materials.
2 Any confinement of water on ground cavities shall be dewatered and presence of
water saturated loose or soft compressible soil shall be scraped off from the area and
be replaced by good backfill and compacted prior to embankment works execution.
3 Trial embankment will be carried out to determine the thickness of one layer for the
filling operations and the number of passes of a vibrating roller or compactor.
4 Strict control and supervision will be maintained continuously to obtain the required
quality of materials and compaction, in accordance with the criteria established
through the trial embankment.
5 Materials for the embankments will be transported from the quality approved cutting
areas or borrow pits by Dump Truck directly unto the filling area and will be spread by
Motor Grader or Bulldozer or Loader uniformly.
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6 Water Truck with sprinkler will be used to water the embankment materials prior to
compaction to obtain the optimum moisture content after compaction. Vibrating roller
10ton class will be used in compaction to obtain the required density in compliance
with the Specifications.
3.3 ROADWORKS
3.3.1 BASE COURSE WORK
1 General
Base course work will comprise of furnishing, placing and compacting base material in
required thickness on the accepted subgrade layer in accordance with the technical
specification to the line, levels, grades, dimensions and cross section indicated on the
construction drawings or as required by the Engineer.
2 Materials
i. Base course materials will consist of a mixture of hard durable crushed rock
particles and sand (crushed sand/natural sand/ river sand) which satisfy the
grading limits and other requirements of the technical specifications.
ii. The mix design shall be proposed in accordance with the Specifications for
approval by the Engineer.
iii. Quality control of materials will be carried out properly to the specified standards
as routinely scheduled during the construction period.
3 Production of Aggregates for Base Course

(This procedure is for reference only as sand & aggregates may be purchased from local
Market/Supplier)
i. The Crushing Facilities and the Mixing Plant shall be established at the proposed
Plant Site.
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ii. Raw materials for crushing shall be hauled from approved quarry or natural stone
sources if available.
iii. Base aggregates will be produced from the crushing plant and each size of
crushed aggregates will be combined in the mixing plant to obtain the required
grading parameter as per the mix design approved by the Engineer.
iv. The mixed base course materials will be transported from the mixing plant to the
job site by dump trucks.
4 Laying Procedure
i. The transported materials by dump truck will be dumped directly into the hopper
of the base paving equipment or Motor grader, to form the specified uniform
thickness on the prepared subgrade layer without any segregation.
ii. Compaction will be executed by vibrating roller after spraying of water from water
truck to maintain optimum water content. If required, additional compaction will be
made by the tire roller.
iii. Rolling operations will begin from the outer edge of the roadbed towards the
center, gradually in a longitudinal direction, except on super elevated curves
where rolling will begin at the low side and progress towards the high side. The
number of passes of road roller to achieve the required compaction shall be
determined after trials and testing.
iv. After compaction, all voids in the surface shall be filled with base course
aggregate meeting the requirement. Water shall be applied to the surface and
compaction continued. In no case shall any vehicle be allowed to travel in single
tract during compaction to avoid formation of depression or ruts in the finished
surface.
5 Maintenance of Completed Base Course Layer
i. The completed base will be maintained throughout the work except where
portions of the succeeding course are under subsequent construction.
Maintenance will include drainage, rolling, shaping, and watering as necessary to
maintain the layer in proper condition.
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ii. After careful inspection of the completed base layer, prime coat MC will be
sprayed at the pre-determined rate by the bitumen distributor to prevent any
damage from the site traffic or heavy rain.
3.3.2 ASPHALT CONCRETE PAVEMENT
Bituminous mixture will be considered to be purchased from local suppliers (Delivery

Basis) and Asphalt concrete pavement work will be considered to be subcontracted.
1 General
i. This section of the method statement covers the provision, transportation,

spreading and compaction of bituminous mixture to construct the asphalt
pavement in accordance with the technical specifications.
ii. Bituminous Mixture will be supplied from an approved commercial mixing plant or
the asphalt mixing plant of adequate capacity will be erected at the Plant Site.
iii. The mix design shall be proposed by the Contractor for the Engineer’s approval
prior to starting asphalt paving work.
iv. Before commencing the work, the Contractor shall perform a site trial for the
asphalt paving.
v. The following data shall be recorded and submitted by the Contractor for the
approval of the Engineer.
 Density and voids achieved
 Compacted thickness of the layer
 Gradation of aggregates
 Bitumen content
 The temperatures of the mix material on discharge from the mixer, on
commencement of laying on the site, on commencement of compaction and on
completion of compaction
2 Preparation of Primed Surfaces
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Before placing the bituminous mixture, the primed surface will be cleaned of all loose
materials with power broom or power air hose.
3 Temperature Control
The temperature of the asphalt mixture will be carefully controlled in accordance with the
Specifications.
4 Transportation of Asphalt Mixture
i. Hot bituminous mixture will be transported to the site from the asphalt mixing
plant by dump truck.
ii. During the transportation, care will be taken to avoid contamination or
segregation.
iii. Each loaded dump truck will be covered with canvas to protect the loaded
bitumen from the effects of weather and dust, if necessary.
5 Laying of Bituminous Mixture
i. The asphalt mixture will be discharged from the dump trucks into the hopper at
the front of the asphalt finisher.
ii. The asphalt finisher will spread, vibrate and compact the bituminous mixture to
the required uniform thickness and surface regularity within the specified
tolerance limits.
6 Compaction of Bituminous Mixture
i. Immediately after the bituminous mixture has been spread, it will be thoroughly
and uniformly compacted by Tandem Roller and Pneumatic Tire Roller.
ii. The speed of each roller will not exceed 5 km/hr.
iii. To prevent adhesion of the mixture to the rollers during the initial compaction, the
wheels will be kept lightly moistened with water.
iv. The water will be carried in a tank equipped on the roller.
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v. Rolling will commence from the outer edge and proceed longitudinally parallel to
the center line of the road.
7 Treatment of Transverse Joints
i. Transverse joints will be formed by cutting neatly in a straight line across the
previous run to expose the full depth of the layer.
ii. The vertical face so formed will be painted lightly with a tack coat just before the
abutting layer is placed against it.
8 Treatment of Longitudinal Joints
i. In the first layer, asphalt mixture will be spread to a width which is approximately
100-200 mm wider than the designed half layer in order to make good
longitudinal joints.
ii. The longitudinal joints will be compacted to keep the correct surfacing.
iii. The following day, or after a few days, tack coating will be carried out on the free
face.
iv. In the second layer, the asphalt mixture will be spread to overlap on the
longitudinal joint by 50~100mm.
v. Then the mixture placed in the abutting lane will be tightly compacted against the
free face of the lane previously placed.
vi. Before rolling, any excess mixture on the longitudinal joints will be raked off and
discarded.
vii. The edges of both sides of the bituminous layer will be compacted finally by tire
rollers.
9 Mixing Plant Operation
i. The bituminous plant will be of such capacity to produce the quantities of

bituminous mixture required. All hauling equipment, paving machines, rollers,
miscellaneous equipment and tools will be provided in sufficient numbers and
capacity and in good working condition.
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ii. The bituminous mixture will be produced by the asphalt mixing plant in
accordance with the mix design.
iii. The mixing plant will be an automatically controlled commercially manufactured
unit designed and operated to produce a consistent mixture based on the job-mix
formula.
iv. The mixing plant used by the Contractor for the preparation of asphalt mixtures
will conform to all the requirements of the technical specification.
v. When the Contractor has completed the installation of the mixing plant, the
Engineer will be informed to check the completeness and calibration of the plant
before permitting the asphalt concrete work to commence.
10 Aggregate and Materials for Asphalt Concrete
i. Samples of aggregates will be provided to the Engineer for his approval of

aggregate sources and stockpiles prior to the start of production.
ii. Samples of bituminous materials will be obtained by the contractor and delivered
to the Engineer for his approval and will be heated to the specified temperature
so designed as to avoid local overheating and provide a continuous supply of
asphalt material at uniform temperatures at all times.
3.3.3 CONCRETE PAVEMENT WORK
1 Sequence
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2 Equipment
Equipment conforming to the following will be furnished:
i. Forms
 -. Straight steel forms will be used and for edge radii less than 200 feet, flexible or
curved forms will be used.
 -. Depth equal to thickness of edge of pavement;
 -. 10-foot minimum length;
 -. Stabilizing devices to withstand paving operations;
 -. Joint locks to join form lengths tightly together; and
 -. Clean and oil before each use.
ii. Vibrations - Internal immersed tube or multiple spud type vibrators will be used for
all paving more than 8-inches-thick. Surface pan type vibrators are more
acceptable for full-width concrete consolidation of slabs 8 inches or less in
thickness. For construction of irregular areas, hand-held vibrators will be used.
iii. Joint sealing - Sealing equipment will be provided according to the sealant
manufacturer's recommendations. Joints and concrete removal - An adequate
supply of concrete saws will be used with sufficient power to saw full depth and
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complete the work with water-cooled, diamond-edged blades or abrasive wheels.

Saws will be equipped with blade guards and guides or devices to control
alignment and depth. Standby equipment will be available along with an adequate
supply of replacement blades. Drop hammers, hydro hammers, and jack
hammers will be used to break concrete. Concrete saws shall conform to above.
Equipment will be used that will not damage the sub-grade, base, or existing
concrete slabs designated to remain.
3 Preparing Roadbed
Care will be taken to ensure the roadbed is properly prepared. The roadbed will be
uniformly dampened before placing the concrete. If traffic is allowed to use the prepared
roadbed, the surface will be checked and corrected immediately before the concrete is
placed.
4 Pre-paving Check Points
i. Samples of all materials to be used on the job will be taken.

ii. Certificates of Compliance will be on hand for materials that will be incorporated
into the project.
iii. Forms, equipment, and tools necessary to perform minimum sampling, testing,
finegrade and paving checks will be on hand.
iv. Equipment Checks:
 Presence of equipment prior to paving:

a. Fine grader and paver cutting edges, paver vibrators
b. Finishing straightedge
c. Carpet drag and tining machines
d. Curing compound
e. Concrete saws
f. Forms
 Checks of equipment during paving:

g. Fine grader cutting edge, crown & width
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h. Paver vibrators, strike offs, floats, etc.

i. Saws on the project are ready to saw when needed
 Checks of reinforcing steel (if needed):
j. Checks of lap, tie twists, staggering, bar size, elevation of steel from base
distance between bars
v. Other Pre-paving Checks:

k. String line elevation and alignment
l. Surface soft spots identified will be repaired
m. Transitions will be marked for curves
n. Steel inspected for correct alignment, elevation, staking with transverse
joints marked
o. Size and length of center line bars are correct
p. Adjustment of the hubs on super-elevated curves
q. The transition section is marked for removal of the crown
r. Steel checks as per plan details
5 Placing Concrete
Care will be taken to ensure the storing, handling, batching, and mixing material and
delivering concrete, conform to the Specification. Concrete will be placed with side form or
slip form. When a paving machine is impractical, concrete shall be placed according to
irregular area method below. When concrete is placed adjoining a previously-constructed
lane of pavement, mechanical equipment will not be allowed to be operated on the
existing lane until the lane has attained sufficient strength. The previously constructed
lane will be protected from damage by the paving equipment.
Reinforcing steel will be constructed according to the Specification. The reinforcement will
be firmly positioned on acceptable supports before placing the concrete, or after
spreading, the reinforcement will be mechanically placed and vibrated to the required
depth in the plastic concrete.
6 Construction of Irregular Areas
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In irregular areas or areas inaccessible to paving equipment, the pavement will be

constructed using side forms. The concrete surface furnish will be struck off, consolidated
and floated as followings:
i. The concrete will be thoroughly and uniformly vibrated and compacted during
placement without segregating the material.
ii. The concrete will be shaped to the required cross-section between the forms
using templates or screeds. A slight excess of concrete will be carried in front of
the leading edge of the template or screed.
iii. The surface will be floated to the required grade and cross-section.
iv. The surface will be furnished according to the Specification.
7 Joints
Joints will be installed according to the Specifications including the following method:
 Longitudinal joints will not vary more than 1/2 inch and transverse joints more than
1/4 inch from the true alignment. When curbs or medians integral with the pavement
are constructed, continuously transverse joints will be constructed through the curb or
the median. All joints will be protected from the intrusion of deleterious matter until
sealed.
 Isolated joints at structures will be formed by placing 1/2 inch expansion joint filler
around each structure that extends into or through the pavement before concrete is
placed.
 All newly-placed concrete pavements will be removed and replaced where
uncontrolled cracking occurs.
i. Longitudinal joints
Longitudinal joints will be constructed by forms or sawing. Sawed longitudinal joints (with
tie bars) will be constructed when the concrete pavement placement width exceeds 15
feet. The longitudinal joint will be constructed continuously with no gaps in either the
transverse or longitudinal joints at intersections.
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Tie bars will be placed perpendicular to the longitudinal joints with mechanical equipment
or rigidly secured chairs without damaging or disrupting the concrete. Tie bars will not be
painted or coated with any material or enclosed in tubes or sleeves.
Where adjacent lanes of pavement are constructed separately, slip form paving machines
or steel side forms will be used to form a keyway along the construction joint. Tie bars
may be bent at right angles against the form of the first lane constructed and straightened
into final position before placing concrete in the adjacent lane. Broken or badly-damaged
tie bars will be repaired or replaced.
Threaded hook bolts may be used instead of tie bars. Hook bolts will be fastened to the
form of the longitudinal construction joint. With slip form paving, tie bars may be
hydraulically inserted through metal keyways.
 Formed joints
Joints will be formed with an approved non-metallic or removable device while the
concrete is plastic. When adjacent lanes are constructed separately, the sealant reservoir
will be formed in the lane placed last.
 Sawed joints
After placing concrete, joints will be sawed as soon as equipment can be supported and
before uncontrolled cracking occurs. Longitudinal joints will be sawed immediately after
sawing transverse joints. The sawed concrete faces will be protected from drying during
the curing period. Sealant reservoirs will be saved no sooner than 72 hours after placing
the concrete.
If necessary, sawing will continue day and night, regardless of weather conditions. The
saw cut and slurry residue of adjacent concrete surface will be cleaned of slurry residue
after sawing each joint.
A joint will not be sawed if a crack occurs at or near the joint location before sawing.
Sawing will be discontinued when a crack develops ahead of the saw.
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ii. Transverse expansion joints
Transverse expansion joints will be formed according to the above. Dowel bars will be
placed through transverse joints. Dowels will be held parallel to the surface and centerline
of the slab by a metal device that remains in the pavement.
Dowel placement implanters may be used while the concrete is plastic provided they
conform to the dowel tolerance specified. All concrete that leaks into the expansion joint
space will be removed.
The preformed joint filler will be installed to the full-depth, perpendicular to the subgrade,
and continuously across the full-pavement width. Damaged or repaired joint filler will not
be used. If joint filler is assembled in sections, it will be constructed without an offset
between adjacent sections.
iii. Transverse contraction joints
Where required by the contract, dowel bars will be placed according to above. Dowel bar
sleeves and finishing caps are not required. Joints will be sawed according to above. For
adjacent lanes placed separately, joints will be constructed continuously across full width
of pavement.
Concrete edges adjacent to the joint may be rounded or beveled to a radius or length as
approved. Any joint having an insufficient opening will be re-sawed or ground. Where a
joint is larger than required, a larger size joint seal will be provided as approved.
iv. Transverse construction joints
Unless an expansion joint occurs at the same location, a transverse construction joint will
be constructed at the end of each day or where concrete placement is interrupted for
more than 30 minutes. A transverse joint will not be constructed within 3m of any parallel
joint.
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If sufficient concrete has not been mixed to form a slab at least 3m long when an
interruption occurs, the excess concrete will be removed back to the last preceding joint.
A metal or wooden bulkhead will be used to form the joint, shaped to the pavement cross-
section, and designed to permit the installation of dowel bars. Dowel bars will be installed
in all transverse construction joints whose location does not coincide with the location of a
transverse expansion or a contraction joint.
8 Surface Finishing
After floating, the surface of the fresh concrete will be checked with a 3m straightedge.
High areas indicated by the straightedge will be removed. Each successive check will lap
with the straightedge 1.5m over the previous check path.
Pavement edge slump in excess of 1/4 inch in 3m will be corrected before the concrete
has hardened. If edge slump exceeds 25mm on any 30cm or greater length of hardened
concrete, the entire panel between the transverse and longitudinal joints will be removed
and replaced.
Before the concrete has initially set, the pavement edges will be worked on each side of
transverse expansion joints, formed joints, transverse construction joints, and emergency
construction joints to produce a 1/4 -inch continuous radius and a smooth, dense mortar
finish. Mortar build-up will not be used to round edges.
9 Checkpoint for Paving
 Paving hubs are correctly set.

 The string line is tight enough to eliminate sag.
 The crown, width, and alignment on fine-grade trimming are being checked.
 Soft spots located in the grade are repaired.
 If forms are being used, check the alignment and elevation.
 Check center line tie-bars to ensure they are the size and length called for in the
plans, and they are placed in the correct position.
 Check dowel baskets to ensure they are set properly.
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 Dowel basket locations are marked accurately outside of the concrete slab to
assure accurate placement of transverse joints.
 Reinforcing steel bar types correct wire ties per lap correct, minimum stagger is
correct, rebar lap correct, level elevation along surface.
 Check plans to see if a keyway is required.
 Check plans for the size and tolerance for preformed joint material (if preformed
joints will be used).
 The pad line (the area the paver track runs on) is smooth and uniform; if it doesn't
have the contractor levels the area.
 Check proper alignment of the paver as it moves off and away from the
transverse construction header.
 Concrete is being hauled and placed correctly within the time limits; the cushion
surface is being kept moist.
 Measure the distance from the slab to the offset hub to determine if the paver is
set correctly.
 Do not add water to the concrete after it leaves the mixer.
 Take fresh concrete samples and make cylinders per the Specification.
 Required depth checks are being taken and the results recorded.
 Foreign materials such as cigarette butts; candy wrappers; soda cans; oil rags;
bits of wood, metal, and hard concrete are not permitted on the fine grade or mat.
 Check the pavement width, depth, and crown.
 Air content, slump tests, and unit weight are being performed.
 Check the concrete finishers are using the proper techniques when straight
-edging.
 The straightedge blades are checked for straightness at least twice daily.
 Use a hand float if concrete is rough or porous.
 Avoid using a bucket & brush to apply water to the concrete surface. Use a fog
spray to moisten the concrete surface under extreme conditions, and then only in
isolated areas.
 Fill any low areas in the surface with good mortar.
 The carpet drag shall be mounted on a bridge and drawn over the surface in a
longitudinal direction. The dimensions of the drag must be such that a strip of the
carpet at least 0.6m wide is in contact with the pavement surface while it is
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operated. The drag shall be kept clean and free of encrusted mortar; if it can't be
cleaned, it must be replaced.
 The surface texture should be uniform with grooves.
 Check the cure application time and rate.
 Curing blankets (if used) must be wet when laid and kept damp for at least 72
hours. Are the blankets large enough for proper coverage?
 Verify correctness of distance of header from last transverse joint.
 The concrete is properly vibrated after the header board and header steel gets
placed.
 The header is not removed until 12 hours have elapsed.
 Proper alignment is attained prior to taking off from the header the following day.
 Transverse and longitudinal joints are sawed at the proper time.
 Watch for uncontrolled cracking, when sawing transverse joints.
 Check the plans for width & depth of saw joints.
 Any cure that is removed or damaged during the curing period (72 hours) is being
reapplied correctly.
 Joint widening saw cuts and joint cleaning are inspected in accordance with the
Specification.
 Check for proper placement of backer rod and silicone sealant. Ensure tooling is
performed correctly.
 Obtain the amount of concrete batched and wasted at the concrete plant;
complete the Daily Paving Report.
 Discuss any problems encountered during the day with the Engineer to initiate
any needed corrections before the next day.
 Efforts should be made to walk along the slab, sidewalk, or curb and gutter and
observe the texture, tining or finishing, curing and saw cuts.
 Ensure the spreader and paver are cleaned and the salvage material is removed
from the grade or mat.
10 Curing
Immediately after finishing and when marring will not occur, the concrete will be cured for
a minimum of 72 hours. The concrete will not be left exposed for more than one half hour
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during the curing period. Concrete curing will be carried out by one of the following
methods:
i. Water method
The surface of the pavement and the edges of the slab will be entirely covered with water
saturated mats. Mats will be extended at least twice the thickness of the pavement
beyond the edges of the slab. The mats will be placed in complete contact with the
surface.
ii. Liquid membrane curing compound method
Sawed joints will be protected from intrusion of foreign material into the joint before
sealing. Damaged areas will be replaced immediately with additional compound.
iii. Waterproof cover method
The surface will be thoroughly moistened using a fog mist applicator. The entire surface
will be covered with a waterproof cover. The cover will be extended beyond the edges of
the slab at least twice the thickness of the pavement. Lap joints will be sealed to prevent
opening or separating while curing.
Forms will be removed when the concrete has hardened sufficiently to resist damage but
not earlier than 12 hours after placing concrete. The sides of the exposed slabs will be
protected immediately with a curing method equal to that provided for the surface. Erosion
of the sub-base course beneath the exposed pavement edges will be prevented until
shoulders are constructed.
11 Sealing Joints
Joints will be saw cut and sealed before the pavement is opened to construction or public
traffic. Sealant reservoirs will not be sawed within 72 hours after placing concrete. Each
joint will be cleaned of all foreign material, including membrane curing compound and
concrete slurry, immediately after sawing the joint. Joints will be dry blown with
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compressed air. Sealing material will not be applied unless the joint faces are clean and
dry. Preformed joint seals, silicone sealant, or hot-poured sealant will be used for
expansion joints. Silicone or hot-poured sealants will be used for longitudinal and
transverse contraction joints.
i. Silicone or hot-poured sealants.
Backer rod with a steel wheel will be installed to the depth required. The backer rod will
not be stretched or twisted during installation. The length of backer rod installed will be
limited to that which can be sealed during the same workday. Any excess or spilled
material will immediately be removed and the pavement surface cleaned. Sand or similar
material will not be used to cover the seal.
ii. Preformed joint seals
The seal will be provided in one piece in the size specified for the joint opening. Seals will
be installed with a lubricant adhesive covering both sides of the concrete joint. The seal
will be compressed to between 20 and 50 percent of its nominal width. The top of the seal
will be installed about 1/4 inch below the pavement surface. Seals that are damaged,
twisted, improperly positioned, or stretched more than 3 percent will be removed and
replaced.
12 Opening to Traffic.
Traffic will not be allowed on new concrete pavement earlier than 14 days after concrete
placement, unless concrete tests indicate that the strength of concrete has met the
requirements of the Specification or the joint sealant is not anymore tacky and traffic
debris would not imbed into the sealant.
3.4 CONCRETE AND DRAINAGE STRUCTURES
3.4.1 GENERAL
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This procedure covers the site condition survey, setting out, excavation, ground
preparation, placing of blinding concrete, installation of pipes, fabrication of reinforcement
bars and preparation of forms and placing of concrete for concrete pipe/box culvert
construction including other minor structural works.
3.4.2 SETTING OUT
The location of the pipe culverts and box culverts will be obtained from the drawings.
However the actual location on site will be determined with respect to the established
centerline and stationing after joint inspection with the Engineer.
The area to be excavated will be marked out with white sand to guide the excavator
operator. A temporary benchmark will be made at a suitable distance away from the
roadway and will be used by the surveyor to determine the bottom of excavation and other
elevations of the pipe culverts and box culverts during the construction.
3.4.3 EARTHWORKS FOR STRUCTURAL WORKS
1 Excavation
Excavator and Dump trucks will be used for excavation and haulage. If the excavated
material is not suitable to use for backfilling, the excavated materials will be disposed to
an approved dumping area and graded with Bulldozer.
The slope shall be kept in proper gradient such to prevent sliding and collapse for safety
control. For excavation in rock and limestone layers, excavated face may be kept close to
vertical.
After excavating, the sides and bottom of the formation level will be prepared manually if
usage of machines and equipments is not viable.
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The final excavated surface will be shaped properly and compacted by compactor in
accordance with the Specifications.
2 Sand or Aggregate bedding
After inspection of the excavated surface of the bed, if necessary, sand or aggregate will
be spread uniformly and compacted by vibrating compactor.
If the water level is higher than the excavated surface, drainage and sump pits will be
constructed for dewatering. Water will be sucked by water pump with proper piping
system.
3 Backfilling
After completion of the structural works, backfilling with selected material and compacted
in layers will be carried out obtaining the required density in accordance with the
Specifications. Suitable compactor will be used for compaction of backfilling materials.
3.4.4 BLINDING CONCRETE
Formwork for the blinding concrete will be set and braced to the required dimensions of
the blinding. The required top level will be checked by the surveyor and marked on the
forms.
The formwork will be checked to ensure straightness, strength and tightness. The
elevation of the top of blinding will be also checked before placing the blinding concrete.
Blinding concrete will be provided as required by the Specification.
3.4.5 BOTTOM CONCRETE AND WALL CONCRETE
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Formwork and reinforcement for the bottom slab will be fabricated on the blinding
concrete. Precast spacer blocks will be used to provide the required concrete cover for the
sides and bottom. The top level will be marked out by surveyor and a line will be drawn to
guide the masons of the limit when placing concrete.
The completed reinforcement and formwork will be inspected to ensure that the required
number and sizes of bars have been used and their lengths and locations are correct. The
dimensions, squareness and adequacy of the forms will also be checked.
When the Engineer is satisfied with the results of the inspection, concrete will be placed.
Sufficient number of vibrators will be used to ensure thorough compaction of the slab.
3.4.6 INSTALLATION OF PIPES
The pipes will be set in position on the bottom, where bedding and foundation become
hard through compaction work, by the lifting crane. The pipes will be well arranged, tied,
braced, wedged and packed as tightly as possible.
After setting, it is needed to be examined whether the connection remains in position.
3.4.7 FABRICATION OF SURROUND FORMWORK
Timber and plywood needed for the formwork will be cut to shape at the carpentry shop
and transported to the site. Form material will be cleaned and coated with form release
agent or form oil before placing concrete.
The formwork will be erected and firmly braced against the walls of the excavation to
restrain any possible movement during the placing of concrete.
The completed formwork will be inspected by the Engineer before placing concrete.
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3.4.8 PLACING OF SURROUND, WINGWALL AND HEADWALL

CONCRETE
Concrete for structural works will be produced in the batching plant in accordance with the
required mix design. Prior to placing concrete, form & foundation will be moistened by
clean water.
Concrete mixer trucks will be used to transport the concrete to the site for concrete
pouring of the pipe culvert within appropriate interval to prevent it from setting before
placing and to avoid cold joint. Concrete admixture, if necessary, will be added to the
batch during mixing to increase its workability and likewise the setting time. Concrete will
be placed by concrete pump car 47~80m3 class. Sufficient numbers of concrete vibrators
will be used to avert any voids or honeycombs and provide adequate compaction but
avoiding over vibration to prevent concrete segregation. Concrete will be placed in layers
of 300mm ~ 500mm. Placing of concrete will start from one end of the culvert to the other,
placing the wing walls first as priority. To avoid cold joints, appropriate pouring sequence
shall be decided prior to commencement.
3.4.9 CURING CONCRETE
The completed culvert will be covered with wet sacks/cloth for curing. A water tanker will
be used to spray water on to the new concreted culvert from time to time until it is fully
cured. Moistened hemp sack will be placed on the fresh concrete to help provide sufficient
hydration and to prevent shrinkage cracks. Wide areas or difficult places for wet curing will
be cured by curing compound. Curing compound material shall be approved by Engineer
prior to use.
3.4.10 STRIPPING OF FORMS AND DRESSING
After the elapsed of 24 hours after pouring of concrete, the formwork may be stripped off
from the sidings of walls and ground slabs taking care not to damage the concrete
corners. For suspended slabs and members, sufficient number of days is necessary for
curing to achieve enough strength prior to removal of bottom forms.
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After removing all the forms any defects on the concrete surfaces will be repaired and the
surface dressed to a smooth finish for all exposed areas depending on the applicable
finishes mentioned in technical specifications.
3.4.11 BACKFILLING
After stripping of forms and dressing the completed structure will be inspected by the
Engineer before backfilling proceeds.
Backfilling will be carried out in approved layer thicknesses as per technical specification
requirement for assuring good compaction using selected materials. Water, if necessary,
will be mixed with the backfilling material to ensure that the right moisture content is
attained for full compaction.
Mechanical vibrators shall be used whenever applicable otherwise manual compaction

shall be done on narrow sections where usage of mechanical vibrators is unviable using
tamping tools and rods.
3.5 PIPELINE WORKS INCLUDING PIPE JACKING
3.5.1 GENERAL
This procedural write-up presents a method that includes setting out, earthworks, pipes
and fitting materials and ancillary structures for the proper laying and installation of pipes
for major pipelines, inter-process pipework and other pipe network for conveying raw and
treated sewage from sourced process structure into another process structure of STW.
3.5.2 PIPE MATERIALS
In this procedure, it is hereby proposed to use two kinds of pipe for sewer network namely
the Ductile Iron (DI) pipe and the Glass Reinforced Plastic (GRP) pipe. These two
proposed pipes are nowadays extensively used in small and large scale sewerage
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projects due to its technological edge and economical advantages greater than other
kinds of pipe.
Pipes of good quality and satisfy the technical specification requirement can only be used
in the work when approved by the Engineer.
3.5.3 PIPE PROCUREMENT, LOADING, UNLOADING, STOCKPILING &

SHIFTING
The materials shall be procured in advance to site prior to commencement of piping work
to avoid possible delays in the work. The material department shall, in coordination with
planning department based on work schedule, in advance prepare the ordering,
purchasing, receiving, unloading and stockpiling of materials on site for a minimum
quantity that could last for at least 3 months continuous work. The pipes and fittings shall
be purchased from approved vendors only. A suitable place for stockpiling and storing the
materials shall be appropriated on site for safekeeping most preferably nearby the working
areas.
The delivery, loading and unloading of pipes will be strictly controlled on site so as not to
collide with the other pipe sections or fittings or hard objects during lifting operations. Care
should be taken to avoid collision, chipping, i.e., to the spigots and sockets during
stockpiling. As much as possible, stockpiling of pipes will be done as near as possible to
where the pipes will be installed to enhance the velocity of work. The classes of pipes
shall be stocked separately based on diameters & length. Avoid mixing up smaller
diameter and bigger diameter pipes in one file to prevent damages or crushes of smaller
pipes.
The pipes should be unloaded and stored on levelled ground surfaces to have stability.
Use wooden flanks and wedges on the sides of pipes to level, separate and restrain from
moving and rolling of pipes laid on uneven surface to avert damages. When pipes are
stored in layers, wooden flanks and wedges shall be used as separator between each
layer to avoid direct contact of pipes surfaces and leaving a gap in between for easy lifting
especially for the big diameter pipes. Leaving no gap or clearance between the bigger
diameter pipes laid down in layers shall cause difficulty during lifting because the lifting
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sling or strap cannot be inserted properly to be fastened or wrapped around the pipes. If
the lifting strap or sling is not fastened adequately, it may cause serious accident when the
sling gives in during lifting. Avoid very high stocking heights of pipes in multi layers
stockpiling for safety operations.
Covering the pipes with old unused burlap or cloth or tarpaulin will be of benefit as it can
protect the pipes from getting damage, direct sunlight, rain and preserve its good quality.
As for loading to and unloading from trucks, caution will be needed not to damage the
pipes by rolling on slope as shown below.
When the pipes are moved from storage to working areas for installation, the lifting
devices such as sling, chain, steel wire, cable and rope should be connected and wrapped
around the pipe in a way that strong grip is established while maintaining the balance free
lengths of rope to maintain the horizontal position of pipe when suspended during lifting.
Figure below may be referred to.
3.5.4 SURVEY, SETTING OUT AND PIPELINE ALIGNMENT

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The location and alignment of pipe elements of the network will be obtained from the
orientation data of the drawings. Staking out during survey works shall first be reckoned
from co-ordinates of the Qatar National Grid. The actual locations, however, of pipe
networks on site will be determined with regard to the established centerlines and
stationing after joint inspection with the Engineer. All pipelines will be accurately laid to the
lines, levels and gradients designated on drawings. The pressure pipelines will be located
at the position of bends and fittings and the gravity pipelines will straightly be located at
the position of the center of manholes and chamber covers. The work on each element
will be commenced after approval of the setting out by the Engineer.
Temporary benchmarks reckoned from true benchmarks provided by the Engineer as

survey references shall be established and populated in the vicinity of the working areas
by the survey team of the Contractor at suitable intervals keeping a distance away from
the excavation areas and the roadways. These temporary benchmarks shall then be used
as occupied backsight and offset points by the surveyor for laying out the exact route of
the pipe network and for determining the formation level of excavation bottom and other
elevations of the pipe during the construction. The lines to be excavated will be marked
out with white sand or gypsum powder to guide the excavator operator during excavation.
For pipelines alignment, the lines and grades are usually established by one or
combination method; a) reference line established by a laser of EDM (Electronic Distance
Measuring) or Total Station instrument; b) control points consisting of stakes, spikes, plug
and so on set at the ground surface and offset a certain distance from the pipe centerline;
c) control points established at the trench bottom after the trench is excavated; d) trench
bottom and pipe invert elevations while excavation and pipe installation progresses. When
pipe is installed by the trenchless excavation, such as jacking or tunneling, an accurate
control point will be established at the bottom of the jacking pit or work shaft by precision
survey instruments.
3.5.5 EARTHWORKS FOR SEWERAGE WORK
1 Excavation, stockpiling, dewatering and disposal
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The trench grades, as the excavation progresses, shall continuously be monitored against
the elevations established in pipeline profile. Improper trench depths can result in high or
lower spots in the line. Very wide trench shall require more backfilling materials and
increase the time of construction and likewise its cost. While very narrow trench can result
into difficult pipe installation, slow pace of work and delays in installation. Excavation
trenches and pits shall be shaped with appropriate depth, side slopes and side clearances
to expedite the pipe installation work and save time and money. Trenchless excavation
shall be explained separately.
For an open excavation and stockpiling, the Backhoe 0.8m3 class and Dump trucks 15ton
class with overhead bucket cover will be used. If the excavated material is unsuitable to
use for backfilling, the same will be disposed to an approved disposal sites and graded
with Bulldozer. The slope shall be kept more than 1:1 for loose soil to prevent sliding and
collapse for safe control. Preferably, QC personnel shall attend in the excavation work to
check and determine the good excavated soil which can be utilized for backfilling of pipe
trenches. Good excavation materials shall be stockpiled beside the trench on one side
only while leaving the other side open to serve as entry point of pipes and other materials
during installation.
As the ground formation level of the bottom of trench

after excavation may not be even by means of
mechanical excavation, an attention will be required. The
materials such as rocks, metal pieces, hard objects and
the likes that caused undulations or irregularities on the
excavation surfaces of trench, will be removed by all means because they are the major
attributes for damaging the installed pipes.
The trench sides will be battered to form vertical face on the hard and stable soil to be
approved by Engineer and if necessary, the sides shall be provided by the side supports
to avoid collapses in accordance with the specification and good practice.
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When excavating the very sensitive area wherein accuracy is needed on specified levels,
the bottom of excavations will be carefully boned in and trimmed to grade with the aid of a
straight edge.
To control the presence of surface and subsurface water in the trench, dewatering using
submersible pumps inside the sump pits of suitable interval along the trench length is
required so that dry conditions will be provided during the pipe laying. Ground water
conditions will be investigated before they are actually encountered on site to determine
the applicable work strategy during the course of the excavation.
2 Bedding
After the inspection of the trench formation surface, if necessary,

approved bedding materials will be spread on the trench
uniformly and compacted by vibrating compactor 0.6ton class or
plate or tamping compactors.
For laying procedure of DIP and GRP pipes, the pipe will be bedded on compacted
granular material or densely compacted backfill placed on the flat bottom trench. The
bedding materials will have a minimum thickness as specified and will extend upward the
sides for appropriate width.
If the water level is higher than the excavated surface, drainage and sump pits will be
constructed and the water will be discharged by water pump action.
3 Backfilling
After the completion of the bedding work and the installation of pipes & fittings, backfilling
with approved materials and compacting in layers will be carried out and compacted to
obtain the required density in accordance with the specifications. Water sprinkling shall be
done prior to compaction to help achieved the require moisture content during
compaction.
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If the excavated material from the trench is to be used as backfill, the stockpiled materials
will be inspected to get rid of the big rocks and other objectionable and deleterious
substance. If the excavated materials have not met the requirement of technical
specification or there is a need of additional materials for filling up the trench, the same
will be imported from approved borrow pits or may be purchased from the selected backfill
materials from the market.
Once the envelope of backfill material is put in place and properly compacted, the
reminder of the fill or backfill will be placed in layers and compacted to prevent settlement
at the surface. Several types of compaction equipments are available and certain types
are best for particular purposes based on types of soils. Regardless the type of
compaction equipment used, the backfill material will be consistent with the requirement of
the specification.
Usually, the compaction of the hunch part of foundation of pipe

is insufficient due to difficulty and space constraint. The ratio of
deformity in installed pipes will be increased if compaction is not
taken care of. After the lining up of pipes, the compaction on hunch part shall immediately
be conducted again.
Normally, the procedure and method for compaction and backfilling

around pipes are as follows:
Firstly, it is necessary to allocate and position the filling materials into

both side of pipe and compacted manually on both sides underneath
of the pipes prior to placement of succeeding backfill, because it will
create difficulty in filling the materials up at the floor side of pipe.
Secondly the floor side of pipe will manually be compacted to prevent

the void. For compaction at side of pipe, it is necessary to backfill
through the compacting device gradually achieving a proper unit
depth. The backfilling will proceed in approved thickness of layers and
be compacted as per specifications up to designed height at the crown
of pipes until it is completed.
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3.5.6 LAYING OF PIPES
After excavating the trench and the suitable bedding material has been casted and
compacted in place, the worker then will furnish all necessary equipments for properly
lowering and placing sections of the pipe into the trench without damaging it while
installing the pipe on place. The pipes will be carefully lowered onto its prepared bed by
means of appropriate slings and tackle.
Prior to installation of the pipes, the Contractor may read more information about the
installation and jointing procedure of the pipes from the manufacturer’s installation
manual.
Generally, there are common cautions needed for properly installing the pipe in the trench
as enumerated below:
1 Bedding and foundation for pipes will become hard through

compaction work which will lose its absorption or cushion
effect. Thus, pipes may get damage during installation or after
complete compaction. Sand or gravel bedding usually is not
compacted so hard so as to act as shock absorber or cushion for pipes during
installation and operation.
2 For leveling of bedding, it is needed to remove the

unevenness of the bottom of trench. Wooden or perishable
blocks are not allowed to be used as wedges for leveling of
pipes as it may create voids when it decayed.
3 Where it is necessary to find out the position of connection part, the ground at
connection part will be excavated cautiously toward
proper depth to prevent the pipes become messy of the
excavated soil when jointing again in the connection as
this may cause leakage in the joint.
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4 For transportation of the pipes to working place, it is necessary to carefully handle the
lifting and the lowering operations of pipes using the lifting and moving device.
Special attention will be required to prevent the happening of hard strike against the
bottom of trench and other pipes to avoid the pipes getting damaged.
5 Prior to homing the spigot into the bellmouth, it is

lubricant
necessary to lubricate the surface of spigot with gasket
and socket to enhance the connection process. Only
approved lubricant will be used.
6 The backfilling will only proceed after removing all the

temporary pipe supports out of the trench.
 GRP Pipe Installation
As for the installation of GRP pipes, firstly, the

connecting mouth will be made clean and be eye-
spot checked for any damage on pipes. The sand or
any contaminations entered into rubber seal will also
be removed prior to homing procedure.
For installation works using insertion device and wire rope, the devices such as fixture
tools and wire rope used for connection of pipes will always be checked for firmness and
adequacy to prevent any untoward incident. Ropes with cuts and clumsy clutch tools are
forbidden in the work. Use only new and reliable ropes and tools.
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At any time of the day, it is necessary to check the safe stance and position of the work
carefully. In case of installing the rather large diameter pipe, the connection work will be
supported using the
wire rope tied at inner
side of pipe. The wire
rope will be fixed with
shackles for allowing
the body adjustment.
Moreover, the wire
rope shall be hung and
supported by the metal
holdings or any
adequate structure strong enough to carry the load with 3 time safety factor to avoid
accident during the installation work.
To increase the efficiency of jointing work,

lubricant is recommended to be applied on
surfaces of the joining pipes to enhance the
insertion time. A vegetable lubricant, mixed ratio
with oil over water is 1:1, or a neutral detergent
dissolved in water will be recommended to be
used as lubricator so that it may reduce the force required for insertion by 50% or more.
As sand or soil may stick on the surface after coating with lubricant, it is necessary to
recoat again the surfaces with lubricant to get rid of the dirts.
After finishing the work preparation for pipe connection described above, the lining up of
pipes will proceed. At the time of lining up, while the pipes are
brought down in queue for connection in the trench, the spigot
and mouthbell arrangement shall be done in succession forming
a straight line. For sleeve type, it must be pipe-sleeve-pipe
arrangement system. All necessary accessories for joints and
fittings, i.e. rubber sleeves, caulk, watertight rings and etc, shall
be got prepared together with the pipes. Once the above exercise has been done, homing
shall proceed by pushing one pipe to the other succeeding pipe inclusive of required
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accessories for jointing. Extra care shall be observed when connection work is undertaken
as hands of workers may get caught while maneuvering pipes during insertion. During
insertion work, an approximately 12~15mm gap between the stopper and cross section of
pipe shall be provided so that adjustments could be made for making straight alignments
or bends.
Regarding the checking after the connection of pipe, it is needed

to both examine whether the marked line at insertion is matching
to the tip of fitting with parallelism and whether there is any tearing
or grazing of ring. If it is so, then repeat the procedure and replace
the ring.
Lifting eyes and adjusting metals attached on the

pipes and sleeves shall immediately be removed if
not required prior to backfilling. This could be
detached by hand cutting tools and to finish off the
work by grinding with disc blade grinder. Proper
safety gears and paraphernalia, i.e., helmet, safety
shoes, hand gloves & etc. shall be worn by all
workmen at work all the time for safety and protection.
 DI Pipe Installation
The laying procedure in case of the DI pipe will be described briefly as bellow:
Placement of pipe will start at the outlet end of the line of pipe sections. The socket end
will be pointed upstream and the spigot will be pointed downstream. This helps prevent
bedding material from being forced into the socket during jointing and it enhances the
coupling of pipe sections. The joint is designed for ease of installation and the
manufacturer’s recommendations regarding to the jointing procedures will be closely
followed to assure resistance to infiltration of groundwater and/or backfill materials into the
installed pipes.
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The inside of the socket, gasket and the inserting plain end will be kept clean throughout
the assembly period and bearing in mind that joints are only as watertight as they are
clean. If joint is somewhat difficult to assemble, it is necessary to inspect again for proper
gasket position, adequate lubricant, and presence of foreign matter in the joint.
Prior to insertion of gasket in place, all foreign matters, such as

mud, sand, cinders, gravel, pebbles, trash materials and the
likes, in the socket shall be removed out from the socket and
spigot. Then gasket seat will carefully and thoroughly be
inspected to be clean. The gasket will be wiped with a clean
cloth. Then the gasket will be placed in the socket’s groove with
the large round end entering first so that the gasket will be
seated evenly around the inside of the socket reel with the heel of the gasket fitting snugly
in the retainer seat. As gaskets are usually kept in warm water for improving flexibility &
plasticity during installation, they will be wiped with cloth to dry up before placing into the
pipe socket.
Upon completion of the above exercise, a thin film of joint

lubricant recommended by supplier will be applied to inside
surface of gasket which will come in contact with entering plain
end of pipe. The plain end of the pipe up to the stripes will be
thoroughly cleaned of all foreign matter on the outside surface
prior to insertion work. Since the foreign matter that adhered to the plain end will cause a
leak, therefore the plain end of pipe will be handled with care without touching to the
ground or trench side after lubricating. As per initial entry of pipe, the plain end of that will
be aligned and carefully entered into the socket until it just makes contact with the gasket.
In order to complete the assembly, the joint will be placed by forcing the plain end of the
entering pipe through the gasket, which is thereby compressed, until it makes contact with
the bottom of the socket by one of the methods stated herein. It is
necessary to confirm whether the first painted stripe has
disappeared in the socket and the front edge of the second stripe
will be flushed with the bell face. If the assembly is not
accomplished by the application of reasonable force on the
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recommended method, then the plain end of the pipe will be removed again to check for
the proper positioning of the gasket. Then the procedure shall be repeated until the
assembly is homed.
For the joint assembly, a jack typed tool may be used

to make up the joint. The jack will be placed on top of
the pipe with the double hooks on the bottom of the
jack placed immediately at back of the bell of the next
adjoining pipe and rack extending over the plain end
of the entering pipe. The bell sling is placed under and around the pipe with double hooks
and eyes of the sling placed over the hooks. After the choker sling is double-wrapped
around the plain end with one eye hooked to the end of the rack, the plain end is pushed
in by movement of the jack handle.
Alternately, the joint will be disassembled by placing jack

on plain end as indicated with lug on back end of rack
bearing on face of bell. The motion of jack handle will
cause lug on rack to push against face of bell and move to
end out of socket.
3.5.7 PIPE JACKING METHOD FOR TRENCHLESS EXCAVATION
1 General
Pipe jacking, is a technique for installing

underground pipelines, ducts and culverts.
Powerful hydraulic jacks are used to push
specially designed pipes through the ground.
The method provides a flexible, structural,
watertight, finished pipeline.
There is no theoretical limit to the length of individual pipejacks although practical

engineering considerations and economics may impose restrictions. Drives of several
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hundred meters either in a straight line or to a radius are routine. A number of excavation
systems are available including manual, mechanical and remote control. Pipe in the range
150mm to 3000mm, can be installed by employing the appropriate system. The pipe
jacking method generally requires lesser overbreak than segmental tunnels, providing
better ground support.
Excavation methods are similar to those employed in

other forms of tunneling using either manual or
machine excavation. Shields, excavation and face
support can be provided for a wide variety of ground
conditions.
In order to install a pipeline using this technique, thrust

and reception pits are constructed, usually at manhole positions. The dimension and
construction of a thrust pit may vary according to the specific requirements of any drive.
The excavation to be mechanized may require larger pits than hand excavated drives,
although pipe jacking can be carried out from small shafts to meet specific site
circumstances.
A thrust wall plays a roll to provide a reaction against which to jack. In poor ground, piling
or other special arrangements may have to be employed to increase the reaction
capability of the thrust wall. Where there is insufficient depth to construct a normal thrust
wall, for example through embankments, the jacking reaction has to be resisted by means
of a structural framework constructed above ground level having adequate restraint
provided by means of piles, ground anchors or other such methods for transferring
horizontal loads.
High-pressure jacks driven by hydraulic power packs provide the substantial forces
required for jacking concrete pipes. The ram diameter and stroke of the jack may vary
according to an individual Contractor’s technique. Short stroke jacks with multiple spacer
blocks, medium stroke jacks with shorter length pipes or long stroke jacks, which can
push a full length pipe at one setting may be used.
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To ensure that the jacking forces are distributed around the circumference of a pipe being
jacked, a thrust ring is provided of a design dependent on the number of jacks being used.
The jacks are interconnected hydraulically to ensure that the thrust from each is the same.
The number of jacks used may vary because of the pipe size, the strength of the jacking
pipes, the length to be installed and the anticipated frictional resistance.
A reception pit of sufficient size for removal of the jacking shield is normally required at the
completed end of each drive. The initial alignment of the pipe jack is obtained by
accurately positioning guide rails within the thrust pit on which the pipes are laid. To
maintain accuracy of alignment during pipe jacking, it is necessary to use a steerable
shield, which must be frequently checked for line and level from a fixed reference. For
short or simple pipe jacks, these checks can be carried out using traditional surveying
equipment.
2 Conditions of Construction
 Choosing hydraulic jack capacity based on the ground condition and matching with
hydraulic unit which accommodate the required thrust.
 Proper thrust equipment installation to accomplish the hydraulic jacking.
 After the engineering estimation of the required thrust force, reaction wall which
contains the strength comforting to the thrust force should be erected. In general,
reaction wall is constructed with plain concrete. However, Reinforced Concrete
bearing wall should be used in the cases of bad ground condition, highly required
thrust force and difficulty securing the thrust fortress space.
 The applicable pipe diameter ranging from 700 mm to 3,400mm
 The length from the top soil surface to the planned pipe level should be more than 1.5
times of the pipe diameter. Otherwise, investigation of the ground should be
thoroughly carried out in advance
< Jacking Set-up View>
Variable Road
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Platform
Sheet or Cut Back Earth If required
Trench / Pit
Vertical Earth Face

GRP Pipes
Vertical Earth Face
Backstop
Jack(100ton)
Guide Timbers/Platform
Rope, Metal Strips, Tarpaper
or Grout in Joints
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Work Procedure, Description & Site View
< Procedure > < Description >

Soil & Structural ① - Investigation of soil & Structural facility in the working area for
Investigation geological feature and analysis
② - Acquisition of the working boundary for initiating the pipe

Work Area Acquisition
jacking works.
③ - Survey for positioning thrust & arrival mouth

Workshop Construction - Excavation up to the planned level
(Thrust & Arrival Mouth) - Temporary facilities(Sheet pile and Strut)
- Water Pit for dewatering (Well Point Method)if necessary
④ - Reinforced Concrete in conformity with drawing.

- Bearing power equal to 200% of the estimated maximum
Reactive Wall Installation
jacking pressure.
(Thrust Mouth)
- Installation of H-Pile deep into the ground to support the wall
against the thrust force.
Lean Concrete Placement at the ⑤ - Placement of lean concrete parallel to the pipe line to be
Bottom (Thrust & Arrival Mouth) installed after placing rubble
⑥ - The type of backstop and jacking frame to be decided based

Hydraulic Jack & Unit Guide Rail on the nature of site and character of the material.
Installation - Jacking head leaving an opening for an entry and exit of
(Thrust Mouth) workman and material.
- Guide rail installation according to the planned thrust line
Digging the Soil ⑦ - Digging soil inside the pipe and one inch above grade at the
inside & around the Pipe (GRC) bottom and one inch larger than the pipe around the pipe.
⑧ - Jacking until the effective limit of the jack.

Jacking & Blocking - Blocking and Jacking until enough room for another piece of
(GRC) pipe is made.
- Maintenance of the planned pipe line and level
- Cleaning of dirt or other matter for effective jointing & bonding

Jointing & Bonding ⑨ of the new pipes
(GRC) - Solid jointing and bonding keeping the planned pipe line
- Place Rope, Metal Strip, Tarpaper or Grout in Joint
⑩ - After the completion of the pipe jacking into place,

Backfill & Compaction
- Backfill should be tightly compacted around the pipe
Completion Clearance of the site area for the pipe jacking

⑪
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< Working Site View >
Jacking under the road - 1 Jacking under the road - 2 Hydraulic Jacking Equipment
Thrust Pit - 1 Thrust Pit - 2 Site View
Hydraulic Unit
Generator
Arrival Mouth
GRC
Pipe
Thrust Mouth
Jack
Reactive Wall
Lean Concrete Guard Rail
GRP Pipe
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Guard Rail
Lean Concrete
3 Equipment Setting for Pipe Jacking

 Hydraulic Jack
 Hydraulic Unit
 Electrical Welding Machine
 Generator
 Guide Rail (Timber & Steel)
 Steel Plate & H-Pile for supporting the estimated thrust force
 Transportation for Discharge Soil
 Air Compressor for discharging soil inside the pipe
 Reinforced Concrete Wall (Reaction / Retaining Wall)
3.5.8 METHOD OF CONNECTING

PIPE TO EXISTING SEWER
MANHOLE
Specific connection method shall be employed

using perforation technique through the manhole
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wall. The perforation work shall be executed without suspension of inflow of sewage in the
manhole for continuous operation by using a special machine for coring. This perforation
method is proven advantageous as;
1 It shortens the working time of connecting the pipes in just an hour or two.
2 It minimizes the force impact exerted against manhole structure thereby preserving
the structural adequacy of the existing manhole during perforation
3 The perforation and connection works can be done simultaneously without stopping
the flow of sewage in the manhole.
The brief work procedure may be stated as below:
1 Examine the pattern of sewage inflow of existing

manhole and the time in the event of lesser inflow will
be determined. The time of lesser inflow occurrence
shall be used as referenced time for perforation work
undertakings.
2 The point of perforation on the wall of manhole will be
determined in reference with the onsite condition and
will be marked out after removing any obstruction and foreign matter on target part.
3 Bypass operations using the submersible pump/s for transferring the inflow of sewage
from manhole to bypass pipelines shall be prepared. Submersible pump/s will be
installed inside the manhole and then will be ready
to operate once required.
4 The perforation work will then be performed along
the line of mark on the face of the wall of manhole
to be finished perpendicular to tangent line of center
of manhole while the pump will be put into operation
simultaneously.
After the perforation work has been finished, the connecting pipe will be connected with
manhole by means of sealer or water proof materials.
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3.6 APPURTENANT WORKS
3.6.1 PERMANENT PAVEMENT MARKINGS
This work consists of applying permanent pavement markings and raised pavement
markers on the completed pavement.
Where existing and final pavement marking locations are identical, the limits of all existing
pavement markings (no-passing zones, edge stripes, etc.) will be staked before any
pavement work. Upon completion of the final surface course, the line limits for the new
pavement will be established for approval. Markings will be established according to the
Specification. In curve widening areas, application of the pavement edge markings will be
applied at the edge of the traveled way and the centerline markings midway between the
pavement lines.
Loose particles, dirt, tar, grease, and other deleterious materials will be removed from the
surface to be marked. Temporary pavement markings will be removed the same day
permanent pavement markings are applied. Markings will be applied to a clean, dry
surface according to the Specification.
A field demonstration may be required to verify the adequacy of manufacturer’s

recommendations. Pavement markings will be applied in the direction of traffic according
to the manufacturer's recommendations. All markings will be applied to provide a clean-
cut, uniform, and workmanlike appearance by day and night.
Marked areas will be protected from traffic until the markings are fully dried to avoid
damages on applied markings. All tracking marks, spilled marking material, markings in
unauthorized areas and defective markings will be removed.
On areas to be marked on rigid pavements and old asphalt pavements, an epoxy resin
primer/sealer will be applied according to the manufacturer's recommendations. The
primer/sealer will be allowed to dry paint on surfaces when the pavement and air
temperatures are within the manufacturer’s recommendations. For application, the
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recommended dry film thickness or dosage rate will be sprayed or extruded. The minimum
bond strength of the thermoplastic shall comply with the specified requirements.
3.7 BUILDINGS
3.7.1 CONCRETE WORKS
A. General
The Site Construction Manager shall be responsible for the concrete work operation. His
duties also include liaising with the Resident Engineer for inspection prior to concrete
work. The QA/QC Manager shall be directly responsible for assuring compliance with the
specifications. His duties further include:
Implementation of the quality control plan to ensure accurate and adequate inspection
compliance with specification and direct corrective action upon occurrence of non-
compliance to specification.
B. Plan for Concrete Works
C. Materials
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D. General
Concrete shall be made of cement, aggregate and water. No other constituent material
shall be used without the approval of the Engineer. All materials used in the work shall
comply in all respect with the specified standard or specification, unless especially be
excluded or modified to suit the requirement.
i. Cement
The cement used shall be Portland cement unless otherwise specified. The
manufacturer’s test certificates shall in general be accepted as proof of soundness.
ii. Aggregate
Because aggregates make up roughly three-quarters of the volume of concrete, the

structural strength of a concrete is heavily dependent on the quality of its aggregate.
The aggregate shall be hard, durable and clean, and shall not contain deleterious material
in such a form or in sufficient quantity to affect adversely the strength at any age or
durability of the concrete.
iii. Water
All water used in the concrete works shall be from the public mains and shall be fresh,
clean and free form all harmful matter in suspension or solution.
iv. Admixture
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The only approved admixture shall be used strictly in accordance with the manufacturer’s
instruction and recommendations, particularly with regard to the dosage requirements of
the admixture in concrete.
The admixtures shall not be the materials, which can adversely impair the strength,
durability or appearance of the finished concrete works, to use without Engineer’s
approval.
E. Concrete Mixes
The concrete mixes shall be designed to have a target mean strength greater than the
specified characteristic strength.
The concrete mixes and its production shall be carried out according to the designed
concrete mixes of tender specification.
F. Batching Plant
The system shall be inbuilt protection codes to stop unauthorized batching or mix changes
in both automatic and semi-automatic modes. These codes shall be known to QA/QC
Manager, the Plant Manager and Batch Plant Supervisor.
The plant shall be run in manual mode in the following cases:
 Partial system failure i.e. admixture pump breakdown during auto cycle requires plant
to be switched to manual to change pump number and continue.
 Total system failure whilst supplying critical sections that cannot be stopped. This
would only happen in the presence of the QA/QC Manager or Plant Manager and
recorded in the delivery note batch records. If possible, the pour shall be stopped at
the earliest opportunity to avoid the formation of cold joints.
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An independent check shall be carried out for the produced concrete. Adequate spare
parts shall be stored and maintained ready to use in case of breakdown. Internal
calibration of the batching plant shall be carried out at 3 monthly intervals.
The raw material quality control procedures shall be in place to identify any deviations in
all aspects of concrete production at the earliest possible opportunity. It is a system based
on preventative measures and includes ensuring a single source of materials and regular
QA/QC testing.
Material is stored in a separate stockpile and is batched from separated overhead bins,
which are designed to prevent contamination from 20mm bins. A separate stockpile of
1000MT of sand and 1500MT of aggregate shall be kept covered at all times.
This stockpile shall be kept for use in extended heavy rain periods and when concrete
temperature is becoming different to maintain requiring sand of a lower moisture content
to be used to allow for a higher addition of chilled water.
G. Ready-Mixed Concrete
Ready-mixed concrete shall be produced at an approved depot, which shall be certified to

meet requirements of the local authorities.
All delivery tickets shall be retained and included following items after discharge of each
batch of concrete.
 Arrival and departure times of the truck

 Details of extra water or other materials added on site
 Position in the works where concrete is placed.
In the case of truck mixed concrete, the water shall not be added after arrival at site. The
concrete is to be agitated continuously by rotation of mixer drum during transport to the
site and while awaiting discharge. Concrete shall be discharge from the delivery vehicle
within 2 hours after the time of loading.
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H. Concrete Order
The ordering of all concrete supplies shall be arranged by the construction supervisor who
completes a Concrete order form; obtain an approval signature from the Site Construction
Manager before ordering details to the concrete supplier and distributes a copy to the
QA/QC Manager for the purpose of arranging inspection. The concrete shall include such
details as mix code, quantity, and grade, interval of load, lot number and day/time
required.
The lot number basically identifies the location of the concrete to be poured. This shall
help with product traceability.
I. Distribution of Concrete
Traffic controller each from the Contractor and supplier shall be stationed at the entrance
and lead concrete truck to the pump station.
Concrete shall be delivered to the point of placing, as quickly as possible & economically
as possible without allowing segregation, loss of any constitutes, contamination with
water, or any other material, after it has left the mixer.
The two most common methods for distributing concrete area from a concrete mixer truck
by pump or crane handled skips.
J. Concrete Pumping Method
i. The sitting of the pump shall be such that delivery vehicles have easy access and
that two vehicles can be accommodated, so that as the first vehicle finishes, the
other can immediately start thus maintaining a continuous flow of concrete. The
choice of pump location shall also take into account the need to keep pipelines as
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short and as straight as possible. Good communication between the pump

operator and the placing gang is essential.
ii. The pour shall be planned so that pipe may be removed as it progresses. Pipes
shall never be added. All couplings shall be completely free from leakage,
otherwise loss of fine materials from such locations is more likely to result in
problems free from leakage, and otherwise loss of fine materials from such
locations is more likely to result in problems due to blockage. In hot, sunny
weather it shall be necessary to protect the pipeline from overheating. In such
conditions, concrete in the pipeline shall be keep moving.
iii. Concrete in pump pipelines is often under considerable pressure. Where pipes
are to be disconnected during concrete pour, the pump shall be stopped and, if
possible, reversed. Flexible and sections of pipes shall move violently when a
cleaning plug is passed through and personnel shall be kept well clear.
Scaffolding shall be designed to accommodate the vibration and additional
loading caused by pipelines testing on it.
iv. Concrete shall be placed by a mobile pump method with either flexible or static
lines. The concrete shall be placed into the pump hopper from the concrete mixer
delivery truck and pumped to its placement area. The delivery hose shall be
placed towards the bottom of the pour and raised at the same rate as the
compacting vibrator poker. The pump output shall be matched to the rate at which
the poker can compact.
v. If the height of pour exceeds 3 meters the flexible delivery pump hose and/or air
and power lines to the vibrators shall have sufficient length to reach the bottom of
the pour.
K. Crane Handled Skip Method:
i. The sitting of the crane should be such that :-
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 Delivery vehicles have easy access to the skip loading point.
 The crane operator has a good view of the skip loading point and the point of the
discharge, or alternatively, is guided by an experienced supervisor / signalman
with a good view and does not limit the crane operator or the supervisor /
signalman to use radio communication.
ii. Concrete shall be placed in the skip from the delivery vehicle ensuring that it is
not over filled. The skip shall be lifted to the place of discharge by crane. The
crane operator shall receive signals from the appointed supervisor / signalman for
the small movements for the skip position of the concrete or sloping layers.
iii. Connection
 Connecting Shackle
 Connecting pin to the end of rope.
 Making pin’s direction vertical.
 Connecting Wire clip
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 Hook angle and Safe weight
L. Placing & Compacting:
i. General Method
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ii. Speed of pouring
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iii. Check Point
Before concrete placing begins, the insides of the forms should be inspected to make sure
they are clean. If the forms are deep, temporary openings shall be provided for this
inspection and/or subsequent removal of rubbish etc. Rubbish, such as sawdust, shavings
and reinforcement tying wire shall be blown out with compressed air.
Before placing concrete to metal deck, surface of metal deck shall be checked whether
holes and gaps exists or not. If there are holes and gaps, taping up to them are to be
carried out to prevent from the leaking of concrete paste.
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Compaction shall be achieved by the use of poker vibrators. The spacing and pattern of
insertions of the poker shall be determined by the size of poker and the workability of the
concrete. As a guide, a spacing of 500mm centres is about right for a 60mm diameter
poker with concrete of medium workability.
The poker shall be inserted vertically as quickly as possible under its own weight and
penetrate some 100mm into any previous layer, thereby knitting the two layers together. It
shall remain in the concrete until the air bubbles cease to come to the surface (normally
about 10 seconds).
The poker shall then be withdrawn slowly so that the concrete can flow into the space that
the poker previously occupied. The poker shall be keep about 75mm to 100mm away from
the formwork face and shall not touch the reinforcement wherever possible.
Discharging from the skip shall be carefully controlled, with the skip being moved to allow
deposition of concrete by a ribbon method, placed in uniform layers and avoiding large
deposits of concrete or inclined layers.
For wall and column, layers shall not exceed more than 450mm thick (300mm when a
short poker – head is used). Concrete shall be placed as quickly as the compacting and
placing method shall allow and the rate of compaction and placing shall be matched.
The opening of skips shall be large enough to allow easy discharge, although poker
vibrators may have to be used to assist discharge of low workability concrete and mixes.
After concreting is completed, the skip shall be thoroughly cleaned and washed down the
gate operating mechanism oiled and greased.
A built-up of hardened concrete on the outside of the skip shall be prevented by rubbing it
over, before it is used, with a light coating of diesel oil or chemical releasing agent to
prevent adhesion of any splashed or over split concrete during initial filing or discharging.
In deep lifts of columns and walls, delays and interruptions shall be avoided to prevent
color variations on the surfaces. On columns and walls, care shall be taken discharging
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from the skip to ensure that the concrete does not strike the face of the formwork, which
could affect the surface finish.
Care shall also be taken to avoid displacing reinforcement or ducts, and to ensure that the
correct cover is maintained.
Whenever concrete is being vibrated at least one spare vibrator of each type in use shall
be available in case of breakdown.
iv. Placing And Compacting Concrete Around Openings, Ducts And Void Formers
Etc. :
Concrete shall be placed and compacted from one side, using the poker to make the
concrete flow. Vibrating shall continue until the concrete is fully compacted under the
obstruction and we can be seen to be flowing out at the other side.
Further steps shall be taken placing and compacting concrete in webs of post-tensioned
cellular structures, in order to prevent plastic settlement and voids in the concrete beneath
the ducts. A period of about 30 minutes shall elapse after the concrete has been placed
around the duct before re-vibrating along the line of the duct and continuing to place
further concrete.
v. Large Concrete Pours
Back-up arrangements shall be made with the concrete supplier in case there is a failure
of supply of concrete to the pour. Where mass or continuous pouring of concrete takes
place, care shall be taken to avoid for the formation of cold joints. The area of exposed
concrete shall be restricted wherever practical and fresh concrete shall not be cast against
that which has already hardened. Referring to this matter with respect of pours greater
than 0.8 meters. In depth this is important when temperature control is required.
vi. Re-vibration
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Provided that it is still workable, no harm shall be done if concrete, which has already
compacted, is re-vibrated. In fact, tests have shown that the strength is likely to be slightly
increased.
In the top 600mm of a lift and where blowholes might occur and in thick sections where
plastic settlement could be a problem, re-vibration shall be carried out provided the
concrete is still workable.
vii. External Vibrators
External vibrators are occasionally used, but their usefulness is limited on site by the
heavy formwork needed to resist the stresses and shaking they produce. Their use is
mainly confined to precast concrete elements but they shall be necessary for heavily
reinforced walls and the webs of deep beams where it is difficult or impossible to insert a
poker.
Where external vibrators are used their spacing shall depend on size and section and
specialist advice shall be obtained from the manufacturer.
M. Curing & Protection
i. General Requirements
Curing is carried out such that thermal and plastic cracking of the concrete does not occur.
Particular attention shall be given to the curing of concrete containing cement replacement
material.
Until a period of seven days has elapsed from the time of placing the concrete, the
concrete shall be kept protected against loss of moisture, rapid temperature change, rain
and flowing water, mechanical injury, contamination by airborne dust and sand, drying
winds and surface heating by the sun’s rays. This period shall be varied at the direction of
the Engineer.
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ii. Curing Methods
Severe Exposure Mixes: Curing methods shall consist of wet curing combined with
impervious sheet membranes.
Other Mixes: Curing of other mixes shall use wet methods, curing compounds or other
techniques that are in compliance with this Specification.
Temperature Protection: Special attention shall be given to temperature protection

measures as outlined in this Specification. These provisions shall be incorporated within
the method statement for curing all concrete mixes.
iii. Sheet Membranes:
Where used, sheet membranes shall consist of either of the following:
a) Impervious paper consisting of two sheets of construction grade paper glued together
with bituminous material. Following initial wetting the sheet is held firmly to the concrete
surface.
b) Plastic sheeting, minimum thickness 100μm. The concrete is kept continuously
wetted by the application of water under the sheet.
iv. Water Curing
Where water curing is adopted, the concrete shall be covered with sacking, Hessian,
burlap, or other absorbent material, or a 75mm layer of sand, kept constantly wet for 7
days and, where directed by this Specification or the Engineer, also covered with plastic
sheeting to reduce loss by evaporation. Care shall be taken to ensure that the
temperature of all water used at all stages of the curing process is as close as possible to
that of the concrete being cured.
v. Use of Covers
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Curing of concrete surfaces shall be carried out by sealing with opaque, reflective plastic
sheeting held in close contact with the surface of the concrete and forming an airtight fit
around the element being cured. The sheeting shall form a continuous seal and be without
tears or holes.
vi. Wetting of Formed Surfaces
Formed surfaces shall, to compensate for any surface drying that has occurred and as
soon as the form is removed, be sprayed with water and allowed to reach a uniformly
damp appearance before continuing with curing.
vii. Curing of Concrete in Hot Weather
When the daytime ambient temperature is greater than 25℃ or at such other times as the
Engineer may direct, for example, when there is a hot dry wind or low relative humidity,
curing shall proceed as detailed below.
Large Flat Area, e.g. Slabs (Preferred Method)
 Immediately after the required surface finish is applied, cover the concrete surface
with polythene sheeting/wooden frames to minimize evaporation. All gaps at sides
and ends shall be filled in to avoid wind-tunnel effects.
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 When the surface can carry weight, replace the frames by a layer of damp
Hessian covered by polythene sheet. The Hessian shall be kept continuously
damp for 7 days, (i.e., not wet/dry cycles), and suitable weights shall be used to
keep the polythene in place.
N. Contingency Plans
i. Wet weather
The commencement of concreting in wet weather shall be accessed and decided on site
by the Contractor’s Quality Manager. For major pour, weather protection and adequate
pumping facilities shall be made available prior to approval for concreting.
ii. Concrete pumps

A concrete pump mechanic shall be available to service any pump breakdown during
casting.
iii. Batching plants

The batching plants are fully independent of each other. Concrete can be delivered to site
from the plant which eventually forms the second backup supply.
iv. Concrete vibrators

Reserve vibrator and engine shall be provided. Standby supervisors and workers shall be
provided.
v. Night time concreting

Sufficient manpower, equipment and concrete supply shall be provided for night
concreting including standby service supporting personnel (e.g. pump mechanics,
electricians, etc.). Sufficient illumination lighting shall be provided at work areas.
O. Identification of Test Specimen
A paper tag shall be cast into molds together with the concrete to keep track of test
specimens. The information to be included in the tag shall be as follows:
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 Date and Time

 Cube Reference Number
 Grade of Concrete
 Delivery Order Number
In the testing laboratory, test specimens shall be treated carefully to trace the information
written on the tag.
P. Construction Joints
The Contractor’s engineer shall supervise and inspect the application of the surface
reader. The first horizontal and vertical construction joint shall be a trial/sample.
Construction joints shall be cleaned and loose or foreign materials shall be removed
before concrete is cast against them.
Q. Testing Procedures
The supplier’s technicians shall sample the concrete as per instructions from the
Contractor’s QA/QC inspector.
When the specimens are stripped from the modules, should be immediately marked with a
permanent marker with reference to the testers report corresponding to the tags. This
shall prevent any specimen mix-up. Tester’s report from shall be field for each set of
specimens cast.
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R. Finishing of Concrete Slab Areas
i. General
On completion of pouring and compacting, the concrete shall be finished in accordance

with the requirements of the Contract Documents. The timing and finishing operations are
dependent on the required type of finish, the concrete mix, the weather and the skill of the
operatives. Screed boards shall be fixed accurately and at suitable spacing for the works.
ii. Hand-Trowelling
Immediately after screeding or compaction, the surface shall be located just sufficiently to
level it while not bringing too much laitance to the surface. The surface shall then be
allowed to dry and stiffen until all the excess water has disappeared before any further
trowelling is attempted. The next trowelling shall be accompanied by considerable
pressure, sufficient enough to tighten and smooth the surface. Further trowelling shall be
required as the mix stiffens, so that a hard compact surface is produced without bringing
laitance to the surface.
iii. Vibrating Beams And Screeds
The side forms shall beam accurately set with leveled

square edges. The leading edge of the beam shall have
sufficient surcharge to of concrete to function properly.
High and low spots shall be corrected by hand
shovelling.
Vibrating beams combine the action of a screed and a vibrator, but they are only effective
for a limited depth. A slab more than 150mm thick shall be compacted with a poker
vibrator and finished with a vibrating beam. The edges of all slabs butting up to side forms
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and / or construction joints shall always be poker vibrated. Where necessary, the surface
shall be finished by hand trowelling.
Vibrating screed (razor-back) shall be generally requiring the additional use of poker
vibrators for slabs less then 300mm thick. The vibrators across the section of the beam
shall be set and adjusted to suit the type of work being carried out. There shall also be
less need to finish with hand trowelling.
iv. Floated finish
After placing, compaction and leveling of concrete and at a time

that concrete is stiff enough; power floating shall proceed.
This shall be done with an impact type power float, or disc type
power float. Inaccessible areas shall be floated with a hand float of
the wood cork type. The desired finish is uniform and smooth.
v. Steel trowel finish
Trials shall be carried out on site with the power float and trowel equipment to establish
the timing and period required for achieving a power float finish in accordance with the
specified requirement. Generally, the placing of concrete shall be completed in the
morning to allow the power trowel finish to be completed by the end of the normal working
day.
After the concrete has stiffened sufficiently after laying, the power float shall be used to
smooth and close the previously leveled concrete surface. After allowing the excess
surface moisture to evaporate, the slab surface shall be further smoothed and made
dense by using a power trowel. The timing and extent of each application is critical and
shall be established during the site trails.
3.7.2 THE STEEL REINFORCEMENT WORKS
1 General
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The Site Construction Manager shall be responsible for the steel reinforcement work
operation. His duties also include liaising with the Resident Engineer for inspection prior to
the steel reinforcement work.
The QA/QC Manager shall be directly repressible for assuring compliance with the
compliance to specification.
2 Materials
Steel used to concrete reinforcement shall comply with the requirement of the drawing
and specification. All material in the Works shall comply in all respects with the specified
standard, unless specially excluded or modified hereafter.
The tag for reinforcement which certificates complying relevant specifications and drawing
shall be supplied.
When faced with shortage of steel bars or wires of sizes specified by the standards,
alternatively, other commercial steel sizes shall be used specified by corresponding
Standard after obtaining the Engineer’s prior approval.
The bars in each lot shall be legibly tagged by the manufacturer before being offered for
inspection.
The tag shall show the manufacturer’s test and lot number. The manufacturer shall supply
three copies of a certificate showing the heat number from which each size of bar in the
shipment was fabricated.
The sampling testing and inspection of reinforcement bars shall be made at the source of
supply when the quantity to be shipped or other conditions warrant such inspection.
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Bars not inspected before shipment shall be inspected after arrival on site. Test samples
provided shall be replicated bars not less than 1m long.
3 Storing and Cleanliness of Reinforcement
Reinforcement steel shall be stored clear of the ground and be adequately supported
along its length to prevent distortion.
Reinforcement shall be clean and free from loose mill scale, loose rust, oil, grease, tar,
paint, salt and other deleterious matter.
Loose scale shall be removed before the bars are used. There shall be no evidence of
pitting or visual flaw in the bar or on the sheared ends
4 Transporting of Reinforcement Steel
i. Carrying reinforcement steel by man power, the followings shall be observed.
 Weight of steel per carry per person shall not exceed 25kg.
 When carried by more than 2 persons, steel shall be carried on shoulder.
 When carrying, both ends of reinforcement steel shall be tied together.
 When lying down, reinforcement steel shall not be suddenly dropped.
 When working together, directions shall be made by signaling.
ii. Transporting reinforcement steel by machinery, the followings shall be observed.
 For transporting steel, a team leader shall be assigned to control the work.
 When hanging steel, allowable load for the machinery shall be checked to prevent
overloading.
 Large quantity of steel shall not lay on scaffolding or formwork.
 In the proximity of area of hanging steel, unauthorized persons shall not be
allowed.
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 Operation of machinery for transporting and hanging steel shall be made by the
person designated by the Contractor.
iii. For prevention of electric shock and other accidents, the followings shall be
observed.
 No electric wire shall be laid on ground in the proximity of area of transporting
reinforcement steel.
 Wiring of electric line in the proximity of steel transporting area shall be installed
at height greater than the maximum length of reinforcement steel and spacing of
greater than 2m.
 Steel transporting machinery shall be operated after inspecting the wiring of
electric line.
5 Installation of Reinforcement Steel
The minimum bending radii for high tensile steel and mild steel bars shall not be less than
3 times and 2 times the nominal bar diameter respectively.
Cold worked bars and hot rolled high yield bars shall not be straightened or bent again
once having been bent. Where it is necessary to bend mild steel reinforcement projecting
from the concrete, the internal radius of bend shall be not less than twice the diameter of
the bar.
All bending shall be done cold by the use of an approved bending machine. Only
experienced steel benders and fixers shall be
employed.
Bending or cutting of reinforcement with use of

heat, such as oxygen torch, shall be strictly
prohibited.
The quantity, sizes, form, positions and spacing

of all steel reinforcement bars shall be in
accordance with the Drawings.
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Bar spacing shall be large enough that coarse aggregate can pass through easily.
Concrete cover protects the steel against fire and corrosion.
All cutting and trimming of bars and wires shall be done cold with the use of approved
manual or power operated cutters.
Welding of reinforcement shall not be permitted except in special circumstances where

approved by the Engineer.
Reinforcement projecting from work already concreted shall not be bent out of its correct
position for any reason, unless permitted by the Engineer, and shall be protected from
deformation or other damage.
In case of using epoxy steel bars, bar intersections shall be securely tied together with the
ends of the tying wire turned into the main body of the concrete.
1.2mm diameter stainless steel wire shall be used for members having exposed soffits.
1.6mm diameter soft annealed iron wire shall be used elsewhere.
Spacer blocks shall be placed at regular intervals to support first layers of reinforcement
off the concrete blinding or bottom formwork. Spacers shall be securely fixed to the
reinforcement at the time of placing. The number of spacers shall be the minimum
necessary to maintain the reinforcement in its correct position. Spacer blocks shall be of
standard cement mortar or such other composition as previously approved by the
Engineer.
In slabs provided with two or more layers of reinforcement, the upper layers of steel shall
be supported in position by the use of steel chairs.
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6 Foundation
The location of connecting reinforcing in the foundation beams
The location of fixing reinforcing in the foundation beams
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7 Wall
Wall reinforcement detail
Reinforcement of wall opening
8 COLUMN
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Electrical Box
Location for connection and fix of steel reinforcement
9 GIRDER AND BEAM
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3.7.3 FORM WORKS
1 General
The Site Construction Manager shall be responsible for the steel reinforcement work
form work.
 Implementation of the quality control plan to ensure accurate and adequate inspection
compliance to specification
2 Materials
FORMWORK: When selecting materials for formwork, its strength, stiffness, durability,
workability and its effect on poured concrete shall be considered.
i. Wood Formwork
 Formwork with numerous flaws and knots or structurally weak plywood shall not
be used.
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 Partially broken or cracked waling of formwork shall not be used.
ii. Steel Formwork
 Steel materials, if battered or twisted, shall be used after correcting the

deformation.
 Rusted surface of steel framework shall be polished with wire brush or sand paper
and shall be coated with form oil.
iii. Supporting Post
 When selecting materials for supporting post, its strength, stiffness, durability,
workability and its effect on poured concrete shall be considered, and the
followings shall be observed.
 Post with apparent damage, deformation, corrosion or deep knot shall not be
used.
 Bended or twisted rectangular lumber or steel post shall not be used.
 Post material assembled of steel post and beam with load exceeding the
maximum allowable load shall not be used.
iv. Connecting Material
 Connecting materials shall have the following properties;

 shall have precise and sufficient strength
 shall be easily disassembled and draw back
 shall be of few numbers of parts
 When use of other material is necessary, the Contractor shall receive the
Engineer’s approval on the use.
3 Pre-Test and Preparation
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Before the commencement of the construction, solutions for some problems that could
occur during the construction shall be prepared by thoroughly inspecting on-site
conditions and specifications, and these shall be negotiated with the Engineer.
All nearby structures, public facilities, and buried materials shall be protected from
damage during the construction.
4 Setting Up the Form
A strut should be installed in order to firmly fix the form.

The concrete shall not be damaged while the form is being dissembled.
The joint should be water sealed in a straight line.
Beams, joints, and outer corners of pillars should be processed using fillet treatment. A
size of 20 X 20mm should be set as the standard, and this shall be adjusted according to
on-site circumstances.
If it is discovered that the form is in contact with the reinforcement bars due to insufficient
concrete coating, the Contractor shall take a method by corresponding Standard after
obtaining the Engineer’s prior approval.
5 Application of Form Release Agent
The release agent shall be applied before the installation of reinforcements and fixtures.
The release agent may not be used on concrete surfaces where special finishing shall
take place, and surfaces where the release agent is not used should be soaked with clean
water.
6 Insert and Openings
For walls where openings are necessary, form works shall be executed during concrete
casting, as directed.
Materials to be directed put into the concrete should be at their appropriate locations.
Continuous waterstops should be installed on the construction joints according to the
guidebook of the manufacturer. The joints of the waterstops shall be watersealed using
heat.
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Temporary windows or openings may be installed in order to make cleanups and

inspections convenient.
Temporary openings should be watersealed using fitting panels, and for exposed
concrete, it shall be manufactured with perfect fitting so that the joint portion does not
show.
7 Form Cleaning
Before setting up the form, it shall be cleaned and foreign substances shall be removed
using water or pressurized air.
8 Inspection of Construction Condition
For inspection of the detailed drawing of form works, the Contractor shall take a method
by corresponding Standard after obtaining the Engineer’s prior approval.
9 Form Dismantlement
The retention period for the form boards of footings, beam sides, and walls shall be until it
is confirmed that the pressure strength has reached 50kgf/㎠
If the average temperature is over 10℃ during the form board retention period, the form
may be removed without a pressure strength test, as long as minimum retention period
has passed.
The form boards under floor slabs, roof slabs, and beams shall be removed after being
dismantled.
The retention period of the support pillars shall be set as until the time when it is verified
that the concrete pressure strength has reached 85% of the design strength under the
slabs and 100% under the beams.
After the dismantlement of the support pillars, if the load applied to the appropriate
component exceeds that of the existent component, dismantlement shall occur only after
verifying that it is sufficiently safe, regardless of the set retention period.
10 Retention Period for Supporting Posts
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Shall be dismantled after 17 days if the average temperature during concrete aging is over
15℃; 25 days if over 5℃; and 28 days if over 2℃.
Shall be dismantled only after it is verified through calculations that the concrete’s
compression strength is 85% of what is specified in the design.
Shall be dismantled after retention of either 1) or 2), whichever is earlier.
In order to prevent local damage to the cured concrete, braces should be removed and
reinstalled according to a set schedule. Reinstallation of braces should take place at
appropriate locations for it to safely support the structure without excessive stress or
deflections.
After casting the next top layer, the braces should be maintained at that place for at least
15 days.
Reinstalled pillar should be supported by a wedge or other materials for it to exert the
same amount of supporting strength as the previous pillars.
11 Reusing the Form
The surface of the form to be reused should be cleaned and repaired.

Cracked, worn out, or split forms shall not be used.
3.7.4 STRUCTURAL STEEL WORKS
1 General
The Site Construction Manager shall be responsible for the Structural steel work
the structural steel work.
compliance to specification
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2 Preparations
Shall confirm the preparedness and installation condition of the safety equipments.
Shall confirm the appropriateness of the lifting equipments as well as the safety of other
equipments, including wires and shackles.
Shall confirm the preparedness of working and measuring tools. Materials shall be stored
separately according to the corresponding building, area, and material type in order to
increase efficiency of the site facilities.
During material storage, damage to the components shall be minimized through the usage
of prop woods.
The amount of stored items shall be adjusted according to various conditions by

considering the securing of appropriate materials for the minimization of damage to the
components due to long-term storage, as well as the efficiency in installation.
Passages within the storage space shall be sufficient taking the short transport
equipments into account.
In order to minimize damage to the components during short transport, a urethane,

rubber, or fabric cover shall be attached to the short transport equipment.
3 Pad Installation
The mortar used for pad installation shall be the same product as the mortar used for
grouts.
Laitance shall be removed from the concrete surface that the mortar comes in contact
with, and it shall be sufficiently soaked in water.
It shall be confirmed that the pad top level matches that of the drawings.
The mortar shall be cured for at least 3 days before the installation of the steel frame.
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4 Erection of the Steel Frame
It shall be confirmed that the steel frame components match those on the drawings.
Accuracy of the above-ground assembly shall be secured through the usage of

appropriate zigs.
It shall be confirmed that the worktable and access ways have been secured for erecting,
bolting, welding, etc.
It shall be confirmed that various tools for erecting has been prepared. At least 2 erection
bolts shall be installed for each connection point. Plumbing and firefighting works shall be
commenced after the completion of the erection of columns, girders, and beams.
Grouting, bolting, and welding shall be commenced after the completion of the plumbing.
5 Inspection
Both the level and perpendicularity inspections shall be executed.
The pad’s level is measured for the level inspection. All pads shall be inspected for
leveling.
The inclination of the column is measured for the perpendicularity inspection. Only the
main column shall be measured for inclination.
The bolt shall be inspected for any harmful defects.
The fastening inspection executed in comparison to the torque of primary bolting and the
nut rotation angle of the secondary bolting.
Inspections for primary bolting shall be executed on over 10% for each junction.
Inspections for secondary bolting shall be executed on all bolts.
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6 Welding
Welding of connection shall be carried out in strict compliance with specification or

relevant code.
All welding operations shall be performed at well-established, qualified, reputable

workshops properly equipped with the necessary facilities and equipment for complete
welding.
i. Welding Materials and Equipment
 All welding materials and the equipment used shall be such that the mechanical
properties of the weld metal deposited by the welding are not less than those of
the parent metal to be welded.
 All welding materials and consumable shall be stored and handled carefully to
avoid any damage.
 Welding Procedure
 Welding procedure shall be in strict compliance with specification during the
welding operation; welding inspector in charge shall monitor and check the
welding current frequently with a tong tester.
 Welding shall not be carried out in a strong wind and / or rain, unless with
adequate shielding facilities.
ii. Inspection and Tests
 Each of the welding connection is subjected to inspection and tests by an

independent licensed welding inspector or agency.
 Visual inspection for all the welds and NDT tests as per specification.
7 Painting Methods
Painting shall be executed according to the guidebook of the manufacturer.
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All steps of painting shall be finished uniformly.
Painting shall be executed using the airless spray method. The spray gun shall maintain
perpendicularity and uniform distance from the painting surface.
In order to acquire a uniform paint coat, corners, welded parts, and edges shall be
partially recoated, and it shall be made sure that there are no drip pages due to excessive
spraying.
Portions of the products that have completed the painting process where there is
insufficient dry film thickness (DFT) or other test results shall go through extra painting
procedures in order to satisfy the standards.
After completion of painting, all used tools and equipments shall immediately be cleaned
with thinners and cleansers appropriate for the used paints.
8 Safety Rules for Field Erection
Safety rules is used to ensure the health and safety of the all staffs and employees and
other persons that involved in the construction.
The Contractor shall enhance safe working practices on all jobs and create a healthy and
safe working environment for all concerned by:
 Compliance, implementation, and enforcement of the regulations

 Accident prevention by having pre-tack planning and instructions and constant
education.
3.7.5 HOLLOW CONCRETE BLOCK MASONRY WORKS
1 Product Handling
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Store masonry materials so as to be protected from the ingress of foreign materials.

Handle masonry units carefully to avoid damage to faces, edges, and corners which,
when so damaged, shall be rejected from use in finished work.
Store mortar materials in covered sheds on plank floors raised not less than 20cm above
ground.
2 Concrete Masonry Units
Hollow concrete units shall have the standard dimensions of 40×20×20cm, 40×20×15cm,
and 40×20×10cm as shown on the drawings. Units shall include closer, jamb, header,
lintel, and special shapes and sizes as indicated or required to complete the work. Units
shall have following characteristics:
 Minimum Face Shell Thickness : 25mm

 Minimum Compressive Strength, Average of 10 Blocks : 70Kg/cm2
 Maximum Water Absorption : 30%
3 Mortar
 Portland cement
 Ordinary or rapid-hardening Portland cement complying with Specification
 Sand
 Clean, hard, durable and free from any organic or deleterious matters
 Hydrated Lime
First quality pressure hydrated materials free from substances which would impair the
work
4 Anchor and Ties
 Anchors
 Galvanized iron straps, 3mm thick × 25mm wide × 350mm long with 50mm
 Bends at each end
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 Cavity wall Ties

 Double-triangle type, 4.5mm diameter and 150mm long galvanized mild steel wire
5 Other Materials
All other materials not specifically described but required for a complete and proper
installation of the work of this section, shall be as selected by the Contractor subject to the
6 Mixes
All mixes shall be by volume, unless otherwise specified.
BEDDING MORTAR
 1 Part Portland Cement
 3 Parts Sand
 1/4 Part Hydrated Lime
7 Installation
At the time of installation, concrete masonry units shall be in an air-dry condition. Units
shall be laid plumb, true to line, with level courses accurately spaced and bond patterns
shall be kept plumb throughout. Each unit shall be adjusted to the final position while the
mortar is still soft and plastic, and any unit that is disturbed after the mortar has hardened
shall be removed and re-laid with fresh mortar.
8 Mortar Mixing
Materials shall be measured accurately and mixed with mechanical mixers for mixing
mortar except where hand mixing of small batches is accepted.
Before adding water, materials shall be mixed to have uniform colour, then proper
amounts of water shall be added and mixed sufficiently to the desired consistency. The
moisture content in the sand for each batch shall be controlled.
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Only as much mortar as can be used in one hour shall be mixed after water has been first
mixed into the batch.
Re-tempering shall not be permitted and no admixture shall be used to hasten set. Mortar
which has begun to stiffen shall be discarded.
9 Cutting
Wherever possible, full units of the proper size shall be used in lieu of cut units. The
detailed setting-out of masonry work shall be arranged to reduce cutting of units to a
minimum.
Cut edges shall be clean, true and sharp. Webs of hollow masonry units shall be cut the
minimum required for the installation.
10 Embedment
Anchors, ties, wall plugs, accessories, flashings, pipe sleeves, and other items shall be
built in and fully embedded in mortar as the work proceeds.
Cells receiving anchor bolts shall be filled solidly with mortar or grout.
Grout for filling cells shall be consolidated in place by vibration or other methods which
ensure complete filling of the cells or cavities.
Chases, slots, recesses, boxing, etc. for electrical, plumbing, or other mechanical
installations shall be neatly formed.
11 Reinforcement
ANCHORAGE TO CONCRETE
Abutting walls and columns shall be anchored with galvanized iron straps, spaced not
over 40cmvertically.
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Cells within vertical planes of these anchors shall be filled solid with mortar for the full
Block Piling Const height of walls.
The underside of beams and slabs shall be anchored with galvanized iron straps, spaced
not over 80cm horizontally.
12 Masonry Wall or Partition Intersection
Each course shall be masonry bonded at exterior corners and where masonry bond is
indicated.
At other intersections, masonry walls shall be tied with 25×3mm galvanized iron straps,
35cm long with 5cm bends at each end, installed in every 4th course for non-fortified walls
and every 3rd course for reinforced walls. Cells within the vertical plane of ties shall be
filled solid with mortar for the full height of the wall or partition.
13 Joints
The thickness of mortar joints shall be 10mm except for small variations required to make
bonds.
Every joint shall be truly vertical and horizontal and shall be thoroughly filled with mortar.
All vertical joints shall be staggered unless otherwise specified.
Joints in exposed or painted walls and partitions and joints to be painted, calked or sealed
shall be tooled slightly concave with mortar.
Tooling shall be done when the mortar is thumb print hard.
The tooled joints shall be finished to be uniformly straight with true lines, and surfaces,
smooth and free from tool marks.
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Joints between metal door frames for exterior doors and abutting masonry shall be raked
to 10mm depth along both sides of the frame.
Horizontal joints between the top of masonry and underside of concrete slabs or beams
shall be filled solidly with mortar.
Expansion joints shall be provided in block walls and laid in continuous straight lines as
required or indicated on the drawings.
All the mortar joints shall be finished smooth and cleaned out at expansion joints.
The expansion joint filler shall be built in as the work proceeds and before the sealant is
applied, the external surfaces of the expansion joint shall be primed with an approved
primer recommended by the sealant manufacturer.
Sills, lintels, and copings shall be set with faces plumb and true, in a full bed of mortar,
except that sills with lugs shall have mortar beds under the ends of the sill only.
Sills shall be levelled and tapped into place on these beds.
Upon completion of the walls, the remainder of the bed joint shall be filled solidly with
mortar front and back, and the exterior face of the mortar tooled smooth.
Lintels shall be set in a full bed of mortar and blocked up as necessary to provide a full
13mm (1/2 in.) clearance above the top of the frames.
 Unfinished Works
Masonry walls or partitions shall be constructed to maintain a uniform height at all times
around the perimeter of the building as the work proceeds.
Unfinished work shall be stepped back for joining with new work.
Before laying new work, loose mortar shall be removed and the exposed joint shall be
thoroughly cleaned.
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Surfaces of masonry not being worked on shall be properly protected at all times.
Adequate provisions shall be made during construction to prevent damage by wind.
 Lintels
Lintels shall be specially formed load-bearing lintel or U-shaped units filled solid with
concrete and reinforced as shown on the drawings.
Lintels shall extend beyond each side of masonry openings at least 20cm for openings up
to 2.5m wide, 40cm for openings over 2.5m up to 5m wide.
14 Cavity Wall Construction
i. General
Both the inner wall and the outer wall shall be laid up together. The inner and outer walls
shall be completely separated by a continuous airspace of width as shown on the
drawings installing cavity wall ties as specified.
The airspace between the walls shall be kept clear and free of mortar droppings by
temporary wood strips laid on the wall ties and carefully lifted out before placing the next
row of ties.
ii. Wall Ties
Wall ties shall be spaced not more than 80cm horizontally and 40cm vertically, staggered
in alternate courses.
Wall ties shall be placed additionally within 20cm of each side of the jambs of openings
and not over 60cm apart vertically except where walls are bonded together with masonry
returns at jambs, and shall be placed 40cm on centers vertically within 20cm of each side
of control joints and expansion joints.
Wall ties shall be placed with one end centered on the room side face shell of the inner
wall and with the other end centered on webs or vertical joints of the outer wall.
iii. Weep Holes

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Weep holes shall be provided in mortar joints of the outer wall along the bottom of the
cavity over foundations, and other water stops in the wall, spaced not more than 1m apart
on centers.
The holes may be formed by placing pencil rods or sash cord in mortar joints and
withdrawing before the mortar is set.
iv. Insulation
Exterior cavity walls shall be insulated with the specified insulation as shown on the
drawings.
Insulation shall be brought up completely to the elevations indicated to the underside of

windowsills, bond beams, lintels, through-wall flashing, and similar interruptions through
the cavity before installing these items.
v. Cleaning and Protection
Remove mortar droppings on connecting or adjoining work before its final set.
The surfaces of the unfinished work of the previous day or any old work shall be
thoroughly cleaned of all loose mortar, dirt, or other foreign matter and wetted before new
work is undertaken.
Protect the masonry work from damage during subsequent construction operations. Keep
the surface watered continuously for at least 7 days.
3.7.6 WATER PROOFING WORKS
1 Transport, Storage and Treatment
The materials shall be carried in within unopened packaging, and the manufacturer’s
name, product name and type, manufactured date, expiration date, and storage methods
shall be noted.
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The waterproofing shall be stored clean and dry in a safe place in its original
manufacturer’s package, and the temperature range designated by the manufacturer shall
be maintained. The stored materials shall avoid direct sunlight and moisture.
2 Construction and Site Condition
Environment-Limited: Construction shall take place within the surrounding / surface

temperature range designated by the waterproofing materials manufacturer.
The waterproofing compounds shall not be left in wet or moist surfaces, and waterproofing
construction cannot be executed if relative humidity is over 85% or if the temperature is
under 5℃.
Construction shall not be executed if there is (or if it is positively predicted during the
construction / curing period that there is) snow, rain, or fog.
3 Membrane Water Proofing
i. Inspection
 With the attendance of the installation, the background, portion, and conditions of the
waterproofing construction shall be checked for their abilities to meet demanded
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conditions. The construction shall not continue until insufficient conditions have been
improved.
 The construction shall not continue until the manufacturer’s suggested concrete
curing period has been secured.
 It shall be confirmed that the background is externally dry and free from moisture.
ii. Surface Preparations
 The background shall be cleaned and prepared according to the directions of the
manufacturer. The surface where the waterproof compound is to be spread shall be
confirmed to be clean, dry, and free from dust.
 Surrounding surfaces where the waterproof compound is not to be spread shall be
covered up to prevent splashing.
 Drai
ns
and
other penetrated parts shall be plugged in order to prevent the infiltration or leakage
of the waterproofing liquid.
 Grease, oil, release agent, paint, and other concrete protrusions shall be removed.
The protruded parts, including parts with scale prints or bulging parts shall be
removed, and honeycombs and pockets shall be filled in.
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iii. Preparation of tips and penetrated portions
 Horizontal / Perpendicular tips and portions penetrated by waterproofing, new

construction connection, drain, and slabs shall be prepared according to the
directions of the manufacturer.
 If suggested by the manufacturer of the waterproof materials, the penetrated portions
and the parts where the slab and the wall meet shall be processed at an angle.
 Handling the connected portions and cracks.
 The joints of the background and cracked portions shall be prepared, handled, and
filled according to the suggestions of the manufacturer of the waterproof materials.
Dust and other particles shall be removed from the joints or cracks.
 Application of the Waterproofing Materials
 The rubber coat waterproofing compound shall be applied according to the

manufacturer’s guides.
 The rubber asphalt shall be heated in an oil or air smelter machine and be mixed in a
rubber asphalt waterproofing compound exclusive mixer.
 The primer, mixed in the ratio suggested by the manufacturer, shall be applied to the
prepared surfaces and then dried.
 The waterproofing compound shall be applied to the designated background and
surrounding parts. Fused rubber asphalt waterproofing compound is to be applied in
uniform thickness and then reinforced completely with fiber reinforces.
 The waterproofing compound shall be applied to the perpendicular and sectional
surfaces of the wall up to the manufacturer’s suggested height.
 After the passage of the designated curing period, a protective layer shall be laid onto
the waterproofing material before the following procedures may be commenced.
4 Curing, Protection and Clean Up
The waterproofing should be cured according to the manufacturer’s guidebook.

Precautionary measures should be taken to prevent contaminations during the application
/ curing period of the waterproofing materials.
There shall be no passage over coats without protection.
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The waterproofing should be protected from damages during the following construction
activities.
Contaminants from portions contaminated by an adjacent construction should be removed
according to the suggested methods of the material’s manufacturer.
3.7.7 TILE WORKS
1 Preparations
Surrounding constructions shall be protected in order to prevent damage and change in

shape.
The surface shall be cleaned to remove dust and moisture.
Cracks on the background surface shall be filled with filers. Existent background surfaces
shall be adjusted to be within the allowable tolerance.
The floor mortar shall be applied to be within the flatness. Allowable tolerance, and if
necessary, the background of the floor may be graded.
It is set as the standard to wait at least 1 week before installing the tiles after applying the
mortar.
2 Wall
Wall tiles shall be installed according to the details on the drawings and the work methods.
Tiles shall be places according to the designated patterns. It shall be made sure that the
pattern does not end due to openings.
If necessary, tiles shall be cut in order to fit penetrated portions of the tile wall. The floor,
ground, and wall joints shall be lined up.
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The tiles shall be placed so that the tile joint widths are uniform within the allowable
tolerance of the tile size. It shall be made sure that mortar and grout is not excessive on
joints, and that there are no cracks or air holes, and that they are waterproofed.
All parts internally and externally shall be adjusted to fit.
Ceramic components should be firmly attached to the openings.
Expanded joints and adjusted joints shall not have any adhesives or grouts. Sealants
shall be used for joint portions.
The tiles shall be cured for at least 48 hours before grouting.
The tile joints shall be grouted.
Sealants shall be used for places where the tile and other materials create level
differences.
3 Floor
Floor tiles shall be installed according to the details on the drawings and the work
methods
Tiles shall be placed according to the designated patterns. It shall be made sure that the
pattern does not end due to openings.
Edge strips shall be installed at the ends of the exposed tiles.
If necessary, tiles shall be cut in order to fit penetrated portions of the tile wall. The floor,
ground, and wall joints shall be lined up.
The inner and the outer angles shall be perpendicular.
Ceramic components should be firmly attached to the openings.

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The tiles shall be placed so that the tile joint widths are uniform within the allowable
tolerance of the tile size. It shall be made sure that mortar and grout is not excessive on
joints, and that there are no cracks or air holes, and that they are waterproof.
Tiles shall go through sounding after installation. During sounding, ones with air holes
shall be replaced.
Expanded joints and adjusted joints shall not have any adhesives or grouts. Sealants
shall be used for joint portions.
The tiles shall be cured for at least 48 hours before grouting.
The tile joints shall be grouted.
Sealants shall be used for places where the tile and other materials create level
differences.
4 On-Site Quality Control
i. Adhesive Power Test
 Tested tile shall be separated from surrounding tiles by the joint portion being
cut to the concrete surface.
 The tile to be tested shall be the attached size. Bigger tiles shall be cut to
180×60mm to the concrete surface.
 Test shall be executed 4 weeks after tile construction.
 Judgment of test results: adhesive power shall exceed 4kg/㎠.
ii. Construction Condition Inspection
 Inspection for background dryness and surface conditions

 Inspection to see if the position and spacing of joints are accurate.
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 Inspection for foreign substances on the tile adhesion background and crack
treatment.
5 Clean-Up and Curing
The tile and grout surface shall be washed.

Contaminated, damaged, or out-of-line tiles shall be replaced.
The tiles shall be cleaned after the completion of installation and grouting. The suggested
procedures of the designated type’s manufacturer shall be followed.
6 Protection of the Completed Construction
Protection: The tile surface shall be protected after the installation of the grout.
Portions with floor tile installation should be covered with protective paper before passage.
A passage board shall be installed above the tile floor and used as a passage.
Damaged or defective tiles shall be replaced.
Passage over the finished surface shall be prohibited for 4 days after the completion of
the construction.
3.7.8 CEILING WORKS
1 Preparations
The ceiling line height shall be measured and marked by setting the level height standard
line. The location and usage number of the installed inserts shall be verified.
After the insert verification, insufficient parts shall be added with hilt, etc. Equipments
exposed from the ceiling line, including curtain boxes, shall be constructed first.
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2 Installation - Frame
The construction shall be executed according to the manufacturer’s installation guidelines

and these regulations.
A small amount of ceiling rotation materials must be installed using screws along the
ceiling line.
The carrying channel shall be hanged in one direction using hanger pin clips with 900mm
spacing. When the channel is being connected, the minimum connection length shall be
200mm, and both sides shall be firmly fixed with specially created suspension clips.
The supporting channels shall be hung on the carrying board using zinc steel clips with
2.0m spacing in a 90° direction from the carrying channel.
M shaped channel installation
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 A single M shaped channel shall be hung on the carrying channel using M shaped
channel clips with 300mm spacing in a 90° direction.
 At points where the wall is met, the channels should be installed by moving less
than 150mm.
When a ceiling background agent is necessary, a small amount of background material

(gypsum board) shall be installed using screws with 300mm spacing in the center and with
200mm spacing in the connection points and edges.
3 Installation - Finish
Finishing without background: A small amount of finishing agents shall be installed on the
M channel using screws, and the minimum number of screws per textile (300x600) is 6
pieces. When a textile is used, the edge must be at least half-size.
Finishing with background: A small amount of finishing agents (rock wool tex, etc) shall be
attached to the background (gypsum board) hidden on the surface using rubber
adhesives, and the finishing agent and the background surface shall be fixed with staples.
The manufacturer’s product specifications and installation guidebooks should be followed
for other issues.
4 Gypsum Board
Background Gypsum Board
 The finishing agent shall be attached to the M shaped channel by penetrating the
background material using screws.
Finishing Gypsum Board
 The finishing gypsum board shall be placed so that its connection point is at the
center of the background gypsum board.
 The installation spacing of the screws shall in 300mm in the center and 200mm in
the connection points and edges.
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5 Preparation of Construction Conditions
 The surface condition (including reinforcement conditions of the bar, molding, and
components).
 The strengths of the installed bar, molding, reinforcements, and subsidiary
materials.
 Sinking, bending, contamination, and other omissions.
 The connection condition and finishing treatments of each opening.
3.7.9 OTHER WORKS
1 Plastering Works
The wall surface will be cleaned and watering with water is made before plastering.
For large wall, it’s surface will be divided into smaller square by control spacers of fresh
mortar. Installation of spacer block will be done by theodolite.
Plastering shall not commence until all mechanical and electrical services, conduits, pipes
and fixtures have been installed.
Metal lathe shall be installed as required with stainless steel fasteners and lapped joints
tied with galvanized wire.
Corner (angle) beads shall be installed at openings and fasten with stainless steel
fasteners.
Finished surfaces shall be flush with grounds, corner beads, outlet lobes and similar
details, they shall be free from trowel marks and other trowel marks and other blemishes
and shall display straight arises and true angles.
2 Painting Works
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i. Mixing and Thinning
At the time of application, paint shall show no signs of hard setting, excessive skinning,
livering or other deterioration.
Paint shall be thoroughly stirred, strained, and kept at a uniform consistency during
application.
Paints of different manufacturers shall not be mixed together.
Where necessary to suit the surface conditions, temperature weather, and method of
application, packaged paint other than cement-emulsion filler may be thinned immediately
prior to application in accordance with the manufacturer's instructions.
ii. Paint Application
 Finishing
The finished surfaces shall be free from runs, drops, ridges, waves, laps, brush marks,
and variations in colour, texture, and finish.
The hiding shall be complete, and each coat shall be so applied as to produce a film of
uniform thickness.
Special attention shall be given to ensure that all surfaces including edges, corners,
crevices, welds, and rivets receive a film thickness equivalent to that of adjacent painted
surfaces.
Adjacent areas and installations shall be protected by the use of drop cloths, or other
approved precautionary measures.
Metal or wood surfaces adjacent to surfaces to receive water-thinned paints shall be
primed and touched up prior to the application of water thinned paints.
The first coat on plaster shall include such repeated touching up of suction spots or overall
applications of primer-sealer as necessary to produce a uniform colour and gloss.
 Drying
Surfaces that have been cleaned, pre-treated, or otherwise prepared for painting shall be
given
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A coat of the specified first-coat materials as soon as practicable after such preparation
has been completed, but in any event prior to any deterioration of the prepared surface.
Sufficient time shall elapse between successive coats to permit proper drying. This period
shall be modified as necessary to suit adverse weather conditions.
Oil base or oleo-resinous solvent type paints shall be considered dry for recoating when
the paint feels firm, does not deform or feel sticky under moderate pressure of the thumb,
and the application of another coat of paint does not cause lifting or loss of adhesion of
the undercoat.
 Coating
Metal Surface : First coats shall be applied by brush, except that where the item has been
shop primed or field primed, the first coat may be applied by brush, roller, or spray.
Subsequent coats shall be applied by brush, roller, or spray.
Other surfaces shall be coated by brush, roller, or spray, as recommended by the
manufacturer.
 Cleaning Protection
Place cloths and cotton waste that might constitute a fire hazard in closed metal
containers or destroy at the end of each day.
Remove spots, oil, or stains upon adjacent surfaces and leave the entire job clean and
acceptable.
Protect the paint work from the weather, dust, or damage during subsequent construction
operations. In the event of damage, immediately make all repairs necessary to the
3 Gypsum Board Works
i. Delivery, storage and handling

 Shall deliver materials in sealed containers and bundles, fully identified with
manufacturer’s name, brand, type and grade: store in dry, well ventilated space,
protected from the weather, under cover and off the deck levels.
 Shall install gypsum board vertically to eliminate end-butt joints.
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 Shall form control joints and expansion joints with space between edges of boards,
prepared to receive trim accessories.
 Shall isolate edges of gypsum board from abutment with structure. Provide space as
required for trim and sealant.
 Shall space fasteners in gypsum boards in accordance with applicable reference
Standards and manufacture’s recommendations, except as otherwise indicated.
 here feasible, shall use the same fasteners to anchor trim accessory flanges as
required to fasten gypsum board to the supports.
 Shall install metal edge trim whenever edge of gypsum board would otherwise be
exposed or semi-exposed. Provide type with face flanges for embedment in jointing.
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4 Aluminum Window and Door Works
All sashes, frames and fittings shall be installed as specified in sections, in strict
accordance with the recommendations of the manufacturer and the approved shop
drawings. Installation shall be performed by workmen skilled in handling aluminium
fabrications.
Doors and hardware shall be installed and adjusted under this Section as specified in
Section
After erection of windows, doors and frames, precautionary methods shall be employed to
adequately protect exposed surfaces of installed items from damage due to installation of
other work or from lime, acid, cement or other harmful compound.
Adjustment and cleaning
The aluminium windows and doors shall be maintained in a clean condition throughout the
construction period, so that they will be without any evidence of deterioration or damage,
other than effects of normal weathering, at the time of acceptance. Select methods of
cleaning which will promote the achievement of uniform appearance and stabilized colors
and textures for materials that weather or age with exposure.
Aluminium window and door systems, including glass and glazing, shall be protected from
damage throughout the construction period.
Aluminium window and door components that have been damaged, including finish,
beyond successful repair, shall be removed and replaced with new materials. Minor
damage shall be repaired.
At the completion of the work, adjacent work marred by the work of this Section shall be
cleaned or replaced.
All materials and debris shall be removed and this Section shall be cleaned or replaced.
Window and door systems shall be totally free of abrasions, nicks, scars, etc, and shall be
in good operating condition at final acceptance.
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5 Caulking and Sealant Works
Remove temporary wood or other type fillers that have been installed to preserve joint
width during concrete placement. Surface condition of joints to receive sealant shall be
sound, smooth, clean, dry and free of contaminants.
Apply primer to all joints that will be submerged or those that may be exposed to
incidental water immersion. Apply to other joint surfaces as recommended by sealant
manufacturer. Apply to clean dry surfaces prior to installation of backer rods or bond
breaker tape.
Sealant depth shall be controlled by backer rods. Backer rod shall be about 3mm larger in
diameter than the width of the joint. Do not stretch, twist, puncture, or tear rods. Butt joint
rods at intersections. Where depth of joint does not permit use of backer rod, a
polyethylene strip bond breaker shall be used to prevent three point bonding.
Where weather molds, staff beads, etc, do not form an integral part to frames to be
caulked, but are remove same prior to sealing, apply sealant, replace removed part and
point.
Do not use asphalt based products as joint fillers in joints to receive sealant in immersion
areas. All asphalt based products shall have backer rod to physically separate the joint
sealant from the joint material.
Apply sealant in full compliance with manufacturer’s application manual and instructions,
using hand guns or pressure equipment, with proper nozzle size, on clean, dry, properly
prepared substrates. Force sealant into joint and against sides of joint to make uniform.
Avoid pulling the sealant from the sides. Fill sealant space completely with sealant.
Place all exterior door, thresholds, and windowsills in a full bed of sealant during setting
procedures.
Tooling is required to ensure firm full contact with the interfaces of the joint.
Tool joints to form smooth, uniform beads with slightly concave surfaces. Finish joint shall
be straight, uniform, smooth and neatly finished. Remove any excess sealant from
adjacent surfaces of joint, leaving the work in a neat, clean condition. Tooling agents
should only be used if recommended by the sealant manufacturer.
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Where an irregular surface or sensitive border exists, apply masking at edge of joint to
ensure neatness and protection of adjoining element. Remove tape after sealant is
applied.
6 Toilet Works
 Shall install partitions and screens rigid, straight, plumb and level, spaced as shown.
 Shall use concealed fastenings where so designed.
 Shall provide clearances of 25mm maximum at walls and 13mm maximum between
panels and pilasters.
 Shall attach accessories securely to walls and partitions in locations as shown or
directed.
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 Where required, shall install concealed mounting devices and fasteners fabricated of
the same material as the accessories, or of stainless steel, as recommended by
manufacturer.
 Shall secure toilet in accordance with the manufacturer’s instructions for each item
and each type of substrate construction.
7 Miscellaneous Metal Works
i. Delivery, Storage and Handling
 Shall deliver items to be incorporated into the work of other trades so they can be
checked prior to installation without causing a delay.
 Shall store materials on skids and not on the ground and block up so that they will
not become bent or otherwise damaged.
 Shall handle materials with cranes or derricks.
 Shall do not dump material off cars or trucks nor handle in any other way that will
cause damage.
 Shall repair or replace items, which are damaged or corroded at no additional cost
to the Owner, prior to incorporating them into the work.
ii. Materials
Materials shall be conforming to the requirements specified for the particular item, and
where these requirements are not specified in detail, the materials shall be suitable for the
intended usage of the item. For fabrication of miscellaneous metal which are smooth and
free of surface blemishes including pitting, seam marks, roller marks, rolled trade names,
and roughness.
iii. Installation
Delivery items which are to be built into the work of other sections shall be coordinated in
time so as not to delay the progress of the work
Anchorage shall be provided where necessary for fastening miscellaneous metal items
securely in place.
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Abrasions in the shop primer shall be repaired immediately after erection. Areas left
untrimmed for welding shall be cleaned and painted with primer after welding.
iv. Handrail posts indicated to be grouted in embedded sleeves:
 Shall remove oil or other deleterious substances which may affect the bond or
performance of the grout from posts and sleeves.
 Level, plumb and align the handrail using shims, wedges, blocks or other
approved mean. Brace handrail until grout sets.
 Shall not mix cement grout by hand. Mix cement grout in a mortar mixer with
moving blades. Pre-wet the mixer and empty excess water.
 Shall add pre-measured amount of water for mixing, followed by the cement.
 Shall place grout into the sleeves and prevent segregation or entrapment of air.
Fill all spaces and provide full contact between the grout and adjoining surfaces.
 Shall coordinate and allow for installation of piping provided by other Sections and
connected to coupling at access hatches where indicated on the Drawings.
Remove and dispose of caps at these locations. Leave caps in place where no
piping is indicated.
v. Protection and final adjustment
 Shall protect all finishes from damage during construction period. Remove
temporary protective coverings at time of Substantial Completion.
 Shall clean welds, bolted connections, and abraded areas.
 Shall touch up galvanizing or finishes immediately after erection.
 Final adjustment: Shall check and readjust operating items, leaving items
undamaged and in complete and proper operating order.
8 Glass Works
i. Materials
Glass shall be obtained from a single Manufacturer with resources to provide materials of
consistent quality in appearance and physical properties.
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ii. Installation/ Erection
iii. Surface Conditions
 The glazier shall examine the framing and glazing channel surfaces, backing,
removable stop design, and the conditions under which the glazing is to be
performed
 Shall not proceed with the glazing until unsatisfactory conditions have been
corrected in a manner acceptable to the glazier and Engineer.
iv. Standard Performance
 Watertight and airtight installation of each piece of glass in required. Each

installation shall withstand normal temperature changes, wind loading, impact
loading (for operation sash and doors) without failure of any kind, including loss or
breakage of glass, failure of gaskets to remain watertight and airtight,
deterioration of glazing materials, and other defects in the work.
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 Inspect each piece of glass immediately before installation, and eliminate any that
have observable edge damage or face imperfections.
 Install the work of this Section in strict accordance with the Shop Drawings and
Manufacturer’s recommendations as approved by the Engineer.
 Glass Size : Sizes for glass shall be determined from actual size of frames. Glass
shall be so set to ensure equal bearing and continuous sealing of the entire
perimeter of each pane.
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 Metal stops, stop screws, and washers are specified elsewhere but shall be
applied as a part of the work of this specification. Use neoprene, vinyl, or other
approved setting blocks and spacer to achieve proper bearing and uniform beads
of glazing compound or sealant approved by the manufacturer.
v. Cleaning and Repair
 Remove paint and other coatings from the glass. Wash and polish both sides of
glass as required to leave surfaces thoroughly clean.
 Upon completion of the works, replace cracked or broken glass.
3.8 BLOCK PAVING
3.8.1 MATERIAL
Cement for concrete paving blocks (pavers) shall comply with BS EN 197-1, natural
aggregate with BS EN 12620. Water shall be free from matter in a quantity harmful to
concrete. Any chemical admixture used in the concrete shall comply with BS EN 934-2.
1 Dimensions and Physical Characteristics
The concrete pavers shall be rectangular, 100mm thick, with the length nominally twice
(2x) the width, such that they can be laid in a herringbone pattern. The number of pavers
per square metre shall be between 38 and 40.
The dimensional deviations of any pavers shall be as follows:
Dimensional Deviation of Pavers
Parameters Value
Height ± 2.0 mm
Width/Length ± 1.6 mm
Dimensional tolerance checks shall take place at the place of manufacturer and on-site for
each individual pallet. The thickness of each sample shall be measured to the nearest
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0.1mm at four equally spaced locations using steel callipers. The length and width shall be
measured to the nearest 0.1mm across two locations along each face.
In the event of paving blocks outside the specified dimensional tolerances reaching site,
pallets shall be clearly sprayed with a red cross and immediately removed to a quarantine
area for disposal or return to the manufacturer.
2 Strength
The compressive strength of paving blocks sampled and tested in accordance with BS EN
1338, shall not be less than 55MPa.
The minimum flexural strength (modulus of rupture) shall be 4MPa determined in

accordance with AS/NZ 4456.5.
The minimum characteristic breaking load shall be 18kN determined in accordance with
AS/NZ 4456.5.
3 Abrasion Resistance
The mean abrasion index shall not exceed 7, determined in accordance with AS/NZ
4456.9.
4 Appearance
All pavers shall be sound and free from cracks or other defects which would interfere with
proper placing or impair the strength following proper construction. Minor cracks incidental
to the usual method of manufacture or minor chipping resulting from the usual methods of
handling, shipment and delivery shall not necessarily be deemed grounds for rejection.
The Contractor shall make every effort to minimise the number of handling times to
reduce the incidence of such defects.
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The colour of blocks shall be uniform and as detailed on the Drawings or as directed by
PWA.
5 Sampling and Testing
Sampling and testing of blocks shall be carried out in accordance with BS EN 1338.
Sampled blocks shall be subjected to all the tests covered by Appendices A and B of BS
EN 1338.
The Contractor shall give PWA twenty eight (28) days notice of any proposed shipment of
pavers so that inspection of the pavers can be made at the manufacturing yard before
delivery.
Unless specified to the contrary, sampling and testing shall take place for each lot. A lot
shall represent a maximum of 1200m2 or one day's (10 hours) production, whichever is
the smaller quantity.
3.8.2 TRIALS
Prior to commencing any block laying works, the Contractor shall construct a trial area of
at least 500m2. The trial will be used to determine the adequacy of Contractor’s
equipment, placement methods and ability to meet with the specified tolerances:
Block Work Paving Tolerances
Specified Tolerance
Parameter
(Final as-built)
Joint Spacing 1.5mm - 3.0mm
Difference in level between

≤ 2mm
adjacent pavers (lapping)
Parameter Specified Tolerance (Final as- built)
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Level of paver above edge restraint 5mm
Level of paver above gully surround 10mm
Maximum ± 10mm deviation from

Horizontal alignment of pavers
Best fit line over 50 metres
Horizontal gap between paver and edge
1.5mm-3.0mm
restraint/gully surround/ drawpit/obstacle
Level of paver above electrical
5mm
drawpits, valve pits etc.
Maximum ± 5mm deviation from
Horizontal alignment of edge restraint
Best fit line over 30 metres
Bedding Sand Thickness 30mm ± 5mm
3.8.3 LABELLING REQUIREMENTS
Each pallet of pavers shall be labelled before delivery with a waterproof and UV proof
label listing the following information:
 Pallet number
 Date of manufacturer
 Mould number
 Date of mould commencement
 Strength tests of the lot (compressive, flexural and breaking load)
 Mean abrasion index
 Dimensional tolerances for pallet (height, width and length)
3.8.4 DELIVERY
Pavers shall be delivered, stored and handled in such a way that no damage occurs prior
to laying.
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3.8.5 BEDDING SAND
Bedding sand shall comprise a clean, well graded sand complying with BS7533: Part 3
1997. The sand shall comply with the following grading limits when tested in accordance
with the requirements of BS EN 1097:
Sieve Size % Passing
10.00mm 100
5.00mm 90-100
2.36mm 75-100
1.18mm 55-90
0.60mm 35-70
0.30mm 8-35
0.15mm 0-10
0.075mm 0
The sand shall be obtained from a single source, allowed to drain before use and covered
to minimise moisture changes. Protection shall be to the satisfaction of PWA.
The edge restraints to the paved area shall be installed before the laying course.
The sand shall be laid at a uniform moisture content and carefully screeded to form a
smooth compacted surface.
The profile of the bedding sand before compaction shall be similar to that of the finished
surface. The maximum deviation from the design levels shall be ±5mm. The laying course
shall be placed to a level which takes into account the compaction which occurs during
vibration of the blocks; the amount of this compaction shall be determined by trials prior to
commencement of surfacing.
3.8.6 JOINTING SAND
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The jointing sand shall comply with BS7533-3, except that the grading shall comply with
the following limits :
Sieve Sizes % Passing
1.18mm 100
0.60mm 55-100
0.30mm 15-50
0.15mm 0-15
0.075mm 0-3
3.8.7 CONSTRUCTION OF EDGE RESTRAINTS
Edge restraints shall be of structural grade concrete (C40) and hunched with C30 grade
concrete and shall be in accordance with BS 7533-3.
Edge restraints shall be installed along the exposed perimeter of paving.
Both sides of the restraint shall be vertical, free from excess concrete, shall be trowelled
smooth, extend into the base course and shall be such that the top edge of the edge
restraint is 5mm below the finished surface profile of the pavers.
3.8.8 LAYING OF SAND BEDDING COURSE
The Contractor shall use an approved mechanical spreader (e.g. asphalt paver) to spread
and screed the bedding sand.
Bedding sand shall be screeded in a uniform thickness of 30mm ± 5mm. Under no

circumstances shall the thickness of the bedding sand exceed 35mm.
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Vehicular traffic shall not be permitted on the screeded sand. Pedestrian traffic shall be
kept to a minimum and limited to block layers setting up string lines.
3.8.9 LAYING OF PAVING UNITS
Pre-cast paving blocks shall be laid in accordance with BS7533-3.
The Contractor shall lay the pavers in the designated laying pattern throughout the
pavement to form a homogeneous herringbone pattern. Once the laying pattern has been
established it shall continue without interruption over the entire pavement surface. Cutting
of pavers will not be permitted except along outer pavement boundaries, and adjacent to
drains and manholes.
Only plant and equipment necessary for the construction of the paver layer shall be
permitted to traverse the pavement during laying, compacting, joint filling and finishing.
The Contractor shall place the pavers on the uncompacted screeded bedding sand to the
nominated laying pattern. The specified bond shall be maintained throughout the works.
Pavers shall be placed to achieve joints 1.5mm-3.0mm wide between adjacent pavers,
such that all joints are correctly aligned.
The pavers shall be laid manually and the laying of pavers shall follow an order which
maintains an open face. Paver alignment shall be checked by stringline.
Special edge blocks shall be used on all edges of interlocking block paving which are
parallel to or perpendicular to the main pavement axis. Where the shape of or dimensions
of paved areas precludes the use of special or standard blocks on all edges, cut blocks
shall be used.
When it is necessary to cut pavers against edge restraints, cut pavers shall consist of not
less than 25% of a full paver.
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All cut pavers shall be saw cut with a bench mounted saw and chamfered with a nominal
45° x 5mm chamfer.
3.8.10 INITIAL COMPACTION
After laying, and if necessary adjusting the paver alignment and joint spacing, the pavers
shall be bedded by not less than two passes of a suitable plate compactor.
The compactor shall be a high frequency, low-amplitude mechanical flat plate vibrator with
a mass of 350kg (770lbs) and generating a centrifugal force of 0.5N/mm2 (9000lbf),
having a plate area sufficient to cover a minimum of twelve pavers. The compactor shall
not damage the pavers. The Contractor may elect to provide a rubber mat on the base of
the plate vibrator to prevent premature damage to the pavers.
The compaction methodology shall take into account further compaction from the
pneumatic tyred roller to achieve the final as-constructed levels required.
Compaction shall not be attempted within 1 metre of the laying face. Compaction shall
continue until lipping between adjoining pavers has been minimised and in any case shall
not exceed 2mm. Joints shall then be filled and compacted.
Any pavers which are structurally damaged during compaction shall be immediately
removed and replaced before the end of the working day.
3.8.11 JOINT FILLING
Before the commencement of joint filling, the pavement surface shall be checked for joint
spacing, height of pavers against edge restraints and lapping. Any non conformities shall
be corrected immediately.
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As soon as practical after compaction, and in any case prior to the termination of works on
that day, and prior to the acceptance of construction traffic, the Contractor shall spread
jointing sand over the pavement. The jointing sand shall be dry.
The jointing sand shall be broomed to fill the joints. Excess sand shall then be removed
from the pavement surface and the jointing sand shall be compacted by not less than two
passes of the 350kg (770lb) plate vibrator. Further sand shall be broomed to fill the joints,
and the procedure repeated until the joints are filled to the level of the chamfers. No traffic
other than pavement laying plant and equipment shall be permitted to use the pavement
until all joints have been completely filled with sand and compacted.
3.8.12 FINAL COMPACTION
As soon as possible after the filling of joints, construction traffic shall be encouraged to
use the pavement to assist in the development of "lock-up". Such traffic shall traverse the
greatest possible area of the pavement.
The pavement shall be subjected to not less than four passes of a heavy pneumatic tyred
roller having wheel loads of 5,000kg (11,000 lbs) at tyre pressures of 8bar (116 lb f/in2).
This operation shall be performed on the completion of large areas and may be over
extended periods.
If found necessary, on the completion of the rolling, joints shall be topped up by adding
and vibrating more joint filler sand so that the joints are left filled.
3.8.13 EXCESS SAND

The Contractor shall remove excess surface sand by brooming prior to handing over each
section of pavement.
Where mechanical methods are used, care shall be taken not to remove sand between
the paver joints and compromise lock-up of the pavers.
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3.9 MAJOR MATERIAL
3.9.1 CEMENT AND CONCRETE
Basically, cement will be supplied from local commercial sources and cement concrete will
be produced by the Contractor using their own batching plants, however, purchasing of
concrete from local suppliers shall also be an alternative.
After batching at the cement concrete plant, the concrete will be transported in 6 cubic
meter truck mixers to the job sites and place layer by layer with proper vibrating
compaction into place by stationary concrete pump or mobile concrete pump track. In hot
weather condition, a cold joint in concrete must be avoided by all means through timely
supply of concrete. Adequate lighting facilities in the site will be established in order to
allow full production of concrete even during the night shift and concrete pouring can be
continuously done during extended or night time. All the necessary laboratory tests shall
be carried out to ensure the materials are in full compliance with the specification.
Necessary devices like concrete vibrators shall be used for concrete compaction and to
avoid over vibration to prevent segregation of fine and course aggregates and bleeding of
the concrete. Adequate curing will be applied after pouring concrete.
3.9.2 AGGREGATE, SAND AND BOULDERS.
Normally, crushed aggregates, sand and boulders will be supplied from local commercial
sources and each type of aggregates will be separately stored in suitable stockyards
adjacent to the batching plant.
Before the supply, the materials shall be tested either by the third party laboratory or the
Contractor’s own laboratory on site to ensure that materials are satisfying the requirement
of the specification prior to its usage in the work.
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3.9.3 REINFORCING STEEL BAR.
The required quantities of reinforcing steel shall be procured either from overseas or local
suppliers for the project. All the necessary tests, inspections and quality control
requirements will properly be fulfilled.
After delivery to the site the material will be kept in a proper place to avoid further rusting
or preventing deterioration of the quality.
Cut and Bar bending schedules will be prepared well in advance and the reinforcing steel
shall be cut, bent and made ready for use in accordance with the sequence of operations
on the work program. Normal procedures will be followed for fixing of reinforcement,
ensuring cleanliness and correct spacing and cover etc. before placing or casting of the
concrete can be made.
4 MECHANICAL AND ELECTRICAL WORKS
4.1 GENERAL
This method statement defines the minimum guide line that are to be met in the
installation procedure of Mechanical and Electrical Works.
4.1.1 REFERENCES
 Contract drawings
 Approved drawings
 Manufacturer Installation Instruction
4.1.2 RESPONSIBILITIES
(a) Site Engineer
The Site Engineer shall be responsible for the following:
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 To explain the required precautions to be taken while handling such equipments/

chemicals
 To explain and provide all necessary information for installation to his Foreman
and crews
 To ensure that this method statement is understood and followed by his Foreman
and crews.
 To ensure that Installation is carried out according to specification.
 To make ensure that all materials, approved drawings, Tools and Equipment’s are
available at site.
 To initiate inspection and /or testing request (ITR) for inspection.
(b) Supervisor
The site supervisor shall be responsible for the following:

 Supervisor shall provide all technical assistance to his Foreman.
 To ensure that work is being done as per approved drawing.
 To meet with all safety measures and ensure the same for his subordinates.
 To provide work front and schedule.
(c) Foreman
The site foreman shall be responsible for the following:

 To ensure that construction is being done as per approved drawing and
specification.
 To provide his crew with adequate information to carry out the their job efficiently.
 To provide daily report of works progress.
 To prepare material issue voucher.
 Responsible to transport all required material from store to site.
(d) Safety Officer
The safety officer shall be responsible for the following.

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 To be aware about the required first aids may be required as a result of any
incident in the site
 Barricades and safety warning tape shall be erected around the excavated
trenches.
 To make regular inspection of the site to ensure proper working method and
proper equipment are used.
 All material brought to site shall be stacked and blocked and secured to prevent
sliding, collapse.
 Daily toolbox talks on safety aspects.
4.1.3 HANDLING & STORAGE
 All materials shall be transported by suitable vehicles. Loading and Un-loading

shall be done carefully to avoid damage.
 All material shall be stocked at safe place to avoid any damage.
 Chain block / Nylon sling shall be used for lifting the equipment.
 All material handling operations shall be supervised by store supervisor
4.1.4 TOOLS AND EQUIPMENTS
Chain block, sling , Spirit level.
4.1.5 INSTALLATION PROCEDURE
(a) Pre-installation
 Having unpacked the mechanical equipment, check all parts for obvious damage,
if any damage is apparent contact the manufacturer before proceeding in the
installation
 The intended mounting of all equipment should be carefully planed in advance.
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 The cable length should be carefully planned in advance to avoid unnecessary

cable jointing
 Make sure that the equipment plinth is cast as per the required level and
dimensions
 Make sure that the equipment are fixed in the exact location as per the approved
drawings
 Unauthorized persons to be excluded from installation
(b) Installation
 Install the equipment as per the approved drawings and manufacturer

instructions providing space, support , electrical power and alarm system if
required
 Install the equipment and the whole other accessories following the manufacturer
 Check that the pipes from the equipments are securely connected
4.2 MECHANICAL WORKS
4.2.1 MECHANICAL BAR SCREENS
(a) Scope
installation procedure of mechanical bar screens.
(b) Tools and Equipments
Crane, Chain block, Spirit level, Tool box with complete Spanner set, Temporary
supports.
(c) Installation Procedure
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1 Conform that the concrete work for the screen channel was done as per the
required arrangement to suit the bar screen installation
2 Fix the stationary bar screen to the bottom of the screen channel
3 Install the mechanical bar screen components as per the manufacturer
installation instructions insuring the followings:
 The angle of inclination is for the main frame is as per the required angle
 The moving rake supported correctly to the main frame and it is engaged to
the fixed bar screen from the bottom of the channel up to the discharge
point
 The gear drive is coupled to the gear box and supported by the bearings
and carries the two pinions holding the roller chain
 The tilting plate system is engaged to the moving rake in proper way to
insure conveying the screened matters to the chute properly
 Insure that the level sensors upstream and down stream of the bar screen
are installed as per the approved arrangement to enable the mechanical
operation of the bar screen efficiently
 The local protection panel is installed and wired properly to the screening
equipment.
4.2.2 DEGRITTER
(a) Scope
This method statement define the minimum guide line that are to be met in the
installation procedure of degritors.
supports.

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1 Conform that the concrete work was done as per the required arrangements to
suit the degritter installation
2 Inspect the gear drive for any damage
3 lift the gear drive and install it on its position over the mounting bolts provided
on the drive platform, the hole in the drive platform must be checked to insure
that it aligns correctly with the gear drive on
4 The gear drive to be shimmed up by machinery wedges
5 carefully level the unit by using wedges , place the machinery level on the
machined surface where the outlet
6 The mounting nuts to be tightened for the final leveling
7 Grout the gap under the gear drive
4.2.3 RAS AND SAS PUMPS, FILTER FEED PUMPS, WORKS DRAINAGE PUMPS,
SCUM PUMPS
(a) Scope
This method statement covers the minimum guide lines that are to be met during
the installation of This procedure is specifically applicable to the above referenced
pumps:
(b) Tools and Equipement
Crane, A frame, Chain block, sling , Spirit level, Tool box with complete Spanner
set, anchoring equipment , Temporary supports
1 Preinstallation
 Inspect the pump for cracks, dents damaged threads, and other obvious
damage.
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 Check for and tighten loose attaching hard ware.

 Carefully read all warning and caution contained in the manual.
 Check the levels and lubrication as necessary.
 All materials shall be transported by suitable vehicles. Loading and
unloading shall be done carefully to avoid damage.
1. Chain block / Nylon sling shall be used for lifting the equipment.
2. All material handling operations shall be in accordance with manufacturer
instruction.
2 Preparation of foundation
 Ensure that pump plinths are complying to the approved shop drawing .
 Make sure the top level of the plinth is ok and in true horizontal plane.
 Plinth size to be verified for dimensional accuracy .
 Cross check the location of the plinth is matching in relation to the puddle
pipes / openings for suction / delivery piping.
 Mark the center line on the pump frames.
 Mark the center lines on the plinth for the first pump.
 Mark the center lines on the plinth for the other pumps.
 Mark the exact location for foundation bolt drilling.
3 Installation Procedure
 Lower the base frame and match the marked center lines.
 Ensure that the marked location of the foundation bolts matches with the
base frame of the pumps.
 Drill the required hole of the correct size and depth.
 Ensure that the fix length of the anchor bolt being used is sufficient to cover
the base frame and fix the nut.
 Installation of anchor bolts to be as per the approved method statement for
Installation of anchor bolts.
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 Equipment shall be placed on foundation very steadily to avoid any damage

to foundation bolts, using the correct lifting procedure.
 Check if the top of the base frame are in correct level and in true horizontal
plane, If not ,provide shims or wedges to attain the same.
 Although the pump and motor is aligned and pre assembled in the factory,
verify the same after connecting the suction / delivery piping.
 Follow the manufacturers installation instruction, as applicable for different
pumps.
 Manufacturer Installation Instruction shall be strictly followed.
4.2.4 FILTER BACKWASH PUMPS, ULTRAFILTRATION FEED PUMPS,

ULTRAFILTRATION BACKWASH PUMPS, WASHWATER PUMPS, CHLORINE
BOOSTER WATER PUMPS
(a) Scope
the installation. This procedure is specifically applicable to the above referenced
pumps
Chain block, sling , Spirit level, Tool box with complete Spanner set, Temporary
supports
1 Pre-installation
 Inspect the pump for cracks, dents damaged threads, and other obvious
damage.
 Check for and tighten loose attaching hard ware.
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 Carefully read all warning caution and instruction contained in the manual.
3. Chain block / Nylon sling shall be used for lifting the equipment (if
required ).
4. All material handling operations shall be in accordance with manufacturer
instruction.
2 Preparation of Foundation
 Ensure that pump plinths are complying to the approved shop drawing .
 Make sure the top level of the plinth is correct and in true horizontal plane.
 Plinth size to be verified for dimensional accuracy .
 Cross check the location of the plinth is matching in relation to the puddle
pipes / openings for suction / delivery piping.
 Mark the center line on the pump frames.
 Mark the center lines on the plinth for the first pump.
 Mark the center lines on the plinth for the other pumps.
 Mark the exact location for foundation bolt.
3 Installation
 Lower the base frame and match the marked center lines.
 Ensure that the marked location of the foundation bolts matches with the
base frame of the pumps.
 Ensure that the fix length of the anchor bolt being used is sufficient to cover
the grout thickness, base frame and fix nut.
 Provide shims for the leveling and to attain the grout thickness.
 Equipment shall be placed on foundation very steadily to avoid any damage
to foundation bolts, using the correct lifting procedure.
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 Check if the top of the base frame are in correct level and in true horizontal
plane.
 Steady place and connect the motor / pump shaft.
 Install the suction pipe works for the pumps.
 Install the delivery pipe works for the pumps.
 Check the alignment of the pumps / motor assembly.
 Grout the pump base and the anchor bolt pockets with approved non-
shrinkage grout.
 Eliminate any possible Vibration during functioning.
 Check clearance around pumps for easy maintenance.
 Make reference to electrical installation requirements.
 Follow the manufacturer’s installation instruction, as applicable for different
pumps
4.2.5 AERATION AIR BLOWERS
(a) Scope
the installation of the backwash air blowers for pumping station No.3.
supports.
1 Pre-installation
 Inspect the air blowers upon delivery and the whole involved persons to be
familiar with the equipment
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 Make sure that the concrete plinths are cast as per the required
dimensions and heights
 All material handling operations shall be in accordance with manufacturer
instruction.
2 Installation
 Place the air blower units on oven , vibrationless and slope-free ground
 Normally, piping is fitted after having put the machine in its final position.
 Before erecting piping, it is essential to isolate the machine by inserting a
sheet metal disc between each flange and the element immediately
adjacent to it (valve, flanged adaptor, expansion joint etc.). This prevents
foreign bodies from getting into the machine during this phase.
 Ensure sufficient aeration and ventilation at place of assembly, inlet and
exhaust air
 Check the blower for smooth running , tight running may be the
consequence of distortion or foreign particles
 In order to avoid electrostatic supercharging of the blower units, these
units to be earthed via the provided connections
 Fix piping separately , so that stable connection can be established
 Connect the electrical motor as per the technical details provided by the
manufacturer
 Install connection cable for electric motor in such away that no damage
may occur by movements of the motor support
 Noise prevention to be taken into consideration
 Ensure that the safety instructions and technical documents of the
component supplier are observed
 Fill up the lube oil
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 Mount the special accessories delivered separately – if there are any

 Install the electrical connection completely
4.2.6 FILTER BACKWASH BLOWERS, SAS TANK BLOWERS, AEROBIC DIGESTER

BLOWERS, PRE- AND POST-DIGESTION BALANCING TANK BLOWERS
(a) Scope
the installation of the above referenced blowers
supports
1 Pre-installation
 Inspect the air blowers upon delivery and the whole involved persons to be
familiar with the equipment
 Make sure that the concrete plinths are cast as per the required dimensions
and heights
 All materials shall be transported by suitable vehicles. Loading and unloading
shall be done carefully to avoid damage.
 All material handling operations shall be in accordance with manufacturer
instruction.
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2 Installation
 Place the air blower units on oven , vibrationless and slope-free ground
 Remove the packing materials completely in case of acoustic hood design,
ensure free section of the inlet and exhaust silencer.
 Ensure sufficient aeration and ventilation at place of assembly, inlet and
exhaust air
 Check the blower for smooth running , tight running may be the consequence
of distortion or foreign particles
 In order to avoid electrostatic supercharging of the blower units, these units
to be earthed via the provided connections
 Fix piping separately , so that stable connection can be established
 Connect the electrical motor as per the technical details provided by the
manufacturer
 Install connection cable for electric motor in such away that no damage may
occur by movements of the motor support
 Noise prevention to be taken into consideration
 Ensure that the safety instructions and technical documents of the
component supplier are observed
 Fill up the lube oil
 Mount the special accessories delivered separately – if there are any
 Install the electrical connection completely
4.2.7 RAPID GRAVITY SAND FILTERS
(a) Scope
the construction and installation of rapid gravity sand filters
The rapid sand filters consist mainly of the following units:
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 Filtered water outlet main

 Backwash pumps
 Filtration tanks
 Lifting beam
 Filter media
 Weir plates
 Support floor
 Dwarf wall
 Drain
 Penstocks
(b) Tools and Equipment
Crane, A frame, Chain block, sling , Spirit level, Tool box with complete Spanner set,
anchoring equipment
1 Verify the civil work is completed as per approved shop drawings .confirming the
dimensions and levels
2 Make sure that the whole required puddle pipes ,water distribution orifices and all
impeded items are installed as per the required levels and dimensions
3 Make sure that the whole interconnecting piping is installed as per the required
general arrangements of piping
4 Install the channel weir plates to match the required level and arrangement
5 Install the Penstocks as per the required arrangement
6 Make sure that the top of dwarf walls are leveled
7 Install the filter support floor on the top of the dwarf walls
8 Fix the lifting beam
9 Recheck the whole required mechanical details and make sure the tanks are
ready to add the filter media
10 Add the approved filter media to the tanks
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11 Make sure that the top of filter media inside each filtration tank is at the correct
level insuring a media thickness of one meter exactly
12 Clean the filters area removing the whole non-required matters
4.2.8 ULTRAFILTRATION SYSTEM
(a) Scope
the construction and installation of Ultrafiltration system
The UF system consist mainly of the following units:
 UF skids
 Chemical dosing equipment
Crane, A frame, Chain block, sling , Spirit level, Tool box with complete Spanner
set, anchoring equipment
 Using the Crane, lower each skid carefully on the foundation and match the
marked centre lines.
 Check the alignment and distance of both skids based on the dimension given
on the approved drawing.
 Mark all locations of the foundation bolts and drill the required hole of the
correct size and depth.
 Ensure that the fix length of the anchor bolt being used is sufficient to cover the
base frame and fix the nut.
 After completing all the anchor bolts, connect all the necessary piping
accordingly
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4.2.9 ULTRAVIOLET DISINFECTION SYSTEM
(a) Scope
the construction and installation of Ultraviolet disinfection system
Crane, lifting device (maximum load 120 kg), Chain block, sling , Spirit level, Tool
box with complete Spanner set, anchoring equipment
UV Module
 Using the Crane, lower each module carefully to the bottom of the channel and
match the marked centre lines.
 Check the alignment and distance of modules based on the dimension given
on the approved drawing.
 The distance between the centerline of the UV lamps and the channel walls
has to be according the general arrangement drawing. Move the wiping
cylinder manually and check that the wiping system does not touch the channel
walls.
 After completing the correct alignment, connect all the necessary cabling
accordingly.
Baffle plates
 Install both attachments into the channel vertically.
 Slide the baffle plate into the attachments and check for easy replacement.
 If necessary drill hole through the attachments and baffle plate and fix with bolt
and nut.
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Level Probe
 Install the Low level probe behind the last UV Bank.
 Cut the electrodes to the required length and fix it below the holder.
 Check that the lower end of the electrodes is maximum 5 mm below the top of
the highest quartz sleeve.
 Put the signal cable into the cable conduit/duct and connect with the
corresponding terminals in the electrical cabinet.
 Fill the channel with water and check the correct operation.
Motorized Weir
 Lift the motor weir into the channel and position it vertically.
 Mark the position of the boreholes on the channel walls.
 Lift the weir out of the channel and drill all holes. Clean the boreholes from any
dirt and push the dowels in.
 Fix the weir with bolts and washers to the channel.
 Loose both lower nuts of the slide rod. Move the weir plate manually and check
that the plate can be moved easily.
 Take the weir out again. Put silicon between the
- weir plate and attachments,
- weir plate and channel bottom,

- attachments and channel walls to reduce water leakage
 Fix the weir with bolts and washers to the channel.
 Move the weir plate manually and check that the plate can be moved easily.
 The limiting switches and slide rod of the motor weir are preset. But final
adjustment might now be done. Both end position have their own limiting
switch. The preset travel range of the weir motor is the distance between the
open and close position. The slots in the slide plate are some millimeter longer
than necessary to avoid that the weir blocks mechanically.
 Turn the slide plate up or down manually by the handwheel until the
corresponding limiting switch reacts.
 Tide both nuts of the slide rod in the way that the slide plate is now open or
close (depending on which end position you check first).
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 Turn the slide plate to the opposite direction manually until the other limiting
switch reacts. Now the slide plate has to be open or close (depending on which
end position you have checked first).
 The limiting switches and slide rod are set properly when
- one limiting switch reacts in the open position,
- the other limiting switch reacts in the close position and
- the slide plate does not block anywhere.
4.2.10 CHLORINATION SYSTEM
(a) Scope
installation procedure of Chlorine equipment.
Chain block, sling , Spirit level.
1 Install the chlorine booster pumps as per the approved drawings and
manufacturer instructions providing space, support , electrical power and
alarm system if required
2 Install the chlorine drums as per the required arrangement making sure that
the whole supply valves of the drums are tightly closed to avoid any chlorine
gas leak
3 Install the chlorinators and the whole other accessories following the
manufacturer
4 Locate the injection system , water supply ,and solution delivery lines to the
point of application as per the approved drawings and instructions
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5 Ensure the gas supply lines from the chlorine drums are securely connected
and all the valves in the system are closed
6 Check that the boosted water line from the chlorine booster pumps is securely
connected
7 Ensure the injector vacuum line is connected tightly between the chlorinators
and the injector
8 Check the chlorine solution line from the injector to the point of application and
make sure it is correctly fitted
9 Before starting up the chlorination system , it must be precommissioned and
commissioned carefully making sure it operating normally with out any
operational problem
4.2.11 CENTRIFUGE
(a) Scope
This method statement define the minimum guide line that are to be met in the
installation procedure of sludge centrifuges.
supports.
1 Make sure that the concrete plinth for the centrifuge is cast , and the finish
plinth level is at the correct level
2 Install the centrate and solid discharge chutes as per the required
arrangement
3 Install the sludge cake conveyors and inlet boxes as per drawing and check
alignments
4 Install the centrifuge as per the manufacturer instructions
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5 Ensure that the polyelectrolyte storage tanks are installed accompanied with
the whole piping
6 Ensure that the polyelectrolyte pumps are installed , and the interconnecting
piping is ready as per the approved drawings
7 Ensure that the whole required piping for the centrifuge is constructed as per
the approved drawings
4.2.12 DUCTILE IRON PIPES
(a) Scope
This method statement details the procedure for installation of Ductile Iron pipes

Spanners, Spirit level, Sling belts, D-Shackles, Chain blocks, Half round file, Angle
Grinder.
1 Before starting the Installation of puddle piping, Layout drawing shall be

studied carefully.
2 The pipe shall be carefully handled during installation to ensure that the sand,
dirt and any other foreign material is removed from the interior of the pipe
before installation.
3 Check the dimension of the pipe.
4 Ensure that the height level (top level) of the installed pipe has been checked
as well as the final level of the pipe to be extended before cutting.
5 Before installation of the pipe check surface defects such as paintings internal
lining (in case of any damage shall be rectified).
6 Ensure that pipe to be used as extension is of same approved material.
7 If the pipes are cut on site, they should be cut square to the pipe axis with the
use of angle grinder.
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8 The pipe axis should be chamfered to a depth of half the wall thickness and at
an inclination angle of 15 degree to the pipe axis.
9 After all preparation has been done, connect the pipes with the use of universal
adapter.
10 Check the final level and Plumpness of the extended pipe before tightening the
bolts of the universal adapter
4.2.13 GRP PIPING
(a) Scope
This method statement details the procedure for installation of Glass reinforced
plastic (GRP) piping.
Crane (10 ton), Sledge hammer, Spanners, Spirit level, Sling belts, D-Shackles.
1 Joining of Pipe
 Before starting the Installation of GRP piping, layout drawing shall be

studied carefully.
 The pipe shall be carefully handled during installation
 Ensure that the sand, dirt, any other foreign material is removed from the
interior of the pipe before Installation.
 Clean double bell coupling grooves and rubber gasket ring.
 Insert the rubber gasket into the grooves and with uniform pressure push
each loop of the rubber gasket into the gasket groove.
 Lift either mechanically or by hand, the double bell coupling and align with
the pipe section.
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 Pushed the coupling onto the pipe, using levers and protective timbers, until
it aligned between black alignment strips.
2 Hydrostatic Test
 After completion of the installation, the piping shall be made ready for hydro
testing. The pipe joints, valves & fittings shall be made accessible for
examination.
 Vent shall be provided at high point so that air can be removed easily.
 The pipe line shall be filled with water slowly. The vent shall remain open
until trapped air is removed from the piping.
 After the trapped air has been expelled & the vent valve is closed, then the
pressure shall be increased gradually till the test pressure is obtained.
 FORCE MAIN: The test pressure shall be 1.5 times the operating pressure
of the system but not less than 1035 kpa (10.35 bar).
 Check each joint Max. allowable leakage is 4.6L/mm of nominal pipe size
(NPS) per km of pipe. During 24 hour period.
 Only calibrated pressure gauges shall be used for hydro testing.
 Check for leakage or sweating from the valves, fitting & pipes. If found
defective the same shall be replaced.
After hydro test is over, the pressure shall be released till the pressure gauge
comes to zero, then vent valve & drain valve shall be opened to release the entire
fluid.
4.2.14 uPVC PIPES
(a) Scope
This method statement details the procedure for installation of uPVC pipes and
fittings below and above the ground.
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Ring spanner, Sledge Hammer, Sling belts, D-Shackles, Spirit level, Saw and file
1 Check the invert level of trench as per drawing and the sand bedding as
per contract drawing.
2 Before starting the Installation, pipes, fittings & valves, the Layout drawing
shall be studied carefully.
3 The pipes, fitting & valves shall carefully handled during installation Ensure
that the sand, dirt, any other foreign material is removed from the interior of the
pipes, fittings & valves before Installation.
4 The flanged ends of Pipes & Valves shall be assembled together by putting
full face gasket. Hardware of suitable length shall be used.
5 Bolts shall be tightened properly so that there shall be no leakage during

hydro testing. adopt cross tightening method for uniform tightening.
6 Provide Pipe Supports as & where required as per approved drawings.
7 Installation shall be done as per approved drawings.
8 Before lowering the pipe into trench the following checks to be carried out:
 Check the rubber sealing ring is correctly positioned and fully depressed in
place.
 Check the inside surface of the sockets for any foreign material particularly
behind rubber o rings
 Lower the pipes into the trench by means of nylon rope or belt so that the
pipes are not damaged.
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Carefully align the pipes vertically & horizontally. Ensure that the
pipes & fittings are in straight line
4.3 ELECTRICAL WORKS
4.3.1 WORK PROCEDURE FOR CABLE TRAY AND SUPPORT
1) General
All electrical material shall be installed and connected in a complete workmanlike

manner in accordance with the specifications and drawings, the manufacturer’s
installation instructions and the applicable codes and standards.
Special care shall be taken to prevent damage of any electrical material due to
welding or other fabrication or installation operations.
All electrical material shall be substantially aligned with surrounding structural

members and installed in such a manner as to present a finished installation.
All electrical material shall be installed in a manner which provides ease of access
for operation, service and maintenance of all equipment, piping and valves.
2) Procedure
The installation of main cable trays layout has to be done according to the Issued for
Construction drawing issued by the Contractor. Secondary tray runs shall be
installed as required in order to complete the installation.
Before installation, equipment (cranes) ladders or trunking should be positioned near

the structures and located in proper position to assure installation of cable trays.
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The Man-Lifter will be used to install cable trays up to the height of 20m from the
ground level.
In other cases, wherever necessary, suitable scaffolds shall be used.
The cable trays (perforated type) ladders or trunking will be bolted in previously
drilled holes on the existing structures foreseen to be cable tray risers in vertical
section.
Welding and drilling are to be avoided as much as possible. Clamping arrangements

are to be used for fixing support where possible.
In order to facilitate the lifting of trays to various heights on the tanks, pulley systems
shall be installed on their tops with the appropriate size of rope.
Where the installation takes place on structures with access or with mobile or fixed
scaffolding the lifting will be carried out with hoists and/or tackles as required.
Installation of Cable tray hardware (e.g. fasteners, clips, nuts, bolts and washers),
material of hardware shall be of stainless steel.
Individual sections of cable trunking and cable trays shall be interconnected using
low impedance bonding straps at both edges. Preferably, U-shaped coupling plates
should be used.
Cable trunking and cable trays shall be bonded with supporting steel structures
every 2.5 meter. For this purpose, mechanical supports, like beams and vertical
girders may be used, provided a low impedance electrical bond is ensured.
In case insulating plastic spacers are installed between stainless steel cable trunking
and steel supports, to prevent corrosion, adequate bonding shall be provided by
means of earth straps with appropriate fixing material.
Cable trunking and cable trays shall be bonded to equipment and MDF cabinets,
junction box enclosures, electrical equipment housings, instrument housings, metal
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conduits, PECs, etc to form a single parallel earthing conductor (PEC) as detailed in
applicable drawing.
a) Safety
- All Equipment shall be installed following the safety regulations indicated in

Daewoo HSE Procedure.
- All the necessary work permits shall be obtained wherever applicable prior to
begin the works. All works shall be done in accordance with the plant safety rules
and regulations.
b) Cable Tray Usage
- Cable tray shall not be used as walkways, scaffolding, or for any purpose not
intended. Cable tray shall not be used as a means of support for other raceways,
tubing, or any other equipment.
c) Metallic Tray
- Aluminum tray shall be isolated from mounting brackets and other dissimilar
metals using 1/8 inch neoprene strips and neoprene washers or 3/16 inch
fiberglass plate. Isolation from dissimilar metals shall be provided regardless of
whether or not this shown on the design or detail drawings.
- Metallic tray cuts shall be cold and all holes shall be drilled, burrs and sharp
edges shall be cleaned, all sharp edges shall be smoothed and the finished shall
be restored. Metallic tray shall no t be welded or cut with a torch.
3) Testing and Procedure
Quality records shall be prepared as per the respective ITTs.
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Installation process sheets shall be signed off by PWA inspector and shall be counter
signed by the Contractor and/or PWA signature as applicable
All the records shall be submitted to the Contractor on mechanical completion of the
system as advised by the Contractor.
4) As-Built Drawings
All drawings as specified in the project specification shall be marked up (in Red Line)
during and at the end of the construction, and handed over to the Contractor clearly
marked with “As-Built”. If no change is made, this shall be recorded as “No Change”.
4.3.2 WORK PROCEDURE FOR CABLE CONDUIT AND SUPPORT
1) General


All electrical material shall be installed in a manner which provides ease of access for
operation, service and maintenance of all equipment, piping and valves.
All joints connections shall be threaded. All threaded connections on conduit fittings,
cable fittings, cable terminators, junctions box covers, hubs, conduit fittings, covers
bolts, etc., shall be coated with lithium based thread lubricant during initial installation
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of equipment to prevent galling and minimize corrosion. Thread lubricant shall not
interfere with the bonding continuity of the cable system.
2) Procedure
(1) Conduit Installation
Use of conduit is limited to interior wiring in building or modules and short runs on
packages. Conduit is not to be used for general facility wiring. The use of conduit
is discouraged and will only be allowed for specific cases after prior approval is
obtained.
 The installation of conduit has to be done according to the Issued for
Construction applicable drawing issued by the Contractor.
 The material type and quality is in accordance and have to be checked
with the requirement of project specifications and technical requirement.
 Conduit shall be cold cut square. Field made threads shall be cut clean
and true with sharp unworn dies. The threads shall be cut to the proper length
and depth for standards ¾ inch (19mm) taper per foot threads. Threads cutting
lubricant shall be used, all thread ends and cut ends shall be reamed after
threading to removed burrs and rough edges.
 Conduit installation inside rooms and buildings shall be hidden inside
walls or run in ceiling spaces and chases unless otherwise indicated on the
design drawings.
 Install conduits and fitting shall be of the specified sizes in accordance
with the drawing.
 All conduit runs shall be installed with a minimum number of bends and
offsets, run of conduit containing low voltage (600 volt maximum) wire shall
have a maximum pulling distance of 300 feet (91440mm) and contain no more
than three and one-half quarter bends (315 degrees total), including offsets and
bends located immediately adjacent to pull location. On runs over 300 feet
(91440mm) this shall be reduced to two quarter bends (180 degrees total).
Cable tension and side wall pressure at bends shall exceed the cable
manufacturer’s recommendations.
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 For 600- volts cables, the minimum radius of conduit bends shall be six
times the made with suitable conduit bending equipment. A uniform circular
cross section of the conduit shall be maintained at bends. No single bend shall
be greater than 90º.
 Threaded conduit fittings shall be used to terminate cable glands before
entrance into boxes and enclosures. Conduit fittings shall meets and/or exceeds
NEC requirement for cable bending radius.
 Fitting and opening in pull boxes shall have adequate access.
 Install all fittings are made wrench-tight to ensure adequate ground
returns.
 Conduit unions shall be installed, where necessary at removable
devices/equipment, so that devices/equipment can be easily and independently
removed.
 Flexible conduit is called for on the installation drawings and by NEC,
and where field conditions indicate vibration could be a problem for a rigid
conduit. Liquid-tight flexible metallic conduit with a PVC jacket complying with
NEC Article 250-91 shall be used in Class 1 Zone 2 and non-hazardous areas,
where flexibility is required. On liquid – tight flexible metallic conduit larger than
1-1/4 inches (32mm) terminations shall be made using liquid tight connectors
with integral insulated bushing and ground lugs and shall have external bonding
jumpers installed. The maximum flexible conduit length shall be 24 inches
(609mm) for instruments and equipment and 18 inches (457mm) for motors.
 Flexible coupling PVC coated, explosion –proof shall be used in Class
1, Zone 1 hazardous areas where flexibility is required, and at motor connection
boxes if shown on details or required flexibility. Use of explosion-proof flexible
coupling shall be kept to a minimum.
 Conduit shall be terminated with insulated bushing to prevent damage
to wire during pulling operations, except in enclosure where hub design and
additional protection is adequate to prevent insulation damage. Grounding
connections shall be provided on all installed bushing for grounding continuity.
 Pull-type conduit fitting shall not be installed between sealing fittings
and explosion proof equipment.
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 Method for draining the conduit shall be provided at low point and
where a conduit enters equipment from overhead. Either drain seals or drains
installed at the low side of a tee fitting may be used.
(2) Seal and Drains
 Conduit systems shall be provided with suitable drain fittings at the low point
of vertical runs and low point of the overall conduit system. If sealing is
required in a vertical run, a drain seal fitting shall be installed. To the extent
possible, drain fittings shall not be installed until after internal conduit
cleaning.
(3) Support Installation
 Care should be exercised in installing conduit so that adequate clearance is

allowed for maintenance access.
 Conduit shall be supported at intervals as shown on the drawings and as
required by NEC 346-12, “Supports” and Table 346-12, “ Support for Rigid
Metal Conduit” to prevent sag. Support must not infringe upon OSHA-required
unobstructed areas. Damaged conduit support shall be repaired to original
condition after conduit installation.
 Conduit shall not be installed directly on the surface of vessels exceeding
140ºF. Where a support is attached directly to the vessel, suitable I insulating
pads shall be inserted between the conduit and the support. Provision shall
be made for conduit expansion where conduit is supported within 12 inches
(305mm) of lines and vessels exceeding 140ºF.
(4) Conduit Penetrations
The following options are acceptable for wall penetrations of overhead conduit.
 After installation of the conduit, the penetration opening shall be sealed with a
nationally recognised testing laboratory (NRTL) approved sealant on both
sides of the wall.
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 Myers hubs, or equivalent, shall be installed in a minimum ¼ inch (6.4mm)

thick plate of a material compatible with the conduit. The plate shall
completely cover the conduit openings and shall provide a watertight seal.
The Myers hub option shall not be used for conduit wall penetrations.
 Conduit wall penetrations between differing area classifications shall conform
to NEC Article 300-21. Penetration shall be sealed from leakage of gas
between the differing classified areas
(5) Protection During Construction
All open conduit ends shall be capped during construction to prevent entrance of
foreign materials and moisture, and to protect threads. Conduit shall be capped
with pipe caps or conduit pennies with bushings. Paper or rags shall not be used
as capped.
(6) Sealing Compound
Sealing compound shall not be poured until final checkout and acceptance of
electrical acceptance of electrical systems is complete. Upon pouring and
acceptance, each seal fitting shall be sprayed with red paint to indicate that seals
have been poured.
(7) Safety
All conduit and support shall be installed following the safety regulations per
Daewoo HSE Procedure.
All the necessary work permits shall be obtained wherever applicable prior to
and regulations.
(8) Testing and Records
Quality records shall be prepared as per the respective ITT’s

Installation process sheets for conduit installation shall be signed off by inspector
and shall be counter signed by Contractor and/or PWA signature as applicable
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All the records shall be submitted to the Contractor on mechanical completion of

the system as advised by the Contractor.
(9) As-Built Drawings
All drawings as specified in the project specification shall be marked up (in Red
Lines) during and at the end of the construction, and handed over to the
Contractor clearly marked with “As-Built”. If no change is made, this shall be
recorded as “No Change”.
4.3.3 WORK PROCEDURE FOR CABLING AND WIRING OF LV CONTROL CABLE
1) General

2) Procedure
(1) Installation
 Wire and Cable shall be as identified on the cable schedule, installation

drawings, and as per requirement of project specifications.
 Where cable is supported in ladder type cable tray:
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√ The cable shall be contained by the side channels and fastened with cable
ties to the cable support system. Cables shall be individually tie-wrapped
to every other rung on tray with rung spacing of 9 inches (229mm). On
other trays, cables shall be tie-wrapped to the tray at no more 3 foot
(914mm) intervals. Additional tie-wrapped is required on vertical runs to
eliminate cable slippage. One tie shall not be used to secure more than
one cable; cables shall not be tie wrapped to tray rungs in groups bundles.
Cables shall lay flat and shall not cross, be twisted, or tangled with other
cables.
√ Cable ties shall be made from high-strength, UV resistant nylon suitable

for outdoor use such as Thomas & Betts Ty-raps type or equivalent.
√ All cables, including vertical entries into buildings or control rooms, vertical
runs to motors and other equipment at grade, shall be supported.
Exposed cable runs shall be installed in a neat and workmanlike manner,
parallel or perpendicular to structural members. Drip loops shall be
provided in exposed overhead cables before entering buildings.
√ Cable which leaves the main ladder-tray system or is routed separately

from the main tray system shall not be supported from equipment or
piping.
 All cables shall be supported so as to ensure that no weight is taken by the

terminations.
 Accurate records of cable lengths installed and cable part length on drums
shall be kept.
 Excess spare length of laid cables shall be avoided.
 Heat tracing cable shall be installed as per relevant typical installation details
provided.
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(2) Cabling in Hazardous Areas
 Cables with a continuous sheath that is capable of transmitting gases or

vapors inside the cable shall be sealed with an approved fitting at the cable
end that terminates in a Zone 1 or Zone 2 (classified) location.
 Armoured cables installed in classified areas shall be sealed in accordance

with the following:
√ Zone 1 cables shall be sealed with an approved sealing device such as

Crouse Hinds TMCX series cable terminators or approved equivalent.
√ Zone 2 cables shall be sealed using seal accordance with NEC article
501-5 and API-14FZ such as Crouse Hinds TMCX series cable
terminators or approved equivalent.
(3) Colour Code
Control cable shall be colour coded as per requirement of Specification for Power
Wire and Cable.
(4) Main cabling and branch wiring
Main cables shall be pulled and installed from the junction boxes and/or local
instruments/panels to the designated area, such as control room, local control
room or I/O room located near to the substation rooms as indicated in IFC
drawings of main cable layout drawing, cable connection list, cable schedule, etc.
Branch wires shall be pulled and installed from the local instrument/sensors to the
allocated junction boxes as indicated in IFC drawings of instrument layout
drawing, cable layout drawing, cable connection list, cable schedule, etc.
Any projection and foreign matters which may damage the cable shall be
removed and cleaned from the duct bank, trench and cable tray before cabling.
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Before the cable pulling, cable insulation resistance test shall be performed and
Contractor shall discuss about length of cables and the cutting schedule of
drums, rolled bundles. After that the cable drums shall be moved to the pre-
selected position by the pick-away truck.
Sufficient number of workers shall be engaged during the work so as not to injure
the cables with trailing, chafe and other carelessness.
Good care shall be taken to have the cables properly and firmly supported as
specified in construction drawings.
When hauling cables and wires to the locations, care shall be taken not to
damage cables or unwind cables from drums.
Where excessive stresses or forces are expected due to thermal expansion or

movement of vessels, proper looping of cable shall be performed under
instructions of Contractor’s supervisor.
Installed cables shall be coiled around the control room and local junction boxes
or near to equipment and instruments, and properly covered and protected until
the termination works are started.
Pulled cables and wires shall be well arranged, tied and marked as follows and
bound so as not to be stranded, twisted, over- lapped and entangled.
 On the perforated tray: Tied max. 0.5m distance by UV-resistance cable tie.
 On the cable tray: Tied max. 3m distance by UV-resistance cable tie. Marked
both end and every 20m distance by SUS cable mark tie.
 Under ground: Marked as indicate in cable trench drawing by cable route
marker.
 Cable marker : Marked every 20m interval by cable marker
√ Marked inlet and outlet of duct bank by cable marker.

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√ Marked inlet and outlet of cable trench by cable marker.

√ Marked inlet and outlet of building by cable marker.
√ Marked termination point of panel and instrument by cable marker.
 When cables are installed in conduit pipes, cables shall be pulled using steel
wire having guy, with good care so as not to be strained, twisted, entangled,
nor undesirably stretched.
 After inspection and testing, the cables on the cable tray shall be covered with
cable tray covers. The cables in the cable trench shall be filled with soil and
handover to civil group.
(5) Termination
 Cable glands or sealing fittings when required shall be installed at the inlets to
equipment and instruments in accordance with construction drawing.
 The sheath of cables and wires shall be carefully stripped so as not to injure
the conductors and their insulations. Insulators for conductors shall be
stripped with wire stripper. Knife or wire clipper shall not be used.
 The grounding of drain wire for screen cable shall be performed at the
instrument panels and/or racks in the building. The other ends of instrument
shall not be grounded, and shall be insulated so as not to touch other circuits
or groundings.
 The steel wire armoured grounding shall be connected at earth bar in the
building.
 Standard conductors shall be connected to the equipment and instruments by
using terminal-lugs.
 Markings for wire identification shall be provided at each terminating points.
 All cables shall be terminated to proper terminals or locations in accordance
with wiring connection lists.
 Visual inspection and test shall be performed.
 After inspection and test, all junction boxes, instruments and control panels
shall be covered with canvas or packing box with warning plates/tapes until
the Contractor’s supervisor permit to remove the covers.
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(6) Inspection and Testing
 After the installation and/or termination of the cables, all required inspection
and test shall be carried out and the results shall be recorded and controlled in
accordance with the relevant Inspection and Test Plan.
 Test for Optic Fiber cable shall be performed as per the recommended
procedure by the vendor of optic fiber cable.
 When the other test methods not specified in this procedure are presented,
those methods can be applied with mutual agreement between Contractor &
Subcontractor.
 The following inspection and testing shall be performed.
√ Visual inspection
√ Continuity test
√ Insulation resistance test
Visual inspection
Visual inspection of the cables shall be carried out in accordance with the following
items.
(1) Cabling and wiring
 Collation with drawings

 Status of material damages
 Supporting and fixation status
 Grounding bonding wire
 Welding visual check
 Touch-up paint with approved paint material
 Sharp part or any other defects
 Cabling and wiring in conformity with specification and drawing
 Routing of cables and perforated tray.
 Designated class, size and quality of materials
 Quality, location and intervals of cable tie
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 Quality, location of cable marker

 Influence of high or low temperature and not being placed inside the insulation
material of process piping or equipment
 Influence of vibration and thermal expansion from process piping or equipment
 No disturbance for passage and plant operation
 Sealing of building entrance
 Sealing of duct bank
 Segregation of zone A/B/C
 Back filling
 Cable route marker
(2) Termination
 Collation with drawings

 Termination in conformity with specification and drawing
 Sealing method in terminal box, instruments and panels
 Grounding for cable shield and equipment
 Tube numbering
 Terminal type
 Right connection and tightness
Test
(1) General
Continuity test and insulation resistance test shall be conducted as following items:
 Main cable test: between junction box / local panel / instrument / etc. and
control room panel.
 Branch cable test : between instrument / sensor and junction box / local
panel / etc.
(2) Continuity test

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 The continuity of conductors shall be checked by the circuit tester or the

buzzer.
 The continuity test shall be done in such a way that, at first, the cable shall be
disconnected from both terminals of RIOE / marshalling cabinet / junction box /
field instrument and etc. Secondly, a circuit tester or buzzer shall be
connected to one side of cable conductors and other side of cable conductors
shall be shorted / opened. Thereby the continuity of conductors shall be
confirmed.
 Wireless transceivers will be used for communication.
(3) Insulation Resistance Test
 The megohm tester with 500V for signal cables, 1000V for power cables,
unless otherwise specified, shall be used for this inspection.
 The insulation resistance test shall be done between conductors and earth. In
this case, the wiring shall be disconnected from instruments, junction box and
etc. After inspection, the cables shall be grounded to discharge electric
potential.
 Unless otherwise specified, the value of insulation resistance shall be for
signal cable :
 Between conductors : 1 megohm and over
 Between conductor and earth : 1 megohm and over
 For power cable
 Between conductor : 1 megohm and over
 Between conductor and earth : 1 megohm and over
3) Safety
All material/equipment shall be installed following the safety regulations indicated in

the Contractor safety procedure and Sub Contractor HSE Procedure.
All the necessary work permits shall be obtained wherever applicable prior to begin
the works. All works shall be done in accordance with the plant safety rules and
regulations.
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4) Testing and Records

Applicable installation process sheets shall be signed off by inspector and shall be
counter signed by the Contractor and/or PWA signature as applicable
5) As-Built drawings
4.3.4 WORK PROCEDURE FOR INSTALL TRANSFORMER
1) General
All electrical material and equipment shall be installed and connected in a complete
workmanlike manner in accordance with the specifications and drawings, the
manufacturer’s installation instructions and the applicable codes and standards.
Special care shall be taken to prevent damage of any electrical material and
equipment due to welding or other fabrication or installation operations.
Whenever possible, all welding and painting of the structure and pipe shall be done
before any electrical equipment is installed. No sandblasting shall be done around
the equipment after it is installed.
All electrical equipment and instrument shall be covered with fire resistant tarps or
wrapped with plastic during the painting of the structure, pipe, vessels, tanks and
other equipment. All electrical materials and equipment shall be covered with thick
plastic or thick plastic bags taped or tied securely in placed. The integrity of the
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covering shall be periodically checked and replaced as necessary. Covering

nameplates only is not acceptable.
All electrical material and equipment shall be substantially aligned with surrounding
structural members and installed in such a manner as to present a finished
installation.
2) Procedure
(1) Transformer Inspection
Prior to installation, external inspection of the transformer shall be carried out to

check damages such as rust or deformation. The foundation of the transformer
shall be checked for levelness and it shall be ensured that level is within the
manufacturer’s tolerance. The equipment shall be installed as per the location
given in the equipment layout drawing.
(2) Installation
Installation shall be done with a suitable crane. Detailed studies shall be

performed based on the transformer outline drawings, transformer basement
drawings, transformer weights and other nearby equipment layout drawings.
Based upon these studies necessity of other items like wooden sleepers,
mechanical transmission, hydraulic jacks shall be assessed. Before installation
the labelling and rating shall be checked. Also the condition of the transformer
shall be visually checked for any transportation damage, and if any, it has to be
notified to the Contractor.
(3) Installation of all ground connections

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Check the operation of manual tap-changers and protective/indicating devices.

Setting and securing manual tap-changers in position in accordance with the
transformer tap position schedule.
(4) Termination
Termination of all the cables shall be done as per the termination diagram.
Termination of HV cables shall be done by trained / certified personnel. Vendor
drawings shall be referred if necessary. Crimping tools of proper size shall be
used. After crimping operation checking shall be done on the integrity of crimping.
Cable lugs of proper size according to the project specification shall be used.
Before Bus Duct Installation, External & Internal Inspection shall be done to check
damage such as Rust or Deformation.
Bus Duct joint Assembly shall be done in accordance with Vendor Specification.
Elevation and position of fix points shall be duly checked. Proper size tool shall be
used. Tightening shall be performed by a calibrated torque wrench. Heater cables
should be installed properly.
Before starting of testing it shall be ensured that the equipment has been
calibrated.
Insulation ratio test shall be carried out with megger 5000 V. and high pot tester
shall be used to check Phase to earth, phase to phase and continuity of heater
cable and temperature sensor.
Testing requirement for grounding system shall be in accordance with Specification of

Checkout and Commissioning of Electrical system.
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Before starting of testing it shall be ensured that all the relevant data, vendor
manuals, necessary testing equipments are duly calibrated are available.
Insulation resistance test shall be conducted in accordance with Specification of “DC

Insulation Testing of Electrical Equipment” and prior to energize the equipment earth.
Oil electric strength test shall be carried out.
Electrical Continuity of transformer to main earth shall be tested.
Temperature sensors, temperature alarms, Safety relief valve and Buchholze relay
shall be verified for their functionality.
It shall be verified that the wrapping of the bus bars inside the cable connection
boxes is correct.
All busbar connections shall be torqued and micro ohm/conductivity test, including
cable termination.
Quality records shall be prepared as per the respective ITT’s.
Installation process sheets shall be signed off by PWA inspector and shall be counter
signed by Contractor and/or PWA signature as applicable
4) Non-Conforming Item(s)
Non-Conforming item shall be reported and corrective action approval given as

required by Non-Conformance Report.
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All drawings as specified in the project specification shall marked up (in Red Line)
4.3.5 PROCEDURE FOR TERMINATION AND SPLICING LV, CONTROL CABLE
1) General

manner in accordance with the requirement of project specifications and drawings,
the manufacturer’s installation instructions and the applicable codes and standards.

2) Procedure
Before execution of termination, cables shall be fixed inside boards input/output

boxes, motors etc. by using glands, clamps, sleeves, cable ties etc. and cut with
sufficient length to connect the cable conductors to the relevant terminal block. Over
sheath, armour, filler and insulation of cables shall be cut and removed in order to
permit the disjoining of conductors and the installation of the cable lugs on copper
conductors.
Before the cores are connected, cable lugs shall be checked that they are correct in
both size and type for the cores being terminated. For cables with solid conductors
the lugs are not required. Lugs shall be compressed type only.
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Metallic cable glands (of appropriate type and degree of protection certification) shall
be used for electric power and signal cabling entering the housing of field
instruments, motors, lighting fittings, transformers etc and JB’s.
Cables shall be clamped just below the cable glands to prevent excessive stress on
the cable gland. Cable glands shall be of the correct size to match the appropriate
cable.
Termination of cables shall be executed in accordance with the equipment and/or

cable manufacturer’s instructions.
Effective earth continuity for LV power cables shall be ensured between the
armour/braid and the gland plate including earthing tags to ensure proper earth path
at all times between armour/gland and main earthing system.
Non-metallic cable glands shall be used with non-metallic termination boxes and the
conductors shall be terminated at the internal earth terminal, as appropriate to the
type of cable construction.
Screens of signal cables, for signals levels 1,2,3,4 inclusive, shall be connected to
the instrument earth (at one point) at MDF cabinets
Fields cables (incoming/outgoing) shall be grounded in accordance with earthing

installation detail drawing and EMC implementation requirement document.
For fibre optic cables, the Manufacturer’s instructions shall be followed with respect
to termination, allowable bending radius and pulling force.
All cable cores should be self-coloured and, if needed, coloured sleeves compliant
with project specification, indicating the phase shall be used. Where cores are to be
numbered e.g. control cables, they shall be provided with numbered ferrules to
indicate to which terminal they are connected (according to Project drawing).
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(1) Manufacturer’s instructions
During the execution of cable connection activities, instruction / manual supplied

by Manufacturer and/or Vendor shall be followed. If there is any conflict between
procedure and Manufacture instruction, the Subcontractor shall bring to the
attention of the Contractor supervisor for clarification.
(2) Inspection, Measuring and Test equipment
All Inspection, measuring, and test equipment used for installation, alignment and
final inspection shall be calibrated in accordance with Measuring and Monitoring
Devices Control Procedure and should have valid calibration certificate and
calibration sticker attached to it at the time of inspection as well as at the time of
use.
(3) Equipment
Special tools like cable-cutting tools, knife, crimping tools, etc and some of the
tools to be used for splicing and termination activities shall be in conformance with
the requirement of project specifications.
3) Safety
All Equipment shall be installed following the safety regulations indicated in Daewoo
HSE Procedure.
regulations.
4) Non- Conforming Item(s)

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Quality records shall be prepared as per the respective ITT.
Installation process sheets shall be signed off by inspector and shall be counter
signed by Contractor and/or PWA signature as applicable.
4.3.6 PROCEDURE FOR INSTALL CONTROL LOCAL STATION
1) General
All electrical equipment shall be installed and connected in a complete workmanlike

before any electrical equipment is installed. No sandblasting shall be done around the
equipment after it is installed.
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installation
2) Procedure
(1) Manufacturer’s instructions
During the equipment/accessories installation, instruction/manual supplied by

Manufacturer and/or Vendor shall be followed. If any differences occur between
this procedure and Manufacture instructions, the Manufacturer instruction shall
prevail and shall bring to the attention of the Contractor’s supervisor.
(2) Receipts, Loading, Transportation & Unloading
The Contractor shall issue the Equipment and accessories according to the
material requisition prepared by Material Supervisor. Material Supervisor in co-
ordination with QCI shall check the received equipment at designated area.
Inspection shall be performed jointly between Subcontractor and Contractor.
For all loading / unloading operations and the movement and placement of plant
equipment Subcontractor shall only employ approved lifting equipment.
Subcontractor shall prepare the rigging studies for lifts 20 metric tonnes and
above, all multi-crane lifts or extended or difficult lifts as specified by the
Contractor. Such lifting studies shall be submitted to the Contractor for approval
prior to the rigging operation.
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The lifting and handling shall be carried out in such a manner so as to avoid
distortion, jolt or damage to the equipment from any cause whatsoever. While
transportation care shall be taken in order to avoid violently shaken and damage
to the instruments mounted inside. Also make sure that the equipment is not
placed upside down while loading and transporting.
All lifting appliances, including chain blocks, lifting beams, spreader bars, ropes,
slings and shackles must be regularly inspected by the HSE Safety Engineer and
full records of all such inspections and tests shall be made available to the
Contractor’s representative immediately upon demand.
The equipment is to be unpacked according to Supplier instructions with a

minimum amount of breakage and splintering of the wood crate. In case part of the
crate serves as a skid, this should be left bolted to the equipment until just before
transferring of the equipment to its final location. Prior to unpacking the Vendor
representative has to be called wherever applicable.
If upon unpacking any visual damage of the equipment is observed, the same
shall be reported to the Contractor. Care shall be taken to ensure that the water
protective packaging is intact and undamaged.
After unpacking the packing materials has to be collected together and transported
and dumped at the location specified by the Contractor.
Protective wraps, coats, flange and nozzle covers, etc., shall be left in place as
long as possible.
The equipment shall be handled taking care of painted and exposed-machined

surfaces. Handling shall be carried out, utilizing the seizing points designated by
the Supplier. All precautionary markings on the crates are to be respected in order
to avoid equipment denting marring or unduly stressing. Glass gauges and
exposed delicate parts to be attached to equipment shall be safely stored.
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Material Supervisor shall co-ordinate for the transfer of accepted equipment from
the Contractor warehouse to Subcontractor site area according to the preservation
and prevention maintenance procedure.
(3) Pre-installation verification
Prior to the installation of any equipment Electrical and Erection Superintendent

shall verify the following items.
 Availability of equipment Drawing and/or Vendor Installation maintenance and

operating Instruction (IMOI) with any special (maintenance) tools.
 Check that the nameplate is properly attached to the equipment and compare
its details with applicable IFC drawing.
 Foundation and other civil work is checked and accepted by Subcontractor &
Contractor and released for erection.
 Availability of proper lifting equipment approved by Contractor
 Lifting studies for heavy equipment have been prepared by Subcontractor and
approved by Contractor.
 Foundations for which grouting is required have been chipped off.
 All anchor bolts are available and clean
 Greasing of foundation bolts and trial fitting of nuts carried out
 Foundation co-ordinates have been checked to trace the axis.
 Foundation elevation accepted by Contractor. Deviation if any found on
foundation dimension and elevation shall be notified to the Contractor.
 To check panel orientation in accordance with installation and Equipment
drawings.
(4) Installation of Local Panels
 Local panels shall be located at the place designated in accordance with IFC
drawings and installed in accordance with Manufacturer’s instruction manuals,
but precise locations, elevations and directions shall be finally discussed and
decided with the PWA supervisor at site, if it is necessary.
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 Necessary fabrication and installation of the racks or steel supports, channels,

or angle bars shall be prepared for the installation of the Local panels to be
mounted on foundation or on platform.
 Fabrication of the foundation and anchoring bolts shall be prepared for the
installation of the Local panel to be mounted on the ground.
 Cable entry, Nameplate, dimension and lug for bolting of Local panel shall be
checked with applicable IFC drawings so that all panels can be installed pre-
determined position exactly.
 When the Local panels are moved to the installation position, the pick-away
truck shall be used and fastened up with the fasten belts or ropes tightly based
on Manufacturer’s lifting procedure.
 When the local panels are laid down on the installation position, safety and
care shall be taken so as not to damage the local panels and personnel.
 Panel leveling shall be checked and all required corrections be performed.
 Local panel shall be bolted firmly with supporting base after installation.
 In case of there are any loose shipped instruments and other components,
they shall be mounted inside of the local panels carefully in accordance with
IFC drawing
 All devices inside of the local panels such as controllers, I/O cards, terminal
blocks and relays, etc shall be checked and tightened as required.
 After the installation work, all openings (cable entries, hubs for pipes or air
connections) shall be plugged or temporarily covered with fire proofed blanket
to keep internals clean from dust and humidity etc.
 In case of there are scratches or damaged part during the installation, touch-
up paint and correction shall be carried out.
 After inspection, all local panels and associated peripherals shall be covered
with plywood or canvas with warning plates/tapes until the pre-commissioning
stage.
a) Installation in Control Buildings
Required number of openings of correct dimension has to be prepared on the

floating floor to facilitate cable entry. After checking the correct location the
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equipment shall be positioned, aligned and fixed as per installation drawings.

Check of verticality shall be done.
b) Installation in substation
Check the position where the panel has to be placed. If required, drill the
required holes to fasten the panel. Place the panel on the correct location, and
align according to the requirement and fasten it as per installation instruction.
All electrical equipment shall be installed in accordance with installation detail

drawing. Earthing connection to individual items of equipments shall be made
and connected as per earthing layout drawings and standard drawing.
During the installation, the following points shall be checked/verified by

supervisor in coordination with QCI.
 Cubicle doors and hatches close properly and are fitted with relevant keys.
The relevant locks and keys are labelled, specific numbers registered and
keys are kept in a designated place. Spare keys shall be kept and
administered by the Contractor’s authorized person.
 Glass on front door of panels and instrument are not damaged.
 Ventilation openings are fitted with gratings or insect nets and are not
hindered by any object.
 The location of panels and equipment meets working and safety space
requirements as per design document.
 There is no damage to the substation roof and there are no openings or
cracks through which water can drip or objects fall.
 All floor and wall penetrations have been sealed properly and the floor, ceiling
and walls surfaces have been treated in such a way as to keep dust to a
minimum.
 Protection against corrosion is provided and is complete or made good where
necessary.
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 All equipment is properly tagged as per documents with their correct

tag/identification number. All tag numbers shall be fixed to a none removable
part of the equipment
c) High Voltage Panels
 Panel base frame to be installed at the level as provided for on the drawing
and perfectly flush after having carried out a dimensional check to see if the
frame is aligned with the panel base and with the slits provided in the slab for
the cables to go through.
 Any deviation in dimension has to be notified to Contractor and approval shall
be obtained prior to any rectification work.
 Detached parts to be coupled and bolted to the base frame.
 The busbars belonging to the different sections to be connected together after

checking for correct line-up and also those surfaces are free from grease, rust
or Insulating materials. Prior to the busbar connections, the main bus bar and
the coupling part have to be cleaned with appropriate materials as
recommended by the manufacturer.
 Connecting bolts and fittings to comply with Supplier's instructions, and to be
tightened with a torque wrench calibrated to the prescribed value.
 Where insulated busbars are installed, joints to be covered with suitable
insulating butt joints. If insulation is required and no insulating butt joints are
provided, connections to be filled with suitable plastic filler and then wrapped
around with suitable insulating tape as per manufacturer’s instruction. If no
instruction is available Subcontractor shall check with Contractor for ruling /
instruction.
 Connections of the earthing bar shall be made after checking its continuity
amongst the various sections.
 All continuity connections of the auxiliary circuits shall be made according to
the wiring diagrams.
 Equipment and Switches shall be plugged into the corresponding rack without
forcing the sliding mechanism. If needed, in-and-out movements should be
adjusted.
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 Before plugging them permanently, de-ionizing cells for air circuit breaker are
to be installed. Manufactures instructions shall be referred prior to the
activities are carried out.
 Instruments and equipment separately delivered to be installed in their
corresponding housings and connected according to the wiring diagrams.
 The end flooring of the electric stations to be made after the base frames of
the cabinets have been installed.
 The level of the floor should be so flushed that, there shall be no difference in
height between the floor and the sliding guide of the equipment, after the
insulating mat required by the safety regulations is installed.
d) Low Voltage Panels
 Panel base frame to be made by keeping with size and panel base drilling.
 The base frame shall be installed only after having carried out a dimensional
check to see if the frame is aligned with the slits provided in the panel base,
by maintaining dimensions and after perfectly flush.
 The detached sections shall be coupled and bolted to the base frame.
 Busbars and auxiliaries’ connections shall be restored according to the
Supplier's diagrams.
 Prior to the busbar connections, the main bus bar and the coupling part have
to be cleaned with appropriate materials as recommended by the
manufacturer. No solvents to be used (for HOLEC Panels).
 Where insulated busbars are installed, joints to be covered with suitable
insulating butt joints. If insulation is required and no insulating butt joints are
provided, connections to be filled with suitable plastic filler and then wrapped
around with suitable insulating tape as per manufacturer’s instruction. If no
instruction is available Subcontractor shall check with Contractor for ruling /
instruction.
 The connections of the earthing bar shall be made after checking its
continuity amongst the various sections.
 Equipment (reactors, transformers, resistors, etc.) and instrumentation
separately delivered to be installed in to their housings and relevant
connections to be made according to the wiring diagrams.
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 All switches plug-in boxes to be plugged into the corresponding rack without
forcing the sliding mechanism. If needed, in-and-out movements should be
adjusted.
 The final flooring of the electric station to be made after panel base frames
has been installed.
 The transformer-panel assemblies coupled as a single unit is to be installed
by making any necessary adjustments for the flanged coupling.
e) Protection against Direct Contact
 Barriers, screens, guards, rails and protective enclosures against direct

contact as foreseen in the design document shall properly be installed and in
accordance to the degree of protection requested.
 The safety distance between exposed live parts (if applicable) and any body
part of a person shall comply with relevant IEC codes.
 It shall be ensures that personal protection against thermal effects is in place.
f) Warning and Functional Notices
 Warning notices shall be installed in accordance with law’s requirement or if

considered necessary for safety. Warning plate will be installed in particular at
the entrance of Substation and at the entrance of electrical room and
wherever there is a risk of electrical shock or any other injuries for persons.
 In bitumen, brick or tile paved areas red / yellow colored plastic warning tapes
can be used in place of cable tiles provided the trench refill consists of
compacted clean sand only. These warning tapes shall be laid parallel to the
cables, the distance between warning tapes shall not exceed 300 mm.
 Equipment, junction boxes, remote control unit and motors will be identified
with Tag plate as per design documents. All tags shall be fixed to a non-
removable part of the equipment.
 If requested by manufacturer "WARNING" plate with specific operation
information will be installed.
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 All switch rooms of Substations shall be provided with panel showing the
relevant As-built single line diagram and kept up to date on a day-to-day
basis, clearly indicating any change made.
g) Inspection, measuring and test equipment
All Inspection, measuring, and test equipment used for installation, alignment
and final inspection shall be calibrated in accordance with Measuring and
Monitoring Devices Control Procedure and should have valid calibration
certificate and calibration sticker attached to it at the time of inspection as well as
at the time of use.
3) Safety
All Equipment shall be installed following the safety regulations indicated in

Contractor safety procedure and Subcontractor HSE Procedure.
All the necessary work permits shall be obtained wherever applicable prior to
and regulations.
4) Non- Conforming Item(s)

5) Testing Records
After completion of installation activity, applicable testing shall be carried out as per
applicable ITT and as specified in Checkout and Commissioning of Electrical
System.
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Applicable inspection process sheets shall be signed off by PWA inspector and
shall be counter signed by Contractor and/or PWA signature as applicable.
All the records shall be submitted to the Contractor on mechanical completion of

the system as advised by the Contractor.
Line) during and at the end of the construction, and handed over to the Contractor
clearly marked with “As-Built”. If no change is made, this shall be recorded as “No
Change”.
4.3.7 WORK PROCEDURE FOR UNDERGROUND CABLING IN TRENCH
1) General
All underground works will be set out in accordance with the drawings and with
requirement of project specification.
All under ground work will be coordinated and supervised by an Engineer who is fully
conversant with the operational area.
Special care shall be taken to prevent damage of cables, during underground pulling.
Where facilities fail to meet acceptable standards or intended function during

commissioning and testing, Contractor shall be immediately advised.
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The insulation resistance of the cable shall be check before and after pulling and prior
to final termination.
Cable in drum should be rolled to open off and not stretched to avoid kinks.
Earth continuity of glands and termination must be assured. This should be achieved
by the rigid clamping of the armored within the gland and the intimate contact
between the threaded components of the gland and the equipment.
U/G cables shall be routed according to electrical and/or I&C engineering documents
and civil excavation layout.
If, due to practical reasons it is not possible, the responsible person of the cables
pulling team, has to inform the electrical or instrumentation contact person in order to
find an alternative route to be submitted for the Contractor approval
Installation of cables routed on PVC pipes, cable duct and cable trays shall be in
accordance with PWA requirements.
2) Procedure
(1) Civil Trenches
Cable trench, excavation, back filling and compaction shall be made in accordance
with the applicable Contract/Project specifications and Cable trench shall be
prepared by using relevant excavator, dumper and wheeler loader only if allowed
on the excavation permit. If necessary the cable trench sides shall be shored as
per applicable detail drawing. Where/when required polyethylene sheet for trench
side protection against rain erosion, would be provided and installed. Soil / Sand
are to be removed from site after excavation of trenches to an off-site storage area.
(2) Backfilling of Trenches
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 Trench shall be backfill with layer of sand to a depth as indicated on the

drawings
 The fill material shall be well tamped and any hard or sharp objects, which
may cause damage, shall be removed before cable installation
 After each layer of cables have been installed, the trench shall be backfill with
sand to a level indicated on the drawing, again compacting the fill before
continuing with the next layer, etc
 Where cables leave the ground they shall be mechanically protected by
means of protection sleeves, up to minimum of 150mm above ground level.
 Direct buried cables shall be provided with sand backfill above the final layer
of cables followed by cables followed by cable protection tiles.
 All cables shall be fitted with suitable markers at the points of termination, at
points approximately 10metre along the route length, where cable leaves the
main trench, and where they change direction
 Where cables enter the Substation through cut -outs installed in the
foundation, the sand shall be well compacted into the opening from inside and
outside.
 All underground cable ducts and cable protection pipes that rise above ground
shall be sealed as specified in the construction installation drawings
 All ducts shall be sealed, including spare ducts, immediately after installation.
 In substation and buildings with basements or cable trenches, opening holes
shall be seal with expansion foam
 Cable slab for Electrical cables shall be slightly indented with the symbol “E” to
indicate it is for electrical.
(3) Excavation
 Cable route excavation shall be done with caution using heavy-duty machine
(excavator) and manual labour where necessary because of the underground
lines; electrical, instrument & telecommunication cables, piping and sewage
lines.
 Inside existing facilities, only manual method shall be permitted to prevent
damage to existing facilities.
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 Wet or flooded area shall be drained completely using dewatering and water
pump machine prior to commencement of the job.
 The trenches shall be excavated in accordance with IFC drawing, detail
drawing and project specifications.
(4) Cable Laying
 Care shall be taken when uncoiling cables that have been left waiting final
fixing to prevent kinks and bird caging of the cable.
 Where cable passes through walls, and other structure, they shall be
protected by conduit or sleeves that shall be packed and sealed after cable
installation.
 The insulation resistance shall be checked before and after pulling of cable.
 Cable ends that are not immediately fixed and/ or terminated to equipment
shall be capped, coiled and left in such a manner to minimize the possibility of
damage and ingress of moisture.
 Cable ends that are not immediately fixed and/ or terminated to equipment
shall be capped, coiled and left in such a manner to minimize the possibility of
damage and ingress of moisture
 During cable pulling, the tension shall not exceed those recommended by the
cable manufacturers
 Particular attention shall be given to the bending of cables. During pulling or
final positioning no cable shall be bent less than the minimum-bending radius
recommended by manufacturer. Bending radius shall be a minimum of 6 times
cable diameter.
 A suitable lubricant may be used on the cables to ease pulling provided the
lubricant use is compatible with the cable outer covering and does not leave a
residue that will cause cable to bind to each other after the lubricant has dried
 Where cables leave cable trays, they shall be installed so as to prevent the
cable from coming into contact with corners. Also sharp bends of 90 degrees
shall be avoided in cable ducts
 All ducts shall be swabbed out and lefts clean and free from stones and other
objects and draw tapes installed.
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 Cable shall be pulled manually or with hand operated winches. The cable
pulling tension advised by the cable manufacturer shall not be exceeded
 The physical location and spacing of cables in trenches shall be as indicated
on the drawing. Cable spacing shall be maintained throughout the trench
route. Where spacing cannot be maintained, then written agreement to reduce
spacing shall be sought from MPN
 Cables shall be located in a manner that will reduce crossings of other cables
to a minimum. Where cable crossings are unavoidable, the crossing shall be
made at 90 degrees to through runs, subject to the minimum-bending radius of
the cable and site conditions. In this case sand shall separate the crossing
layers.
(5) Grounding and Bonding


 Grounding cable shall be installed wherever possible in the same trenches,
ducts, rack and trays as the power cables.
 Ground electrodes shall be located as indicated on earthing layout drawings.
 Earthing busbars shall be fixed where possible to a lower convenient section
of steel structures thus serving a double purpose of also earthing the
structure.
 Earth’s to individual items of equipment shall normally be provided with their
own earthing branch circuits, but in certain cases, the branch circuit may be
looped to other items of equipment
 All earthing connections to equipment and any exposed copper termination’s
etc., shall be protected with corrosion resistant coating
 Earthing conductors at the substations shall be terminated at earthing busses
connected to foundation pile reinforcement bars
3) Safety
All excavation, Backfilling, Cable Laying and Ground and Bonding shall be carried in
accordance with the regulations indicated in Contractor safety procedure and
Subcontractor HSE Procedure.
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All necessary work permits shall be obtained wherever applicable prior to begin the
works.
4) Non-Conforming Items(s)
Non-Conforming items shall be reported and corrective action approval given as

After completion of installation activities applicable testing shall be signed off by PWA
inspector and shall be carried out as per applicable ITT and as specified in Checkout
and Commissioning of Electrical System.
EGTL1-DAE-QAS-QF-000227 Installation process sheets shall be signed off by PWA

inspector and shall be counter signed by Contractor and/or PWA signature as
applicable.
All records shall be submitted to the Contractor on mechanical completion of the

All drawings as specified in the project specification shall be marked up (in RED line)
during and at the end of the construction, and handed over to the CONTACTOR
clearly marked with “As Built” if no change is made, this shall be recorded as “No
Change”
4.3.8 WORK PROCEDURE FOR INSTALL LIGHTING WORKS
1) General
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before any electrical equipment is installed. No sandblasting shall be done around the
equipment after it is installed.
installation.
2) Procedure
(1) General
 The lighting systems have to be built according to the applicable code and
standard, particularly as far as safety and accident prevention are concerned.
 Each location of work shall be checked against the construction drawing.
 The lighting systems shall be carefully constructed with consideration given to
overall and each detail drawing.
 The lighting systems work shall be executed after confirmation of the schedule
for the items of other work which may interfere. It shall be carried out in
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coordination with the personnel for the other work, so that losses, injuries and
damages will not be incurred
 Preparation of lighting system materials, accessories, support materials and
tools Prepare required tools, materials necessary for the installation work
(2) Lighting equipment installation work
 Lighting fixtures shall be located at points where the lighting is most effective
and maintenance is easy
 Equipment foundations shall be checked for conformance to the drawings
prior to the equipment installation.
 Equipment foundation concrete shall be cured for a sufficient period of time.
 In case where equipment is to be placed on steel materials, the following
requirements shall be satisfied :
√ The steel members shall be fabricated accurately to dimensions including

bolt positions.
√ Steel base shall be constructionally sturdy and of good appearance
√ Each edge and projection shall be chamfered.
√ Steel members shall be covers with rust inhibitive and finish coats.
 After installation of equipment, their alignment, level and perpendicularity shall

be adjusted.
 Foundations shall have a sufficient bearing capacity for the weights of the
equipment and external force.
 Confirm that equipment to be installed is not damaged.
 Lighting panels shall be positioned in the centre of the installation involved.
Panels shall be installed in as easily accessible position for circuit-breaker
operation and maintenance. If the position defined in the design is incorrect,
the Supervisor shall inform Engineering Team.
 All lighting poles shall be carefully plumbed with heavy square nuts on the
anchor bolts under the pole base plate and hexagonal nuts on top. After the
pole has been completely equipped and connected the space between the
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steel base and the top of the concrete it shall be grout filled in accordance with
site requirements
 Pull boxes shall be installed at all necessary points, whether indicated or not,
to prevent injury to the insulation of cable or other damage that may result
from pulling resistance or other reason during installation.
(3) Handling of equipment
 In the disassembly and re-assembly of explosion-proof equipment, care shall

be taken not to cause injury to the (gasket) contract face, and bolts and nuts
and other accessories shall be stored so as not to be lost.
 When the joint of explosion-proof equipment are to be bolted, their (gasket)
contact faces shall be coated with non-drying seal material a measure against
entrance of moisture and each bolt shall be tightened firmly and evenly.
 In equipment terminal boxes, terminations and connections shall be made so
that no mechanical stress is placed on the cables or lead wires: they shall be
housed, so that their dielectric strength will not decrease.
 In the pulling of cables in to equipment terminal boxes, consideration shall be
given to the cable bending radius, maintainability and appearance.
(4) Installation work of lighting fixture and junction box
 Lighting fixture junction boxes and canopy boxes shall be installed in

accordance with the drawings
 Lighting fixtures and junction boxes shall be installed with consideration given
to their maintenance.
 Junction box covers shall permit easy removal and inspection.
 Lamps another lighting fixtures shall be easily replaceable.
 Passages and operating floors shall be effectively lit.
 Junction box covers shall not interfere with wires.
 Cover shall not be installed forcibly.
 Generally dome covers are fitted for specific purposes. If J.B’s are so full that
ordinary cover will not fit, box should be changed to a larger size.
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(5) Conduit installation work
 Conduit pipe ends and other cut edges shall be chamfered using a deburring
reamer
 Conduit pipe connections to fittings and equipment shall be made with more
than five effective threads engaged.
 Threads shall be cut to the specified thread geometry.
 Conduit pipe bends, if required, shall be made by use of a bender
 Sealing compound shall be poured after completion of insulation resistance
measurement and continuity testing.
 Specified quantities of sealing compounds shall be poured into conduit by
proper means
 Sealing fittings (drain types, universal types and vertical types) suitable for
each application shall be selected.
 Conduit pipe accessories (unions, elbows, and junction boxes) shall be
properly used in accordance with the typical drawings.
 Conduit pipes and supports shall be fixed by the use of clamps, saddles, U-
type bolts, etc., so that they may not become loose.
(6) Steel fabrication work
 Steel fabrication shall be done by using such suitable tools and machines
that either stress nor strain may be caused.
 Sharp edges shall be grinded off smoothly.
 Steel fabrication shall be done in accordance with the drawings. Regarding

welding, fillet welds shall be made. Fillet welds shall have the same thickness
as the steel member.
 Welds made on steel members shall be completely cleaned of slag and all
other foreign matter and coated with rust inhibitive coating.
 Steel to be used shall be of such proper size and materials that the
fabricated parts and components will have a good appearance and sufficient
strength.
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(7) Cable installation work
 The schedule for (progress status) of the work assigned to the other work
team shall be confirmed
 Cable laying schedule shall be planned after discussions and arrangements
with other discipline concerned, so that no undue inconvenience will be
encountered in the course of the work.
 For overhead work, proper scaffolding and sufficient safety measures shall
be provided
 Cable delivered shall be checked against the shipping list to confirm that
specifications are correct.
 Cables shall be checked for any damage which may have occurred during
transit.
 The cable laying routes shall be checked to measure the length of cables
actually required.
 Cable drums shall be placed at points from which cable laying can be most
easily conducted.
 Cable numbers, size, tag, cable laying equipment, etc., shall be checked
against the cable schedule table, to ensure that no errors may occur during
the cable laying work.
 Specified spaces shall be provided between high voltage cables and low
voltage cables and control cables
 To prevent damage to cables, protection shall be provided at points where
piping, trenches or other obstructions cross cable routes.
 Cables shall be laid so as to be in a neat, orderly arrangement without twists
or warps.
 Cable laying shall be conducted by individual cables being placed in orderly
arrangement and/or bundle.
 Intermediate cable markers of indicated specifications shall be firmly
attached to the cables where required.
 Both ends of each cable shall be firmly sealed with insulating tape and/or
other sealing material to prevent the entrance of water.
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 Cable laid shall be checked for damage.

 Sand filling, protection cover and back filling work shall be conducted as early
and promptly as possible.
 Lighting cables shall be installed as follows :
√ Lighting cables shall be supported at intervals specified.

√ Cables installed between junction boxes and canopy boxes shall not be
loose or sagging.
√ In cases where cable glands are to be used, cables shall be cut after
confirmation of the cable gland dimensions and box-to- box dimensions.
√ Cable glands shall be firmly grounded in the case or armoured cables.
(8) Cable Termination and Connection Work
 Since terminations and straight run conductor connections cannot be re-made,

they shall be made by adequate methods under proper guidance and after
sufficient investigation.
 Earth conductor which is in cables shall be connected at both panel and
Lighting fixture, armoured cables shall be grounded, generally, at the panel
side.
 The following check shall be conducted before cable termination work.
√ Confirm that the continuity test, insulation resistance measurement, cable

size and cable number checks have been completed.
√ Checks that cable supports have been installed completely
√ Check that the panel termination boards are fit for the cable sizes.
√ Check that the cables have the surplus length required for termination.
√ Check that the panel boxes to which cable connections are to be made
have been installed and fixed completely.
 In case where cable glands are to be used for cable termination, the following
requirement shall be satisfied:
√ Check that the cable gland size is fit for the cable outside diameter.
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√ Check that the cable gland packing is suitable for the cable finish.
√ Make cable gland connections to cable armour as follows.
 Check that cable glands are suitably connected to the armour.
 Check that the conductors have not been damaged in the cutting of the
armour.
 Check that the armour is not exposed.
 Attach the cable gland after completely cleaning the armour of tar.
√ Cable gland shall be attached properly to the terminal box: it shall not be
loose.
√ Cable shall not be loose in the cable gland but shall be firm fit.
√ Bolting and clamping shall be firm.
√ Cable terminations shall be made by using the specified materials in
accordance with the specification.
√ Pressure terminals and compression terminals to be used shall be the
correct size for the cable size.
√ Cable arrangement after termination shall be neat and orderly.
√ After completion of termination, insulation resistance tests and inter-
phasing test shall be conducted and test values shall be recorded
(9) Inspection, Measuring and Test Equipment
All Inspection, measuring, and test equipment used for installation, alignment and
final inspection shall be calibrated in accordance with Measuring and Monitoring
Devices Control Procedure and should have valid calibration certificate and
calibration sticker attached to it at the time of inspection as well as at the time of
use.
3) Safety

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regulations.
4) Non-Confirming Item(s)

System.
4.3.9 WORK PROCEDURE FOR EARTHING WORKS
1) General
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Grounding system meeting requirement of National Electrical Code Article 250 shall
be installed in accordance with the design drawings and details to ground
transformer neutrals, non carrying metal parts of all electrical apparatus, metallic
conduit, cable sheaths and shields, steel structures, and fences around electrical
equipment. All grounding systems shall be interconnected.

2) Procedure
(1) Installation
In order to avoid any possible interferences, before installing earthing systems,

the locations and depth to be installed shall be verified by checking all other
foundations, underground works, piping or sewage systems, electrical &
instrument cables.
Work and Excavation permit shall be provided prior to starting any mechanical or
hand excavation work.
(2) Installation of Earth Rod, Pit and Cover
Earth electrodes shall be installed at locations as per Issued for Construction

(IFC) drawings.
The earth grid shall extend throughout the area which is indicated on the
drawings.
Earthing rods elements can be installed by using of de-watering system and

mean of proper hammer or mechanical devices.
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Prior to paving work, Earth Pits and Cover shall be installed on the proper
elevation and position as per detailed installation instruction.
If pipeline earthing is to be installed to mitigate the effect of AC induced voltage

on the pipeline, this would be done at the locations where the anticipated or
measured voltage to ground are highest, and where the pipeline is exposed and
can be touched by personnel.
Earthing electrode type shall be as per project specification.
(3) Earthing Connections and Terminations
Earthing connection and termination shall be installed at located as per IFC

drawing.
Branch earthing conductor sizing shall be conformed to instruction details drawing

and shall be terminated to a certain point as conformed to cable schedule
requirement and layout drawing.
Earthing conductors installed shall be properly identified at the side of main earth
busbar, as per installation drawings.
Earth inspection pit shall be properly identified on the fixed external part of the pit.
All bare parts of underground earthing conductors shall be suitably protected as
per latest revision of standard drawing.
Aboveground interconnection shall be made by crimping tool, and the point of all
earthing terminations shall be made with compression cable lugs to earthing
boss.
Underground interconnection shall be directly made using thermoweld

connection, cross connection and parallel connection, and shall be wrapped as
per Earthing Installation Details.
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Before applying adhesive tape, continuity test of interconnection should be made

for integrity. Earthing conductor rising from ground has to be protected with PVC
conduit as per Earthing Installation Details.
(4) Underground Laying
The arrangement of main earthing conductor laid on cable trench shall be

conformed to drawing layout and their spacing should be strictly followed as per
installation.
(5) Earthing of Local equipment and structures
The combined resistance to the general mass of earth shall not exceed 10Ω if
non-electrical equipments are provided with their own duplicate earth electrodes.
Continuity test of vessel tank, structure and any applicable equipment to branch
earthing conductor should be securely verified.
(6) Lightning and static electricity
The combined resistance to the general mass of earth of the electrodes provided
for lightning protection shall not exceed 10Ω when isolated from the plant earth
ring.
Testing requirement for grounding system shall be in accordance with Checkout and
Commissioning of Electrical system.
signed by Contractor and/or PWA signature as applicable
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The resistance between the grounding grid and the following grounding points shall
not exceed 1 ohm:
 Each point used to ground platform lightning protection equipment.

 Each point used to ground surge protection equipment.
 Each point used to ground electrical equipment enclosures.
 Each point used to ground wiring support systems such as cable armor
conduits and trays.
The resistance between the grounding grid and system neutrals shall not exceed the
following:
 600-volt or less equipment – 1ohm

 High-resistance ground system – 15 ohms
 Low-resistance ground systems – 1 ohm

All drawings as specified in the project specification shall marked up (in Red Line)
4.3.10 WORK PROCEDURE FOR INSTALL COMMUNICATION SYSTEM
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1) General
before any electrical equipment is installed. No sandblasting shall be done around
the equipment after it is installed.
installation.
2) Procedure
(1) Preparation of communication system materials, accessories, support

materials and tools
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 Prepare required tools, necessary materials for the installation work
(2) Installation of Communication equipment.
 Telecom equipment installation work is Telecom Contractor’s scope

 Equipment foundations shall be checked for conformance to the drawings
prior to the equipment installation.
 Equipment foundation concrete shall be cured for a sufficient period of
time.
 In case where equipment is to be placed on steel materials, the following
requirements shall be satisfied :
√ Steel supporting materials shall be fabricated accurately to dimension

including bolt positions and shall be covered with approved rust inhibitive
and finish coats.
√ Steel base shall be constructionally sturdy and of good appearance
√ Each edge and projection shall be chamfered.
 Alignment, level, and verticality shall be adjusted after installation of

equipment.
 Foundations shall have a sufficient bearing capacity for the weights of the
equipment and external force.
3) Handling of equipment
 Extra care shall be taken during the disassembly and re-assembly of explosion-
proof equipment not to cause damaged to the sealing gasket, or lost of bolts and
nuts and other accessories.
 When the joint of explosion-proof equipment are to be bolted, sealing gasket
contact faces shall be coated with non-drying seal material as a measure against
ingress of moisture and each bolt shall be tightened firmly and evenly.
 In equipment terminal boxes, terminations and connections shall be made so that
no mechanical stress is placed on the cables or lead wires: they shall be housed,
so that their dielectric strength will not decrease.
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 During pulling of cables in to equipment terminal boxes, consideration shall be

given to the cable bending radius, maintainability and appearance.
4) Steel Support Fabrication Work
 Support fabrication shall be done by using suitable tools and machines. Sharp
edges shall be grind off smoothly.
 Support fabrication shall be done in accordance with the requirement of IFC
drawings. Material shall be as per requirement of project specifications.
 Welds made on support members shall be completely cleaned of slag and all
other foreign matter and coated with approved painting.
5) Cable way Installation
 The material of all trays, raceways, brackets, stirrups and their other accessories
shall not constitute a fire ignition or propagation risk, shall be stable and inert as
well as corrosion resistant or suitably treated against corrosion associated with
the installation environment.
 Installation conditions for trays, raceways, brackets, stirrups, etc., shall be
confirmed in the design.
6) Installation of Conduit for Communication System
 Set out locations of fittings to junction boxes and drop points and marked out
conduit runs and locate fixing.
 Conduit pipe bending shall be made by use of a pipe bender and standard proper
tools and equipment shall be applied for forming, reaming and cleaning of
conduit.
 Exposed conduit shall be supported by threaded rod hangers hanging from the
soffit of roof slab, concrete roof beams or steel beams, C-channel or angular
steel bars fixed to the walls, columns or beams.
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 Exposed conduit pipe and support shall be fixed to the wall, foundation or steel
structure with clamps, saddles and u-bolts, etc., so that they may not become
loose.
 Check conduit alignment and rigidity of installation. Hanging support of conduit
shall avoid moving by means of bracket support strategic locations.
 Steel support shall be clean and free of rust prior to installation and painted with
approved painting system.
 Conduit pipe connections to fittings and equipment shall be made with more than
five effective threads engaged and threads shall be cut to the specified thread
geometry.
 Conduit pipe accessories (unions, elbows, and junction boxes) shall be properly
used in accordance with the IFC drawings. Sealing fittings (drain types, universal
types and vertical types) suitable for each application shall be selected.
 Conduit shall be selected every 3.0 meter unless special conduits require closer
clamps, hangers or straps. Where two or more raceways run parallel (vertical or
horizontal) raceways shall be supported by a framework, rack, or trapeze
constructed with pre-fabricated channel.
 Conduit shall be fitted with bushing and ends just before the devices, boxes or
sleeves through the wall giving sufficient distance for cable bend, tagging or
glanding to devices or boxes.
 Conduit pipe cutting ends and other sharp edges shall be chamfered and filed
with reamer and applied with approved galvanizing paint.
 Specified clean sealing compound shall be poured into the conduit after
completion of cable insulation resistance and continuity test.
7) Installation of Communication Cable
 Work schedule /plan (progress status) of communication cable shall be

discussed and confirmed with the other work team before commence work.
 Cable laying schedule shall be planned after discussions and arrangement with
other discipline concerned, so that no undue inconvenience will be encountered
in the course of the work.
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 Safety measures such as proper scaffolding etc. shall be provided sufficiently for
overhead work.
 Cables shall be checked with shipping list to confirm that specifications are
correct and visually checked for any damage which may have occurred during
transit and cable drums shall be placed at points from which cable laying can be
most easily conducted.
 Cable laying routes shall be checked to measure the length of cables actually
required.
 Cable numbers, sizes, tag, cable laying equipment, etc, shall be checked with
cable schedule to ensure that no errors occur during the laying work.
 Specified spaces shall be provided between Communication cables and High,
Low voltage cables/control/signal cables.
 Protection materials/method shall be provided at point piping, trenches or
obstructions cross cable routes to prevent cables damages.
 Cables shall be pulled continuously without cutting or splicing.
 Communication cables shall be laid so as to be in a neat, orderly arrangement
without twist or wrap and cable pulling /laying shall be conducted by individual
cables being placed in orderly arrangement and/or bundle.
 Ensure that cable sizes comply with the required percent fill of the conduits and
trays that will be pulled in.
 Both ends of each cable shall be firmly sealed with insulating tapes and/or other
sealing materials to prevent the entrance of water.
 Shielding of calves shall be terminated to the terminals provide to the jumper to
ensure its electrical continuity.
 Sand filling, protection cover and back filling work shall be conducted as early
and promptly as possible.
 Intermediate cable markers of indicated specifications shall be firmly attached to
the cables where required.
 Communication cables shall be installed as follows:
√ Communication cables shall be supported as specified intervals in

accordance with IFC drawings.
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√ In cases where cable glands are to be used, cables shall be cut after
confirmation of the cable gland dimension and box-to-box dimensions.
√ Cables glands shall be firmly grounded in the case of armor cables.
8) Cable Termination and connection work
 Termination shall be done with adequate methods under proper guidance

and after sufficient investigation.
 Shielded cables and armored cables shall be grounded, generally at the
panel side.
 Following shall be done before cable termination work.
√ Confirm the continuity test, insulation resistance test, cable number checks
have been completed.
√ Check that the cable supports have been installed completely.
√ Check that the panel termination boards are fit for the cable sizes.
√ Check the cables have the surplus length required for termination (Tail
length shall be at least 2.5meter on both ends of a cable)
√ Check that the panel/boxes and Fire alarm equipment have been installed
and fixed completely.
9) Following requirement shall be satisfied in case of cable glands applied for cable
termination.
 Check that the cable gland size is fit for the cable outside diameter.
 Check that the cable gland size is fit for the cable finish.
 Connection of cable gland to cable armor shall be done as follows:
√ Check that cable glands are suitably connected to the armor.

√ Check that the conductors have not been damaged in the cutting of the
armor.
√ Check that the armor is exposed.
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 Cable glands shall be attached properly to the terminal box and it shall not be
loose.
 Cables shall not be loose in the cable gland but shall be firmly fit.
 Bolting and clamping shall be firm.
 Cable termination shall be done with specified materials in accordance with the
specification.
 Terminals to be used shall be correct size for the cable size.
 Cable arrangement after termination shall be neat and orderly.
 After completion, insulation resistance test shall be conducted and test values
shall be recorded.
 Install tagging on the cables.
10) Safety

regulations.

System.
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Line) during and at the end of the construction, and handed over to the Contractor
clearly marked with “As-Built”. If no change is made, this shall be recorded as “No
Change”.
Page 224 of 224

Method Statement (DW) Final

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DOHA SOUTH SEWAGE TREATMENT WORKS

SECTION 1 : GENERAL, CIVIL, MECHANICAL &

3.4.3 EARTHWORKS FOR STRUCTURAL WORKS...................................................................42

3.9.2 AGGREGATE, SAND AND BOULDERS...........................................................................140

4 MECHANICAL AND ELECTRICAL WORKS.....................................................141

1.1 OUTLINE NARRATIVE

 Timely transportation of the Contractor’s personnel and materials.

1.2 PHASE II EXPANSION UNDER CONTRACT C361/1

1.3 WORK SCOPE FOR PHASE II UNDER CONTRACT C361/1

In accordance with Section C EMPLOYER’s Requirement Part I Clause 4 “Scope” issued

 2 No. inlet screens in existing channels at the inlet works.

1.4 SEWAGE TREATMENT PLANT EXPANSION WORKS

Upon contract commencement, all areas of sewerage treatment plant pertaining to

If blasting is necessary for excavation of underground rocks for foundation of the

To avert accidents or untoward incidences to happen on site, safety precautions and

Electro-mechanical pumps, motors, penstock and other process components shall

Construction of sub-grade will be completed with all above-mentioned Inter-process

 Occasional storage of treated sewage effluent that cannot be disposed of (where

Both Lagoons are to be constructed with inlet/outlet structures made of reinforced

Immediately upon receipt of the Notice to Proceed/Award the designated project

The major tasks to be carried out by the team are as follows:

2.1.2 CONTRACTOR’S MAJOR FACILITIES

1 Main Field Office

2.2 TEMPORARY FACILITIES

2.2.2 ENGINEER’S TEMPORARY FACILITES

2.2.3 CONTRACTOR’S TEMPORARY FACILITIES

Outdoor storage will be categorized as under covered or uncovered storage with

Accommodation facilities meeting the requirements stipulated in the contract will be

The labour camp is proposed to be located at the designated ‘off-site’ area.

2.2.5 CAMP MANAGEMENT AND SECURITY

These will includes the following ;

2.3 WATER SUPPLY

Potable water will basically be obtained from commercial water supplier.

2.4 ELECTRIC POWER SUPPLY

2.5 COMMUNICATION SYSTEM

3.1 SITE CLEARANCE

3.1.1 SETTING OUT OF BENCHMARKS (“BM”)

3.1.2 WORK PROCEDURE

3.2 EARTH WORKS

3.2.3 GENERAL WORK PROCEDURE FOR EARTHWORKS

 Stripping of top soil

 Rock Excavation (if applicable)

1 Whenever possible, excavation by excavator with hydro-breaker or jack hammer or

3.3.1 BASE COURSE WORK

3 Production of Aggregates for Base Course

5 Maintenance of Completed Base Course Layer

3.3.2 ASPHALT CONCRETE PAVEMENT

Bituminous mixture will be considered to be purchased from local suppliers (Delivery

i. This section of the method statement covers the provision, transportation,

2 Preparation of Primed Surfaces

4 Transportation of Asphalt Mixture

5 Laying of Bituminous Mixture

6 Compaction of Bituminous Mixture

7 Treatment of Transverse Joints

8 Treatment of Longitudinal Joints

9 Mixing Plant Operation

i. The bituminous plant will be of such capacity to produce the quantities of

10 Aggregate and Materials for Asphalt Concrete

i. Samples of aggregates will be provided to the Engineer for his approval of

3.3.3 CONCRETE PAVEMENT WORK

Equipment conforming to the following will be furnished:

complete the work with water-cooled, diamond-edged blades or abrasive wheels.