Spec OICT

Qasim International Container Terminal Terminal 2 Main Works Contract Tender Documents Volume 2 Specifications: Part 1 Civils Works
DP World February 2008 Tender Issue 9S5537
A COMPANY OF
HASKONING UK LTD. MARITIME
Rightwell House Bretton Peterborough PE3 8DW United Kingdom +44 (0)1733 334455 01733 333462 Telephone Fax
Document title
Qasim International Container Terminal Terminal 2 Main Works Contract Tender Documents Volume 2 Specifications
Document short title Status Date Project name Project number Employer Reference
Issue 3 Revision 1 Tender Issue February 2008 QICT Terminal 2 9S5537 DP World 9S5537/R013/GP/PBoro
Issue
001 002 003
Status
Draft Tender Issue Tender Issue
Date
02/11/07 20/11/07 22/02/08
Author
M Liston M. Liston M. Liston
Checked
Approved
G.Peckham G. Peckham T. Neal
QASIM INTERNATIONAL CONTAINER TERMINAL TERMINAL 2 - MAIN WORKS CONTRACT TENDER DOCUMENTS VOLUME 2 SPECIFICATIONS
Volume 1 Conditions of Contract
Volume 2
Specifications
Volume 3
Drawings
Volume 4
Bills of Quantities
Volume 5
Site Data
QICT Terminal 2, Main Works Contract Volume 2 Specifications
9S5537/R/013/GP/PBoro February 2008
QASIM INTERNATIONAL CONTAINER TERMINAL TERMINAL 2 - MAIN WORKS CONTRACT TENDER DOCUMENTS VOLUME 2 SPECIFICATIONS
CONTENTS PAGE
1
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19
GENERAL REQUIREMENTS
Brief Description of Works Works Reasonably Inferred Facilities for Other Contractors/Suppliers Drawings Dimensions / System of Measurement Site Investigation Information Site location, Boundaries and Possession Access to the Site Other Contractors on Site Site Datum and Base Lines Setting out of the Works and Surveys Existing services on Site Contractor's Offices, Stores, etc. Contractor's Plant, Equipment, Labour, Personnel, Fuel and Consumables Sanitary Provisions Accidents, First-Aid and Medical Facilities Safety, Health and Welfare; Protection, Life-Saving etc. Temporary Fencing and Security Fire-Fighting Equipment and Storage of Dangerous Materials
i
1
1 3 3 3 4 5 5 6 7 7 7 9 10 10 11 11 11 12 12
1.20 1.21 1.22 1.23
Temporary Site Services Telecommunications and Contractor's Radio Equipment Site laboratory Weather Station
13 13 13 14 14 14 14 24 24 25 25 26 26 26 26 27 27 28 28 28 29 29 30 30 30 31 32 32 32
1.24 Services to the Engineer 1.24.1 General 1.24.2 On Site Offices for the Engineer 1.24.3 Survey Equipment 1.24.4 Road Transport 1.24.5 Launch and Echo Sounding Equipment 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 1.40 1.41 1.42 1.43 Contractors Attendance on the Engineer Contractors Attendance on Other Contractors Progress Reports Details of Plant Equipment, Labour and Personnel on Site Advance Notification of all Operations Method Statements Temporary Works Records to be kept of all Engineering Operations Contractor to Supply Set of "As-Built" Drawings Reinforcement Detail Drawings and Bar Bending Schedules Statement at Completion Standard of Works Materials Inspection and Testing Supply of Samples Names of Manufacturers and Suppliers Subletting Storage and Usage of Plant and Materials at Site Despatch of Plant and Materials
ii
1.44 1.45 1.46 1.47 1.48 1.49 1.50 1.51 1.52 1.53 1.54 1.55 1.56 1.57 1.58 1.59 1.60 1.61 1.62 1.63 1.64 1.65 1.66
Test Certificates Standards Appearing in this Specification Regulations of Statutory Authorities and Customs Port Regulations, Temporary Lighting and Marking Watching and Lighting Removal of Sunken Craft, Equipment or Materials Use of the Permanent Works Care of Existing Services etc. Works Not to Interfere With Normal Operations / Business of the Port Avoidance of Nuisance, Pollution and Clearance of Obstructions, Debris, etc. Disposal of Surplus / Unsuitable Material off Site Supply of Materials - General No Damage to Public Access Use of Divers Use of Explosives Use of Subcontractors Site Clearance, Make Good, etc. on Completion Access to Works, Equipment Etc. Daywork Project Signboard Alteration to Design at Contractor's Request Site Meetings Quality Assurance
32 32 32 33 33 33 34 34 34 35 36 36 36 37 37 37 38 38 38 38 39 39 40 41 41 41 41 41 42
1.67 Environmental effects 1.67.1 Suspended solids 1.67.2 Waste disposal 1.67.3 Sewage disposal 1.67.4 Construction materials and methods 1.67.5 Environmental Recommendations & Conditions
iii
DEMOLITION AND SITE CLEARANCE
43
43 43 43 43 43 43 44 44 44 45 45 45 46 46 46
2.1 DEMOLITION PARTICULAR REQUIREMENTS 2.1.1 Description of the Demolition Works 2.1.2 Codes and Standards 2.1.3 Site Data 2.2 GENERAL 2.2.1 Standard of Works 2.2.2 Scope of Work 2.2.3 Damage to Existing Structures 2.2.4 Programme and Method Statement 2.2.5 Services 2.2.6 Use of Explosives, Blasting 2.2.7 Materials Arising from Demolition 2.2.8 Testing of Materials Arising from Demolition 2.2.9 Demolition Records 2.2.10 Vegetation
DREDGING
47
47 47 47 47 47 47 47 48 48 48 48 48 48 49 49 50 50 50 50 51 51 51 51 54 54 54
iv 9S5537/R/013/GP/PBoro February 2008
3.1 DREDGING PARTICULAR REQUIREMENTS 3.1.1 Particular Requirements 3.1.2 Description of the Dredging Works 3.1.3 Location of the Disposal Site 3.1.4 Level Tolerances 3.2 GENERAL 3.2.1 Definitions 3.2.2 Site Information 3.2.3 Site Investigation 3.2.4 Sequence of Dredging Works 3.2.5 Materials to be Dredged 3.2.6 Safety of Navigation 3.2.7 Contractors Dredging Plant 3.2.8 Maintenance of Split Hull Vessels 3.2.9 Spillage and Siltation 3.2.10 Standing time 3.2.11 Anchors and Moorings 3.3 SUBMISSIONS: METHOD OF WORKING 3.3.1 Particulars of Dredging 3.4 GENERAL EQUIPMENT REQUIREMENTS 3.4.1 Tide and Wave Gauges 3.4.2 Removal of Floating Debris 3.4.3 Setting out and Surveys for Dredging 3.5 DREDGING 3.5.1 Commencement of Dredging 3.5.2 Dredging
3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8 3.5.9
Method of Dredging Storage of Dredged Material Spoil Disposal Side Slopes Obstructions Including Munitions Dredging in Hard Material Dredging Material Suitable as Fill
54 54 54 55 55 55 55 55 55 56
3.6 TOLERANCES 3.6.1 Dredging Tolerances 3.6.2 Deposition of Dredged Material
RECLAMATION
57
57 57 57 57 57 57 58 58 59 59 60 61 61 61 61 61 61 63 63 64 64 64 64 65 65 65 65 65 65 65 66 66
4.1 RECLAMATION PARTICULAR REQUIREMENTS 4.1.1 Particular Requirements 4.1.2 Description of the Reclamation Works 4.1.3 Assessment of Liquefiable Soils 4.2 GENERAL 4.2.1 Definitions 4.2.2 Sequence of Reclamation Works 4.2.3 Spillage and Siltation 4.3 MATERIALS 4.3.1 Fill Material 4.3.2 Granular Filter 4.3.3 Geotextiles 4.3.4 Prefabricated Vertical Drains 4.4 SUBMISSIONS 4.4.1 Description of Reclamation Works 4.5 GENERAL RECLAMATION WORKS REQUIREMENTS 4.5.1 Setting Out and Surveys for Reclamation Works 4.5.2 General Requirements for Filling 4.5.3 Ownership of Fill Material 4.5.4 Temporary Side Slopes 4.5.5 Temporary Works for Reclamation 4.5.6 Commencement of Deposition of Fill Material 4.5.7 Handling and Storage of Fill Material 4.5.8 Protection from Water and Weather 4.5.9 Fill Material allowed to become unsuitable or to deteriorate 4.5.10 Removal of Fill Material for Reclamation Works 4.5.11 Surplus Material 4.6 DEPOSITION OF FILL MATERIAL BELOW SEA LEVEL 4.6.1 Site Clearance 4.6.2 Deposition of Fill Material 4.6.3 Deposition of Fill Material in Dredged Trenches 4.6.4 Deposition of Rock Fill Material Adjacent to Structures and Utilities
QICT Terminal 2, Main Works Contract Volume 2 Specifications v
4.6.5 4.6.6 4.6.7 4.6.8 4.6.9
Reclamation Method Siltation and Turbidity Formation of Mudwaves Erosion Adjoining Property, Bunds and Drains
66 67 67 67 67 67 67 68 68 69 69 69 69 69 69 69 70 70 70 70 70 70 71 71 71 71
4.7 DEPOSITION OF FILL MATERIAL ABOVE SEA LEVEL 4.7.1 Surface Preparation for Fill Material 4.7.2 Haulage of Fill 4.7.3 Deposition of Fill Material 4.7.4 Overfilling 4.8 LEVELLING AND COMPACTION OF FILL MATERIAL 4.8.1 Levelling of Rock Fill Material placed Underwater for Foundations 4.8.2 Levelling of Rock Fill Material for Sea Wall Construction Below Sea Level 4.8.3 Compaction of Fill Material Above Sea Level 4.8.4 Moisture Content of Fill Material Above Sea Level 4.8.5 Compaction of Fill Materials Adjacent to Structures and Utilities 4.8.6 Compaction of Rock Fill Material Above Sea Level 4.9 COMPLETION OF RECLAMATION FINAL SURFACE 4.9.1 Completion of Reclamation Final Surface 4.10 TOLERANCES: DEPOSITION OF FILL 4.10.1 Tolerances: Deposition of Fill Material below Sea Level 4.10.2 Tolerance: Deposition of Fill Material above Sea Level 4.11 TESTING: FILL MATERIAL GENERAL REQUIREMENTS 4.11.1 Fill Material 4.11.2 Samples of Fill Material 4.11.3 Testing of Fill Material for Reclamation and Marine Structures
4.12 TESTING: FILL MATERIAL PSD, ATTERBERG LIMITS, COEFFICIENT OF UNIFORMITY AND SULPHATE CONTENT 72 4.12.1 Samples: PSDs, Atterberg Limits, Coefficient of Uniformity, Sulphate Content 72 4.12.2 Testing: PSDs, Atterberg Limits, Coefficient of Uniformity, Sulphate Content 72 4.12.3 Non-compliance: PSDs, Atterberg Limits, Coefficient of Uniformity, Sulphate Content72 4.13 TESTING : FILL MATERIAL - OPTIMUM MOISTURE CONTENT AND MAXIMUM DRY DENSITY 4.13.1 Samples: Optimum Moisture Content, Maximum Dry Density 4.13.2 Testing: Optimum Moisture Content, Maximum Dry Density 4.13.3 Consistency: Optimum Moisture Content, Maximum Dry Density 4.14 TESTING: FILL MATERIAL MOISTURE CONTENT 4.14.1 Samples: Moisture Content 4.14.2 Testing: Moisture Content 4.14.3 Compliance Criteria: Moisture Content 4.14.4 Non-Compliance: Moisture Content 4.15 TESTING: FILL MATERIAL RELATIVE COMPACTION
vi
72 72 73 73 73 73 74 74 74 74
4.15.1 4.15.2 4.15.3 4.15.4
Testing: Relative Compaction Compliance Criteria: Relative Compaction Non-compliance: Relative Compaction CBR testing
74 75 75 75
4.16 TESTING : RELATIVE DENSITY, WATER ABSORPTION, AGGREGATE IMPACT VALUE, TEN PERCENT FINES VALUE, AGGREGATE ABRASION VALUE, SOUNDNESS AND RESISTANCE TO FRACTURE OF ROCK FILL MATERIAL 75 4.16.1 Batch: Rock for Rock Fill 75 4.16.2 Samples: Rock for rock armour 75 4.16.3 Testing: Rock for Rock Fill 76 4.16.4 Samples: Rock for Rock Fill 76 4.16.5 Non-compliance: Rock for Rock Fill 76 4.16.6 Non-compliance: Weighing test 76 4.17 TESTING: GRANULAR FILTER MATERIAL 4.17.1 Testing: Granular Filter Material 4.17.2 Sampling: Granular filter material 4.17.3 Testing: Granular filter material 4.17.4 Non-compliance: granular filter material 77 77 77 77 77
GROUND IMPROVEMENT
79
79 79 79 79 80 80 81 81 81 82 83 83 83 83 84
5.1 GROUND IMPROVEMENT PARTICULAR REQUIREMENTS 5.1.1 Particular Requirements 5.1.2 Description of the Ground Improvement Works 5.1.3 Assessment of Liquefiable Soils 5.2 GENERAL 5.2.1 Definitions 5.2.2 Sequence of Ground Improvement Works 5.3 MATERIALS 5.3.1 Band Drains 5.3.2 Drainage Layer 5.3.3 Surcharge 5.3.4 Stone for Constructing Vibrated Stone Columns 5.4 SUBMISSIONS 5.4.1 Pre-loading Accelerated by the use of Band Drains 5.4.2 Vibrated Stone Columns
5.5 GENERAL REQUIREMENTS FOR PRE-LOADING ACCELERATED BY THE USE OF BAND DRAINS 85 5.5.1 Design 85 5.5.2 Pre-installation Survey 85 5.5.3 Installation of the Band Drains 85 5.5.4 Obstructions 86 5.5.5 Records of Prefabricated Vertical Drains 86 5.5.6 Drainage Layer 87 5.5.7 Surcharge Embankment 87
QICT Terminal 2, Main Works Contract Volume 2 Specifications vii 9S5537/R/013/GP/PBoro February 2008
5.5.8
Compaction Criteria for Surcharge
88 89 89 89 89
5.6 GENERAL REQUIREMENTS FOR VIBRATED STONE COLUMNS 5.6.1 Design 5.6.2 Installation of the Vibrated Stone Columns 5.6.3 Records of Vibrated Stone Columns
5.7 INSTRUMENTATION FOR PRE-LOADING ACCELERATED BY THE USE OF BAND DRAINS 90 5.7.1 Scope of Work 90 5.7.2 Definitions for Geotechnical Instrumentation 91 5.7.3 Instruments for Geotechnical Instrumentation 91 5.7.4 Location and Arrangement of Instruments 92 5.7.5 Installation of Instrumentation 92 5.7.6 Tubes and Cables for Instruments 93 5.7.7 Inspection of Monitoring Installations 93 5.7.8 Frequency of Monitoring 94 5.7.9 Maintenance of Instruments 94 5.7.10 Records of Geotechnical Instrumentation 94 5.7.11 Prefabricated Vertical Drains 94 5.7.12 Recording readings 95 5.7.13 Installation of Settlement Plates 95 5.7.14 Piezometers 96 5.7.15 Magnetic Extensometers 98 5.7.16 Inclinometers 102 5.8 ACCEPTANCE TESTING FOR VIBRATED STONE COLUMNS 5.8.1 General 5.8.2 Frequency of Testing 5.8.3 Standards 105 105 105 105
PILING
107
107 107 107 108 108 108 108 109 109 110 110 111 111 111 111 112
6.1 PILING PARTICULAR REQUIREMENTS 6.1.1 Description of Work 6.1.2 Pile Working Loads 6.1.3 Corrosion Protection 6.1.4 Number of pile tests 6.2 GENERAL 6.2.1 Standards 6.2.2 Definitions 6.2.3 Pile Design and Construction 6.2.4 Pile Lengths 6.2.5 Ground Conditions 6.2.6 Piling Programme 6.2.7 Piling Plant 6.3 PILE INSTALLATION AND ACCEPTANCE CRITERIA 6.3.1 Use of support liquid 6.3.2 Permanent sacrificial casing
QICT Terminal 2, Main Works Contract Volume 2 Specifications viii
6.3.3 6.3.4 6.3.5 6.3.6
Position and Tolerances Continuity of construction Pile trimming Piling Records
112 112 112 113 113 113 113 113 113
6.4 INTEGRITY TESTING OF PILES 6.4.1 Specialist sub-contractor 6.5 STATIC LOAD TESTING OF PILES 6.5.1 Method of testing 6.5.2 Static Pile Testing
ROCK WORKS
116
116 116 116 116 117 117 117 117 118 119 119 120 121 121 121 122 122 122 123 123 123 123
7.1 ROCK WORKS PARTICULAR REQUIREMENTS 7.1.1 Description of Work 7.2 GENERAL 7.2.1 General 7.2.2 Terms and Definitions 7.3 MATERIALS 7.3.1 Source of Rock 7.3.2 Rock Grading 7.3.3 Rock Properties 7.4 ROCK TRANSPORT, STOCKPILING AND PLACEMENT 7.4.1 Rock Transport and Stockpiling 7.4.2 Handling and Placement of Rock 7.4.3 Surplus Rock 7.5 TOLERANCES 7.5.1 Rock Profiles and Placement Tolerances 7.5.2 Settlement of the Structures 7.6 SURVEYS FOR ROCK WORKS 7.6.1 Pre-Construction Survey 7.6.2 Interim Surveys 7.6.3 Post-Construction Surveys 7.6.4 Inspection and Control 7.6.5 Measurement Techniques
CONCRETE
125
125 125 125 125 125 126
8.1 GENERAL 8.1.1 Standards 8.1.2 Concrete for the Works 8.1.3 Self-compacting Concrete 8.1.4 Quality Assurance and Standards 8.1.5 Terms and Definitions
ix
8.2 SITE SPECIFIC REQUIREMENTS 8.2.1 Concrete Schedule 8.2.2 Permitted Types of Cement and Combinations 8.2.3 Cement Properties 8.2.4 Permitted Aggregates 8.2.5 Aggregate Properties 8.2.6 Maximum Chloride Content 8.2.7 Information to be submitted to the Engineer 8.2.8 Identity Testing Requirements
127 127 127 127 128 128 128 128 129
8.3 STANDARD SPECIFICATION CONCRETE MATERIALS, BATCHING, MIXING, TRANSPORTATION, PLACING, COMPACTION & CURING 129 8.3.1 Permitted Types of Materials 129 8.3.2 Approval of Supply of Materials 129 8.3.3 Sampling and Testing of Materials 129 8.3.4 Failure to Supply Certificates or Carry Out Tests 130 8.3.5 Delivery of Materials 130 8.3.6 Storage of Materials 130 8.3.7 Performance Characteristics 132 8.3.8 Permitted Types of Cementitious Materials 132 8.3.9 Aggregates - Standard Specifications 132 8.3.10 Sources of Aggregates 132 8.3.11 Grading of Aggregates 132 8.3.12 Aggregate Properties 133 8.3.13 Staining 133 8.3.14 Drying Shrinkage 133 8.3.15 Washing of Aggregates 133 8.3.16 Sampling and Testing of Aggregates 133 8.3.17 Fines Content (Silt, Clay & Dust) 133 8.3.18 Site Processing of Aggregates 133 8.3.19 Water for Concreting 134 8.3.20 Testing of Water 134 8.3.21 Approval of Admixtures 134 8.3.22 Supply and Storage of Admixtures 134 8.3.23 Use of Admixtures 135 8.3.24 Chlorides 135 8.3.25 Corrosion Inhibitor 136 8.3.26 Polypropylene Fibres 136 8.3.27 Concretes 136 8.3.28 Chloride Content of Concrete Mixes 136 8.3.29 Prior Approval of Mix Proportions 136 8.3.30 Trial Mixes 136 8.3.31 Compressive Strength Requirement for Trial Mixes 137 8.3.32 Consistence (Workability) 138 8.3.33 Alterations to Approved Mixes 138 8.3.34 Minimising the Risk of Damaging Alkali-Silica Reaction 138 8.3.35 Temperature of Concrete 138 8.3.36 Approval of Concrete Batching Methods 139 8.3.37 Batching of Materials 139 8.3.38 Weigh Batching Plant 139 8.3.39 Water Content 139
QICT Terminal 2, Main Works Contract Volume 2 Specifications x 9S5537/R/013/GP/PBoro February 2008
8.3.40 8.3.41 8.3.42 8.3.43 8.3.44 8.3.45 8.3.46 8.3.47 8.3.48 8.3.49 8.3.50 8.3.51 8.3.52 8.3.53 8.3.54 8.3.55 8.3.56 8.3.57 8.3.58 8.3.59 8.3.60 8.3.61 8.3.62 8.3.63 8.3.64
Cement Batching Rejection of Batched Materials Mixing Plant Mixing Requirements Hand Mixing Plant and Equipment Transportation of Concrete Preparation for Placing Placing of Concrete Compaction of Concrete Setting Concrete Records of Concrete Placing Hot Weather Concreting Cold Weather Concreting Protection against Rainfall Curing - General Requirements Curing Methods Curing Membrane Water Curing Use of Covers Wetting of Formed Surfaces Curing of Concrete in Hot Weather Thick Sections Curing Notices Curing of Repairs
140 140 140 140 141 141 141 142 142 143 143 143 144 144 144 145 145 145 146 146 146 146 147 147 147
8.4 STANDARD SPECIFICATION REINFORCEMENT, FORMWORK, FINISHES, JOINTS, TESTING & CONTROL 8.4.1 Reinforcement Steel Specifications 8.4.2 Testing of Reinforcement Steel 8.4.3 Storage of Reinforcement Steel 8.4.4 Cutting and Bending of Reinforcement 8.4.5 Fixing of Reinforcement 8.4.6 Spacers 8.4.7 Welding 8.4.8 Mechanical Joints 8.4.9 Concrete Cover 8.4.10 Cleaning and Protection of Reinforcement 8.4.11 Steel Fixer in Attendance 8.4.12 Formwork Construction 8.4.13 Internal Ties 8.4.14 Permanent Void Formers 8.4.15 Formwork Liners 8.4.16 Chamfers 8.4.17 Preparation of Forms and Formwork 8.4.18 Removal of Formwork 8.4.19 Tolerances for Concrete Surfaces 8.4.20 Formed Concrete Finishes 8.4.21 Remedial Treatment to Formed Surfaces 8.4.22 Unformed Concrete Finishes 8.4.23 Protection of Surfaces
QICT Terminal 2, Main Works Contract Volume 2 Specifications xi
148 148 148 148 148 149 149 150 150 150 150 151 151 151 152 152 152 152 153 153 154 155 155 156
8.4.24 8.4.25 8.4.26 8.4.27 8.4.28 8.4.29 8.4.30 8.4.31 8.4.32 8.4.33 8.4.34 8.4.35 8.4.36 8.4.37 8.4.38
Construction Joints Movement Joints Debonding Coat Pre-formed Joint Filler Joint Sealing Materials Application of Joint Sealants Water Bars Inspection and Tests Control of Mix Proportions Determination of Fresh Concrete Temperature Identity Testing for Compressive Strength Records Identity Testing for Slump, Flow and Air Content Non-Destructive Testing Concrete Core Testing
156 157 157 157 158 158 159 159 159 159 159 160 161 161 161 162 162 162 163 163 163 163 164 165 165 165 166 166 166 166 166 166 167 167 168 168 168 168 168 169 169 169 170 170 171 171
8.5 STANDARD SPECIFICATION PRECAST CONCRETE 8.5.1 General 8.5.2 Contractor's Option to Precast 8.5.3 Drawings and Schedule of Weight 8.5.4 Approval of Plant and Working Methods 8.5.5 Provision for Handling 8.5.6 Moulds 8.5.7 Manufacturing Tolerances 8.5.8 Curing of Units 8.5.9 Surface Finishes 8.5.10 Rejection of Units 8.5.11 Marking and Records 8.5.12 Sampling and Testing 8.5.13 Certificate of Manufacture 8.5.14 Erection Programme 8.5.15 Handling and Erection - General 8.5.16 Handling of Precast Concrete Units 8.5.17 Storage of Precast Concrete Units 8.5.18 Installation of Precast Concrete Units 8.5.19 Installation Tolerances 8.5.20 Bearings 8.6 STANDARD SPECIFICATION PRESTRESSED CONCRETE 8.6.1 Scope of This sub-Section 8.6.2 Prestressing Tendon Materials Specifications 8.6.3 Delivery of Prestressing Tendons 8.6.4 Testing of Prestressing Tendons 8.6.5 Handling and Storage of Prestressing Tendons 8.6.6 Positioning of Prestressing Tendons, Sheaths and Duct Formers 8.6.7 Tensioning Apparatus 8.6.8 Pretensioning of Tendons 8.6.9 Drawings of Prestressed Elements
STRUCTURAL STEELWORK
xii
173
9.1 GENERAL 9.1.1 Scope of this Section 9.1.2 Standard Specifications 9.1.3 Quality Assurance and Standards 9.1.4 Alternative Construction Methods 9.1.5 Alternative Materials 9.1.6 Sub Let Orders 9.1.7 Inspection of Materials and Work in Progress 9.1.8 Test Certificates 9.2 PROJECT SPECIFIC REQUIREMENTS 9.2.1 Documents and Drawings 9.2.2 Setting Out 9.2.3 Construction Method 9.2.4 Contractors Drawings 9.2.5 Inspection Facilities 9.2.6 Improved Deformation Properties 9.2.7 Internal Imperfections 9.2.8 Datum Temperature 9.2.9 Trial Erection 9.2.10 Hardness and Quality of Edges 9.2.11 Bolts, Nuts and Washers 9.2.12 Welding Procedure Trials 9.2.13 Butt Welds 9.2.14 Marking for Erection 9.2.15 Unacceptable Defects in Welding 9.3 GENERAL STEELWORK CLAUSES 9.3.1 Fabrication and Erection 9.3.2 Structural Steels 9.3.3 Straightening and Flattening 9.3.4 Stainless Steel 9.4 WELDING 9.4.1 Welding - General 9.4.2 Welding Procedures 9.4.3 Temperature of Steel 9.4.4 Welding Procedure Trials 9.4.5 Qualifications and Testing of Welders 9.4.6 Supervision of Welding 9.4.7 Welding Plant 9.4.8 Fit up of Welded Parts 9.4.9 Identification 9.4.10 Welded Attachments 9.4.11 Site Welding 9.4.12 Welding of Structural Hollow Sections 9.5 WELDING INSPECTION 9.5.1 General 9.5.2 Loose Rust and Scale 9.5.3 Visual Inspection
QICT Terminal 2, Main Works Contract Volume 2 Specifications xiii
173 173 173 174 174 174 174 175 175 175 175 175 175 176 176 176 176 176 176 176 177 177 177 177 177 177 177 178 178 178 179 179 179 179 180 180 180 180 180 181 181 181 181 181 181 182 182
9.5.4 9.5.5 9.5.6 9.5.7 9.5.8
Magnetic Particle Inspection Dye Penetrant Testing Ultrasonic Inspection Production Test Plates Repair of Welds
182 182 182 182 183 183 183 183 183 183 183 183 184 184 184 184 184 184 185 185 185 186 186 186 186 186 186 187 187 187 188 188 188 188 188 188 188
9.6 DIMENSIONAL CONTROL 9.6.1 General 9.6.2 Camber 9.6.3 Bearing Surfaces 9.6.4 Ends of Stiffeners 9.7 STUD SHEAR CONNECTORS 9.7.1 General 9.7.2 Test Studs at Start of Each Day 9.7.3 Test on all Studs 9.8 MISCELLANEOUS STEELWORK 9.8.1 Holding Down Bolts 9.8.2 Anchor Bolts 9.8.3 Bearing Pads 9.8.4 Lining, Levelling and Grouting 9.8.5 Handrailing and Standards 9.8.6 Steel Flooring 9.8.7 Staircases 9.8.8 Ladders 9.8.9 Purlins 9.9 BOLTING 9.9.1 Lack of Fit 9.9.2 Assembly of Bolted Joints 9.9.3 Tightening of H.S.F.G Bolts 9.9.4 Galvanizing and Sherardizing 9.9.5 Stainless Steel Bolts 9.10 HANDLING, TRANSPORT AND ERECTION 9.10.1 Handling of Structural Steelwork 9.10.2 Loading of Structures 9.10.3 Erection Plant and Equipment 9.10.4 Falsework and Temporary Bracing 9.10.5 Safety of Pedestrian and Vehicular Traffic 9.10.6 Marking for Erection
10
CORROSION PROTECTION
190
190 190 190 190 190
10.1 CORROSION PROTECTION PARTICULAR REQUIREMENTS 10.1.1 Scope of Works 10.1.2 Schedule of Steelwork Treatments 10.1.3 Schedule of Colour Finishes 10.1.4 Schedule of Protective Treatments
xiv
10.2 GENERAL 10.2.1 General 10.2.2 Painting 10.2.3 Safety 10.2.4 Storage of Paint 10.2.5 Sampling and Testing 10.2.6 Workmanship 10.2.7 Prepared Surfaces 10.2.8 Protective Treatments 10.2.9 Shop Painting 10.2.10 Preparation of Bare Metal Surfaces 10.2.11 Storage of Steel and Fabricated Steelwork 10.2.12 Metal Coatings 10.2.13 Handling of Coated or Painted Steelwork 10.2.14 Repairs to Damaged Area 10.2.15 High Strength Friction Grip (HSFG) Bolted Joints 10.2.16 Other Bolted Joints 10.2.17 Welded Joints 10.2.18 Treatment of Completed Joints 10.2.19 Sealed Box Girders
192 192 192 192 192 192 193 194 194 195 195 195 196 197 197 197 197 198 198 198
11
FENDERS AND MOORINGS
199
199 199 199 199 199 200 200 200 200 200 201 201 201 201 202 202 202 203 203 203 204 204 204
11.1 FENDERS AND MOORINGS PARTICULAR REQUIREMENTS 11.1.1 Scope of Work 11.1.2 Specific Requirements, Design 11.1.3 Fender Testing Requirements 11.1.4 Bollards 11.2 GENERAL 11.2.1 British Standards and other Codes of Practice 11.2.2 Particular Specification 11.2.3 Materials 11.2.4 Quality Management 11.3 DESIGN OF FENDERS 11.3.1 Introduction 11.3.2 Specified Fender Unit 11.3.3 Fender Panels 11.3.4 Chains and Fixings 11.4 MATERIALS AND WORKMANSHIP 11.4.1 Rubber Fender Units 11.4.2 Records of Fender Units 11.4.3 Fender Panels 11.4.4 Facings to fender panels 11.4.5 Chains 11.4.6 Fixings for Fenders, Chains, and Support Brackets 11.5 INSTALLATION
xv
11.6 11.7
TESTING OF FENDERS BOLLARDS
205 205
12
CRANE RAILS AND QUAY SIDE FITTINGS
207
207 207 207 207 207 208 208 208 208 208 209 209 209 210 210 211 211 212 212 212 213 214
12.1 CRANE RAILS AND QUAY SIDE FITTINGS PARTICULAR REQUIREMENTS 12.1.1 General 12.1.2 Crane data 12.1.3 Rail Size 12.1.4 Design Loading 12.1.5 Design life 12.1.6 Storm Anchor Pin Sockets 12.1.7 Buffer Stoppers 12.2 GENERAL 12.2.1 Design 12.2.2 Crane Rail Installation 12.2.3 Tolerances 12.2.4 Sole Plates 12.2.5 Bearing Pads 12.2.6 Rail Clips 12.2.7 Crane Rail 12.2.8 Welding of Crane Rails 12.3 MISCELLANEOUS QUAY FURNITURE 12.3.1 Ladders 12.3.2 Service Pit Covers 12.3.3 Service Pit Covers 12.3.4 Resin Anchors
13
EARTHWORKS
215
215 215 215 215 215 216 216 217 217 218 218 218 218 218
13.1 EARTHWORKS PARTICULAR REQUIREMENTS 13.1.1 Description of the earthworks 13.1.2 Scope of Works 13.2 GENERAL 13.2.1 Definitions 13.3 MATERIALS 13.3.1 Fill Material 13.4 SUBMISSIONS 13.4.1 Particulars of Earthworks 13.5 GENERAL EARTHWORKS REQUIREMENTS 13.5.1 Ownership of Earthworks Material 13.5.2 Disposal of Earthworks Material 13.5.3 Temporary Works for Earthworks 13.5.4 Handling and Storage of Earthworks Material
QICT Terminal 2, Main Works Contract Volume 2 Specifications xvi
13.5.5 13.5.6 13.5.7 13.5.8 13.5.9 13.5.10
Protection from Water and Weather Earthworks material Allowed to Deteriorate or Become Unsuitable Additional Excavation and Stabilisation Additional Excavation Stabilisation Removal of Earthworks Material
218 219 219 219 219 220 220 220 220 220 220 221 221 221 221 221 221 222 222 222 223 223 223 223 224 224 224 224 224 224 226 226 226 226 227 227 227 227 227 228 228 228
13.6 EXCAVATION 13.6.1 Disposal of Excavated Material 13.6.2 Use of Excavated Material 13.6.3 Obstructions in Excavations 13.6.4 Excavation 13.6.5 Excavations adjacent to Structures and Utilities 13.6.6 Excavations for Structures Pits and Trenches 13.7 DEPOSITION OF FILL MATERIAL 13.7.1 Types of Fill Material 13.7.2 Sources of Fill Material 13.7.3 Surface preparation for Fill 13.7.4 Commencement of Deposition of Fill Material 13.7.5 Haulage of Fill Material 13.7.6 Deposition of Fill Material 13.7.7 Overfilling 13.7.8 Deposition of Fill Material Adjacent to Structures or Utilities 13.7.9 Deposition of Rock Fill Material 13.7.10 Deposition of fill Material in Excavations for Structures, Pits and Trenches 13.8 COMPACTION OF FILL MATERIAL 13.8.1 Compaction of fill Material 13.8.2 Moisture content of Fill Material 13.8.3 Compaction of Fill Material Adjacent to Structures and Utilities 13.8.4 Compaction of Rock Fill Material 13.8.5 Compaction of General Fill Material with a Large Portion of Coarse Material 13.9 COMPLETION OF EARTHWORKS SURFACES 13.9.1 Completion of Earthworks Final Surfaces 13.9.2 Completion of Formations 13.9.3 Protection of Earthworks Final Surfaces and Formations 13.10 INTERMEDIATE AREAS OF FILL 13.10.1 Deposition of Fill Material in Intermediate Areas of Fill 13.10.2 Compaction of Fill Material in Intermediate Areas of Fill 13.11 TOLERANCES 13.11.1 Tolerances: Earthworks Final Surfaces and Formations 13.12 TESTING: FILL MATERIAL GENERAL REQUIREMENTS 13.12.1 Batch: Fill Materials 13.12.2 Samples: Fill Materials
xvii
13.13 TESTING: FILL MATERIAL - PARTICLE SIZE DISTRIBUTION, LIQUID LIMIT, PLASTICITY INDEX, COEFFICIENT OF UNIFORMITY AND SULPHATE CONTENT 13.13.1 Samples: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of Uniformity and Sulphate Content 13.13.2 Testing: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of Uniformity and Sulphate Content 13.13.3 Non-compliance: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of Uniformity and Sulphate Content 13.14 TESTING: FILL MATERIAL - OPTIMUM MOISTURE CONTENT AND MAXIMUM DRY DENSITY 13.14.1 Samples: Optimum Moisture Content and Maximum Dry Density 13.14.2 Testing: Optimum Moisture Content and Maximum Dry Density 13.14.3 Consistency: Optimum Moisture Content and Maximum Dry Density 13.15 TESTING: FILL MATERIAL - MOISTURE CONTENT: 13.15.1 Samples: Moisture Content 13.15.2 Testing: Moisture Content 13.15.3 Compliance criteria: Moisture Content 13.15.4 Non-compliance: Moisture Content 13.16 TESTING: FILL MATERIAL - RELATIVE COMPACTION 13.16.1 Testing: Relative Compaction 13.16.2 Compliance criteria: Relative Compaction 13.16.3 Non-compliance: Relative Compaction 13.17 APPENDIX 13.1 - TEST METHODS FOR FILL MATERIAL 13.17.1 General 13.17.2 Terms and symbols 13.17.3 Grouping of material
228 228 229 229
230 230 230 230 231 231 231 231 231 232 232 233 233 233 233 233 234
13.18 APPENDIX 13.2 - DETERMINATION OF THE MOISTURE CONTENT OF FINE GRAINED AND MEDIUM GRAINED MATERIAL BY THE MICROWAVE OVEN DRYING METHOD 234 13.18.1 Scope 234 13.18.2 Apparatus 234 13.18.3 Procedure 234 13.18.4 Calculation 235 13.18.5 Reporting of results 235 13.19 APPENDIX 13.3 - DETERMINATION OF THE MAXIMUM CONVERTED BULK DENSITY BY THE HILF METHOD 236 13.19.1 Scope 236 13.19.2 Apparatus 236 13.19.3 Procedure 236 13.19.4 Calculation 239 13.19.5 Reporting of results 240 13.20 APPENDIX 13.4 - ADJUSTMENT OF THE MAXIMUM CONVERTED BULK DENSITY FOR THE DETERMINATION OF THE RELATIVE COMPACTION
QICT Terminal 2, Main Works Contract Volume 2 Specifications xviii
240
13.20.1 13.20.2 13.20.3 13.20.4 13.20.5
Scope Apparatus Procedure Calculation Reporting of results
240 240 241 241 242
13.21 APPENDIX 13.5 - DETERMINATION OF THE INSITU BULK DENSITY OF FINE GRAINED AND MEDIUM GRAINED MATERIAL BY THE NUCLEAR DENSITOMETER METHOD 242 13.21.1 Scope 242 13.21.2 Apparatus 242 13.21.3 Procedure: Comparability of Test Methods 243 13.21.4 Procedure: Routine Densimeter Check 243 13.21.5 Procedure: Determination of in-situ Bulk Density 244 13.21.6 Calculation 245 13.21.7 Reporting of Results 245
14
PAVEMENT
246
246 246 247 247 247 249 250 250 251 251 251 254
14.1 PAVEMENT PARTICULAR REQUIREMENTS 14.1.1 Description of Work 14.2 ROADS AND PAVING CONSTRUCTION 14.2.1 Pavement Construction 14.2.2 Horizontal Alignments, Surface Levels and Surface Regularity of Pavement Courses 14.2.3 Use of Surfaces by Traffic and Construction Plant 14.2.4 General Requirements for Sub-bases and Road bases 14.2.5 Excavation, Trimming and Reinstatement of Existing Surfaces 14.3 ROADS AND PAVING - UNBOUND MATERIALS 14.3.1 Unbound Materials for Sub-bases 14.3.2 Compaction 14.3.3 Granular Sub-base 14.4
ROADS AND PAVING - CEMENT BOUND MATERIALS (LEAN MIX CONCRETE) 254 14.4.1 Constituent Materials 254 14.4.2 General Requirements for Cement Bound Materials 255 14.4.3 Induced Cracking of Cement Bound Material 258 14.4.4 Testing of Cement Bound Materials 261 262 262 262 265 265 265 266 266 266
xix 9S5537/R/013/GP/PBoro February 2008
14.5 ROADS AND PAVING - BITUMINOUS BOUND MATERIALS 14.5.1 Constituent Materials 14.5.2 General Requirements for Bituminous Bound Materials 14.5.3 Prime Coats and Tack Coats 14.5.4 Rolled Asphalt Basecourse 14.5.5 Regulating Course 14.5.6 Rolled Asphalt Wearing Course 14.5.7 Testing of Bituminous Mixtures and Their Component Materials 14.6 KERBS AND PAVED AREAS
14.6.1 14.6.2
Precast Concrete Kerbs, Channels, Edgings and Quadrants Concrete Block Paving
266 266 267 267 267 267 268 270 270 271 271 272 272 274 274
14.7 Road Markings and Road Signs 14.7.1 Work Scope and Function 14.7.2 Definition Dimensions and Layout 14.7.3 Design Criteria and Materials 14.7.4 Workmanship 14.8 TRAFFIC SIGNS 14.8.1 Foundations for Permanent Traffic Signs and Signals 14.8.2 Posts for Permanent Traffic Signs 14.8.3 Sign Plates for Permanent Traffic Signs 14.8.4 Faces for Permanent Traffic Signs 14.8.5 Construction and Assembly of Permanent Traffic Signs 14.8.6 Location and Erection of Permanent Traffic Signs 14.8.7 Covering of Permanent Traffic Signs
15
SURFACE WATER DRAINAGE
276
276 276 276 276 276 276 276 276 276 276 276 277 277 277 277 277 277 277 277 277 278 278 278 278 279 279
xx 9S5537/R/013/GP/PBoro February 2008
15.1 Project Specific Requirements for Surface Water Drainage System 15.1.1 Contractor Design 15.1.2 Basis of Hydraulic Design 15.1.3 Requirement for Sulphate Resistance of Concrete Pipes 15.1.4 Nominal Stiffness (SN) of GRP Pipes 15.1.5 Permitted Pipe and Pipe Bedding Class Combinations 15.1.6 Filter Drain Material Type F 15.1.7 Thermoplastic Pipe Characteristics 15.1.8 Rigid Pipe Joints 15.1.9 Use of Saddles 15.1.10 Requirements for Connecting Existing Drains to New Drains 15.1.11 Requirements for Sealing, Removal or Grouting of Existing Drains 15.1.12 Chamber Types (refers to Clauses 15.7.7) 15.1.13 Construction of Chambers (refers to Clauses 15.7.7 ) 15.1.14 Chamber Covers, Gratings and Frames 15.1.15 Gully Gratings and Frames (refers to Clause 15.7.8) 15.1.16 In-Situ Concrete Gullies 15.1.17 Requirement for Trapped/Untrapped Gullies 15.1.18 Requirements for Cleaning New Drainage Systems 15.1.19 Limiting distance for deposition of materials referred to in Clauses 15.6.2, 15.6.5 and29.6.2 and 29.6.4. 15.1.20 Testing of Gravity Pipelines (refers to Clauses 15.8.1) Scope of Work and General Items 15.2 15.3 Definition of Terms Design of Permanent Works by the Contractor
15.4 Specification of Materials 15.4.1 Pipes for Drainage

15.4.2 15.4.3 15.4.4 15.4.5 15.4.6 15.4.7 15.4.8 15.4.9 15.4.10 15.4.11 15.4.12 15.4.13 15.4.14 15.4.15 15.4.16 15.4.17 15.4.18 15.4.19 15.4.20 15.4.21 15.4.22 15.4.23 15.4.24 15.4.25 15.4.26 15.4.27 15.4.28 15.5
Corrugated Steel Pipes Bolted Segmental Plate Pipes Hot Dip Galvanised Coatings Procedures for Treatment at Areas of Mechanical Damage or Other Surface Defects Procedures for Treatment of Local Failure in Protective Coatings Thermoplastics Structured Wall Pipes and Fittings Granular materials for bedding, haunching and surrounding pipes Selected Granular Surround Material to Corrugated Steel Buried Culverts Granular Material Used For Trench Infill With Filter Drains Filter Material Selected Granular Material for Trench Infill Type 1 Unbound Mixture Concrete for Drainage Purposes Precast Concrete Chamber Rings, Reducing Slabs and Cover Slabs Chamber Covers, Gratings and Frames Gully Pots Gully gratings Bricks Light Liquid (Oil) Separators Penstocks Flap Valves Flexible Joint Couplings and Flange Adaptors Pipes for Filter Drains Joint Filler Board Marker Tape Combined Drainage and Kerb Systems Mortar
279 279 280 280 281 283 288 290 291 291 292 293 295 297 297 297 297 298 298 299 301 302 303 303 305 305 305 306 306 306 307 309 310 315 315 317 318 318 319 319 319 320 320 320 321 321 324
Requirements for material handling and storage
15.6 Workmanship requirements, installation and erection 15.6.1 Excavation for Pipes and Chambers 15.6.2 Bedding, Laying and Surrounding of Pipes 15.6.3 Jointing of Pipes 15.6.4 Backfilling of Trenches 15.6.5 Connecting to Existing Drains, Chambers and Channels 15.6.6 Chambers 15.6.7 Gullies and Pipe Junctions 15.6.8 Brickwork 15.6.9 Land Drains 15.6.10 Combined Drainage and Kerb Systems 15.7 Cleaning 15.7.1 Cleaning 15.7.2 Cleaning: Existing Drainage Systems 15.7.3 Cleaning: Gullies, Catchpits, Soakaways and Oil Separators 15.7.4 Cleaning or Testing of Piped Drainage Systems 15.7.5 Cleaning Kerb or Channel Offlet Pipes 15.7.6 Low Pressure High Volume Jetting of Drainage Systems 15.8 Testing
xxi
15.8.1 Testing General 15.8.2 Air Test 15.8.3 Water Test 15.8.4 Testing Pipe Profile 15.8.5 Permeability Testing 15.8.6 Testing for Constituent Materials in Recycled Aggregate and Recycled Concrete Aggregate325 15.9 Termination of Drainage Pipes for Future Expansion
324 324 324 324 324
329
16
POTABLE WATER
338
338 338 338 338 339 340 340 341 341 342 342
16.1 POTABLE WATER PARTICULAR REQUIREMENTS 16.1.1 Description of Work 16.2 POTABLE WATER GENERAL REQUIREMENTS 16.2.1 Under-Ground Pipework And Fittings 16.2.2 Valves and Fittings 16.2.3 Surface boxes 16.2.4 Installation of Under-Ground Pipework 16.2.5 Flushing of Pipe System 16.2.6 Testing and Commissioning 16.2.7 Sterilisation of Drinking Water Services 16.2.8 Inspection and Tests
xxii
1 1.1
GENERAL REQUIREMENTS Brief Description of Works

The site of this development is located immediately to the west of QICT Terminal 1, at Port Qasim, near Karachi in Pakistan. The project comprises the construction and commissioning of Phase 1 of the Terminal 2 container terminal. The site has an area of approximately 25 hectares and is currently inundated at high water. Approximately 2,000,000 m3 of reclamation will be required to bring the site to the required level. The construction of Phase 1 will comprise the reclamation of approximately 65% of the development area. Preparation works for the reclamation of the site are due to commence in Q4 2007, and will comprise the construction of a bund for retention of reclaimed material under the Advanced Reclamation Retention Bund Contract. The site lies adjacent to the main navigation channel serving QICT Terminal 1 and the separately operated Marginal Quays (Berths 1 to 4). The construction operations shall not cause disruption to services at any of the existing facilities. The site lies within the boundary and jurisdiction of Port Qasim Authority. The Contractor shall be responsible for obtaining all consents and licences necessary for execution of the works. The geology of the site comprises a mixture of inter-bedded soft clays and sands, overlying firm to hard clays. Intermittent and variable bands of conglomerate may be encountered below dredged level. More information can be found in Volume 5 of the Contract Documents. In general terms, the ground conditions will require the use of band drains and surcharge or similar methods to promote consolidation of soft soils, and the dredging of the berth pocket is unlikely to yield suitable material for use as fill. The site lies in a seismically active zone. The classification is Zone 2B as defined in the Uniform Building Code UBC-1997. The Main Works Contract will include all civil engineering and building works, mechanical and electrical services and commissioning. The works will include the construction of a generator station for supply of power to the new terminal. The works include but are not necessarily limited to the items detailed in the table on the following pages.
Works
Description
Marine Protection Works
Bund and rock revetment extending from the quay line to the northern boundary of the Phase 1 container terminal, Rock revetment along the northern boundary of the terminal, Scour protection along the quay wall (if required). Dredging of the existing navigation channel to a level of 16.0m below chart datum and the creation of a berth pocket suitable for the design vessel, Reclamation / filling of the Phase 1 terminal area (approximately 16ha). Construction of 727m of contiguous, cased, bored reinforced concrete piles through the reclamation bund, including anchorage wall and ties, Construction of cope structure, using in-situ as well as pre-cast concrete elements, Construction of independent rear crane rail foundation, comprising a piled reinforced concrete beam, Provision & installation of fenders, bollards, quay crane rails and other quayside fittings, including extension to existing crane rails and curved rails to allow transfer of STS gantry cranes from Terminal 1 to Terminal 2. Filling (see above) and ground improvement works, to achieve consolidation of soft soils through band drains and surcharge, Paving for container handling and storage, Ducting for power, lighting, data link & telecommunications, Fencing & gates, Roads, traffic management & signage, Reefer gantries, RTG maintenance and washdown areas and other small structures, Storm water drainage & outfalls, sewerage, fire fighting & potable water supply. Guard house building; 2-storeys high, Generator house, Gate-complex; with a total of 8 out gates, Substations, Fuel station, Fire system pump house and seawater intake,
Dredging & Reclamation
Quay Wall
Terminal Infrastructure
Buildings
Works
Description
Electrical & Communication Services
Power generation and distribution, MV and LV, with provision for supply from the local grid, including substations, transformers, cabling etc. Power supply for Ship-to-Shore Container Cranes, RTGs, reefers, light masts, perimeter lighting and buildings. Installation of stand-by generators. Installation of following services; fibre optic cabling, telephone network, data network, CCTV security control system
1.2
Works Reasonably Inferred

The Contractor shall execute the Work in accordance with the intent and meaning of the Drawings and Specification taken together and shall supply all accessories and other items essential for the proper execution of the work and shall execute all work which may be reasonably inferred whether or not specifically shown or described.
1.3
Facilities for Other Contractors/Suppliers

At least two months before the completion of the Works the Contractor shall have completed and shall made available to another contractor engaged by the Employer for installation and commissioning of the STS gantry cranes:
the length of quay wall including the strengthened part between Ch. 77.5 and Ch. 102.5 for crane erection; for crane parking, a length of 200 m of quay wall adjoining the strengthened part; a depth of 100 m of paved area from the quay wall over the length of the strengthened part of the quay wall and over the 200 m adjoining this strengthened part; the complete power supply to this area or, if the Contractor so chooses, the provision of temporary power supply to this area, sufficient for installation and commissioning of the STS gantry cranes, at the Contractors cost; the installation of all fenders, bollards, ladders etc, in the areas mentioned.
1.4
Drawings
Contract Drawings are the Drawings referred to in the Conditions of Contract and elsewhere in this Specification, together with such other Drawings as are issued by the Engineer or produced by the Contractor and approved by the Engineer in accordance with the Conditions of Contract. Drawing issue and control shall be as required by the Engineer.
The Contractor shall prepare all detail, shop, fabrication and erection drawings as required or necessary for the construction of the Works, as well as calculations relating thereto. The Contractor shall submit three paper copies of each drawing to the Engineer for approval. One digital copy of each drawing shall also be submitted to the Engineer, in AutoCAD 2007 or compatible format. All drawings shall be in metric dimensions, and prepared using AutoCAD 2007 or compatible drafting software. The Contractor shall check, sign and date all proposals prior to submission to the Engineer. The Contractor shall ensure that any drawings requiring approval are submitted to and received by the Engineer at least 14 (fourteen) days before approval is required or at such earlier date as required by individual Sub-Clauses of the Specification. In all cases where drawings for any work included in the Contract are specified or required to be supplied by the Contractor for the approval of the Engineer any alteration to such drawings which the Engineer may require shall be made, without additional cost, by the Contractor. The Contractor shall be responsible for undertaking: modification of the Engineers Drawings of standard precast concrete units, if necessary, to incorporate any additional reinforcement which may be necessary to accommodate the loading imposed during the construction of the works in accordance with the Contractors proposed methods; modification of the Engineers Drawings for typical standard bays/elements of insitu concrete work, if necessary, to suit the Contractors proposed sequence of work or construction joint positions (note that the position of all construction joints shall be subject to the approval of the Engineer); provision of all reinforcement detail drawings and bending schedules, both for the reinforcement which has been specified on the Drawings issued by the Engineer and on the Contractors drawings. Refer to Cl 1.34.
Any review or approval by the Engineer of the Contractors drawings or bending schedules shall not relieve the Contractor from responsibility for any additional costs or delays which result from any errors which are subsequently found on these drawings or schedules.
1.5
Dimensions / System of Measurement

Should there be any doubt as to the intention or as to the dimension of any part of any drawing, the Contractor shall bring this to the notice of the Engineer for clarification before proceeding with the construction. This Specification and the Drawings of the Works have been prepared utilising the S.I. system of measurement. Where components are not locally available to this standard, similar sizes may be substituted, subject to the approval of the Engineer.
QICT Terminal 2, Main Works Contract Volume 2 Specifications 4 9S5537/R/013/GP/PBoro February 2008
The Contractor shall notify the Engineer immediately of any discrepancies between figured dimensions given on the drawings and measured dimensions on Site to the attention of the Engineer immediately. At tie in locations to the existing Terminal 1, the Contractor shall verify all dimensions shown on drawings prior to ordering any materials or commencing work in this area.
1.6
Site Investigation Information

Available site investigation information in the vicinity of the works is included in Volume 5. The Employer and the Engineer shall not be responsible for the accuracy of the available subsurface investigation data. The Contractor shall be responsible for interpretation of the available data and shall be deemed to have taken all this information into account in the preparation of his Tender, in addition to his own local knowledge of the likely subsurface conditions at the site. The Contractor shall clearly understand that all such information provided is explicitly not part of the Contract and the Contractor must satisfy himself as to the soil and subsoil conditions, water table, location of aquifers and other site conditions. If the Contractor considers it necessary, he shall, at his own cost, carry out additional investigations.
1.7
Site location, Boundaries and Possession

The location and boundaries of the Site are shown on the Drawings. The Contractor shall confine his activities to the allotted site area(s) and shall not allow his personnel to trespass upon any other areas occupied by the Employer. The Contractor shall note that the construction of the Works is in open water subject to tidal conditions. The Contractor's attention is drawn to the relation of Highest and Lowest Astronomical Tides compared with the construction levels for the Works shown on the Drawings. Tides higher and lower than these tides can occur from time to time. No Extension of Time or Claims from the Contractor will be entertained in respect of working under these circumstances. All in-service pipes, cables and similar services whether above or below the ground which are encountered during the course of the Works shall be left in position and shall be carefully supported and guarded from injury by the Contractor to the satisfaction of all owners and proper authorities so that such pipes and cables may continue to be in full use until the completion of the Works or until no longer required. The Contractor will be held responsible for any damage to telephone cables, electric power cables, water pipes, sewage and drainage pipes, manholes, foundations, buoys, etc damaged by him or his sub-contractors during the execution of the works, even though these may not be shown on the Drawings. Except with the written permission of the Employer, no person in the employment of the Contractor or any sub-contractors or any agent of the Contractor will be permitted to
enter any buildings or lands or workshops of the Employer, other than those handed over to him in accordance with the Contract or open to the public. The Contractor shall warn any persons in his employment, sub-contractors and agents that any person found within any such site or building without authority is liable to be removed from the Site. The Contractor shall not, without the approval of the Employer, set up or cause or allow to be set up on the Site any business or retail establishment of any sort. The Contractor shall not erect or allow to be erected advertisements in any form on the Site or on adjoining ground but shall provide an approved board at the entrance of the Site. The removal, storage and return of items initially located within the Working Area shall be the responsibility of the Contractor. On completion of the Works the Contractor shall clear all debris arising from the works and shall reinstate the area to the satisfaction of the Engineer. The Contractor shall submit three copies of a video camera survey, photographs and topographic survey of the Contractors Working Area to the Engineer prior to occupation of the area. The Contractor shall submit a detailed survey indicating salient features of the Contractors Working Area. The Contractor shall be responsible for all aspects of the Contractors Working Area during the construction period. The Contractor shall submit a plan detailing the nature and extent of reinstatement works eight (8) weeks prior to demobilization, for approval by the Engineer. The video survey, photographs and topographic survey carried out previously shall serve as reference for reinstatement. On completion of the Works the Contractor shall clear away all debris arising from the works and shall reinstate the area to the satisfaction of the Engineer. The Contractor's arrangements for the supply of electricity and water required for the Works shall require the prior approval of the Engineer and the Contractor shall comply with the requirements of all Authorities having jurisdiction over such supplies and installations. The Employer will support the Contractors applications if required. The Contractor shall submit a plan for the proposed site office layout and establishment for approval by the Engineer within 30 days of the Commencement Date. The plan shall include areas designated for disposal of oil and non-oil liquids, hazardous and nonhazardous solid and liquid waste materials by means of skips, drums and refuse bins.
1.8
Access to the Site

The Contractor, his staff, sub-contractors and agents shall at all times make use only of the Contractors site entrance as instructed by the Engineer for access to the site. Vehicles and persons will be restricted to the Contractor's working area and the site. Except for making deliveries, the Contractors vehicles shall be parked within a dedicated area close to the Contractors Site Office. The Contractor shall make arrangements to obtain from the Employer all necessary Entry Gate Passes for vehicles and persons entering the port for the purposes of carrying out the Works. The Contractor shall at his own cost provide any temporary access routes, parking and lay-by areas required in connection with the access to Site for transport of materials and
labour and such other uses. Existing roads used by the Contractor shall be maintained throughout the course of the works at his own cost. The site is also accessible by sea The Contractor shall make his own arrangements either by road, sea or air transport or all to mobilize his equipment, plant and materials to and from the Site. All costs associated with these transports are deemed to be included in the rates and prices in the Contract. When moving to and from the spoil / dumping areas, the Contractors or his subcontractors dredgers will sail through shipping lanes. During such situations the normal traffic of shipping operation in the Port Qasim must be considered. The Contractor shall at all times allow the unhindered progress of such other shipping. This could involve the Contractors dredging plant to be idle or slow-sailing for some time. Details of the payment for such idle time are provided elsewhere in the Specification.
1.9
Other Contractors on Site

At the commencement of the works, the Advance Reclamation Works Retention Bund Contract will still be in progress. The Contractor will be deemed to have taken this into consideration in his programming and methods of construction for the works as well as in his Tendered rates and prices, especially with respect to any liaison and services which may reasonably be required by the Employer to enable the interfaces between the Contractors to operate smoothly, for example weekly programme coordination meetings arranged and chaired by the Contractor.
1.10
Site Datum and Base Lines

The datum for all Works shall be Chart Datum at Port Qasim. A base line shall be established within the working area by the Contractor. The base line shall be referenced to the site co-ordinate system (which will tie into the Port Authorities co-ordinate system should one exist). This bench mark and base line will be the basis for the setting-out for all the Works. The main levels and lines for each portion of the Works shall be established from the bench mark and base line by the Contractor.
1.11
Setting out of the Works and Surveys

Suitably qualified and experienced Surveyors (Land/Hydrographic) shall be used by the Contractor for all survey work. The Contractor shall submit, to the Engineer for his approval, the names and qualifications of the surveyors he proposes to use. Furthermore the Contractor shall, prior to commencing the Works, submit to the Engineer, for approval, details of the equipment and methods to be used for the establishment of a primary setting out and level control system and the subsequent setting out of the Works. All primary setting-out shall be undertaken using an EDM and a one second theodolite.
The Contractor shall establish the site grid in accordance with the directions of the Engineer. The local site grid shall be established such that it ties into the national grid and shall be agreed jointly with the Engineer. Prior to commencing the Works, the Contractor shall carry out jointly with the Engineer a topographic survey of the Site and associated facilities. These shall be plotted to a scale of 1:500. Spot levels shall be taken on a 10m (maximum) grid and shall be recorded on the survey drawings. Additional levels shall be taken where there are significant changes in level or gradient or for the purpose of identifying ground features including the nature of the ground, manhole covers, walls, etc, etc. The Contractor shall record the results of the above surveys on drawings and shall supply to the Engineer, three paper prints and an electronic drawing file of each drawing. All drawings shall be in metric dimensions and prepared in AutoCAD 2007 or similar drafting software compatible with AutoCAD 2007 and approved by the Engineer. These drawings shall be verified and agreed by the Engineer and when so agreed the original drawings shall be signed by both the Contractor and the Engineer. The Contractor shall take any copies of the signed drawings they require and return the original drawings to the Engineer. The land boundaries of the Site and adjoining properties shall be shown on the drawings. Survey stations, bench marks and triangulation points shall be clearly identified on the drawings and on the ground, they shall be made as permanent as possible and protected against displacement. When construction requires their removal, the approval of the Engineer shall be obtained prior to the removal. Where removal of an existing permanent survey control station or bench mark is required, an appropriate replacement shall be provided in a position and of a design to the approval of the Engineer. In parallel with the work for the Topographic Survey there will be a Bathymetric Survey. The Topographic Survey must overlap with the Bathymetric Survey, and the Topographic and Bathymetric Surveys must be co-coordinated both in plan and level to ensure compatibility of Datum and to avoid leaving any foreshore areas where the survey data is not in accordance with the Specification. Where reasonably practicable, the Contractor shall obtain spot levels extending over the sea bed for an adequate distance to ensure overlap of the Topographic and Bathymetric Survey. The Contractor shall establish permanent benchmarks on the Site which shall be referenced to Chart Datum as directed by the Engineer. The Contractor shall agree the position of the permanent site benchmarks with the Engineer. The Contractor shall protect and maintain both the local site grid and the permanent site bench marks, at his own cost. The benchmarks shall contain a 25mm diameter steel pin which is adequately labeled and secured into the ground as agreed with the Engineer. The Contractor shall not commence setting out the Permanent Works until the survey and coordination of the site grid and the permanent benchmark has been approved by the Engineer. Any survey control marks (planimetric control or vertical control) established by the Contractor for setting out or leveling shall be of stable construction and unaffected by
settlement. The locations and designs of these shall be submitted for the approval of the Engineer prior to any survey work. The Contractor shall prepare and submit to the Engineer a location drawing of control markers showing the general locations as well as a schedule giving the following information: station designation; plan co-ordination (National Grid System); level values (Chart Datum); description.
The location drawing and schedule shall be revised and updated by the Contractor as and when required throughout the works to meet the needs of the works. The Engineer shall be issued with three paper and one digital copy (in a format compatible with AutoCAD 2007) of all revisions. Prior to the commencement of the Works the Contractor's Agent and the Engineer shall survey and agree all levels on which the measurements of the Works are to be made. The Contractor shall, at his own expense provide and maintain survey stations on land, in the sea and on buoys which he may require to carry out the Works, and shall remove the same on completion of the Works. The Contractor will be required to check the accuracy of the levels of these points from time to time against the control reference marks. As the Contract execution progresses the Contractor's attention is drawn to the necessity to recheck bench marks to verify any changes in level due to settlement. The results of all surveys shall be submitted to the Engineer as a drawing in digital form prepared using AutoCAD 2007 or other drafting software compatible with AutoCAD 2007 and agreed with the Engineer. Any such drawings shall be produced to a scale not greater than 1:500
1.12
Existing services on Site

Care should be exercised when carrying out excavation, especially when excavating near existing structures. Drains, pipes, cables, overhead or underground electric wires data cables and similar services encountered in the course of the Works shall be guarded from damage by the Contractor at his own cost, so that they may continue in full and uninterrupted use to the satisfaction of the Employer and the Contractor shall not store materials or otherwise occupy any part of the "Site" in a manner likely to hinder the operation of such services. Should any damage be done by the Contractor on any mains, pipes, cables or lines (whether above or below ground), whether or not shown on the Drawings, the Contractor must make good or bear the cost of making good the same without delay to the satisfaction of the Engineer and of the Employer.
1.13
Contractor's Offices, Stores, etc.

The Contractor shall make arrangements, on or off the Site, for his own site establishment including parking, storage, workshops, offices, concrete batching and prefabrication yard, temporary jetties and all other facilities that the Contractor requires and shall pay all local rates and charges in connection therewith. If established on site, they shall be in positions to be approved by the Employer. On completion of the Works these buildings shall be removed and the sites restored to the satisfaction of the Engineer. Contractor's staff and labour will not be permitted to have any living accommodation at the Site or within the Employer's premises. The Contractor shall make his own arrangements for the accommodation of labour, which shall be outside the Contractors Working Area. The Contractor shall be responsible for obtaining all approvals, providing all labour accommodation and messing facilities, utilities and services. The Contractor shall be fully responsible for all transportation of personnel from the labour accommodation to the Site and vice versa. At the completion of the Works, the Contractor shall remove at his own cost offices, toilets, sheds and other temporary buildings, equipment services and service connections, with the exception of any equipment specified herein as becoming the property of the Employer. In addition the Contractor shall remove chains, wires and any other equipment, plant or materials introduced by him. All working areas and any other areas damaged by Contractor's activities shall be made good and reinstated to the satisfaction of the Engineer.
1.14
Contractor's Plant, Equipment, Labour, Personnel, Fuel and Consumables

The Contractor shall provide and mobilise all necessary plant, equipment and labour for the Construction of the Works. He shall provide all necessary maintenance facilities for the plant and equipment which shall not be demobilised and removed from site before the completion of the Works without the written permission of the Engineer. The Contractor shall provide and pay for all fuel, lubricants, gas and other consumable stores etc required for his plant, equipment and transport and for the execution of the Works. The Contractor shall ensure that all work is carried out by trained and competent personnel under the supervision of responsible persons, experienced in the particular aspect of the work concerned and with the required qualifications. All Contractors staff shall be regularly trained in safety and emergency procedures which shall be included in the Contractor's safety policy. While working over water, workers must be accompanied at all times by at least one other worker in case of accident. The Contractor shall include on his staff a Safety Officer whose qualifications and experience are acceptable to the Engineer. The Contractor shall include in his Workforce and/or staff a suitable number of qualified first-aid trained personnel at each area of work.
10
1.15
Sanitary Provisions
The Contractor shall, at all times during the continuance of the Contract, adopt such precautions as may be necessary to prevent soil or water pollution on the Site (including any area occupied by temporary accommodation) and shall compel his and his SubContractors' employees and labour to use the facilities provided which shall be carefully maintained by the Contractor throughout the currency of the Contract to the satisfaction of the Engineer / Employer Where the workplace is over water the Contractor shall provide reasonable access to sanitary accommodation for all persons employed on the Works, by providing toilets and washing facilities onboard floating plant if necessary.
1.16
Accidents, First-Aid and Medical Facilities

The Contractor shall maintain at their own cost to the satisfaction of the Engineer, firstaid facilities on site sufficient to deal with minor injuries, cuts and abrasions. Such facility shall be available for use at all times during working hours. Where injuries are more serious the Contractor shall liaise with the Local Authorities to provide hospital or other medical attention. In the event of any casualty or accident occurring on the site during the execution of the Works the Contractor shall comply with all existing legal obligations requiring him to give notice of the casualty or accident to any person or persons and shall notify as soon as possible both the Employer and the Engineer of any such occurrence.
1.17
Safety, Health and Welfare; Protection, Life-Saving etc.

The Contractor shall comply with all the regulations of the Statutory Authorities in respect of safety, health and welfare requirements. All facilities provided shall also be subject to the approval of the Engineer, in respect of location, type, quality, maintenance and cleanliness. The Contractor shall adhere to safe construction practices and guard against hazardous and unsafe working conditions. The Contractor shall give prompt and due consideration to any matters to which the Engineer may find it necessary to call attention, for the purpose of ensuring compliance with the foregoing requirements. The Contractor shall provide safe access to all parts of the site for the Engineer, the Employer and their staff and shall give prompt and due consideration to any matters to which the Engineer or his staff may find it necessary to call attention, for the purpose of ensuring compliance with the Specification and Conditions of Contract. The Contractor shall provide temporary fencing, handrails, scaffolding, and take such other safety precautions as are consistent with normal good safety practice. This shall include for the provision of a safety boat while working over water, crewed by suitably trained staff and equipped with life saving and first aid equipment.
11
The Contractor shall ensure that all open pits and trenches are so covered or otherwise protected that they present no hazard and that on completion they are completely filled in and consolidated using approved materials. Site operatives shall be fully conversant with the use of safety equipment and training shall be carried out, by the Site Safety Officer, sufficiently frequently to ensure that all necessary procedures can be correctly observed. The Contractor shall provide all necessary personal protective equipment (PPE) to his workforce and that of his sub-contractors, free of charge. This shall include, but shall not be limited to; safety boots, hard hats, gloves, lifejackets, eye protection, ear defenders, high visibility vests, harnesses etc. The Contractor shall make sure that the use of PPE is a requirement of working on site.
1.18
Temporary Fencing and Security

Temporary fencing is required around the perimeter of the Contractor's Working area. The Contractor shall erect fencing before commencing construction work and shall maintain it in good condition throughout the period of the Works, at their own cost. The Contractor may be required from time to time to erect temporary fencing at other locations as directed by the Engineer, and the price quoted will be deemed to be inclusive of the same. Temporary fencing shall be of a type agreed with the Engineer and adequate for his requirements of safety and security. The Contractor shall erect fencing and notices around any casting yard, material stockpiling areas, site offices and other such areas as directed by the Engineer. The Contractor shall erect public information boards to inform the public, in Urdu and English, of the works at suitable locations as agreed with the Engineer. The Contractor shall provide safe and suitably fenced areas where public information boards with messages shall be erected.
1.19
Fire-Fighting Equipment and Storage of Dangerous Materials

The Contractor shall, at his own cost, provide and maintain sufficient fire-fighting equipment at the Site to deal with any outbreaks of fire on the site of the Works or within the Contractors Working Area, as required by the relevant authority. All possible precautions shall be taken to provide for the safe storage of petroleum, gas bottles, or any other inflammable / dangerous materials. All hazardous materials shall be stored in locked compounds. Permits shall be obtained for the storage of such materials wherever this is required by the relevant authorities and the Contractor will be deemed to have included all costs in his Tender for the provision of necessary storage and handling requirements. Hazardous materials shall only be handled by specifically trained personnel.
12
Except as allowed under Clause 1.58, the use of explosives in the Works is not permitted. No explosives shall be stored on site or be brought to site. The Contractor shall observe and abide by all fire and safety regulations of the Employer before starting and during execution of construction work. The Contractor shall consult with the Employer's Safety Engineers or Engineer and must meet their requirements.
1.20
Temporary Site Services

The Contractor shall make his own arrangements, at his own cost, for the location of possible junction points, supply and the distribution of all temporary services. These shall include, but not by way of limitation, all pipework, cabling, switchgear, generators, compressors, pumping equipment and all arrangements necessary for adequate and safe distribution of service supplies. The Contractor shall make his own arrangements at his own cost for connection, metering and payments for all supplies obtained from Electricity and Water Undertakings.
1.21
Telecommunications and Contractor's Radio Equipment

The Contractor shall make his own arrangements, at his own cost, for the installation of telephone facilities for his own use. These shall include a international telephone/fax line and an internal extension telephone line from the Contractor's office to the Engineer's office. The requirements for the Engineer are detailed elsewhere in this Specification. Telephone bills will be paid by the Contractor and the price quoted will be deemed to be inclusive of the same. If the Contractor uses radio equipment for communication, the radio frequencies used shall be to the approval of the statutory authority. The Contractor shall be responsible for arranging, at his own expense, all necessary licences and permits that are required to operate radio and other communications equipment.
1.22
Site laboratory
In order to carry out the specified tests the Contractor shall provide a site laboratory to be approved by the Engineer. The laboratory shall be completely staffed and properly equipped to the satisfaction of the Engineer or any other person authorized by the Engineer, to carry out the tests as specified. Specialist tests or one-off tests may be made at alternative laboratories subject to the agreement of the Engineer and the Engineers approval of the alternative laboratory. The Contractor's site laboratory shall be available for the use of or inspection by the Engineer as required by him. The Engineer may require his representative to be present at any test and at any time during the working hours of the laboratory. The laboratory shall have adequate electrical wiring and fittings and plumbing fixtures. A regular and dependable supply of water and electricity shall be available throughout 24
hours of each day from time of erection to completion of Contract. The laboratory shall be provided with utility services, furniture, equipment, apparatus and fittings to enable it to operate efficiently. The Contractor shall furnish and maintain the laboratory, apparatus and supplies necessary to permit execution of the tests required by the Specifications. The Contractor shall submit to the Engineer for his agreement, within 28 (twenty-eight) days after signing the Contract, a complete list of the equipment, apparatus and supplies with which he proposes to furnish the laboratory. The list shall include the manufacturer's names and descriptive literature. Laboratory technicians and labourers in the numbers deemed necessary by the Contractor and to the approval of the Engineer shall be provided by the Contractor to carry out day to day operation in the laboratory and in the field. Such personnel once assigned to the laboratories shall not be removed except at the direction or with the agreement of the Engineer. The facilities provided under this Section shall not be measured nor paid for. All costs required to comply with the stipulations as described in this section shall be borne by the Contractor.
1.23
Weather Station
The Contractor shall provide, set up and maintain for the full period of the Works a weather station containing a rain gauge, maximum-minimum thermometer and anemometer, of types agreed with the Engineer, suitable for daily reading. The equipment is to be properly housed in a fenced enclosure at a site to be agreed with the Engineer and the records submitted to the Engineer weekly.
1.24
1.24.1
Services to the Engineer

General The Contractor shall provide for the exclusive use of the Engineer and his staff, the office accommodation, equipment and services listed in this Specification. The Contractor shall maintain and service all such facilities and equipment. He shall also provide all consumables at his own cost and pay for all other incidental or running costs. Unless otherwise specified below, the Contractor shall completely remove all temporary site offices and all equipment upon completion of the Works or as directed by the Engineer. The Contractor shall also supply, service and maintain emergency generators, including all fuel, oils, other lubricants, maintenance and repair/replacement as may be required, to ensure that the Engineers site office has a constant electricity supply at all times.
1.24.2
On Site Offices for the Engineer The Contractor shall provide and maintain, at his own expense, an office space of 335 m2 (not including entrance, reception or corridor areas) for the sole use of the Engineer
and his representatives, adequately furnished and decorated as detailed in this Specification. Office and other facilities shall be provided complete within two weeks of the Works Commencement Date or at a later date to be agreed with the Engineer. The office shall be equipped and maintained by the Contractor to the satisfaction of the Engineer until at least 3 months into the Defects Notification Period or such time as agreed with the Engineer, whereupon the buildings, furniture and equipment shall return to the Contractor and be removed from the Site. The Contractor shall submit full details of the proposed layout and construction of the offices and of the proposed furniture and equipment to the Engineer immediately after signing the Contract. Construction of the offices shall commence within one week of the Engineer giving his approval of the layout and construction. The office building shall be of timber frame construction or in any other construction material suitable for the conditions on site as agreed with the Engineer. It shall be lined and sound insulated throughout, weatherproof and provided with an adequate number of windows in each room. Blinds shall be fitted to all office windows. The internal finish to all walls, except laboratories and shower rooms, shall be of plywood or equivalent, with an easy clean decorative hardwearing, washable finish. Floors are to have an easy clean finish of heavy-duty floor covering. Laboratories and shower rooms shall have tiled walls and suitable non slip flooring as agreed with the Engineer. All of the rooms shall be provided with air-conditioning, heating and lighting. Minimum artificial light intensity shall be 215 LUX, with an intensity of 400 LUX in office rooms. All potable water, hot and cold running water, electricity, lighting and attendance including a regular supply of soap, washing-up liquid, clean hand and tea towels, toilet paper, etc, etc shall be provided by the Contractor and deemed to have been included in his Contract Price. Toilet facilities shall include WC bowls with flushing system and showers shall be of a type agreed with the Engineer. Waste connections shall be made to an existing/new sewer or suitably constructed septic tank as agreed with the Engineer. Rainwater shall be discharged clear of the buildings into an existing/new surface water system as agreed with the Engineer. A water main stop tap shall be provided inside the office building at a location agreed with the Engineer. An external mains water tap, with bibcock fittings and 10m length of hose shall be provided outside the office for general cleaning purposes at a location agreed with the Engineer. Fuse boxes and controls for heating and lighting shall be independent of those for the Contractor. An adequate number of electric socket outlets shall be provided in each room to permit proper use of the electrical equipment scheduled elsewhere in this Specification. Boot scrapers and boot cleaning facilities shall be provided outside all external doors. Coat hooks shall be affixed to the inside of all office doors or coat stands provided in all office rooms. All built-in furniture shall be constructed using dressed timber. All external doors shall open inwards (with the exception of fire doors) and be fitted with self-closing devices. Each external door shall be provided with a 5 lever mortise dead
lock (Yale locks or equivalent and approved by the Engineer) and 20 No. keys. Internal doors shall also be provided with locks and shall be to the approval of the Engineer, each internal door shall come with three keys. Each room shall have external overhead door lights and door mats. Internal signing shall be provided as directed by the Engineer. A covered car parking area for 10 vehicles shall be provided for the exclusive use of the Engineer and his staff adjacent to the Engineers Site Office. The car parking area shall be kept clean and in good repair until at least 3 months into the Defects Notification Period or such time as agreed with the Engineer. Footpaths 1 metre wide shall be provided linking all external doors to car parking areas, the access road and all other site accommodation and facilities used by the Contractor and as agreed with the Engineer. The Contractor shall be responsible for obtaining planning permission for the erection of all accommodation if required by the relevant Authorities. The requirements of this Sub-clause shall all be agreed with the Engineer prior to any work on the office accommodation commencing. The Table on the following pages gives office requirements when staff numbers will be at a maximum.
16
Office
Internal Room Area (m2)
Equipment Per Room
Room Type 01 Conference Room Number Required - 1
40
Heavy duty floor covering 1 No. Conference table(s), size 8000 x 2000mm; 20 No. Stackable chairs (upholstered seats and backs with armrests); 1 No. 2000 x 1000 mm high white board with cleaning equipment and at least 8 non-permanent pens in a mixture of colours; 1 No. Fire extinguishers; 6 No. 13 amp double wall socket outlets; 1 No. Telephone handset with speaker phone and conference call capability; 2 No. Telephone Sockets (1 exclusive international direct dial line); 2 No. Computer Network Sockets. Heavy duty floor covering 1 No. Kneehole desk 2000 x 1000mm with at least 3 lockable drawers and two keys; 1 No. Drawing bench 3000 x 1000mm supported at a height of 1000mm with an inclined surface and a plan chest of 6 No. A0 size drawers beneath; 1 No. Revolving upholstered desk chair with arm rests; 2 No. Upholstered chair with armrests; 1 No. Bookcase 1300 x 2000 x 300mm deep with lockable cupboards over bottom section and two keys; 2 No. 4 drawer lockable steel filing cabinet with two keys; 1 No. 3 tier filing tray with base; 2 No. 13 amp double wall socket outlets; 1 No. Telephone handset with speaker phone and conference call capability; 2 No. Telephone Sockets; 2 No. Computer Network Sockets; 1 No. Fire extinguishers; 1 No. Laptop Computer with keyboard, mouse and 19 monitor; 1 No. A3 Colour Printer.
Room Type 02 Resident Engineers Office Number Required - 1
30
Room Type 03
20
Heavy duty floor covering

17 9S5537/R/013/GP/PBoro February 2008
Office
Equipment Per Room
Assistant Resident Engineers Office (Inc. Planning Engineer) Number Required - 4
1 No. 1 No. 1 No. 2 No. 1 No. 1 No. 1 No. 1 No. 2 No. 1 No. 2 No. 2 No. 1 No. 1 No.
Kneehole desk 2000 x 1000mm with at least 3 lockable drawers and two keys; Layout table 2000 x 1000mm ; Revolving upholstered desk chair with arm rests; Upholstered chair with armrests; Bookcase 1300 x 1500 x 300mm deep; Lockable cupboard 1300 x 2000mm high with two keys 4 drawer lockable steel filing cabinet with two keys; 3 tier filing tray with base; 13 amp double wall socket outlets. Telephone handset with speaker phone and conference call capability; Telephone Sockets; Computer Network Sockets; Fire extinguishers; Laptop Computer with keyboard, mouse and 19 monitor;
Room Type 04 PQA Consultants Office Number Required - 1
20
Heavy duty floor covering 1 No. Kneehole desk 2000 x 1000mm with at least 3 lockable drawers and two keys; 1 No. Layout table 2000 x 1000mm ; 1 No. Revolving upholstered desk chair with arm rests; 2 No. Upholstered chair with armrests; 1 No. Bookcase 1300 x 1500 x 300mm deep; 1 No. Lockable cupboard 1300 x 2000mm high with two keys 1 No. 4 drawer lockable steel filing cabinet with two keys; 1 No. 3 tier filing tray with base; 2 No. 13 amp double wall socket outlets. 1 No. Telephone handset with speaker phone and conference call capability; 2 No. Telephone Sockets; 2 No. Computer Network Sockets; 1 No. Fire extinguishers; 1 No. Desktop Computer with keyboard, mouse and 19 monitor; 1 No. A3 Colour Printer; Heavy duty floor covering 8 No. Kneehole desk 2000 x 1000mm with at least 3
Rooms Type 05 Inspectors
60
Office
Equipment Per Room
Office Number Required - 1
8 No. 8 No. 4 No. 4 No. 4 No. 4 No. 8 No. 12 m 4 No. 8 No. 8 No. 8 No. 1 No. 4 No.
lockable drawers and two keys; Revolving upholstered desk chair with arm rests; Upholstered chair with armrests; Layout table 2000 x 1000mm ; Bookcase 1300 x 1500 x 300mm deep; Lockable cupboard 1300 x 2000mm high with two keys 4 drawer lockable steel filing cabinet with two keys; 3 tier filing tray with base; 300mm deep shelving 13 amp double wall socket outlets. Telephone handset with speaker phone and conference call capability; Telephone Sockets; Computer Network Sockets; Fire extinguishers; Desktop Computer with keyboard, mouse and 19 monitor;
Room Type 06 Admin Support Room Number Required 1
40
Heavy duty floor covering 3 No. Kneehole desk 2000 x 1000mm with at least 3 lockable drawers and two keys; 8 No. Revolving upholstered desk chair with arm rests; 2 No. Table 1500 x 750 mm; 1 No. Xerox document reproducer, Xerox workcentre PRO 265 or equivalent, complete with automatic document feeder, scanning capability, network capability, paper and other consumables for 5,000 copies per month; 4 No. 4 drawer lockable steel filing cabinet with two keys; 2 No. Lockable cupboard 1300 x 500 x 2000mm high with two keys 9 No. Filing baskets. 10 m 225 mm wide shelving. 1 No. Ten drawer desk high cabinet, to hold A3 size paper. 2 No. Telephone handset with speaker phone and conference call capability; 8 No. Telephone Sockets; 8 No. Computer Network Sockets; 6 No. 13 amp double wall socket outlets. 1 No. Fire extinguisher. 1 No. Telephone Switchboard (incoming unit) with 2
Office
Equipment Per Room
1 No. 1 No.
1 No. 2 No. 1 No. Room Type 07 Kitchen Number Required - 1
exclusive international lines and Hands Free Plus handset or equivalent. Tone-controlled answering machine Facsimile machine (with its own dedicated international line for incoming and out going calls) capable of transmitting different types of documents including charts and graphs at a speed of one A4 size paper in less than 15 seconds. Comb-binder, Ibico Kombo, or similar with consumables as required. Desktop Computers with keyboard, mouse and 19 monitor A3 Colour Printer
20
Heavy duty floor covering 1 No. Sink unit, double drainer, stainless steel, hot and cold taps, with cupboards underneath. 3.5 m Laminate work top units with shelved cupboards under. 1 No. Cupboard approximately 1500 x 600 x 2000mm high with locking door and adjustable shelves. 1 No. Cupboard approximately 600 x 600 x 2000mm high (for office cleaning equipment). 1 No. Microwave oven, capacity, 0.25m3. 1 No. 4 Ring cooker with grill and oven. 1 No. 4 slice toaster. 6m 225mm wide shelving. 2 No. Electric kettles (1.75 litres min.) 2 No. teapots 2 No. sugar bowls 2 No. milk jugs 20 No. cups, saucers and teaspoons 5 No. trays. 20 No. glass tumblers 30 No. mugs 20 No. large plates, small plates and bowls 20 No. sets of cutlery 4 No. Saucepans 2 No. Frying Pans 2 No. Milk Saucepans. 2 No. Table 1500 x 1000mm with laminate faced surface. 6 No. Chairs, stackable. 1 No. Electric Clock (wall mounted).
Office
Equipment Per Room
Refrigerator, minimum capacity 1.0m3, with freezer compartment 0.5m3. 10 No. 13 Amp socket outlets. 1 No. Soap dispenser. 1 No. Towelmaster or equivalent approved. 2 No. Cruet sets. 2 No. Bottle opener. 2 No. Tin opener. 1 No. First Aid Kit (for 20 persons). 1 No. Stretcher. 1 No. Vented fume extraction unit. 1 No. Heavy duty floor covering 10 m 600mm shelving 2 No. Cupboard approximately 1300 x 500 x 2000 mm high with shelves 1 No. Calculator 5 No Paper punch 1 No Heavy duty paper punch with guide 1 No Heavy duty stapler 5 No Stapler 6 No Anglepoise desk lamps with plugs 1 No Digital Camera (exact requirements to be agreed with Engineer) 5 No Scissors, 150 mm blade 2 No Steel straight edge 300 mm x 25 mm 4 No Date stamp and ink pad Swarfega 5 kg Heavy duty floor covering 1 No. A0/A1 size, Plotter (network capable). 2 No. Table 1500 x 1000 mm with laminate faced surface. 1 No. Plan chest, 6 drawer A0 size. 5 m. 225 mm wide shelving. 1 No. Fire extinguisher. 2 No. 13 Amp double wall socket outlets. 1 No. Vented fume extraction unit. 8 No. Telephone handset with speaker phone and conference call capability; 1 No. Computer Network Sockets; 2 No. Telephone Sockets; 2 No. 13 amp double wall socket outlets.
Room Type 08 Store Number Required 1
20
Room Type 09 Print Room Number Required 1
15
Room Type 10
Additional to the above and sized to cater for a total staff of 20

Office
Equipment Per Room
Shower Room & Toilets (male & female)

Total Office Area Required (excludes corridor, shower room, prayer area etc as detailed above)
335m2
One of the above rooms shall have an area set aside for prayers. The Contractor shall provide and maintain for use by the Engineer's staff at site, at least until 3 months into the Defects Notification Period or such time as the Engineer agrees, a comprehensive assembly of computer equipment with reliable continuity of operation. This computer equipment shall include but not be limited to: Description Hardware Details 5 Laptops Minimum Specification Intel Based with Pentium 2.0 GHz Processor 1024 Mb RAM 64 Mb Graphics Card 80 GB Hard Disk PCMCIA Network Adaptor (10 base T) 15 TFT Screen DVD/CD re-writeable drive 56Kbps Fax/Modem 1 GB USB Memory Stick Microsoft multimedia keyboard, Intelli mouse and mat Intel Based with Pentium 2.0 GHz Processor 2048 Mb RAM 64 Mb Graphics Card 250 GB Hard Disk PCMCIA Network Adaptor (10 base T) 19 TFT Monitor DVD/CD re-writeable drive 56Kbps Fax/Modem 1 GB USB Memory Stick Microsoft multimedia keyboard, Intelli mouse and mat 10 base T cabling and connectors for office as described in table above 2 No. 16 port Ethernet hubs 1 No ASDL router or alternative high band width internet connection with built in firewall 1 No. Server and back up both as per
Desktops
Network with
Description
Details
Minimum Specification specification for Desktop. HP 5550 A3 Colour Laserjet or equivalent 28 ppm mono / 14 ppm colour 600 x 600 dpi 160 Mb RAM (544 Mb max) 533 Mhz processor USB and parallel interfaces Network ready Duplex capable HP Designjet T610 or equivalent 1200 x 600 dpi 128Mb memory USB interface (minimum) Network ready Microsoft Windows XP Operating System Microsoft Office XP Professional Edition Suite Trend Micro Officescan Client anti-virus or similar and agreed with the Engineer AutoCAD 2007 or similar drafting software compatible with AutoCAD 2007 MS Project 2003 Professional Edition or similar programming software used by the Contractor and approved by the Engineer. Windows XP professional or other system agreed with the Engineer
Printers
Plotter
Software
12
Copies
Copies
Network server / back-up
The network equipment and all computers shall be complete with UPS and voltage regulation equipment and all necessary network cabling and switchboxes. After the Completion of the Works all hardware and software shall be returned to the Contractor. The Contractor shall provide 4 land lines and 10 mobile telephones. The mobile phones shall come provided with carrying cases, battery chargers, spare batteries, in-car hookups and in-car chargers for the sole use of the Engineer and his staff. All the land lines and 5 (five) of the mobile telephones shall be capable of receiving and making international telephone calls, All equipment shall be to the approval of the Engineer and fully comprehensively insured against damage, loss and theft and shall be returned to the Contractor, after Completion of the Works.
23
1.24.3
Survey Equipment The Contractor shall provide to the Engineer for the duration of the Contract: 1 (one) Total Station with all the accessories as indicated by the Engineer; 1 (one) theodolite and automatic level as specified by the Engineer; 2 (two) leveling staffs with metric graduations; 6 (six) 30 m steel tapes; an adequate number of ranging rods, lead lines, and spirits levels, etc. as required by the Engineer; hardhats and other appropriate safety / rain weather / protective clothing, and life jackets as required by the Engineer.
The Contractor shall be responsible for routine checks, maintenance and repairs of all surveying equipment 1.24.4 Road Transport The Contractor shall supply for the exclusive use of the Engineer and his Site supervision team, a total of 3 (three) motor vehicles no more than two years old and with a mileage of less than 80000 Km, together with 3 (three) experienced drivers, from Commencement of the Contract until the end of the Defects Notification Period or such time as agreed with the Engineer. The drivers shall be available on any working day, public holiday and for night shifts during which site operations continue with the consent of the Engineer or at such other times as the Engineer may request. The Drivers shall have an adequate command of the English Language and may have their duties combined with other tasks during the day such as providing assistance to the Engineers staff as chainmen or other office duties. 2 (two) of these vehicles shall be air conditioned, heavy duty, four-wheel drive type, with an engine capacity of not less than 2.5 liters. They shall be Mitsubishi Pajero or similar and approved by the Engineer. 1 (one) of these 3 vehicles shall be a double cabin pickup of the same requirements and shall be a Mitsubishi or similar and approved by the Engineer. The estimated average mileage for the vehicles during the contract is 25000 (twenty-five thousand) Kilometres per annum. If any vehicle is out of service at any time the Contractor shall provide a similar vehicle, approved by the Engineer, as a replacement. If any driver is absent for reasons of leave or otherwise the Contractor shall provide a fully qualified replacement. In the case of vehicle breakdowns the Contractor shall arrange for immediate repair or replacement to the approval of the Engineer. The Contractor shall keep clean and maintain the vehicles in first class condition for the duration specified in this Sub-clause or until such time as the Engineer may advise the
Contractor that they are no longer required. He shall provide all fuel, oil and necessary consumables and shall keep each vehicle insured under a fully comprehensive policy (which shall include for driving by the Engineer's Site staff and for passengers). The Contractor shall submit both the policies and the name of the insurance company for approval by the Engineer. After the Completion of the Works, the motor vehicles shall be returned to the Contractor. 1.24.5 Launch and Echo Sounding Equipment From time to time, as required by the Engineer, the Contractor will make available to the Engineer a survey launch or inspection boat with competent crew and equipped with an adequate positioning system (DGPS) and calibrated echo sounder. The Contractor, at his own cost, shall ensure all permits, licences, insurance, approvals, etc as necessary to undertake the tasks required are obtained. In the event of any breakdown or inability to operate the launch for whatever reason the Contractor shall provide, upon request, equivalent craft for the task to be undertaken.
1.25
Contractors Attendance on the Engineer

The Contractor shall provide such assistance and supply such labour, plant, materials and equipment as may be required by the Engineer, to enable him to carry out his duties, as provided for in the Contract Documents. The Contractor shall provide a suitable experienced independent diving company on request by the Engineer for use by the Engineer to carry out underwater inspections of the Works. The Contractor shall provide and maintain free of cost during the Contract period, to the approval of the Engineer or his Representative, and for the use of the Engineers site staff, following materials as the Engineer or his Representative may require. The Contractor shall make available to the Engineer or his Representative and his Site staff the services of experienced Chainmen and other trades men as and when required by the Engineer for assisting in measuring, supervising, checking or testing the work at any time. The Contractor shall make available to the Engineer and his authorised staff full use of first aid equipment and any other medical facilities provided on Site for use by the Contractors own senior site staff. Contractors quoted rates shall cover for all such changes and all equipments will revert to the Contractor at the end of the Contract
25
1.26
Contractors Attendance on Other Contractors

The Contractor should be aware of the interfaces with other Contractors and parties associated with the works described in Section 1.1.
1.27
Progress Reports
The Contractor shall submit to the Engineer on the first day of each month, or at such periods as the Engineer may from time to time direct, a progress report showing the current rate of progress and progress during the previous period on all important items of each section of the Works measured against the Programme approved by the Engineer. In addition to the copies of the report the Contractor shall submit, at the same time as the report, a complete set of photographs in digital format on a CD to the Engineer. The format and layout of the Progress Report shall be agreed with the Engineer prior to submission of the first Progress Report. The Programme shall be updated by the Contractor every three months, so as to ensure completion within contracted period, at his own cost.
1.28
Details of Plant Equipment, Labour and Personnel on Site

The Contractor shall submit a weekly schedule to the Engineer (on the first day of each following week) listing all plant, equipment, labour and other personnel on site, both his own and that of any sub-contractors.
1.29
Advance Notification of all Operations

In addition to his general obligations under the Contract, full and complete notice shall be given by the Contractor of all operations to be carried out on the site. Such notice shall be provided in sufficient time for the Engineer to make all necessary arrangements for inspection and checking. Such inspection and checking shall not relieve in any way the obligations to the Contractor under the Contract. Where the Engineer is required by the specification to give approval to the supply of materials or plant to be used in, or method of construction of any part of the Works, this notice shall be sufficient to allow time to carry out inspections, checks or test prior to giving such approval and shall also allow time for the Contractor to make any alteration, or provide alternative sources, of supply in the event of the Engineer failing to give his approval, or as directed by the Engineer. The Contractor shall submit to the Employer for his approval every week a statement showing the proposals for mooring his craft of all sizes and floating equipment during the ensuing week.
26
1.30
Method Statements
Prior to the commencement of any section of the Works the Contractor shall submit a full and detailed method of construction statement. This shall include details of plant to be used, construction sequences and temporary loadings applied to permanent works. Details to be provided shall include drawings of any works to be undertaken by specialist sub-contractors. No work shall commence until the approval of the Engineer has been given. For each approval (including approvals of method statements that the Engineer requires to be resubmitted) the Contractor shall allow the Engineer at least 28 calendar days.
1.31
Temporary Works
Temporary Works carried out by the Contractor for the purpose of constructing the Permanent Works shall be undertaken exclusively at the risk and expense of the Contractor. Design of all temporary works shall be the responsibility of the Contractor. The Contractor shall furnish such details of his Temporary Works as may be called for by the Employer or Engineer and shall satisfy the Engineer as to their safety and suitability. Such review shall not relieve the Contractor of his responsibilities under the Contract. The Engineer may direct that Temporary Works which he considers to be unsafe or unsuitable be removed and replaced in a satisfactory manner. The Contractor shall submit to the Engineer for his approval full details including drawings and design calculations of any Temporary Works for which details have been requested by the Engineer. These submissions shall be submitted sufficiently in advance, as directed by the Engineer depending on the nature of work, but not less than thirty (30) calendar days, before work on the erection of such Temporary Works commences on the Site. The Contractor shall also submit as made record drawings of these Temporary Works, 3 in paper and a digital copy (in a format compatible with AutoCAD 2007). All submissions to the Engineer shall be checked, signed and dated by the Contractor prior to submission. If so required, the Contractor shall amend such designs, calculations and drawings of Temporary Works to the satisfaction of the Engineer. The Engineer will stamp and sign the Contractors submission with the notation REVIEWED when satisfied the submission is appropriate. The Contractor will not be permitted to commence any works or order any materials prior to receipt of such stamped submission which confirm that the submission has been reviewed and does not require resubmission The submission to and approval by the Employer or Engineer of such Temporary Works shall not relieve the Contractor of any of his duties or responsibilities under the Contract in connection with the Works.
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1.32
Records to be kept of all Engineering Operations

The Contractor shall supply such records of the Works as may be required by the Engineer. In particular, these shall include dates and details of all engineering operations, temperature, rainfall, wind speed and direction, other weather conditions as appropriate and water levels including tidal data. The Contract Price quoted shall be deemed to be inclusive of the same.
1.33
Contractor to Supply Set of "As-Built" Drawings

The Contractor shall provide to the Engineer on completion of the Works a full set of the Contract and/or Working Drawings together with any other relevant details and information fully marked up, revised and updated to indicate the final construction and form of the whole of the Works as completed. The Engineer will provide one copy of each of the Engineers Working Drawings in AutoCAD format on compact disc, to assist in the preparation of this set of "as-built" drawings. One set of all Contract Drawings shall be kept by the Contractor on Site and shall be marked up by the Contractor as work progresses to show any changes to the details shown on the drawing and the locations of any structural alterations to services. Within one month of the date upon which the Taking-Over Certificate is issued by the Engineer, the Contractor shall hand over to the Engineer one digital (in a format compatible with AutoCAD 2007) and two hardcopies of the final as-built drawings covering Permanent Works, which records shall be prepared in a format to the satisfaction of the Engineer. Draft as-built drawings shall be submitted periodically, at the latest within 8 weeks of completion of the construction of a section of the work, for checking by the Engineer. The final as-built drawings shall be verified and agreed by the Engineer and when so agreed the original drawings shall be signed by both the Contractor and the Engineer. Any failure of the Contractor to submit the "as-built" set of drawings within the specified time period after the completion of the works will entitle the Engineer to have such drawings prepared by others at the Contractor's expense, and the same will be recovered from money owed to the Contractor under the Contract.
1.34
Reinforcement Detail Drawings and Bar Bending Schedules

The Drawings issued by the Engineer specify the amount of reinforcement that is required in the elements of the Works shown on these Drawings. The Contractor shall prepare and submit fully detailed reinforcement drawings and bar bending schedules to the Engineer for approval for all reinforced concrete elements in the Works. The Contractors reinforcement drawings will detail the reinforcement shown on the construction Drawings and shall detail all additional reinforcement to ensure requirements in respect of bar coverage, curtailment, anchorage and lap lengths are fulfilled. The reinforcement detailing shall be in accordance with current best international practice and provide the minimum lap lengths specified on the drawings or
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in the British Standard appropriate to the design. Refer to Cl 1.4 for drawing format and issue procedure. Bar bending schedules are to be prepared by the Contractor and issued to the Engineer for each drawing detailing reinforcement. One paper print and one digital print in PDF format of each schedule is to be provided. The Contractor shall be responsible for any discrepancies or ambiguities between the schedules and the drawings and make necessary correction to reinforcement on site to comply with the requirements of the drawings as instructed by the Engineer. Bar bending schedules are to be prepared in accordance with BS 8666, and PS 27361989. Reinforcement bent to these schedules shall be bundled with labels to identify the bars by use of the drawing number and bar number from the schedules to ensure that bars can be traced and the correct reinforcement is used on site. No claim for delay or additional expense arising from the Contractor's failure to comply with this clause will be considered by the Engineer.
1.35
Statement at Completion
Not later than 30 days after the issue of the Taking Over Certificate in respect of the whole of the Works, the Contractor shall submit to the Engineer a Statement at Completion with following supporting documents in addition to those specified under Conditions of Contract, showing in detail in a form approved by the Engineer, at their own cost. The technical documents according to which the work was carried out. One set of Record Drawings of Permanent Works as stipulated herein duly approved and signed by the Engineer. Certificates of tests performed for various works. Materials Appropriation statements for the materials issued by the Employer (if any) for the Works and list of surplus materials returned to the Employer's stores duly supported by necessary documents.
1.36
Standard of Works
A high standard of workmanship in all trades will be required. The Contractor shall ensure that only skilled and experienced tradesmen are employed. All materials used in the Works shall be of the best quality of their respective kinds as specified herein, obtained from sources and suppliers approved by the Engineer and shall strictly comply with the tests prescribed herein-after or where tests are not laid down in the Specification, with the requirements of the latest issues of the relevant Pakistan Standards or where Pakistan Standards are not available, with the latest issues of the relevant British Standards.
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1.37
Materials
All materials used in the Works shall be procured by the Contractor unless otherwise specified. Where particular standards to which plant or materials must comply are cited, any goods meeting other authoritative standards which ensure equal or higher quality than specified by the standards mentioned will also be accepted. Similarly, where references to brand names, catalogue numbers or the like are given, it is permissible to offer alternative goods providing performance and quality at least equal to those specified. Any materials not fully specified herein and for which there is no relevant Pakistan or British Standard shall be the best of their respective kind and to the approval of the Engineer. No material shall be used in the Works unless it has first been approved by the Engineer.
1.38
Inspection and Testing

All materials required for the Works shall be supplied by the Contractor and shall be subject to inspections and tests as detailed in the other sections of this Specification. Unless otherwise stated, the cost of all the tests required by the Specifications or the relevant Pakistan or British Standard shall be deemed to be included in the rates and prices named in various sections of the Bill of Quantities. The Contractor shall provide the necessary samples and carry out all the tests in the Site laboratory and shall provide testing apparatus, technicians, helpers and all other facilities at the Site. For the tests which cannot be carried out in the Site laboratory (not due to failure of the laboratory equipment), the Contractor must select the testing laboratory with the approval of the Engineer and must provide conveyance for the transport of test samples and the Engineer's staff. No consignment of a material shall be used unless the tests required by the Engineer are carried out and the test reports are analysed by him and the material is cleared by him for consumption. The Contractor must schedule ordering and receipt of consignments with due regard to the time required for sampling, testing and analysis of test reports.
1.39
Supply of Samples
Samples of all materials proposed to be employed in the execution of the Works may be called for by the Engineer and shall be submitted before the materials are brought to Site. Samples provided to the Engineer or his Representative, are to be in labelled containers suitable for storage. The cost of providing such samples shall be borne by the Contractor. Quality of materials to be used in the Works shall be at least equal to that of the samples submitted to and approved by the Engineer.
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1.40
Names of Manufacturers and Suppliers

Before ordering plant or materials of any description the Contractor shall submit for approval of the Engineer the names of the makers or suppliers proposed, together with the particulars listed under the general heading "Information to be furnished by the Supplier" where this occurs in the relevant Pakistan or British Standard or such other particulars as the Engineer may call for. All submittals (including re-submittals) shall be made sufficiently in advance to provide 14 calendar days for review from the time the Engineer receives them prior to ordering any plant or materials of any description or commencing any construction work in the area involved. Submittals shall contain: The date of submission and the dates of any previous submissions The project title and number The Contractors name The Suppliers name The Manufacturers name Identification of the product with the relevant Specification Section number, page and paragraphs Area of the works in which the item will be incorporated Field dimensions(clearly identified as such) Applicable Standards Identification of any deviations from the Contract Documents Identification of revisions on resubmittals A blank space for Contractor and Engineer stamps. For Product Data 5 (five) copies or a number agreed with the Engineer shall be submitted For samples 3 (three) samples or the number stated in the respective Specification Section shall be submitted.
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1.41
Subletting
The Contractor shall supply the Engineer with two copies of the order and every drawing referred to in the order for all work sublet by the Contractor. All makers and suppliers shall be approved by the Engineer.
1.42
Storage and Usage of Plant and Materials at Site

All plant and materials brought on to the Site shall be stored and protected in such a manner that they remain in perfect condition until such time as they are incorporated in the Works. Methods of storage, protection and handling of plant and materials shall be to the Engineer's approval. Materials shall wherever possible and practicable be used in the order in which they arrive on the Site.
1.43
Despatch of Plant and Materials

Plant and Materials shall not be despatched from the manufacturer's works / from the Supplier to the Site without written authority from the Engineer or his Representative.
1.44
Test Certificates
All manufacturer's certificates of test, proof sheets, mill sheets, etc. showing that the plant and materials have been tested in accordance with the requirements of this Specification, the appropriate Pakistan Standard or other relevant standard specifications, are to be supplied free of charge, on request, to the Engineer or his Representatives.
1.45
Standards Appearing in this Specification

Where Pakistan and British Standards are named in the Specification, the latest current issues and other Specifications and Codes referred to therein, including all official amendments / revisions, if any to all these, issued by the respective Standards Institution, one month prior to the due date of receipt of the Tenders, are intended unless specifically stated otherwise.
1.46
Regulations of Statutory Authorities and Customs

Without limiting his obligations under the Conditions of Contract the Contractor shall observe all regulations laid down by all Statutory Authorities, including, but not limited to the Port Qasim Authority (PQA) The Contractor shall comply with all regulations imposed by the Customs authorities in respect of the passage of all imported Contractor's Equipment, Plant, Materials and vehicles and personnel through Customs barriers.
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1.47
Port Regulations, Temporary Lighting and Marking

The Contractor shall comply with all proper and legal orders, regulations and directions given to him from time to time by PQA and the Employer with respect to the use of floating craft or plant. The Contractor shall also comply with the PQA requirements in respect of watching, marking and lighting all temporary and permanent structures as well as floating plant, craft and equipment used for the construction of the Works. In particular, as construction proceeds seawards the extremities of all works shall be adequately marked by day and night. The marking shall consist of a 2m x 2m red flag by day and two fixed red lights 2m apart vertically at night all at the Contractors cost. The lower light shall be 4m above water level and both lights shall be sufficiently powerful to be visible at a range of 2km. Lighting and marking shall be to the approval of PQA. The Contractor shall also provide at his own cost every description of watching and maintenance required for protecting and securing all places dangerous, whether to the Contractor's workmen or to other persons until the Works shall have been handed over to the Employer unless the Engineer shall decide that such services are no longer required. All lights provided by the Contractor shall be placed or screened so as not to interfere with any navigational lights or with any traffic or signal of any local or other authority, having jurisdiction in connection with the Site.
1.48
Watching and Lighting

The Contractor shall in connection with the Works provide and maintain at his own cost all lights, guards, fencing, warning lights, warning signs and watching when and where necessary or required by the Engineer or by any duly constituted authority for the protection of the Works or for the safety and convenience of the public or others.
1.49
Removal of Sunken Craft, Equipment or Materials

Should any craft or Equipment (floating or otherwise) belonging to or hired by the Contractor or any Sub-Contractor employed by him or any materials or things therein sink from any cause whatsoever in the course of construction and completion of the Works or during Defects Notification Period it shall immediately be reported by the Contractor to the Engineer and the Contractor shall forthwith and with dispatch raise and remove any such craft, Equipment, materials or things at his own cost or otherwise deal with the same as the Engineer may direct, until the same shall be raised and removed. The fact that such sunken craft, Equipment, materials or things are insured or have been declared a total loss or do not represent any further value shall not absolve the Contractor from his obligations to raise and remove the same. Until such sunken craft, Equipment, or materials or things have been raised and removed the Contractor shall
33
set all such buoys and display at night such lights and do all such things for the safety of navigation as may be required by the Engineer at his own cost. In the event of the Contractor not carrying out the obligations imposed on him by this clause, the Employer may or cause to buoy and light such sunken craft or Equipment or materials or things and raise and remove the same without prejudice to the right of the Employer to hold the Contractor liable and all expenses consequent thereon and incidental thereto shall be borne by the Contractor and shall be recoverable from him (as a debt) by the Employer or may be deducted by the Employer from any moneys due or which may become due to the Contractor.
1.50
Use of the Permanent Works

The Contractor shall not utilise any of the Permanent Works for operating or storing any plant, equipment or materials without the approval of the Engineer.
1.51
Care of Existing Services etc.

Notwithstanding any information given herein or by the Engineer or his Representative at any time prior to tendering or subsequently, the Contractor will be held responsible for ascertaining the positions and all relevant information about services and apparatus which may be in any way affected by the construction of the Works and shall be responsible for repairing any damage caused by his own or his Sub-Contractors operations, at this own cost.
1.52
Works Not to Interfere With Normal Operations / Business of the Port

The Contractor shall not interfere in any respect with the normal business of the PQA or QICT and shall co-operate if and when special measures become necessary as a direct consequence of the construction of the Works. The Contractor, shall co-operate, by temporarily removing any of his Equipment, floating craft, obstructions, etc. which may cause a hindrance, as per direction of the Engineer / Employer. All such arrangements are to be made in writing through the Engineer and any extra work which may be involved paid for at appropriate scheduled rates or as Dayworks, if approved by the Engineer in writing. No claim for interference or impedance arising from the PQAs or QICTs normal operations / business will be considered. The Contractor shall take such reasonable precautions as are necessary to prevent undue dust and wind blown materials from interfering with the Employer's operations. These may include wetting of roadways as may be found necessary. The Works and Temporary Works shall be carried out in such a manner as not to interfere with surface or other vessels using the PQA's or QICTs facilities or endanger or interfere with traffic whether by road, rail or water and other normal operations / business of the Employer.
To ensure this: (i) The Employer will afford the Contractor reasonable facilities to enable him to carry out the Contract but the Contractor must strictly observe any rules, regulations or instructions which he may from time to time receive from the Employer or the Engineer or any person or persons authorised by them for the safety and protection of persons and traffic whether by road, rail or water and property on the Site. The Contractor shall only be allowed occupation of land areas and use of roads to the extent laid down in the Specification or agreed by the Employer or to such further extent as may be allowed in writing by the Engineer.
(ii)
The priority of navigation within the waters surrounding the Site will be always at the discretion of the Employer and the Employer shall not be responsible for any loss to the Contractor arising due to priority not being given to his floating crafts for moving about within these waters as per the decision of the Employer.
1.53
Avoidance of Nuisance, Pollution and Clearance of Obstructions, Debris, etc.

The Contractor shall ensure at all times that the site, its approaches and adjacent waterways are not obstructed and kept free from debris and pollution and that no nuisance is created due to the construction of the Works which might affect the site or its environment. The Contractor shall take all precautions, a competent contractor would take, to minimise the impact of any spillages of contaminants. Any such spillages shall be cleared and any areas affected by the spillage made good by the Contractor all at his cost. The Contractor shall consult the Engineer and provide effective anti-pollution measures as necessary at his own cost. During the monsoon(s) and other periods, it shall be the responsibility of the Contractor to keep the portion of construction site on land, free from water at his own cost. Obstructions caused as an unavoidable result of the construction of the Works in accordance with the Contract shall be cleared away as soon as the construction permits. The Contractor shall at any time if directed by the Engineer / Employer, clear away and remove from the site within reasonable time any surplus materials, waste, rubbish, temporary works or unused constructional plant which may in the opinion of the Engineer no longer be required upon the site; surface or other water that may have collected in and around the Works and leave that part of the site affected clean and tidy to the satisfaction of the Engineer / Employer. All Works shall be carried out without unreasonable noise and disturbance.
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1.54
Disposal of Surplus / Unsuitable Material off Site

The Contractor shall be responsible for the disposal of all surplus/unsuitable material off the Site at a dumping ground approved by the Engineer, and in the case of dredged materials, to an approved sea dumping ground, and shall make all necessary arrangements with the Statutory Authorities. Any charges or costs involved in the acquisition and use of land or sea dumping ground, whether for licences or any other costs (for example transportation, handling, loading, unloading etc), will be at the expense of the Contractor and price quoted shall be deemed to be inclusive of the same.
1.55
Supply of Materials - General

The Contractor shall take all necessary precautions to ensure that the supply of materials does not delay the execution of the Works. The Contractor shall, if so requested by the Engineer, show evidence of the orders he has placed for the supply of materials.
1.56
No Damage to Public Access

The Contractor shall take all reasonable measures to ensure that any means of public access to the Site whether by water or land does not become damaged or result in injured by any traffic of the Contractor or his sub-contractors throughout the course of the Works and including mobilisation and demobilisation of plant & equipment. In particular, the Contractor shall arrange by careful choice of route, distribution of loading and means of transport that such extraordinary traffic which inevitably arises from the mobilisation/demobilisation of plant and the movement of constructional materials for large scale civil engineering works is limited as far as is possible and that no unnecessary damage is caused as a result of these movements to highways, bridges, waterways, docks etc., without limitation. The Contractor is deemed to have satisfied himself as to the sufficiency of the local authority defined routes and transport available and to have allowed in his tender for the costs of any special strengthening of highways or bridges, the by-passing of any unsuitable structures, use of special transport, craft etc., as may be necessary. The Contractor is deemed to have investigated and made provision for obtaining permission, at his own cost, to use highways, bridges and waterways from the relevant authorities. The Contractor shall be responsible for ensuring that public roads and waterways are maintained free from deposition of any debris or other materials of whatever kind during transport to or from the site and shall take all necessary steps to remove any deposition or pollution which occurs. Any charges or penalties imposed by the Statutory Authorities for the above shall be borne by the Contractor, and the price quoted deemed to be inclusive of the same.
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1.57
Use of Divers
Diving operations shall be carried out in accordance with regulations in force in Pakistan and with the latest regulations of the UK Health and Safety Executive or equivalent internationally recognised Regulations. The Contractor's attention is drawn, for example, to the UK Health & Safety Series Booklet "A Guide to the Diving Operation at Work Regulations 1990 and any subsequent amendments or additions thereto, or equivalent regulations. All divers shall be experienced in the class of work to be undertaken and shall operate strictly in accordance with latest Codes of Practice and Regulations and be appropriately registered. Prior to any diving taking place the Contractor shall have complied with all instructions and regulations that may have been imposed by the Port Authority. It shall be the Contractors responsibility to make himself aware of any diving instructions and regulations that the Port Authority has in place such as Permits to Dive and the like. Before any diving is undertaken the Contractor shall supply the Engineer with two copies of the code of signals to be employed and shall have a copy of the code prominently displayed adjacent to the diving control station on the craft or structure from which any diving operation takes place.
1.58
Use of Explosives
Except as may be provided in the Contract or ordered or authorised by the Engineer, the Contractor shall not use explosives. Where the use of explosives is so provided or ordered or authorised the Contractor should comply with the requirements of the following paragraphs of this Sub-Clause. (i) The Contractor shall at all times take every possible precaution in and shall comply with the appropriate laws and regulations relating to the importation, handling, transportation, storage and use of explosives and shall at all times when engaged in blasting operations post sufficient warning flagmen to the full satisfaction of the Engineer. (ii) The Contractor shall at all times make full liaison with and inform well in advance and obtain such permission as is required from all Government authorities, public bodies and private parties whosoever is concerned or affected or likely to be concerned or affected by blasting operations, including notification of other Contractors on the site. (iii) The Contractor shall pay all license fees and charges which may be required for handling and storage or in respect of any other matter whatsoever, and the price quoted shall be inclusive of the same.
1.59
Use of Subcontractors
In addition to his responsibilities for the supervision and administration of all subcontracts allowed in accordance with the Conditions of Contract the Contractor shall arrange a programme with each Sub-contractor for the execution of specialist work to
permit the Works to be completed within the stipulated time. Any such programmes shall be subject to the approval of the Engineer. The Contractor shall allow Sub-contractors sufficient space and appropriate accommodation for the storage of materials and fabrication of work prior to fixing. The Contractor shall be responsible for the safe custody and condition of articles and goods provided by any specialist Sub-contractor or supplier.
1.60
Site Clearance, Make Good, etc. on Completion

The Contractor shall on completion of the Works restore, reinstate or make good the surfaces of all ground disturbed by his operations; remove any rubbish, surplus materials etc, from Employers premises and leave the Site clean and tidy to the satisfaction of the Engineer / Employer. Any costs incurred by the Employer in the restoration of the site, due to failure of the Contractor to adequately do so, will be at the expense of the Contractor.
1.61
Access to Works, Equipment Etc.

The Engineer or the Employer or their representatives shall have at all times access to Contractor's floating crafts, equipment, work in progress etc., and the Contractor shall provide necessary water transport facilities at his own cost for them from the location designated by the Employer to above mentioned places.
1.62
Daywork
Daywork shall only be executed by the Contractor on the receipt of written instructions from the Engineer. Daywork returns will not be admitted unless such written authority has been given by the Engineer. During the incidence of Daywork, the Contractor shall submit to the Engineer a daily return, in duplicate, by noon of the following day, showing the names and descriptions of all labour, plant and materials involved and any such other details as the Engineer may reasonably require. The Contractor shall maintain a register for all such Daywork carried out in a format approved by the Engineer.
1.63
Project Signboard
The Contractor shall provide at his own expense a suitable signboard not less than 3m wide by 2m high mounted on suitable posts at a location to be advised by the Engineer, at Contractors own cost. The colours, type, size and lettering shall be to the approval of the Engineer. The board shall give the following information in Urdu and English language. Project Title
Employer's Name Consulting Engineer's Name Contractor's Name Supervising Engineers Name
All details are to be agreed with the Engineer and Employer prior to fabrication.
1.64
Alteration to Design at Contractor's Request

The Contractor may propose changes in design of the permanent works to suit his method of working or for any other reason, as long as such changes are accompanied by an appropriate cost saving to the Employer (including for any checking / review costs required by the Employer in accordance with the Conditions of Contract) and are in line with the basic tender design and are accompanied by a detailed breakdown of the proposed cost saving to the Employer. If so required, the Contractor shall amend such designs, calculations and drawings submitted to the satisfaction of the Engineer. For each alternative design (including resubmissions requested by the Engineer) the Contractor shall allow the Engineer at least 28 calendar days to review the submission. The Engineer will stamp and sign the Contractors submission with the notation REVIEWED when satisfied the submission is appropriate. The Contractor will not be permitted to commence any works or order any materials prior to receipt of such stamped submission which confirm that the submission has been reviewed and does not require resubmission The submission to and approval by the Engineer or Engineer representatives of such alternative designs shall not relieve the Contractor of any of his duties or responsibilities under the Contract in connection with the Works. Any approvals required from regulatory bodies that result from an alternative design shall be obtained by the Contractor at his own expense.
1.65
Site Meetings
Not later than 14 days from the date of Commencement of Works, the Contractor shall call a meeting with the Engineer to discuss the scheduling of drawings, equipment/plant manufacture and installation, construction and other matters which may be pertinent to the completion of the Works. The Contractor shall arrange for his Project Manager and relevant senior staff to attend such meeting. The Contractor shall attend regular co-ordination meetings, with the Engineer, weekly and monthly arranged by the Engineer or the Contractor, during the course of the execution of the work. This is to ensure good communication with the Engineer and to mitigate any delays in the Works if they occur. The Contractor's Project Manager shall be present at these meetings together with any other person who in the opinion of the Engineer or Contractor may be required. The Contractor will prepare an agenda prior to
the meeting, take minutes during the meeting and circulate said minutes within 2 days of the weekly meetings and one week of the monthly meetings.
1.66
Quality Assurance
As required under the Conditions of Contract the Contractor shall operate his own Quality Assurance system to BS EN9001 or equivalent, acceptable to Engineer / Employer. The Contractor shall control quality related activities for key processes to ensure output meets the specified requirements. The submission of any item at any stage to the Engineer shall not form part of the direct quality control process and shall not relieve the Contractor of his responsibility for meeting the specified requirements. Such submissions shall be regarded as part of the commitment and responsibility of the Contractor to interface with the Employer to ensure confidence in the output and work. The Contractor shall prepare a Construction Quality Plan for approval of Engineer before carrying out any construction, inspection and testing of items. This Quality Plan shall be submitted to the Engineer within 2 weeks of the issue of the order to commence the Works. The Contractor shall prepare a schedule of sections of the plan and in general separate sections shall be provided for each item or element of the work. In the context of this clause construction shall be taken to include manufacture and fabrication. The Contractor's Construction Quality Plan shall : list the stages in construction, identifying the processes and all planned inspections and tests to be performed by the Contractor or his sub-contractors to demonstrate the compliance of items with the Specification; define work instructions, inspections and test procedures to be used (control documents); identify records to be generated at each stage of the construction (verification documents); identify, or refer to documents which specify acceptance criteria; identify, or refer to documents which specify the instruments to be used for inspections and tests.
The Contractor should note that the Engineer will choose any items of the work he wishes to inspect and that he may not necessarily inspect all items of work.
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1.67
Environmental effects
Notwithstanding the requirements of individual parts of this Specification the Contractor shall be deemed to have allowed for and shall take the following points regarding the environmental effect of the project into account. The price quoted shall be deemed to be inclusive of the same.
1.67.1
Suspended solids The Contractor shall at all times control the spread and concentration of air or water borne suspended solids generated as a result of his activities. The Contractor shall liaise with the Employer, the Statutory Authorities, to monitor the effect of the engineering works on the water quality of the Site area to ensure that statutory water quality values are complied with.
1.67.2
Waste disposal The Contractor shall at all times maintain the areas of the Site under his control in a clean and tidy condition and shall provide appropriate and adequate facilities for the temporary storage of all waste products prior to their disposal, at their own cost. The Contractor shall provide for special areas for the maintenance of construction plant to allow an effective waste collection and disposal. Particular attention shall be paid to the collection of waste oil. The Contractor shall be responsible for the safe transportation and disposal of all wastes generated as a result of his activities. The disposal should be carried out in such a manner that it will not harm the environment or human life. Where any third party is involved in the management of the wastes, the Contractor shall have to exercise due care to foresee (as far as possible), and therefore to prevent, any mismanagement of the waste generated as a result of his activities. The Contractor will comply and meet all relevant statutory requirements, at their own cost.
1.67.3
Sewage disposal The Contractor shall be responsible for the provision of adequate sanitary facilities for his workforce including sub-contractors. The Contractor shall not allow the discharge of any untreated sanitary wastes to groundwater or waters adjacent to the Site. The Contractor shall liaise with the Statutory Authorities during the construction works on the issue of sewage disposal so that statutory water quality values are complied with.
1.67.4
Construction materials and methods The Contractor shall ensure that the construction and infill materials are of acceptable quality and contain no contaminants harmful to water, or the existing soil surfaces of the
site. Sampling and testing of such materials shall be carried out as directed by the Engineer and the price quoted shall be inclusive of the same. Before starting the work a scheme for environmental control shall be worked out in consultation with the Engineer, which will be acceptable to the Employer and comply with statutory requirements. 1.67.5 Environmental Recommendations & Conditions Not withstanding the above, the Contractor shall comply in all respects with the recommendations and any conditions laid down in the Report Initial Environmental Examination, Qasim International Container Terminal Extension (Phase II) Project, Karachi by Environmental Management Consultants.
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2 2.1
DEMOLITION AND SITE CLEARANCE DEMOLITION PARTICULAR REQUIREMENTS

This section of the demolition and site clearance specification contains particular requirements for the demolition and site clearance works to be undertaken under the Contract. The particular requirements take precedence over the general demolition and site clearance specification contained under the demolition and site clearance specification Clause 2.2 onwards. All methods of demolition and site clearance shall be subject to approval by the Engineer
2.1.1
Description of the Demolition Works It is the Contractors responsibility to visit the site, make himself familiar with any elements that need to be demolished and to include for any structures, buildings etc. he considers need to be demolished to construct the works or may have been overlooked in the preparation of the Contract Documents. The cost of dismantling and demolishing all items required by the Contract Documents and Drawings shall be included in the Contractors rates and prices in the Bills of Quantities.
2.1.2
Codes and Standards All demolition work shall be carried out in accordance with: BS 6187 (2000, Code of Practice for Demolitions); Relevant Pakistan Standards and Local / Municipal Guidelines;
2.1.3
Site Data All information relating to the Site provided under the Contract are believed to be correct and shall be treated strictly as general information which the Employer or the Engineer shall not be held liable for whatsoever. This information shall not relieve the Contractor from making his own investigations to confirm the accuracy of such information provided and the Contractor shall be solely responsible for the interpretation of such information.
2.2
2.2.1
GENERAL
Standard of Works The Contractor shall ensure that only skilled and experienced personnel are employed for the demolition works. All demolition work shall be carried out in a safe manner, minimising the health and safety risks to the Contractors own employees, Employers workers and third parties.
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2.2.2
Scope of Work The extent of the demolition works are shown on the drawings. The whole of the demolition shall be carried out in any materials and finished to the widths, lengths, depths and profiles shown on the drawings or as may be directed by the Engineer. The Contractor shall visit the site and examine the existing structures. The Contractor shall also study any relevant ground investigation data or other relevant data available with the Employer. Based on these, the Contractor shall make his own assessment of the structures to be demolished. The Contractor may at his own cost undertake further investigations on site, and carry out further tests if he so requires to satisfy himself as to the correctness or otherwise of the conditions of the structures to be demolished. The methodology of demolition, and the appropriate equipment and plant for carrying out the required demolition shall be determined by the Contractor based on the data made available and/or on his own further site investigations.
2.2.3
Damage to Existing Structures The Contractor shall exercise great care when undertaking demolition close to existing structures so as to avoid short and/or long term disturbance to these structures. Should disturbance to such structures occur as a result of demolition activities, the Contractor shall be held responsible for the whole cost of repair and reinstatement to the existing condition prior to disturbance. The Contractor shall carry out the work in such a way as to ensure the safety and stability of any remaining structure until its complete removal from Site.
2.2.4
Programme and Method Statement At least 28 days before commencement of demolition works, a detailed Programme and Method Statement, including particulars of demolition methods, and details of equipment which the Contractor proposes to use shall be submitted to the Engineer for his approval. The demolition methods shall be such as to ensure that all demolition is carried out in a safe manner, that no damage is caused to existing structures and that no weakening of ground on which these structures are founded occurs. The Method Statement shall clearly show how the Contractor intends to carry out the required demolition, the form and condition of the structures to be removed, removal methods of any flammable or toxic material, sequence and method of demolition (with particular attention to working near or over water), and lines and levels. The Method Statement shall include, but not be limited to: Sequence of demolition; Disposal of hazardous materials (for example asbestos, oils and greases); Control of suspended sediment or demolition debris; Dust control;
Noise control; Storage of liquids in drums and tanks and disposal of used containers; Temporary loadings to be applied to existing permanent structures; Plant and labour resources; Sub-Contractors; Site supervision and management; Management of health and safety issues;
Should the Contractor find it necessary to supplement / optimise his method of operation during the progress of the Works, he shall at that time, submit a revised Method Statement to the Engineer for his approval. In undertaking demolition and Site clearance works, the Contractor shall comply with all codes and standards listed in Clause 2.1.2 as well as any other environmental legislation and regulations applicable to the Works. The Contractor shall obtain at his own cost any approvals to be obtained from the relevant authorities prior to the commencement of demolition. The Contractor shall make his own assessment of the weights of the items to be lifted and shall ensure that any lifting equipment is suitably rated. The Contractor shall not carry out any operation without the consent in writing of the Engineer. 24 (twenty four) hour's notice shall be given by the Contractor to the Employer and the Engineer in advance of any operation. 2.2.5 Services Unless otherwise noted in the Particular Specification, the Contractor shall arrange for the safe disconnection of redundant electricity, water, telephone, and other services (excluding surface water drains) adjacent to the site of the demolition Works prior to the commencement of work on Site. All live services shall be adequately protected and supported, or diverted as agreed with the Engineer. In the course of demolition the Contractor may expose unknown or unrecorded services that may or may not be in a live condition. The Contractor shall immediately inform the Employer of the type and location of the uncovered services and shall co-operate with the Employer in ensuring that such services are safely disconnected. 2.2.6 Use of Explosives, Blasting Unless otherwise noted in the Particular Specification, the Contractor shall not be permitted to employ blasting techniques without express written instructions from the Engineer. 2.2.7 Materials Arising from Demolition Unless otherwise noted in the Particular Specification, all the materials arising from the demolition shall be the property of the Contractor once the materials have been removed from the site.
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2.2.8
Testing of Materials Arising from Demolition If required by any authority, and prior to disposal, the Contractor shall at his own cost arrange for the testing of materials arising from demolition for classification under relevant regulations relating to hazardous waste/materials. The Contractor shall inform the Employer and the Engineer if such tests are required by any authority and shall submit a copy of the test results.
2.2.9
Demolition Records The Contractor shall maintain records of the progress of demolition and shall submit copies of these records to the Engineer daily / weekly as may be required by him.
2.2.10
Vegetation The Contractor shall grub up, remove and dispose of all vegetation on the site but only to the extent that is necessary to construct the works.
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3 3.1
3.1.1
DREDGING DREDGING PARTICULAR REQUIREMENTS

Particular Requirements This section of the dredging specification contains particular requirements for the dredging works to be undertaken under the Contract. The particular requirements take precedence over the general dredging specification contained under the dredging specification Clause 3.2 onwards.
3.1.2
Description of the Dredging Works The dredging works to be undertaken comprise the following headings: a. Dredging of the berth pocket to the depths shown on the drawings. b. Trimming of the rock bund as detailed in the Contract Documents.
3.1.3
Location of the Disposal Site The Contractor is to locate a disposal site with sufficient capacity to accommodate the volume of dredged materials not suitable for use in the reclamation. The licence to permit the disposal of the dredged material shall be obtained by the Contractor and he shall be responsible for complying with all licence/consent conditions. For the purpose of preparing the Tender the Contractor shall price for an offshore disposal site, including obtaining the necessary permits to use said site for the works. The highest level of disposed material shall not exceed the level defined in the disposal licence.
3.1.4
Level Tolerances Level surfaces defined by a level Dredge Profile shall have a level tolerance of plus 0mm and -300mm.
3.2
3.2.1
GENERAL
Definitions Dredging is the removal of material from areas of seabed and foreshore, tidal inlets or rivers, including adjoining areas, to defined levels and slope profiles and the disposal of the material to offshore deposit sites or to reclamation sites as directed on the drawings and this specification within the limits stated in the Contract. Dredging Profile is the surface, defined by the lines, levels, and slopes on the Drawings, above which all seabed material, regardless of type or nature, is to be removed by dredging under the Contract. The Final Surface of any work is the surface defined by the lines and levels shown on the Drawings to which the works under the Contract are to be finished.
Marine Structures are seawalls, revetments, breakwaters, jetties, quay walls, dolphins, docks, slipways, beacons, lighthouses, landing steps for berthing of vessels and other similar structures. 3.2.2 Site Information All information relating to the Site provided under the Contract are believed to be correct and shall be treated strictly as general information which the Employer or the Engineer shall not be held liable for whatsoever. This information shall not relieve the Contractor from making his own investigations to confirm the accuracy of such information provided and shall be solely responsible for any wrong interpretation of such information. 3.2.3 Site Investigation Any site investigation carried out by the Contractor in accordance with the Contract shall be undertaken prior to the commencement of the dredging works in order to confirm the soils data above and a minimum of two metres below the Dredging Profiles. Any dredging work undertaken by the Contractor before the Engineer has been provided with the Contractors site investigation data and Engineer has confirmed to the Contractor the Dredging Profiles to be achieved will be carried out at the Contractor's own risk. 3.2.4 Sequence of Dredging Works The required sequences of dredging and reclamation, including ground improvement shall be as shown on the Drawings. The Contractor shall organise his working methods and rate of operations to comply with the required construction sequences. 3.2.5 Materials to be Dredged All materials shall be dredged to the dredged profiles by achieving the lines and levels shown on the Drawings. The Contractor shall make his own assessment of the quality and nature of the materials to be dredged, and provide the most suitable plant to achieve the required dredged profiles. The Contractor shall be responsible for determining and constructing stable slide slopes. 3.2.6 Safety of Navigation The Contractor shall ensure that the dredging and reclamation operations are carried out in such a manner as to avoid causing interference or obstruction to existing navigation channels, harbour and port facilities or other off-site navigable waters. 3.2.7 Contractors Dredging Plant The Contractor shall provide all necessary types of dredging plant and ancillary equipment suitable for the execution of the Works. The Contractor shall have provided full details of the principal items of plant proposed in the Schedule of Plant, attached with his Tender, explaining how the equipment would be utilised.
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The Contractor shall at all times allow the Engineer to have access to all dredging plant and ancillary equipment, including all records of the Contractors dredging operations, for the purpose of carrying out inspections and verifying the Contractors operations comply with the Contract. The verification records shall include the total quantities and production rates of dredged materials of each type of dredging plant. If at any time during the currency of the Contract the Contractor should be unable to provide the dredging plant named in the Dredging Method Statement or the Schedule of Plant, the Contractor shall without delay and with the approval of the Engineer provide replacement dredging plant to undertake the work. The replacement dredging plant must not, in the opinion of the Engineer, be inferior to the original named dredging plant in size, production capacity, robustness, condition of repair or horsepower. Any delay to the completion of the Contract caused by a delay in the Contractor providing replacement dredging plant to the approval of the Engineer under this subsection will not be considered to constitute a cause of delay or a special circumstance so as to entitle the Contractor to additional costs or an extension of time under the Contract. All dredging and material transporting equipment shall be fitted with an approved real time track plotting or other recording device, capable of providing the location and plots of the vessels position during dredging and disposal/reclamation cycles. Each piece of dredging plant shall also be fitted with equipment for remotely receiving tide gauge readings. 3.2.8 Maintenance of Split Hull Vessels The Contractor shall ensure that the closing faces of all split barges/dredgers and the doors and chains of hopper barges used to convey dredged material, are in good repair and that such closing faces and doors are kept closed when the barges/dredgers are in the dredging area or are conveying such material to the disposal site. 3.2.9 Spillage and Siltation The Contractor shall strictly abide by all consent conditions defined in any Authorisation granted for the construction and operation of the development/project. All operations shall be conducted so as to minimise spillage and loss of fines, and to ensure that siltation of areas in adjacent navigable waters or areas of the site where the dredging has been completed and handed over, does not occur, nor the recycling of materials during dredging and reclamation operations. Should siltation of navigable waters adjacent to the Site, or areas on the Site previously handed over occur during the currency of the Contract as a result of dredging operations, the Contractor shall change his method of operations to prevent further siltation to these areas. The Contractor shall also remove any such siltation from these areas as soon as possible, such that normal vessel movements are not restricted/affected and previous dredge depths are restored. The Contractor shall also carry out additional surveys as required by the Engineer to confirm whether or not siltation is occurring. Any expense to which these requirements may give rise shall be deemed to be included in the Contract Price.
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3.2.10
Standing time If dredging work is delayed or has to cease temporarily to allow the movement of vessels within or adjacent to the Site, the Contractor will not be paid for this standing time for the first two hours of standing. The Contractor shall maintain close communication with the harbour authorities regarding the movement and operation of the Contractors dredging equipment and plan his short term operations to minimise the impact of vessel movements by others on his dredging operations.
3.2.11
Anchors and Moorings All anchors and moorings used by the Contractor shall be to the approval of the Engineer and all relevant statutory and regulatory authorities such as local Harbour and Port Authorities. The Contractor shall use floating buoys to mark the position of the anchors. All location markers shall be visible day and night. The Contractors anchor wires and floating pipelines shall not obstruct navigable channels.
3.3
3.3.1
SUBMISSIONS: METHOD OF WORKING

Particulars of Dredging The Contractor shall submit a document describing his proposed methods for undertaking the dredging works that shall include the following particulars and shall be submitted to the Engineer prior to the mobilisation of the dredging equipment: (a) a schedule listing any conditions or restrictions imposed by relevant environmental protection authorities responsible for the control of the disposal of dredged material, including copies of applications, marine dumping permits and correspondence, the type and capacity of dredgers, methods of anchorage and positioning of dredgers, the sequence and rate of working, details of silt curtain (if used) for dredging, including manufacturers literature, and arrangements for the transportation and disposal of dredged material.
(b) (c) (d) (e)
(f)
Detailed particulars of each area to be dredged shall be submitted to the Engineer at least 14 days before commencement of any dredging works. The Contractor shall maintain on all vessels used in the dredging operations a record written in English of the times of loading and deposition of dredged material, fuel consumption, and a note, with timing, of any occurrence or eventuality which has a bearing on the progress of the Contract that occurs during dredging operations. These records shall be available for inspection by the Engineer at all times and, when requested by the Engineer, copies of specified parts of these records shall be provided within two hours of receipt of the request.
Records of the volume of material dredged, plant used, water velocity through the suction pipes and material content, working hours, fuel consumption, production and non production hours shall be recorded daily and submitted to the Engineer in English on a weekly basis. These records shall include daily plots from the track plotting equipment and identify the site where material was deposited or disposed of.
3.4
3.4.1
GENERAL EQUIPMENT REQUIREMENTS

Tide and Wave Gauges The Contractor shall provide automatic recording tide and wave gauges at a site approved by the Engineer. The tide gauge shall also transmit tidal data to the Contractors dredging equipment. Electronic records of the wave and tidal data shall be provided to the Engineer and the Contractor shall provide a copy of the program the Contractor uses for determining the tide and wave data. Temporary tide gauges shall be installed around the site as work proceeds. These gauges shall be levelled and calibrated back to the automatic tide gauge. Temporary tide gauges shall be mounted vertically and firmly on rigid supports at locations agreed by the Engineer at all times during execution of the marine works and shall be calibrated, levelled and fixed to give tidal readings within an accuracy of 20 mm. Temporary tide gauges shall be made of 50 mm thick hardwood or other replacement material approved by the Engineer and shall be at least 250 mm wide on the measurement face and a minimum of 3200 mm in length. The length of the tide gauge shall extend a minimum of 1m above HAT and 0.5m below LAT. The gauges shall be painted on the marked faces with alternate 100 mm stripes in red and white and shall be marked and numbered in black at 0.5 m intervals over the tidal range from LAT to HAT. The painting applied shall consist of one primary coat, one undercoat and one finishing coat.
3.4.2
Removal of Floating Debris Floating debris within the Site arising from any source shall be collected and disposed of by the Contractor at regular intervals agreed by the Engineer. Floating debris shall be prevented from dispersing outside the Site.
3.4.3
Setting out and Surveys for Dredging Initial, interim, post and final dredge surveys shall be carried out using echo sounders of 200 kHz to 220 kHz frequency or by other methods agreed by the Engineer. All surveys shall include bar checks. The Contractor shall also have available echo sounders of low frequency of about 35 kHz. The Contractor shall provide surveys using low frequency echo sounders when requested by the Engineer without additional Contract payment. Survey equipment should be equipped with a heavy compensation device, to allow for proper surveying when waves are in excess of 0.5m.
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The initial survey for dredging in any given area shall be carried out at least 28 days before the commencement of dredging works in that area. The final survey for dredging shall be carried out no more than 28 days after the dredging work has been completed. The Contractor shall submit the following surveys to the Engineer, where it should be noted that the conditions as set forward hereafter for the various surveys concern the minimum requirements. As far as the offshore disposal site concerns, also the consent conditions as set forward by the relevant Authorities should be adhered to by the Contractor:a) Pre-Dredging Survey (a) The pre-dredging survey shall be carried out prior to the start of dredging, as soon as possible after the award of Contract, but not more than 28 days before commencement of dredging. It shall comprise both a land foreshore survey and a bathymetric survey. Where applicable pre-dredging surveys of the dredge disposal site and marine borrow sites shall also be carried out. In all cases, survey traverse lines shall be at 20m centres and contours shall be located at 2m level intervals along the traverse lines. Cross check survey lines shall be run at 90 degrees to the 20m survey lines at centres not exceeding 100m.
b)
Interim Surveys. Interim surveys shall be produced for all progress measurements over the full area to be dredged with traverse lines at a maximum spacing of 20m and level contours given at a maximum of 2.0m along the traverse. The surveys shall be submitted to the Engineer and be of a similar standard to the pre-dredge surveys. The site used for the disposal of the excess dredge material shall also be surveyed on a monthly basis with traverse lines at 20m maximum spacing and level positions given at a maximum of 2.0m centres. Cross check survey lines shall be run at 90 degrees to the 20m survey lines and shall be undertaken along the following locations: (a) the centre of the dredged pocket (b) the toe of the side slope (c) the middle of the side slope (d) the crest of the side slope In addition to the locations stated above, levels along the face of the cope shall be checked by dipping from the quayside. These levels shall be incorporated with the other information obtained during the survey and included in the permanent records produced.
c)
Post-Dredging Surveys Post-dredging surveys shall be carried out to confirm that dredging profiles formed as part of the permanent works are to the required tolerance prior to starting subsequent works. The post-dredge hydrographic survey shall be carried out
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within 7 days of completion of dredging in any area and shall include side scan sonar surveys to confirm the required dredged profile of the seabed and dredged slopes has been achieved. Should any part of the area be found to be outside the tolerances specified the Contractor shall re-dredge and re-survey until the tolerances have been achieved. Survey traverse lines shall be at 10m centres and level positions shall be located at 2m along the traverse lines. Cross check survey lines shall be run at 90 degrees to the 20m survey lines and shall be undertaken along the following locations: (e) the centre of the dredged pocket (f) the toe of the side slope (g) the middle of the side slope (h) the crest of the side slope In addition to the locations stated above, levels along the face of the cope shall be checked by dipping from the quayside. These levels shall be incorporated with the other information obtained during the survey and included in the permanent records produced. The post-dredging surveys shall include collection of grab samples on a 50m grid across the extent of the dredged area. The grab samples are required to determine the nature of the seabed for the purposes of assessing requirements for scour protection. Final Surveys The final survey shall, where applicable, include a foreshore survey adjacent to dredged areas, together with a hydrographic survey of the dredged area as defined below, including 100m beyond the boundary of the dredged area. The survey shall be plotted as for the pre-dredging survey. The final dredging survey shall be carried out at the end of the Contract following a clean-up dredge to the areas defined by a required dredge level on the contract drawings. The survey shall also cover below water features of the permanent works. A composite survey shall be drawn showing the results of all final survey data. A final survey of the disposal site shall also be undertaken and presented in the same manner as the Pre-Dredge Survey. e) Survey Presentation The Contractor shall provide to the Employer a licensed copy of the survey programme used for the plotting of his survey drawings. The Contractor shall maintain the version of the programme and supply any updated versions during the period of the Contract. Survey plans shall be plotted to scales agreed with the Engineer (however in no case shall they be greater than 1:500) and related to the Project Grid. The Engineer shall be provided with three prints and a digital copy (in a format compatible with AutoCAD 2007) of each survey drawing as soon as possible after completion of each survey. Survey data shall also be provided to the Engineer on CD in a format suitable for use with the survey programme provided by the Contractor. Survey drawings in the form of properly formatted computer disc output, and compatible with the Engineer's in-house CAD system shall also be provided. All copies of the surveys and survey drawings used for Contract measurement purposes shall be signed by the Engineer and the Contractor when agreed.
d)
3.5
3.5.1
DREDGING
Commencement of Dredging The permission of the Engineer shall be obtained before dredging starts in any area.
3.5.2
Dredging Dredging shall be carried out in such a manner and sequence that semi-fluid or disturbed seabed material will not accumulate in dredged areas. Dredging shall be carried out with due care and to avoid contact in the vicinity of existing structures. During dredging, samples shall be taken from the dredged materials for inspection and determination of the grading of cohesionless materials. The Contractor shall notify the Engineer if there is any sudden or significant change in the properties of dredged material. If required to achieve environmental consent conditions or to limit siltation of adjacent areas, silt curtains shall be provided before dredging commences so as to minimize water quality impact on the surrounding environment.
3.5.3
Method of Dredging The method of dredging shall be to the approval of the Engineer and the areas shall be dredged to the full extent shown on the drawings or as may be directed by the Engineer
3.5.4
Storage of Dredged Material Dredged material shall not be stockpiled on the foreshore, seabed or riverbed within the Site unless permitted under the Contract.
3.5.5
Spoil Disposal Where the dredged material is to be used for reclamation the Contractor shall demonstrate that the material to be used complies with the requirement of the Specification, in accordance with clause 3.5.9. If not re-used as reclamation the dredged material shall be disposed of in the agreed disposal site as defined in the Contract. The Contractor shall control the disposal of dredged material evenly over the disposal site to prevent an accumulation of material in any particular area. A dumping pattern shall be used to ensure that no areas within the disposal area are higher than the level permitted in the consent conditions as put forward by the relevant Authorities.
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3.5.6
Side Slopes The Contractor shall be responsible for determining side slopes to dredged areas. The Contractor shall ensure that his method of forming the slopes does not result in any instability either in the short or long term. The Contractor shall submit his proposals for forming the side slopes to the Engineer for approval.
3.5.7
Obstructions Including Munitions Only non-geological materials will be regarded as obstructions. The removal of obstructions by normal dredging will not be paid for. Where the obstructions cannot be removed by normal dredging operations, only time in excess of the first three hours will be measured under day work items. Notwithstanding the above provisions the Contractor shall be deemed to have allowed in his rates for the dredging and disposal of wires, cables and small items of debris that can be anticipated. Any damage or loss arising from the dredging of such obstructions shall be at the Contractor's own risk.
3.5.8
Dredging in Hard Material Dredging may be necessary in hard material. If rock is encountered the Contractor shall not be permitted to use any explosives without the express authorization of the Engineer. If permission for blasting is not granted, the Contractor shall propose an alternative method of dredging to the approval of the Engineer.
3.5.9
Dredging Material Suitable as Fill Where the Contractor considers material to be dredged would satisfy the specified requirements for use as reclamation material he shall inform the Engineer before dredging so that the Engineer can inspect and schedule tests on the relevant material to confirm its suitability. If the Engineer is satisfied that the material is suitable, the material may then be used for reclamation. Deposition of this material shall comply with the requirements of the Specification. Under no circumstances will the Engineer permit dredged spoil to be placed within any reclamation without evidence, including results of testing detailed in the Specification, to demonstrate that the specified requirements for Fill Material have been satisfied.
3.6
3.6.1
TOLERANCES
Dredging Tolerances The final surface of dredging shall be within the surface tolerance specified in the particular requirements. If no particular tolerance is specified in the particular requirements the specified final surface of dredging shall be plus 0mm to -300mm from the specified dredge level. If the dredge level is defined as a geological interface between two distinct materials rather than a surface defined by lines and levels, then
this surface shall be proven by the recovery of grab samples on a 25 m by 25 m grid or as otherwise agreed with the Engineer. Where the final surface of dredging is found to be outside the specified tolerances, redredging or filling with approved material as appropriate shall be carried out at the Contractor's own expense unless specifically directed otherwise by the Engineer. 3.6.2 Deposition of Dredged Material All dredged material shall be deposited at the disposal area defined in the particular requirements. The Contractor shall obtain coordinates of the boundaries of the disposal area and submit these together with the initial survey for agreement with the Engineer at least 28 days before the commencement of disposal operations at the disposal site. The Contractor shall ensure that the dredged material is not deposited outside the limits of the disposal area. A record shall be kept of the position and date, month and time of each disposal and this record shall be forwarded to the Engineer every week. In case of disposal by the Contractor at unauthorised places and at unauthorised times, such quantities so deposited and as assessed by the Engineer shall not be paid for. The Contractor shall be liable for all cost associated with such unauthorised dumping and any survey and re-dredging costs.. The Contractor shall submit for the Engineer's approval all the necessary details of his scheme for carrying the dredged material to the specified dumping grounds including his proposed measures for safeguarding against leakages of dredged material during transport and safeguards against environmental pollution.
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4 4.1
4.1.1
RECLAMATION RECLAMATION PARTICULAR REQUIREMENTS

Particular Requirements This section of the reclamation specification contains particular requirements for the reclamation works to be undertaken under the Contract. The particular requirements take precedence over the general reclamation specification contained under the reclamation specification Clause 4.2 onwards.
4.1.2
Description of the Reclamation Works The reclamation works to be undertaken comprise the following headings: a. Engineered Fill; For the area between the rear face of the quay wall piles and 10m landward of the anchor wall piles (as indicated on the tender drawings), the Contractor shall use material described as engineered fill which comprises rock fill material with the properties given in Table 4.1. The Contractor shall adopt this specification for the materials placed between the quay wall and the anchor wall such that no obstruction is caused to the piling works. Any reduction in the coarse particle content shall be designed without reduction in the fill strength as placed. The corresponding angle of internal friction of this material should have a peak value of 35 degrees and a critical value of 30 degrees. The Contractor is allowed to place this material by means of end-tipping, provided that a saturated bulk density of not less than 19 kN/m3 is achieved. b. Reclamation Fill; For the remaining area that needs to be reclaimed, the Contractor has the option of using hydraulically placed granular material from an offshore source or granular fill from a land based source. The specification of the material must allow installation of PVD band drains to the depths shown on the drawings. If an offshore source is selected the Contractor will be responsible for obtaining all necessary permissions to win the material and for providing ground treatment to achieve the minimum density specified in these particular requirements. The Contractor shall allow for reclamation losses and settlement loses following ground treatment.
4.1.3
Assessment of Liquefiable Soils In defining whether granular soils are liquefiable or not the Contractor shall comply with the requirements set out in Section 5.1.3 of the Specification.
4.2
4.2.1
GENERAL
Definitions Reclamation is the formation of land over an area of foreshore, seabed, tidal inlet or river, including adjoining areas by the deposition of fill material to the limits stated in the Contract.
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Dredging Profile is the surface, defined by the lines, levels, and slopes on the Drawings, above which all seabed material, regardless of type or nature, is to be removed by dredging under the Contract. The Final Surface of any work is the surface defined by the lines and levels shown on the Drawings to which all of the Works carried out under the Contract are to be finished. Earthworks Final Surface is the surface defined on the Drawings to which all earthworks (including reclamations works) are to be completed Areas of Fill are areas within the Site, including areas in embankments, platforms and slopes and in excavations for structures, pits and trenches, in which fill material is required to be deposited and compacted as part of the permanent work. Fill Material may consist of soil, rock, crushed concrete or inert construction material which is on or below the Site at the commencement of the Contract, or which is imported to the Site and which meets the requirements of the Specification. Surcharge is the Fill Material placed to the lines and levels shown on the Drawings, compacted in accordance with the Specification, maintained to the specified lines and levels for the duration of the Surcharge Period and then removed before the completion of the Contract. Surcharge Period is the period of time, commencing on the date on which the surcharge is completed to the lines and levels shown on the Drawings and ending on the date on which the removal of surcharge can commence. Formation is that part of the Earthworks Final Surface on which a pavement, structure or utility, is constructed, or on which the blinding or bedding for a pavement, structure or utility is placed. Geotechnical Instrumentation is the installation and monitoring of instruments in the ground or structures to provide information on soil and rock parameters for the purposes of construction control and performance monitoring. Marine Structures are seawalls, revetments, breakwaters, jetties, quay walls, dolphins, docks, slipways, beacons, lighthouses, landing steps for berthing of vessels and other similar structures. 4.2.2 Sequence of Reclamation Works The Contractor shall programme his working methods and rate of operations to comply with the required reclamation/dredging sequences. 4.2.3 Spillage and Siltation All reclamation operations shall be conducted so as to minimise spillage and loss of fines from the Site, and to ensure that siltation of navigable channels, turning areas or adjoining facilities does not occur.
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4.3
4.3.1
MATERIALS
Fill Material Fill Material shall consist of naturally occurring or processed material which at the time of deposition is capable of being compacted in accordance with the specified requirements to form stable areas of fill. Fill Material, shall not contain any of the following: (a) material susceptible to volume change, including marine mud, soil with a liquid limit exceeding 65% or a plasticity index exceeding 35%, swelling clays and collapsible soils, peat, vegetation, timber, organic, soluble or perishable material, dangerous or toxic material or material susceptible to combustion, and metal, rubber, plastic or synthetic material.
(b) (c) (d)
Fill Material for Reclamation or Marine Structures shall either be Type 1, rock or inert construction and demolition materials as specified in the Contract. Fill Material shall have the particle size distributions of an appropriate type of fill material within the ranges stated in table 4.1 unless otherwise stated in the Contract. Unless otherwise agreed by the Engineer, inert construction and demolition materials shall not be used as rockfill materials in Marine Structures. Underwater Fill Material (Type 1) shall consist of natural material extracted from the seabed or a riverbed. Engineered Fill Material shall consist of pieces of hard, durable rock, which are free from cracks, veins, discoloration, and other evidence of decomposition, with a uniformity coefficient of greater than 6.
Type of fill material Percentage by mass passing BS test sieve size 75 mm 20 mm 63 m 100 0 10 100 0 20 0-5 Table 4.1: Particle size distributions of Fill Material for Reclamation or Marine Structures Underwater fill material (Type 1) Engineered Fill material
The soluble sulphate content of Fill Material shall not exceed 1.9 grams of sulphate, expressed as SO3, per litre. The total sulphate content, expressed as SO3, of Fill Material shall not exceed 0.5% by mass.
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4.3.2
Granular Filter Granular filter material shall consist of durable, inert, natural material, free of clay, organic material and other impurities. Granular filter material shall have the particle size distribution stated in the table 4.2.
Type of granular filter Percentage by mass passing BS test sieve 50 mm Granular filter (Type 1) Granular filter (Type 2) 100 28 mm 60-100 20 mm 40-80 6.3 mm 100 5 mm 15-35 3.35 mm 80100 2 mm 515 6085 600 m 0 3045 515 0 150 m 63 m
Table 4.2: Particle size distributions of Granular Filter Material
The following particulars of the proposed materials and methods of construction for granular filters shall be submitted to the Engineer: (a) (b) (c) (d) (e) (f) (g) (h) Whether granular filter material is to be supplied ready mixed or is to be mixed on the Site, Source of supply, including name of supplier of ready mixed material, Quantity of each constituent if the material is to be mixed on the Site, Constructional Plant and methods of mixing for material mixed on the Site, Method of storage and location of storage areas on the Site, Methods of deposition and compaction of material, and Results of three tests for particle size distribution of the fill material against which the granular filter is to be placed. Details of filter design including calculations and grading envelopes.
The particulars shall be submitted to the Engineer for approval at least 14 days before deposition of granular filter material starts. Granular filter material shall be thoroughly mixed by the method approved by the Engineer. Material that has been stockpiled shall be remixed before deposition. Granular filter material shall be deposited in a manner which will not result in segregation or contamination of the material. Granular filter material shall be deposited in such a manner that a continuous free draining zone is formed. The surface of each layer shall be cleaned and scarified before the next layer is deposited unless otherwise permitted by the Engineer.
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4.3.3
Geotextiles Geotextile filter shall be of a type and manufacture approved by the Engineer and shall have the properties stated in the Contract.
4.3.4
Prefabricated Vertical Drains Prefabricated band drains shall be of a type and manufacture approved by the Engineer and shall have the properties stated in the Contract.
4.4
4.4.1
SUBMISSIONS
Description of Reclamation Works The following descriptions of the proposed materials and methods of deposition of fill material shall be submitted to the Engineer prior to the mobilisation of reclamation equipment: (a) (b) (c) details of reclamation equipment/plant, sources and properties of each type of Fill Material, details of silt curtains or other methods of controlling turbidity as required by the Contract including all relevant manufacturers literature, methods of deposition and compaction of fill material, methods of controlling moisture content of fill material, and sequence and rate of working.
(d) (e) (f)
The following particulars shall also be submitted if the proposed method involves the deposition of fill material by hydraulic methods: (a) (b) (c) A layout plan showing the pumpline alignments and positions of the discharge points, Calculations of the rate and duration of discharge, and Details of containment bunds and tailwater drainage systems.
4.5
4.5.1
GENERAL RECLAMATION WORKS REQUIREMENTS

Setting Out and Surveys for Reclamation Works The Contractor shall be responsible for all setting out and for carrying out surveys as specified and shall afford to the Engineer all facilities for checking as required. Such checks will not relieve the Contractor of his responsibilities for the accuracy of the setting out and surveys.
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Each dredger and survey launch utilised in hydraulic reclamation works shall be equipped with and shall use an approved electronic position fixing device capable of providing onboard a continuously updating pair of ranges from remote shore stations. The type of position fixing equipment shall be subject to the approval of the Engineer. The Contractor shall carry out accurate pre-reclamation and post-reclamation surveys as described below, together with all necessary interim surveys. The Engineer shall be given adequate advance notice and his approval shall be obtained for any survey which the Contractor may wish to use for measurement or for payment purposes. The Contractor shall provide all necessary surveying equipment launches, electronic position fixing equipment, echo sounders, recording devices and trained personnel meeting with the requirements of the Specification to carry out surveys. All equipment and survey procedures shall be subject to the approval of the Engineer. Bar checks and position fixing checks shall be carried out at the start and finish of each period of surveying. The surveys shall be as follows:(a) Pre-Reclamation Survey The pre-reclamation survey shall be carried out prior to the start of reclamation, as soon as possible after the award of Contract, but not more than 28 days before commencement of reclamation. It shall comprise both a land survey and a hydrographic survey. The land survey shall be sufficient to define all features of the site, and shall include spot levels. The pre-reclamation survey shall extend over the area to be reclaimed plus 50m and far enough to overlap with any offshore dredging surveys. Particular care shall be taken with the overlap between surveys and any anomalies arising there from shall be resolved to the satisfaction of the Engineer. (b) Initial Survey The initial survey for deposition of fill material shall be taken as being the prereclamation survey or the final survey for areas that have been dredged. (c) Interim Surveys The Contractor shall carry out interim surveys as necessary during the currency of the Contract in order to measure individually elements of the Works. The interim surveys shall adequately cover the particular areas of interest and shall be notified to the Engineer at least 7 days prior to the survey. The interim surveys shall be carried out using hydrographic and land survey techniques as appropriate. (d) Post-Reclamation Survey The post-reclamation survey shall be carried out to confirm that the reclamation final surfaces have been achieved and for measurement and payment purposes.
The post-reclamation survey shall cover the same areas as the pre-reclamation survey. The post-reclamation survey shall be carried out within the 28 days prior to the completion of the Contract or immediately after completing the placement of fill. Should any part of the area required to be reclaimed be found to be outside the tolerances specified, the Contractor shall increase such areas to the specified levels and the areas shall be re-surveyed all at Contractor's own expense. Survey base lines shall be as for the pre-reclamation survey. e) Final Surveys The final survey for the reclamation works shall be carried out within 28 days of completion of all dredging and reclamation works. The final survey shall comprise a land survey of the Site and a hydrographic survey of all below water filled areas, and a hydrographic survey of the entire dredged area as detailed in the Specification. Survey base lines shall be as for the pre-reclamation survey. Sectional surveys of below water filling shall extend 50 m beyond the nominal extent of filling. The Contractor shall ensure that the two surveys overlap. At the end of the Contract a composite survey plan showing the results of all surveys except where over-surveyed, shall be provided to the Engineer by the Contractor. Survey plans shall be plotted, to approved scales agreed with the Engineer (however in no case shall they be greater than 1:500) and related to the Project Grid The Engineer shall be provided with three prints and a digital copy (in a format compatible with AutoCAD 2007) as soon as possible after completion of the survey. Copies of surveys used for Contract purposes shall be signed by the Engineer and the Contractor when agreed. 4.5.2 General Requirements for Filling All methods used for placing, grading, levelling and compaction of fill material shall be subject to the prior approval of the Engineer. The Contractor shall be fully responsible for carrying out the works in such a manner as to avoid instability of the fill material and of underlying strata, and to prevent excessive intermixing of seabed material with overlying fill material. 4.5.3 Ownership of Fill Material Fill material within the Site at the commencement of the Contract shall remain the property of the Employer except as stated below.
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Fill material which is required to be disposed of by the Contractor shall become the property of the Contractor when it is removed from the Site and shall be disposed of in tips provided by the Contractor, unless otherwise stated in the Contract. 4.5.4 Temporary Side Slopes Unless otherwise defined in the Contract, the Contractor shall design temporary side slopes such that a factor of safety against rotational or translational slip failure of at least 1.3 is maintained at all times. The Contractor shall submit his proposals for forming each side slope to the Engineer for approval. Should slips, slides or areas of large lateral displacements occur, the Contractor shall notify the Engineer immediately. The Contractor shall do everything necessary to rectify the defect and stabilize the ground to the satisfaction of the Engineer and shall bear all expenses, including replacing at his own expense any fill lost or rendered unsuitable as a consequence of the defect, providing any additional fill which would not have been necessary had the defect not occurred. This may include but not be limited to the reinstallation of Geotechnical Instrumentation, the reinstatement of ground improvement works such as prefabricated vertical drains or the execution of additional remedial works. 4.5.5 Temporary Works for Reclamation The design of Temporary Works associated with reclamation works, ground improvements, revetments and seawalls, including temporary slopes, stockpiles and drainage, shall be such that the risk of failure is not more than that which would be adopted if the Temporary Works were to be permanent. Allowance may be made in the design of the Temporary Works for the shorter design life and for the risk to persons and property and the surface water and groundwater conditions which are likely to occur during construction. 4.5.6 Commencement of Deposition of Fill Material The permission of the Engineer shall be obtained before deposition of Fill Material starts in any area. 4.5.7 Handling and Storage of Fill Material Fill Material shall not be handled or stored in a manner that will result in segregation, deterioration, erosion or instability of the material. Different types of Fill Material shall be kept separate from each other. Fill Material shall not be stockpiled on the foreshore or seabed within the Site unless permitted by the Engineer. The Contractor may store fill material outside the reclamation for transporting to the reclamation area provided he can satisfy the Engineer that the additional handling will not result in increased siltation of existing navigable water or result in significant turbidity problems. Fill material shall not be handled or stored in a manner which will result in contamination, segregation, deterioration, erosion or instability of the material.
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4.5.8
Protection from Water and Weather Earthworks after site clearance, excavation or filling and earthworks material after excavation shall be kept free from water and shall be protected from damage due to water and from exposure to weather conditions which may affect the earthworks or earthworks material. Surfaces shall be maintained in a stable condition and shall be formed to falls to shed water and to prevent deposition of silt and clay as a result of ponding. Water levels in excavations for structures, pits and trenches shall be lowered and maintained by appropriate measures sufficiently to enable Permanent Works to be constructed.
4.5.9
Fill Material allowed to become unsuitable or to deteriorate Fill Material which has been used or is required for use in the permanent work and which is allowed to become unsuitable such that in the opinion of the Engineer it no longer complies with the specified requirements for that type of material shall be replaced or dealt with by methods agreed by the Engineer at the Contractors own cost. The material to be replaced shall be disposed of by the Contractor at his own cost.
4.5.10
Removal of Fill Material for Reclamation Works Fill material which is required for use in the Permanent Works as fill material for reclamation works shall not be removed from the Site unless permitted by the Engineer. The Contractor shall notify the Engineer before any fill material is removed from the Site.
4.5.11
Surplus Material Surplus suitable material remaining on the site at the end of Contract Period which is not required for use in the Works shall be stockpiled at or adjacent to the Site as directed by the Engineer.
4.6
4.6.1
DEPOSITION OF FILL MATERIAL BELOW SEA LEVEL

Site Clearance Prior to the start of filling operations in any area, the area in which filling is to take place shall be cleared of any rubbish, flotsam, seaweed, and other vegetation. Materials arising from this site clearance shall not be burnt or covered up in any part of the works under any circumstance. All materials arising from this clearance shall be removed from the site and disposed of by the Contractor in a manner approved by the Engineer.
4.6.2
Deposition of Fill Material The permission of the Engineer shall be obtained before deposition of fill material starts in any area.
Fill material shall be deposited in a manner and sequence such that minimum disturbance of the underlying material will be induced and such that slopes are stable at all times. The methods and Constructional Plant used for deposition of Fill Material under water shall be such that segregation of the material does not result. Fill Material shall not be deposited by end-tipping unless permitted by the Engineer. Fill material for blanketing layers and drainage layers shall be deposited uniformly by a method agreed by the Engineer. If necessary silt curtains shall be provided before filling activities commence to minimize the impact of the deposition of Fill Material on the surrounding environment. 4.6.3 Deposition of Fill Material in Dredged Trenches The first layer of Fill Material in dredged trenches for seawalls, revetments and breakwaters shall be deposited as soon as practicable after the Dredged Profile has been agreed by the Engineer. The dredged trench shall be free from silt and debris before deposition of fill material starts. Subsequent layers of Fill Material shall be deposited as soon as practicable after the profile of the underlying layer of fill material has been agreed by the Engineer. 4.6.4 Deposition of Rock Fill Material Adjacent to Structures and Utilities Rock fill material deposited adjacent to or above structures, piles or pedestals shall be hand packed or placed by a method approved by the Engineer. Rock fill material deposited around utilities, including pipes for submarine outfalls, shall be hand packed or placed by a method approved by the Engineer and shall be brought up to the specified level equally on both sides. Rock fill material deposited directly on geotextile shall be deposited in such a manner that complies with the geotextile manufacturers instructions and that, in particular, the geotextile is not ruptured and its performance is not otherwise impaired. 4.6.5 Reclamation Method Fill Material for Reclamation may be deposited by either hydraulic filling techniques, or "dry" techniques such as conveyor transport. The techniques and rates of filling adopted by the Contractor shall comply with the Specification and construction programme requirements. Fill material for reclamation shall be deposited in a manner which avoids disturbance of the underlying in-situ soils. Unless otherwise stated in the Contract, the Contractor shall take all necessary measures to ensure that fill material is placed in such a way as to maximise the in-situ density within the constraints above.
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4.6.6
Siltation and Turbidity The Contractor shall provide such silt traps, settling ponds, drains and sluices and other temporary works, including temporary access roads and bridges, as may be necessary for the proper execution of the work and in fulfilment of his obligations under the Contract. The sequence of filling in any area shall be such as to ensure that a build up of fine material does not take place in any area of the Site and shall ensure that it is not drained back into the sea with excessive siltation and turbidity unacceptable to the Engineer.
4.6.7
Formation of Mudwaves If, during the placement of fill material, deep rotational or translational slip failures, mudwaves or large lateral displacements occur, the Contractor shall notify the Engineer immediately. The Contractor shall rectify the defect and stabilize the ground to the satisfaction of the Engineer and shall bear all costs, including replacing at his own expense any fill lost or rendered unsuitable as a consequence of the defect or providing any additional fill which would not have been necessary had the defect not occurred. No claim shall be allowed for rectification of slips and displacements and the Contract Price and the Contract Completion Time are deemed to provide for all costs, expenses and delays which may be incurred.
4.6.8
Erosion When placing the Fill Material, care shall be taken not to erode or wash out the insitu soil or previously deposited Fill Material. Should such erosion occur the cost of replacing the eroded material and repairing any consequential damage shall be borne entirely by the Contractor. The Contractor shall assess and allow, while in a temporary state, for the risk of erosion of fill materials, geotextiles and rock materials, to his placed materials before the completion of the permanent works.
4.6.9
Adjoining Property, Bunds and Drains The Contractor shall ensure that all adjacent properties are not adversely affected by the Reclamation works. Methods such as the construction of bunds and the installation of drains shall be adopted and care shall be taken to avoid flooding to adjoining property and to ensure that no materials are deposited thereon as a result of the Works.
4.7
4.7.1
DEPOSITION OF FILL MATERIAL ABOVE SEA LEVEL

Surface Preparation for Fill Material Unless otherwise stated in the Contract, the deposition and compaction of Fill Material above MHHW shall comply with Section 13, Earthworks, of this Specification.
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Surfaces on which Fill Material is to be deposited above sea level shall be prepared after site clearance in accordance with the following requirements: (a) (b) Topsoil and organic matter shall be removed, where necessary, Soft spots, boulders and other materials which in the opinion of the Engineer are unsuitable or unstable shall be removed. Watercourses shall be diverted as stated in the Contract. Benches shall be cut and sub-soil drainage systems installed as stated in the Contract. Voids shall be dealt with as stated in the Contract or instructed by the Engineer. Surfaces other than rock shall be scarified to a depth of 200 mm and compacted to the same standard as the fill material which is to be deposited.
(c) (d)
(e)
(f)
4.7.2
Haulage of Fill Haulage of fill material to an area of fill shall proceed only when the compaction plant operating at the area to be filled is sufficient to achieve the specified requirements for relative compaction of the fill material.
4.7.3
Deposition of Fill Material Fill Material obtained from excavations within the Site shall be deposited in its final location as soon as practicable after it has been excavated. Fill Material shall be deposited in layers of a thickness appropriate to the compaction method to be used. Unless otherwise permitted by the Engineer, layers of Fill Material shall be horizontal, except for any gradient required for drainage, and the thickness of each layer shall be uniform over the area to be filled. Except in excavations for structures, pits and trenches, if the difference in level between adjacent areas to be filled exceeds 1 m, the edge of the higher area shall be benched before fill material is placed against it. The construction of the Works shall be controlled in such a manner that any compaction of the fill material resulting from the passage of Constructional Plant or haulage vehicles is uniform. Fill material shall not be deposited by end-tipping, by pushing loose material down slope faces or by other methods which may result in segregation or inadequate compaction of the fill material.
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4.7.4
Overfilling In areas of fill formed of fill material other than rock fill material, and where reclamation works final surfaces are sloping at a gradient exceeding 1 vertical to 3 horizontal, slopes shall be formed by overfilling and cutting back after compaction. Over-filling shall extend beyond the earthworks final surface by a horizontal distance of 0.5 m or three times the thickness of the compacted layer, whichever is greater.
4.8
4.8.1
LEVELLING AND COMPACTION OF FILL MATERIAL

Levelling of Rock Fill Material placed Underwater for Foundations The top surface of rock fill material in foundations for structures or pipes shall be thoroughly tamped with a concrete block weighing at least 10 tonnes dropped through a height of at least 500 mm or by other methods agreed by the Engineer. The voids at the top of the foundation shall be filled with Rock Fill Material (Grade 75).
4.8.2
Levelling of Rock Fill Material for Sea Wall Construction Below Sea Level The top surface of rock fill material in foundations for structures below sea level shall be thoroughly tamped with a concrete block weighing at least 10 t dropped through a height of at least 300 mm or by other methods agreed by the Engineer. The voids at the top of the foundation shall be filled with Rock Fill Material (Grade 75).
4.8.3
Compaction of Fill Material Above Sea Level Fill Material in Areas of Fill shall be compacted in layers to a stable formation as soon as practicable after deposition and in a manner appropriate to the location and to the material to be compacted. Fill Material within the top 500 mm below the Formation Level shall be compacted to obtain a relative compaction of at least 98% of the maximum dry density and CBR of not less than 3% throughout. The appropriate standard compaction method shall be used in accordance with BS 1377 Part 4, depending on the gravel content of samples. Fill Material below the top 500 mm of Formation Level shall be compacted to obtain a relative compaction of at least 95% maximum dry density throughout unless otherwise stated in the Contract.
4.8.4
Moisture Content of Fill Material Above Sea Level Fill Material other than rock fill material shall be at optimum moisture material content during compaction. The tolerance on the optimum moisture content percentage shall be +1% -3%, provided that the Fill Material is still capable of being compacted in accordance with the specified requirements to form stable Areas of Fill. All necessary measures shall be taken to achieve and maintain the specified moisture content.
4.8.5
Compaction of Fill Materials Adjacent to Structures and Utilities Fill Material shall be compacted in such a manner that structures or utilities are not disturbed or damaged.
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Fill Material around water, sewage and drainage pipes which are constructed as part of the permanent work shall be compacted by hand-rammers or manually operated power equipment. Fill Material within 300 mm above the top of sewage and drainage pipes shall be compacted to obtain a relative compaction of at least 85 % of maximum dry density throughout. 4.8.6 Compaction of Rock Fill Material Above Sea Level Every layer of rock fill material shall be compacted by at least eight passes of a vibrating roller or by other equivalent compaction method approved by the Engineer. The Final Surface of rock fill material shall be compacted by at least two additional passes of a vibrating roller or by other equivalent compaction method approved by the Engineer. Vibratory rollers used for the compaction of rock fill material shall have a static load per 100 mm width of roll of at least 2 kN for layers with a compacted thickness not exceeding 500 mm and at least 4 kN for layers with a compacted thickness exceeding 500 mm.
4.9
4.9.1
COMPLETION OF RECLAMATION FINAL SURFACE

Completion of Reclamation Final Surface Reclamation Final Surfaces shall be completed to a stable condition as soon as practicable after excavation or after deposition and compaction of fill material has been completed. The subsequent Permanent Works or surface protection shall be carried out as soon as practicable after the Final Surface of the Reclamation has been completed. Reclamation Final Surfaces shall be completed to smooth alignments without abrupt irregularities unless otherwise stated in the Contract.
4.10
4.10.1
TOLERANCES: DEPOSITION OF FILL

Tolerances: Deposition of Fill Material below Sea Level The Final Surface of deposition and compaction of Fill Material, shall be within 150 mm of the specified surface when measured perpendicular to the specified Final Surface. There shall be no abrupt change in level or gradient of the finished surfaces unless explicitly stated in the Contract.
4.10.2
Tolerance: Deposition of Fill Material above Sea Level The Final Surface of deposition of Fill Material, after any compaction or consolidation treatment, shall be the specified reclamation level shown on the drawings within a level tolerance of minus 0mm and plus 100mm.
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4.11
4.11.1
TESTING: FILL MATERIAL GENERAL REQUIREMENTS

Fill Material A batch of Fill Material for Reclamation or Marine Structures is defined as any quantity of Fill Material which in the opinion of the Engineer has similar properties throughout.
4.11.2
Samples of Fill Material One sample of each type of fill material for Reclamation or Marine Structures shall be provided at the same time as particulars of the material are submitted to the Engineer. Unless otherwise agreed by the Engineer, during the currency of the Contract, one sample of each type of fill material for marine works shall be provided from each batch. The size of samples and the method of sampling shall be as stated in table 4.3. Samples of fill material to be tested for particle size distribution, liquid limit, plasticity index, coefficient of uniformity and sulphate content shall be delivered at least 14 days, or such shorter period agreed by the Engineer, before deposition of the fill material starts. The number of samples to be provided from each batch shall be as stated in table 4.3. When the Fill Material is delivered to the site, one sample shall be taken from each 5,000 m3 or part thereof of each batch of each type of Fill Material for Reclamation or Marine Structures works.
Description Special fill material Size of Batch 0 3000 m3 Exceeding 3000 m3 0 9000 m3 Exceeding 15000 m3 No. of samples per batch 3 1 for each 1000 m3 or part thereof 3 1 for each 3000 m3 or part thereof
Fill material other than special fill material
Table 4.3: Number of samples to be tested for particle size distribution, liquid limit, plasticity index, coefficient of uniformity, sulphate content, optimum moisture content and maximum dry density
4.11.3
Testing of Fill Material for Reclamation and Marine Structures Each sample of Fill Material taken as stated in Clause 4.11.2 shall be tested to determine the particle size distribution and calculation of the coefficient of uniformity. Unless otherwise agreed by the Engineer, each sample of fill material other than rock fill material shall be tested to determine the liquid limit and the plasticity index of that portion of the fill material passing a 425m BS test sieve. Each sample of fill material shall be tested to determine the total and soluble sulphate content. The method of testing shall be in accordance with BS 1377:1990.
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4.12
4.12.1
TESTING: FILL MATERIAL PSD, ATTERBERG LIMITS, COEFFICIENT OF UNIFORMITY AND SULPHATE CONTENT
Samples: PSDs, Atterberg Limits, Coefficient of Uniformity, Sulphate Content Samples of fill material for determination of particle size distribution, liquid limit, plasticity index, coefficient of uniformity and sulphate content shall be tested by the Contractor and the results shall be forwarded to the Engineer at least 14 days before deposition of the fill material starts or such shorter period agreed by the Engineer. The number of samples to be provided from each batch shall be as stated in table 4.3. Additional samples required by the Engineer for testing shall be delivered to the Engineer at least 14 days before deposition of that fill material starts.
4.12.2
Testing: PSDs, Atterberg Limits, Coefficient of Uniformity, Sulphate Content Each sample of fill material taken shall be tested to determine the particle size distribution, coefficient of uniformity and sulphate content. Unless otherwise agreed by the Engineer, each sample of Fill Material other than rock fill material shall be tested to determine the liquid limit and the plasticity index of that portion of the fill material passing a 425 m BS test sieve. Each sample of Fill Material shall be tested to determine the total and soluble sulphate content. The method of testing shall be in accordance with the following BS 1377: 1990
4.12.3
Non-compliance: PSDs, Atterberg Limits, Coefficient of Uniformity, Sulphate Content If the result of any test for particle size distribution, plasticity index or coefficient of uniformity of fill material for Reclamation or Marine Structures does not comply with the specified requirements for the property, two additional samples shall be provided from the same batch and additional tests for the property shall be carried out. The batch shall be considered as not complying with the specified requirements for the property if the result of any additional test does not comply with such requirements. If the result of any test for soluble sulphate content of fill material does not comply with the specified requirements for soluble sulphate content, each sample shall be tested to determine the total sulphate content. The batch shall be considered as not complying with the specified requirements for the property if the result of any additional test does not comply with such requirements.
4.13
4.13.1
TESTING : FILL MATERIAL - OPTIMUM MOISTURE CONTENT AND MAXIMUM DRY DENSITY
Samples: Optimum Moisture Content, Maximum Dry Density Samples of Fill Material to be tested for optimum moisture content and maximum dry density shall be tested by the Contractor and the results shall be forwarded to the Engineer at least 14 days before deposition of the fill material starts, or such shorter period agreed by the Engineer. The number of samples to be provided from each batch
shall be as stated in Table 4.3. Additional samples required by the Engineer for testing in the Engineer's laboratory shall be delivered to the Engineer's laboratory at least 14 days before deposition of that fill material starts. The Contractor shall inform the Engineer of the exact location in which the fill material from which each sample is taken is to be deposited. Samples to be tested for optimum moisture content and maximum dry density shall also be taken after the fill material has been deposited in its final position, at intervals of not more than 28 days. Samples shall not be provided from rock fill material which contains an insufficient proportion of particles passing a 20mm BS test sieve to permit determination of the moisture content and maximum dry density. 4.13.2 Testing: Optimum Moisture Content, Maximum Dry Density Each sample of fill material taken as stated in the Specification shall be tested to determine the optimum moisture content and the maximum dry density. The method of testing shall be in accordance with BS 1377:1990. 4.13.3 Consistency: Optimum Moisture Content, Maximum Dry Density If the result of any test for optimum moisture content or maximum dry density of fill material indicates that the batch contains material which in the opinion of the Engineer differs to such an extent that subsequent tests for relative compaction may be affected, the batch shall be divided into smaller batches; each of the smaller batches shall comprise material with similar properties throughout. Additional samples shall be provided from each of the smaller batches and additional tests for optimum moisture content and maximum dry density shall be carried out. The number of additional samples from each new batch to be tested shall be as stated in Table 4 3.
4.14
4.14.1
TESTING: FILL MATERIAL MOISTURE CONTENT

Samples: Moisture Content Samples of Fill Material to be tested for moisture content shall be taken during deposition and compaction of fill material and shall be tested by the Contractor. The results shall be forwarded to the Engineer not more than 24 hour after the fill material has been deposited in its final position, or such shorter period agreed by the Engineer. Additional samples required by the Engineer for testing shall be delivered to the Engineer not more than 3 hours after the fill material has been deposited in its final position. The number of samples to be provided from each batch shall be as stated in the Contract.
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4.14.2
Testing: Moisture Content Each sample of Fill Material taken as stated in the Specification shall be tested to determine the moisture content. The method of testing shall be in accordance with BS 1377:1990, Method 1 or Method 2. Method 1 shall be used unless otherwise agreed by the Engineer.
4.14.3
Compliance Criteria: Moisture Content If in the opinion of the Engineer there is any undue discrepancy between the results of tests for moisture content of fill material using Method 1 and the results of tests using Method 2, the results of tests using Method 1 shall prevail.
4.14.4
Non-Compliance: Moisture Content If the result of any test for moisture content of fill material differs from the optimum moisture content by more than the specified amount and if instructed by the Engineer, the moisture content of the whole of the batch of fill material shall be adjusted. Additional samples shall be provided from the same batch and additional tests for moisture content shall be carried out. The number of additional samples shall be as stated in Table 4.4.
Description Areas of fill in excavations for structures, pits and trenches and on formations Size of area of fill in batch 0 100 m2 100 500 m2 Exceeding 500 m Other areas of fill 0 -1 ha 1 10 ha Exceeding 10 ha Table 4.4:
2
No. of samples/No. of tests per batch 3 2 for each 100 m2 or part thereof 1 for each 100 m2 or part thereof 4 for each 1000 m2 or part thereof 3 for each 1000 m2 or part thereof 2 for each 1000 m2 or part thereof
Number of samples to be tested for moisture content and number of tests for relative compaction
4.15
4.15.1
TESTING: FILL MATERIAL RELATIVE COMPACTION

Testing: Relative Compaction Unless otherwise agreed by the Engineer, each batch of fill material shall be tested to determine the relative compaction. Tests shall be carried out after the fill material has been deposited and compacted in its final position. The number of tests on each batch shall be as stated in Table 4.4.
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Tests shall not be carried out on rock fill material which contains an insufficient proportion of particles passing a 20 mm BS test sieve to permit determination of the relative compaction. Tests shall be carried out at positions which in the opinion of the Engineer are representative of the batch of compacted fill material as a whole. All tests shall be carried out by the Contractor in the presence of the Engineer. The in-situ bulk density and the in-situ dry density of fill material shall be determined in accordance with BS 1377:1990 Method 1 or Method 2. Method 1 shall be used unless otherwise permitted by the Engineer. 4.15.2 Compliance Criteria: Relative Compaction If in the opinion of the Engineer there is any undue discrepancy between relative compaction, the results of tests for relative compaction of fill material using Method 1 and the results of tests using Method 2, the results of tests using Method 1 shall prevail. 4.15.3 Non-compliance: Relative Compaction If the result of any test for relative compaction of fill material does not comply with the specified requirements for relative compaction, additional tests for relative compaction shall be carried out on the same batch. The number of additional tests shall be as stated in Table 4.4. 4.15.4 CBR testing CBR testing shall include laboratory testing of soil samples in accordance with BS 1377 Part 4 and in-situ CVR testing in accordance with BS 1377 Part 9. The frequency of both tests shall be the same as stated in Table 4.4 for soil sampling. Additional tests may be scheduled by the Engineer as appropriate.
4.16
TESTING : RELATIVE DENSITY, WATER ABSORPTION, AGGREGATE IMPACT VALUE, TEN PERCENT FINES VALUE, AGGREGATE ABRASION VALUE, SOUNDNESS AND RESISTANCE TO FRACTURE OF ROCK FILL MATERIAL
Batch: Rock for Rock Fill A batch of rock fill is any quantity of rock of the same type and which in the opinion of the Engineer has similar properties throughout.
4.16.1
4.16.2
Samples: Rock for rock armour One sample of each proposed type of rock fill shall be provided at the same time as particulars of the material are submitted to the Engineer. If instructed by the Engineer, a representative sample of each type of rock fill material, broken down into appropriate sizes, shall be provided for testing.
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4.16.3
Testing: Rock for Rock Fill Each sample of rock for rock fill taken shall be tested to determine the specific gravity, water absorption, aggregate impact value, ten percent fines value, aggregate abrasion value and soundness.
The method of testing shall be in accordance with the following: Relative density Water absorption Aggregate impact value Ten percent fines value Aggregate abrasion value Soundness 4.16.4 Samples: Rock for Rock Fill One sample piece of each type of rock fill of the specified minimum size and one piece of the specified maximum size shall be provided near the deposition location for checking the sizes of material at all times during the deposition of rock armour. The sample pieces of the specified minimum and maximum sizes shall be mounted on individual plinths at locations agreed by the Engineer. The design and details of the plinths shall be prepared by the Contractor and agreed by the Engineer. When the material is delivered to the site, one bulk sample of rock fill consisting of not less than 100 pieces of randomly selected rock shall be taken from each 5,000 m3 or part thereof each batch. 4.16.5 Non-compliance: Rock for Rock Fill If the result of any test for specific gravity, water absorption, aggregate impact value, ten percent fines value, aggregate abrasion value or soundness of rock for rock armour does not comply with the specified requirements for the property, two additional samples shall be provided from the same batch and additional tests for the property shall be carried out. The batch shall be considered as not complying with specified requirements for the property if the result of any additional test does not comply with such requirements. 4.16.6 Non-compliance: Weighing test If the bulk sample does not comply with the Specification, 2 additional bulk samples shall be provided from the same batch and additional weighing tests shall be carried out. The batch shall be considered as not complying with the Specification if the result of any additional test does not comply with such requirements. : : : : : : BS 812:Part 2 BS 812:Part 2 BS 812:Part 112 BS 812:Part 111 BS 812:Part 113 BS 6349:Part 1, Appendix B
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4.17
4.17.1
TESTING: GRANULAR FILTER MATERIAL

Testing: Granular Filter Material A batch of granular filter material is any quantity of granular filter material of the same type and grading delivered to the Site at any one time.
4.17.2
Sampling: Granular filter material (a) One sample of granular filter material shall be provided from each 500 m3 or part thereof of the material delivered to the Site. Unless otherwise permitted by the Engineer, one sample of granular material shall be provided from each 500 m3 or part thereof of granular filter material that has been deposited and compacted. The size of each sample of granular filter material shall be 10 kg. The method of sampling shall be in accordance with BS 812: Part 102. Samples of granular filter material shall consist of material excavated from the compacted layer to form a flat bottomed, steep sided hole of approximately 0.13 m2 to the complete depth of the compacted layer. A template shall be used to fix the edges of the hole if necessary. The sides and bottom of the hole shall be at least 50 mm from other types of fill material.
(b)
(c)
(d)
4.17.3
Testing: Granular filter material Each sample of granular filter material shall be tested to determine the particle size distribution. The method of testing shall be in accordance with the wet sieving method stated in BS 1377:1990.
4.17.4
Non-compliance: granular filter material If the result of any test for particle size distribution on a sample of granular filter material taken does not comply with the specified requirements for particle size distribution, additional samples shall be provided from the same batch and additional tests for particle size distribution shall be carried out. The batch shall be considered as not complying with the specified requirements for particle size distribution if the result of any additional test for particle size distribution does not comply with the specified requirements for particle size distribution. If the result of any test for particle size distribution on a sample of granular filter material taken does not comply with the specified requirements for particle size distribution, additional samples shall be provided from the same batch and additional tests for particle size distribution shall be carried out.
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The batch shall be considered as not complying with the specified requirements for particle size distribution if the result of any additional test for particle size distribution does not comply with the specified requirements for particle size distribution.
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5 5.1
5.1.1
GROUND IMPROVEMENT GROUND IMPROVEMENT PARTICULAR REQUIREMENTS

Particular Requirements This section of the ground improvement specification contains particular requirements for the ground improvement works to be undertaken under the Contract. The particular requirements take precedence over the general ground improvement specification contained under the reclamation specification Clause 5.2 onwards.
5.1.2
Description of the Ground Improvement Works The ground improvement works to be undertaken comprise the following: a. Pre-loading of the soil foundation accelerated by the use of band drains. Pre-loading with band drains shall be carried out in accordance with the drawings and the instructions of the Engineer. b. Ground improvement using vibrated stone columns. Ground improvement using vibrated stone columns shall be used to satisfy both: To control settlements within the zones where installation of band drains and pre-loading surcharge is not practical; Soil strength and liquefaction criteria within the zones of interaction of the quay structures (the quay wall, the anchor wall and the rear crane beam piles) where this is necessary, the effective equivalent internal friction angle of material stabilised using vibrated stone columns shall be not less than 32 peak value and 30 critical value. The factor of safety of this material against liquefaction shall be not less than 1.25 under the Level 1 seismic event and not less than 1.0 under the Level 2 seismic event. The Peak Ground Acceleration for the Level 2 seismic event shall be in accordance with UBC 1997, for Zone 2B. The PGA for the Level 1 seismic event shall be taken as 50% of the PGA for the Level 2 seismic event.
5.1.3
Assessment of Liquefiable Soils In defining whether granular soils are liquefiable or not the Contractor shall use the Seeds Method (as referenced below) to determine the required CRR value to prevent liquefaction for the Contractors particular reclamation material grading and ground improvement design. Note that the use of standard penetration tests (SPT) shall not be permitted in coarse granular materials (gravel or coarser material comprising more than 20% by weight of the overall fill material) and the following techniques should be permitted: For gravels with the mean grain size (D50) less than 10mm and with no inclusions greater in size than what can be classified as gravel in the BS 5930 terminology, SPT technique may be used but the liquefaction assessment shall be carried out
taking into consideration the grain composition of the soil. The correction of SPT data for the grain size of soil shall be carried out using an internationally recognised technique that shall be subject to the Engineers approval prior to mobilisation; For gravels with the mean grain size (D50) greater than 10mm but with less than 10% inclusions greater in size than what can be classified as gravel in the BS 5930 terminology, Large Penetration Test (LPT) shall be used (see for example Kaito, et al). The liquefaction assessment shall be carried out based on the LPT data and taking into consideration the grain composition of the soil. The liquefaction assessment based on the LPT data and correction of the test data for the grain size of soil shall be carried out using an internationally recognised technique that shall be subject to the Engineers approval prior to mobilisation; For materials with more than 10% inclusions with grain size coarser than gravels Becker penetration tests (BPT) shall be used instead. The exact specification for the use, calibration and interpretation of BPT shall be provided by the Contractor at the Tender Stage and will be subject to the Engineers approval. The calibration of BPT shall be carried out in situ against the values of relative density measured in undisturbed fill cores extracted in frozen conditions.
The factor of safety against liquefaction shall not be less than 1.25 under the Level 1 seismic event and not less than 1.0 under the Level 2 seismic event. The Peak Ground Acceleration for the Level 2 seismic event shall be in accordance with UBC 1997, for Zone 2B. The PGA for the Level 1 seismic event shall be taken as 50% of the PGA for the Level 2 seismic event. Reference to the relevant methods:Kaito. T, et al (1971), Large penetration test, Tsuchi-to-Kiso, 629, pp 15-21, Japan. Youd, T.L., et al (2001), "Liquefaction resistance of soils: summary report from the 1996 NCEER and 1998 NCEER/NSF workshops on evaluation of liquefaction resistance of soils", Journal of Geotechnical and Geoenvironmental Engineering, ASCE, Vol. 127 No.4, April 2001, pp.297-313.
5.2
5.2.1
GENERAL
Definitions Commencing Surface Is the level at which the ground improvement equipment first enters the ground. This is the same as the working platform level. The Final Surface of any work is the surface defined by the lines and levels shown on the Drawings to which all of the Works carried out under the Contract are to be finished. Pre-loading Surcharge is the Fill Material placed to the lines and levels shown on the Drawings, compacted in accordance with the Specification and then removed before the completion of the Contract. The level of pre-loading surcharge may change during the
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works and therefore the surcharge shall be compacted so that the base of it can be accommodated into the final work. The Drainage Layer shall be installed to ensure rapid removal and discharge at the agreed points of all water discharging from the prefabricated drains. Surcharge Period is the period of time, commencing on the date on which the surcharge is completed to the lines and levels shown on the Drawings and ending on the date on which the removal of surcharge can commence. The surcharge period may have to be changed in the course of the works based on the monitoring results. The surcharge period stated on the Drawings represents the minimum period required under the Contract, subject to the assessment of the projected medium to long-term settlements being within the Contract requirements set out in this Specification. Plate bearing tests are loading tests carried out using a plate on the prepared top of individual stone columns. These tests represent a measure of quality of installation of the stone columns at the commencement surface. Zone tests are loading tests carried out with a slab, intended to test bearing pressure over a wider and deeper zone than in the plate tests. These tests represent a measure of quality of ground improvement at the commencement surface. Geotechnical Instrumentation is the installation and monitoring of instruments in the ground or structures to provide information on soil and rock parameters for the purposes of construction control and performance monitoring. 5.2.2 Sequence of Ground Improvement Works The Contractor shall programme his working methods and rate of operations to comply with the required work sequence.
5.3
5.3.1
MATERIALS
Band Drains (i) Samples of the proposed prefabricated vertical drains shall be submitted to the Engineer for approval of the source and type of each material at the same time as particulars of the drains are submitted. Prefabricated vertical drains shall consist of a core and a filter. The filter shall be wrapped around the core, overlapped and sealed to contain the core. The drains shall be made from polyethylene, polypropylene, polyolefin or other synthetic material or combination of such materials. Prefabricated vertical drains shall be flexible, capable of being wound without damage on a drum of 300 mm diameter, and strong enough so as not to break, tear or lose their drainage properties during handling and installation. Prefabricated vertical drains shall be able to conform to soil deformation without buckling or crimping of the core or losing continuity, and shall maintain its properties throughout the required period of consolidation.
(ii)
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The prefabricated vertical drain shall have a discharge capacity of at least 250m3/yr when subjected to a lateral pressure of 300kN/m2 and folding by 20% vertical compression. The filter jacket for prefabricated vertical drains shall be constructed from a non woven spin bonded fabric, and shall be a type which: a) b) c) has been previously proved effective under similar soil and pressure conditions; is in all cases able to prevent excessive migration of soil particles into the core; and has a permeability not less than that of the surrounding soil.
Prefabricated vertical drains shall be provided with an outer casing or mandrel of rhomboidal or rectangular cross section for use during installation. The mandrel shall be the minimum cross sectional area necessary to allow drain installation and prevent disturbance of the sub-strata as the mandrel is driven. The prefabricated vertical drains shall also be provided with anchor shoes to ensure embedment of the drain during extraction of the mandrel. The anchor shoes shall be the minimum dimensions necessary to anchor the drain in place at the required depth as the mandrel is withdrawn, and to prevent disturbance of the sub-strata as the mandrel is driven. The Prefabricated Vertical Drains shall be of approved BS standard and shall be approved by the Engineer. (iii) The delivery storage and handling of prefabricated vertical drains shall be in accordance with the manufacturers instructions. Prefabricated vertical drains shall be supplied in rolls, securely packed in light-proof wrappings. Prefabricated vertical drains shall be stored in a clean, dry environment and protected from harmful substances. (iv) The delivery storage and handling of prefabricated vertical drains shall be in accordance with the manufacturers instructions.
5.3.2
Drainage Layer The drainage layer and collector pipe-work shall be installed in accordance with the Drawings. Unless agreed otherwise by the Engineer prior to commencement of works the granular filter shall be constructed to the specification for Granular Filter (Type 1) as set out in the Reclamation section of this Specification. The Contractor shall ensure the adequate performance of the drainage layer through the water discharge monitoring and through the piezometer readings and shall provide remedial works in case of any loss of performance, which shall be done at no additional cost to the Client.
5.3.3
Surcharge The fill material used for constructing the surcharge embankment shall comply with the specification requirements to the fill placed in the formation layer for the pavements, as set out in this Specification.
5.3.4
Stone for Constructing Vibrated Stone Columns The material used to form the columns shall be clean, hard, inert material and shall be natural gravel, crushed rock other than argillaceous rocks, crushed hardcore, crushed concrete, crushed slag or well burnt non-plastic shale. The stones should be angular, hard and resistant to breakage. The material properties for material used for construction of stone columns shall be compliant with the requirements of this Specification to rock material used for construction of revetments. The material shall be nominally single sized coarse aggregate with a value of upper sieve size in the range 10 mm to 40 mm. The material passing the 0.425 mm sieve shall be non-plastic when tested in accordance with BS1377 : Part 2. The crushing value of the stone shall not be more than 30% and Impact Value not more than 25%.
5.4
5.4.1
SUBMISSIONS
Pre-loading Accelerated by the use of Band Drains The following particulars of the proposed materials and methods of construction for prefabricated vertical drains shall be submitted to the Engineer for approval at least 28 days before installation of prefabricated band drains commences: a) b) c) d) e) details of type of drain, including manufacturer's literature; a certificate showing the manufacturer's name, the date and place of manufacture and showing that the drains comply with the requirements stated in the Contract; details of previous installations by the Contractor using similar drains; method of installation, and details of installation mandrel, drain anchor, method of penetration and method of recording depth of installation.
The following particulars of the proposed materials and methods of construction of the surcharge shall be submitted to the Engineer for approval at least 56 days before the commencement of the surcharge construction: a) details of the materials proposed by the Contractor for use as surcharge;
b) c) d) e)
details of the method of placement and compaction of the surcharge; details of the sequence and programme to which the surcharge is to be placed and removed; details of any containment bunds or other temporary structures constructed to contain the surcharge; details of any calculations carried out by the Contractor to ensure that the side slopes and height of the surcharge are such that a factor of safety against rotational failure within the reclamation of at least 1.3 is maintained at all stages of the surcharge construction.
The following particulars of the proposed geotechnical instrumentation shall be submitted to the Engineer for approval at least 28 days before installation of instrumentation starts: a) b) c) d) e) f) g) h) i) j) 5.4.2 details of instruments and any alternative instruments proposed by the Contractor; manufacturer's specifications; test and calibration certificates; method of installation, with the differences between the method of installation and the Specification fully described in writing; method of acceptance testing; details of ancillary measuring equipment; schedule for installing instrumentation in relation to other work; documents showing that the instruments are capable of measuring within the ranges and accuracies stated in the Contract; name and experience of persons responsible for installation, testing and monitoring of instruments; details of the form of records.
Vibrated Stone Columns The following particulars of the proposed materials and methods of construction for vibrated stone columns shall be submitted to the Engineer at least 28 days prior to mobilisation: a) b) c) all details, source of supply and preliminary acceptance test results for the stone to be used in construction; all details of machinery and equipment intended for installation; mechanical arrangement for placing stone(s) around the probe point;
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d) e) f) g) h) i)
manpower to be engaged; Quality control, Quality Assurance Procedures covering details on automatic recording devices to monitor and record stone consumption; construction schedule in the form of a Gantt chart; details of previous installations by the Contractor using similar machinery and equipment; method of installation, and geometry of the proposed installation and supplementary justification of the design.
No mobilisation of materials, equipment and machinery for installation of vibrated stone columns shall be permitted until a written approval by the Engineer of the proposed methods and materials is issued, and no changes to the above details shall be permitted without a prior written approval of the Engineer.
5.5
5.5.1
GENERAL REQUIREMENTS FOR PRE-LOADING ACCELERATED BY THE USE OF BAND DRAINS

Design The works shall be carried out in accordance with the Drawings.
5.5.2
Pre-installation Survey Prior to commencement of works the Contractor shall carry out a pre-installation CPT survey and mapping of the depth of the compressible deposit. The pre-installation survey shall be carried out by a specialist sub-contractor who shall be subject to an approval by the Engineer. The name of the specialist sub-contractor and their method statement shall be submitted with the Tender. The survey shall be carried out to the maximum possible depth and appropriate CPT equipment shall be selected for these works capable of penetrating the reclamation fill placed by the contractor and then the maximum thickness of soft clays present. The Engineer shall adjust and confirm the Drawings as necessary on the basis of the pre-installation survey.
5.5.3
Installation of the Band Drains The installed location of prefabricated vertical drains shall be within 100 mm of the specified location in plan on the ground surface as indicated on the Contractors drawings and the drain shall be within 2% of the installed length to the vertical. Where it is necessary to join two sections of prefabricated vertical drains, the manufacturers instructions for joining two sections of drain shall be complied with to
ensure that the filter and discharge capacity are not impaired. The minimum joint length shall be 300 mm. The depth of penetration of prefabricated vertical drains shall be as stated in this Particular Specification. The Contractor shall notify the Engineer immediately of any sudden change in the penetration resistance to the mandrel. The installation rig shall comprise a suitably adapted crane base including leader mast and steel mandrel fitted with a top drive vibrator. The rig shall be capable of placing drains at the required depth in the anticipated ground conditions. The drain shall be fitted to the rig on a drum of 300 mm minimum diameter, and the end shall be wrapped around the lugs of an anchor shoes after passing down through the steel mandrel. The mandrel (and drain) shall be advanced using the crane operated rope pull down. Where ground conditions are such that the mandrel cannot be advanced using the crane operated rope then the mandrel may be vibrated using the top drive vibrator with the approval of the Engineer. When the drain reaches the required depth, the mandrel shall be withdrawn and the anchor shoes retained at the bottom of the hole, leaving the drain in place. The drain shall be cut off not less than 150 mm above the existing fill level once the installation is complete. On completion of each installation the depth of drain penetration and length of drain shall be recorded. During installation the Contractor shall ensure that disturbance of the sub-strata is kept to a minimum.
5.5.4
Obstructions Where an obstruction is encountered prior to reaching the anticipated depth the Engineer shall be informed immediately, The Contractor shall also submit a proposal of remedial actions in order to satisfy the overall settlement performance of the preconsolidated area.
5.5.5
Records of Prefabricated Vertical Drains The Contractor shall prepare daily records for each prefabricated vertical drain installation, which shall be submitted to the Engineer within 2 days following installation. The daily records shall contain the following information where relevant: a) b) c) d) Contract title Contractor's name Plant in use Date
e) f) g) h) i)
Grid and area reference of each drain Depth of placement of each drain Length of drain used Obstructions encountered and delays Any unforeseen conditions encountered
5.5.6
Drainage Layer The drainage layer shall be installed in accordance with the Specification requirements for filters. The Contractor shall ensure in his Method Statement that no contamination of the drainage layer may occur during the installation and that the drainage layer is fully protected from siltation during the works
5.5.7
Surcharge Embankment Surcharge embankment geometry shall be in accordance with Drawings to a maximum tolerance of +500 mm to -0 mm. If necessary, material shall be added to the surcharge during its construction to ensure that the surcharge is always within the tolerance or to adjust the rate of consolidation if necessary, based on the survey data. Surfaces of the surcharge embankment shall be maintained in a stable condition at all times and shall be formed to falls to shed water and to prevent ponding. The Contractor shall ensure that temporary side slopes of the embankment have a factor of safety against rotational or translational slip failure of at least 1.3, which shall be maintained at all times. The Contractor shall submit his proposals for forming each side slope to the Engineer for approval. The Contractor shall be permitted to use ground stabilisation below and immediately adjacent to the temporary slopes in order to improve the slope stability. Ground improvement using stone columns shall be permitted for these purposes, or another technique approved by the Engineer prior to mobilisation to the site. The cost of such ground improvement works along the edge of the surcharge area shall be included into the overall tender cost of the ground improvement works using pre-loading. Should slips, slides or areas of large lateral displacements occur, the Contractor shall notify the Engineer immediately. The Contractor shall do everything necessary to rectify the defect and stabilize the ground to the satisfaction of the Engineer and shall bear all expenses, including replacing at his own expense any fill lost or rendered unsuitable as a consequence of the defect, providing any additional fill which would not have been necessary had the defect not occurred, reinstalling any prefabricated vertical drains and instrumentation considered to have been affected by the ground movement and reshaping any surcharge embankments.
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When replacing or introducing new prefabricated drains in the areas of slips the Contractor shall provide in-situ investigation of the changes to the design soil parameters within and adjacent to the slip and redesign the vertical prefabricated drain pattern as necessary. All remedial works in case of a slip shall be carried out by the Contractor at no additional cost to the Client. If the Contractor elects, he may sub-divide the surcharge area shown on the Drawings into smaller surcharge areas which may then be surcharged in sequence. If the Contractor chooses to sub-divide the surcharge area, he shall provide details of the surcharging sequence to the Engineer for approval together with calculations to demonstrate that that the surcharge effect at every location is equivalent to the original design or better. The minimum surcharge area shall be no smaller than 100m by 100m. The full design height of the surcharge shall remain in place for the duration of the surcharge period. The performance of the surcharge shall be monitored by the Contractor to confirm the assumptions made in the design about the performance of the prefabricated vertical drains and the effect of the surcharge. The results of the monitoring may indicate that the Surcharge Period needs to be extended, the intensity of surcharge may need to be increased or other actions undertaken to achieve satisfaction of the medium to long-term performance criteria. The Contractor shall provide the monitoring results to the Engineer daily during construction and during the first two weeks of consolidation and weekly afterwards. The Engineer will then interpret the results and instruct the Contractor on the necessary steps to adjust the works. Failure of the Contractor to provide timely monitoring results, to protect the monitoring equipment against damage or vandalism or replace damaged equipment within 24 hours from the time when damage occurred shall make them responsible for any additional works necessary for compliance with the performance Specification if in the opinion of the Engineer a delay or default in interpreting the monitoring results is detrimental to the works. In the case if the Contractor has been fully compliant with the Specification requirements for construction and submitting of the monitoring data they will be eligible for an extension of time up to a period equivalent to the extension to the Surcharge Period. 5.5.8 Compaction Criteria for Surcharge The placement criteria for the surcharge shall be the same as for the fill placed in the formation under the pavement. The unit weight of fill material within the surcharge embankment shall be monitored at a rate of not less 1 test per 500m2 of each placed fill layer. Fill material deposited in the surcharge shall be compacted such that a bulk unit weight of at least 19kN/m3 is achieved, in addition to complying with the Specification requirements for compaction of fill placed above the sea level.
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Fill material placed in the bottom 1.5m of the surcharge shall be placed and compacted in accordance with the Specification requirements for the formation layer for the pavement. The standard compaction tests shall be carried out on the fill material intended for placement into the bottom 1m of the surcharge embankments at a rate of not less than 1 test per 1000m3 of fill.
5.6
5.6.1
GENERAL REQUIREMENTS FOR VIBRATED STONE COLUMNS

Design The works shall be designed and implemented by a specialist sub-contractor to comply with the performance requirements set out in this Specification. The name of the specialist sub-contractor and their method statement shall be submitted with the Tender.
5.6.2
Installation of the Vibrated Stone Columns The stone columns shall be installed by vibrofloat method/technology. Stone(s) shall be fed by mechanical means i.e. use of loader/hopper/chute etc. The slush, muck and other loose materials at work site shall be removed and disposed off suitably by the contractor at a location specified by the Contractor at the Tender stage and to the approval of the Engineer. Contractor shall take adequate measures to ensure stability of boreholes made for installation of stone columns subject to the approval of the Engineer.
5.6.3
Records of Vibrated Stone Columns During construction of each stone column, all details & parameters shall be recorded & maintained and should be available for inspection by the Engineer. The details for each vibrated stone column shall include but not be limited to the following: i) ii) iii) iv) v) vi) vii) viii) ix) Date Contract title Area identification Unique grid location Location, diameter and depth of stone column. Ground level at commencement Material used Stack measurement of stone(s) used in the works. Vibrator power consumption during operation
x) xi) xii) xiii) xiv) xv) xvi)
Jetting pressure (where applicable) Duration of penetration Duration of compaction Obstructions and delays Number and type of tests carried out Monitoring stone consumption vis--vis theoretical requirements. Information to include pressure gauge readings, depth versus time etc. Computation of average quantity of back fill materials consumed per linear metre of the column.
5.7
5.7.1
INSTRUMENTATION FOR PRE-LOADING ACCELERATED BY THE USE OF BAND DRAINS

Scope of Work
Geotechnical instrumentation is to be incorporated into the works in order to monitor the performance of the ground improvement works, in particular the performance of the prefabricated vertical drains and the surcharge. The performance of the geotechnical instrumentation is a critical element of the Works. If, in the opinion of the Engineer, any piece of instrumentation should cease to function properly for whatever reason, then the Contractor shall repair or replace that instrument immediately at his own cost. The following instruments shall be incorporated in the ground improvement works using pre-consolidation with band drains: Settlement plates shall be installed at the ground level before placement of the surcharge embankment. The settlement plates shall be installed on a square equispaced grid at a rate of not less than 1 plate per 2500m2. Piezometers shall be installed to the full depth of the compressible strata, and to be embedded into the underlying stiff, dense or hard soils by at least 5m. Piezometers shall be installed as close as possible to the centre point of the grid of vertical drains, i.e. the piezometers shall be equidistant and as remote as possible from all immediately adjacent drains. The measurement devices within the piezometers shall be positioned at 2.5m depth below the installation level and then at 5m depth intervals to the full monitored depth. The piezometers shall be installed on a square equispaced grid at a rate of not less than 1 piezometer per 10000m2. Magnetic extensometers shall be installed to the full depth of the compressible strata, and to be embedded into the underlying stiff, dense or hard soils by at least 5m. The measurement elements within the extensometers shall be positioned at 2.5m depth below the installation level and then at 5m depth intervals to the full monitored depth. The extensometers shall be installed on a
square equispaced grid at a rate of not less than 1 extensometer set per 10000m2. Inclinometer monitoring sleeves shall be installed to the full depth of the compressible strata, and to be embedded into the underlying stiff, dense or hard soils by at least 5m. They should cover the slopes of the surcharge embankments and shall be installed in pairs one at the toe of the embankment and one at half slope of the embankment, as approved by the Engineer prior to mobilisation. The inclinometer monitoring sleeves shall extend at least 5m below the estimated monitored depth, as approved by the Engineer prior to mobilisation. The inclinometer monitoring sleeves shall be installed on a square equispaced grid at a rate of not less than 1 pair of installations per 200m length of the slope of the embankment. The inclinometer installations may be omitted on the quay side of the surcharge embankment, providing the whole slope of the embankment is adequately supported, as approved by the Engineer prior to mobilisation.
5.7.2
Definitions for Geotechnical Instrumentation Datum station is a mark for which horizontal or vertical values, or both, have been fixed, and which is used as a datum for monitoring or control surveys. Monitoring mark is a mark, fixed or installed, on a structure to be monitored. Reference point is a mark placed close to another important survey mark to aid recovery or replacement. Survey station is a mark on a stone, concrete, metal or wooden block, pipe, peg or other item defining a surveyed position.
5.7.3
Instruments for Geotechnical Instrumentation
All measurements and setting out shall be referenced to the Chart Datum and to the grid co-ordinates agreed with the Engineer for the QICT-Terminal 2 Development.
Instruments for geotechnical instrumentation and their accessories shall be provided complete with all appropriate tubing, connections, monitoring equipment, read-out and data logging units, data processing hardware and software, and any other tools necessary for the installation, calibration, commissioning, monitoring, reading, analysis of readings, and maintenance of the instruments. Instruments shall be manufactured by companies with proven experience and only instruments which are well proven and have been in successful use shall be used, unless otherwise agreed by the Engineer. Instruments and readout equipment shall be calibrated by a laboratory approved by the Engineer. Instruments and readout equipment shall be calibrated at intervals recommended by the manufacturer and at other intervals instructed by the Engineer. Calibration certificates shall be provided to the Engineer within 24 hours after calibration.
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Instruments shall be handled, stored, installed and used in accordance with the manufacturer's recommendations and in such a manner that the performance of the instruments will not be impaired. Instruments shall be protected from damage and measures shall be taken to ensure that the instruments suffer the minimum practicable amount of disturbance. The Contractor shall replace instruments and any monitoring installations which are damaged or disturbed with 24 hours of the damage or disturbance occurring. The Contractor shall include a full explanation in the Tender Method Statement on how he intends to comply with this requirement. Construction or removal of the surcharge embankment or installation of band drains within 50m from the damaged instrument shall not proceed until the installation has been replaced and re-calibrated. Installation, testing and monitoring of the instruments shall be carried out under the supervision of a suitably qualified technician. Particulars of the technician, including qualifications and experience, shall be submitted to the Engineer at least 7 days before commencement of work relating to geotechnical instrumentation. Installed instruments shall be maintained throughout the course of the works and shall become the property of the Employer for the purposes of monitoring future settlements. The instrument clusters shall be installed in locations agreed with the Engineer taking into account future operational requirements, and handed over in a fully working condition. Detachable tubing, connections, monitoring equipment and read-out units shall become the property of the Contractor upon the expiry of the Maintenance Period. 5.7.4 Location and Arrangement of Instruments At least two reference points shall be established for each survey station or monitoring mark. A survey station which is fully protected against disturbing by the works or any other activities shall be selected as datum station. The survey station shall be located in an area that will not be affected by settlement. The datum station shall be stainless steel and shall be protected from damage. At least three reference points shall be established for each datum station. 5.7.5 Installation of Instrumentation The Contractor shall inform the Engineer 24 hours, or such shorter period agreed by the Engineer, before the installation of each instrument for geotechnical instrumentation starts. Boreholes required for instrumentation installation shall be carried out using cable percussion technique in accordance with the method statement approved by the Engineer. Small disturbed samples shall be taken at 1 metre intervals and every change of stratum. A borehole log shall be prepared by a qualified geotechnical engineer / engineering geologist and the small disturbed samples shall be used to provide engineering descriptions to BS 5930 of the strata encountered. Instruments shall be installed, fixed and protected in a manner which will ensure that the instruments will function satisfactorily. Tests shall be carried out after installation to
demonstrate that the instruments have been correctly installed, are functioning correctly and that the readings given are accurate, repeatable and representative of the pore pressure / deformation measured. Instruments which are not correctly installed, or are not functioning correctly, or are not giving readings which are accurate, repeatable and representative of the pore pressure / deformation measured shall be reinstalled or replaced as instructed by the Engineer. Installation of instrumentation shall be complete and instruments shall be fully operational for at least 2 weeks before commencement of adjacent reclamation works. Unless agreed otherwise by the Engineer prior to commencement of works, all installations shall be completed prior to installation of the prefabricated drains and shall then be extended to allow monitoring from the accessible level at the top of the surcharge embankment. All installed instruments, tubes and wires shall be clearly marked with a unique and conspicuous identification number.
5.7.6
Tubes and Cables for Instruments Tubes and cables attached to instruments for geotechnical instrumentation for remote reading shall be impervious to air and water and shall have sufficient strength and stiffness to withstand the internal and external pressures. Tubes and cables shall be protected from mechanical damage and from the harmful effects of direct sunlight, heat and ultra violet radiation at all times. Tubes and cables shall be free from defects and shall be marked with identification colours and numbers at 3 m intervals. The tubes and cables shall be wound onto reels in such a manner that kinks are not formed and strain is not induced. Open ends of tubes and cables shall be blocked with stop ends at all times: Tubes and cables shall be buried at least 0.5 m below ground level in trenches which are lined with geotextile and filled with stone free material. The trenches shall be backfilled in layers not exceeding 150 mm. Tubes and cables shall be laid with sufficient slack, loops and bends to allow for settlement and other ground movements. The routing of tubes and cables shall be as agreed by the Engineer and shall be in straight lines unless otherwise permitted by the Engineer. The radius of bends shall be at least 300 mm. Each tube or cable shall be laid from the measuring instrument to the terminal duct in one continuous length without joints.
5.7.7
Inspection of Monitoring Installations During the installation of band drains, placement of the filter layer and construction of the surcharge embankment the Contractor shall carry out daily inspections of all monitoring installations, including a check of their performance. The reports of daily inspections shall be kept by the Contractor and shall be made available to the Engineer on request.
5.7.8
Frequency of Monitoring Monitoring of all monitoring instruments and installations shall be carried out at not more than 24 hour intervals during the installation of band drains, placement of the filter layer and construction of the surcharge embankment. After completion of the surcharge embankment monitoring shall continue at 24 hour intervals for the first 2 weeks, then continue on a weekly basis until at least 2 weeks after completion of the removal of the surcharge embankment. All readings for the deep installations (extensometers and inclinometers) shall include the readings of the monitoring points installed at the top of the sleeve.
5.7.9
Maintenance of Instruments Instruments and monitoring / readout equipment for geotechnical instrumentation shall be maintained in good working order until the expiry of Maintenance Period. Instruments, survey marks and stations shall be protected by suitable barricades, notices, signs or by other methods agreed by the Engineer. Construction shall be carried out in a manner which will avoid damage to the instruments. The Contractor shall inform the Engineer immediately of any instruments found damaged or instruments found not to be in working order. Replacements shall be provided for read-out units which are faulty or under repair within 24 hours.
5.7.10
Records of Geotechnical Instrumentation Records of activities relating to installation of geotechnical instrumentation shall be kept by the Contractor on the Site and a copy shall be submitted to the Engineer within 24 hours after installation of the instrument is complete. Daily records of the deposition of fill materials, including location, plan area, thickness of fill deposited and the date shall be kept by the Contractor on the Site and a copy shall be submitted to the Engineer at the end of the day. A drawing showing the locations and identification of installed instruments shall be prepared by the Contractor and submitted to the Engineer within 24 hours after installation of the instrument is complete. A drawing showing the locations and details of survey stations, monitoring marks and reference points shall be prepared by the Contractor and submitted to the Engineer within 3 days after the survey network has been established.
5.7.11
Prefabricated Vertical Drains Where, with a prior permission of the Engineer, instrumentation is to be placed after the installation of prefabricated vertical drains then the locations of the prefabricated vertical drains shall be adequately marked and maintained by the Contractor.
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5.7.12
Recording readings Instrument readings and processed data for geotechnical instrumentation shall be recorded by the Contractor on agreed record sheets, and shall be submitted to the Engineer within 24 hours after recording. The format of the record sheets shall be as agreed with the Engineer. The Contractor shall also submit to the Engineer instrument readings and processed data in a digital format, agreed with the Engineer within 24 hours after recording. The Contractor shall prepare a monthly summary report of the instrument readings and processed data which shall be submitted to the Engineer at the end of each month. The form of the summary report shall be as agreed by the Engineer. Unless otherwise agreed by the Engineer, readings shall be taken in the presence of the Engineer. Initial readings shall be taken immediately after the instruments have been installed and after the effects of installation have subsided. The initial readings shall be submitted to the Engineer and shall form the basis of comparison of subsequent readings. The instruments and the initial readings shall be replaced if the initial readings are not accurate, repeatable and representative of the pore pressures / deformations measured. Initial readings shall be repeated if the instruments have been moved or replaced due to damage. The calibration of the initial readings for replaced instruments shall be carried out by the Contractor and shall be subject to the Engineers approval. All installed instruments shall be left in correctly functioning condition after final readings have been taken or at the end of the Maintenance Period. Keys for locks shall be tagged to identify the instrument number and shall be handed over to the Engineer.
5.7.13
Installation of Settlement Plates Settlement plates for geotechnical instrumentation shall be securely founded on level ground free from obstructions and shall be immediately surveyed for level and position and plotted on a plan. Settlement plates shall be protected from damage and shall be kept in position by a 600mm thick layer of granular fill material or bags of sand which shall be placed by manual methods and shall extend 600mm beyond the edges of the plate. The initial survey of levels and positions shall be taken immediately after the fill material or bags of sand have been placed. The base of the settlement plate shall have a minimum area of 1m2 and a maximum area such that it does not obstruct the installation of the vertical drains. The metal rod fixed to the centre of the plate shall be in an upright position, and protected by a tubular sleeve. The sleeve and the metal rod shall be extended as fill material is placed such that at any time the sleeve and rod are at least 500mm above the level of the surrounding fill material or high water mark, and the metal rod is within 2% of the embedded length to the vertical.
The level of the top of the metal rod shall be recorded immediately before and immediately after each extension piece is added. Marker-buoys shall be fixed to the tops of tubular sleeves installed in water, unless otherwise permitted by the Engineer.
5.7.14
Piezometers a) Pneumatic Piezometers Pneumatic piezometers shall have an accuracy of 0.5% full scale deflection (FSD) and the tips shall have a 32mm external diameter and a length of 224mm. The piezometer tip shall be of the low air entry type and shall have a ceramic element of 60 microns average pore diameter. Connections to the piezometer shall be made with approved stainless steel fittings. The piezometer tip shall be connected to twin nylon, colour coded tubes, of 1.9mm inner diameter and 3.2mm outer diameter sheathed with 1mm thick polythene. Immediately prior to installation each pneumatic piezometer element shall be immersed in clean de-aired water for a period of not less than 24 hours. Piezometer tips shall be assembled underwater and remain immersed in deaired water during transportation to the borehole locations. They shall be removed from the water only for the minimum amount of time necessary to complete the installation. b) Vibrating Wire Piezometers Vibrating wire piezometers shall have an accuracy of 0.1% F.S.D, and the tips shall have a 38mm external diameter and a length of 260mm. The piezometer tip shall be of the low air entry type with a ceramic element of 60 microns average pore diameter and shall be capable of measuring up to 50m head of water. Immediately prior to installation each vibrating wire piezometer element shall be immersed in clean de-aired water for a period of not less than 24 hours. Piezometer tips shall be assembled underwater and remain immersed in deaired water during transportation to the borehole locations. They shall be removed from the water only for the minimum amount of time necessary to complete the installation. c) Piezometer Installation Where piezometers are to be installed in the base of a borehole the borehole shall be formed to a depth of 0.5m above the required piezometer location. The piezometer shall be introduced into the borehole using an approved installation adaptor and pushed to a depth of 0.5m beneath the base of the borehole. The base of the borehole shall be sealed using sodium attapulgite tablets to form a 500mm impervious sodium attapulgite seal.
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A grout, consisting of cement and sodium attapulgite in the proportions of 1:2 by weight and shall be prepared by thorough mixing with approved equipment and with just sufficient water to form a pumpable mix. The grout shall have deformation properties similar to the in-situ soils in which the piezometers are to be installed. The grout shall be placed to the top of the sodium attapulgite seal using a tremie pipe. When placing the grout, the end of the tremie pipe shall initially be placed at a point approximately 300mm above the base of the seal and shall be withdrawn smoothly during grout placement such that the end of the tremie pipe is maintained at least 1m below the grout surface, until the grout is brought up to the level of the next piezometer or ground level. Where piezometers are to be installed at intermediate depths within the borehole the piezometer shall be placed in an approved manner centrally in a 500mm long filter of clean sand falling wholly between the limits 500 to 1200 microns. The borehole shall be grouted, as described above, to a level of 500mm below the base of the sand filter. A 500mm long impervious sodium attapulgite seal shall be formed on top of the grout using sodium attapulgite tablets, such that the top of the seal shall be at the interface with the sand filter. The filter sand shall be placed hydraulically to the top of the seal by washing the sand into the borehole with clean water through a 25mm diameter tremie pipe, in a manner approved by the Engineer. Sufficient time shall be allowed to lapse for all the sand to settle before measuring sand layer depth. A 500mm long impervious sodium attapulgite seal shall be formed using sodium attapulgite tablets, above the sand filter. The remainder of the borehole shall be grouted as described above. Throughout the installation of piezometers, the borehole casing shall be withdrawn smoothly and concurrent with installation operations, so as to cause the minimum amount of disturbance. During piezometer installation the levels of piezometer tip sand filter, sodium attapulgite seal and grout, and the length of piezometer tubing or cable used for each piezometer, shall be recorded as installation proceeds. d) Piezometer Terminal Panels and Instrument Cabinets Pneumatic piezometer tube shall be terminated on a terminal panel. The terminal panel shall comprise delivery and return manifolds with separate pairs of isolating valves, and shall be supplied complete with vent valves, and flyleads with quick release couplings. The terminal panel shall be capable of accommodating the number of piezometers specified for each section of instrumentation. Vibrating wire piezometer cable shall be terminated on a terminal panel. The terminal panel shall comprise connecting blocks and cable glands with connector socket and rotary switch to select piezometer, and shall be supplied complete with flylead. The terminal panel shall be capable of accommodating the number of piezometers specified for each section of instrumentation.
Instrument cabinets shall comprise lockable corrosion protected steel cabinets of sufficient capacity to accommodate the piezometer terminal panels. Instrument cabinets shall be constructed on a concrete slab 150mm thick. Access to the instrument cabinets for the piezometer tubing / cable shall be via a 150mm diameter PVC duct set into the concrete slab and extending to the edge of the concrete slab. e) Piezometer Daily Records The Contractor shall prepare for each piezometer a record sheet which shall be of a form approved by the Engineer and shall contain the following information where relevant: f) Contract title and coordinates as required by the Engineer. Contractor's name. Borehole and piezometer reference numbers. Ground level and co-ordinates referred to Chart Datum and the Project coordinate system. Installation details including depth below ground level to piezometer tip, and upper and lower surfaces of grout, sodium attapulgite seals and sand filter. Length of piezometer tubing or cable. Identification details.
Pneumatic Piezometer Readout Equipment The manual readout equipment shall comprise a gauge pneumatic readout unit. The Bordon gauge shall have an accuracy of 0.5% full scale deflection and shall be capable of reading pressures in the range 0m to 50m head of water. The unit shall include twin rechargeable gas cylinders (recharge pressure 70 bars), reservoir pressure gauge, return flow indicator, flow control and fly leads with quick release couplings. The gauge pneumatic readout unit shall be supplied complete with a pressure gas regulator for recharging the readout unit, together with sufficient nitrogen to recharge the unit for the duration of the Contract.
g)
Vibrating Wire Piezometer Readout Equipment The manual readout equipment shall comprise a readout unit and data logger with an 80 character alphanumeric LCD with a rechargeable battery with sufficient capacity for a minimum of 20 hours' continuous use. The automatic battery charger shall be as specified in the Manufacturers manual.
5.7.15
Magnetic Extensometers
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a)
General Magnetic extensometers, including magnets, shall be installed in boreholes and be capable of being extended. The access tube shall be of rigid polyvinyl chloride (PVC) construction with threaded ends to provide an internally flush coupled joint. Access tubes shall be supplied in lengths of 1.0m or 3.0m as required. Telescopic compression/extension couplings for use in deposited fill or surcharge shall be constructed from rigid polyvinyl chloride (PVC) fitted with two O-rings at each end and shall have a profile similar to the access tube. The couplings shall be supplied in lengths of 1000mm installed according to the manufacturers recommendations.
b)
Magnetic Extensometer Installation Magnetic extensometer access tubes shall be installed in boreholes and extended through the deposited material and surcharge. The boreholes shall be of sufficient depth to ensure that the base of the access tube is founded a minimum of 1.0m into suitable bearing stratum. The boreholes shall be grouted before access tube installation with a grout consisting of cement and sodium attapulgite in the proportions 1:2 by weight and shall be prepared by thorough mixing with approved equipment and with just sufficient water to form a pumpable mix. The grout shall have deformation properties similar to the in-situ soils in which the magnetic extensometer access tubes are to be installed. The grout shall be placed to the base of the borehole using a tremie pipe. When placing the grout, the end of the tremie pipe shall initially be placed at a point approximately 300mm above the base of the borehole and shall be withdrawn smoothly during grout placement such that the end of the tremie pipe is maintained at least 1m below the grout surface. The borehole shall be filled with grout to a level which shall ensure that the quantity of grout is sufficient to completely fill the annulus between the combined inclinometer and magnetic extensometer access tube and the ground up to existing ground level. The base of the first length of access tube shall be sealed. PVC sealing cement shall be applied to a rigid PVC end cap which shall be placed over the end of the tubing. The ends of each length of access tube shall be screwed together such that joints are internally and externally flush coupled. A datum ring magnet, housed in PVC of 85mm outer diameter shall be installed on the first length of access tube a distance of 1000mm from the end cap and secured with rivets. Pneumatically released spider magnets shall be prelocated at points on the access tube, as indicated on the drawings or as directed by the Engineer, and shall be at a distance of not less than 300mm from the end of any coupling.
99
The spider magnet shall be housed in PVC of 85mm outer diameter and shall be fitted with six leaf springs, which shall be tied back with nylon twine into their retracted position and shall be suitable for use in the borehole diameter used. The magnets shall be fixed to the access tube using the minimum amount of sealing tape on the nylon twine necessary to prevent dislocation of the magnet whilst inserting the tube into the borehole. The access tube shall be smeared with a silicon based grease in the vicinity of the magnet. The access tubing shall be lowered to the base of the borehole using an installation plate, and adding clean, fresh water into the tube to maintain a pressure balance between the inside and outside of the tube whilst maintaining the integrity of the joints. The installation shall be terminated such that the access tube extends no more than 1.5m above the ground level. The access tube shall be topped up with water an end cap inserted, and temporarily sealed with tape. When the access tube is in position, the borehole casing shall be removed, ensuring that the orientation of the tubing does not alter, and the spider magnets released using a pneumatic cutter. Precise measurements shall be taken when withdrawing the casing to ensure that the magnets are not fired in the casing. The access tubes shall be protected from damage by an approved method during filling operations. The Contractor shall ensure at all stages during installation and after completion that no extraneous material is allowed to enter the access tubing and that deformation or damage to the tube is prevented. The top of the extensometer shall, after completion of construction of the surcharge embankment, be encased in a concrete block with the monitoring markers, which shall be suitable for monitoring of the position of the top of the extensometer monitoring sleeve both in elevation and in plan. The surface monitoring elements shall be robust and sufficiently protected to avoid damage during the works. The exact construction of the elements for monitoring of the top of the extensometer sleeve shall be proposed by the Contractor in his tender method statement and shall be subject to the Engineers approval. c) Magnetic Extensometer Daily Records The Contractor shall prepare for each installation a record sheet which shall be of a form approved by the Engineer and shall contain the following information where relevant: Contract title and co-ordinates as required by the Engineer. Contractors name. Borehole and magnet diameter and magnetic extensometer reference number.
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d)
Ground level and co-ordinates referred to Chart Datum and the Project coordinate system. Depths below ground level of the plate, datum ring and spider magnet installations, including type of magnet. Depth and length of access tube. Level of top of access tube referred to Chart Datum. Date of extension of access tube. Level of top of access tube immediately before and immediately after extension. Depth to base of access tube immediately before and immediately after extension.
Extension of Magnetic Extensometers Where the level of fill material is at a level of 500mm from the top of the access tube the installation shall be extended by means of a telescopic coupling and 1.5m length of access tube. Two O-rings shall be placed over each end of access tube, and the ends of the access tube inserted into the coupling such that there is a minimum of 100mm and maximum of 250mm overlap between the butt ends of the access tube and the coupling. The annulus between the fill material and access tube shall be filled with sand and compacted in an approved manner. After each layer of fill material has been placed the annulus between the fill material and access tube shall be filled before the next layer is placed. When fill material reached the level of the plate magnets indicated on the Drawings the plate magnets shall be placed on the access tube so that they lie horizontally on the surface of the sand filled annulus at the required level. The final length of access tube shall be such that the installation does not protrude more than 100mm above the final surface of the surcharge material as shown on the Drawings. A lockable cover of 100mm diameter and 630mm length shall be fitted over the installation and set in concrete, so that the top is approximately 100mm above ground level. A 1m by 1m by 01 m slab of concrete shall be formed at the top of the access to provide a firm base for the readout equipment.
e)
Magnetic Extensometer Readout Equipment
The magnetic extensometer readout shall comprise a nickel plated brass probe of 150mm length and 17mm diameter, containing a reed switch. The reed switch shall be connected to a buzzer by a nylon coated steel tape 75m in length
101
5.7.16
Inclinometers a) General Inclinometers shall be installed in boreholes and be capable of being extended. The access tube shall be of rigid polyvinyl chloride (PVC) construction 53mm inner diameter and 66mm outer diameter with four internal keyways and one external keyway for probe alignment. Access tubes shall be supplied in lengths of 1.5m or 3m as required. Compression/extension couplings shall be constructed from rigid polyvinyl chloride (PVC) and shall have a profile similar to the access tube. The couplings shall be supplied in lengths of 300mm and 600mm and installed according to the manufacturer's recommendations. b) Inclinometer Installation Inclinometer access tubes shall be installed in boreholes and extended through the deposited fill and surcharge. The boreholes shall be of sufficient depth to ensure that the base of the access tube is founded a minimum of 1m into suitable bearing stratum. The boreholes shall be grouted before access tube installation with a grout consisting of cement and sodium attapulgite in the proportions 1:2 by weight and shall be prepared by thorough mixing with approved equipment and with just sufficient water to form a pumpable mix. The grout shall have deformation properties similar to the in-situ soils in which the magnetic extensometer access tubes are to be installed. The grout shall be placed to the base of the borehole using a tremie pipe. When placing the grout, the end of the tremie pipe shall initially be placed at a point approximately 300mm above the base of the borehole and shall be withdrawn smoothly during grout placement such that the end of the tremie pipe is maintained at least 1m below the grout surface. The borehole shall be filled with grout to a level which shall ensure that the quantity of grout is sufficient to completely fill the annulus between the combined inclinometer and magnetic extensometer access tube and the ground up to existing ground level. Access tube shall be introduced into the borehole in 3m lengths with the keyways orientated in the direction as indicated by the Engineer. The base of the first length of access tube shall be sealed. Sealing mastic shall be applied to a rigid PVC end cap of 80mm length 60mm outer diameter, which shall be inserted in the base of the tubing and secured with four rivets. Mastic shall be applied to the rivet heads and the seal strengthened further by wrapping sealing tape around the cap and moulding it to the tube profile. Sealing mastic shall be applied to the ends of the access tube and inserted into the coupling such that there is a 100mm overlap between the butt ends of the access tube and the end of the coupling. The coupling shall be riveted to the tube at one or two points midway between the keyways, the rivets being sealed
with mastic. Sealing tape shall be wrapped around each joint, at least 50mm above and below the end of the coupling and moulded into the tube profile to prevent ingress of water or grout. The access tubing shall be lowered to the base of the borehole using an installation plate and adding clean, fresh, water into the tube to maintain a pressure balance between the inside and outside of the tube whilst maintaining the integrity of the joints. The installation shall be terminated such that the access tube extends above sea level, but not more than 1.5m above the ground level. The access tube shall be topped up with water, an end cap inserted, and temporarily sealed with tape. When the access tube is in position, the borehole casing shall be removed, ensuring that the orientation of the tubing does not alter. Where inclinometers are to be installed in steel tubular sleeves for pile installation the access tube shall be attached to the inside of the steel tubular sleeve by a method approved by the Engineer. The access tubes shall be protected from damage by an approved method during the earthworks. The Contractor shall ensure at all stages during installation and after completion that no extraneous material is allowed to enter the access tubing and that deformation or damage to the tube is prevented. The top of the extensometer shall, after completion of construction of the surcharge embankment, be encased in a concrete block with the monitoring markers, which shall be suitable for monitoring of the position of the top of the extensometer monitoring sleeve both in elevation and in plan. The surface monitoring elements shall be robust and sufficiently protected to avoid damage during the works. The exact construction of the elements for monitoring of the top of the extensometer sleeve shall be proposed by the Contractor in his tender method statement and shall be subject to the Engineers approval. c) Inclinometer Daily Records The Contractor shall prepare for each installation a record sheet which shall be of a form approved by the Engineer and shall contain the following information where relevant: Contract title and offset, or coordinates as required by the Engineer. Contractor's name. Borehole diameter and inclinometer and reference numbers. Ground level and co-ordinates referred to Chart Datum and the Project coordinate system.
103
d)
Depth and length of access tube. Date of access tube extension. Levels of top of access tube immediately before and immediately after extension. Depth to base of access tube immediately before and immediately after extension. Co-ordinates of the top of the access tube where inclinometers are installed in steel tubular sleeves for pile installation.
Extension of Inclinometers Where the level of deposited fill is at a level of 500mm from the top of the access tube, the installation shall be extended by means of a coupling and length of access tube. The coupling shall be installed in accordance with the manufacturers specification. The annulus between the fill material and access tube shall be filled with sand and compacted in an approved manner. After each layer of fill material has been placed the annulus between the fill material and access tube shall be filled before the next layer is placed. The final length of access tube shall be such that the installation does not protrude more than 100mm above the final surface of the surcharge as shown on the Drawings. A lockable cover of 100mm diameter and 630mm length shall be fitted over the installation and set in concrete, so that the top is approximately 100mm above ground level. A 1m by 1m by 0.1m slab of concrete shall be formed at the top of the access to provide a firm base for the readout equipment.
e)
Inclinometer Readout Equipment The inclinometer readout equipment shall comprise a biaxial torpedo, complete with operating cable, cable reel, grip and carrying case, and readout unit and data logger with automatic battery charger. The biaxial torpedo shall be fully waterproof, stainless steel and incorporate two robust force servo accelerators aligned at right angles to each other. The torpedo shall be fitted with two pairs of centre sprung wheels and shall have a gauge length of 0.5m and be capable of negotiating a tube curvature of 3m. The operating cable shall comprise a 50mm diameter polyurethane sheathed six core cable, with central straining wire, graduated with metal markers at 0.5m intervals and numbered at 1m intervals. The Contractor shall provide a calibration frame with which to check the readout equipment.
104
The readout unit and data logger shall have an 80 character alphanumeric LCD with a rechargeable battery with sufficient capacity for a minimum of 20 hours' continuous use. The automatic battery charger shall be in accordance with the manufacturers manual.
5.8
5.8.1
ACCEPTANCE TESTING FOR VIBRATED STONE COLUMNS

General The acceptance criteria for stone column testing shall be set out in the Contractors Method Statement to justify their design. This will subject to the Engineers approval. The performance criteria for ground improvement shall be as set out above. In addition, the improved soil should behave reasonably linearly and display an efficient Youngs modulus of not less than 20MPa up to the pressures equal to the sum of the weight of fill placed above the commencing surface up to the final pavement level and an additional imposed surcharge of 50kPa.
5.8.2
Frequency of Testing
The number of load test columns shall be as follows:

i) ii) Plate load tests to ensure the workmanship standard of the individual columns 1 test per 50 stone columns installed. Zone load tests on not less than 3 columns each to ensure the workmanship standard of the columns and the allowable bearing capacity of the improved area 5 tests in total.
5.8.3
Standards Plate bearing tests are loading tests carried out using a plate on treated ground. The test is described in BS 1377 : Part 9 : 1990 Method 4.1, including the reporting requirements. Zone tests are loading tests carried out with a slab, intended to test bearing pressure over a wider and deeper zone than in the plate tests. The test is described in BS 1377 : Part 9 : 1990 Method 4.2, including the reporting requirements. The load shall be applied by operating a hydraulic jack against a suitable kentledge taking care to avoid impact, fluctuation of load eccentricity. Loading shall be carried out as per the schematic diagram to be prepared by the Contractor in the tender method statement, which shall be subject to the Engineers approval. Load settlement and time settlement relationship for each stage of loading shall be plotted and submitted to the Engineer. Safe and efficient working of the loading arrangements is entirely the contractors responsibility and any impediment resulting in the failure of the test arrangement may debar the contractor from payment for the test. Alternatively, it may make the contractor
liable to repeat the test on separate column/columns without any extra cost to the Employer.
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6 6.1
PILING PILING PARTICULAR REQUIREMENTS

This section of the piling specification contains particular requirements for the piling works to be undertaken under the Contract. The particular requirements take precedence over the general piling specification contained under the piling specification Clause 6.2 onwards.
6.1.1
Description of Work The scope of piling work covers the following elements: (i) The contiguous quay wall piles comprising large diameter cast-in-place reinforced concrete piles in sacrificial interlocked casings. The pile diameter, toe level and reinforcement details shall be as shown on the drawings. (ii) Closely spaced cast-in-place reinforced concrete piles comprising the anchor system for the quay wall ties. The pile diameter, toe level and reinforcement details shall be as shown on the drawings; (iii) Other cast-in-place reinforced concrete bearing piles. The pile diameter and reinforcement details shall be as shown on the drawings. The Contractor shall determine the toe level of these piles based on the working loads as shown on the drawings. If the minimum pile embedment is specified on the Drawings, the toe level of these piles shall not be higher than that shown on the Drawings.
6.1.2
Pile Working Loads Pile working loads shall be as shown on the Drawings. The Contractor shall submit pile capacity calculations tabulating his proposed pile lengths for all piles for which he is required to determine the toe level. These calculations shall demonstrate how the Contractor arrived at the pile lengths he proposes to install. The summary of pile lengths may be considered as part of the Tender evaluation procedure although the installed pile lengths will be subject to remeasurement for payment purposes. The designed pile length determined by the Contractor will be verified by pile load tests as specified in the clauses hereinafter. The calculated pile ultimate capacity shall satisfy the following requirements (assuming that preliminary tests are carried out in accordance with the Specification): Ultimate capacity Ultimate Capacity Where: > > 2 x (DL + LL) + Negative Skin Friction 1.5 x [(DL + LL) + Negative Skin Friction]
DL means permanent load (Dead Load), LL means imposed load (Live Load) NSF - means the estimated negative skin friction on the basis of calculations undertaken by the Contractor and approved by the Engineer.
The pile movement during the test shall not exceed 10mm under the total of the Specified Working Load (SWL) and the Negative Skin Friction (i.e. not more than 10mm
deflection under the load equal to [SWL + NSF]) and the load-deflection profile shall be substantially linear up to the loads equal to [1.5 x SWL + NSF]. If any of the above criteria is not satisfied in any of the performed tests the pile design shall be deemed inadequate and any remedial measures shall be carried out by the Contractor at no additional cost to the Contract. The test load to be applied in static load tests will depend on the time the Contractor carries out the static load test in the construction sequence. The Contractor shall provide a second set of calculations, based on the data determined to calculate the completed pile ultimate capacity, to determine the test load of the pile to reflect the stage of construction when the test is performed. All the Contractors calculations for the pile lengths will be subject to review and approval of the Engineer at the time of Tender and during construction. During construction pile fabrication shall not commence until the Engineer has approved the Contractors calculations. 6.1.3 Corrosion Protection Corrosion protection of sacrificial casings and tie rods shall be as specified on the Drawings and within this Specification. 6.1.4 Number of pile tests The Contractor shall carry out: For the piles defined in Clause 6.1.1 Position (iii) above - at least one static load preliminary pile test per one hundred of working piles of each dimension installed in different ground conditions, but not fewer than 3 tests of each pile dimension; For the piles defined in Clause 6.1.1 Position (iii) above - at least one static load working pile test per one hundred of working piles of each dimension installed in different ground conditions, but not fewer than 3 tests of each pile dimension; Integrity tests on all concrete cast-in-place piles, except the piles defined in Clause 6.1.1 Position (i) above.
6.2
GENERAL
The works covered by this Section shall include procurement, installation, testing and reporting for construction of all bearing piles, embedded retaining walls and any other piles or piled foundations within the Scope of Work. The Contractor shall be responsible for ensuring that load bearing piles have sufficient capacity to achieve the required ultimate load.
6.2.1
Standards All materials and workmanship shall be in accordance with the appropriate British Standards or other specified standards except where the requirements of these Standards differ from this Specification in which case the requirements of this Specification shall take precedence. In particular, all work is to be carried out in accordance with the principles contained in British Standard BS 8004 and shall follow the requirements of the ICE Specification for Piling and Embedded Retaining Walls, second edition, published by the Institution of
Civil Engineers, London 2007 (referred to hereinafter as the ICE Specification for Piling) except where stated otherwise in this Specification. 6.2.2 Definitions Piling terminology used during the Contract shall comply with definitions given in BS 8004 and as follows: Commencing Surface; Is the level at which piling equipment first enters the ground. This need not be the same as the piling platform level. Compression Pile; A pile which is designed to resist an axial force such as would cause it to penetrate further into the ground. Cut-off Level; Is the level to which the pile is trimmed in order to connect the pile to the structure. Kentledge; Dead load used in a loading test. Preliminary Pile; A pile installed before the main piling works or a specific part of the works for the purpose of confirming the pile design dimensions, installation method and load capacity. In this Contract Preliminary Piles will become Working Piles subject to meeting the Specification. Test Pile; Any pile to which a test load is, or is to be, applied. Working Pile; One of the piles forming part of the structure. Static Load Test; Pile load test where the load shall be applied by hydraulic jacks reacting against kentledge or strong-backs attached to temporary tension piles or ground anchors. Ultimate Bearing Capacity of a Pile; The axial compressive load at which the resistance of the soil becomes fully mobilised or the pile movement exceeds 10% of the pile diameter. Design Verification Load; Comprises the Working Load applied to the pile adjusted to allow for down drag where appropriate. Working Load; Comprises of combinations of the following items: Self-weight of all items applied to the pile Imposed loads applied to the pile; Self-weight of the pile; Wind loads; Wave loads; Current loads. 6.2.3 Pile Design and Construction The Contractor shall undertake the construction and design of the pile length to carry the Design Loads and earth pressures within the specified limits for load-settlement
behaviour. The Contractor shall determine the Ultimate Bearing Capacity from the Working Loads as specified in the particular requirements. The Contractor's installed piles shall have the qualities of materials and workmanship specified and which upon testing meet the requirements of this Specification. The Contractor's design shall include but not be limited to the following: pile type; method of installation; pile layout; pile lengths and cross-sections; pile set and/or toe level required to achieve the specified performance; pile test method statements (static and integrity testing).
The Contractor shall submit his design and/or installation and test method statements to the Engineer for approval at the start of the Contract. The Contractor's submission shall include all supporting calculations where appropriate, criteria used in the design, the assumptions made, the methodology by which he will prove the piles conform to the specified requirements and any other information that may be required by the Engineer. 6.2.4 Pile Lengths The pile lengths and target penetrations necessary to achieve the required Ultimate Bearing Capacity or factors of safety for embedded retaining wall stability shall be determined by the Contractor and agreed with the Engineer The assessment of pile lengths shall take account of the following factors: local variability of soils pile-soil-pile interaction; set-up or relaxation of the soil. The Contractor is solely responsible for determining the final design lengths, and these shall be modified to suit the conditions encountered and the results of the pile tests as appropriate. 6.2.5 Ground Conditions A copy of the available soils information will be provided to the Contractor in Volume 5 of the Tender Documents. The Contractor shall report immediately to the Engineer any observations which indicate that in the Contractors opinion the ground conditions differ from those expected by him from his interpretation of the site investigation reports on which his installation method or pile length was based. However, no variation in price shall be permitted if in the Engineers opinion the observed variation in soil conditions is within the natural reasonable variation which could have been established from the available ground investigation data.
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6.2.6
Piling Programme The Contractor shall submit to the Engineer a detailed piling programme for approval at the start of the Contract. The programme shall include for procurement, construction, Preliminary Pile, Working Pile and integrity pile testing and it shall show the relationship of piling to other activities with identification of the critical path. He shall state the number and type of piling rigs he proposes to use on the Piling Works for the Contract and the average production rate of such rigs, taking into account the conditions prevailing on the Site. The Contractor shall inform the Engineer each day of the programme of piling for the following day. In addition, the Contractor shall each week provide the Engineer with his proposed piling programme for the following fourteen (14) days.
6.2.7
Piling Plant The Contractor shall make his own assessment of the piling plant required to install the piles to achieve all required penetrations and bearing capacities. These shall include all necessary provisions for potential variability of the soil strata. The Contractor shall give all details of his proposed plant and methods, with his Tender Submission. Notwithstanding any review of piling plant at Tender evaluation, if the Contractors piling plant as proposed in his Tender proves to be insufficient to achieve his required ultimate bearing capacities and penetrations within the time allowed in the Contract programme, he shall provide such additional plant as may be necessary to achieve his required capacities and penetrations according to programme at no extra cost to the Contract. The Contractor shall supply for the Engineers approval all details of his proposed method of piling and plant at least four 28 calendar days before the date that he proposes to mobilise his piling equipment. The Contractor shall give due and reasonable notice of his intention to install piles so that the Engineer may make arrangements for inspection if he so requires.
6.3
PILE INSTALLATION AND ACCEPTANCE CRITERIA

This section of the Piling Specifications shall apply to all piles as specified on the Drawings. The installation shall generally be carried out in accordance with Section B3 and B10 of the ICE Specification for Piling.
6.3.1
Use of support liquid If the Contractor intends to construct piles with the use of support liquid he shall submit a detailed proposal together with his Tender. The Method Statement for the use of support liquids shall in particular address the procedures for complying with the environmental restrictions, for testing and for cleaning the base and the walls of the bore.
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The use of support liquids shall be in accordance with Section B18 of the ICE Specification for Piling. 6.3.2 Permanent sacrificial casing The permanent interlocked sacrificial casing shall be used for piles specified in Clause 6.1.1 Position (i). The permanent casing shall be installed in accordance with the Drawings. The placing of permanent casings shall be carried out in accordance with Clause B3.5 of the ICE Specification for Piling. All casings shall be fully clutched upon completion of works. The Contractor shall be responsible for all remedial actions in case of declutching of any casings at any time, which shall be done at no additional cost to the Contract. The Contractor shall ensure that his method of dredging in front of the quay wall is such that no structural damage is caused to the casing.
6.3.3
Position and Tolerances Each pile shall be installed in the position shown on the Drawings within the tolerances stated in Clause B1.8 of the ICE Specification for Piling. No forcible correction of pile position shall be permitted. Reinforcement shall be installed in accordance with the Drawings to the permitted tolerance of +50/-50mm. The Contractor shall ensure that no damage to the pile bore is caused during installation of the reinforcement cages. The Contractor shall be responsible for all necessary remedial works in case of bore damage or disintegration of the reinforcement cage, which shall be done at no extra cost to the Contract.
6.3.4
Continuity of construction The pile shall be bored and the concrete shall be placed without such delay as would lead to impairment of the performance of the pile, or affect its compliance with the design assumptions. The time during which each pile is excavated and the concrete is placed shall not exceed 12 hours. If the Contractor cannot ensure that large diameter piles be installed within the 12-hour period he shall advise the Engineer within his Tender Method Statement on the proposed ways to reduce the effect of weathering and the ways in which he intends to ensure the performance of the pile after completion. This Method Statement will be subject to Engineers approval.
6.3.5
Pile trimming Percussive methods of pile trimming shall not be permitted.
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6.3.6
Piling Records Piling records shall generally be submitted in accordance with Table B1.1 of the ICE Specification for Piling. Pile records shall be submitted within 24 hours of completion of each pile, they shall be subject to the Engineers approval and shall include all information required by Clause B1.12 of the ICE Specification for Piling. The format in which the Contractor intends to submit the records shall be subject to the Engineers approval prior to Commencement of the Works.
6.4
INTEGRITY TESTING OF PILES

This section of the Piling Specifications shall apply to all piles. The integrity testing of piles shall generally be carried out in accordance with Section B13 of the ICE Specification for Piling.
6.4.1
Specialist sub-contractor Integrity testing of piles shall be carried out by an independent specialist sub-contractor, whose name shall be proposed by the Contractor in the Tender Submission and shall be subject to Engineers approval. The Tender Submission shall include sufficient information to demonstrate the satisfactory experience of the specialist integrity test sub-contractor in the required types and extent of works, a description of the test equipment to be used, a test Method Statement and a programme for execution of the specified tests. It should also provide a proposed format of the integrity test reports, which shall be subject to the Engineers approval.
6.5
STATIC LOAD TESTING OF PILES

This section of the Piling Specifications shall apply to all piles listed in Clause 6.1.1 Position (iii) above, as specified on the Drawings. The static load testing of piles shall generally be carried out in accordance with Section B15 of the ICE Specification for Piling.
6.5.1
Method of testing Maintained load tests shall be used.
6.5.2
Static Pile Testing For compressive load tests, the load shall be applied by hydraulic jacks reacting against kentledge or strong-backs attached to temporary tension piles or ground anchors. The jacking system shall be such that the test load can be held substantially constant. The Contractor shall design all temporary works associated with pile testing and submit details for the approval of the Engineer at the same time as submitting his piling programme. The Contractor shall provide shading and screens and demonstrate that
these facilities minimise movement of the test rig from temperature changes and wind effects. Temporary tension piles used for static load pile testing shall be spaced at a minimum distance centre to centre of 4d from the pile under test where d is the diameter or width of the test pile. The piles shall be loaded in the manner described in BS 8004: 1986. For the working pile static loading tests the increments of load and minimum holding time for loads up to the load equal to [1.5 times SWL + NSF] for compression tests shall generally be as follows:
Load Percentage of Design Load 25 50 Minimum Period of Holding Load 30 min. 30 min.
75 30 min. 100 1 hr. 75 10 min. 50 10 min. 25 10 min. 0 1 hr. 100* 6 hr. 125 1 hr. 150 6 hr. 125 10 min. 100* 10 min. 75 10 min. 50 10 min. 25 10 min. 0 1 hr. * - Note: the Contractor is advised that the Engineer may require the 100 percent test load to be maintained for any period up to 7 days.
For the preliminary pile tests, following the completion of the above loading sequence the load shall be restored in two stages ([SWL + NSF], [1.5 times SWL + NSF]) with each load step being held for at least one hour. Then the load shall be increase by increments of 25% of SWL until the ultimate design load is reached or up to the pile failure, whichever condition is reached first. Readings of load, time, temperature and settlement are required at each interval of loading and graphs of load against time, settlement against time, and loads against settlements shall be prepared. At the end of each minimum period of holding load the rate of movement of the pile shall be checked and the load on the pile shall not be altered until the rate of movement is not greater than 0.05 mm in 10 minutes. Within 24 hours of the completion of the pile test the Contractor shall submit the relevant pile test records and graphs to the Engineer.
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The Engineer may alter the loading sequence if necessary, but no extra payment will be made unless the total testing time exceeds 205 hrs. The method of measuring the settlement of the piles shall be agreed with the Engineer. Generally, a properly set up system using reference beams and dial gauges (or direct reading electrical gauges) will be acceptable. Direct measurement from a stretched steel reference wire is not acceptable. The Contractor shall establish a fixed Reference Datum against which pile settlement shall be measured. This Reference Datum shall itself be checked against other fixed datum during the pile test. Pile head settlement shall be measured to an absolute accuracy of plus or minus 0.5 mm and shall be corrected for changes in temperature of the pile and measuring equipment. Rate of settlement shall be continuously recorded with equipment accurate to 0.01mm. Pile load and settlement shall be continuously measured and the results shall be presented to the Engineer both in hard copy (on paper) and digitally (on CD) in a format agreed with the Engineer. The method of measuring the load on the pile shall also be agreed with the Engineer. The adequacy of the pile in a tension test shall be assessed by Engineer by inspection of the pile load and settlement records. In the event that a pile fails a test the Contractor shall submit his remedial proposals to the Engineer for approval. Pile test equipment and temporary works shall not be dismantled from a particular test site without the approval of the Engineer. Pile test equipment shall be maintained on site and available for use throughout the duration of the piling works and until released by the Engineer.
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7 7.1
ROCK WORKS ROCK WORKS PARTICULAR REQUIREMENTS

This section of the rock works specification contains particular requirements for the rock works to be undertaken under the Contract. The particular requirements take precedence over the general rock works specification contained under the rock works specification Clause 7.2 onwards.
7.1.1
Description of Work The scope of Rock Works covers the following elements: (1) Construction of a bund to form the closure behind the Western end of the quay wall as detailed on the Drawings. This bund will tie in with the existing reclamation bund constructed during the Advance Reclamation Bund Contract. (2) Increase the height of the existing bund constructed under the Advanced Bund Reclamation Contract along the section running due north and to the tie in with the existing terminal, to the level shown on the drawings. (3) Regrading of the slopes on the existing retention bund including reuse of suitable material in the Works were possible, to the permanent slopes shown on the drawings. (4) Removal of the bund core and rock armour from in front of the quay wall, after completion of the quay wall construction to form the dredged pocket. (5) Where erodable soil is encountered within the dredged pocket at the required formation level, scour protection may be required as directed by the Engineer.
7.2
7.2.1
GENERAL
General Rock supplies shall conform to BS EN 1338 or alternative standard proposed by the Contractor and approved by the Engineer and the following requirements. The Contractor is responsible for locating the source of the rock to be used in the works. In making his selection of the rock source the Contractor shall satisfy himself that the quarry has sufficient rock reserves to meet the stone volume required by the project and that adequate plant exists or can be procured to meet his construction programme and rock delivery schedules. In making this assessment the contractor shall give proper consideration to the stone delivery method in regard to the transport planning and the impact of the rock delivery on public infrastructure, residential communities and the ecology. Along the rock delivery route the assessment shall include dust, noise, vibration, frequency of vehicle movements, navigation and moorings and hours of working.
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7.2.2
Terms and Definitions Terms and definitions to be applied to this rock specification shall be those defined in EN 13383 Clause 3.
7.3
7.3.1
MATERIALS
Source of Rock The Contractor shall be responsible for locating acceptable sources of rock. No quarrying shall commence until it has been demonstrated to the Engineer that the rock will comply with the requirements of the Contract and that the quarry/(ies) can supply the required quantity and specified stone sizes within the Contractors programme. All rock shall be hard with good durability, free from laminations and weak cleavage planes and be of such character that it will resist disintegration or erosion by the action of air, water, wetting and drying, freezing and thawing and impact due to wave action. Individual pieces shall be prismoidal in shape and shall be free from all holes drilled for blasting purposes. The rock used shall be capable of being handled and placed without fracture. When fracture does occur the fractured rock shall be removed and disposed off-site at the Contractors own expense, unless the Engineers written permission is given for the rock to be incorporated into the final works. The Contractor will be deemed to have allowed for this removal in the Contract rates and prices. At least 21 days prior to the commencement of quarrying operations for rock supplies to the site, the Contractor shall provide a statement of rock armour selection quality control procedures to be operated at the quarry, for the approval of the Engineer. This statement shall include but not be limited to: Assessments of any changes anticipated in the geology of the production faces during the duration of the contract likely to affect block composition or integrity; An assessment of the volume of rock required to achieve each of the specified rock grades; The selection of a blasting pattern such that it minimises the production of latent fractures; Orientation of armour stone production faces to minimise the influence of fractures and discontinuities; Procedure for rejection of out-of-size and fractured materials (as detailed elsewhere in this Specification) prior to dispatch. Procedure for removal of overburden Control of fines content in the rock to be delivered to site.
7.3.2
Rock Grading Rock Armour The gradings of the various classes of rock material for the bund works are shown in the following tables. The grading system is generally in accordance with the system described in "Manual on the Use of Rock in Coastal and Shoreline Engineering", Construction Industry Research and Information Association (CIRIA) Special Publication 83, Netherlands Centre for Civil Engineering Research and Codes (CUR) Report 154.
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Rock Layer Size (m) W50 ELCL LCL UCL EUCL Type D50 0-2% 0-10% 70-100% 97-100% Nominal Range Nominal 0.45 Rock Armour 0.57 0.15 0.225 0.75 1.125 0.5 0.55 Nominal Wt = 0.5t Table 7.1- Rock Armour Grading Rock Weight (tonnes)
The grading system is analogous to Particle Size Distribution charts for aggregates but the horizontal axis is the weight of a rock instead of a sieve size, and the vertical axis is the "cumulative percentage by weight of all rocks in a given sample that are lighter than", instead of the "percentage passing". The system adopted here refers to a series of specified weights of stones (rock sizes ELCL, LCL, UCL and EUCL in increasing size order) and the associated allowable range of "y", the "cumulative percentage by weight lighter than" values. The specified weights and allowable range of "y" are defined as follows: Rock Size Class EUCL Extreme Upper Class Limit UCL Upper Class Limit LCL Lower Class Limit ELCL Extreme Lower Class Limit Table 7.2 Class Limit Definitions y value (%) 97-100% 70-100% 0-10% 0-2%
The median weight (of any random sample comprising at least 20 individual rocks) shall be within the limits stated in the table as the Range for W50. Quarry Run (bund core) The quarry run bund core shall comprise well-graded rock varying in weight from 0.5kg to 5kg. For the purpose of this Sub-Clause the term well-graded shall mean that the coefficient of uniformity (D60 divided by D10) is no less than 3.0. The core material when placed shall contain no more than 5% by weight of stones greater than 3kg. No stone shall have a weight greater than 5kg. Up to 5% by weight may be less than 0.5kg. 7.3.3 Rock Properties Rock properties shall conform to the requirements described in the following table. Clause references refer to BS EN 13383 clauses.
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Property Process Type Petrographic Type Density Length-toThickness Ratio Crushed or Broken Surfaces Water Absorption Resistance to Breakage Resistance to Wear Resistance to Freezing and Thawing Resistance to Salt Crystallization Block Integrity
BS EN Symbol
BS EN Ref 3 Annex C 5.2
Description Production method Geological classification Oven dried particle density Overall shape
Primary Armour Requirement Natural Igneous or metamorphic Min 2.65 Mg/cu.m. Max 5% greater than 3:1 LTA Cat
Secondary Armour & Core Requirement Natural Sedimentary, igneous or metamorphic Min 2.65 Mg/cu.m. Max 20% greater than 3:1 RO5 Max 5% by number with less than 50% crushed or broken surfaces WA1.5 Max STET 1.5% gain in mass CS 80 MDE20 FTA Min mean value of 60 MPa Max micro-Deval coeff: of 30 Max typical value of 0.5% loss of mass MS25 Max 25% loss of mass No significant fracture when dropped 1.5m onto horizontal test bed of secure heavy armour rock SBA No significant sign of decay No requirement SBA MS25 FTA MDE30 CS 60 WA1.5 RO5 LTA Cat
LT
4.3
RO
4.4
Amount of nonrounded surfaces
Max 5% by number with less than 50% crushed or broken surfaces
WA
7.3
Amount of water absorbed when immersed
Max STET 1.5% gain in mass Min mean value of 80 MPa Max micro-Deval coeff: of 20 Max typical value of 0.5% loss of mass Max 25% loss of mass No significant fracture when dropped 1.5m onto horizontal test bed of secure heavy armour rock
CS MDE FT
5.3 5.4 7.4
Compressive strength Resistance to abrasion Resistance to loss of mass due to freezing
MS
7.5
Resistance to magnesium sulphate solution
Annex B
Presence of internal flaws or fissures
Sonnenbrand Colour
SB
7.6 5.6
Decay in basalts General colour within natural variation
No significant sign of decay No requirement
Table 7.3: Rock Properties
7.4
7.4.1
ROCK TRANSPORT, STOCKPILING AND PLACEMENT

Rock Transport and Stockpiling The Contractor shall prepare a report on the proposed method of transporting the rock from its source to delivery on site. The report shall identify the actions taken to minimise the environmental and infrastructure damage resulting from the transportation of the
rock to site. The Contractor shall obtain all necessary permissions from Local or relevant Authorities to his proposed rock transportation procedures and abide by all consent conditions imposed by the Local or relevant Authority. The report shall be submitted to the Engineer as part of the quarry/rock approval process. Each delivery of armourstone shall have a System 4 CE conformity marking if the site is in the EC. If the site is not in the EC the Contractor shall have produced a report showing compliance with the test specification requirements. The number of times the tests to be undertaken to re-confirm the quality of the rock shall be as specified in the remainder of this specification. Each rock delivery shall be accompanied by a written certificate stating the quantity of rock delivered for each rock grading. Different rock classifications shall be stored in separate stockpiles. Stockpiles shall be actively managed to avoid mixing of different rock classifications and contamination of the rock by other materials. Rock stockpiles and the plant used to handle the rock shall be managed to avoid damage to any permanent works or existing pavements or existing structures. The Contractor shall maintain a register of calculated quantities of each category of rock on site in the stockpiles. A copy of the register shall be provided to the Engineer on a weekly basis. The submission of this information shall not be construed as relieving the Contractor of any of his contractual obligations. 7.4.2 Handling and Placement of Rock Primary Armour Rock Rocks shall be individually selected and placed in a systematic manner. Light armour stone with a NUL < 300kg may be placed with several stones at a time. Rocks shall not be dropped into position and the method of handling the rock shall not cause damage to the rock. The Contractor shall submit a method statement showing handling and placement procedures which shall include a risk assessment for handling the rock. Rocks shall be selected and placed to achieve an effective interlock with adjacent rocks. Each rock when placed shall be inherently stable and not liable to rocking movements under the action of wave forces that would degrade the contact points between adjacent rocks. Where rock is placed against existing structures the rock shall be placed to maximise the effective interlock with the structure. The upper surface of the rock layer shall be laid to the required profile and present a rough surface within the level requirements but avoiding concentrations of flat even surfaces. Where all reasonable effort has been made to achieve the required standard of interlock but some individual rocks remain less secure the rock may be made stable by the introduction of a smaller size rock. The smaller size rock should not be used as a packer or levelling rock that could be dislodged if the armour rock moves under wave action, but be a rock placed into a void in the lower rock layer that provides the required support to the larger rock and concurrently is trapped by the larger sized rock so that it cannot be dislodged by wave action. Rocks with a high length to thickness ratio and permitted by the specification, shall be evenly distributed through the rock layer.
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At the interface between rock layers special attention shall be given to the selection of rock to achieve an effective interlock while at the same time maintaining the specified profile. Where rock is required to be placed to a sloping profile the rock on the lower slope shall be placed before the higher level rock. Rock at the toe of a rock slope that provides support for a rock layer on the slope shall be placed before the slope rock is placed. Secondary Armour Stone Stone forming secondary armour shall be carefully placed to minimise disturbance or damage to core stone or underlayer materials. Provided underlayer material will not be damaged secondary armour stone may be dumped or tipped using methods approved by the Engineer to the profiles shown on the drawings. The surface of the secondary armour stone shall be trimmed to level and tolerance. The surface produced shall provide an effective interlocking layer with the main armourstone. Where the rock is to be placed on a slope the same specification requirements for the armourstone shall apply to the secondary armour. Core Material Rock fill forming the core to breakwaters and revetments shall be placed by grabbing, dumping or tipping. The method to be used shall be chosen to minimise the amount of slope profiling required following placement. The core material shall be profiled to the required tolerance and have a finish that provides an effective interlocking surface for covering with armour stone grade rock. The fines content of the core material shall be strictly controlled in accordance with the particular specification requirements. The method of placement of the core material shall not encourage segregation of the different rock sizes. Where the particular specification requirements define a minimum volumetric density or maximum volumetric void ratio the Contractor shall demonstrate that these values have been achieved by the test methods specified. 7.4.3 Surplus Rock All surplus rock supplied to the site shall be removed from site at the Contractors expense unless specific provisions have been made within the Contract for the disposal or storage of the surplus rock on the site. The transportation and storage of rock on the site, or in the port, shall be organised to minimise any disruption to the port operations.
7.5
7.5.1
TOLERANCES
Rock Profiles and Placement Tolerances Rock structures shall be constructed to the formation levels and rock layer profiles as shown on the Drawings and when the surface profile is measured using the techniques specified below, shall comply with the vertical tolerances in the following table.
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Depth Of Placing
All Rock Apart From Primary Armour +0.2m +0.5m -0.3m
Dry, i.e. above C.D. Below C.D.
All Primary Armour Layers On Individual Design Profile To Measurements (m) Actual +0.3 Dn50 +0.35 Dn50 -0.25 Dn50 +0.5 Dn50 +0.6 Dn50 -0.4 Dn50
Table 7.4: Vertical Placing Tolerances for Rock
Note: All tolerances refer to the design profile to actual mean profile unless stated otherwise. Notwithstanding the tolerances in Table 7.4 the following shall apply to armour layers: The tolerances on two consecutive mean actual profiles shall not be negative. Notwithstanding any accumulation of positive tolerances on underlying layers, the thickness of the layer shall not be less than 80% of the nominal thickness when calculated using mean actual profiles. Where an accumulation of positive tolerances arises and is acceptable to the Engineer, the position of the design profiles will need to be adjusted to suit. The difference in level of the peaks of adjacent rocks in upper layers shall not exceed the given tolerance.
7.5.2
Settlement of the Structures The Contractor shall assess settlement of the structure during and after the construction of the structure and shall make due allowance for the same. It is the sole responsibility of the Contractor to estimate the anticipated settlement of the structure based on the available soil data and/or his own soil investigations and his sequence of construction and to suitably construct the structure to an elevation that, at the end of the Maintenance Period, corresponds to the profile as on the Drawings.
7.6
7.6.1
SURVEYS FOR ROCK WORKS

Pre-Construction Survey Before construction commences, the Contractor and the Engineer shall undertake a preconstruction survey of the areas where the works will be constructed. Lines of sounding of the seabed shall be taken at a maximum of 10 m centres orthogonally to the baselines agreed with the Engineer. The Engineer may order, if deemed necessary, additional soundings along intermediate cross lines. The Contractor shall produce drawings showing the seabed levels and revetment profiles relative to CD. The drawings of the seabed soundings shall be to scales agreed with the Engineer (however in no case shall they be greater than 1:500) and, if present, shall show the location and nature of any obstruction such as boulders, wrecks, etc. within the area of rock work construction. Three paper Copies and one digital copy (in a format compatible with AutoCAD 2007) of each drawing shall be produced and retained equally by the Contractor and the Engineer, for record purposes. These drawings shall be approved in writing and signed by the Contractor and Engineer
as a true record before commencement of the actual rock revetment works. These drawings, together with the design drawings, shall be the basis for measurement of the quantities of materials placed in accordance with the Contract. The Contractor shall allow in his work programme for the above-mentioned procedure, which shall be entirely at his expense. 7.6.2 Interim Surveys The Engineer will give monthly certificates on account of sums which may become payable. Interim measurements will be based on agreed joint surveys. These surveys are at the Contractors cost. The Contractor shall present interim measurement certificates for checking including backup calculations. These surveys are for the sole purpose of estimating interim quantities and interim payments. Under no circumstances shall these measurements be considered as final approval for work being carried out. 7.6.3 Post-Construction Surveys On completion, or alleged completion, of all rock work an out or post-survey shall be carried out. If it is found for whatever reason that the required profile has not been attained or the required slopes not properly formed, the Contractor shall further increase, extend or correct such areas as necessary, all to the satisfaction of the Engineer. A further joint survey of the area shall then be made for the purpose of final measurement. These surveys are at the Contractors cost. 7.6.4 Inspection and Control The Contractor shall provide the following for the control and inspection of the breakwater and rock revetment construction: 7.6.5 A system of shore based survey control stations. A system of flexible survey equipment.
Measurement Techniques Measurements to survey the profile shall be carried out using a probe with a spherical end of diameter 0.5Dn50. For a land-based survey this will generally be connected to a staff or EDM target; for an underwater survey it will generally be a weighted ball on the end of a sounding chain. Measurements shall be carried out at the following intervals across the measurement profile: All rock surfaces except the Primary Armour Layers 1m Primary Armour Layers 0.75 x Dn50
Measurement profiles shall generally be at intervals along the length of the structure, not exceeding 10m centres, but may need to be more frequent where the profile is changing rapidly or on tight-radius curves. The sections shall be taken as the work progresses and before the structure is backfilled or covered by a subsequent layer or by a beach.
No layer shall be covered by a subsequent layer until the profile of the former layer has been approved.
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8 8.1
8.1.1
CONCRETE GENERAL
Standards Concrete for the Works shall comply in all respects with BS 63491:2000 supplemented by BS EN 206-1 and BS 8500-2:2006.
8.1.2
Concrete for the Works Where the Contractor proposes to produce concrete on Site, he shall submit details of his conformity and production control procedures to the Engineer for approval prior to the preparation of the trial mixes required by Clause 8.3.30. Once approved, the Engineer will monitor the operation of those procedures during the course of the Works and any deviations there from will be corrected by the Contractor at his own expense. Suppliers of ready-mixed concrete shall be subject to the approval of the Engineer and shall demonstrate to his satisfaction that they can produce concrete conforming to BS 8500-2:2006 and with this Specification. Should the use of ready-mixed concrete from a particular supplier be below the required standard, the Engineer may, at his discretion, withdraw his approval of the use of that supplier. The Contractor will be required to provide the Engineer with the information listed in Clause 8.2.7 for each concrete to be used in the Works. The cost of supplying this information shall be borne by the Contractor. Where the Engineer is satisfied that a ready-mixed concrete producer has adequate quality control facilities combined with satisfactory test records to ensure the consistent production of the required concretes specified in Clause 8.2.1, he will approve the production of concrete accordingly. Notwithstanding such approval the Engineer will require routine identity testing for compression strength.
8.1.3
Self-compacting Concrete Proposals to use self-compacting concrete (SCC) in lieu of one or more concretes specified in Clause 8.2.1 will be given full consideration by the Engineer. The proposals must demonstrate that the performance of the SCC in the hardened state will be at least equal to that for which the designed concrete was specified. The Contractor and Engineer shall agree jointly the parameters and testing regime for the SCC prior to the Engineer giving approval for its use. Concrete Society Technical Report No. 62 Selfcompacting Concrete A Review shall be used for reference and guidance.
8.1.4
Quality Assurance and Standards Where any work, goods or materials covered in this Section of the Specification are the subject of an accredited third party quality management scheme or an accredited third party product certification scheme, then only work, goods or materials conforming to such a scheme shall be used in the Works. In each case the Contractor shall supply the Engineer with a copy of the current certificate of conformity with that scheme.
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8.1.5
Terms and Definitions The terms and definitions given in BS EN 206-1:2000, BS 8500-1:2006 & BS 85002:2006 apply to this Specification.
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8.2
8.2.1
SITE SPECIFIC REQUIREMENTS

Concrete Schedule
The concretes below shall be supplied as designed concretes in accordance with this specification and the relevant clauses of BS 8500Concrete Reference Compressive strength class Minimum cement/combination content kg/m Maximum water/cement ratio Permitted cement or combination types Special cement Aggregate Type Coarse Fine Maximum aggregate size, mm. Chloride class Consistence (Workability) Special Aggregates Admixtures Slump, mm or slump class Coarse Fine Specified Permitted Amount Air content Air Temperature on Placement C Density of Concrete kg/m
3 1 3
C50XS C40/50 380 0.40 CEM1, IIB-V or IIIA 10/20 to BS EN 12620 0/4 (MP) to BS EN 12620 20 C10,20
C40XSF C32/40 360 0.42 CEM 1, IIB-V or IIIA 10/20 to BS EN 12620 0/4 (MP) to BS EN 12620 20 C10,20 S3 Yes -
C40XS C32/40 360 0.42 CEM 1, IIB-V or IIIA 10/20 to BS EN 12620 0/4 (MP) to BS EN 12620 20 C10,20 S3 Yes -
Blinding GEN 0
20 S3
Maximum Minimum Maximum Minimum kg/m

3
Fibres
As clause 8.3.26
Notes
1 The dosage of any admixture shall be in accordance with the manufacturers recommendations and shall be agreed with the Engineer on Site.
Additional grades and cements may be added at the direction of the Engineer. 8.2.2 Permitted Types of Cement and Combinations Permitted types of cement and combinations specified in Clause 8.2.1 are defined in Table 1 of BS8500-2. 8.2.3 Cement Properties
Property Alkali Limit Tricalcium Aluminate (C3A) Value 0.6% 10% max
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8.2.4
Permitted Aggregates
Type Natural Lightweight Standard Specification BS EN 12620 Not Permitted
8.2.5
Aggregate Properties
Property Coarse Aggregate Grading Fine Aggregate Grading Flakiness Index Resistance to Fragmentation Water Absorption Shell Content Aggregate Abrasion Value Drying Shrinkage to BS EN 1367-4 Specific Gravity (Saturated Surface Dry) Fines Content Coarse Aggregate Fines Content Fine Aggregate Acid Soluble Sulphate Content (SO3) Water Soluble Chloride Content Value or BS EN 12620 Category GC85/20 GF85 FI35 LA40 2.5% maximum SC10 AAV15 0.075% maximum 2.6 minimum f1.5 f3 AS0.2 0.10% maximum
8.2.6
Maximum Chloride Content

Use plain concrete reinforced concrete with CEM I or cements containing pfa or ggbs reinforced concrete with CEM I C3A<4% prestressed & heat-cured concrete * See BS EN 206-1, Table 10 Cl0,15 Cl0,10 0.15% 0.10% Chloride Content Class Cl0,50 Cl0,20
*
Maximum Cl content by mass of cement

*
0.50% 0.20%
8.2.7
Information to be submitted to the Engineer

Clause 8.1.4 8.1.5 8.3.2 8.3.3 8.3.10 8.3.18 8.3.21 8.3.25 8.3.29 8.3.34 8.3.36 8.3.42 8.4.24 Requirement Certificates of Conformity Proposal to use Self-compacting Concrete Approval of Supply of Materials Sampling & Testing of Materials Sources of Aggregates Site Processing of Aggregates Approval of Admixtures Approval of Corrosion Inhibitor Prior Approval of Mix Proportions Proposals for Minimising the Risk of Damaging Alkali-Silica Reaction Approval of Batching Methods Mixing Plant Position & Form of Construction Joints Required Yes Contractors option Yes Yes Yes Yes Yes Yes, if appropriate Yes Yes Yes Yes Yes
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8.2.8
Identity Testing Requirements Testing, including identity testing for compressive strength and slump, shall be carried out in accordance with Clauses 8.3.31 to 8.3.38 inclusive.
8.3
8.3.1
STANDARD SPECIFICATION CONCRETE MATERIALS, BATCHING, MIXING, TRANSPORTATION, PLACING, COMPACTION & CURING
Permitted Types of Materials See Clause 8.2 and Clauses 8.3.2 to 8.3.26 of this Specification.
8.3.2
Approval of Supply of Materials Prior to ordering or bringing on to Site any materials for use in the production of concrete, the Contractor shall submit to the Engineer for his written approval the following information:
Material Source, including country of origin Manufacturers Name Brand Name Evidence of conformity with BS 8500-2:2006 Chemical Composition Other Information Clause 8.3.8 Clause 8.3.9 Required Clause 8.3.21 Clause 8.3.26 Clause 8.3.19 Required Required Required Required Required Required Required Required Required Required Required Cementitious Materials Required Required Required Required Required Aggregates Admixtures Fibres Water
The approval of the Engineer to any particular material shall not in any way lessen his power to order the removal of any consignment of that material from the Site if that consignment does not comply in every way with the requirements of this Specification. 8.3.3 Sampling and Testing of Materials Notwithstanding the submission by the Contractor of the information detailed above, the Engineer may at any time order any further tests which he considers necessary for the purpose of establishing the true quality of the concrete produced by the proposed materials under actual Site conditions. Any consignment of material delivered to Site may be subject to testing, if directed by the Engineer. Material in storage may also be subject to testing to check that it has not deteriorated. The Engineer shall take samples from different containers and he will despatch them to a laboratory approved by him. Should the results of any of the tests provided for in this Clause show that any sample fails to meet the minimum requirements of this Specification, the whole consignment to which the sample belongs shall be rejected and be removed from the Site.
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8.3.4
Failure to Supply Certificates or Carry Out Tests Failure to comply with either of Clauses 8.3.2 or 8.3.3 will render liable to rejection by the Engineer all work containing unapproved materials.
8.3.5
Delivery of Materials Materials for concrete shall be delivered to the Site in such consignments as shall ensure satisfactory progress of the Works. Except where bulk delivery is approved, those materials shall be packaged by the manufacturer in bags or containers that are so designed as to prevent any contamination and to minimise the adverse effects of moisture and high humidity during transportation and storage. All bags and containers shall be delivered sealed to the satisfaction of the Engineer. Each bag or container shall be adequately and permanently marked with: the manufacturers name; the name of the producing works; the material type; the standard specification to which it was produced; the date of manufacture or date code and the batch number, so as to enable correlation to be made of every part of each consignment with the relevant test certificates and delivery notes. All materials shall be properly protected from the weather and from contamination of any kind during delivery to Site. Any material which proves to have been damaged or contaminated in transit will be rejected upon delivery. Materials delivered in split bags or containers will be rejected. Where any material is being imported the Contractor shall supply the following details for all shipments intended for delivery to Site: date of manufacture, date of original loading, destinations en-route, date of unloading and intended date of delivery to Site. Where bulk deliveries are proposed the Contractor shall obtain the prior consent of the Engineer to the method of delivery and shall provide all information required by the Engineer concerning off-site storage and loading arrangements. He shall also provide reasonable facilities for the Engineer to inspect these arrangements for approval and routine inspection purposes. The temperature of cement delivered in bulk shall not exceed 65C. Aggregates from separate bins or from separate stockpiles at the source of supply shall be delivered to the Site in separate loads. Different sizes and gradings shall not be transported in the same vehicle simultaneously.
8.3.6
Storage of Materials If materials are to be stored in bulk containers this shall be subject to the prior approval of the Engineer. The containers shall be large enough to contain such quantities as may be required with sufficient reserve to allow for the likely frequency of supply. All material stored in bulk containers shall be, in the opinion of the Engineer, adequately protected against rain, humidity, dewfall and dust, and all charging and discharging
points shall be properly sealed. Aeration equipment for the bulk containers, if available, shall incorporate dehumidifiers. If packaged material is stored in bulk containers it shall be charged into the containers through a 5mm mesh screen which is welded or bolted to and covers the entire feed area of the charging hopper. Material not stored in bulk shall be kept in the bags or containers in which it was delivered until use. It shall be stored in a Dry Store large enough to contain such quantities as may be required with sufficient reserve to allow for the likely frequency of supply. This store shall be dry, well ventilated, weatherproof and waterproof and shall be situated in a location not liable to flooding. Each different type of material, especially cementitious material, shall be stored separately from any other material. All cementitious materials shall be used in the order in which the consignments are delivered to the Site. In general they shall be used as soon as possible after delivery and in any event they shall not be used more than 12 months after manufacture, or when tests carried out on instruction of the Engineer show that the loss on ignition exceeds 4%. Notwithstanding the above provision, any cement which the Engineer considers has become stale or unsuitable through absorption of moisture from the atmosphere or for other reasons shall be rejected and removed from the Site at the Contractors expense. Any cement in containers damaged so as to allow the contents to spill or to be affected by atmospheric moisture prior to opening at the time of concrete mixing shall be rejected and removed from the Site at the Contractors expense. Aggregates shall be stored in approved containers or on hard paved areas with adequate dividing walls to prevent mixing of different types and sizes of aggregates. The surrounding areas where aggregates may be handled shall also be hard paved. Containers and storage areas shall be self-draining. Particular care shall be taken in the construction and maintenance of such containers or storage areas and in the handling of materials to ensure that contamination by extraneous material such as air-borne dust or by harmful salts in the ground is prevented. During delivery to and handling from the stockpile, care shall be taken to avoid crushing the aggregates or contamination with extraneous matter. The general or localised build-up of fines or segregation of sizes in aggregate stockpiles shall not be allowed. If the Engineer is not satisfied that such segregation or build up of fines has been prevented he may instruct the Contractor to turn over the contents of any stockpile or to remove all or part of the contents of any stockpile and either reprocess or dispose of such material. The Contractor shall also employ such methods as may prove necessary to ensure effective cooling of the aggregates prior to batching for concrete (such as provision of sun-shades), subject to the approval and/or discretion of the Engineer. Spraying the aggregates with water will not be permitted.
8.3.7
Performance Characteristics Notwithstanding apparent compliance with all other requirements of this Specification, the Contractor shall be responsible for satisfying himself that the performance characteristics of the materials used in the Works are not such as to necessitate the use of excessive cementitious contents or be likely to cause or accentuate any undesirable properties in the fresh or hardened concrete.
8.3.8
Permitted Types of Cementitious Materials Cement or combinations of cement with ground granulated blastfurnace slag (ggbs), pulverised-fuel ash (pfa) or microsilica (also referred to as slag, fly ash and silica fume respectively) or other additions such as super fine ash and metakaolin shall comply in all respects with the requirements of Clause 8.2.2. Unless specifically stated elsewhere, CEM I conforming to BS EN 197-1 shall be Class 42.5N.
8.3.9
Aggregates - Standard Specifications Aggregates supplied to the Site shall generally be naturally occurring gravel, sands and/or crushed rock complying with the requirements of BS EN 12620, except as otherwise stated in this Specification. Lightweight aggregates shall not be used without the written approval of the Engineer unless specified as a requirement.
8.3.10
Sources of Aggregates In selecting his sources of aggregate, the Contractor shall take due account of the requirements of Clause 8.3.34 of this Specification. The Engineer shall have the right to inspect all proposed quarries. No surface of decomposed rock shall be used as coarse aggregate. Coral or coral caprock shall only be used after a rigorous programme of testing and trial concretes have shown it to be suitable for concrete for use in the Works and where evidence of the satisfactory performance over a period of at least 10 years of concrete made with aggregate from the same source or sources is available.
8.3.11
Grading of Aggregates Grading categories shall be as defined in BS EN 12620.

Coarse Aggregate Fine Aggregate All-in aggregate Coarse aggregate shall be delivered to the site already graded to category GC85/20. Alternatively it shall be delivered and stored in single sizes and combined on batching to provide grading category GC85/20. Fine aggregate shall be grading category GF85 and the limits shall be 0/4(CP), 0/4(MP) or 0/2(MP), unless otherwise approved by the Engineer. Neither All-in aggregate to grading category GA90 nor crushed stone sand shall be used for reinforced concrete. They shall only be used for unreinforced concrete with the express written permission of the Engineer.
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8.3.12
Aggregate Properties Where aggregate properties are given in Clause 8.2.5 as maximum or minimum values, lower or higher values as appropriate may be required to satisfy the overall limits for chloride contents specified in Clauses 8.2.6 and 8.3.28. Further requirements are given in Clause 8.3.34.
8.3.13
Staining Aggregates shall not be composed of or contain inclusion of materials likely to cause staining or otherwise disfigure finished concrete surfaces.
8.3.14
Drying Shrinkage The properties of the aggregates shall be such that the Initial Drying Shrinkage of all proposed concretes shall not exceed the limits given in Clause 8.2.5. These concretes shall be prepared and tested in accordance with BS EN 1367-4 under approved conditions in the laboratory on the Site or in an approved independent laboratory.
8.3.15
Washing of Aggregates Aggregates shall be washed free of all organic or other impurities in an efficient washing plant before delivery to Site. Tests to check the efficiency of the washing of the aggregates shall be made at regular and frequent intervals and any found to be unsatisfactory shall be rejected.
8.3.16
Sampling and Testing of Aggregates Tests, including grading and tests for chemical, physical and mechanical properties of the aggregate and the presence of deleterious impurities, shall be carried out as required by the Engineer. The Engineer shall have the right to require the Contractor at any time to test samples of aggregates drawn from locations as indicated by the Engineer. Sampling shall be carried out in the presence of the Engineer.
8.3.17
Fines Content (Silt, Clay & Dust) The fines content of aggregate shall be as specified in Clause 8.2.5.
8.3.18
Site Processing of Aggregates If the Contractor wishes to process his own aggregates on Site he shall submit to the Engineer full details of his proposals, including details of plant and equipment to be used and supervision, and shall obtain the approval of the Engineer, in writing, before proceeding. In giving his approval for Site processing the Engineer may lay down additional requirements with regard to sampling and testing of aggregates or may call for additional processing stages in order to ensure that the full requirements of this Specification are met.
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8.3.19
Water for Concreting All water used for the mixing of concrete, grouts or mortar shall conform to BS EN 1008.
8.3.20
Testing of Water Tests on the purity, soluble sulphate, chloride or other chemical content, sediment and pH value shall be carried out at such times as the Engineer may direct. The Contractor shall arrange for the despatch of samples of water to an approved testing laboratory and for the testing required. The Engineer shall witness sampling and testing.
8.3.21
Approval of Admixtures Except where specified in Clause 8.2.1, no materials of any description shall be used in any concrete mix other than aggregates, cement and water without the written instruction or approval of the Engineer in each case. The following information shall be submitted to the Engineer for each proposed or specified admixture: Information required by Clause 8.3.2 Chemical composition Shelf life Storage & handling requirements Effect on concrete mix, including adjustments required to the mix proportions to achieve required compressive strength and rate of strength gain.
The Engineer will call for trial batches of concrete to be prepared to demonstrate the effect of the proposed admixtures both on the fresh concrete and on the hardened concrete before giving his approval. He may also lay down additional requirements for the control of the use of such admixtures. Admixtures shall not be used which produce concretes that are more porous, have inferior surface structure, or are more susceptible to humidity or temperature movement than the corresponding concrete grade made without admixture. Admixtures that affect the density of the concrete, such as air-entraining agents, may be permitted provided strict control is maintained over the amount of entrained air. Notwithstanding any previously given approval, the Engineer may withdraw such approval at any time with respect to any concrete containing admixtures if, in his opinion, the performance of the particular admixture under actual Site conditions is not completely satisfactory. 8.3.22 Supply and Storage of Admixtures Admixtures for concrete shall comply with BS EN 934-2 unless otherwise Specified or agreed.
All admixtures to be used in dose forms shall be supplied in containers or packages marked with the recommended dosage for each type of mix in which they are to be used. Admixtures shall be stored strictly in accordance with manufacturers recommendations and precautions shall be taken during delivery and storage to prevent damage to or adulteration of admixtures. This may include cleaning off sediment from the bottom of a storage tank, regular stirring, etc. Any cement containing admixtures shall be supplied in bags or containers clearly marked to show the nature and quantity of such admixtures and shall be stored separately in accordance with the requirements of Clause 8.3.6. 8.3.23 Use of Admixtures Admixtures approved by the Engineer shall be used strictly in accordance with the manufacturers instructions, within his recommended ambient temperature range and at the approved dosage. Any batch of concrete which has received an incorrect dose of an admixture or which shows deterioration after placing as a result of incorrect use of admixtures shall be broken out or otherwise replaced without charge to the Contract. Both liquid and powder admixtures to be used as solutions shall be dispensed by an appliance fixed to the mixer, which measures weight, volume or dosing time and is provided with a recorder. This appliance shall be accurately calibrated and the calibration and dosage shall be checked at regular intervals or as directed by the Engineer. All such admixtures shall be dispensed with the mixing water. All admixture dispensers shall be thoroughly cleaned before commencing each days work and at every interruption to the work. Where admixtures are to be used in bulk form, these shall be weigh-batched as is provided in this Specification for the batching of cement. Powder admixtures to be used in dose form shall only be allowed if premixed and used as solutions, providing that the premixing procedure has been previously approved by the Engineer. Trial mixes shall be prepared as described in Clause 8.3.30, together with additional trial mixes showing the effects of overdosing and underdosing of the admixture. 8.3.24 Chlorides Under no circumstances shall calcium chloride or chloride based admixtures be used in any concrete mix, grout or mortar. The chloride content of the total mix shall comply with Clause 8.3.28.
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8.3.25
Corrosion Inhibitor The use of proprietary cast in corrosion inhibitors, whether specified or not, shall be subject to the written agreement of the Engineer. Their prime function shall be to form a protective film on the reinforcing steel. Proprietary corrosion inhibitors shall be added to the concrete in accordance with the recommendations of the manufacturer. The dosage and rate of application shall be established by the Contractor following consultation with the admixture manufacturer and shall be confirmed to the Engineer in writing.
8.3.26
Polypropylene Fibres Polypropylene fibres shall be properly engineered for use in concrete and shall be manufactured from virgin polypropylene. They shall be added to the concrete in accordance with the manufacturers recommendations. Unless otherwise agreed or recommended, the nominal dosage shall be at a rate of 0.9 kg/m3 of concrete.
8.3.27
Concretes Concretes for use in the Works shall comply with the requirements given in Clause 8.2.1.
8.3.28
Chloride Content of Concrete Mixes Notwithstanding the requirements given in this Specification for chloride contents of the constituent materials of the concrete mixes, Clause 8.2.6 shall apply to all concretes used in the Works. These limits shall be calculated as the total of the chloride contents of the individual constituents of each mix. The method for determining the chloride content of the individual constituent materials shall be in accordance with Table 4 of BS 8500-2:2006.
8.3.29
Prior Approval of Mix Proportions As soon as practicable after the commencement of the Contract, the Contractor shall produce in writing, for the Engineers approval, his proposals for all concretes set out in this Specification, stating proportions of all constituent materials, including admixtures, consistence, etc. The Contractor must note that ample time should be allowed for testing and obtaining the approval of the Engineer for all concretes, as provided below, before commencing the mixing of concrete for the permanent works on the Site.
8.3.30
Trial Mixes Prior to the use of any concrete in the Works the Contractor shall either: A) Prepare trial mixes for each different concrete to be used in the Works. Preparation and testing of trial mixes shall be carried out in the presence of the Engineer, if he so desires.
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For each trial mix three separate batches of concrete shall be made using the materials approved for use in the Works and, unless otherwise approved, under full-scale production conditions. If for any reason it is not possible to make any trial mix under full-scale production conditions then it may be made in a laboratory but only with the express permission of the Engineer and under such conditions as he may require. Particular attention shall be given to the water/cement ratio and consistence of these trial mixes. The free water content of all the aggregates used shall be accurately determined by drying or other approved means before mixing begins in order to give an accurate measure of the free water/cement ratio. The consistency of each trial mix concrete batch shall be measured by the Slump Test using the equipment and method given in BS EN 12350-2. The slump shall have a tolerance of 25mm or 1/3 the required value, whichever is the greater. In hot weather conditions graphs of slump v time since adding the water to the mix and slump v concrete temperature shall be prepared for use in production testing. If the slump is not within the permitted tolerance of the value specified, the proportions of the mix shall be adjusted accordingly and new trial batches shall be made. Both the ambient temperature and the temperature of the fresh concrete shall be noted when each slump test is made. For two of the trial mix batches a total of six 150mm cubes shall be made. These test cubes shall be made, cured and tested in accordance with the provisions of BS EN 12390-1. Unless otherwise directed by the Engineer, three of the six test cubes shall be tested for compressive strength at 7 days and three at 28 days. The third trial mix shall consist of twelve cubes, three cubes being tested at each of 3, 7, 14 and 28 days. OR B) If ready-mixed concrete is used, the Contractor may submit appropriate existing data as evidence of satisfactory previous performance for target mean strength, current margin, consistence, water/cement ratio and rate of gain of strength, together with details of the current product conformity certification held by the producer, as referred to in BS 8500-2.
8.3.31
Compressive Strength Requirement for Trial Mixes The compressive strength of a trial mix shall be considered satisfactory if the following requirements are met:(a) The nine cubes from the three batches of a trial mix that are tested at 28 days age shall have an average compressive strength not less than 1.2 x fcu + 5 where: fcu is the required characteristic cube strength in N/mm The compressive strength of each of the nine individual cubes tested at 28 days age shall not be less than 1.2 x fcu - 2.5
b)
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8.3.32
Consistence (Workability) Concrete shall be of such consistency that it can be readily worked into the corners and angles of the formwork and around reinforcement without segregation of the materials or bleeding of free water at the surface. On striking the formwork it shall present a face which is uniform, free from honeycombing, surface crazing, or excessive dusting, and which shall not, in the opinion of the Engineer, be inferior to the standard specified. To satisfy the Engineer that the consistence of the proposed concretes is adequate for the requirements of the Specification, the Contractor shall carry out a series of consistency tests on the preliminary trial mixes. The tests shall be carried out in accordance with BS EN 12350, or such other procedure as may be approved by the Engineer. The samples to be tested shall be obtained from the batches used for the preliminary test cubes. In addition the Contractor shall supply for each of the qualities of concrete a section of formwork complete with reinforcement fixed in position and generally representative of the sections commonly to be employed in the Works. The capacity of this trial section of formwork shall be at least half a batch of concrete, but in any case not less than half a cubic metre. The formwork shall comply with the requirements specified. The moulds shall be filled in the presence of the Engineer with concrete of the same mix and batch from which the preliminary test cubes are made and shall be compacted in the same manner and with the same equipment as are proposed for the Works. This procedure shall, if necessary, be repeated with modified mixes until the appearance of the concrete after striking the mould is acceptable to the Engineer, after which it shall be used as the standard for that quality.
8.3.33
Alterations to Approved Mixes If during the period of the Contract the Contractor wishes to alter the proportions of any mix or any constituent of the mix or the source of any constituent, he shall obtain the prior permission of the Engineer in each case. Additionally, if experience shows that any previously approved mix when used in the Works is inconsistent with satisfying the requirements of this Specification, then the Engineer may withdraw approval for this mix and direct the Contractor to produce an alternative. In either case the Engineer may require that additional trial mixes for the altered mixes be made and tested, all in accordance with the requirements of the preceding Clauses.
8.3.34
Minimising the Risk of Damaging Alkali-Silica Reaction The Contractor shall submit to the Engineer for approval his proposals for minimising the risk of alkali-silica reaction which shall be one of the sets of requirements given in Clause 5.2 of BS 8500-2. Detailed guidance is given in BRE Digest 330:2004.
8.3.35
Temperature of Concrete The strengths specified at 28 days or other earlier ages refer to test cubes cured at the temperatures specified in BS EN 12390-2. In order to allow for the effect of temperature outside this range which may occur during the mixing and curing of concrete, the Contractor shall prepare for the Engineers approval a table or graph showing the probable variation of characteristic strengths with temperature for each concrete to be
used in the Works taking the characteristic strengths quoted in this Specification at 20C as a datum. Once agreed these tables or graphs shall be used as a basis for the assessment of strength of concrete where the concrete was wholly or partly mixed and cured with temperatures outside the range specified in BS EN 12390-2. Similar sets of tables or graphs shall be prepared for approval for the strengths at appropriate earlier ages. 8.3.36 Approval of Concrete Batching Methods The Contractors arrangements for handling, batching, transporting and mixing of materials for concrete, together with all control procedures, shall receive approval in principle from the Engineer before any work commences on site. Detailed arrangements and Contractors personnel involved shall be approved by the Engineer before any concrete is produced for the Permanent Works. Particular attention shall be given to the batching of concrete containing cement replacement material. To ensure the proper dispersal of densified cement replacement material consideration shall be given to the mixing of cement replacement material with coarse aggregate and water prior to the addition of cement and fine aggregate. 8.3.37 Batching of Materials All materials for concrete shall be batched separately and by weight. 8.3.38 Weigh Batching Plant Weigh batching plant shall control delivery of cement, aggregates and bulk admixture to an accuracy of not worse than 2% on the individual weighing. For added water the accuracy shall be within 1% and for any dose-type additive the accuracy shall be within 5%. The weighing mechanism shall be checked and adjusted monthly and the Contractor shall provide simple and convenient means for this. He shall supply to the Engineer on request records of all check tests and adjustments made to the plant. The Engineer may at any time call for a check test to be made. 8.3.39 Water Content Due allowance shall be made for the weight of the moisture content of the coarse and fine aggregates and the Contractor shall make readily available to the Engineer assistance and equipment as required to carry out moisture content tests at intervals deemed necessary by the Engineer to suit local conditions. The amount of water used shall also take into account the moisture content of the aggregates. Water shall not be added to the mixer until just prior to the time when the concrete is to be mixed.
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8.3.40
Cement Batching If the cement is delivered in bags or individual containers, the sizes of batches shall be such that only full bags or containers of cement shall be used.
8.3.41
Rejection of Batched Materials Notwithstanding his previously given approval of the contents of any storage area, the Engineer may order the removal of any batch of aggregates prepared for charging into the mixers if he has reason to believe that such a batch is improperly graded or contaminated in any way.
8.3.42
Mixing Plant Concrete shall be mixed in mechanical mixers. The type and manufacture of these mixers, together with all associated plant, shall be subject to the approval of the Engineer. Where small quantities of high grade concrete are required the Contractor shall, if the Engineer so requires, provide small, portable, covered pan mixers of approved type for this particular work. Such covered pan mixers shall only be used as the Engineer may direct and all the conditions covering the mixing of concrete for large scale concreting shall apply to any mix prepared in pan mixers. Mixers shall be maintained within the manufacturers tolerances, with particular attention to mixing blade clearances and sizes, throughout the period of the Contract and any mixer or plant that is not so maintained or is faulty in any respect shall be removed from the work. All mixing plant, truck mixers and concrete delivery vehicles shall be wind proof. The requirements of Clause 8.3.52 shall apply in hot weather conditions.
8.3.43
Mixing Requirements The maximum size of the batch shall not exceed the maximum rated capacity of the mixer as stated by the manufacturer and as stamped on the mixer and the batch size shall not be less than 75% of such maximum. Mixing shall begin immediately after the cement has been added, either to the water or aggregate, and shall continue until there is a uniform distribution of the materials and the mass is uniform in colour and consistency or as directed by the Engineer. In any event, concrete shall be mixed for at least the period and at the drum speed specified by the manufacturers of the mixer. The entire contents of the mixer shall be removed from the drum before materials for a succeeding batch are placed in it. The solid materials composing a batch shall be deposited in the mixer in accordance with the manufacturers directions for use.
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Within 30 minutes after the introduction of the mixing water to the cement and aggregate, or the cement to the aggregate, the concrete shall be placed in its final position in the forms. This period may be extended with the prior permission of the Engineer provided the weather conditions are favourable and the concrete is continuously agitated in an approved purpose-built supply vehicle or an approved retarding admixture is included in the mix. If any mixer is out of operation for more than 20 minutes, it shall be thoroughly cleaned out together with all the handling plant, before any further concrete is mixed. All mixing and handling plant shall be thoroughly cleaned out before concrete, using a different type of cement or admixture, is used. 8.3.44 Hand Mixing Normally hand mixing of concrete will not be allowed, but where the total quantity is small, the mixing may be done by hand but only with the express permission of the Engineer. For hand mixing, the quantity of cement for any given concrete mix shall be increased by ten per cent and not more than one quarter of a cubic metre shall be mixed at one time. The water/cement ratio shall not exceed that approved for the particular class of concrete concerned. Hand mixing shall not be permitted for any structural concrete or where there is a particular requirement for the concrete to be durable. 8.3.45 Plant and Equipment The Contractor shall provide adequate means of transporting and placing mixed concrete in sufficient quantities to meet the programme. All plant and equipment shall be properly designed and constructed with regard to the efficient and rapid placing of the concrete and the safety of the Works and shall be approved by the Engineer before being used. All plant and equipment used for transport and deposition of concrete shall be kept clean and shall be washed out after each interruption in the work and at the end of each shift. Any proposal for the use of a concrete pump or placer and associated equipment shall be submitted to the Engineer, together with the fullest possible description of the apparatus and methods to be used. Trials may be required to demonstrate their suitability and that the concrete mix design is appropriate to this method of placing. The Contractor is to ensure that he has adequate back-up facilities to continue placing concrete if a mechanical breakdown occurs. 8.3.46 Transportation of Concrete The contents of the mixer shall be discharged in one continuous operation and the concrete transported in such a manner that there shall be no segregation of its constituents. If, in the opinion of the Engineer, any segregation of the concrete materials has taken place during transport, the concrete shall be again turned over and mixed just before it is finally placed in position. No water shall be added to the concrete between the time of mixing and placing except on the written instructions of the Engineer.
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Whilst being transported from the mixer to the site of placing, all concrete shall be properly protected from contamination by dust or sand and from excessive moisture gain or loss from rainfall or high temperature, and all equipment used shall be purpose-made for the correct transportation of concrete. 8.3.47 Preparation for Placing In preparation for the placing of concrete, all construction debris and extraneous matter shall be removed from the interior of forms. Standing water on areas to receive concrete shall be removed before concrete is placed. All exposed reinforcement shall be free from loose rust, scale and wind blown salts and spray. Placing of concrete shall not be commenced until the Engineer has inspected and passed the formwork or other areas to receive concrete and any reinforcement, cast in fixings etc., against which the concrete is to be placed. Any approval so given shall not relieve the Contractor of any of his responsibilities under the Contract. Where concrete is to be cast against an existing concrete face, that face shall have been prepared to expose the aggregate and all loose particles removed. This surface shall be wetted prior to receiving concrete. This preparation shall be subject to inspection by the Engineer. 8.3.48 Placing of Concrete Concrete shall be placed in the shortest possible time after mixing is completed and before it has taken an initial set. It shall be placed as close as possible to its final position to avoid segregation of materials and displacement of reinforcement. Normally concrete may be deposited with a maximum free fall of 1.5metres without the use of pipes, providing suitable measures are taken to prevent segregation and premature coating of upper reinforcing steel. When pipes are used they shall, as far as is practicable, be kept full of concrete during placing and their lower ends shall be kept buried in the newly placed concrete. In certain circumstances greater heights than 1.5metres may be allowed but only with the written authority of the Engineer following trials to establish the effect on the concrete. Chutes may also be used and shall be of steel or steel lined. They shall be constantly kept clean from coatings or hardened concrete or other obstructions. Chutes shall be set at such an angle that the concrete neither sticks to them nor does it become segregated. Concreting of any section or unit of the work shall be carried out in one continuous operation and no interruption of the concreting will be allowed without the approval of the Engineer. In cases where the approval of the Engineer is obtained and where delays of more than one hour occur between successive concreting when, in the opinion of the Engineer, the previously placed concrete has had time to harden, the resulting joint shall be treated as a Construction Joint. The previously placed concrete shall be cut back to a vertical and/or horizontal face and the joint face treated as required by Clause 8.4.24.
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8.3.49
Compaction of Concrete Except where self-compacting concrete is used, after concrete has been placed it shall be thoroughly compacted by mechanical vibration applied by immersion vibrators or, for surface finishing on thin slabs, approved surface vibrators or vibrating tampers. Vibrators shall only be used by competent operatives properly trained in the handling of the particular equipment in use on the Site. The equipment, manner and duration of use shall be selected and controlled to reduce health and safety effects on operatives, with particular reference to Hand Arm Vibration Syndrome (HAVS) and Whole Body Vibration Syndrome (WBVS). Immersion vibrators shall be of sufficient power to perform satisfactorily when immersed. The active part of the vibrator shall be fully immersed while in use and vibration shall be of sufficient duration and intensity to compact the concrete thoroughly, but shall not be continued at any one point to the extent that segregation occurs. Vibrators shall not be used to transport concrete in the forms. Vibrators shall be manipulated so as to work thoroughly the concrete around the reinforcement and embedded fixtures and into the corners and angles of the forms. Vibrators shall not be applied directly, or through the reinforcement, to sections or layers of concrete which have hardened to the degree that the concrete ceases to be plastic under vibration. Every care shall be taken to see that reinforcement and fittings attached to the shutters are not disturbed and that no damage is caused to the internal face of the shutters when using immersion type vibrators. Vibration shall be supplemented by such spading as is necessary to ensure smooth surfaces and dense concrete along form surfaces and in corners and locations impossible to reach with the vibrators. The Contractors attention is drawn to the importance of achieving a high degree of compaction in order to produce as dense a concrete as possible, but not over vibrating concrete against shutters thus causing an increase in the water/cement ratio local to the shutter. Where casting against existing concrete surfaces compaction should be ensured by local use of vibration to remove pockets of air that may be trapped, especially under horizontal surfaces.
8.3.50
Setting Concrete After the initial set of the concrete the forms shall not be jarred and no strain shall be placed on the ends of reinforcing bars which project. Adjacent works, which may cause vibrations to be transmitted to any setting concrete, may be ordered to be stopped at the discretion of the Engineer.
8.3.51
Records of Concrete Placing The Contractor shall keep a record of the date, time, shade air temperature, mix temperature, mix type and quantity and place of deposition for all concrete used in the Works and records of the samples taken and shall permit the Engineer to inspect these at any time.
8.3.52
Hot Weather Concreting In hot weather conditions, specific arrangements shall be agreed with the Engineer for controlling the temperature of fresh concrete. These arrangements shall include night or early morning working, prior cooling and/or shading of reinforcement and forms, shading of aggregate stockpiles, and shading of placed concrete from direct rays of the sun. The Contractor shall further note that the times quoted for mixing and placing and the frequency of cleaning of equipment may have to be modified in hot weather. Covering or other protection of concrete during transport may also be necessary. Trials shall be carried out to determine the adequacy of the control measures and the workability of the fresh concrete under those conditions. Chillers shall be used to cool the mixing water. Ice shall not be used. The Contractors attention is drawn to the recommendations of American Concrete Institute Standard ACI 305R-99, Recommended Practice for Hot Weather Concreting and of the CIRIA/Concrete Society Guide to the construction of reinforced concrete in the Arabian Peninsular. Unless otherwise directed by the Engineer, all items of equipment covered by this Clause shall be painted white to minimise solar heat absorption.
8.3.53
Cold Weather Concreting When concrete is placed at air temperatures below 2C, the following requirements shall be met: (i) (ii) The aggregates and water used in the mix shall be free from snow, ice and frost. The surface temperature of the concrete at the time of placing shall be at least 5C and shall not exceed 30C. The surface temperature of the concrete shall be maintained at not less than 5C until the concrete reaches a strength of 5 N/mm as determined by tests on cubes that were cured under identical conditions to the structural concrete, in a manner approved by the Engineer. Before placing concrete, the formwork, reinforcement, prestressing steel and any surface with which the fresh concrete will be in contact shall be free from snow, ice and frost. Cement shall not be allowed to come into contact with water at a temperature greater than 60C.
(iii)
(iv)
(v)
8.3.54
Protection against Rainfall The Contractor shall provide adequate cover as necessary to protect concrete whilst being placed against damage from rainfall.
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8.3.55
Curing - General Requirements The Contractor shall ensure that 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 suns rays. This period may be varied at the direction of the Engineer. Following the completion of the above period, a further period of controlled drying out will be required as directed by the Engineer. This may require that covers, sand layers and the like be kept in place for longer than the 7 day minimum curing period otherwise specified. The Contractors attention is particularly drawn to the importance of starting curing as early as possible after placing concrete and maintaining full curing procedures throughout, as specified and directed. Any concrete which exhibits plastic settlement or plastic or drying shrinkage cracking or which has not been properly cured is liable to rejection by the Engineer.
8.3.56
Curing Methods All methods to be used for curing and protection of freshly placed concrete must receive the prior approval of the Engineer. These methods shall include the use of curing membranes, water, covers, shades and any other precautions that are required for the Contractor to ensure satisfactory curing of the concrete. The Contractors attention is drawn to the recommendations of the American Concrete Institute Standard ACI 308-92, Standard Practice for Curing Concrete. The Contractor shall provide the necessary equipment and check for conditions in which plastic cracking is likely to occur (Ref. ACI 305R-99).
8.3.57
Curing Membrane Where used, curing membranes shall be of resin based white reflective type and shall be sprayed on the surface of the concrete as soon as all free water has evaporated from the surface, except where provided for below. In the case of formed surfaces, where formwork has been eased or struck before seven days have elapsed from the date of placing concrete within them, the curing membranes shall be applied immediately after the formwork has been removed. In every case the rate of coverage and method of application shall be according to the manufacturers instructions. Where a surface treatment is to be applied to the concrete (e.g., a surface hardener) a curing membrane shall only be used if it is compatible with the surface treatment.
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8.3.58
Water Curing Where water curing is adopted, the concrete shall be covered with sacking, hessian, or other absorbent material, or a 75mm layer of sand, kept constantly wet for 7 days and, where directed by the Engineer, also covered with plastic sheeting to reduce loss by evaporation. Water for curing shall comply with Clause 8.3.19. 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.
8.3.59
Use of Covers Curing of concrete surfaces may 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. If necessary, the Contractor shall provide frames for the plastic sheeting so that the covers can be placed over deck slab pours immediately after the concrete has been floated off and before the brush finish is applied. Such frames can be removed as soon as the concrete is strong enough to support the plastic sheeting without leaving an impression in the concrete surface.
8.3.60
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.
8.3.61
Curing of Concrete in Hot Weather When the daytime ambient temperature is greater than 25C 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. Any necessary repairs or finishing processes shall be carried out as soon and as quickly as possible, only exposing a small area at any one time. (a) Large Flat Areas, e.g. Slabs (Preferred Method) (i) Immediately after the required surface finish is applied, cover the concrete surface with polythene sheeting/wooden frames to minimise evaporation. All gaps at sides and ends must be filled in to avoid windtunnel effects. When the surface can carry weight, replace the frames by a layer of damp hessian covered by polythene sheet. The hessian must be kept continuously damp for 7 days, (i.e., not wet/dry cycles), and suitable weights must be used to keep the polythene in place. After 7 days wet curing, 7 days cover-only curing is required.
(ii)
(iii) (b)
Alternative Method for Large Flat Areas (if potable water is in scarce supply)
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(i) (ii)
As item (a)(i) above. When the surface can carry weight, apply white-pigmented resin-based curing compound as per the manufacturers instructions. No curing compound shall be sprayed on construction joints. Cover with dry hessian for 14 days.
(iii) (c)
Flat Surface with Starter Bars (i) Shade the whole area from sunshine before concreting commences, leaving enough room for personnel/placing access, and ensuring that no gaps are left in the sides/ends which would allow wind-tunnel effects. As soon as concreting is complete, cover the top surface with damp hessian, (which is to be kept continuously damp for 7 days) and a layer of polythene. Maintain cover-only curing from the 8th to the 14th day.
(ii)
(iii) (d)
Vertical Surfaces (i) Leave formwork in place for at least 24 hours and keep continuously wet, then, after removing the forms, immediately wet the surface and cover the sides with damp hessian (which is to be kept continuously damp for 7 days) or curing compound (as item b)(ii) above), both of which are in turn to be covered by polythene. Maintain cover-only curing from the 8th to the 14th day.
(ii) 8.3.62 Thick Sections
The Contractors attention is drawn to the need to take special precautions, such as careful planning of construction joint locations, to limit the build-up of heat in thick sections of concrete, particularly during hot weather. 8.3.63 Curing Notices Curing notices shall be exhibited for each concrete pour, stating the time and date when the concrete was placed, date for last wet curing and the date for completing of cover curing. 8.3.64 Curing of Repairs All concrete repairs shall be cured in accordance with this Section of the Specification.
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8.4
STANDARD SPECIFICATION REINFORCEMENT, FORMWORK, FINISHES, JOINTS, TESTING & CONTROL Reinforcement Steel Specifications Steel used for concrete reinforcement shall comply with the following British Standards: BS 4449:2005 Steel for the reinforcement of concrete Weldable reinforcing steel Bar, coil and decoiled product Specification BS 4483:2005 Steel fabric for the reinforcement of concrete - Specification
8.4.1
All steel shall be Grade B500B or B500C unless otherwise agreed. Alternative reinforcement specifications may be proposed by the Contractor for the approval of the Engineer, however the minimum yield stress shall be not less than 460N/mm2 for high yield nor less than 275N/mm2 for mild yield steel and the bond classification shall be equal to or better than that defined in BS 4449. 8.4.2 Testing of Reinforcement Steel A manufacturers test certificate shall accompany each consignment, a copy of which shall be handed to the Engineer before such reinforcement is incorporated in the Works. 8.4.3 Storage of Reinforcement Steel Reinforcement shall be stored on racks clear of the ground and shall be protected to prevent accumulation of dust, wind blown salt and sand and other harmful substances. The separate types and sizes of bar reinforcement shall be stored in separate racks, the type and diameter being clearly marked in each case. Similarly, different sizes and arrangements of mesh shall also be stored separately and clearly marked in each case. Where large daily variations in ambient temperature and/or humidity occur, storage racks shall be enclosed in a light building. 8.4.4 Cutting and Bending of Reinforcement The Contractor shall prepare his own bar bending schedules from the Drawings and his designs. They shall be in accordance with BS 8666 and shall be submitted to the Engineer for approval. Notwithstanding any comments or approval of these schedules by the Engineer, it is the sole responsibility of the Contractor to ensure their accuracy and compliance with good detailing practice and, where appropriate, the Engineers Drawings. The Contractor shall allow sufficient time and resources to ensure that any deficiencies in the reinforcement noted once it has been fixed can be rectified without delay to the programme. Reinforcing bars shall be accurately cut and bent to the shapes and sizes shown on the Contractor's schedules. All bars shall be bent cold unless the written permission of the Engineer is obtained for hot bending. Any reinforcing bar that has already been bent shall not be rebent at the site of the original bend without the Engineers permission.
Reinforcement shall be bent by gradual and uniform application of pressure by suitable machines to the forms and dimensions shown on the Contractor's schedules and in accordance with BS 8666. Any bending of reinforcement left projecting from a construction joint or precast element shall be done only at locations and in a manner approved by the Engineer and without damaging the concrete. Stirrups and binders shall fit closely around the main bars. Storage of cut and bent reinforcement shall comply with Clause 8.4.3. 8.4.5 Fixing of Reinforcement The Contractor shall be responsible for maintaining the reinforcement in the correct position during concreting and to this end reinforcing bars shall be fixed together as shown on the Drawings with such laps as are indicated, all to form a rigid cage. Bar crossings shall be secured with at least one turn of stainless steel tying wire of minimum 1.2mm diameter, the ends of the tie being twisted together and turned down into the work. Every bar shall be secured in at least 2 places and in addition tie wire spacing shall be not greater than every fourth intersection. Patent stainless steel ties may be used for securing bars but the Contractor shall obtain the approval of the Engineer for the type and number to be used. Sufficient mild steel chairs shall be supplied to support rigidly the top reinforcement of all slabs. Subject to the Engineers approval, spacer units fixed to the reinforcement shall be used in all reinforced concrete to give the cover specified herein, on the Drawings or as directed. No ferrous metal part of any device used for connecting bars or for maintaining reinforcement in the correct position shall remain within the specified minimum concrete cover to the reinforcement except where expressly instructed or provided for within the Contract. No permanent spacers to reinforcement shall be allowed to affect the overall uniformity of the surface appearance of Classes F2, F2P, F3, U2 and U3 surface finishes which shall, in any event, comply with the Specification requirements. Reinforcement temporarily projecting from the concrete at construction or other joints shall be adequately supported and shall not be bent out of position unless expressly permitted or directed. Temporary supports to the reinforcement, other than the mild steel chairs referred to above, shall not be incorporated within the finished concrete. 8.4.6 Spacers Spacers shall be as small as practicable for their purpose and shall be securely fixed in place, by approved means, to ensure that they will not be displaced during the placing, vibration or finishing of the concrete.
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Favourable consideration will be given to the use of proprietary plastic or precast concrete spacers provided these are suitable for the particular use required. Any precast spacer blocks approved for use shall be at least equal in strength to the body of the concrete in which they are being placed. They shall be of equal durability and where used on an exposed face shall provide a good colour match as required under the preceding Clause. Any blocks cast on site will normally be required to be of a similar mix to the main body of the concrete. The use of spacer blocks with tying wires cast in will not normally be permitted but where approval for such blocks is given the wire shall be of stainless steel. 8.4.7 Welding Generally welding of reinforcement shall not be permitted. However in specific cases, welding of reinforcement may be permitted provided the Engineers written approval is obtained in each case. Where this is given welding shall be to BS 7123. Prior to giving approval the Engineer will require performance trials of welded joints to be undertaken. 8.4.8 Mechanical Joints The use of mechanical joints and/or mechanical jointing systems for reinforcing bars shall be subject to the prior approval of the Engineer who shall be provided with full details of such joints together with the proposed locations for use and the methods of installation before making a decision. Notwithstanding the provision of such information the Engineer may direct that site tests be carried out on the use and strength of such joints. 8.4.9 Concrete Cover The nominal concrete cover to reinforcement including stirrups and binders, shall be as indicated on the Drawings, unless otherwise indicated. Provided always that the required minimum cover is maintained, the actual position of any bar shall be that indicated on the Drawings with the following tolerances: 8.4.10 Plus or minus 5 mm on bars up to and including 12 mm diameter. Plus 10 mm or minus 5 mm on bars over 12 mm up to and including 25 mm diameter. Plus 15 mm or minus 5 mm on bars over 25 mm diameter.
Cleaning and Protection of Reinforcement The Contractor shall ensure that all reinforcement is free from loose mill scale, excessive rusting or pitting, oil or grease, dust, salts, mud, paint, retarders, deposits or curing membrane, and other harmful matter immediately before concrete is placed. The Contractor shall take care to ensure that any matter cleaned off reinforcement does not become incorporated in the concrete or accumulate on other concrete surfaces.
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Any reinforcement that the Engineer considers has become excessively rusted in storage or prior to casting in concrete shall be rejected and shall be removed from Site at the Contractors expense. Before concreting all reinforcement shall be carefully cleaned of all set or partially set concrete which may have been deposited thereon during previous concreting operations. All reinforcement projecting from construction joints or likely to be exposed to the weather for long periods before concreting is commenced shall be covered with polythene, binding tape, cement grout or other materials to the satisfaction of the Engineer in order to prevent corrosion of reinforcement or staining of the surrounding concrete. Should, in spite of these precautions, rust staining occur on any permanently visible surfaces, it shall be removed at once. 8.4.11 Steel Fixer in Attendance During concreting a competent steel fixer shall be in attendance to adjust and correct the positioning of the reinforcement. 8.4.12 Formwork Construction Formwork shall be rigidly constructed and shall ensure that the finished concrete is true to the required shape, position and level, and to the standard of finish specified. Formwork shall be of suitable design and substantial construction to carry the loads due to the wet concrete and any incidental loads such as during concreting operations without excessive bulging, distortion, deflection, instability or grout loss. Formwork for recesses, pockets, apertures and internal voids and all bolts and fittings shall be accurately positioned and securely fixed before commencement of concreting such that they are not dislodged by the concreting operation. All forms shall be constructed with removable panels or openings to permit inspection of the inside of the formwork and to allow removal of debris and water from the interior of the forms before the concrete is placed. The Contractors attention is also drawn to the requirements of the Clauses relating to Concrete Finishes that contain some particular requirements for formwork construction. The Contractor shall take into account the structural behaviour of the concrete elements being cast, and shall ensure that the formwork and stagings are adequately stiff to support partially completed works when subsequent pours are placed. Any eccentric loads shall be properly provided for. 8.4.13 Internal Ties Internal ties shall not be used without the Engineers consent, and if used they shall be of metal and capable of either being removed without permanent injury to the concrete or of being left in place without any part being nearer than 75mm to the finished surface of the concrete. Holes left by the removal of internal tie locking devices shall be neatly filled and finished to the satisfaction of the Engineer.
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8.4.14
Permanent Void Formers Permanent void formers, designed to remain in place after casting of concrete, shall be of a material approved by the Engineer.
8.4.15
Formwork Liners Where use of a controlled permeability formwork (CPF) liner is specified the CPF liner shall have the following properties: A maximum decrease in thickness of 10 % under a pressure of 200 kPa A maximum pore size of 0.030 mm A minimum water retention capacity of 0.35 litres per sq.m A minimum tensile strength of 5 kN per m at a maximum of 5 % elongation
The CPF liner shall have independent third party certification and details shall be submitted to the Engineer for approval. The certification shall demonstrate that the use of the CPF liner improves the performance of a CPF cast concrete against that for conventionally cast concrete. A minimum improvement of 50% for surface tensile strength, initial surface absorption and chloride ingress is required. For liners without independent certification, tests to establish liner performance shall be performed on an appropriate concrete, prior to approval for use being given. The CPF liner shall be installed and used in accordance with the manufacturers instructions and may only be used more than once with the prior approval of the Engineer. 8.4.16 Chamfers Except where specifically detailed on the Drawings or where further elements are to be placed against them, all exposed horizontal and vertical arrises shall have a symmetrical chamfer of 25mm x 25mm unless detailed otherwise on the drawings. 8.4.17 Preparation of Forms and Formwork Before commencement of pouring concrete, all forms shall be thoroughly cleaned out by approved means to the satisfaction of the Engineer. A coating of approved mould oil or other approved material shall be applied to all surfaces coming into contact with the concrete to allow easy removal of the forms without damage to the concrete. No mould oil or other lubricating medium shall be allowed to come into contact with the reinforcement and embedded steelwork. Any material that will adhere to, discolour or impair the finish to the concrete shall not be used. Shuttering shall be thoroughly scraped, cleaned and, if necessary, repaired before being re-used. Any part of a formwork panel which the Engineer judges incapable of producing
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a finish of the specified standard by reason of excessive use or the employment of substandard materials shall be replaced by the Contractor at his own expense. 8.4.18 Removal of Formwork For concrete made with Portland Cement, formwork shall not be stripped, unless otherwise approved, until the following times have elapsed after the concrete has been poured:
Vertical formwork to columns, walls and beams (unless specified otherwise - see Clause 3.3.61) Soffit formwork to slabs, with props left under Props to slabs Soffit formwork to beams, with props left under Props to beams Note: T is the surface temperature of the concrete between 0C & 25C 100/(T+10) days 250/(T+10) days 230/(T+10) days 360/(T+10) days 300/(T+10) hours
Following the results of the trial mix, the Engineer may direct that the above times are increased by up to 50 per cent for cement replacement concretes. In addition to the above times no loading (including self weight) shall be imposed on the concrete which would cause a compressive bending stress greater than one-third of the concrete strength at the time of loading, or one-third of the 28 day strength, whichever is less. Soffit formwork should be so designed as to facilitate striking, if required, without removal of props being necessary until the times stipulated above have elapsed. The Contractors attention is drawn to the need to maintain side shutters as insulation on large concrete pours to prevent surface cracking due to thermal effects. The Contractors proposals for stripping shutters on pours of greater than 25m3 shall be submitted to the Engineer at least 2 weeks before the pour is due to be made. No superimposed load shall be allowed on any part of the concrete work prior to the removal of the forms and props and/or until such loading is approved. Where concrete is to have filling placed against it the methods of backfilling shall be approved by the Engineer. Where there is a particular requirement for the early removal of formwork or for concrete made with alternative cements to Portland Cement a procedure for establishing whether or not the concrete has reached the required standard shall be agreed with the Engineer beforehand. This shall be based on strength gain characteristics determined from testing of concrete test cubes and/or non-destructive testing. At all times the Contractor shall delay the removal of the formwork if, in the opinion of the Engineer, the concrete contained has not attained sufficient strength. 8.4.19 Tolerances for Concrete Surfaces Permissible tolerances for concrete surfaces are given in Table 8.2. The template to be used in determining the deviation in long dimensions shall be:
(a) (b)
For straight surfaces, 3m; For curved surfaces, 1.5m.
Type of Structure General exposed concrete
Type of Irregularity Departure from alignment and grade as shown on Drawings Variations in cross-sectional dimensions Abrupt Deviations from template in long dimensions
Tolerances mm Type of Finish Formed Unformed Class F1 Class F2 Floated Tamped +10 +10 +5 +10 -10 -10 -5 -10 +10 +10 NA NA -5 -10 0 5 5 5 +5 -5 +5 -5 +5 -3 3 +5 -5 +10 -10 NA NA NA NA NA +10 -10 +3 -3 NA 3 +3 -3 +10 -10 NA NA NA NA NA
Exposed concrete where steelwork is to be fixed; also, tolerance for cast in steelwork
Departure from alignment and grade as shown on Drawings Variations in cross-sectional dimensions Abrupt Deviation from template in long dimensions
(Note: NA denotes not applicable) Table 8.2 - Tolerances for Concrete Surfaces
8.4.20
Formed Concrete Finishes a) Class F1 This finish is formed for surfaces at construction joints. The surface produced shall be free from voids, honeycombing or other large blemishes, steps, sharp protrusions or local hollows. The shutters shall be removed as soon as possible without disturbing the concrete or reinforcement and the surface be well brushed or hosed down to remove all excess laitance and fine aggregate. Coarse aggregate is to be left exposed but undisturbed. Class F2 This finish is for surfaces that are permanently exposed to view. The surface produced by the formwork shall be free from voids, honeycombing or other large blemishes. Any small blemishes shall be carefully filled immediately after the removal of the formwork and other marked imperfections such as fins or steps shall be made good. To achieve this finish wrought timber boards, plywood sheets, steel panels or such other material as is approved by the Engineer shall be used. In large panels, the panels shall be arranged in an approved uniform pattern with vertical or horizontal joints, unless otherwise directed. Joints shall be carefully filled or sealed before concreting. The same type and brand of shutter release agent shall be used throughout the Contract on surfaces of a structure where a Class F2 finish has been specified. Class F2P
b)
c)
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This finish is similar to Class F2 except that in addition to the requirements for Class F2 the formwork is to be lined with a proprietary controlled permeability formwork liner as specified in Clause8.4.15. The same type and brand of controlled permeability formwork liner shall be used throughout the Contract on surfaces where a Class F2P finish has been specified. d) Class F3 This finish is for surfaces not permanently exposed to view. The surface produced shall be free from voids, honeycombing or other large blemishes, steps, sharp protrusions or local hollows. The formwork may be sawn boards, metal panels or other approved suitable material.
8.4.21
Remedial Treatment to Formed Surfaces Any remedial treatment to formed surfaces shall be agreed with the Engineer following inspection immediately after removing the formwork and shall be carried out without delay unless otherwise specified or directed. Any concrete, the surface of which has been treated before being inspected by the Engineer or has been treated by unapproved methods, shall be liable to rejection. Normally, the only form of treatment which will be allowed for Class F2 concrete finish after removal of the formwork will be the filling of minor surface blemishes with a specially prepared approved cement and fine aggregate paste and/or rubbing down with abrasive blocks and water to produce a smooth surface followed by a thorough washing down with water. Apart from the filling of minor surface blemishes, as provided for above, plastering of defective concrete shall not be permitted. Any defective concrete finish will be rejected and the Engineer may order the defects to be cut out and repaired or may reject the entire section incorporating the defective concrete finish. All cement and fine aggregate pastes used for remedying formed concrete surfaces shall be designed to produce, as near as is possible and to the satisfaction of the Engineer, a good colour match with the main body of concrete.
8.4.22
Unformed Concrete Finishes a) Screeded Finish - Class U1 A screeded finish shall be applied where indicated on the Drawings. The concrete shall be levelled and screeded to produce a uniform surface to the profile shown on the Drawings. Floated Finish - Class U2 A floated finish shall be applied where indicated on the Drawings. Steel floats shall be used unless otherwise approved or directed. Floating shall be done as soon as the concrete has hardened sufficiently and may be done by hand or machine. Care shall be taken that the concrete is worked not more than is necessary to produce a uniform surface free from screed marks which is finished level or to the falls specified on the Drawings.
b)
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c)
Brushed Finish - Class U3 A brushed finish shall be applied to all unformed upper surfaces of concrete unless noted otherwise on the Drawings. The surfaces shall be finished to the levels and falls shown on the Drawings and shall be brushed with a stiff brush, as directed, to give a good running surface. A 100 mm wide strip at the edge of the slab and adjacent to all joints shall be finished smooth with a steel float. The requirements for the surface finish of rigid concrete pavements shall be a brushed finish as defined above, subject to the approval of the Engineer.
d)
Brushed Finish - Class U4 A textured screeded finish shall be applied to unformed upper surfaces of concrete where indicated on the Drawings. The concrete shall be levelled and screeded to produce a uniform surface. When the concrete has sufficiently hardened and the bleed water evaporated the surface shall be trowelled to produce a hard dense surface free from screed marks and exposed aggregate. Finally the surface shall be lightly textured with a wooden float or equivalent. Alternatively the concrete shall be levelled, screeded and floated to produce a uniform surface and immediately before the waterproofing operation this surface shall receive surface preparation by water jetting or grit blasting to provide a lightly textured finish. The finished surface shall not deviate from the required profile by more than 10mm over a 3m gauge length or have any abrupt irregularities more than 3mm.
8.4.23
Protection of Surfaces The Contractor shall ensure that permanently exposed concrete surfaces are protected from rust marks, spillage, stains or damage of any kind. Any marks or damage shall be removed or remedied, all to the satisfaction of the Engineer. In the case of severe damage that may affect the serviceability of the concrete section involved or where unsatisfactory appearance of permanently exposed surfaces may result from repairs, the Engineer may order the breaking out and reconstruction of any section.
8.4.24
Construction Joints The position and form of construction joints, except where shown on the Drawings, shall be agreed with the Engineer before concreting begins. Unless otherwise directed they will be made across planes of minimum shear. They shall be made only along a horizontal or vertical plane except that, in the case of inclined or curved members, they shall be at right angles to the principal axis of the member. Vertical construction joints shall be made against properly constructed stop-ends, firmly fixed and holed to permit the reinforcement to pass through, or by means of expanded metal. If expanded metal is used, it shall be kept back from the face of the concrete by a distance equal to the minimum concrete cover to reinforcement. It shall be securely held
in position so as not to distort or move, in accordance with the requirements for normal formwork. It shall be left in position and new concrete placed against it when construction is resumed. All necessary steps shall be taken to ensure that good dense concrete is achieved against construction joints. Prior to concreting, stop-ends may be treated with an approved surface retarder, instead of mould-oil, if required, to facilitate the exposing of the coarse aggregate. Such a retarder may also be applied after concreting to upper surfaces which subsequently are to form construction joints. All such uses of retarders for construction joint surfaces shall be subject to the prior approval of the Engineer. Stop-ends shall be carefully removed, without disturbing the concrete and reinforcement as soon as possible after concreting depending on the ambient temperature and curing conditions, as approved by the Engineer. This will normally be within 9 hours of placing the concrete. Immediately on removal of the stop-ends, all horizontal and vertical joints are to be well brushed and hosed down in order to remove all excess laitance and fine aggregate. Coarse aggregate is to be left exposed but undisturbed. When concreting is resumed against a construction joint the surface of the previously placed concrete shall be hosed down and the surplus water allowed to drain away before placing the new concrete. 8.4.25 Movement Joints The spacing, location, dimensions and construction of all movement joints shall be as shown on the Drawings, unless otherwise instructed by the Engineer. 8.4.26 Debonding Coat Where a debonding coat is required, e.g. at a movement joint between two concrete members, this shall be achieved by the use of an approved debonding membrane or bituminous paint. 8.4.27 Pre-formed Joint Filler Where pre-formed joint filler is detailed on the Drawings, for expansion or other joints, it shall comply with one of the specifications given below. Joint filler shall be of the thickness shown on the Drawings with a tolerance of 1.5 mm, fixed in single thickness sheets, unless otherwise directed, being of suitable lengths, not less than 1.2 metres. Wherever possible joints shall be filled with a single sheet of filler, but where the size of the joint is such that two or more sheets have to be used, these sheets shall be cut and butt-jointed so that the edges are in continuous contact. The sheet joint shall then be wrapped in approved self-adhesive PVC jointing tape to prevent any grout leakage through the joint. The pre-formed joint filler used for expansion or other joints shall be as detailed or directed and shall normally be bitumen impregnated fibreboard.
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Where detailed or directed, bitumen-bonded cork shall be used as pre-formed joint filler, complying with the requirements of ASTM D1751. Where detailed or directed, low density cellular filler shall be used as pre-formed joint filler. All the above products shall be from a reputable manufacturer and shall be subject to the approval of the Engineer. 8.4.28 Joint Sealing Materials Where detailed or directed, in particular for vertical or inclined joints, surface sealing of joints shall be by two-part, polysulphide liquid polymer sealant material, complying with the requirements of BS EN ISO 11600:2003. Where detailed or directed, hot-poured rubber/bitumen sealing compounds shall be used, for low movement horizontal joints only, complying with the requirements of BS EN 14188-1. For similar joints where the potential movement is outside the range of the hot poured rubber/ bitumen sealing compounds, a suitable approved cold poured sealing compound shall be used complying with BS 5212 of a type approved by the Engineer. All the above products shall be from a reputable manufacturer and shall be subject to the approval of the Engineer. 8.4.29 Application of Joint Sealants Joint sealants shall be applied to the dimensions indicated on the Drawings or as otherwise approved or directed by the Engineer. All joint sealants shall be mixed and applied strictly in accordance with the manufacturers instructions and the requirements of this Specification. Immediately prior to permanent sealing the groove shall be thoroughly cleaned and any dirt or loose material or any temporary sealing former or other filling material, grease or oil shall be removed. The surfaces of the groove shall be dry at the time of sealing. Any spalling at the edges of the grooves shall be repaired to the satisfaction of the Engineer using an approved material, compatible with the sealant, before the sealant is applied, and care shall be taken not to damage the edges of the groove during sealing. If recommended by the manufacturer or directed by the Engineer the groove shall be primed with an approved priming compound compatible with the sealant, and/or an approved bond breaker strip shall be applied to the back of the joint cavity before sealing. Unless otherwise detailed or directed sealants shall be applied so as to be 5 mm below the concrete surface.
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8.4.30
Water Bars Where specified on the drawings, water bars shall be provided at construction joints. These shall be installed in accordance with the manufacturers recommendations and shall be continuous.
8.4.31
Inspection and Tests The Contractor shall ensure that the Engineer is afforded all facilities and assistance for the inspection of materials, storage, manufacture of concrete and precast concrete, workmanship and testing, and for carrying out all tests as specified or as instructed.
8.4.32
Control of Mix Proportions A check on the moisture content of the aggregate shall be made as required by this Specification for the purpose of assessing the amount of free water to be added at the mixer. The Contractor shall provide himself with a chart, a copy of which shall be given to the Engineer for approval, relating moisture content in the aggregate to water to be added at the mixer for all grades of concrete in use. Full supervision of the concrete batching and mixing shall be provided by the Contractor to ensure correct proportions of all the various constituent materials. If required by the Engineer, equipment shall be installed and maintained for making autographic records of the constituent materials of each batch. Control shall ensure that the proportions are within the tolerances laid down in this Specification. The Engineer may direct that checking of mix proportions used shall be made by analysis of hardened concrete in accordance with BS 1881-124.
8.4.33
Determination of Fresh Concrete Temperature In order to satisfy the requirements of this Specification for measurement of fresh concrete temperature, the following method shall be adopted:Within 2 minutes of taking a sample, a type A 100 mm immersion thermometer supplied by the Contractor having a range -5C to +110C, graduated at each 1C and complying with BS 1704, shall be inserted in the sample to a depth of at least 100 mm. When steady conditions have been maintained for 1 minute the temperature shall be recorded to the nearest 1C. Unless otherwise directed by the Engineer, the above test shall be carried out on each delivery of concrete that is to be placed in the Works, at the point of delivery. Temperature records, together with records of humidity and wind speed, shall be submitted daily.
8.4.34
Identity Testing for Compressive Strength Identity testing for compressive strength shall be carried out in accordance with Annex B of BS EN 206-1.
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For the purposes of B.2 of Annex B, sampling for making test cubes shall be carried out at least once for each concreting operation carried out in one continuous operation, or in the event of more than 40 cubic metres being placed in one continuous operation, at least once for each 40 cubic metres or part thereof placed. If the Engineer directs, the figure of 40 cubic metres shall be reduced to take account of the extra control needed on the more critical structures. From each sample, taken as provided for above, six 150mm cubes shall be made for testing for compressive strength and such sampling shall be carried out by the Contractor at the point of placing of the concrete in the construction. Cubes required by the Contractor for his own use in determining the rate of increase of strength or other properties of any mass of concrete shall be considered as additional to the six routine test cubes. All cubes shall be marked at the time of casting with the date, the grade of concrete and other necessary marks to identify the part of the Works from which such cubes were taken. Test specimens shall be made, cured and tested in accordance with Annex B. For each set of six test cubes, 3 shall be tested at 28 days and the remaining 3 shall be tested at an earlier age, as directed by the Engineer. This earlier age shall normally be 7 days. The results of the tests made at 28 days shall be the basis of the standard of acceptance for concrete strength unless the Engineer directs that tests at an earlier age shall form this basis. Identity criteria for compressive strength shall be as BS EN 206-1 Annex B B.3. 8.4.35 Records Cube test results shall be submitted in duplicate to the Engineer on standard certificate forms completed in ink and signed by both the laboratory manager and the Contractor. They shall be presented to the Engineer as soon as possible after the test results are known to the Contractor and shall include the following information:(a) (b) (c) (d) (e) (f) The date of casting the cubes The date of testing the cubes The age of cubes when tested A note of any marks on the cubes The part of the Works from which the cubes were taken The aggregate, type of cement and admixtures used and specified grade of concrete The mixer employed (Site plate or ready-mixed concrete supplier) The curing conditions, including temperature
(g) (h)
(i) (j) (k) (l) (m) (n)
The conditions of the cubes when put into the testing machine The weights of the cubes The volume of the cubes, determined by displacement Density The compressive strengths The appearance of the concrete and the nature of the fracture if these are unusual.
In addition, the Contractor shall maintain records showing the performance over time of the concrete for each grade with regard to strength and such other properties as can be assessed on this basis. These records shall be made available to the Engineer and may be used when assessing the need to change mix proportions, as provided for elsewhere in this Specification. The results of all other routine tests, as required under this Specification, shall also be recorded in a standard form, to be agreed with the Engineer, and shall be submitted on a regular basis, all as directed by the Engineer. 8.4.36 Identity Testing for Slump, Flow and Air Content When required by Clause 8.3.8, identity testing for slump, flow and air content, as appropriate, shall conform to the requirements of BS 8500-1 Annex B. The point and time of sampling shall be at the point of placing the concrete in the construction. Sampling shall be in accordance with BS EN 12350-1. Identity criteria shall be as stated in Annex B. 8.4.37 Non-Destructive Testing All methods of non-destructive testing of the hardened concrete in the works shall be subject to the approval of the Engineer and any information submitted prior to approval shall include details of the calibration of the tests and shall show how the tests are able to indicate the desired properties of the concrete. Where approved or directed by the Engineer such non-destructive testing methods may be used in the event of failure to meet the strength requirements by Works test cubes, as provided for above. Such methods may also be used in the routine control procedures if approved or directed by the Engineer. 8.4.38 Concrete Core Testing As and where directed by the Engineer, following the failure by Works test cubes to meet the strength requirements or at such other times when the Engineer has reason to doubt the standard of the concrete placed in the Works, cylindrical core specimens shall be cut from the hardened concrete in the Works for the purpose of examination and testing.
The cutting equipment and method shall be subject to the approval of the Engineer and shall, unless otherwise directed or approved, produce specimens of diameter 150 mm. If required by the Engineer ultrasonic testing of the concrete to BS EN 12504-4 shall be used to determine abnormalities or density changes within the concrete and to determine the location where cores will be taken. All examination and testing of such specimens shall be carried out in accordance with the requirements of BS EN 12390 and prior to testing the specimens shall be made available for examination by the Engineer. Cores from suspect areas shall be tested as required by the Engineer. Those tests will include: Analysis of hardened concrete to BS 1881-124 Testing concrete core compressive strength to BS EN 12504-1 A full report of examination and testing results, as defined by BS EN 12390, shall be submitted to the Engineer for each specimen and the Engineer will then decide what further action may be required.
8.5
8.5.1
STANDARD SPECIFICATION PRECAST CONCRETE

General All precast concrete shall comply with the previous sections of this Specification. All precast concrete units, hereinafter referred to in this Clause as units, shall be indelibly marked with a unique reference mark that includes the date of casting and identification of the manufacturer. Units shall be stored in a manner such that additional bending stresses in the units are prevented. The accumulation of trapped water and deleterious matter in the units shall be prevented. Care shall be taken to avoid rust staining, efflorescence and the effects of salt spray. Units shall be lifted or supported only at designated lifting and support points. Units shall be handled and placed without impact. At all stages of construction, units shall be properly protected to prevent damage to concrete surfaces especially arrises and other features.
8.5.2
Contractor's Option to Precast In addition to those sections of the Works where the Drawings indicate the use of precast construction, and provided that his proposals meet the Engineer's approval, the Contractor may opt, at Tender stage, to precast any sections which are shown on the Drawings as in situ concrete.
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If the Contractor wishes to exercise this option then, following approval in principle as required above, he shall submit to the Engineer all calculations and layout and detail drawings necessary for the manufacture and installation of the precast units and for the completion of each section of the Works to satisfy the original design requirements. All these calculations and drawings shall be approved by the Engineer before any work is commenced on the manufacture of precast concrete units. 8.5.3 Drawings and Schedule of Weight The Contractor will be required, before commencing work on precast concrete to prepare layout drawings of each section of the work showing units to be produced. Detail drawings shall also be prepared for each type of unit showing in detail the grade of concrete, finishes to concrete, joint details, reinforcement, joggles, mortices for dowels, clamps, cramps, lifting hooks and the like. These drawings are to convey faithfully the Engineer's intention and are to be submitted to the Engineer for approval before production of units or moulds etc. begins. The Contractor shall also supply to the Engineer, as soon as possible after the start of the Contract, a schedule of weights for each type of unit. 8.5.4 Approval of Plant and Working Methods Full details of the plant and equipment to be used and method and location of precast concrete manufacture, curing, handling, storage, transportation and installation in the Works shall be submitted to the Engineer for approval before any work is commenced on the manufacture. 8.5.5 Provision for Handling Except where these are already detailed on the Drawings, the Contractor shall make provision for all lifting hooks, etc. which are required for handling, lifting and erecting the units in position. All such lifting and fastening devices shall be subject to the prior approval of the Engineer and shall be shown on the Drawings prepared by the Contractor for the Engineer's approval. In designing and locating such devices the Contractor should note the requirements of this Specification for avoiding damage or distress due to handling, maintaining concrete cover to embedded metal and providing the required standard of finish, particularly on exposed faces. Every attempt should therefore be made to incorporate any such devices on faces which will not be exposed in the finished works. Where he has exercised his option under Clause 8.5.2, the Contractor shall provide such reinforcement as is necessary to prevent damage and distress due to cracking whilst loading, transporting, off-loading and erecting in position in addition to the reinforcement required for structural stability of completed works. Such additional reinforcement shall also be shown on the drawings prepared for the Engineer's approval. 8.5.6 Moulds All moulds shall be of adequate strength and stiffness to carry without deformation the loads and pressures of wet concrete during the casting and compaction operations.
Moulds shall be sufficiently tight to prevent leakage of the concrete and shall be adequately supported, braced and maintained so as to produce units within the tolerances specified. Details of materials to be used in the manufacture of the moulds or formwork must be submitted to the Engineer for his approval before commencing work. The assembled moulds shall be checked for accuracy immediately prior to the first casting of each type of unit, and thereafter prior to every third casting or at such closer intervals as the Engineer may require. The Contractor must allow in his price for a sufficient number of moulds to enable him to maintain the required progress of the Works. No extras will be allowed in the event of additional moulds being required to achieve the stated programme. Each mould shall be allocated a code number and all units cast in that mould shall have the mould code number and date of casting marked on. 8.5.7 Manufacturing Tolerances Unless otherwise detailed on the Drawings or directed by the Engineer, manufacturing of precast units shall be strictly within the following specified tolerances:a) Length Up to 3m 3 to 4.5m 4.5 to 6m Additional for every subsequent 6m For beam-type sections the length shall be the major dimension of the unit. For slab-type sections the above tolerances for length shall apply to the two major dimensions (ie side length). b) Cross Section Up to 500mm 500 to 750mm Additional for every subsequent 250mm With a maximum tolerance of These tolerances shall apply to the two minor dimensions of beam-type sections and to the thickness only for slab type sections. c) Straightness or Bow (deviation from Intended Line) Up to 3m 3 to 6m 6 to 12m Additional for every subsequent 6m d) Squareness When considering the squareness of a corner, the longer of the two adjacent sides being checked should be taken as the base line. The shorter side should not vary in its distance from a perpendicular so that the difference between the greatest and the shortest dimensions exceeds:Length of shorter sides Up to and including 1.2m Over 1.2m but less than 1.8m 1.8m and over For the purpose of this requirement any error due to lack of straightness should be ignored; squareness should be measured with respect to the straight lines which are most nearly parallel with the features being checked. When the nominal angle is other than 90 the included angle between check lines should be varied accordingly. e) Twist Any corner should not be more than the tolerance stated from the plane containing the other three corners:3mm 5mm 6mm 6mm 9mm 12mm 6mm 3mm 5mm 2mm 15mm 6mm 9mm 12mm 6mm
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Up to 600mm wide and up to 6m length Over 600mm wide and for any length f) Flatness The maximum deviation from a 1.5m straight edge placed in any position on a nominally plane surface should not exceed 5mm. g) Camber The variation in camber between closely associated units should not be greater than 6mm for units up to 4.5m in length, nor 9mm for longer units, and should be visually close-matched wherever possible. h) Reinforcement Reinforcement shall be fixed in accordance with Clauses 8.4.5 & 8.4.9 of this Specification. i) Position of Connecting Bolts and Other Devices The position of individual connecting bolts, bolt holes, projecting steel or other devices in any associated group should be within 6mm of its true position in the group in which they are cast. The longitudinal location of any such group or of any individual device should be within 6mm of its true position in the unit in which it is cast, provided that such tolerance does not adversely affect the proper assembly of the whole structure.
6mm 12mm
Notwithstanding the above requirements for tolerance, the overall dimensions and shape of any precast unit shall not be such as to prevent the proper erection of that unit in conjunction with any other unit, steelwork or in situ construction. Reference should also be made to Clause 8.5.19. 8.5.8 Curing of Units Curing of precast concrete units shall be in accordance with the requirements of Clauses 8.3.54, 8.3.55 to 8.3.64 of this Specification. All proposals for accelerated curing shall be fully detailed including all arrangements for ensuring the effectiveness of curing under all possible climatic conditions. 8.5.9 Surface Finishes Surface finishes of precast units shall comply with the requirements given in Clauses 8.4.20 to 8.4.23 of this Specification, with the class of finish being as detailed on the Drawings or as directed. In general no construction joints will be permitted within any precast unit. 8.5.10 Rejection of Units All finished units, whether erected in position or not, which do not comply with the Drawings and Specifications shall be removed and replaced with new items to the Engineer's satisfaction. Reasons for rejection of units shall include the following: a) b) c) d) The presence of cracks or repairs The presence of broken edges whether reinforcement is exposed or not. Concrete cover to any reinforcement being less than that required by this Specification. A surface finish inferior to that indicated on the Drawings and/or defined in this Specification.
e) 8.5.11
Out of tolerance dimensions.
Marking and Records As soon as possible after casting, each unit shall be indelibly marked in an agreed location with its type and a unique reference number. The Contractor shall maintain records for each unit, which shall include the following information: a) Type & reference number. b) Date of manufacture. c) Mould number. d) Cube test results. e) Location in the Works. f) Curing method and duration. These records shall be in a format agreed by the Engineer and shall be available for his inspection at all times. Copies of these records shall be supplied to the Engineer on completion.
8.5.12
Sampling and Testing Where precast concrete units are manufactured off site, unless specifically provided for herein, all costs involved in sampling and testing required by the Specification shall be borne by the Contractor.
8.5.13
Certificate of Manufacture For precast concrete units which are manufactured off site, the Contractor shall supply to the Engineer, prior to any unit being delivered to site, a certificate stating that that unit complies in all respects with the approved Drawings and Specifications.
8.5.14
Erection Programme Prior to erection of precast concrete units, the Contractor shall submit to the Engineer for his approval a detailed erection programme giving full descriptions of the methods and plant to be employed for lifting, assembling and fixing the units and safeguarding the structure during erection. No erection shall be carried out until the Engineer has approved the methods to be used.
8.5.15
Handling and Erection - General The Contractor shall be responsible for the safety of the structure and operatives at all stages during the handling and erection of precast concrete units and shall provide all necessary frames, guys, wedges and other temporary supports.
8.5.16
Handling of Precast Concrete Units All units shall be handled, lifted and transported in a manner which does not cause damage or cracking. When units are lifted by tackle or crane the weight shall be taken up gradually without snatch. When units are being lowered they shall not be dropped but shall be let down gently into position without impact. Any units dropped and/or damaged
during handling, storage, installation, etc. shall be replaced by the Contractor at his expense. When the positions for sling, lifting holes or lifting eye bolts are shown on the drawings or otherwise indicated they shall not be departed from without the permission of the Engineer. The Contractor shall not introduce any holes, cavities, lifting loops, bolts or other features for his own convenience without the written approval of the Engineer. Where no particular fixings or holes are built in for lifting any unit, the unit shall be supported on blocks firmly bedded and adjusted to align in a true plane in order to avoid twisting. The points of support shall be as indicated on the Drawings or as directed. Similar supporting blocks shall be used when storing precast units. 8.5.17 Storage of Precast Concrete Units All precast units shall be stored off the ground in a manner and in the positions which will prevent damage or cracking of any kind and permit erection with a minimum of preliminary handling and transportation. If the Engineer permits precast units to be stacked in storage, they shall be arranged so that the supporting timber packs for any unit coincide with the supporting packs for all the units below. Under no circumstances shall any element be supported on a point on any other unit which is not itself supported. Bolt hole recesses and other cavities, shall be plugged in an approved manner to prevent entry of rain or other water unless such water can freely drain away. 8.5.18 Installation of Precast Concrete Units The Contractor shall accurately set out the work within tolerances described in the following Clause. The Contractor shall ensure that all precast concrete units come together without strain in their correct relative positions as shown on the Drawings. If, due to inaccuracies in position or level or in the dimensions of the units, it is found impossible to assemble the units without straining them into position, no such straining shall be done without the permission of the Engineer and when so directed the Contractor shall dismantle the work and re-erect and make good to the satisfaction of the Engineer. No cutting of units, enlarging of holes for fixing bolts or other operations for the correction of lack of fit of units shall be carried out except with the permission of the Engineer. Unless otherwise specified or shown on the drawings, approved bearing or washer pads shall be inserted at all joints and seatings to prevent direct contact of concrete to concrete or concrete to metal. The use of expanding agents or other additives to the mortar or insitu concrete for the fixing of precast units shall be subject to the approval of the Engineer.
During the installation of precast units, or the casting of associated insitu concrete, the Contractor shall not impose any abnormal loads on foundation, pile caps, piers or abutments without the written permission of the Engineer in each and every case. The Contractor shall be responsible for ensuring the stability of the quay wall precast cope units during their installation. Additionally, the Contractor shall be responsible for ensuring the stability of the units prior to, during and after the casting of the in-situ concrete element of the cope beam. Voids have been detailed into the rear of some of the cope unit types to facilitate a temporary vertical holding down bolt arrangement to connect the unit to the rear of the bulkhead wall pile. However the design of any such arrangement shall be the responsibility of the Contractor and shall be subject to the approval of the Engineer. Any changes to the geometry of the precast unit to accommodate temporary holding down arrangements shall be subject to the approval of the Engineer. 8.5.19 Installation Tolerances Precast units shall be installed so that the completed structure complies with the tolerance requirements for insitu concrete. The various faces of the completed structure shall comply with the tolerance requirements for the classes of finish specified for those faces. The following particular tolerances apply to the installation of precast units: The difference in the exposed vertical face line between adjacent units shall not exceed 5mm. This requirement shall also apply to the top level of units. In addition, the face line shall be visually matched to show a true straight or curved line (as appropriate). 8.5.20 Bearings Bearings for all units shall be as shown on the Drawings and as required by the calculations.
8.6 8.6.1
STANDARD SPECIFICATION PRESTRESSED CONCRETE Scope of This sub-Section This sub-Section applies to the prestressing of precast units and is to be read in conjunction with Clauses 8.5.1 to 8.5.20.
8.6.2
Prestressing Tendon Materials Specifications Steel wire and stressed-relieved seven-wire strand shall both comply with BS 5896. Cold worked high tensile alloy steel bars shall comply with BS 4486.
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8.6.3
Delivery of Prestressing Tendons All tendons shall be delivered in sealed weatherproof protection to the satisfaction of the Engineer. The tendon protection shall be designed to minimise the adverse effects of moisture and high humidity during transportation and storage. Coils of wire or strand shall be of sufficiently large diameter to ensure that they pay off straight. Bars shall be delivered straight and any bent in the threaded portion shall be rejected. Straightening of bars shall not be carried out without the written approval of the Engineer. Each coil of wire or strand or bundle of bars shall clearly identify the following: the name of the manufacturer; country of origin/manufacture; the specification to which the tendon was manufactured; the date of manufacture; unique coil or bundle number; test certificate reference number.
Where prestressing tendon is being imported to the Site or the place of production of the precast elements, the Contractor shall supply details for all shipments intended for delivery including date of original loading, destinations en-route, date of unloading and intended date of delivery, so as to enable correlation to be made of every consignment of tendons with the relevant test certificates and delivery notes. 8.6.4 Testing of Prestressing Tendons Manufacturers test certificates confirming compliance with the relevant British Standard for all tendon deliveries shall be submitted to the Engineer. Where super strand to BS 5896 Table 6, or other than the lowest strength wires complying with Tables 4 or 5 of that Standard are to be used, then the following shall also apply: (a) (b) A sample from each reel of material proposed for use in the Works shall be taken in the presence of the Engineer. A reel shall only be accepted if both the breaking load and the 0.1% proof load of the sample exceeds the specified characteristic loads given in the British Standard.
No prestressing tendon shall be used in the Works until the Engineer has confirmed that he is satisfied that the tendon has been tested and complies with Specification requirements and that an auditable trail of documents from the place of tendon manufacture to delivery to Site or the place of production of the precast units, has been provided. Failure to comply with these requirements will result in the rejection by the Engineer of all work containing unapproved tendon. 8.6.5 Handling and Storage of Prestressing Tendons When incorporated into the Works the tendon shall be clean, dry and free from rust and any oil based materials. Pitted tendons will be rejected by the Engineer and shall not be incorporated into the Works.
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Care shall be taken to avoid mechanically damaging, work hardening or heating prestressing tendons while handling. All prestressing tendons shall be stored clear of the ground and protected from the weather including sea spray, from splashes from any other materials and from splashes from the cutting operation of an oxy-acetylene torch, or arc-welding processes in the vicinity. In no circumstances shall prestressing tendons after manufacture be subjected to any welding operation, or heat treatment or metallic coating such as galvanising. This does not preclude cutting as described below. Cutting of wire, strand or bar shall be by either: (a) a high-speed abrasive cutting wheel at a distance of at least one diameter from the anchor; or (b) an oxy-acetylene cutting flame, using excess oxygen to ensure a cutting rather than a melting action and be cut at least 75 mm away from the anchor. The temperature of the tendon adjacent to the anchor shall not be greater than 200 C. Care shall be taken to ensure that neither the flame nor metal splashes come into contact with the anchorages or tendons. The requirements of Clause 8.4.3 shall also apply to the storage of prestressing tendons. If prestressing strand is stored for a period in excess of six months prior to use, the Engineer will require samples to be taken from each reel and to be tested in accordance with BS 5896 to demonstrate that the mechanical properties of the strand have not been impaired. 8.6.6 Positioning of Prestressing Tendons, Sheaths and Duct Formers Tendons, sheaths and duct formers shall be accurately located at the positions shown on the Drawings in both the vertical and horizontal directions. The tolerance in the location of the centreline of the sheath or duct shall be 5mm. Where tendons are required to be debonded from the concrete they shall be covered with sleeves approved by the Engineer. The ends of the sleeves shall be taped to prevent the ingress of grout. Joints in adjacent sheaths shall be spaced at least 300mm apart and all joints shall be securely taped to prevent concrete ingress. 8.6.7 Tensioning Apparatus All tendons stressed in one operation shall be taken, where possible, from the same coil or bundle. Each tendon shall be identified with its coil or bundle number. No strand that has become unravelled shall be used. The tensioning apparatus shall meet the following general requirements. (a) (b) The means of attachment of the tendon to the jack or tensioning device shall be safe and secure. Where two or more wires or strands are stressed simultaneously, they shall be approximately of equal length between anchorage points at the datum of load
170
(c)
(d)
(e)
and extension measurement. The degree of variation shall be small compared with the expected extension. The tensioning apparatus shall be such that a controlled total force is imposed gradually and no dangerous secondary stresses are induced in the tendons, anchorage or concrete. The force in the tendons during tensioning shall be measured by direct-reading load cells or obtained indirectly from gauges fitted in the hydraulic system to determine the pressure in the jacks. Facilities shall be provided for the measurement of the extension of the tendon and of any movement of the tendon in the gripping devices. The load measuring device shall be calibrated to an accuracy of 2% and checked at intervals to the approval of the Engineer. Elongation of the tendon shall be measured to an accuracy of 2% or 2 mm, which ever is the lesser. The tensioning equipment shall be calibrated before the tensioning operations commence and subsequently at intervals approved by the Engineer.
8.6.8
Pretensioning of Tendons Where pretensioning methods are to be used, the tension shall be fully maintained by some positive means during the period between tensioning and transfer. The transfer of stress shall take place slowly to minimise shock. In the long-line method of pretensioning, sufficient locator plates shall be distributed throughout the length of the bed to ensure that the wires or strands are maintained in their proper position during concreting. Due account shall be made of any frictional forces developed by tendon deflection devices. Where a number of units are made in line, they shall be free to slide in the direction of their length and thus permit transfer of the prestressing force to the concrete along the whole line. In the individual mould system, the moulds shall be sufficiently rigid to provide the reaction to the prestressing force without distortion. Concrete shall not be stressed until it has reached at least the age at which 2 test cubes taken from it attain the specified transfer strength. The test cubes shall be made and tested as described in BS EN 12390-1 and BS EN 12390-3 respectively. They shall be cured in similar conditions to the concrete to which they relate in a manner approved by the Engineer. The Contractor shall cast and test sufficient cubes to demonstrate that the required strength of the concrete at transfer has been reached. The Contractor shall ensure that those carrying out the stressing are fully conversant with stressing procedures and are provided with particulars of the required tendon loads and extensions. In particular, prestressing operations including the control of tendon delivery and storage, installation and tensioning shall be supervised by an individual nominated by the Contractor who has extensive experience in prestressing works. The Contractor shall furnish to the Engineer a detailed summary of the nominated prestressing supervisors experience, together with the names of two referees.
8.6.9
Drawings of Prestressed Elements The Contractor shall prepare detailed drawings of the precast prestressed elements showing the following details:QICT Terminal 2, Main Works Contract Volume 2 Specifications 171 9S5537/R/013/GP/PBoro February 2008
Overall length, span between centre of bearings. Cross sectional dimensions. Position, sizes, steel type and cover of non-prestressed steel reinforcement. Holes and lifting details, unit weights relating to each beam. The location, number, type of tendon, stressing force and extension of tendon together with debonding details. The type of cement and constituent concrete materials, water cement ratio and admixture details, together with transfer and 28 day cube strengths. The unit mark, where the mark is located on the unit, together with casting date and identification of how the unit should be positioned using points of the compass.
Three copies of the drawings should be submitted to the Engineer for approval three weeks before any manufacture of the unit components is programmed to commence. Drawings shall be on drawing sheets the same size as the Contract drawings and be titled in a similar manner to the approval of the Engineer. Drawings shall be in ink and clearly presented with a minimum letter/figure size of 3 mm high.
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9 9.1
9.1.1
STRUCTURAL STEELWORK GENERAL

Scope of this Section This section covers all structural steelwork required for the project as well as all welding procedures, tests and inspections; but excludes protective treatment, piling materials and pile fabrication.
9.1.2
Standard Specifications Unless otherwise stated in this Specification, the materials and construction of the Works covered by this Section shall comply in all respects with the latest editions of all relevant British Standard Specifications and Codes of Practice, including all current amendments. A list of British Standards and Codes of Practice referred to is given below.
BS Number BS 4 BS 4190 BS 4395 BS 4604 BS 4872 BS 5135 BS 5400 BS 7371 BS 7668 BS EN 287 BS EN 288 BS EN 571 BS EN 875 BS EN 895 BS EN 910 BS EN 970 BS EN 1011 BS EN 1290 BS EN 1291 BS EN 1712 BS EN 1714 BS EN 10113 BS EN 10025 BS EN 10029 BS EN 10088 BS EN 10155 Title Structural Steel Sections ISO metric black hexagon bolts, screws and nuts High strength friction grip bolts and associated nuts and washers The use of high strength friction grip bolts in structural steelwork metric series. Approval testing of welders when welding procedure approval is not required Arc welding of carbon and carbon manganese steels Steel, concrete, and composite bridges Coatings on metal fasteners Weldable structural steels Hot finished structural hollow sections in weathering steels Approval testing of welders for fusion welding Specification and approval of welding procedures for metallic materials Non-destructive testing Penetrant testing Destructive tests on welds in metallic materials Impact tests Test specimen location, notch orientation, and examination Destructive tests on welds in metallic materials Transverse tensile test Destructive tests on welds in metallic materials Bend tests Non destructive examination of fusion welds Visual examination Welding Recommendations for welding of metallic materials Non destructive examination of welds Magnetic particle examination of welds Non-destructive examination of welds Magnetic particle testing of welds Acceptance levels Non-destructive examination of welds Ultrasonic examination of welded joints Acceptance levels Non destructive examination of welded joints Ultrasonic examination of welded joints Hot rolled products in fine grained structural steels. Hot rolled products of non-alloy structural steels Technical delivery conditions Tolerances on dimensions, shape and mass for hot rolled steel plates 3 mm thick or above Stainless steels Structural steels with improved atmospheric corrosion resistance. Technical delivery conditions
BS Number BS EN 10160 BS EN 10163 BS EN 10164 BS EN 10210 BS EN 22553 BS EN 25817 BS EN ISO 1461 BS EN ISO 6947
Title Ultrasonic testing of steel flat product of thickness greater than or equal to 6mm (reflection method) Deliver requirements for surface condition of hot rolled steel plates, wide flats, and sections Steel products with improved deformation properties perpendicular to the surface of the product Technical delivery conditions Hot finished structural hollow sections of non-alloy and fine grain structural steels Welded, brazed and soldered Joints Symbolic representation on drawings Arc-welded Guidance on quality levels for imperfections Hot dipped galvanised coatings on fabricated iron and steel articles specifications and test methods Welds Working positions Definitions of angles of slope and rotation
9.1.3
Quality Assurance and Standards Where any work, goods or materials to be used in the Works covered in this Section of the Specification are the subject of an accredited third party quality management scheme or an accredited third party product certification scheme the Contractor shall supply the Engineer with a copy of the certificate of conformity with that scheme. Design Work Where the drawings indicate that a part of the steelwork is to be designed by the contractor, then the Contractors design shall be in accordance with BS 5400 Part 3 using loads from the drawings, and from BS 5400 Part 2.
9.1.4
Alternative Construction Methods If the Contractor proposes to adopt an alternative construction method and/or sequence to that referred to in Clause 9.2.3, the Contractor shall submit to the Engineer and the Planning Supervisor sufficient information to enable them to satisfy themselves that the alternative method and/or sequence can be used safely and without detriment to the permanent works.
9.1.5
Alternative Materials Should the Contractor wish to provide alternative sections, vary the grade of steel or make any such alteration which may affect the design he shall obtain prior written approval for the substitution from the Engineer
9.1.6
Sub Let Orders In the event of material or sub-let orders being proposed for the whole or any part of the work, full details and names of Sub-Contractors and Suppliers must first be submitted to the Engineer for approval, including if required, evidence of past successful completion of works of a similar nature. No such orders shall be placed without the prior written approval of the Engineer. A copy of each approved order shall be forwarded to the Engineer.
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The Contractor shall ensure that all Sub-Contractors and Suppliers are fully informed of all Specification requirements applying to the materials to be supplied and the work to be done at the time that approved orders are placed. 9.1.7 Inspection of Materials and Work in Progress The Engineer shall have the right of access at all reasonable time to the stores and places of work of the Contractor, his Sub-Contractors and his Suppliers for the purposes of inspection of materials and work in progress. The Engineer shall be afforded the opportunity to witness all mechanical tests. 9.1.8 Test Certificates The Contractor shall maintain a record of the source of, and test certificates for, all plates, sections, welding consumables, bolts, rivets, washers, nuts and shear connectors.
9.2
9.2.1
PROJECT SPECIFIC REQUIREMENTS

Documents and Drawings The structural steelwork requirements are to be found in the drawings.
9.2.2
Setting Out The required lines and levels of the completed structure are to be found in the drawings. Information in these documents is believed to be correct, however they do not relieve the contractor of his responsibility to carry out his own survey and notify the engineer of any discrepancies before commencing fabrication.
9.2.3
Construction Method The design is based on the construction method and/or sequences to be found on the drawings. Where no construction methods and / or sequences are shown on the Drawings, the Contractor shall submit a details of his Construction Method and Sequences of Construction to the Engineer for approval (including any temporary works, plant, labour etc that the Contractor deems necessary to erect the structure). Such approval shall not be unduly withheld or affect in anyway the Contractors responsibilities under the Contract. The Contractor shall submit his Method Statement at least 28 days prior to the date he wishes to commence erection of the structure.
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9.2.4
Contractors Drawings The Contractor shall provide fabrication and as-built drawings. If these drawings are produced by amending the Engineers drawings then the title blocks shall be amended to show that they are now the contractors drawings. The shop fabrication drawings shall give complete information for the fabrication of the component parts of the structure, including location, type and extent of bolts and welds. The drawings shall clearly distinguish between black and high strength friction grip bolts. Where welding symbols are used these shall be in accordance with BS EN 22553.
9.2.5
Inspection Facilities Steel material supplied to the site will only be accepted from a supplier with an accredited QA scheme. Details of this QA scheme need to be provided to the Engineer at least 28 days prior to the ordering of any material by the Contractor.
9.2.6
Improved Deformation Properties Where indicated on the drawings, material shall comply with the requirements for improved deformation properties perpendicular to the surface of the product according to BS EN 10164, Class Z25.
9.2.7
Internal Imperfections In addition to the areas mentioned in BS 5400 Part 6 Clause 3.1.4, and where indicated on the drawings, the areas of plate listed below shall not have internal imperfections exceeding the limits of Class S1 or E1 (as appropriate) to BS EN 10160.
9.2.8
Datum Temperature The steelwork dimensions given on the drawings are specified for a mean temperature of 20 degrees Celsius. The Contractor shall make adjustments as necessary to achieve the specified dimensions at this temperature.
9.2.9
Trial Erection If no trial erection is to be performed, the fabricated steelwork shall be measured for length in the workshop: i. on length over each span, measured between bearing centrelines.
ii. on length of transverse bracing members. The results of the measurements shall be reported to the Engineer. 9.2.10 Hardness and Quality of Edges Outside arrises of plates and sections which are to receive corrosion protection shall be smoothed by grinding or filing to a radius of at least 2mm.
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9.2.11
Bolts, Nuts and Washers All bolts described on the drawings as grade 4.6 or 8.8 shall be in accordance with BS 4190. All bolts used on site should be grade 8.8
9.2.12
Welding Procedure Trials The Contractor shall carry out welding application trials in accordance with Clause 9.4.4 for the all weld details.
9.2.13
Butt Welds All butt welds shown on drawings are full penetration butt welds. Where access from both sides is possible the root of the weld shall be inspected, and ground out as necessary, before welding from the second side. When welds are only accessible from one side then full penetration must be achieved by the use of a backing strip. Where additional butt welds not shown on the engineers drawings are required to suit the available materials and the contractors transport and erection arrangements the locations of these butt welds shall be agreed with the Engineer. Where butt welds are to be ground flush there shall be no loss of parent metal. The final grinding shall be in the direction of the applied stress.
9.2.14
Marking for Erection The Contractor shall prepare marking plans for steelwork erection and all steel sections delivered to site shall be clearly marked with its erection mark.
9.2.15
Unacceptable Defects in Welding In addition to the requirements of 5.5.2.4 of BS 5400 Part 6, stray-arcing spots shall be considered as unacceptable defects. Where welds are deemed unacceptable by testing they shall be ground out, the parent material suitably prepared, the weld performed again and the test repeated, all at the Contractors own cost
9.3
9.3.1
GENERAL STEELWORK CLAUSES

Fabrication and Erection Fabrication and erection shall be generally in accordance with BS 5400 Part 6. Any materials drawn from stock and not specifically rolled for this Contract shall be properly authenticated by tension and impact test certificates, ladle analyses etc., as if it had been ordered from the mills specifically for this Contract.
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9.3.2
Structural Steels All structural steel shall be to BS EN 10025 grades S235, S275 or S355 or to BS EN 10137 grade S460. Steel shall be marked by painting to ensure that correct grades are used for all fabrication work. Steel sections and plate shall be to BS EN 10034. Structural hollow sections shall be to BS EN 10210. Steel equal and unequal angles shall be to BS EN 10056. Steel bulb flats shall be to BS EN 10067
9.3.3
Straightening and Flattening Before fabrication is started all plates shall be carefully examined for laminations and other defects and shall be passed at least twice through levelling rollers. Rolled sections shall be straightened if necessary and made free from twist. The limitations on laminations given in BS 5400 shall apply, however BS 5996:1993 has been replaced by BS EN 10160:1999. The equivalent grades are given below.
Location At a bearing diaphragm At a single sided bearing stiffener Plates with corner welds Cruciform Joints BS 5996 grade B4 B4 E B4 BS EN 10160 grade S1 S1 E1 S1
9.3.4
Stainless Steel Unless specified elsewhere all stainless steelwork shall be grade 1.4401 in accordance with BS EN 10088. Technical Delivery Conditions The following optional technical delivery conditions shall be invoked: i. The maximum carbon equivalent values set out in Table 4 of BS EN 10025:1993 shall apply.
ii. Where indicated on the drawings, the material shall be suitable for hot-dip galvanised coating. iii. Where material is to be bent in the cold condition, it shall be of a grade suitable for cold forming. Surface Condition The surface condition of the steel shall comply with Class A3 (for flat products) or Class C3 (for sections) to BS EN 10163. Surface defects revealed during fabrication or blast cleaning shall be treated in accordance with BS EN 10163. Repair by welding of any surface defect or exposed edge lamination shall only be carried out with the approval of the Engineer and using a procedure complying with BS 5135 or BS EN 1011-1.
Flame Cutting and Shearing Procedures The Contractor shall submit written procedures for flame cutting and shearing before commencing fabrication. Documentary evidence shall be submitted to show that procedure trials witnessed by an independent inspection authority have been carried out to demonstrate that these procedures comply with the requirements of Clause 4.3.3 of BS 5400 Part 6.
9.4
9.4.1
WELDING
Welding - General Metal-arc welding shall comply with BS 5135 or BS EN 1011. All welds shall be continuous, unless otherwise specified by the Engineer. Low hydrogen electrodes shall be stored in a dry heated store. Prior to use they shall be baked in an oven for at least the time and at the temperature recommended by the manufacturer and then stored in heated containers alongside the work. If for any reason the container loses its heat or the electrodes are inadvertently exposed, they shall be returned to the oven and the heating process repeated. Electrodes and fluxes shall be used in accordance with the manufacturers instructions. Slag and weld spatter shall be removed from welds and the surrounding surfaces using a flexible abrasive disk mounted on a power driven flexible pad, or a flexible abrasive flap wheel before cleaning or painting of these areas is carried out. A burnished appearance caused by polishing in of paint, rust, or dirt, will not be acceptable.
9.4.2
Welding Procedures No welding shall be carried out until the Engineer has approved the relevant welding procedures. These may be procedures developed specifically for this project or generic procedures certified by an independent inspection authority. Welding procedures shall be written in accordance with BS 5135 or BS EN 1011. They shall specify minimum heat inputs or run sizes. These minima shall apply to all runs of weld, including tack welds. The fillet weld sizes shown on the drawings are those required for strength purposes only. The sizes shall be increased where necessary to comply with the heat-input requirements just described. In the fabrication of built-up assemblies, all butt welds in each component part shall be completed, whenever possible, before the final assembly. The sequence of assembly shall be in accordance with Clause 9.2.3.
9.4.3
Temperature of Steel The temperature of steel before and during welding shall be as set out in BS 5135 or BS EN 1011 but not less than 10C. Where pre-heating is necessary it shall be carried out by slow and uniform warming. Intense local heating is prohibited. Attainment of the
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correct pre-heating temperature shall be determined by means of temperature-sensitive crayons. 9.4.4 Welding Procedure Trials Weld procedure trials shall be carried out as set out in clause 5.4 of BS 5400 Part 6. In table 4 of BS 5400 Part 6, the words when specified by the Engineer shall be deleted at both places where they occur. The trials shall be valid for thickness ranges and positions as set out in BS EN 288. The trials shall include specimen weld details representative of the actual construction, which shall be welded in a manner simulating the most unfavourable conditions liable to occur in the particular fabrication. If any surface treatment is to be applied to the work prior to fabrication, it shall be applied to the sample material before the procedure trials are made. After welding the specimens shall be held at a temperature not less than 100C for a period not less than 72 hours and shall then be sectioned and examined for defects. Welding positions for procedure trials shall be as set out in BS EN ISO 6947. 9.4.5 Qualifications and Testing of Welders The approval and testing of welders shall be in accordance with BS EN 287 or BS 4872 as appropriate. The Engineer may accept proof of previous qualification upon submission of a recent welder performance qualification certificate. The Engineer reserves the right to retest any welder working on the fabrication if he has reasons for doubting the welder's ability. All welders carrying out underwater work shall be certified to AWS 3.6. 9.4.6 Supervision of Welding Welding should be carried out only under the direction of an experienced and competent supervisor. A Certificate in Welding Supervision issued under the CSWIP scheme or equivalent will be accepted as evidence of competence. Unless otherwise agreed by the Engineer, a record shall be kept to enable major butt welds to be identified with the welders responsible for the work but finished work shall not be marked by hard stamping for this purpose. 9.4.7 Welding Plant The welding plant shall be capable of maintaining at the weld the voltage and current specified on the procedure sheet. The Contractor shall supply instruments for verifying voltages and current as and when required by the Engineer. 9.4.8 Fit up of Welded Parts The fit-up of parts joined by fillet welds shall comply with the requirements of BS 5135 or BS EN 1011.
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Gaps between parts joined by fillet welds shall not exceed 1mm average (measured over 1m or the length of the weld, whichever is smaller). Where this additional requirement cannot be achieved, the Contractor shall increase the size of the fillet weld accordingly, unless otherwise agreed by the Engineer. In butt joints the root edges or root faces shall not be out of alignment by more than one eighth of the thickness of the thinner material for materials up to 12mm thick or by more than 2mm for thicker materials. 9.4.9 Identification Identification shall be provided to enable each weld to be traced to the welder or operator who made it. 9.4.10 Welded Attachments Attachment of cables, pipework and auxiliary fittings etc. by site welding is absolutely prohibited and the Contractor shall ensure that all his Sub-Contractors and Suppliers are informed accordingly. Normally such attachments will be by properly co-ordinated shopwelded fittings and drillings. Should the need for further attachments on site become apparent the Engineer shall be informed and he will then decide what form such attachments may take. Removal of temporary welded attachments shall be by cutting or chipping and not by breaking the back of the fillet weld. The surface of the material shall be ground smooth with the final grinding in the direction of the highest stress. The positions of welds required for temporary attachments shall be agreed by the Engineer before the work commences. 9.4.11 Site Welding The clauses in this specification which refer to welding apply both to shop welding and to site welding. The method statements referred to in Clauses 9.2.3 and 9.4.2 shall identify any welds to be made on site. The quality acceptance standard for site welds shall be the same as for shop welds. 9.4.12 Welding of Structural Hollow Sections Welding of Structural Hollow Sections (SHS) shall follow the recommendations of British Steel Corporation Technical Document TD 394 SHS Welding.
9.5
9.5.1
WELDING INSPECTION
General The Contractor shall appoint an independent inspector approved by the Engineer. The Contractor shall ensure that the inspector carries out all the necessary testing in sufficient time to permit any remedial work to be carried out. Copies of all the inspectors reports shall be sent direct to the Engineer as soon as possible after each inspection.
9.5.2
Loose Rust and Scale All loose rust and scale, slag residue and weld spatter shall be removed prior to inspection.
9.5.3
Visual Inspection Close visual inspection to BS EN 970 shall be carried out by the independent specialist on 100% of all welds. The acceptance standard shall be BS EN 25817 class D Moderate.
9.5.4
Magnetic Particle Inspection Magnetic particle inspection to BS EN 1290 shall be carried out by the independent specialist on 10% of all fillet welds. The welds to be inspected shall be agreed by the independent specialist and the engineer. The acceptance standard shall be BS EN 1291.
9.5.5
Dye Penetrant Testing The Engineers preferred method of NDE for fillet welds is magnetic particle inspection. However where for any reason MPI cannot be used the Engineer will give permission for dye penetrant testing in accordance with BS EN 571 Part 1 to be used instead.
9.5.6
Ultrasonic Inspection Ultrasonic inspection to BS EN 1714 shall be carried out by an independent specialist on 10% of all butt welds. The welds to be inspected shall be agreed by the independent specialist and the engineer following completion of the visual inspection. The acceptance standard shall be BS EN 1712 level B.
9.5.7
Production Test Plates The Engineer will decide the number and choice of production test plates. A minimum of production test plates from 20% of tension flange welds and one from each compression flange and web plate will be required for test specimens. The tests to be carried out on the production test plates shall be as set out in clause 5.5.1 of BS 5400 Part 6. The size of the plates shall be sufficient to provide two sets of specimens for these tests. Tests shall be carried out by the methods described in BS EN 875, BS EN 895 BS EN 910, and BS EN 288-3. The weld metal and heat affected zone in production test plates shall be tested to ensure compliance with Clause 5.4.1.2 of BS 5400 Part 6, assuming that the applied principal tensile stress at the ultimate limit state is greater than 100 N/mm2. In the event of failure to meet the test requirements, the welded joint represented by the tests shall be completely cut out. The joint shall then be re-welded and the tests
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repeated. Failure of a joint to meet test requirements may lead to the Engineer increasing the number of joints to be tested. 9.5.8 Repair of Welds Should any sections of a weld be found to be faulty the weld will be deemed unacceptable and the Contractor required to repair or replace the weld at his own cost in accordance with BS 5400 Part 6 Clause 4.7.5. If the welding procedure for the repair is different from the original weld then a separate welding procedure will be required. The Engineer may also ask for an investigation into the cause of the defect to be carried out.
9.6
9.6.1
DIMENSIONAL CONTROL
General The tolerance on thickness of plates and flats shall be Class A to BS EN 10029. Fabrication tolerances shall be as set out in Table 8 of BS 5400 Part 6. The Contractor shall demonstrate to the satisfaction of the Engineer that he has procedures in place to control distortion and contraction so as to achieve these tolerances.
9.6.2
Camber Where cambering is achieved by a series of straight chords to a continuous curve, the chord lengths shall be agreed by the Engineer.
9.6.3
Bearing Surfaces As an alternative to machining of bearing surfaces in accordance with BS 5400 Part 6 clause 4.2.3, an equivalent fit may be achieved between two surfaces by grinding until the two surfaces mate to give a maximum 0.5mm gap.
9.6.4
Ends of Stiffeners Where ends of stiffeners are required to be fitted, they shall be ground or otherwise prepared, so that the maximum gap between the end of the stiffener and the surface against which it is fitted does not exceed 0.25mm over 60% of the fitted area and does not exceed 0.75mm over the remainder of the fitted area.
9.7
9.7.1
STUD SHEAR CONNECTORS

General The Contractor shall submit written procedures for welding stud shear connectors before commencing fabrication. Documentary evidence shall be submitted to show that procedure trials demonstrate that these procedures comply with the requirements of
clauses 4.7.4 and 5.4.4. of BS 5400 Part 6. The procedure trials shall have been witnessed by an independent inspection authority. Existing trial results will be considered, provided the procedure trials and written procedures are compatible in all respects. 9.7.2 Test Studs at Start of Each Day Before the start of each days welding, 3 no. studs shall be welded to a plate of the same thickness as the flange plate and tested in accordance with Clause 5.4.4(b) of BS 5400 Part 6 (i.e. it shall be bent and re-straightened). If any of these studs fail, further sets of 3 no. studs shall be welded and tested until satisfactory results are obtained before any studs are welded to the girders. 9.7.3 Test on all Studs All stud shear connectors shall be tested in accordance with Clause 5.5.4(a) of BS 5400 Part 6 (i.e. the side of the head shall be struck with a 2 kg hammer). Test Studs Selected by the Engineer In addition, approximately 1 in 50 studs on each girder or piece of steelwork, with a minimum of 2 per piece, shall be selected by the Engineer for a test to Clause 5.5.4(b) of BS 5400 Part 6. The Contractor shall ensure that the direction of the test does not interfere with the fixing of reinforcement.
9.8
9.8.1
MISCELLANEOUS STEELWORK
Holding Down Bolts Holding down bolts shall be set by the Contractor and their setting out and support must be approved by the Engineer prior to placing of the surrounding concrete. Where anchor bolts are to be cast into concrete the bolts shall be set accurately in position with a steel template. Before the concrete sets the Sub-Contractor shall check that the bolts are truly vertical and located to their correct position within 2mm. The Sub-Contractor shall leave the nuts screwed onto the bolts and shall ensure that they are protected against accidental damage. The Sub-Contractor shall thoroughly clean the top of the foundation around the bolts before the erection of steelwork.
9.8.2
Anchor Bolts Anchor bolts shall be resin anchors of the sizes shown on the drawings. They shall be installed in accordance with the manufacturer's recommendations.
9.8.3
Bearing Pads Bearing pads consisting of steel shims and plates set in cement/sand mortar shall be set under all bearings (except rubber bearings) and accurately lined and levelled prior to grouting of the bearings. Should the Contractor wish to leave the shims permanently in place a suitable compressible layer shall be provided in the shim assembly to the approval of the Engineer. The Engineer may require tests to prove that such shim assemblies will not overstress the bearings when subject to the full design load.
9.8.4
Lining, Levelling and Grouting Each bay shall be plumbed and levelled prior to grouting as the work proceeds. When, in the opinion of the Engineer, a sufficient section of the structure is ready for grouting, the Engineer will check the work and only after the Engineer's approval will grouting be carried out. Should any further adjustment be necessary the Engineer will inform the Contractor who shall, without delay, undertake the necessary works to the Engineer's approval and at the Contractor's own expense?
9.8.5
Handrailing and Standards Handrailing and Standards shall be manufactured from mild steel, circular hollow sections to the dimensions and sizes stated on the Drawings. All materials shall be in accordance with BS EN 10025 ; hollow sections in accordance with BS EN 10210 Part 2 and welding to BS 5135 or BS EN 1011. Handrailing and fixings shall be designed to withstand a horizontal force at handrail level of 740 Newtons per metre run. The deflection of rails shall not exceed 0.8% of their height. The handrailing shall be fixed true to line and the standards set plumb and securely fixed to the structural concrete, on a mortar bed.
9.8.6
Steel Flooring Unless otherwise specified on the drawings the steel flooring to walkways shall be open type panel flooring designed to support an imposed loading of 5kN/m with a maximum deflection of span/200 or 10mm whichever is less. For service walkways over which vehicles will travel, the open type flooring is designed to support an imposed loading of 13.6kN/m with a maximum deflection of span/200 or 10mm whichever is less. All floors, walkways and platforms with edges over which it would be possible for material to drop, or where shown on the drawings, shall be provided with steel toe boards at least 125mm high above the top of the walkway. The main bars of the flooring shall be not less than 3mm thick and shall span across the shortest distance between supporting steelwork. For trafficked sections of service walkway, the main bars of the flooring shall be not less than 5mm thick and shall span across the shortest distance between supporting steelwork. All floor panels shall be clipped to supporting steel along each edge at centres not greater than 1200mm. Clip bolts shall have either spring washers or lock nuts. Where two floor panels meet along an unsupported edge they shall be stitch bolted together with fixings at not greater than 200mm centres with bolts of diameter not less than 6mm. Open type flooring panels and fixings shall be given corrosion protective system type D.
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9.8.7
Staircases The slope of the staircase stringers shall be arranged to give a nominal 200mm rise and 225mm going. The width of the stairs shall be as shown on the drawings but in no case shall be less than 1000mm. No flight of stairs shall have more than 16 risers. Treads and landings shall be manufactured from open type flooring as specified in Clause 9.8.6.
9.8.8
Ladders Unless specified elsewhere, ladder rungs, stringers and supporting brackets for fixed ladders shall be from steel complying with BS EN 10025 grade S235.
9.8.9
Purlins Where practicable purlins shall span continuously over at least two spans, joints in adjacent lines of members shall be staggered.
9.9
9.9.1
BOLTING
Lack of Fit If members do not properly fit because holes do not match, such holes shall be reamed out and the next larger size bolt shall be inserted. If in the Engineer's opinion that connection requires new holes, then new holes shall be drilled. No burning of existing or new holes will be permitted. No correction shall be carried out without the prior approval of the Engineer.
9.9.2
Assembly of Bolted Joints When a joint has been assembled, the matching holes shall be accurately located with standard parallel barrel drifts of the appropriate diameter. Sufficient temporary service bolts shall then be inserted and tightened up to draw all the connected parts tightly together. All connections shall be completed as soon as practicable after assembly. High Strength Friction Grip (H.S.F.G.) Bolts, Nuts and Washers All H.S.F.G. bolts, nuts and washers shall comply with BS 4395 and shall be used in accordance with BS 4604. All H.S.F.G. bolts, nuts and washers shall be sherardized to BS 7371 Part 8 before despatch and given protective treatment after tightening. All H.S.F.G. bolts, nuts and washers shall be packed prior to despatch by the manufacturer in waterproof containers and stored under cover in those containers until required for use in the works. H.S.F.G. bolts shall not be used as substitutes for black bolts without the permission of the Engineer.
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9.9.3
Tightening of H.S.F.G Bolts All H.S.F.G bolts shall be lightly lubricated with an approved lubricant immediately prior to insertion in the connection. Lubricant should be kept off the faying surfaces. The H.S.F.G. bolts shall be tightened in a staggered pattern from the centre of the joint outwards, care being taken to ensure that no bolts have been slackened by the tightening of adjacent bolts. Wherever possible the nut shall be the element to be rotated. H.S.F.G. bolts shall be tightened by a part-torque part-turn method. The part-torque tightening shall be in accordance with BS 4604: Part 1 except that it shall be carried out by a calibrated tightening device such as a torque controlled manual wrench or power operated wrench. The part torque to be applied to the bolts shall be as shown in the following table
Nominal diameter of bolt - mm 16 20 22 24 Bedding torque + /- 10%N.m 180 258 350 445
After bedding down of the joints, each nut and the protruding threads of the bolt shall be permanently marked to record their relative positions. The nut shall then be tightened by the part-turn of the nut method in accordance with BS 4604: Part 1. All tools used for tightening shall be regularly calibrated on the actual bolts being used to verify that the pre-loads within the specified range are being achieved. Ten percent of all H.S.F.G bolts shall be tested for tightness, at least one bolt per connection being tested. If a test indicates insufficient tightening of any bolt tested, all bolts in the particular connection shall be tested. All bolts found to be insufficiently tightened shall be tightened to the correct torque with a recently calibrated wrench. Alternatively, approved load indicating washers or similar may be used in accordance with the manufacturers recommendations. 9.9.4 Galvanizing and Sherardizing Where items are described on the drawings as galvanized they shall be hot dip galvanized to BS EN ISO 1461. Bolts for fixing galvanised items are to be galvanised to BS 7371 Part 6. The threads of the nuts may be 0.4 mm oversize. A sparing application of tallow to ease assembly is permitted. Bolted joints in galvanized steel shall be sealed using zinc rich primer to BS 4652. 9.9.5 Stainless Steel Bolts Where stainless steel bolts make contact with other dissimilar metals, an electrically insulating washer shall be provided between the two metals to prevent bi-metallic corrosion.
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9.10
9.10.1
HANDLING, TRANSPORT AND ERECTION

Handling of Structural Steelwork All structural steelwork shall be erected in accordance with BS 5400 Part 6. The structural steelwork shall be transported to site, handled, stored and erected so that it is not subjected to stresses in excess of those for which it was designed and is not damaged in any way. Means shall be provided to minimise damage to the protective treatment and any damage which does occur shall be made good. All work shall be protected in transit. Particular care shall be taken to stiffen free ends and prevent permanent distortion and adequately protect all machined surfaces. All bolts, nuts, washers, screws, small plates and small articles generally shall be suitably packed and identified. Any members which in the opinion of the Engineer have been damaged or overstressed shall be removed from the Site at the Contractors expense and repaired or replaced to the approval of the Engineer.
9.10.2
Loading of Structures The Contractor shall not at any time load any structure or any part thereof in excess of the designed working load. No loads shall be placed on any parts of the structure without the prior approval of the Engineer.
9.10.3
Erection Plant and Equipment The Contractor shall not employ any plant or equipment which in the Engineers opinion may be unsuitable, unsafe, or likely to cause damage to the structure during erection or damage to existing buildings etc.
9.10.4
Falsework and Temporary Bracing The Contractor shall supply and erect all necessary falsework and staging and shall supply all labour, tools, erection plant, lifts, services and other necessary materials. The Contractor shall take all necessary measures, by the addition of temporary bracing and guying, to ensure adequate resistance to wind and stability against collapse during construction.
9.10.5
Safety of Pedestrian and Vehicular Traffic Due consideration shall be given at all time to the safety of pedestrian and vehicular traffic during the period of erection.
9.10.6
Marking for Erection Every piece of steelwork shall be distinctly marked before despatch, in accordance with an erection marking plan to be prepared by the Contractor. The figures shall be in paint not less than 50mm high corresponding with the erection marks on the working drawings
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and material lists. The weights of the various members shall also be painted on. Markings shall be made on at least two sides of each member.
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10 10.1
CORROSION PROTECTION CORROSION PROTECTION PARTICULAR REQUIREMENTS

This section of the corrosion protection specification contains particular requirements for the corrosion protection works to be undertaken under the Contract. The particular requirements take precedence over the general corrosion protection specification contained under the corrosion protection specification Clause 10.2 onwards.
10.1.1
Scope of Works The Contractor shall be responsible for providing the protective coatings in line with the specifications as set forward in the schedule below.
10.1.2
Schedule of Steelwork Treatments

SCHEDULE OF PROTECTIVE COATINGS FOR STEELWORK AND METALWORK Item Ladders, handrailing, fenders (all related steelwork including shackles, eyelets, chains, panels, etc and all Reefer Gantry Steelwork Protective Treatment Protective Treatment Type C
Miscellaneous steelwork supports, walings, , all Protective Treatment Type A crane rail associated steelwork but not the crane rails themselves (including sole plates, flexible pads, clips HD bolts and all fixtures and fittings), buffer stoppers and all related steelwork, crane storm pin sockets and all related steelwork, storm tie downs and all related steelworks, brackets and the like Manhole Covers, Gully Gratings & Frames Protective Treatment Type A
Unless otherwise noted, all bollards shall have a clean unblemished surface and receive two coats of black bitumastic solution to BS 3416. The second coat shall be applied after installation.
10.1.3
Schedule of Colour Finishes The colour shall be to the approval of the Engineer.
10.1.4
Schedule of Protective Treatments Protective Treatment Type A This system applies to all external steelwork, except where hot dip galvanizing is specified. It shall be suitable for seawater splash zone, or frequent salt spray environment, corrosivity category C5-M to BS EN 12944 Part 2. i. Surface preparation ISO-Sa 21/2 or ISO-St 3 to BS 7079 blasting profile (Rz) 50 - 100 microns. ii. Two component polyamide cured epoxy primer at 50-100 microns
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iii. Two component high solids glassflake reinforced polymide cured epoxy coating at 200-400 microns The system shall be designed to provide 15 year life to first maintenance taking into account its exposure and conditions. The system shall be subject to the approval of the Engineer. Protective Treatment - Type B This system generally refers to interior structural steelwork, corrosivity category C3 (medium) to BS EN 12944 Part 2. i. ii. iii. iv. v. Surface preparation Sa 2 to BS 7079 Profile 50 - 75 microns Primer coat two pack zinc rich, nominal dry film thickness 75 microns. Undercoat two pack epoxy nominal dry film thickness 75 microns. Finish coat two pack polyurethane gloss nominal dry film thickness 50 microns. Total nominal system thickness to be 200 microns
The system shall be designed to provide 15 year life to first maintenance taking into account its exposure and conditions. The system shall be subject to the approval of the Engineer. Protective Treatment - Type C This system refers to miscellaneous steelwork components such as hand railing, kerb railing, light structural frameworks, ladders and the like. This system involves the hot-dip galvanising of the steelwork to BS EN ISO 1461 for items over 5mm in thickness. i. Surface preparation shall be to BS EN ISO 1461. ii. Hot-dip galvanising shall produce a minimum average coating weight of 610g/m2 for any individual test area (nominal coating thickness >85 microns). For large articles, the minimum coating weight referred to above is the average of determinations over a test area of 600mm2 to 1200mm2. All bolts, nuts and washers for use with galvanised steel shall be hot dip galvanised. Nut threads shall be cut 0.4mm oversize in accordance with BS 7371 part 6. Bolted joints in galvanised steelwork shall be sealed using zinc rich paint. Protective Treatment - Type D This system refers to the sherardizing of nuts, bolts and washers. To comply with the sheradizing process to BS 4921 Class 2. All items to be sherardized shall be free from any contamination which cannot be removed by normal pre-treatment methods. When fixed, all sherardized items shall be degreased with a suitable organic solvent, e.g. trichloroethylene and dried. The protective treatment of the surrounding steelwork shall then be applied. Testing of coatings shall comply with the requirements of BS EN ISO 1461.
10.2
10.2.1
GENERAL
General The work covered in this Section of the Specification is for the protection against corrosion of all the structural steelwork.
10.2.2
Painting All paints shall be from an approved manufacturer. The fullest possible use shall be made of the Technical Services of the manufacturer concerned. Unless otherwise noted in the Particular Specification, the colour shall be to the approval of the Engineer.
10.2.3
Safety All due care shall be taken by the Contractor and his employees in the handling of all materials and equipment for painting, and the correct disposal of all waste materials to prevent danger from fire, explosion or toxic fumes being experienced by any person on the site. A high standard of personal hygiene shall be practised by all operatives including the use of protective clothing, gloves, masks and barrier creams to prevent the risks of dermatitis or other complaints from occurring.
10.2.4
Storage of Paint Paints shall be delivered in sealed containers bearing the manufacturers name and labelled to show the colour, the specification with which the paint complies, whether for interior or exterior use, and whether for a priming coat, an undercoat or a finishing coat. No materials of any description shall be added to the contents of the containers except in strict accordance with the manufacturers instructions and paints of different types or of different manufacturers shall not be mixed together. Each batch shall be dated on delivery and shall be used strictly in order of delivery. Paint not used within the shelf life period specified on the containers or within 18 months of the date of manufacture - whichever is the lesser, shall be replaced. Paint shall be stored in sealed containers in a store where it will not be exposed to extremes of temperature. The temperature of the store shall be kept between 4oC and 27oC unless the storage conditions recommended by the manufacturer allow temperatures outside this range. Any special storage conditions recommended by the manufacturer shall be observed.
10.2.5
Sampling and Testing Samples for testing may be taken both from the sealed containers and from the workmens kettles on the works. Any work coated with materials, the samples from which prove unsatisfactory, shall be cleaned off and re-executed, and work on which the
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paint is found to be unduly thin shall be repainted, all to the satisfaction of the Engineer and at the Contractors own expense. 10.2.6 Workmanship General All brushes, tools, pots, kettles, etc., used in carrying out the work shall be clean. They shall be thoroughly cleaned before being used for a different type or class of paint. Paint Preparation All paint shall be prepared and applied strictly in accordance with the manufacturers instructions. All painting shall be carried out by skilled and experienced painters under constant supervision of competent qualified staff. Paint shall be thoroughly stirred when the containers are opened and when fresh supplies are being transferred to paint pots. All paints shall be strained free from skins, etc. Paint shall be supplied from the Contractors paint store to the painters ready for application. Two pack or any similar chemically cured type paint shall not be used after the expiration of the pot life stipulated by the manufacturer and such paints shall not be mixed with fresh paints. Paint Application Paints shall not be applied when the ambient temperature or the relative humidity falls outside the limits recommended by the manufacturer, nor shall such paints be applied when the temperature is likely to fall below the specified minimum during the curing period. Paints shall not be applied externally during rain, fog or mist, or where the amount of moisture on the surface, or that likely to be caused by subsequent condensation, may have a harmful effect. All shop painting shall be carried out in a fully enclosed workshop unless otherwise agreed by the Engineer. Steelwork shall not be moved outside the fully enclosed workshop until the shop protective treatment is complete. Unless otherwise described in the specification, a coat of paint shall be applied by one of the following methods: Brush Roller supplemented by brush where necessary. Air pressure spraying. Airless spraying.
Spray-painting will not be allowed where the soiling of adjacent surfaces is likely to occur, unless these surfaces are adequately protected, and neither will spray-painting be allowed in the case of paints containing lead.
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10.2.7
Prepared Surfaces The Contractor shall carefully inspect and prepare all surfaces to the approval of the Engineer. Surfaces of steelwork or metalwork that have been previously primed are to be examined to ensure that they have been properly prepared before priming and that the primer is of a suitable type, firmly adhering and in good condition. If the condition of the surfaces or of the primer is unsatisfactory and if the surfaces of any small items remain un-primed, then the surfaces are to be thoroughly cleaned by mechanical chipping or wire brushing to remove all defective primer and all rust and loose scale back to the bare metal. If necessary, the primer shall be stripped off completely. The surfaces are then to be primed immediately with the appropriate primer. If the condition of the surfaces and the primer is satisfactory then the surfaces are to be thoroughly cleaned to remove all dirt, grease, etc, any metal exposed as a result of damage to the primer is to be wire brushed and scraped to remove rust and primed immediately with the appropriate primer. Surfaces that have been galvanized are to be thoroughly cleaned to remove all dirt, grease, etc. and then primed with a primer suitable for this type of surface. After preparation, the required protective treatment shall be applied. The Contractor shall examine all surfaces prepared by others and if the working surfaces or conditions are in any way unsuitable he shall advise the Engineer immediately in writing. The Contractor shall keep all working surfaces clean and properly brushed off as the work proceeds.
10.2.8
Protective Treatments The contractor shall provide the protective treatment systems given in the Particular Specification. Protective System and Paint Data Sheet For all painted items, the Contractor shall submit to the Engineer for approval a `Paint System Sheet' stating full details of each paint system proposed indicating the following information: surface preparation. system reference together with manufacturer's brand name and product reference. dry film thickness. colour. time to repaint.
The Contractor shall also submit with Paint System Sheet, copies of a Paint Data Sheet, provided by the paint manufacturer, for each of the paints he proposes to use. The requirements of the Paint System Sheets shall only be adopted for the Works following the Engineers approval.
The Contractor shall ensure that the paint manufacturers Data sheets cover the conditions at Works or at Site, including temperature and humidity, under which the paints are to be applied. 10.2.9 Shop Painting The shop in which the protective system is to be applied shall be approved by the Engineer before the work commences and shall be of such design and construction that the specified conditions of temperature, humidity and cleanliness are maintained throughout the Contract period. 10.2.10 Preparation of Bare Metal Surfaces Blast Cleaning All steelwork to be blast cleaned shall be treated in accordance with BS 7079 Preparation of steel substrates before application of paints and related products Grade Sa 2 using automatic impeller machine blasting or manual blasting as appropriate. The maximum grade of abrasive permitted shall be as specified in the above British Standard. Non-metallic abrasives will only be permitted for use with portable equipment where agreed with the Engineer. The abrasive used for blasting shall be free from contamination and any recovered material shall be cleaned to the satisfaction of the Engineer before reuse. The maximum amplitude peak to trough of the blast cleaned surface shall not exceed 100 microns. A sample blast-cleaned panel measuring not less than 150 x 150 x 6 mm adequately protected by sealed transparent wrapping, shall be submitted to the Engineer for approval before any work is commenced. The approved sample shall be retained by the Engineer for comparison with prepared steelwork. Hand Cleaning All steelwork to be manually cleaned, by grinding disc, power wire brush, chipping hammers, or needle guns shall be treated in accordance with BS 7079 Grade St 2. Pickling All steelwork to be galvanized shall be pickled in diluted Hydrochloric acid. 10.2.11 Storage of Steel and Fabricated Steelwork The Contractor shall take precautions to minimise exposure to chemical pollution of steel awaiting fabrication. Fabricated steelwork which is stored, awaiting delivery to site or erection, shall be kept clear of the ground and shall be laid out or stacked so as to prevent water or dirt accumulating on or against any of the surfaces. Suitable packing shall be placed between layers of stacked steelwork. Where cover is provided it shall be ventilated sufficiently to keep condensation to a minimum.
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Care shall be taken during loading, unloading, stacking and erection of any painted steelwork to minimise damage to the protection system. All slings, ropes and chains used to handle the steelwork shall be protected with rubber sheaths or similar. The Contractor shall make good to the approval of the Engineers Representative all paint work damaged during fabrication, transport, assembly and erection. Unless otherwise described in the Contract, exposure times for blast cleaned or coated surfaces other than at joints shall not be longer than those in the table below. Outside refers to any area outside a fully enclosed workshop. The exposure times tabulated refer to any part of the surface cleaned in accordance with 10.2.10.
Max Exposure Times Surface Enclosed Workshop S1 Blast Cleaned S2 Metal Sprayed S3 Mechanically Cleaned S4 Chemically Cleaned S5 Blast Primer on S1 S6 Etch Primer on S1 S7 Primer on S3 S8 1st Undercoat on S4, S5, S6 or S7 S9 Subsequent Undercoats Table 9.1: Maximum Exposure Times 4 hours 4 hours 48 hours As agreed with Engineer Max. exposure of 8 weeks with up to 2 weeks of this time outside 24 hours 48 hours 48 hours As agreed with Engineer Nil Nil Nil Outside Nil Nil Nil
For surface condition S5 where blast primed steelwork is exposed outside, the minimum dry film thickness of paint over the peaks of the blast cleaned steel shall not be less than 13 microns. 10.2.12 Metal Coatings Metal coatings shall be provided as required in the Particular Specification. Where metal coating are required for threaded fasteners and not otherwise covered in the Particular Specification, the following standards shall apply: BS 4921 Sherardized coatings on Iron and Steel Articles. BS 3382 Parts 1 and 2, Electroplated Coatings on threaded Components (Cadmium and Zinc). This Standard shall cover the electroplating of components up to and including 36 mm in diameter. The minimum thickness of coating shall be 5 microns.
Where the metal coating is by a hot dip process the Contractor shall be responsible for the provision of all holes required for purposes of filling, venting and draining. The
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Contractor shall propose the location, size and method of plugging where required of all such holes which must be approved by the Engineer before fabrication commences. Where a metal coating is required only on part of an assembled section it shall be applied before the rest of the section receives its priming coat. Where nuts and bolts are to be metal coated, attention is drawn to the additional clearances required on screw threads as shown in BS 4921, Table 2. 10.2.13 Handling of Coated or Painted Steelwork The Contractor shall exercise the maximum care in handling, transportation and erection of protected steelwork so that damage to the coating may at all times be avoided. The use of properly assigned slings and soft non-adherent packs shall be used throughout. 10.2.14 Repairs to Damaged Area Areas of paint which have been damaged during handling, storing, loading and off loading, transporting and erecting shall be cleaned to bare metal by grit blasting, grinding wheels or other approved means and the edges of the undamaged paint bevelled by at least 50mm. The full specified painting system shall then be re-applied and the new paint shall overlap the existing paintwork by at least 50mm. All steelwork which is to be painted in coal tar/epoxy which has been damaged or been stripped to permit welding shall be repaired using an equivalent approved coal tar/epoxy suitable for application on wet or damp surfaces. In some instances this will have to be carried out under tidal conditions. In all circumstances the steel surface shall be adequately cleaned as specified in BS EN 12944 and coated to provide the paint thickness corresponding to adjoining surfaces. 10.2.15 High Strength Friction Grip (HSFG) Bolted Joints The interfaces of all HSFG bolted joints shall be cleaned as specified, left unpainted masked off to protect them until the joint is bolted up. Blast primer or metal spray as appropriate shall be taken 10mm to 20mm inside the perimeter of the joint area. Subsequent paint coats shall be stopped off progressively at intervals of 75mm from the bolted joint. Before the joint is made the facing surfaces shall be lightly hand wirebrushed to give a clean surface free of corrosion products and any foreign matter. Immediately after the joint has been made the primed steelwork shall be hand wirebrushed and the specified painting systems completed. 10.2.16 Other Bolted Joints For shop joints the Blast primer shall be applied to parent and joint material. The joint shall be assembled immediately after the first undercoat of the painting system has been applied to the parent and contact surfaces.
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For site joints all surfaces, excepting those of fasteners, shall receive in the shop the paint system which is applied to the parent surfaces. 10.2.17 Welded Joints Welds and surfaces which have been affected by welding shall receive the preparation and protective systems which are applied to the parent surfaces. Metal surfaces shall be kept at least 15mm clear of area to be welded and these areas shall be masked off during spraying. Where paints other than blast printers are to be applied to the parent surfaces before the making of a joint, they shall be stepped back at 30mm intervals commencing at 80mm from welded joints and at 10mm from the perimeter of all other joints. 10.2.18 Treatment of Completed Joints Within 14 days of the joints having been made and passed by the Engineer, the parent and joint materials, exposed parts of bolts, nuts and washers, weld and weld affected areas shall be prepared and painted. All bolted joints shall be sealed against the ingress of moisture. Before painting commences, and subject to the approval of the Engineer, gaps at joints shall be plugged with approved filler. The perimeter of all joints shall be sealed with subsequent coats of paint. 10.2.19 Sealed Box Girders Box girders shall be sealed by welding. Inside faces of the box that are not exposed need have no protective treatment.
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11 11.1
FENDERS AND MOORINGS FENDERS AND MOORINGS PARTICULAR REQUIREMENTS

This section of the fenders and mooring specification contains particular requirements for the fenders and moorings works to be undertaken under the Contract. The particular requirements take precedence over the general fenders and moorings specification contained under the fenders and moorings specification Clause 11.2 onwards.
11.1.1
Scope of Work The works required are the design, fabrication, installation and testing of fenders, in the locations shown on the drawings. The Contractor shall also provide chains to prevent mooring lines passing behind the fender panels.
11.1.2
Specific Requirements, Design The fenders shall be as shown on the drawings, as supplied by or similar approved. The fender panels shall be designed by the Contractor to satisfy the following criteria:
Fender panel required Maximum hull pressure Dimensions Low friction facing Yes 40t/m2 As shown on drawing Ultra high molecular weight polyethylene, minimum of 60 mm thick and with a maximum coefficient of friction to steel of 0.2 Minimum coefficient of friction to be used in design of panel and chains Minimum Chains required Additional requirements for corrosion protection Shackles, shear and tension chains as required Refer Section 10 for corrosion protection for all steelwork 0.5
Table 11.1: Fender Panels and Chains
11.1.3
Fender Testing Requirements For the purposes of testing the fenders, the Rated Performance Data (RPD) as defined in Guidelines for Design of Fender Systems 2002 published by the International Navigation Association shall be taken as follows: One fender unit shall be selected at random from each batch of ten units produced of a particular size, grade and specification. Where different moulds are used or the manufacturing process is altered, this shall be treated as a new batch of fenders for the purpose of this clause. Where there are less than ten fenders in a batch, then one fender shall be tested from that batch.
11.1.4
Bollards Bollards shall be of the tee-head type with a design working load of 125t and shall be as shown on the drawings.
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Bollards shall be manufactured from cast iron to BS EN 1561. The factor of safety on the design of the bollard shall be 3. The bolt group shall be designed to BS 5950 with a factor of safety of 1.4. The bollards shall be designed for a horizontal operating range of 180 and a vertical operating range of 10 depression and 45 rise. All parts of the bollard in contact with the mooring lines shall be smooth and not induce wear on mooring lines. All bolt recesses shall be filled with a mixture of pitch and sand to form a smooth surface to the top of the base plate.
11.2
11.2.1
GENERAL
British Standards and other Codes of Practice All materials and workmanship shall be in accordance with the appropriate British Standards, Codes of Practice and other specified standards current at the date of tender except where the requirements of these Standards or Codes of Practice are in conflict with this Specification in which case the requirements of this Specification shall take precedence. In particular, all work is to be carried out in accordance with the principles contained in British Standard BS 6349 Parts 1 and Parts 4. In addition fenders shall also comply with Guidelines for Design of Fender Systems 2002 published by the International Navigation Association, hereafter referred to as the INA Guidelines.
11.2.2
Particular Specification The following matters are, where appropriate, described in the Particular Specification: (a) (b) (c) (d) (e) description of the works responsibility for design performance criteria for the fenders performance criteria for fenders under test other particular requirements
11.2.3
Materials The sources of supply of materials shall not be changed until the Contractor has demonstrated that the materials from the new source can meet all the requirements of the Specification. Materials failing to comply with the Specification shall be removed promptly from the site.
11.2.4
Quality Management The Fender Manufacturer shall apply a system of Quality Management which conforms to ISO 9000/9001 or a recognised equivalent. This system must be certified by an
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acknowledged and accredited organisation, and proof of this system must be submitted with the Tender.
11.3
11.3.1
DESIGN OF FENDERS
Introduction The Contractor shall be responsible for designing any fender panels, chains and fixings in accordance with this Specification. The Contractor shall submit calculations, documentation and drawings for the following for the Engineers review to show that the requirements of the Particular Specification are met: fender system if designed by the Contractor; the fender panel, chains and fixings
Such design details shall be submitted not less than four weeks before the programmed commencement of fabrication or other such time as specified in the Particular Specification. Fabrication shall not commence until the Engineers agreement has been obtained. 11.3.2 Specified Fender Unit The fender unit shall be as specified in the Particular Specification. The Contractor may propose alternatives for the consideration of the Engineer, but no guarantee is given that any alternative will be acceptable. 11.3.3 Fender Panels Fender panels shall be designed and detailed by the Contractor to BS 5950, to distribute the fender load onto the vessel and to carry all loads induced by the fender reactions. The panel shall be designed for the case when the panel is in contact with a plane hull, and shall also be designed to carry the loads associated with the panel being loaded by a knife edge load equal to the design fender reaction, applied at any level corresponding to contact with belting on a vessel. Panel sides and the bottom edge shall be chamfered, whilst the top edge shall be profiled to prevent beltings being caught on top of the fender units. The panels shall be designed and detailed such that corrosion traps are avoided and to provide a durable structure suitable for the marine environment. Minimum steel thicknesses shall be as follows: Plates exposed on two surfaces Plates exposed on one surface Internal members (not exposed) 12mm 10mm 8mm
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The Contractor shall be responsible for designing the fender panels and shall take the design liability for this design. 11.3.4 Chains and Fixings Fender systems shall be designed such that a minimum of maintenance will be required and such that their removal for repair or maintenance work can be carried out quickly and easily. Chains shall only be incorporated in the Contractors design insofar as they are necessary for the correct functioning of the fender system. The number of chains shall therefore be minimised, but the Contractor shall consider the following in his design: a) Tension chains may be needed to the top of the panel to resist forces caused by vessels making contact along the lower part of the fender panel; Vertical sag chains may be needed to stop the weight of the fender and the front panel causing the system to droop with time; Shear chains may be needed at high and low level to restrain the fender panel and limit the forces on the rubber units when the berthing vessel has a component of velocity along the quay.
b)
c)
Chains shall be designed and detailed by the Contractor to carry the loads induced by the fender reactions combined with frictional loads based on the coefficient of friction specified in the Particular Specification. Chain assemblies shall be designed with a factor of safety of 3 on normal loads and a factor of safety of two on accidental berthing. The Contractor shall be responsible for designing all the fixings and shall take design liability for this design.
11.4
11.4.1
MATERIALS AND WORKMANSHIP

Rubber Fender Units Rubber fender units shall be compression moulded from natural or synthetic or both rubber compounds in compliance with Section 7.3 of Appendix A of the INA Guidelines. The rubber shall be fully vulcanised and homogeneous with no foreign particles and free from voids, cracks and cuts. Steel plates shall be fully embedded and fully adhered to the rubber during the vulcanization process to avoid separation between the rubber and steel. All fender units shall be subjected to at least one break in compression cycle to rated deflection prior to installation. The fender units shall satisfy the requirements for durability in compliance with Section 7.2 of Appendix A of the INA Guidelines. Documentation shall be provided to prove that
the combination of fender type and energy absorbing material has been successfully tested in accordance with this, verified by an independent body to the Engineers approval. If such documentation can not be provided, then a specific test shall be carried out for this project. 11.4.2 Records of Fender Units All fender units shall be permanently marked with a unique reference so that they can be individually identified both during construction and once incorporated into the permanent works. For the latter case, the marks are to be clearly legible to someone standing on the quay. For all fenders, full records of manufacture and installation are to be kept on forms to the approval of the Engineer. These records shall include: a) b) c) d) e) f) g) h) i) j) k) Identification marks Manufacturer, location of manufacture Size and rubber grade of fender unit Method of manufacture Mould reference where appropriate, supervisor in-charge Date(s) of manufacture Location of unit in works, and date of installation Test results Confirmation that the fender has been subject to a break in cycle, including details Any other relevant information Authorised signatures confirming details are correct
Preliminary forms shall be submitted to the Engineer prior to delivery of the fender units to site. Final forms shall be submitted within two weeks of installation of the fenders. 11.4.3 Fender Panels Front panels shall be closed box type, fabricated from steel sections and plate. All steelwork and fabrication shall be of good workmanship, and shall be in accordance with the Steelwork Specification as provided in Section 9. Fender panels shall be protected from corrosion in accordance with Section 10 of this Specification. Painting shall comply with the Painting Specifications as provided in Section 10. All external welds shall be sealed welds to prevent water from entering the panel and each panel shall be pressure tested to ensure that it is water tight. Any leaks found shall be repaired and the pressure test repeated until no further leaks are found. 11.4.4 Facings to fender panels Where specified, the panels shall be fitted with low friction facing pads, to minimise shear loads on the fender and the structure, and the need for chains. Fender facing pads shall be manufactured from ultra high molecular weight polyethylene and shall be suitable for their use. They shall be a minimum of 60mm thick, of an approved colour and have a maximum coefficient of friction to steel of 0.2. They shall be UV stabilised
and shall be secured to the steel fender panel using stainless steel Grade 316 studs, nuts and washers. All facing pads shall be drilled and counter bored for the mounting studs. The face of the studs shall be a minimum of 15mm below the front face of the pads and at least 10mm of facing pad should be below the nut and washer securing the facing pad. Fender panels shall be fitted with corner and flat front pads whose edges shall be chamfered. 11.4.5 Chains All chains shall comply with either BS 6405, BS 1663, JIS G3105 or other equivalent Standard and written proof in the form of a test certificate shall be furnished by the Contractor. After fabrication, all fins caused by welding shall be removed and the weld shall be smoothly finished all round. All chains, shackles, eyebolts, tensioning devices, U-bolts and the like shall be supplied with a protection system as stated in the Corrosion Protection Specification (Section 10). Where no system is specified in the Particular Specification, the chains shall as a minimum be hot dip galvanised to EN ISO 1461. Chains shall include a means for tensioning during installation and subsequent maintenance. The tensioning device shall be locked off after the tensioning of the chain. All shackles, pins, eyebolts, tensioning devices and U-bolts and the like shall be such as to provide strength and performance at least equal to the chain to which they are attached. 11.4.6 Fixings for Fenders, Chains, and Support Brackets Fender units shall be fixed using proprietary grade 316 stainless steel bolts and sockets cast into the concrete. Chains shall be fixed using cast in U bolts and shackles or similar approved unless otherwise stated. All fixings shall be such that they are stronger than the items they are fixing, in order to avoid damage to the fixings in the concrete.
11.5
INSTALLATION
Fenders and their components shall be handled, stored and installed in accordance with the manufacturer's instructions. Great care shall be taken to prevent cutting or tearing of the rubber, particularly in the area of embedded plates and around bolt holes and washer recesses in the fender base, flanges or fins.
Fenders shall normally be stored in the protection packings in which they have been transported. Fenders shall be handled in such a way as to prevent them from being distorted, overstressed or damaged in any way. All slings, ropes or chains for handling fenders shall be rubber or nylon sheathed. In particular great care shall be taken to prevent any damage to the paintwork of any fender panels. Any such damage shall be made good to the satisfaction of the Engineer.
11.6
TESTING OF FENDERS
Verification testing to determine compliance with the specified energy and reaction requirements shall be carried out in accordance with Section 6 of Appendix A of the INA Guidelines. Samples for verification testing shall be actual fender elements selected at random. The number of fender units to be tested shall be as stated in the Particular Specification. The Engineer shall be given at least four weeks notice of when and where the fenders are to be tested. The Contractor shall provide facilities to permit the Engineer or an independent inspector to witness the tests. This shall include assistance in acquiring visas to visit the testing location, and all local travel. Where the test is not carried out at the Design Conditions specified in the Particular Specification, then tests to establish the Temperature Factor and Velocity Factor shall be carried out in accordance with Appendix A of the INA Guidelines. These tests shall be considered as part of the verification testing, and the requirements of the previous paragraph shall apply. Full details of the tests shall be provided, including certification of the test equipment used.
11.7
BOLLARDS
The Contractor shall supply and fix in position bollards as stated in the Particular Specification. All works shall be in accordance with the manufacturers recommendations. All bollard holding down bolts shall be galvanised and shall be installed as detailed on the drawings and in accordance with the manufacturers requirements. Templates shall be used where appropriate to ensure that bolts are in the correct position. The bollards shall be installed horizontally on a minimum of 20 mm of approved cementitious grout. The bollards shall be filled with approved cementitious grout or concrete and the bolts retightened after the grout under the base has set.
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The holding down bolts shall not project above the top of the base plate. Where specified, the bolt recesses shall be filled with an approved sealant.
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12 12.1
CRANE RAILS AND QUAY SIDE FITTINGS CRANE RAILS AND QUAY SIDE FITTINGS PARTICULAR REQUIREMENTS
This section of the crane rails and quay side fittings specification contains particular requirements for the crane rails and quay side fittings works to be undertaken under the Contract. The particular requirements take precedence over the general crane rails and quay side fittings specification contained under the crane rails and quay side fittings specification Clause 12.2 onwards.
12.1.1
General The crane rail installation shall be of continuously welded rail, restrained by rail clips and underlain by a continuous steel reinforced resilient pad bearing on a steel sole plate, supported on an approved high strength grout. All components of the rail system shall be designed by a competent designer. All components shall be supplied by a single manufacturer.
12.1.2
Crane data The design of the crane rail shall take account of the following data relating to the cranes which will be supported by the rail.
Crane gauge No of wheels per corner Wheel spacing 27m 8 Total loaded length of the crane is assumed to be 10.5m, at a wheel spacing of 1.5m and 8 wheels per corner Minimum 800mm, maximum 1000mm 690 N/mm2 Not greater than 1.5m/sec Not more than 40 moves per hour
Wheel diameter Wheel steel grade Speed of travel No of crane travel movements per hour
12.1.3
Rail Size The rail size shall be A150 and GCR108 as specified on the drawings.
12.1.4
Design Loading The crane rail shall be designed to support the following (in service) corner loads from the crane.
Quay crane in-service wheel loads Design Parameter Equivalent UDL in service Horizontal wheel loads perpendicular to rail Horizontal wheel loads parallel to rail Design value Waterside 70t/m 10% 10% Landside 70t/m 10% 10%
Table 12.1: Quay crane in-service wheel loads
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The loaded length of the crane is assumed to be 10.5m at a wheel spacing of 1.5m and 8 wheels per corner; Load combinations for wheel loads are as per BS 6349; Crane load is considered a superimposed dead load with fl of 1.2 as per recommendations of BS 6349;
12.1.5
Design life The design life of the crane rail shall be 20 years.
12.1.6
Storm Anchor Pin Sockets Details and spacing of the storm anchor pin sockets are subject to confirmation from the chosen crane supplier. Prior to procurement of any materials, or the fabrication of the storm anchor pin sockets, the Contractor shall seek confirmation on the storm anchor pin sockets details and spacing from the Engineer. All items of steelwork shall receive a corrosion protection as defined in Section 10 of this specification.
12.1.7
Buffer Stoppers Details the buffer stoppers are subject to confirmation from the chosen crane supplier. Prior to procurement of any materials, or the fabrication of buffer stoppers, the Contractor shall seek confirmation on the buffer stopper details and spacing from the Engineer. All items of steelwork shall receive a corrosion protection as defined in Section 10 of this specification.
12.2
12.2.1
GENERAL
Design The crane rail system shall be designed by the Contractor, using a competent designer, who shall be responsible for the design of all components relating to the crane rail. The design of the rail shall be based on the wheel loadings defined in Clause 12.1.4 of the specification and the information shown on the drawings. The design shall include but not be limited to: the size of the rail the steel grade of the rail the bearing pad the rail clips and their fixings the sole plate the grout bed the holding down bolts
the rail earth connections
The Contractor shall submit details of the design to the Engineer for approval. 12.2.2 Crane Rail Installation The Contractor shall ensure that the installation of the crane rails is undertaken by suitably experienced personnel and details of their experience shall be submitted to the Engineer for approval prior to the commencement of crane rail installation on Site. . The supplier of the rails and the fixings shall provide a detailed method statement for installation. The following points shall be addressed: i. Rails when stored on site shall be properly and carefully stacked on suitably spaced support blocks and only to a reasonable height in such a way as to avoid distortion. They shall be handled at all times with adequate care and with proper appliances.
ii. Bent rails shall be straightened before laying in by means of a proper rail straightening screw. Kinked rails or rails distorted in a vertical plane shall be rejected. iii. The rails shall be laid to the alignment and levels shown on the drawings. Rails shall be laid so that the leading end from the rolls during manufacture is placed against the trailing edge of the adjacent rail. 12.2.3 Tolerances The crane rails are to be installed to the following tolerances: 12.2.4 Maximum deviation from specified gauge Maximum deviation from rail design line Maximum rate of deviation from a straight line Maximum deviation from design level Maximum gradient Maximum transverse inclination of rail from horizontal 5mm 3mm 1mm in 2000mm 2mm 1 in 1000 0.003 radians
Sole Plates The sole plates shall be of galvanised steel to BS EN 10025: minimum grade S275-J0 or equivalent and of minimum thickness 25mm. The sole plates shall be drilled to suit the bolting requirements and with suitable attachments to permit fine adjustments for levelling of the sole plate to within the requisite tolerances. All levelling bolts shall be removed on completion and, where necessary, coatings shall be applied to the bolts to facilitate removal. The sole plate assembly shall be galvanised to achieve a long life of 20 years. Sockets that are to be cast or grouted into the concrete shall not receive any protective
treatment. All areas of protective coating damaged during installation, particularly nuts and the heads of bolts shall be made good to the satisfaction of the Engineer. The holding down bolts shall be placed in corrugated tubes, which are cast into the concrete or shall be grouted in position using an approved high strength pourable non-shrink grout of either cementitious or epoxy grout into holes drilled to match the bolt holes in the sole plates. holding down bolts shall be. The tubes shall be supplied as part of the crane rails and fixings contract. The sole plate assembly shall be supplied and installed in not less than 6m lengths such that the sole plate is discontinuous over each joint in the supporting concrete beam. The Contractor shall confirm the joint spacing before ordering the sole plate assembly. The sole plate shall be grouted in position using an approved high strength pourable non-shrink grout material. Proposals for the use of either cementitious or epoxy grout will be considered. It should be noted that thicker layers are required with the use of cementitious grouts. The sole plate grout shall be supplied by the supplier of the crane rails and the crane rail fixings. The sole plate holding down bolts shall be of a length such that future re-levelling of the rails by up to 75 mm (outer [quay edge] rail) or 50 mm (land rail) may be undertaken without replacement of the sole plate holding down bolts. 12.2.5 Bearing Pads The design of the rail system shall incorporate resilient steel reinforced bearing pads, placed between the rail and the sole plate. The pads shall be of an approved proprietary type and be designed for use with the type of installation and for the size of rail proposed. 12.2.6 Rail Clips Rail clips shall be provided to restrain the crane rails. They shall be of an approved proprietary type with rubber facings, designed for use with this type of installation and fitted to the size of rail proposed. They shall be placed at a spacing determined by the rail system designer. The rail clips shall secure the rail against surge along its length and against transverse and overturning forces. The fixings shall be designed to satisfactorily absorb the stresses resulting from the interaction between the rail beam and the rail, including the bow-wave effect created by the crane while travelling. The rail clips shall accommodate crane induced rail movements. The rail clips shall allow for free longitudinal expansion and contraction of the rail due to temperature variation. The rail clips shall allow damaged rail to be removed and replaced with ease. The lower part of the rail clip shall be welded to the dole plate prior to galvanising. The size of the weld shall be determined by the rail system designer. The welds shall be
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continuous around each clip to prevent corrosion by penetration between the clip and the sole plate. The rail clips shall be installed in accordance with the manufacturers recommendations and the Contractor shall demonstrate that the designed fixing system prevents in-service loosening of the bolts. 12.2.7 Crane Rail The steel grade of the rail shall be determined by the Contractor, in association with the rail system designer, based on the crane data, rail width, design loading and design life specified in the project specific clauses of this specification. The contractor shall submit test certificates verifying that the steel used in the rails conforms to the requirements of the design. 12.2.8 Welding of Crane Rails Welding of lengths of crane rails to form a continuous length shall be carried out by one of the following two methods: Puddle Arc welding process Thermit welding process
Welding shall be carried out in accordance with the Recommended Practices for the Welding of Rails and Relating Components for Use by Rail Vehicles ANSI/AWS D15.2.94 published by the American Welding Society, or equivalent, and these Requirements. In the event of conflict between documents the higher standard shall take precedence. All welder(s) shall have appropriate demonstrable experience of the type of welding selected, and shall possess appropriate certificates. The same welder(s) shall return during subsequent visits to ensure familiarity with Site conditions and site-specific welding procedures. Where puddle arc welding is used, the rails shall be pre-heated a distance of 150mm either side of the joint. The temperature shall be maintained throughout welding. The pre-heat temperature shall be dependent on the carbon content of the steel as follows : Carbon Content up to 0.5% 0.5% - 0.7% 0.7% - 0.8% Above 0.8% Pre-Heat Temperature 200C 300C 350C Consult the Engineer.
Confirmation of the heated temperature shall be made using heat sticks. All welded fittings and fixtures shall be fitted in accordance with BS 5135 'Specification for Arc Welding of Carbon and Carbon Manganese Steels' and the manufacturer's recommendations. Completed joints shall be ground smooth and checked for edge fusion and possibility of cracking. Grinding shall take place over the section of rail
exposed to the gantry crane bogies and where an anti-tipping plate is fitted around the rail profile. Full details of the Contractors welding proposals shall be submitted to the Engineer for prior approval together with welder qualification. The Contractor shall show that the techniques proposed are satisfactory and that his welders are suitably qualified and this may include a requirement to carry out welding and/or welder qualification trials. The Contractor shall provide weather protection during welding operations. Testing of welds shall be undertaken by an independent accredited testing authority selected by the Contractor to the approval of the Engineer. The Contractor shall be responsible for all costs of such testing. All welds shall be tested. Testing of welds shall be by ultrasonic examination and shall be carried out by the Contractor in accordance with standards to the approval of the Engineer. The Engineer shall have the opportunity to witness any or all of the tests. The Contractor shall give adequate prior notice to the commencement of any tests. All ultrasonic operators shall be fully qualified, and each weld shall be examined with sufficient probe angles to guarantee full coverage of the joint. During production weld testing the Contractor shall produce a test report for each weld joint or weld repair examined in addition to a sketch of all flaw sizes and location and dB level for each flaw required. The report shall include conclusions as to acceptance or rejection of the flaws with reference to these Employers Requirements. The Contractor shall make an initial assessment of defects against acceptance criteria. All ultrasonic reports including recommendations shall be reviewed by the Engineer. Acceptance criteria shall be in accordance with Category A of BS 5135 Appendix H, Table 18, or other approved standard. The standard on which the slag indication acceptability is to be finally determined is to be agreed and confirmed prior to commencement of any UT. When positive flaw type interpretations cannot be ascertained in any instance the flaw shall be considered planar and in need of repair.
12.3
12.3.1
MISCELLANEOUS QUAY FURNITURE

Ladders Ladders shall be located and constructed as shown on the Drawings, and shall comply with BS 4211 and the recommendations of BS EN ISO 14122. The ladders shall be fabricated with side rails of the full length of the ladder without any joint. The side rails shall be finished straight and square. All holes for rungs and edges shall be free of burrs.
12.3.2
Service Pit Covers Service pits shall be fitted with a heavy duty galvanised steel or concrete cover sat on a rebate. The covers shall be made watertight by the addition of a polysulphide sealant all round. All materials and workmanship shall comply with this Specification.
12.3.3
Service Pit Covers Bolts, cast-in sockets, frames etc to be fixed in situ to concrete shall be set accurately in the shuttering or hung from special supports in their correct positions. They shall be firmly fixed so that they cannot be displaced during the placing of surrounding concrete. Unless otherwise specified, all such steelwork which is to be cast into concrete shall be provided with Protective System A as specified in Section 10 of these specifications. Where approved, holes for bolts may be drilled in concrete after it is hardened. Care shall be taken to ensure that damage to steel reinforcement does not occur. The holes shall be drilled using a rotary percussive drill employing air or water flushing of the hole. Holes shall be carefully cleaned and blown out before the fixings are placed and grouted. The use of diamond drilled holes will not be permitted, unless the Contractor can demonstrate to the Engineer that reinforcement has been accurately displaced and will not therefore be cut by the drilling. In the event that approval for diamond drilling is given and reinforcement is subsequently cut, the Contractor shall carry out any additional remedial works that the Engineer may instruct at the Contractors expense. Any diamond drilled holes to accommodate grouted anchor bolts shall be thoroughly roughened as recommended by the bolt manufacturer and to the satisfaction of the Engineer. Preformed holes for foundation and holding down bolts shall be formed by boxes of approved type which can be struck cleanly or which are suitable to be left in or by expanded metal sleeves. Polystyrene shall not be removed by burning. After the concrete surrounding the boxes or sleeves has hardened and the form stripped if necessary, the holes shall be cleaned out and temporarily plugged until the bolts are to be fixed. Any damage to holes shall be made good by the Contractor. All ragbolts or indented bolts shall be of approved type and shall be accurately set in position with the shank extending so that two threads will protrude past the nuts. They shall be set before the concrete is placed and care shall be taken to protect the bolt threads. Galvanised ragbolts or indented bolts shall be used with galvanised steel sections. Before bolts are grouted in, the holes shall be thoroughly cleaned. Grout of the type indicated or otherwise approved shall be placed in the hole and around the bolt and the surface shall be finished to present a uniform appearance with its surroundings. Angles forming frames or edges to pits and trenches shall be given an approved protective system. They shall be fixed to the concrete with fish-tailed lugs as shown on the drawings. Patent fixing arrangements shall be fitted in accordance with manufacturers recommendations. Cartridge driven pins shall only be used when approved and shall not be used for any fixing subject to tensile stress. All fixings into concrete shall be electrically isolated from the reinforcing steel to avoid bimetallic corrosion. Where fixings are of dissimilar metal to the items being fixed, they
shall include suitable isolating washers to ensure that there is no electrical contact between the fixing and item. 12.3.4 Resin Anchors Anchor bolts, nuts and washers shall be stainless steel to BS 970-1 or equivalent approved. The bolts shall be installed in polyester resin. Where anchorage holes are drilled horizontally the resin shall be installed in capsules and the anchor bolt installation shall be carried out strictly in accordance with the manufacturers written instructions. The drilled holes shall be irregular and dust free and shall be drilled using a rotary percussive drill on air or water flush. Diamond drills shall not be used. The Contractor shall provide to the Engineer for review and approval details of the anchorage system proposed, which shall include the following: name of resin anchorage manufacturer type of resin bolt diameter bolt anchorage length hole diameter method of installation When requested by the Company, the Contractor shall undertake in situ tension tests on selected anchorages to demonstrate the adequacy of the anchorage, at the Contractors own expense.
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13 13.1
13.1.1
EARTHWORKS EARTHWORKS PARTICULAR REQUIREMENTS

Description of the earthworks This section of the earthworks specification contains particular requirements for the earthworks to be undertaken under the Contract. The particular requirements take precedence over the general earthworks specification contained under the earthworks specification Section 13.2 onwards.
13.1.2
Scope of Works The works under this specification cover the following activities: The grading and formation preparation for pavements and any other form of surface finish following site clearance and reclamation of the terminal area. The earthworks specification covers all movement of material in both onshore and offshore areas, whether excavating or filling, to construct the works, not covered by the reclamation Specification. Excavation of material for all foundations, onshore retaining walls, pavement edge details and backfilling following construction of the buried structure. Excavation of trenches for the installation of all underground services and the backfilling of the trenches when the service has been laid and tested where appropriate. Excavation and filling as necessary to form earth platforms and graded designed slopes between platforms of different levels.
13.2
13.2.1
GENERAL
Definitions Areas of Fill are areas within the Site, including areas in embankments, platforms and slopes and in excavations for structures, pits and trenches, in which fill material is deposited and compacted as part of the permanent work. Earthworks Final Surface is the surface defined on the Drawings to which all earthworks (including reclamations works) are to be completed. Reclamation is the formation of land over an area of foreshore, seabed, tidal inlet or river, including adjoining areas by the deposition of fill material to the limits stated in the Contract. The Final Surface of any work is the surface defined by the lines and levels shown on the Drawings to which all of the Works carried out under the Contract are to be finished. Fill Material may consist of soil, rock, crushed concrete or inert construction material which is on or below the Site at the commencement of the Contract, or which is imported to the Site and which meets the requirements of the Specification.
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Surcharge is the Fill Material placed to the lines and levels shown on the Drawings, compacted in accordance with the Specification, maintained to the specified lines and levels for the duration of the Surcharge Period and then removed before the completion of the Contract. Surcharge Period is the period of time, commencing on the date on which the surcharge is completed to the lines and levels shown on the Drawings and ending on the date on which the removal of surcharge can commence. Formation is that part of the Earthworks Final Surface on which a pavement, structure or utility, is constructed, or on which the blinding or bedding for a pavement, structure or utility is placed. Intermediate Areas of Fill are Areas of Fill which are stated in the Contract in which Fill Material is deposited and compacted directly into shallow water or onto naturally occurring soft ground. Geotechnical Instrumentation is the installation and monitoring of instruments in the ground or structures to provide information on soil and rock parameters for the purposes of construction control and performance monitoring.
13.3
13.3.1
MATERIALS
Fill Material Fill Material shall consist of naturally occurring or processed material which at the time of deposition is capable of being compacted in accordance with the specified requirements to form durable and stable areas of fill. Fill Material, shall not contain any of the following: (a) material susceptible to volume change, including marine mud, soil with a liquid limit exceeding 65% or a plasticity index exceeding 35%, swelling clays and collapsible soils, (b) peat, vegetation, timber, organic, soluble or perishable material, (c) dangerous or toxic material or material susceptible to combustion, and (d) metal, rubber, plastic or synthetic material. The different types of Fill Material shall have the particle size distributions within the ranges stated in Table 13.1. Granular Fill Material shall consist of clean, hard, durable material. Rock Fill Material shall consist of pieces of hard, durable rock of which in the opinion of the Engineer not more than 30% by mass is discoloured or shows other evidence of decomposition. Crushed rock or crushed concrete may be permitted subject to approval by the Engineer.
The soluble sulphate content of fill material placed within 500 mm of concrete, cement bound material or cementitious material shall not exceed 1.9 grams of sulphate, expressed as SO3, per litre. The total sulphate content, expressed as SO 3, of fill material placed within 500 mm of metalwork shall not exceed 0.5% by mass. Well-graded material shall consist of material which has a coefficient of uniformity exceeding 10. Uniformly-graded material shall consist of material which has a coefficient of uniformity of 10 or less.
Type of fill material Size 400 mm Fine Fill Material General Fill Material Special Fill Material Granular Fill Material Rock fill material(Grade 200) 200 mm 100 100 75 mm 100 75 - 100 100 100 20 - 75 0 - 50 0-5 Percentage by mass passing BS test sieve size 20 mm 600 m 63 m 0 45 -
Rock fill material(Grade 100 20 - 75 10 - 30 0 - 25 400) Table 13.1: Particle size distributions of Fill Material for Earthworks
13.4
13.4.1
SUBMISSIONS
Particulars of Earthworks The following particulars of the proposed materials and methods of construction for earthworks shall be submitted to the Engineer: (a) (b) (c) details of Constructional Plant and haulage vehicles, methods of excavation and of deposition and compaction of Fill Material, use of different types of excavated material and sources of imported fill material, arrangements for stockpiling excavated material and fill material and for disposing of earthworks material, methods of controlling the moisture content of fill material, methods of controlling surface water and groundwater and of protecting earthworks and earthworks material from damage due to water and from weather conditions which may affect the earthworks or earthworks material,
(d)
(e) (f)
(g) (h)
methods of monitoring groundwater levels, and methods of monitoring the ground and structures for movements.
The particulars shall be submitted to the Engineer at least 14 days before the relevant work starts.
13.5
13.5.1
GENERAL EARTHWORKS REQUIREMENTS

Ownership of Earthworks Material Earthworks material within the Site at the commencement of the Contract shall remain the property of the Employer except as stated in Clause 13.5.2
13.5.2
Disposal of Earthworks Material Earthworks material which is required to be disposed of by the Contractor shall become the property of the Contractor when it is removed from the Site and shall be responsibly disposed of in licensed tips by the Contractor, unless otherwise stated in the Contract.
13.5.3
Temporary Works for Earthworks The design of Temporary Works associated with earthworks, including earthworks, temporary slopes, stockpiles, drainage and excavation propping systems, shall be such that the risk of failure is not more than that which would be adopted if the Temporary Works were to be permanent. Allowance may be made in the design of the Temporary Works for the shorter design life and for the risk to persons and property and the surface water and groundwater conditions which are likely to occur during construction.
13.5.4
Handling and Storage of Earthworks Material Earthworks material shall not be handled or stored in a manner which will result in segregation, deterioration, erosion or instability of the material. Different types of earthworks material shall be kept separate from each other. Earthworks material which is suitable for use as fill material shall be maintained in a suitable condition and shall not be contaminated.
13.5.5
Protection from Water and Weather After site clearance, excavation or filling, earthworks material shall be kept free from water and shall be protected from damage due to water and from exposure to weather conditions which may detrimentally affect the earthworks or earthworks material. The measures to be taken may include the following: (a) (b) (c) Surfaces shall be maintained in a stable condition and shall be formed to falls to shed water and to prevent ponding. The area of exposed surfaces shall be kept to a minimum. The area is overfilled as protection and subsequently trimmed to level.
Excavations for structures, pits and trenches shall not be carried out on or adjacent to slopes unless measures are taken to drain the excavation and to prevent water from the excavation entering the slope. 13.5.6 Earthworks material Allowed to Deteriorate or Become Unsuitable Earthworks material which has been used, or is required for use, in the permanent work and which is allowed to become unsuitable such that in the opinion of the Engineer it no longer complies with the specified requirements for that type of material shall be replaced or dealt with by methods agreed by the Engineer. Earthworks material which is not stated in the Contract to be excavated and which the Contractor causes or allows to deteriorate such that in the opinion of the Engineer the permanent work will be affected shall be replaced or dealt with by methods agreed by the Engineer at no additional cost to the Contract. Material provided to replace earthworks material which has been allowed to become unsuitable or which the Contractor causes or allows to deteriorate shall be an equivalent material approved by the Engineer. The replacement material shall have the same volume after compaction as the material replaced. The material which is to be replaced shall be disposed of by the Contractor at his own expense. 13.5.7 Additional Excavation and Stabilisation Earthworks material which is not stated in the Contract to be excavated but which in the opinion of the Engineer has inadequate strength, durability or stability shall be dealt with by additional excavation or filling as stated in Clause 13.5.8 or by stabilisation as stated in Clause 13.5.9 or by other methods instructed by the Engineer. 13.5.8 Additional Excavation Additional excavation shall be carried out and the resulting voids shall be dealt with as follows: (a) General fill material, fine fill material or special fill material shall be deposited and compacted below areas of fill and below formations other than in rock. Grade GEN 0 concrete shall be placed and compacted below formations in rock. Granular fill material shall not be deposited below standing water.
(b)
(c) 13.5.9 Stabilisation
Stabilisation shall be carried out using rock fill material deposited directly into the original unstable material and compacted to form a stable foundation on which to construct the subsequent work.
13.5.10
Removal of Earthworks Material Earthworks material which is required for use in the permanent work as Fill Material shall not be removed from the Site unless permitted by the Engineer. The Contractor shall notify the Engineer and receive his permission before any earthworks material is removed from the Site.
13.6
13.6.1
EXCAVATION
Disposal of Excavated Material Excavated material which in the opinion of the Engineer cannot be selected, processed or mixed in a practical manner to make it suitable for use in the permanent work as fill material shall be disposed of by the Contractor unless otherwise stated in the Contract. Excavated material which is surplus to the requirements of the permanent work shall be disposed of by the Contractor unless otherwise stated in the Contract.
13.6.2
Use of Excavated Material Excavated material required for use in the permanent work which is capable of being selected, processed and mixed to make it suitable for use as Fill Material shall not be used for any other purposes unless permitted by the Engineer. Excavated material which is required for use in the permanent work as fill material and which the Engineer permits to be removed from the Site or used for other purposes shall be replaced by an equivalent material approved by the Engineer. The replacement material shall have the same volume after compaction as the material replaced.
13.6.3
Obstructions in Excavations The Contractor shall inform the Engineer without delay of the nature excavations and location of any unforeseen obstruction encountered during excavation. Boulders which intersect the earthworks final surface or formation shall be dealt with as excavation proceeds by methods agreed with the Engineer. Boulders shall not be left protruding unless permitted by the Engineer.
13.6.4
Excavation Temporary supports or other methods shall be used to maintain excavations in a stable condition and to prevent settlement of structures or utilities due to excavation or dewatering. Constructional Plant or other vehicles shall not be operated or parked adjacent to excavations and earthworks material or other materials shall not be placed adjacent to excavations unless this has been allowed for in the design of the Temporary Works for the support of the excavation. Excavations shall be adequately marked and protected to prevent personnel or vehicles accidentally falling into the excavation.
13.6.5
Excavations adjacent to Structures and Utilities Prior to commencement of excavations required to construct the works the Contractor shall search and locate the route, size and level of existing services and all excavations shall be carried out by hand adjacent to utilities that are suspected, known or proven to exist. Unless otherwise permitted by the Engineer excavations next to structures shall be carried out by hand.
13.6.6
Excavations for Structures Pits and Trenches Excavations for structures, pits and trenches shall be the minimum size necessary to construct the permanent work. The sides of excavations shall be vertical unless otherwise permitted by the Engineer. The length of trench excavation left open at any one time shall not exceed that agreed by the Engineer. Unless permitted by the Engineer, trenches for utilities in areas of fill shall not be excavated until the fill material has been deposited and compacted up to the earthworks final surface or formation or up to 1 m above the top of the utility, whichever is lower. The Contractor shall install ground markers showing the route of services if there is plant operating on the site that could damage the service if the plant were to cross the route of the service.
13.7
13.7.1
DEPOSITION OF FILL MATERIAL

Types of Fill Material Unless otherwise stated in the Contract, Areas of Fill shall be formed of General Fill Material.
13.7.2
Sources of Fill Material Fill material shall be obtained from excavation within the Site. If there is insufficient fill material of the required types within the Site, imported Fill Material shall be provided by the Contractor from sources outside the Site.
13.7.3
Surface preparation for Fill Except as stated in the Contract surfaces on which fill material is to be deposited shall be prepared after site clearance in accordance with the following requirements: (a) (b) Topsoil, grass, and other organic matter shall be removed. Soft spots, boulders and other materials which in the opinion of the Engineer are unsuitable or unstable shall be removed.
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(c) (d)
Watercourses shall be diverted as stated in the Contract. Benches shall be cut and sub-soil drainage systems installed as stated in the Contract. Voids shall be dealt with as stated in the Contract or instructed by the Engineer. Surfaces other than rock shall be scarified to a depth of 200 mm and compacted to the same standard as the Fill Material which is to be deposited.
(e)
(f)
13.7.4
Commencement of Deposition of Fill Material The permission of the Engineer shall be obtained before deposition of Fill Material starts in any area of fill.
13.7.5
Haulage of Fill Material Haulage of Fill Material to an Area of Fill shall proceed only when the compaction plant operating at the area to be filled is sufficient to achieve the specified requirements for relative compaction of the Fill Material.
13.7.6
Deposition of Fill Material Fill material obtained from excavations within the Site shall be deposited in its final location as soon as practicable after it has been excavated. Fill material shall be deposited in layers of a thickness appropriate to the compaction method to be used. Unless otherwise permitted by the Engineer, layers of fill material shall be horizontal, except for any gradient required for drainage, and the thickness of each layer shall be uniform over the area to be filled. Except in excavations for structures, pits and trenches, if the difference in level between adjacent areas to be filled exceeds 1 m the edge of the higher area shall be benched before fill material is placed against it. The construction of the Works shall be controlled in such a manner that any compaction of the fill material resulting from the passage of Constructional Plant or haulage vehicles is uniform. Except as stated in the Contract, Fill Material shall not be deposited by end-tipping, by pushing loose material down slope faces or by other methods which may result in segregation or inadequate compaction of the Fill Material.
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13.7.7
Overfilling In Areas of Fill formed of Fill Material other than rock fill material, Earthworks Final Surfaces sloping at a gradient exceeding 1 vertical to 3 horizontal shall be formed by overfilling and cutting back after compaction. Over-filling shall extend beyond the earthworks final surface by a horizontal distance of 0.5 m or three times the thickness of the compacted layer, whichever is greater.
13.7.8
Deposition of Fill Material Adjacent to Structures or Utilities Fill Material deposited within 0.5 m of a structure or utility shall be fine fill material unless otherwise stated in the Contract. In addition, the material may contain up to 5% by weight of fresh, slightly decomposed or moderately decomposed rock fragments of up to 200 mm provided that these do not cause any damage to structures or structural waterproofing, nor do they interfere with the compaction requirements. Fill material shall not be deposited adjacent to or above structures or utilities until the construction of the structure or utility is sufficiently advanced to accept the imposed forces without disturbance or damage. Fill material shall be deposited evenly on all sides of structures and utilities and in such a manner that the structure or utility is not disturbed or damaged. Unless otherwise stated in the Contract, fill material around water, sewage and drainage pipes which are constructed as part of the permanent work shall be special fill material. They shall be deposited in layers not exceeding 100 mm thick to a level of 300 mm above the top of the pipe. The Fill Material shall be deposited in such a manner that the layer on one side of the pipe is not more than 100 mm higher than the layer on the other side.
13.7.9
Deposition of Rock Fill Material The final compacted thickness of each layer of rock fill material shall exceed 1.5 times and shall not exceed twice the nominal Grade size of the rock fill material. The surface voids of each layer of rock fill material shall be filled with fragments of rock before the next layer is deposited. The final surface of rock fill material shall also be blinded with fine fill material.
13.7.10
Deposition of fill Material in Excavations for Structures, Pits and Trenches If sheet piling, timbering or other temporary supports to excavations for structures, pits and trenches are not to be left in place, the sheet piling, timbering or supports shall be removed as deposition of fill material proceeds. The supports shall be removed in such a manner that the stability of the adjacent ground is maintained and the compacted fill material is not disturbed.
223
13.8
13.8.1
COMPACTION OF FILL MATERIAL

Compaction of fill Material Fill material in areas of fill shall be compacted in layers to a stable condition as soon as practicable after deposition and in a manner appropriate to the location and to the material to be compacted. The permission of the Engineer shall be obtained before the next layer is deposited on each layer of compacted fill material. Except as stated elsewhere in the Contract, Fill Material shall be compacted to obtain a relative compaction of at least 95% throughout.
13.8.2
Moisture content of Fill Material Fill material other than rock fill material and material as stated in Clause 13.8.5 shall be at optimum moisture content during compaction. The tolerance on the optimum moisture content percentage shall be 3%, provided that the fill material is still capable of being compacted in accordance with the specified requirements to form stable areas of fill. All necessary measures shall be taken to achieve and maintain the specified moisture content.
13.8.3
Compaction of Fill Material Adjacent to Structures and Utilities Fill material shall be compacted in such a manner that structures or utilities are not disturbed or damaged. Fill material around water, sewage and drainage pipes which are constructed as part of the permanent work shall be compacted by hand-rammers or manually operated power equipment. Fill material within 300 mm above the top of sewage and drainage pipes shall be compacted to obtain a relative compaction of at least 85% throughout.
13.8.4
Compaction of Rock Fill Material Every layer of rock fill material shall be compacted by at least eight passes of a vibrating roller or by other equivalent compaction method approved by the Engineer. The final surface of rock fill material shall be compacted by at least two additional passes of a vibrating roller or by other equivalent compaction method approved by the Engineer. Vibratory rollers used for the compaction of rock fill material shall have a static load per 100 mm width of roll of at least 2 kN for layers with a compacted thickness not exceeding 500 mm and at least 4 kN for layers with a compacted thickness exceeding 500 mm.
13.8.5
Compaction of General Fill Material with a Large Portion of Coarse Material For general fill material of which less than 90% passing a 20 mm BS test sieve, it will be difficult to permit determination of the moisture content and maximum dry density using standard methods. This type of material shall be compacted to the following requirements:
Spread and level each horizontal layer of general fill material with a thickness not less than 1.5 times of the maximum size of the general fill material and not exceeding the maximum depth of compacted layer in accordance with table 13.2. If this criterion is not met due to the presence of over-sized coarse material in the general fill, the over-sized coarse material shall be removed or broken down to sizes acceptable to the Engineer. Each layer shall be systematically compacted by a vibratory roller with the stipulated minimum number of passes corresponding to the minimum static load per 100 mm width of the roller. The number of passes of the roller shall only be counted when the roller is travelled on the material to be compacted at a speed of not more than 2 km per hour with full vibration. The plant other than vibratory roller to carry out material spreading or to provide some preliminary compaction only to assist the use of heavier plant shall be disregarded in counting the number of passes. Variation from the method or the use of plant different from that specified in the second paragraph of Clause 13.8.5 will be permitted only if the Contractor demonstrates at site trials that equivalent compaction is achieved by the alternative method or plant. The procedure to be adopted for these site trials shall be agreed with and approved by the Engineer. Without prejudice to the provision of the Conditions of Contract and in order that the Engineer may take proper provision for the supervision of compaction in the permanent work, the Contractor shall, not less than 24 hours before he proposes to carry out compaction processes, apply in writing to the Engineer for permission to do so. When materials of widely divergent grading are used in embankments and fill areas, they shall be spread and compacted in separate clearly defined areas. If more than one class of material is being used in such a way that in the opinion of the Engineer it is not practicable to define the areas in which each class occurs, compaction plant shall be operated as if only the material which requires the greatest compactive effort is being compacted.
Force per 100mm width (kN) 0.25 0.45 0.46 0.70 0.71 1.25 1.26 1.75 1.76 2.30 2.31 2.80 2.81 3.50 3.51 4.20 4.21 4.90 125 150 150 175 200 225 250 12 8 4 4 4 4 4 Well-graded material Maximum depth of compacted layer (mm) Minimum no. of passes Uniformly-graded material Maximum depth of compacted layer (mm) 150 150 150 200 225 250 275 300 300 Minimum no. of passes 16 12 10 10 10 10 8 8 8
Table 13.2: Compaction requirement for general fill material with a large portion of coarse material
13.9
13.9.1
COMPLETION OF EARTHWORKS SURFACES

Completion of Earthworks Final Surfaces Earthworks Final Surfaces shall be completed to a stable condition as soon as practicable after excavation or after deposition and compaction of Fill Material has been completed. The subsequent permanent work or surface protection shall be carried out as soon as practicable after the earthworks final surface has been completed. Earthworks final surfaces shall be completed to smooth alignments without abrupt irregularities unless otherwise stated in the Contract.
13.9.2
Completion of Formations Formations above structures or utilities shall be completed after construction of the structure or utility. Except in areas of fill formed of placed rock material or fill material as stated in Section 13.8.5, the soil within the top 500mm below the Formation Level shall be compacted to obtain relative compaction of at least 98% of the maximum dry density and CBR of not less than 3% throughout. The appropriate standard compaction method shall be used in accordance with BS 1377 Part 4, depending on the gravel content of samples. Unless otherwise permitted by the Engineer, proof rolling shall be carried out on formations. The formation shall be rolled in the presence of the Engineer by at least two passes of a non-vibrating rubber tyred roller. The roller shall have a static load per 100 mm width of roll of at least 4 kN and shall travel at a speed not exceeding 2 km/h. Any defect in the formation which is revealed during proof rolling by deformation of the formation which in the opinion of the Engineer is excessive shall be made good as instructed by the Engineer. After all other formation work and testing have been completed and damage caused by testing reinstated, formations for pavements shall be rolled with one pass of a smooth steel-wheeled non-vibrating roller. The roller shall have a load per 100 mm width of roll of at least 2 kN. Unless otherwise permitted by the Engineer, formations which will not be immediately covered by the subsequent permanent work shall be protected by methods agreed by the Engineer.
13.9.3
Protection of Earthworks Final Surfaces and Formations Earthworks final surfaces and formations shall be maintained in a stable condition and shall be protected from damage due to water or other causes and from exposure to conditions which may adversely affect the surface. Formations shall not be used by Constructional Plant or vehicles other than those which in the opinion of the Engineer are essential to construct the subsequent work.
226
13.10
13.10.1
INTERMEDIATE AREAS OF FILL

Deposition of Fill Material in Intermediate Areas of Fill Fill Material may be deposited in Intermediate Areas of Fill by end-tipping or by pushing into position until, in the opinion of the Engineer, it is sufficient to form a stable foundation on which to construct the subsequent work.
13.10.2
Compaction of Fill Material in Intermediate Areas of Fill Fill material in Intermediate Areas of Fill up to the level stated in Clause 13.10.1 shall be compacted to a degree which in the opinion of the Engineer is practicable. Except as stated in Clause 13.8.5, fill material above the level stated in Clause 13.10.1 shall be compacted to obtain a relative compaction of at least: (a) (b) (c) 90% throughout, 95% within 1.5 m of Earthworks Final Surfaces and Formations, and 98% within 200 mm of Formations.
13.11
13.11.1
TOLERANCES
Tolerances: Earthworks Final Surfaces and Formations Earthworks final surfaces and formations shall be within the final tolerances stated in table 13.3 of the specified lines and levels. The tolerances for formations do not apply for pipes or preformed structures which require to be supported over their complete length or area. In excavation, a positive tolerance refers to insufficient excavation and a negative tolerance refers to excess excavation. In areas of fill, a positive tolerance refers to excess fill material and a negative tolerance refers to insufficient fill material.
Type of surface Formations for structures and utilities Formations for pavements Method of forming surface Excavation except in rock Excavation in rock Deposition and compaction of fill material Excavation except in rock Excavation in rock Deposition and compaction of fill material Earthworks Final Surfaces other than Formations with gradient not exceeding 1v to 10 h Other Earthworks Final Surfaces Excavation except in rock Excavation in rock Deposition and compaction of fill material Excavation except in rock Excavation in rock Deposition and compaction of fill material Table 13.3: Tolerances for earthworks final surfaces and formations Tolerance (mm) + 0 0 0 0 0 0 0 0 0 100 100 100 25 150 25 50 150 50 100 200 100 100 200 100
227
13.12
13.12.1
TESTING: FILL MATERIAL GENERAL REQUIREMENTS

Batch: Fill Materials A batch of Fill Material is any quantity of Fill Material of the same type and which in the opinion of the Engineer has similar properties throughout. For the purpose of testing for moisture content and relative compaction a batch shall, in addition to the above, be fill material which is deposited in a single layer in any area of fill presented by the Contractor for testing on one occasion.
13.12.2
Samples: Fill Materials Each sample of fill material shall consist of at least four increments taken from different parts of the batch. The increments shall be combined and thoroughly mixed and shall then be divided by quartering or by using a riffle box to obtain specimens of an appropriate size to carry out the individual tests. The size of samples of fill material other than rock fill material shall be in accordance with BS 1377: Part 1; 1990. Each sample of rock fill material of Grade size not exceeding 200 shall have a mass of at least 250 kg and each sample of rock fill material of Grade size exceeding 200 shall have a mass of at least 1000 kg.
13.13
TESTING: FILL MATERIAL - PARTICLE SIZE DISTRIBUTION, LIQUID LIMIT, PLASTICITY INDEX, COEFFICIENT OF UNIFORMITY AND SULPHATE CONTENT
Samples: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of Uniformity and Sulphate Content Samples of fill material to be tested for particle size distribution, liquid limit, plasticity index, coefficient of uniformity and sulphate content shall be delivered at least 14 days, or such shorter period agreed by the Engineer, before deposition of the fill material starts. The number of samples to be provided from each batch shall be as stated in table 13.4.
Description Size of batch 0 3,000m3 Special Fill Material Exceeding 3,000m3 Fill Material other than Special Fill Material 0 15,000m3 Exceeding15,000m
3
13.13.1
No. of samples per batch 3 1 for each 1,000m3 or part thereof 3 1 for each 1,000m3 or part thereof
Table 13.4: Number of samples to be tested for particle size distribution, liquid limit, plasticity index, coefficient of uniformity, sulphate content, optimum moisture content and maximum dry density
13.13.2
Testing: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of Uniformity and Sulphate Content Each sample of fill material taken as stated in Clause 13.13.1 shall be tested to determine the particle size distribution. In the case of Special Fill Material testing shall include calculation of the coefficient of uniformity as stated below. Unless otherwise agreed by the Engineer, each sample of fill material other than rock fill material shall be tested to determine the liquid limit and the plasticity index of that portion of the fill material passing a 425m BS test sieve. Each sample of fill material which will be deposited within 500 mm of concrete, cement bound material, cementitious material or metalwork shall be tested to determine the soluble sulphate content. The method of testing shall be in accordance with the following: Particle size distribution: See following paragraph Liquid limit: BS 1377: Part 2 :1990, Clause 4.3 Plasticity index: BS 1377: Part 2 :1990, Clause 5 Soluble sulphate content: BS 1377: Part 3: 1990, Preparation by Clause 5.3 Total sulphate content: BS 1377: part 3: 1990, Preparation by Clause 5.2
The particle size distribution of fill material passing a 75 mm BS test sieve shall be determined in accordance with BS 1377:1990 or as instructed by the Engineer. The size of particles of fill material which do not pass a 75 mm BS test sieve shall be taken as the largest dimension measured in any plane. The coefficient of uniformity (Cu) shall be calculated from the equation: Cu = D60/D10 where:
D60 and D10 are the equivalent sieve sizes in millimetres, interpolated from the particle size distribution curve, through which 60% and 10% of the fill material would pass respectively. 13.13.3 Non-compliance: Particle Size Distribution, Liquid Limit, Plasticity Index, Coefficient of Uniformity and Sulphate Content If the result of any test for soluble sulphate content of Fill Material does not comply with the specified requirements for soluble sulphate content, each sample shall be tested to determine the total sulphate content. If the result of any test for particle size distribution, liquid limit, plasticity index, coefficient of uniformity or total sulphate content of Fill Material does not comply with the specified requirements for the property, additional samples shall be provided from the same batch and additional tests for the property shall be carried out. The number of additional samples shall be as stated in table 13.4.
229
13.14
13.14.1
TESTING: FILL MATERIAL - OPTIMUM MOISTURE CONTENT AND MAXIMUM DRY DENSITY
Samples: Optimum Moisture Content and Maximum Dry Density Samples of fill material to be tested for optimum moisture content and maximum dry density shall be delivered at least 72 hours, or such shorter period agreed by the Engineer, before deposition of the fill material starts. The number of samples to be provided from each batch shall be as stated in table 13.4. The Contractor shall inform the Engineer of the exact location in which the fill material from which each sample is taken is to be deposited. Samples to be tested for optimum moisture content and maximum dry density shall also be taken after the fill material has been deposited in its final position, at intervals of not more than 28 days. Samples shall not be provided from: (a) fill material including rock fill material which contains an insufficient proportion of particles passing a 20 mm BS test sieve to permit determination of the moisture content and maximum dry density, and fill material which is to be deposited as stated in Clause 13.10.1.
(b) 13.14.2
Testing: Optimum Moisture Content and Maximum Dry Density Each sample of fill material taken as stated in Clause 13.14.1 shall be tested to determine the optimum moisture content and the maximum dry density. The method of testing shall be in accordance with the following: Optimum moisture content: BS 1377: Part 4: 1990, Clauses 3.3 and 3.4 Maximum dry density BS 1377: Part 4: 1990, Clause 3.3 and 3.4 adjusted in accordance with Specification Appendix 13.4 where necessary. If agreed by the Engineer, the Hilf method stated in Appendix 13.3 may be used instead of the methods stated above to determine the optimum moisture content and maximum dry density. If in the opinion of the Engineer there is any undue discrepancy between the results of tests for optimum moisture content of fill material using methods stipulated above and the results of tests using the Hilf method, the results of tests using methods stipulated above shall prevail.
13.14.3
Consistency: Optimum Moisture Content and Maximum Dry Density If the result of any test for optimum moisture content or maximum dry density of fill material indicates that the batch contains material which in the opinion of the Engineer differs to such an extent that subsequent tests for compaction may be affected, the batch shall be divided into smaller batches; each of the smaller batches shall comprise
material with similar properties throughout. Additional samples shall be provided from each of the smaller batches and additional tests for optimum moisture content and maximum dry density shall be carried out. The number of additional samples shall be as stated in table 13.4.
13.15
13.15.1
TESTING: FILL MATERIAL - MOISTURE CONTENT:

Samples: Moisture Content Samples of Fill Material to be tested for moisture content shall be taken during deposition and compaction of fill material and shall be delivered not more than 1 hour after the fill material has been deposited in its final position. The number of samples to be provided from each batch shall be as stated in table 13.5. Samples shall not be provided if, in accordance with Clause 13.14.1 the optimum moisture content has not been determined.
13.15.2
Testing: Moisture Content Each sample of fill material taken as stated in Clause 13.15.1 shall be tested to determine the moisture content. The method of testing shall be in accordance with one of the following methods: (a) (b) Method 1: BS 1377: Part 2:1990, Clause 3.2 as instructed by the Engineer. Method 2: Microwave oven drying method as stated in Appendix 13.2.
Method 1 shall be used unless otherwise agreed by the Engineer. 13.15.3 Compliance criteria: Moisture Content If in the opinion of the Engineer there is any undue discrepancy between the moisture content results of tests for moisture content of fill material using Method 1 and the results of tests using Method 2 in Clause 13.15.2, the results of tests using Method 1 shall prevail. 13.15.4 Non-compliance: Moisture Content If the result of any test for moisture content of fill material differs from the optimum moisture content by more than the specified amount and if instructed by the Engineer, the moisture content of the whole of the batch of fill material shall be adjusted. Additional samples shall be provided from the same batch and additional tests for moisture content shall be carried out. The number of additional samples shall be as stated in table 13.5.
231
Description
Size of area of fill in each batch 0 100 m2
No. of samples/No. of tests per batch 3 2 for each 100 m2 or part thereof
Areas of fill in excavations for structures, pits and trenched and on Formations
100 500 m2 Exceeding 500 m 0 1 ha

2
1 for each 100 m2 or part thereof

2 4 for each 1000 m or part thereof
Other areas of fill
1 10 ha Exceeding 10 ha
3 for each 1000 m2 or part thereof 2 for each 1000 m2 or part thereof
Table 13.5: Number of samples to be tested for moisture content and number of tests for relative compaction
13.16
13.16.1
TESTING: FILL MATERIAL - RELATIVE COMPACTION

Testing: Relative Compaction Unless otherwise agreed by the Engineer, each batch of fill material shall be tested to determine the relative compaction. Tests shall be carried out after the fill material has been deposited and compacted in its final position. The number of tests on each batch shall be as stated in table 13.5. Tests shall not be carried out on: (a) fill material including rock fill material which contains an insufficient proportion of particles passing a 20 mm BS test sieve to permit determination of the relative compaction, and fill material which has been deposited as stated in Clause 13.10.1.
(b)
Tests shall be carried out at positions which in the opinion of the Engineer are representative of the batch of compacted fill material as a whole. The relative compaction of fill material shall be determined in accordance with one of the following methods: (a) Method 1: The relative compaction (RC) shall be calculated from the equation: RC = IDD/MDD x 100% where:
IDD is the in-situ dry density. MDD is the maximum dry density. (b) Method 2: The relative compaction (RC) shall be calculated from the equation:
232
RC = IBD/MCBD x 100%
where:
IBD is the in-situ bulk density MCBD is the maximum converted bulk density determined by the Hilf method as stated in Appendix 13.3. Method 1 shall be used unless otherwise permitted by the Engineer. The in-situ bulk density and the in-situ dry density of fill material shall be determined in accordance with one of the following methods: (a) Method 1: BS 1377: Part 9: 1990, Clause 2.1 or 2.2 as appropriate to the grain size of the material. (b) Method 2: Nuclear densimeter method as stated in Appendix 13.5. Method 1 shall be used unless otherwise permitted by the Engineer. The maximum converted bulk density of fill material of which more than 5% is retained on a BS 20 mm test sieve shall be adjusted as stated in Appendix 13.4. 13.16.2 Compliance criteria: Relative Compaction If in the opinion of the Engineer there is any undue discrepancy between the relative compaction results of tests for relative compaction of fill material using Method 1 and the results of tests using Method 2 in Clause 13.16.1, the results of tests using Method 1 shall prevail. 13.16.3 Non-compliance: Relative Compaction If the result of any test for relative compaction of fill material does not comply with the specified requirements for relative compaction, additional tests for relative compaction shall be carried out on the same batch. The number of additional tests shall be as stated in Table 13.5.
13.17
13.17.1
APPENDIX 13.1 - TEST METHODS FOR FILL MATERIAL

General The definitions, terms, abbreviations symbols, and grouping of materials stated in BS 1377:1990 shall apply except as stated in Clauses 13.17.2 and13.17.3.
13.17.2
Terms and symbols Terms used in the Specification and in BS 1377 are identified in the Specification by the symbols stated in table 13.6.
233
Abbreviation / Symbol BD CBD DD IBD IDD MDD MCBD RC W Wi Wo
Term Bulk Density Converted Bulk Density Dry Density In-situ Bulk Density In-situ Dry Density Maximum Dry Density Maximum Converted Bulk Density Relative Compaction Moisture Content in-situ Moisture Content Optimum Moisture Content
Table 13.6: Abbreviations and Symbols
13.17.3
Grouping of material Fine Grained Material is material of which at least 90% passes a 2 mm BS test sieve. Medium Grained Material is material of which at least 90% passes a 20 mm BS test sieve and more than 10% is retained on a 2 mm BS test sieve.
13.18
APPENDIX 13.2 - DETERMINATION OF THE MOISTURE CONTENT OF FINE GRAINED AND MEDIUM GRAINED MATERIAL BY THE MICROWAVE OVEN DRYING METHOD
Scope This method covers the determination of the moisture content of fine grained and medium grained material as a percentage of the mass of the dry material.
13.18.1
13.18.2
Apparatus The following apparatus is required: (a) (b) (c) (d) A microwave oven with a timer and an adjustable power setting. An airtight container of microwave safe and non-reflective material. A balance readable and accurate to 0.01g. A desiccator containing anhydrous silica gel.
13.18.3
Procedure The procedure shall be as follows: (a) The container shall be cleaned, dried and weighed to the nearest 0.01g (m1).
234
(b)
A specimen shall be crumbled and placed loosely in the container and the lid shall be replaced. Each specimen of fine grained material shall be at least 30 g and each specimen of medium grained material shall be at least 300 g. Specimens of medium grained material may be tested in several parts each less than 300 g and the results aggregated. The container and contents shall be weighed to the nearest 0.01g (m2). The lid of the specimen container shall be removed and the container with its lid and contents shall be placed in the microwave oven and dried. The specimen shall be considered to be dry when, after an initial drying period, successive weighings at intervals of 1 minute produce results which are the same to the nearest 0.01g. Alternatively, the oven may be set to an appropriate time and power setting to dry the specimen as determined by calibration of the oven on soil of a similar type. After drying, the container and contents shall be removed from the microwave oven and placed in the desiccator to cool. The lid shall be replaced and the container and contents shall be weighed to the nearest 0.01g (m3).
(c) (d)
(e)
(f)
13.18.4
Calculation The moisture content of the material (w) shall be calculated as a percentage of the dry mass of the material from the equation: w = (m2 - m3)/(m3 - m1) x 100% where:
m1 is the mass of the container (g) m2 is the mass of the container and contents before drying (g) m3 is the mass of the container and contents after drying (g) 13.18.5 Reporting of results The following shall be reported: (a) (b) (c) Source and identification of the soil. The moisture content of the material to the nearest 0.1%. That the test method used was in accordance with this Specification.
235
13.19
13.19.1
APPENDIX 13.3 - DETERMINATION OF THE MAXIMUM CONVERTED BULK DENSITY BY THE HILF METHOD
Scope This method covers the determination of the maximum converted bulk density and the difference between the optimum moisture content and the in-situ moisture content of a material by relating the converted bulk density and the moisture added.
13.19.2
Apparatus The following apparatus is required: (a) Apparatus in accordance with BS1377: Part 4:1990, Clauses 3.3.4.1 and 3.3.4.2, or as instructed by the Engineer. Apparatus for determination of the moisture content in accordance with either Method 1 or 2 as specified in Clause 13.15.2 or as instructed by the Engineer. Apparatus to extract specimens from the mould. Apparatus, such as a warm air blower, for rapid drying of the material.
(b)
(c) (d) 13.19.3 Procedure
The procedure shall be as follows: (a) A sample of material shall be taken immediately after completing the in-situ bulk density test at the same location as the test. The sample shall be obtained by digging to the same depth as that of the in-situ bulk density test, keeping the sides of the excavation vertical and the bottom flat and level. The size of the sample shall be sufficient to yield a minimum of 10 kg after screening over a 20 mm BS test sieve. The sample shall be weighed to the nearest 0.01 g. The sample shall be screened over a 20 mm BS test sieve, ensuring that moisture loss is kept to a minimum and that any free moisture appearing in the containers is worked back into the sample. The amount retained on the sieve shall be weighed to the nearest 0.01 g and expressed as a percentage of the mass of the sample. If the percentage exceeds 5%, an adjustment for coarse material shall be made in accordance with Appendix 13.4. If the percentage does not exceed 5%, no adjustment is required. The material to be tested shall be thoroughly mixed and divided by quartering or by using a riffle box to obtain a minimum of four specimens of at least 2500 g each, ensuring that moisture loss is kept to a minimum. Alternatively, if it has previously been ascertained that the material is not
(b) (c)
(d)
(e)
susceptible to crushing, a single specimen of at least 2500 g may be used for repeat testing. (f) Each specimen shall be weighed to the nearest 0.01 g and the result shall be taken as the mass of the specimen at the in-situ moisture content. Each specimen and any remaining material shall be placed in separate moisture-tight containers and the containers sealed. The converted bulk density of at least three specimens shall be plotted against the amount of water added or removed as a percentage of the mass of the specimen at the in-situ moisture content on a graph in accordance with the procedure stated below. The first point on the graph shall be obtained as follows: A specimen shall be compacted at its in-situ moisture content in accordance with BS1377 Part 4: 1990, Clauses 3.3.4.1 and 3.3.4.2 or as instructed by the Engineer. A diametrical slice of approximately 400 g to 500 g shall be cut from the specimen along its entire length. The in-situ moisture content of the slice (wi ) shall be determined in accordance with either BS1377: Part 2: 1990, Clause 3.2 or to Appendix 13.2, as instructed by the Engineer. The bulk density (BD1) shall be calculated as stated in Clause 13.19.4 and plotted on the 0% ordinate of the graph as the converted bulk density(CBD1).
(g)
(h)
(i)
(j)
The second point on the graph shall be obtained as follows: A second specimen shall be examined and, if the in-situ moisture content obviously exceeds the optimum moisture content, the procedure stated in Clause (k) shall be followed. The moisture content of the specimen shall be increased by adding an amount of water equal to 2% of the mass of the specimen. The specimen shall be thoroughly mixed and compacted in accordance with the method stipulated in BS 1377: Part 4: 1990, Clause 3.3.4.1 or Clause 3.3.4.2.. The bulk density (BD 2) shall be calculated as stated in Clause13.19.4, adjusted to converted bulk density (CBD 2) as stated in Clause 13.19.4 and plotted on the +2% ordinate of the graph.
(k)
If the in-situ moisture content of the second specimen obviously exceeds the optimum moisture content, the specimen shall be dried until the amount of water removed is approximately 2% of the mass of the specimen and cooled. The specimen shall be thoroughly mixed and compacted in accordance with the method stipulated in BS 1377: Part 4: 1990, Clause 3.3.4.1 or Clause 3.3.4.2. The amount of water removed shall be
determined. The bulk density (BD2) shall be calculated as stated in Clause 13.19.4 adjusted to converted bulk density (CBD2) as stated in Clause 13.19.4 and plotted on the negative ordinate of the graph at a point which corresponds to the amount of water removed. (l) The third point on the graph shall be obtained as follows: If the plotted value of CBD2 is equal to or greater than the plotted-value of CBD1, the moisture content of a third specimen shall be increased by adding an amount of water equal to 4% of the mass of the specimen. Alternatively, if the procedure stated in Clause 13.19.4(h) has been followed, the specimen shall be dried until the amount of water removed is approximately 4% of the mass of the specimen after cooling. If the plotted value of CBD 2 is less than the plotted value of CBD 1, the third specimen shall be dried until the amount of water removed is approximately 2% of the mass of the specimen after cooling. Alternatively, if the procedure stated in Clause 13.19.413.19.3(h) has been followed, the moisture content shall be increased by adding an amount of water equal to 2% of the mass of the specimen. The specimen shall be thoroughly mixed and compacted in accordance with the method stipulated in BS1377: Part 4: 1990, Clause 3.3.4.1 or 3.3.4.2. The amount of water removed shall be determined. The bulk density (BD3) shall be calculated as stated in Clause 13.19.4, adjusted to converted bulk density (CBD3) as stated in Clause 13.19.4, and plotted on the graph at a point which corresponds to the amount of water added or removed.
(m)
If the centre point of the three points plotted is lower than one of the other two points, or is higher than one point and equal to the other, an additional point or points shall be obtained by proceeding in 2% increments or decrements as appropriate. If it is apparent that the moisture condition of the material is such that a total of five points will not result in the determination of the optimum moisture content, increments and decrements of 3% moisture content may be adopted for the entire procedure. A smooth approximately parabolic curve shall be drawn to the plotted points. The peak value of the curve shall be determined as the maximum converted bulk density (MCBD). The amount of water added or removed as a percentage of the mass of the specimen at the in-situ moisture content corresponding to the maximum converted bulk density shall be determined (zm). The value of the moisture correction curve passing through the peak value of the plotted parabolic curve shall be determined (zc). If there is no moisture correction curve passing through the peak value of the curve, a
(n)
(o)
(p)
(q)
moisture correction curve shall be drawn through the peak by interpolating to the nearest 0.1%. 13.19.4 Calculation The bulk density (BD) shall be calculated from the equation: BD = (m2-m1)/V Mg/m3 where: m1 is the mass of the mould and base (g) m2 is the mass of the mould, base and wet material (g) V is the volume of the mould (ml) The converted bulk density (CBD) shall be calculated from the equation: CBD = BD/(1+z/100) Mg/m3 where:
z is the amount of water added or removed as a percentage of the mass of the specimen at the in-situ moisture content z is negative for values below the in-situ moisture content The difference between the optimum moisture content (wo) and the in-situ moisture content (wi) of the material shall be calculated from the equation: wo - wi = zm + zc % where:
zm is the amount of water added or removed as a percentage of the mass of the specimen at the in-situ moisture content corresponding to the maximum converted bulk density (%) zc is the value of the moisture correction curve passing through the peak value of the plotted parabolic curve (%) The optimum moisture content (wo) shall be calculated from the equation: wo = wi + (1 + wi/100) zm % where:
wi is the in-situ moisture content of the material (%) The maximum dry density (MDD) shall be calculated from the equation: MDD = MCBD/(1 + wi/100) zm where:
MCBD is the maximum converted bulk density of the material Mg/m3 The relative compaction (RC), if required, shall be calculated from the equation: RC = IBD/MCBD x 100% where:
239
IBD is the in-situ bulk density of the material determined in accordance with BS 1377: Part 9: 1990, Clause 2.1 or Clause 2.2 as appropriate to the grain size of the material or in accordance with specification Appendix 13.5. 13.19.5 Reporting of results The following shall be reported: (a) (b) Source and identification of the soil. The graph showing the plotted points and the parabolic curve passing through them. The maximum converted bulk density to the nearest 0.01 Mg/m3. The optimum moisture content to the nearest 0.1%. The maximum dry density to the nearest 0.01 Mg/m3. The relative compaction to the nearest 0.1%, if determined. The percentage retained on the 20 mm BS test sieve and the percentage retained on the 37.5 mm BS test sieve to the nearest 1%, if applicable. Whether the test was carried out using individual specimens or repeat testing of a single specimen. Whether a manual or an automatic compaction rammer was used. That the test method used was in accordance with this Specification.
(c) (d) (e) (f) (g)
(h)
(i) (j)
13.20
13.20.1
APPENDIX 13.4 - ADJUSTMENT OF THE MAXIMUM CONVERTED BULK DENSITY FOR THE DETERMINATION OF THE RELATIVE COMPACTION
Scope This method covers the adjustment of the maximum dry density determined in accordance with BS 1377: Part 4: 1990, Clause 3.3 and 3.4 and the maximum converted bulk density determined in accordance with Appendix 13.3 for the determination of the relative compaction of a material containing more than 5% of the mass of the material at the in-situ moisture content retained on a 20 mm BS test sieve.
13.20.2
Apparatus The following apparatus is required: (a) Apparatus in accordance with either BS 1377: Part 4: 1990, Clause 3.3 and 3.4 or Appendix 13.3. A 20 mm and a 37.5 mm BS test sieve.
(b)
(c)
A mould with collar as used for determination of the California Bearing Ratio (CBR mould). An extrusion device as used for determination of the California Bearing Ratio.
(d)
13.20.3
Procedure The procedure shall be as follows: (a) If the amount of material retained on the 20 mm BS test sieve exceeds 5% and does not exceed 20%, the material passing the sieve shall be compacted in accordance with BS 1377: Part 4: 1990, Clause 3.3 and 3.4 or specification Appendix 13.3. The maximum converted bulk density (MCBD20) shall be determined and adjusted as stated in Clause 13.20.4. If the amount of material retained on the 20 mm BS test sieve exceeds 20%, the retained material shall be screened over the 37.5 mm BS test sieve. The procedure stated in either Clause 13.20.3(c) or Clause 13.20.3(d) as appropriate shall be followed. If the amount of material retained on the 37.5 mm BS test sieve does not exceed 5%, the procedure stated in Clause 13.20.3(e)shall be followed. If the amount of material retained on the 37.5 mm BS test sieve exceeds 5% and does not exceed 20%, the retained material shall be replaced with an equal mass of material which is of a similar nature and which is retained on a 20 mm BS test sieve but passes a 37.5 mm BS test sieve. The procedure stated in Clause 13.20.3(e)shall be followed. The procedure stated in Appendix 13.3 shall be followed except that the material shall be compacted into the CBR mould and each layer shall be subjected to 62 blows of the rammer.
(b)
(c)
(d)
(e)
13.20.4
Calculation The maximum converted bulk density (MCBD) shall be calculated from the equation: MDD = MDD20[1+m(1-MDD20)(1+Gs(w0-wi)/100] where:
MCBD20 is the maximum converted bulk density of the material passing the 20 mm BS test sieve (Mg/m3) (w0-wi) is the difference between the optimum moisture content and the insitu moisture content (%). m is the mass of the material not passing the 20mm BS sieve expressed as a fraction of the mass of the material at the in-situ moisture content. Gs is the specific gravity of the material not passing the 20mm BS test sieve.
The maximum converted bulk density (MCBD) shall be calculated from the equation: MCBD = MCBD20[1+(1-MCBD20/Gs)(m/(1+z/100))] Where:
MCBD20 is the maximum converted bulk density of the material passing the 20mm BS test sieve (Mg/m3). Z is the amount of water added as a percentage of the mass of the specimen at the in-situ moisture content corresponding to the maximum converted bulk density (%) 13.20.5 Reporting of results The following shall be reported: (a) (b) The source and identification of the soil. The results in accordance with either BS 1377: Part 4: 1990, Clause 3.3 and 3.4 or Appendix 13.3. The mass of the original material not passing the 20 mm and 37.5 mm BS test sieve as a percentage of the mass of the material at the in-situ moisture content to the nearest 0.1%. The type of mould used. The number of blows per layer. Whether the specific gravity was measured or assumed and, if measured, the method used. That the test method used was in accordance with this Specification, and the results have been adjusted in accordance with this Appendix.
(c)
(d) (e) (f)
(g)
13.21
APPENDIX 13.5 - DETERMINATION OF THE INSITU BULK DENSITY OF FINE GRAINED AND MEDIUM GRAINED MATERIAL BY THE NUCLEAR DENSITOMETER METHOD
Scope This method covers the determination of the in-situ bulk density of fine grained and medium grained material by the attenuation of gamma rays and calculation of the in-situ dry density using a moisture content determined in accordance with either BS 1377 : Part 2: 1990, Clause 3.2 or Specification Appendix 13.2.
13.21.1
13.21.2
Apparatus The following apparatus is required:
242
(a)
A nuclear device for the measurement of density (densimeter). The details of construction of the densimeter may vary but the following general requirements shall apply: (i) The probe shall be an adjustable probe containing a gamma source, which can be readily positioned in a pre-formed hole. The probe assembly shall be graduated in increments not exceeding 50mm and shall be constructed in such a manner that it will be securely held in the test depth position. The instrumentation shall display the results directly in metric units.
(ii) (b) (c) (d)
(e) (f)
A reference standard of uniform and constant density to establish the background count and count reproducibility. Site preparation equipment, such as spades, straight-edges, scoops and brushes, required to prepare a suitably cleared and level surface to accommodate the densimeter. A hole forming device, such as an auger or steel pin, to form a hole to accommodate the probe. The device shall have a nominal diameter that exceeds the probe diameter by not more than 3mm and shall be graduated to indicate the depth of the hole. The device shall have a guide, which will ensure that the hole is formed normal to the prepared surface. Sampling equipment, such as augers, spades, picks, small digging tools, scoops, airtight containers and bags, to obtain samples of the material. Apparatus for the determination of the moisture content in accordance with either BS 1377: Part 2: 1990, Clause 3.2 or Specification Appendix 13.2.
13.21.3
Procedure: Comparability of Test Methods The procedure for comparing test methods shall be as follows:(a) Before using the densimeter on material for which it has not previously been used, the results of determinations of in-situ bulk density using the densimeter shall be compared with the results of determinations of in-situ bulk density in accordance with BS 1377:Part 9:1990, Clause 2.2 The location of each determination in accordance with BS 1377:Part 9:1990, Clause 2.2 shall correspond to the midpoint of the densimeter probe and the gamma sensor. A minimum of ten pairs of determinations shall be carried out. If the difference between any pair of results does not exceed 0.08 Mg/m and if the densimeter produces results which are both higher and lower than those produced in accordance with BS 1377:Part 9:1990, Clause 2.2, the densimeter may be used without correction. If either of the criteria stated in Clause 13.21.3(b) is not met, the densimeter shall not be used.
(b)
(c)
13.21.4
Procedure: Routine Densimeter Check The procedure for carrying out a routine densimeter check shall be as follows: (a) The densimeter shall be warmed up in accordance with the manufacturers recommendations.
243
(b)
A standard count shall be carried out in accordance with the manufacturers recommendations. The standard count shall be carried out by placing the reference standard on a hard, level surface consisting of material with a density of at least 1.6 Mg/m. The reference standard shall be placed at a distance of at least 10m from any other nuclear device and at least 3m from any large object. At least three count readings shall be the standard count reading for the day. The standard count reading for the previous 4 days. If the difference is greater than that recommended by the manufacturer or if no recommendation is made and the difference is greater than 1%, the densimeter shall not be used. The densimeter shall be left switched on with the probe in the locked position. If the densimeter is switched off a further standard count shall be carried out in accordance with Clause 13.21.4(b) and (c).
(c)
(d)
13.21.5
Procedure: Determination of in-situ Bulk Density (a) A level surface of sufficient size to accommodate the densimeter shall be prepared and cleared of all disturbed and loose material. The depth of any depression below the densimeter shall not exceed 3mm. Depressions exceeding 3mm in depth shall be filled using fine sand or material taken from the adjacent soil which passes a 600m BS test sieve. A suitable hole for the probe shall be prepared using the hole forming device. The hole shall be normal to the prepared test area and at least 50mm deeper than the intended test depth. If a driven pin is used to form the hole, the pin shall be rotated every two or three blows to facilitate its removal. The test depth shall be the same as the maximum depth required for determination of the in-situ bulk density in accordance with BS 1377: Part 9: Clause 2.1 or 2.2 as appropriate to the grain size of the material. The probe shall be positioned and inserted into the hole in such a manner that the gamma source is shielded at all times. The probe shall be seated firmly against the side of the hole nearest to the back of the densimeter by gently pulling the densimeter backwards until contact is achieved. The operator shall ensure that the densimeter is correctly seated and the depth setting on the control panel is the same as the probe depth. The operator shall ensure that there are no other radioactive sources within 10m of the densimeter. Three readings of the in-situ bulk density shall be taken in accordance with the manufacturers recommendations and the mean determined. If any one reading differs from any other reading by more than 0.015Mg/m, additional readings shall be taken until three consecutive readings which do not differ by more than 0.015Mg/m are obtained and the mean determined. The mean of the three readings shall be taken as the in-situ bulk density (IBD). If the above criterion is not met after six readings, the densimeter shall not be used. The densimeter shall be removed and a minimum 500g sample of the material directly beneath the densimeter position shall be taken for determination of the moisture content. The sample shall be obtained by auguring or digging to the test depth. The sample shall be placed in a moisture tight container and the lid replaced. The
(b)
(c)
(d)
(e) (f)
244
moisture content (w) shall be determined in accordance with either BS 1377: Part 2:1990, Clause 3.2 or Specification Appendix 13.2. (g) If a sample of material at the same location as the densimeter test is required for determination of the maximum dry density or the maximum converted bulk density, the sample shall be obtained by digging to the test depth, keeping the sides of the excavation vertical and the bottom flat and level. The appropriate quantity of material required for the test shall be taken, placed in a moisture light container and the container sealed.
13.21.6
Calculation The in-situ dry density of the material (IDD) shall be calculated from the equation: IDD = IBD/(1 + w) Mg/m, Where: 100 IBD is the in-situ bulk density of the material (Mg/m), and w is the moisture content of the material (%)
13.21.7
Reporting of Results The following shall be reported: (a) (b) (c) (d) The location of the test The in-situ dry density to the nearest 0.01 Mg/m. The moisture content to the nearest 0.1%. That the test method used was in accordance with this Specification.
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14 14.1
PAVEMENT PAVEMENT PARTICULAR REQUIREMENTS

This section of the pavement specification contains particular requirements for the pavement works to be undertaken under the Contract. The particular requirements take precedence over the general pavement specification contained under the pavement specification Clause 14.2 onwards.
14.1.1
Description of Work The Terminal will have the following types of pavement on various locations as indicated in the Drawings: Paving - Type A The Paving Type A is an operationally flexible design that can accommodate the loads from container stacks, tractor/trailers, Reach-Stackers and RTGs all within a single paving construction. The paving will consist of: Concrete block paved surface 80mm thick Bedding sand 30mm thick CBM 4 base (batch-mixed sand-cement) 450mm thick Selected compacted sand sub-base (CBR not less than 30%) 200mm thick Selected compacted fill capping (CBR not less than 10%) minimum 600mm thick On treated soil layers having CBR not less than 3%
Paving - Type B The Paving Type B can accommodate principal traffic comprising tractor/trailers, reach stackers handling empty containers, mobile harbour cranes, containers and vessel hatch covers. The paving will consist of: Concrete block paved surface 80mm thick Bedding sand 30mm thick CBM 4 base (batch-mixed sand-cement) 300mm thick Selected compacted sand sub-base (CBR not less than 30%) 200mm thick Selected compacted fill capping (CBR not less than 10%) minimum 600mm thick On treated soil layers having CBR not less than 3%
Paving - Type C The Paving Type C can accommodate only tractor/trailers. The paving will consist of: Concrete block paved surface 80mm thick Bedding sand 30mm thick CBM 4 base (batch-mixed sand-cement) 250mm thick Selected compacted sand sub-base (CBR not less than 30%) 200mm thick Selected compacted fill capping (CBR not less than 10%) minimum 600mm thick On treated soil layers having CBR not less than 3%
Paving - Type D The Paving Type D concerns a concrete paving, which will be subject to oil and fuel spills. The paving will consist of:
Pavement Quality (Grade 40) Concrete (with mesh reinforcement) 250 mm thick Selected compacted sand sub-base (CBR not less than 30%) 200mm thick Selected compacted fill capping (CBR not less than 10%) minimum 600mm thick On treated soil layers having CBR not less than 3%
Paving - Type E The Paving Type E will be lighter duty, not intended for normal traffic usage. This paving will consist of: 50mm thick precast concrete paving slabs, 500mm x 500mm Bedding sand 30mm thick Selected compacted sand sub-base (CBR not less than 30%) 200mm thick Selected compacted sand fill (CBR not less than 10%), as required. Precast Concrete Kerbs Precast concrete kerbs are to be provided: At the transitions between pavement Types as shown on the drawings; At the borders of the pavement and the perimeter fence, boundary walls or revetment structures;
14.2
14.2.1
ROADS AND PAVING CONSTRUCTION

Pavement Construction The pavements shall be constructed as shown on the drawings. All services including pipes, cable, ducting etc, crossing or running along the pavements must be completed and backfilled prior to commencement of pavement works.
14.2.2
Horizontal Alignments, Surface Levels and Surface Regularity of Pavement Courses Horizontal Alignments The edge of the pavement as constructed and all other parallel alignments shall be correct within a tolerance of 25mm there from, except for kerbs, channel blocks and edge lines which shall be laid with a smooth alignment within a tolerance of 13mm. Surface Levels of Pavement Courses The level of any point on the constructed surface of the pavement courses shall be design level subject to the appropriate tolerances stated in Table14.1.
Surface Pavement Base Layer Pavement adjacent to drains / gullies or other structures Pavement not adjacent to drains / gullies or other structures Sub-base Sub-bases other than above Tolerance 6mm +6mm -0mm +6mm -0mm 15mm +10mm -30mm
Table 14.1: Tolerances in Surface Levels of Pavement Courses
247
Not withstanding the tolerance permitted in surface levels of pavement courses, the cumulative tolerance shall not result in a reduction in thickness of the pavement, excluding the sub-base, by more than 15mm from the specified thickness. The levels of any two adjacent concrete blocks shall not differ by more than 2mm. For checking compliance with this Clause, measurements of the surface levels of all courses will be taken on a 10m grid of points. In any length of pavement, compliance shall be deemed to be met for all surfaces, other than the final pavement surface, when not more than one of ten consecutive measurements taken longitudinally or one in any transverse line, exceeds the tolerances permitted in table 13.1, provided that this one measurement shall not exceed by more than 5mm the tolerance for the course concerned. For the final pavement surface the tolerance given in table 13.1 shall apply to any point on that surface. The Contractor shall perform level surveys of the port area to be paved to demonstrate that the design levels have been achieved and are within tolerance. Surveys shall be undertaken at the following stages and submitted to the Engineer for approval a minimum of 3 working days before the ensuing section of works are to be undertaken: Prior to placing the sub-base Prior to placing the lean mix concrete After placing the lean mix concrete.
If the level survey demonstrates that the levels are not within the specified tolerances, the Contractor shall submit proposals for remedial action for the approval of the Engineer. Such proposals will only be accepted if the specified constituent pavement thicknesses are achieved as a minimum. Surface Regularity The regularity of the surfaces of finished concrete blocks, wearing courses, base courses, and cement bound materials shall be such that the number of surface irregularities is within the relevant limits stated in table 13.2. An irregularity is a variation of not less than 4mm or 7mm of the profile of the pavement surface as measured by the rolling straight-edge, of the type designed by the Transport and Road Research Laboratory in UK set at 4mm or 7mm as appropriate, or equivalent apparatus capable of measuring irregularities within the same magnitudes over a 3m length. No irregularity exceeding 10mm shall be permitted. Prior to checking any final surface for level or regularity it shall be cleaned of loose or extraneous materials. These operations shall be carried out without damaging the surface of the pavement, as soon as possible and within 3 working days of construction of the pavement. Compliance with table 14.2 shall be checked by the rolling straight-edge along any line or lines on sections of 300m selected, whether or not it is constructed in shorter lengths. Sections shorter than 300m forming part of a longer pavement shall be assessed using the number of irregularities for a 300m length pro-rata to the nearest whole number.
248
Surfaces of Pavements Irregularity (mm) Length (m) Number permitted 4 300 20 75 9 300 9 7 75 1
All bituminous base courses & cement bound materials 4 7 300 75 300 75 40 18 4 2
Table 14.2: Maximum Permitted Number of Surface Irregularities
Rectification Where any pavement area does not comply with the Specification for regularity, surface tolerance, thickness, material properties or compaction, the full extent of the area which does not comply with the Specification shall be made good and the surface of the pavement course shall be rectified in the manner described below. Unbound sub-bases
The top 75mm shall be scarified, reshaped with material added or removed as necessary, and re-compacted. The area treated shall be not less than 30m long and 2m wide or such area to be selected as necessary to obtain compliance with the Specification. Cement bound material layers
The method of correction will depend on the period which has elapsed between detection of the error and the time of mixing of the material. If this is less than 4 hours, the surface shall be scarified to a depth of not less than 50mm, surplus material removed or freshly mixed material added as necessary, and re-compacted in accordance with the Specification. If the period is 4 hours or more the full depth of the layer shall be removed from the pavement and replaced with material in accordance with the Specification. In either case the area treated shall be least 5m long and the full width of the paving laid in one operation. Wearing courses and base-courses
These shall have the full depth of the course removed and replaced with fresh material laid and compacted in accordance with the Specification. The area rectified shall be the full width of the paving laid in one operation and at least 5m long if basecourse or 15m long if wearing course. Where the number of surface irregularities exceeds the limits in Table 14.2, the area to be rectified shall be as necessary to make the number of surface irregularities conform to the limits. Areas to be removed shall be delineated both longitudinally and transversely by saw cutting prior to the material being removed. Joints shall be formed by coating the exposed face with hot bitumen. 14.2.3 Use of Surfaces by Traffic and Construction Plant Construction plant and traffic used on pavements under construction shall be suitable in relation to the material, condition and thickness of the courses it traverses so that damage is not caused to the subgrade or the pavement courses already constructed. The wheels or tracks of plant moving over the various pavement courses shall be kept free from deleterious materials.
249
Where the Contractor proposes to use the sub-base for construction plant he shall improve the sub-base where necessary, to accommodate the method of construction and the type of plant and vehicles which he propose to use, in order to avoid damage to the sub-base, any capping and the subgrade. Any permanent thickening shall be across the whole width of the pavement, unless otherwise agreed. Temporary thickening shall not impede drainage of the sub-base or the subgrade. The cement bound material layer shall not be used by traffic until the specified 7-day cube compressive strength is reached. 14.2.4 General Requirements for Sub-bases and Road bases The Contractor shall, in his choice of permitted material for sub-bases and road bases have regard to the nature of those materials and of the subgrade or any capping and the need to protect them from deterioration due to the ingress of water, the adverse effects of weather and the use of constructional plant. The Contractor shall programme the laying and compaction of the sub-base and the subsequent pavement courses and take such other steps as may be considered necessary, to afford protection to the road base, sub-base and subgrade. Transporting Unbound and cement bound plant-mixed material shall when mixed be removed at once from the mixer, transported directly to the point where it is to be laid and protected from the weather both during transit from the mixer to the laying site and whilst awaiting tipping. Laying All material shall be placed and spread evenly; spreading shall be undertaken either concurrently with placing or without delay. Unbound and cement bound road base material shall be spread using a paving machine or a spreader box approved and operated with a mechanism which levels off the material to an even depth. 14.2.5 Excavation, Trimming and Reinstatement of Existing Surfaces The Contractor shall not excavate pits, trenches or other openings in paved areas which have been constructed as part of the permanent Works in order to construct other parts of the Works, including service works, except when such excavations are unavoidable and then only with the prior approval of the Engineer. Excavations Excavations in existing pavements and other paved areas, including surfacing, road base and sub-base, shall be cut to neat lines to dimensions at least 75mm greater on such side than the dimensions of any further excavation below formation level. Excavations in capping shall be taken at last 75mm outside the dimensions of any excavation below. If excavations are required to inspect the condition of lower layers, each layer shall be excavated separately and cleaned of debris to permit inspection.
250
Concrete blocks and precast concrete slabs, kerbs and channels shall be lifted without cutting, to the nearest joint satisfying Clause 14.6.2 and carefully stored for re-use. In situ kerbs and channels shall be broken out to at least 150mm beyond the excavation. Reinstatement of Paved Areas Where joints in concrete slabs are affected by the excavation they shall be reinstated by cutting back to at least 0.5m on each side of a transverse joint.
14.3
14.3.1
ROADS AND PAVING - UNBOUND MATERIALS

Unbound Materials for Sub-bases Unbound sub-bases shall be made and constructed using materials described in the following Clauses. They shall be free from silt, clay, dust and organic impurities and shall be laid over the finished earth formation and compacted. The sub-base material shall have a CBR value of more than 20% when compacted. Materials shall have a water soluble sulphate content not exceeding 1.9g of sulphate (expressed as SO3) per litre when tested in accordance with BS 1377-3. Unbound material up to 225mm compacted thickness shall be spread in one layer so that after compaction the total thickness is as specified. Unbound material of compacted thickness greater than 225mm shall be laid in two or more layers and the minimum compacted thickness of any such layer shall be 110mm. Where the layers of unbound material are of unequal thickness the lowest layer shall be the thickest.
14.3.2
Compaction Compaction shall be completed as soon as possible after the material has spread and in accordance with the requirements for the individual materials. Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse joints. Compaction of unbound materials shall be carried out by a method specified in Table 14.3, unless the Contractor demonstrates at site trials that a state of compaction achieved by an alternative method is equivalent to or better than that using the specified method. The procedure for these trials shall be subject to approval by the Engineer. The surface of any layer of material shall on completion of compaction and immediately before overlaying, be well closed, free from movement under compaction plant and from ridges, cracks, loose material, pot holes, ruts or other defects. All loose, segregated or otherwise defective areas shall be removed to the full thickness of the layer, and new material laid and compacted. For the purposes of table 14.3 the following shall apply: The number of passes is the number of times that each point on the surface of the layer being compacted shall be traversed by the item of compaction plant in the operating mode (or struck, in the case of power rammers).
251
The compaction plant in table 14.3 is categorised in the terms of the static mass. The mass per metre width of roll is the total mass on the roll divided by the total roll width. Where a smooth wheeled roller has more than one axle, the category of the machine shall be determined on the basis of the axle giving the highest value of mass per metre width. For pneumatic-tyred rollers the mass per wheel is the total mass of the roller divided by the number of wheels. In assessing the number of passes of pneumatic-tyred rollers the effective width shall be the sum of the widths of the individual wheel tracks together with the sum of the spacings between the wheel tracks provided that each spacing does not exceed 230mm. Where the spacing exceeds 230mm the effective width shall be the sum of the widths of the individual wheel tracks only. Vibratory rollers are self-propelled or towed smooth-wheeled rollers having means of applying mechanical vibration to one or more rolls: The requirements for vibratory rollers are based on the use of the lowest gear on a self-propelled machine with mechanical transmission and a speed of 1.5-2.5km/h for a towed machine with hydrostatic transmission. If higher gears or speeds are used an increased number of passes shall be provided in proportion to the increase in speed of travel. Where the mechanical vibration is applied to two rolls in tandem, the minimum number of passes shall be half the number given in the table 14.3 for the appropriate mass per metre width of one vibrating roll but if one roll differs in mass per metre width from the other, the number of passes shall be calculated as for the roll with the smaller value. Alternatively the minimum number of passes may be determined by treating the machine as having a single vibrating roll with a mass per metre width equal to that of the roll with the higher value. Vibratory rollers operating without vibration shall be classified as smooth-wheeled rollers. Vibratory rollers shall be operated with their vibratory mechanism operating at the frequency of vibration recommended by the manufacturer. All such rollers shall be equipped, or provided with devices indicating the frequency at which the mechanism is operating is the speed of travel. Both devices shall be capable of being read by an inspector alongside the machine. Vibration plate compactors are machines having a base-plate to which is attached a source of vibration consisting of one or two eccentrically-weighted shafts: The mass per square metre of base-plate of a vibrating-plate compactor is calculated by dividing the total mass of the machine in its working condition by its area in contact with compacted material. Vibrating-plate compactors shall be operated at the frequency of vibration recommended by the manufacturer. They shall normally be operated at travelling speeds of less than 1km/h but if higher speeds are necessary, the number of passes shall be increased in proportion to the increase in speed of travel.
252
Vibro-tampers are machines in which an engine driven reciprocating mechanism acts on a spring system, through which oscillations are set up in a base-plate. Power rammers are machines which are actuated by explosions in an internal combustion cylinder; each explosion being controlled manually by the operator. One pass of a power rammer shall be considered to have been made when the compacting shoe has made one strike on the area in question. Combinations of different types of plant or different categories of the same plant will be permitted; in which case the number of passes for each shall be such proportion of the appropriate number in table 14.3 as will together produce the same total compactive effort as any one operated singly, in accordance with table 14.3.
Number of layers not exceeding the following compacted thicknesses 110mm 150mm 225mm 16 8 Unsuitable 16 Unsuitable Unsuitable
Type of Compaction Plant Smooth wheeled roller (or vibratory roller operating without vibration) Pneumatic tyred roller
Category Mass per metre width of roll over 2700kg up to 5400kg over 5400kg Mass per wheel over 4000kg up to 6000kg over 6000kg up to 8000kg over 8000kg up to 12000kg over 12000kg Mass per metre width of vibrating roll over 700kg up to 1300kg over 1300kg up to 1800kg over 1800kg up to 2300kg over 2300kg up to 2900kg over 2900kg up to 3600kg over 3600kg up to 4300kg over 4300kg up to 5000kg over 5000kg Mass per square metre of base plate over 1400kg/m up to 1800kg/m over 1800kg/m up to 2100kg/m over 2100kg/m Mass over 50kg up to 65kg over 65kg up to 75kg over 75kg Mass over 100kg up to 500kg over 500kg
12 12 10 8
Unsuitable Unsuitable 16 12
Unsuitable Unsuitable Unsuitable Unsuitable
Vibratory roller
16 6 4 3 3 2 2 2
Unsuitable 16 6 5 5 4 4 3
Unsuitable Unsuitable 10 9 8 7 6 5
Vibrating plate compactor
8 5 3 4 3 2 5 5
Unsuitable 8 6 8 6 4 8 8
Unsuitable Unsuitable 10 Unsuitable 10 8 Unsuitable 12
Vibro tamper
Power rammer
Table 14.3: Compaction Requirements for Granular Sub-base Material
253
14.3.3
Granular Sub-base Granular material shall be crushed rock or crushed concrete and may contain up to 12.5% by mass of natural sand which passes the 5mm BS sieve. The material shall lie within the grading envelope of Table 14.4, and not be gap graded. The particle size shall be determined by the washing and sieving method of BS 812-103. The material passing the 425m BS sieve shall be non-plastic as defined by BS 1377-2 and tested in compliance therewith. The material shall be transported, laid and compacted without drying out or segregation. The material shall have a 10% fines value of 50kN or more when tested in compliance with BS 812-111. The test sample shall be in a soaked condition at the time of the test. All aggregate shall be from an approved source. Source approval for aggregate shall be given if either when tested in accordance with BS 812-121 it has a soundness value greater than 65 or evidence can be provided to the Engineer of satisfactory use elsewhere. The water absorption of the coarse aggregate from the source determined in accordance with BS 812-2 shall also be declared.
BS Sieve Size 75mm 37.5mm 20mm 10mm 5mm 600m 75m
Percentage by Mass Passing 100 85-100 60-100 40-70 25-45 8-22 0-10
Table 14.4: Sub-base Range of Grading
14.4
14.4.1
ROADS AND PAVING - CEMENT BOUND MATERIALS (LEAN MIX CONCRETE)

Constituent Materials The lean mix concrete layer shall conform to the requirements for Cement Bound Material as defined in the following Clauses. Cement The general term, cement, in this Section means any of the materials listed in Section 8. Water Water from any source may be used if it conforms to BS 3148 or is approved. The water content shall be the minimum required to provide the agreed workability for full compaction of the cement bound material to the required density, as determined by trial mixes or other means approved. The requirements for standard mixes shall be in accordance with specification Section 8. Aggregate
Aggregates for all cement bound materials shall be natural material complying with BS 882 or concrete which when crushed complies with the quality and grading requirements of BS 882. Once the appropriate gradings have been determined and approved they shall not be varied without the permission of the Engineer. Aggregate shall have a soundness value greater than 75 when tested in accordance with BS 812-121. The water absorption of the coarse aggregate from the source determined in accordance with BS 812-2 shall also be declared. The nominal size of coarse aggregate shall not exceed 40mm. The chloride ion content of the aggregate to be used in concrete with embedded metal, determined in accordance with BS 812-117 shall satisfy the requirements of BS 882. Sand (i.e. fine aggregate) containing more than 25% by mass of acid-soluble material as determined in accordance with BS 812-119, in either the fraction retained on, or the fraction passing the 600m BS sieve, shall not be used in the top 50mm of the layer. This requirement will not apply if it can be shown that the sand (i.e. fine aggregate) retained on, or the fraction passing, the 600m BS sieve contains less than 25% by weight of calcium carbonate. Tests shall be carried out on three samples taken at random from the source prior to use. Tests shall also be carried out during stockpiling or paving, once a week or at a lesser rate as directed. The grading of the aggregate shall be within the limits in table 14.5.
Percentage by Mass Passing Nominal Maximum Size 40mm 20mm 100 95-100 100 45-80 95-100 25-50 35-55 8-30 10-35 0-8* 0-8* 0-5 0-5
BS Sieve Size 50mm 37.5mm 20mm 5mm 600m 150m 75m
Table 14.5: Allowable Range of Aggregate Grading Notes: The particle size distribution shall be determined by the washing and sieving method of BS 812-103. * 0-10 for crushed rock fines
Chloride Content The limits of chloride content of the concrete shall be as stated in BS 5328-1. 14.4.2 General Requirements for Cement Bound Materials Cement bound materials shall be made and constructed as described in the following Clauses.
Cement bound materials shall comply with table 13.6 and be tested in accordance with Clause 14.4.4. Delivery, Storage, Batching and Mixing Cement shall be kept dry and used in the order in which it is delivered to the site. Different types of cements shall be stored separately. Aggregate shall be delivered to and stored on the Site in one of the following ways: In separate nominal single sizes of coarse aggregate and sand (i.e. fine aggregate); As graded coarse aggregate of appropriate size and sand (i.e. fine aggregate).
If the Contractor proposes to blend aggregate off the site from two separate sources, he shall obtain the Engineers prior approval for the blending process, and for the arrangements for inspection during the course of the work. Aggregate brought on to the Site shall be kept free from contact with deleterious matter. Sand nominally below 5mm sieve size shall have been deposited at the site for at least 8 hours before use. Batching plant and storage for aggregate shall comply with the following requirements as appropriate to the method of delivery: If separate gradings of aggregate are stockpiled, separate accommodation shall be provided for each nominal size of coarse aggregate or blend of sand (i.e. fine aggregate). The bases for stockpiles shall be suitably surfaced to prevent contamination of the aggregate. Drainage of the stockpile bases shall be provided. Aggregate shall be measured by mass and provision shall be made for batching each nominal size or blend of aggregate separately, to the tolerances specified in BS 5328-3. All-in aggregate shall be delivered and stockpiled in such a manner, and to a height, that avoids segregation. Batching and mixing shall be carried out in the appropriate manner described in table 13.6. The materials shall be batched and mixed in compliance with BS 5328-3.
Transporting Plant-mixed cement bound material shall when mixed be removed at once from the mixer, transported directly to the point where it is to be laid and protected from the weather both during transit from the mixer to the laying site and whilst awaiting tipping. Laying All cement bound material shall be placed and spread evenly in such a manner as to prevent segregation and drying. Spreading shall be undertaken either concurrently with placing or without delay. Cement bound material shall be spread using a paving machine or a spreader box approved and operated with a mechanism which levels off the cement bound material to an even depth.
Cement bound material shall be spread in one layer so that after compaction the total thickness is as specified. Cement bound material shall be laid in individual widths. Individual widths of construction shall be not less than 2m and not exceed 4.75m. Positions of joints shall be agreed with the Engineer before construction is commenced. At construction joints, unless vertical forms are used, the edge of compacted cement bound material shall be cut back to a vertical face where the correct thickness of properly compacted cement bound material has been obtained. Compacting Compaction shall be carried out immediately after the cement bound material has been spread and in such a manner as to prevent segregation. Special care shall be taken to obtain full compaction in the vicinity of both longitudinal and transverse construction joints. Compaction shall be carried out in compliance with table 14.6 and be completed within 2 hours of the addition of the cement. The 2 hour period may be varied at the discretion of the Engineer, if the preliminary trial described below indicates that this is necessary or appropriate. After compaction has been completed, compacting equipment shall not bear on cement bound material for the duration of the curing period. The surface of any layer of cement bound material shall on completion of compaction and immediately before overlaying, be well closed, free from movement under compaction plant and from ridges, cracks (except those induced in accordance with Clause 14.4.3), loose, segregated or otherwise defective areas shall be removed to the full thickness of the layer, and new cement bound material laid and compacted. Curing Immediately on completion of compaction, the surface of cement bound material shall be cured for a minimum period of 7 days by one of the following methods: Covering with an impermeable sheeting with joints overlapping at least 300mm and set to prohibit egress of moisture. The sheeting shall be removed at the end of the curing period. Bituminous spraying with materials in accordance with the relevant British Standard shall be carried out in compliance with the requirements for preparation and application as set out in Document Road Note 39 published by the UK Transport and Road Research Laboratory. Spraying shall only be applied when there is no visible water. To offset the effects of high temperatures and solar radiation, the bituminous spray shall be blinded with light coloured hard clean crushed rock, fine aggregate or sand at a rate of application of 5.5 to 7.0kg/m. Spraying with an approved resin based aluminised curing compound complying with the requirements of BS 7542. The curing compound shall not react chemically with the material to be cured and shall not crack, peel or disintegrate within three weeks of application.
Spraying with an approved plastic film which, when hardened, shall be removed before applying any other pavement layer.
Whichever method is used, immediately prior to overlaying with any bituminous layer, a cationic bituminous tack coat shall be applied at a rate between 0.35 and 0.55 litres/m in accordance with Clause 14.5.3. Preliminary Trial At least 10 days before the start of the main cement bound material works, a trial area of at least 1000m shall be laid to assess the suitability of the proposed materials, mix proportions, mixing, laying, compaction plant and construction procedures. The area shall include at least one longitudinal and one transverse construction joint. The location and area of the trial shall be subject to the approval of the Engineer. The rate of testing for the trial area shall not be less than that required by Clause 14.4.4. The trial area will only be accepted for inclusion in the Permanent Works if it complies with the Specification. The construction in the Permanent Works shall not start until the trial has been approved. After approval has been given, the materials, mix proportions, mixing laying, compaction plant and construction procedures shall not be changed without the approval of the Engineer who may require the Contractor to lay a further trial area to demonstrate the suitability of proposed changes.
Item Mixing Method of Batching Moisture Content Minimum Compaction Compaction of Cube Curing of Cube Compressive Strength Testing of Cube 7 Day Cube Compressive Strength Table 14.6: Cement Bound Material Notes: a) The average in situ wet density of each group of five determinations carried out in accordance with Clause 14.4.4 shall not be less than 95% of the average wet density of the corresponding group of five cubes made in accordance with Clause 14.4.4. b) The average strength of each group of five cubes made in accordance with Clause 14.4.4 shall not be less than 18N/mm. The strength of any individual cube made in accordance with Clause 14.4.4 shall not be less than 12N/mm. Requirement Mix-in-plant By mass To suit requirements for strength, surface level, regularity and finish 95% of cube density (see Note a) Refer to Clause 14.4.4 BS 1881-111 BS 1881-116 See Note b
14.4.3
Induced Cracking of Cement Bound Material The cement bound material layer shall be cracked with approved plant and equipment to comply with the following Clauses prior to overlaying with asphalt or concrete blocks.
Induced Cracking Induced cracking of the cement bound material layer shall be carried out in accordance with the special requirements of Clause 14.4.3. Cracks at the pre-set spacing described in Clause 14.4.3 shall be induced by suitable plant and materials. Cracks may be induced either in the fresh cement bound material layer, prior to compaction, or after 7 days. The induced cracks shall be predominantly vertical and continuous. When cracks are to be induced in fresh cement bound material layer, they shall be induced by grooving the surface of the fresh cement bound material layer to a depth which leaves a groove not less than half the thickness of the layer after compaction. A crack retention material, as specified in 14.4.3, shall be inserted into the groove prior to compaction. Upon compaction the grooves shall have "closed up" and during the curing period hairline cracks shall propagate vertically to the base of the cement bound material layer. When cracks are to be induced in the cured cement bound material layer, they shall be induced by suitable plant capable of delivering variable pre-set impact loads to the surface of the cement bound material layer. Cracks shall be induced by one strike of the impacting head of such plant without producing (undue) surface shatter. The plant and impact head shall be of sufficient mass and geared to prevent head bounce and any associated surface damage arising therefrom. The impact load shall be adjustable to achieve the cracking specified and the minimum load consistent with no surface shatter. Parallel passes of the crack inducing plant shall be made so that all subsequent cracks are aligned with those from the preceding pass within the tolerances specified in 14.4.3. The Contractor shall be responsible for varying his equipment and methods so that the crack pattern is maintained and areas of cement bound material are in the opinion of the Engineer, rendered suitable for overlaying. The plant used to induce cracks in a fresh cement bound material layer, prior to compaction, shall be such as to minimise rutting of the pavement layer. When cracking is to be induced after curing of the cement bound material, the plant shall be self-propelled with wheels having rubber (pneumatic) tyres. Trial Areas The Contractor shall demonstrate that the plant, equipment and methods that are proposed for inducing cracks in the cement bound material layers are capable of producing the required type and pattern of cracks by first executing a trial over a minimum area of 1000m. The location of the trial shall be approved. The Contractor shall demonstrate that the tolerances of the cracking operation can be achieved consistently. Subject to the approval of the Engineer, these trial areas can be the same as that used for the preliminary trials required under 14.4.2. Completed cement bound material trial areas shall be cured for a minimum period of 7 days in accordance with Clause 14.4.2. Assessment Compliance with the crack inducing requirements shall be assessed as follows:
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The surface pattern of cracking shall be checked by applying clean water to saturate the surface of the cracked cement bound material allowing it to dry naturally and visually inspecting the resultant induced crack pattern. The depth of cracking shall be determined by coring through the full depth of the cement bound material layer symmetrically (at about) the crack position. The coring shall take place once the cracks are visible at the surface and, as a minimum, 7 days after compaction. 10 cores shall be taken within the trial area at locations selected. These locations will generally be where cracks are not visible at the surface. The trial area shall be deemed acceptable if at least 8 of the 10 cores are cracked in accord with the requirements specified in 14.4.3. To monitor the cracking in the works, cores shall be taken at a rate not less than one for every 300m. The cores will be located by the Engineer as described in paragraph b) above. The cracking shall be acceptable if at least 4 cores in any adjacent set of 5 cores are cracked in accordance with the requirements specified in Clause 14.4.3. Holes from which core samples have been extracted shall be backfilled with cement bound material and shall be well compacted in layers not exceeding 50mm thick.
Approval and Acceptance Approval to use the plant, equipment and methods will be given by the Engineer following a successful demonstration in the trial area that the induced cracking complies with the Specification requirements. The Contractor shall not proceed with the works until the plant, equipment and methods used in the trial area have been approved. When approval has been given, the plant, equipment and methods shall not thereafter be changed without the prior approval of the Engineer. Should it be necessary for the Contractor to change any plant, equipment and/or method the Contractor shall carry out a further trial area. Induced Cracking of Cement Bound Material Layers Location: A trial area in accordance with Clause 14.4.3 shall be carried out for each separate design mix of the cement bound material. Cracking:
Spacing of cracks Category of crack Finished depth of crack Alignment Longitudinal Transverse of tolerance 50mm 50mm 3.0m grid Hairline Full depth of layer. The cracks shall be vertical through the full depth of the layer.
Crack Retention Treatment in Fresh Cement Bound Material:

Emulsion K1-40 bituminous spray to BS 594-2 and BS 4987-2
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Sealing of Induced Cracks when Induced Seven Days or Longer After Compaction:
Hairline (just visible) and Narrow (less than 0.5mm) Medium (greater than 0.5mm, less than 1.5mm) Wide (greater than 1.5mm) General surface application of K1-40 bituminous spray to BS 594-2 and BS 4987-2 minimum 0.5l/m "Over-banding" with 50 or 70 pen bitumen Chase out and seal with 15D x 10W sealant to BS 2499 (1993)
14.4.4
Testing of Cement Bound Materials Frequency of Sampling for Cube Specimens Samples shall be provided in accordance with BS 1924-1 Clause 5 from the laid cement bound material before compaction. One group of five samples shall be provided from five locations equally spaced along a diagonal that bisects each 800m or part thereof laid each day. The number of groups may be increased if required. Making of Cubes One 150mm cube shall be made from each sample taken. The cubes shall be made in accordance with BS 1924-2 Clause 4.2.5 without further mixing of the material and within 2 hours of the addition of the cement. Cubes shall be cured and tested in accordance with Table 14.6. To determine the wet density of cubes the mould shall be weighed prior to making the cube and the mass recorded. Immediately after completion of compaction, the cube and mould shall be weighed and the mass recorded. These masses together with the nominal volume of the mould shall be used to derive the wet density of the cube. In situ Wet Density The in situ wet density of a layer of cement bound material shall be taken as the average of the wet densities at five locations equally spaced along a diagonal that bisects each 800m or part thereof laid each day. The wet density at each location shall be the average of two readings obtained in accordance with Clause 14.4.4 using a nuclear density gauge complying with BS 1377-9. The two readings shall be taken at 180 to each other using the same source rod hole. The source rod shall be lowered to within 25mm of the bottom surface of the layer. Readings shall be taken within two hours of completing final compaction. Use of Nuclear Density Gauges with Cement Bound Materials The operation, warming-up period, if any, and standardisation of the gauge shall be carried out in compliance with the manufacturers recommendations. The gauge shall be calibrated in accordance with BS 1377-9. The gauge shall be used in the direct transmission mode of operation. Nuclear gauges or other sources of ionising radiation shall only be used where permitted or required. The Contractor shall advise the Engineer of his designated "radiation protection advisor" and provide the Engineer with a copy of the Contractors "local rules" covering the use of nuclear gauges or other sources of ionising radiation; these expressions having the meanings given in the United Kingdom Ionising Radiation Regulations 1985.
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Prior to the preliminary trial and whenever the constituents of the mix are altered the cement bound material shall be checked by the procedure given in BS 1924-2 Clause 3.The determination of bulk density by direct transmission shall be in accordance with BS 1924-2 Clause 3.7.8.
14.5
14.5.1
ROADS AND PAVING - BITUMINOUS BOUND MATERIALS

Constituent Materials Bituminous pavement courses shall be made using the materials as described in the Specification and on the Drawings. Aggregates for Bituminous Materials Aggregates shall be clean, hard and durable. Coarse aggregates for bituminous materials shall have the following properties: 10% fines value not less than 140kN for natural crushed and uncrushed aggregates and not less than 85kN for blastfurnace slag when tested in a dry condition in accordance with BS 812-111; Aggregate impact value not greater than 30% for natural crushed and uncrushed aggregates and not greater than 35% for blastfurnace slag when tested in a dry condition in accordance with BS 812-112.
The aggregate source shall be tested in accordance with BS 812-121 and shall have a soundness value greater than 75. Thereafter, for routine testing of such aggregates, the water absorption value of the coarse aggregate shall be determined as in BS 812-2. If the water absorption value of the coarse aggregate is greater than 2%, or 4% for blastfurnace slag, the soundness test shall be carried out on the material delivered to site. The fraction of material passing 75m, for coarse and fine aggregates for bituminous materials, shall not exceed the limits stated in BS 594-1 when tested in accordance with the washing and sieving method of BS 812-103. 14.5.2 General Requirements for Bituminous Bound Materials Bituminous material shall be kept clean and uncontaminated. Except by prior agreement with the Engineer the only traffic permitted to run on bituminous material to be overlaid shall be that engaged in laying and compacting the next course. Should any bituminous material become contaminated the Contractor shall make it good by cleaning it and, if this proves impracticable, by rectification in compliance with Clause 14.2. Basecourse material shall not remain uncovered by wearing course for more than three consecutive days after being laid. With prior agreement with the Engineer this period may be extended by the minimum amount of time necessary to allow for adverse weather conditions or for other reasons. Transporting
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Hot bituminous materials shall be transported in clean insulated vehicles, unless otherwise agreed, and shall be covered while in transit or awaiting tipping. To facilitate discharge of the mixed materials, dust, coated dust, water or the minimum of liquid soap, vegetable oil, or other non-solvent solutions may be used on the interior of the vehicles. When a fluid coating is used then, prior to loading, the body shall be tipped to its fullest extent with the tailboard open to ensure drainage of any excess. The floor of the vehicle shall be free from adherent bituminous materials or other contaminants. Laying On each day, and at each location where hot bituminous material is laid, at least 300t from a plant approved shall be placed before material from another approved plant is used. If the Contractor demonstrates that the materials from different plants are of equivalent quality and possess equivalent laying and compaction characteristics, this requirement can be waived. Wherever practicable, bituminous materials shall be spread, levelled and tamped by an approved self-propelled paving machine, which may be equipped with an averaging beam. As soon as possible after arrival at site the materials shall be supplied continuously to the paver and laid without delay. The rate of delivery of material to the paver shall be regulated to enable the paver to operate continuously and it shall be so operated whenever practicable. The travel rate of the paver, and its method of operation, shall be adjusted to ensure an even and uniform flow of bituminous material across the screed, so that the material is free from dragging, tearing and segregation of the material. Hot bituminous materials shall be laid in accordance with the requirements and recommendations for laying in BS 594-2. The minimum thickness of material laid in each paver pass shall be in accordance with BS 594-2 or the full course thickness where this is less than the specified minimum in BS 594-2. Hand placing of bituminous materials shall only be permitted in the following circumstances: For laying regulating courses of irregular shape and varying thickness; In confined spaces where it is impracticable for a paver to operate; Adjacent to structures.
Hand-raking of wearing course material or the addition of such material by handspreading to the paved area, for adjustment of level, shall only be permitted at the edges of the layers of material and at gullies and manholes. Hand laid work shall conform with the requirements of this Clause except those relating to pavers. Compaction
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Bituminous materials shall be laid and compacted in layers which enable the specified thickness, surface level, regularity requirements and compaction to be achieved. Compaction of bituminous materials shall commence as soon as the un-compacted material will bear the effects of the rollers without undue displacement or surface cracking. Compaction shall be substantially completed before the temperature falls below the minimum rolling temperatures stated in BS 594-2. Rolling shall continue until all roller marks have been removed from the surface. Except where otherwise specified compaction shall be carried out using 8-10t deadweight smooth wheeled rollers having a width of roll not less than 450mm, or by multi-wheeled pneumatic-tyred rollers of equivalent mass, or by vibratory rollers or a combination of these rollers. Wearing course and basecourse material shall be surface finished with a smooth-wheeled roller which may be a deadweight roller or a vibratory roller in non-vibrating mode. Vibratory rollers may be used if they are capable of achieving at least the standard of compaction of an 8-tonnes deadweight roller. They shall be equipped or provided with devices, indicating the frequency at which the mechanism is operating and the travel speed, which can be read from the ground. The performance of vibratory rollers proposed for use shall be assessed as follows: by means of site trials in accordance with BS 598-109; or by the Contractor producing evidence of independent trials demonstrating that, under comparable conditions, a state of compaction at least equivalent to that obtained using an 8-tonnes deadweight roller is achieved by the make and model of vibratory roller proposed for use.
Bituminous materials shall be rolled in a longitudinal direction, with the driven rolls nearest the paver. The roller shall first compact material adjacent to joints and then work from the lower to the upper side of the layer, overlapping on successive passes by at least half the width of the rear roll or, in the case of a pneumatic-tyred roller, at least the nominal width of one tyre. Rollers shall not be permitted to park or stand on warm compacted materials. Joints Except where specified otherwise in this Specification, where longitudinal joints are made in wearing courses, the material shall be fully compacted and the joint made flush in one of the following ways; only method (b) shall be used for transverse joints: By using two or more pavers operating in echelon, where this is practicable, and in sufficient proximity for adjacent widths to be fully compacted by continuous rolling. By cutting back the exposed joint, for a distance equal to the specified layer thickness, to a vertical face, discarding all loosened material and coating the vertical face completely with a suitable hot bitumen, or a cold-applied polymer modified intermediate or premium grade bitumen emulsion, or polymer modified adhesive bitumen strip with a minimum thickness of 2mm, before the adjacent width is laid.
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All joints shall be offset at least 300mm from parallel joints in the layer beneath. Where practical, joints in the wearing course shall coincide with lane markings. 14.5.3 Prime Coats and Tack Coats Prime coat and tack coat shall be sprayed onto the existing surface prior to overlay. Prime coats and tack coats for hot rolled asphalt shall be in accordance with BS 594-2. Application shall be by spray tanker. For small areas application may be by hand held sprayer with the agreement of the Engineer. The preparation of a surface for a bituminous spray and the application of a spray shall be carried out in accordance with BS 594-2. The binder shall be cut-back bitumen complying with BS 3690-1 or bitumen emulsion complying with BS 434-1. The accuracy of transverse distribution of the binder sprayer and the tolerance on the rate of spread of binder shall be Class 1. For small areas where application is by hand held sprayer, the rate of spread shall be measured by calculating the volume applied per square metre. Before binder spraying is commenced, the surface shall be free of all loose material and standing water. Where cut-back bitumen is to be used the surface shall be dry. All loose material on the sprayed surface shall be removed before any further layer of the pavement is laid. 14.5.4 Rolled Asphalt Basecourse Rolled asphalt basecourse shall comply with BS 594-1 Table 2 Column 2/5 for basecourse mixtures and this Specification. When the coarse aggregate is gravel, 2% by mass of total aggregate of Portland cement or hydrated lime shall be added. The percentage of fine aggregate shall be reduced accordingly. Cement or hydrated lime is not required when limestone gravel is used as the coarse aggregate. Binder shall comply with BS 3690-1 and have a penetration of 50. 14.5.5 Regulating Course Regulating courses, which may consist of one or more layers of a bituminous material, shall have their finished surfaces laid to achieve the appropriate tolerances for horizontal alignments, surface levels and surface regularity, for pavement layers, in accordance with Clause 14.2. Rolled asphalt shall be used for regulating courses and shall meet the requirements specified for rolled asphalt material herein. Where the total depth of a regulating course exceeds 150mm then the course shall be laid so that each regulating layer has a compacted thickness of between 75mm and 150mm.
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14.5.6
Rolled Asphalt Wearing Course Rolled asphalt wearing course shall comply with BS 594-1 Table 3 Column 3/3 for wearing course mixtures and this Specification. The binder shall comply with the requirements of BS 3690-1 or 3 and shall have a penetration of 50. When determined in accordance with BS 812-114, coarse aggregate shall have a polished stone value not less than 45.
14.5.7
Testing of Bituminous Mixtures and Their Component Materials The sampling, testing and analysis of bituminous mixtures shall comply with BS 598 except where modified by this Specification. The bulk density of blastfurnace slag shall be determined by the compacted density test described in BS 812-2 carried out on oven-dried aggregates passing the 14mm and retained on the 10mm BS sieves.
14.6
14.6.1
KERBS AND PAVED AREAS

Precast Concrete Kerbs, Channels, Edgings and Quadrants Precast concrete kerbs, channel edgings and quadrants shall be hydraulically pressed complying with BS 7263-1. They shall be laid and bedded in accordance with BS 7263-2 on a mortar bed. All precast units shall be backed with Grade C10/20 concrete. For curves of radius 12m or less, kerbs of appropriate radius shall be used. The surface level of units of kerb, channel, edging and quadrant shall not deviate from the design level by more than 6mm, nor shall the longitudinal surface regularity deviate more than 3mm in 3m when checked with a 3m straight edge. The edge of the pavement as constructed and all other parallel alignments shall be correct within a tolerance of 25mm therefrom, except for kerbs, channel blocks and edge lines which shall be laid with a smooth alignment within a tolerance of 13mm.
14.6.2
Concrete Block Paving Manufacture Precast concrete paving blocks shall be 80mm thick and chamfered, and comply with BS 6717: 2001. The compressive strength of paving blocks at 14 days shall be not less than 55N/mm2 when tested to BS 6717:1993. The mean tensile splitting strength at 14 days shall be 4N/mm2 when tested to BS 6717:2001. The abrasion index shall be class A2 or better in accordance with BS 6717. Blocks shall be manufactured in a single layer. Limestone aggregate shall not be used. No admixtures will be accepted without prior approval of the Engineer.
Blocks shall be natural coloured. The Contractor shall make all reasonable attempts to provide blocks to a uniform colour. Some limited colour variation will, however, be acceptable provided the blocks when laid do not produce a patchy colour in appearance. Representative samples of blocks, and of any anticipated variation in colour shall be provided, in advance, for the Engineers approval.
Laying Precast paving blocks shall be laid in accordance with BS 7533-3. Blocks shall be laid in a herringbone pattern on bedding sand which shall be laid directly on the cement bound material. Edge restraints shall be installed prior to laying of the blocks. The Contractor shall ensure that any of his traffic, which the Engineer permits to use partly finished paving areas, shall not be allowed to approach unrestrained edges. If such traffic causes disturbance or loosening of the block interlock pattern, the Contractor will be required to remove and relay, at his own expense, all areas that the Engineer considers to be unsatisfactory. The layout of blocks and details at edges, chamber covers, gullies and other openings shall be subject to the approval of the Engineer prior to laying. Block pieces less than one-third the size of a full block will not be accepted in the final layout.
14.7
14.7.1
Road Markings and Road Signs

Work Scope and Function The Contractor shall provide clear, durable road markings to the Container Terminal to control the movement of vehicles and equipment throughout the Terminal, and to mark out container blocks, empty stacks and ground slot locations and numbers.
14.7.2
Definition Dimensions and Layout The layout and extent of the required road and container yard markings is shown on the Drawings. Dimensional details shall be the same as those used on the existing Terminal or as otherwise directed by the Engineer.
14.7.3
Design Criteria and Materials Marking materials shall be road marking paints with glass beads to BS EN 1871:2000, BS EN 1436:1998, BS EN 1423:1998 and BS EN 1424:1998 and shall be suitable for road surface temperatures of up to 50C as follows: Water-based acrylic road marking paint as Ennis Solids Waterborne Lead Free Fast Dry Traffic Paint by MEON Ltd, or equal approved, for block paving and concrete surfaces. The properties of water-based acrylic line marking paint shall be as follows:
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Description Pigment Non-volatile vehicle (% by mass) Lead, chromium, cadmium, barium Volatile organic compounds Density Viscosity Drying time no pick up
Required Test Method ASTM D3723 FTMS 141
Limit Values 45% to 55% 40% minimum 0% 250g/litre maximum
ASTM D1475 ASTM D562 ASTM D711
1.44kg/litre minimum 75 90 Krebs units 10 minutes
Table 14.6: Test Methods of Road Marking Paint
Chromaticity: The daytime visibility of the road-marking paint shall be defined by the luminance factor . The luminance factor of the paint-marking system shall be greater than or equal to 0.30 for dry road markings (i.e. Class B2) as determined in annex A of BS EN 1436:1998. The colour shall be defined by x,y chromaticity coordinates of the CIE standard system in accordance with BS EN 1436:1998, and shall lie within the regions defined by the corner points given in Table 6 and illustrated in Figure 1 of BS EN 1436:1998. Measurements shall be made in accordance with annex C. The Contractor shall submit for approval full technical details of the proposed marking material. 14.7.4 14.7.4.1 Workmanship General The Contractor shall ensure consistent high quality workmanship is achieved. After an appropriate paint has been selected and successful trials have taken place, a detailed method statement shall be submitted to the Engineer. Markings shall be applied strictly in accordance with the manufacturers instructions and this Specification. Line marking shall be completed to suit the Sectional Completion areas shown on the drawings. In order to achieve these handovers it will be necessary to liaise with the Employers operational staff in order to complete the marking in existing areas of pavement or in areas handed over in previous Sections. The Contractor shall agree mutually convenient times for the line marking of such areas to ensure port operations are not disrupted. 14.7.4.2 Surface Preparation Carriageway markings shall only be applied to surfaces which are clean and dry and clear of loose sand, oil spillages, dirt, grease, laitance, curing compounds and the like that may reduce the bond between the paint and the pavement.
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The pavement surface to be painted shall be cleaned by mechanical brushing, by wet or dry abrasive blasting, or by any other methods necessary to ensure adhesion of the paint to the surface. Adequate maturity of the surface to which paint is to be applied shall be assured. If the pavement has become polished, a tack coat compatible with the marking material may be required. Tack coat shall be applied in accordance with the manufacturer's instructions, before marking. An acid etching solution may be needed to counter leaching alkali and carbonate salts and to improve adhesion to smooth, glassy aggregate particles/surfaces. Such surface preparation shall be subject to trials to assess possible adverse reaction to the paint system(s) selected. 14.7.4.3 Application Paint shall only be applied when the surface is completely dry, and has been prepared in accordance with this Specification. Paint shall be applied strictly in accordance with the manufacturer's instructions. Markings shall be free from raggedness at their edges, and be uniform and free from streaks, splattering or overspray. Carriageway lane and edge lines shall be laid by an approved mechanical means, to a neat, accurate alignment. The painting of alpha-numerics shall be accomplished with the use of full size stencils. On completion of the work the stencils shall be cleaned, repaired and handed over to the Engineer at a port workshop for storage. The Contractor shall control traffic to protect fresh markings from damage. The traffic control shall cause minimum interference to traffic and not affect port operations. Signs, barricades, flagmen and control devices shall be supplied by the Contractor, and a system of spaced warning flags or blocks shall be used to protect the fresh markings until dry. Markings defaced by traffic shall be repaired by the Contractor at his expense. 14.7.4.4 Trials/Testing Trials using the selected line marking systems shall be conducted in the presence of the Engineer and shall determine the required surface preparation; the optimum application conditions; the thicknesses of the resulting applications; the suitability of the proposed equipment and operators
The Contractor shall undertake paper spray tests every two hours during line marking to demonstrate the specified coverage rates are being met.
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14.7.4.5
Removal of Existing Markings Where required existing markings shall be removed using either wet or dry abrasive blasting. Precautions shall be taken to avoid damage to adjacent areas where the markings are to remain. Any such damage shall be rectified by the Contractor.
14.7.4.6
Tolerances The minimum laid thickness of the markings shall be in accordance with BS 6044. Edges of line markings shall not vary from the straight line more than 10mm in 15metres, and the tolerance on the specified width of laid line shall be +10% and 5%.
14.8
TRAFFIC SIGNS
Traffic signs shall comply with BS 873. Traffic signs shall be carefully handled to prevent damage and shall be transported and stored in accordance with the sign face manufacturers instructions. All plastics sheeting shall be fixed in accordance with the sheeting manufacturers instructions. Letters, numerals, symbols and borders shall be clear cut, sharp edged and without crack. Materials for permanent traffic signs and their construction, assembly, location and erection shall comply with this Specification. Each complete traffic sign or part thereof shall be capable of passing the tests in BS 873-1. Before the commencement of fabrication of any traffic sign, the Contractor shall submit fabrication drawings to the Engineer for approval. The backs of traffic signs shall have a location identifying mark.
14.8.1
Foundations for Permanent Traffic Signs and Signals The type and size of foundations for permanent traffic signs and signals shall be as shown on the drawings and, unless otherwise stated therein, shall comply with this Clause. All excavations for foundations shall be cleared of all loose material before placing of concrete and backfilling. Unless otherwise described, traffic signs and signals supported by a single post placed in the ground shall have the post installed centrally in 300mm diameter or square hole filled with grade C10/20 concrete to within 150mm of the ground surface. Unless otherwise described, posts shall be supported for a minimum of three days after placing the concrete and backfilling shall not take place until at least 48 hours after placing.
For traffic signals and illuminated signs provision shall be made for cable entry through the foundation by means of ducting. Where pockets are formed in concrete foundations their plan dimensions shall be sufficiently larger than those of the post to allow for positioning and bedding of the post and backfilling of the pocket. Reinstatement of existing surfaces above foundations shall be to an acceptable standard and to the approval of the Engineer. 14.8.2 Posts for Permanent Traffic Signs Posts for permanent traffic signs shall comply with BS 873-7, the surface protection requirements of BS 873-6 and with the following: Steel posts shall be tubular or rectangular hollow section complying with BS EN 10210, joists, universal beams or columns complying with BS 4, and shall be manufactured from steel complying with grade S275JO or S275J2; Aluminium posts shall be of tubular or rectangular hollow section; Concrete for reinforced or prestressed concrete posts shall comply with Section 10.
Posts shall not protrude above the top of the sign. Signs erected on a single post shall be positioned so that the post is in the centre of the sign. 14.8.3 Sign Plates for Permanent Traffic Signs All permanent sign plates shall comply with BS 873-6, and with this Clause. Plate signs not exceeding 1.2m in height and 2.4m width shall be made of a single sheet. Where more than one sheet is used to make up a sign, the number of sheets shall be kept to a reasonable minimum and the separate sheets shall be rectangular and of comparable size and shape. Extruded plank signs up to 4.8m wide shall have no vertical joints. Above this size, joints in extruded planks should preferably be positioned at a vertical support; if not, then the vertical joints in adjacent planks should not be less than 1.0m apart and only one joint per extruded plank is permitted. Fabricated plank signs up to 4.8m wide shall have no vertical joints, but each plank may be constructed from a maximum of two pieces of sub-strata material, producing one split line. Split lines should be lined up vertically or horizontally. Above 4.8m wide, joints in the stiffening extrusions of adjacent planks should preferably be positioned at a vertical support; if not, then the vertical joints in the stiffening extrusions of adjacent planks should not be less than 1.0m apart and only one such joint per fabricated plank shall then be permitted.
271
Where top and bottom light spill screens are required, these shall extend of the whole width of the sign and be fabricated out of the same material as the sign plate. Top and bottom light spill screens shall be considered as part of the sign plate and any stiffeners and mounting fittings shall be designed to accommodate the combined size. 14.8.4 Faces for Permanent Traffic Signs Faces for permanent traffic signs shall comply with BS 873-6 and with this Clause. All plastics sheeting shall be fixed in accordance with the sheeting manufacturers instructions. Only vertical and horizontal joints shall be permitted and all joints in plastics sheeting shall be overlapped by not less than 6mm. The overlap in the horizontal joints shall be from the top. Butt joints in plastics sheeting shall not be used, except between individual planks or in electrocutable overlay film, or as recommended by the sheeting manufacturer. All materials comprising the sign face, including the background, border and legends shall be carefully matched for colour at the time of sign fabrication to provide uniform appearance both by day and night. The sheeting manufacturers recommendations on colour matching methods shall be observed. Letters, numerals, symbols and borders shall be clear cut, sharp edged and without cracks. Any cut-out letters, numerals, symbols and borders shall be of material compatible with the sheeting to which they are applied. They shall be applied in accordance with the sheeting manufacturers instructions. Screen processed letters, numerals, symbols and borders shall be screen printed with materials in accordance with the sheeting manufacturers instructions. Any inks, pastes and finishing coats used shall be compatible with the sheeting material or the face panel of internally illuminated signs. Sheeting materials including letters, numerals, symbols and borders shall be fully adhered and there shall be no air bubbles, creases, cracks or other blemishes. Where the sheeting manufacturer requires the assemble materials to be provided with a coat of clear lacquer, it shall be uniform and continuous. All lacquer shall be applied at the time of fabrication of the sign face and shall be of a type specified or supplied by the sheeting manufacturer. 14.8.5 Construction and Assembly of Permanent Traffic Signs Construction and assembly of traffic signs shall comply with BS 873-6 and with this Clause. All sign plates and planks, frames, purlins, posts and other components shall be deburred prior to assembly.
272
Where framing and stiffening are not an integral part of the sign plate their joints shall be welded or joined with suitable brackets utilising nuts, bolts and washers. Where purlins are adopted they shall be attached to each vertical member of the sign frame and the sign stiffening and framing shall be continuous in the vertical direction. Purlins shall be spaced equally apart. Connections shall be made at every point where a purlin crosses a post. Where purlins are not adopted the sign stiffening and framing shall be continuous in the horizontal direction. Rivets and other devices used for fixing sheet sign plates to their stiffeners or framework, or in the construction of housings, shall be of a material compatible with the materials being joined. Spacing of rivets or other fixing devices shall be uniform and shall not exceed 150mm around the outside edge of any sheet or section of sheet, and shall not exceed 300mm on cross braces. Hollow rivets shall not be used. Where sign plates need to be stiffened this shall be achieved in a manner such that the sign face material is not punctured or otherwise damaged to accommodate the stiffening. An additional washer of neoprene, nylon or other suitable material shall be used between the sign face and any metal nuts, bolts, washers and screws to protect it from corrosive or other damaging effects. Where supports to traffic signs are required to have flange plates these shall be secured by holding down bolts or anchorages in accordance with the sign manufacturers instructions. The bolts shall be lightly greased before final installation and they and their anchorages shall be installed so as to achieve the loadings, torque settings and other requirements of the sign manufacturer. Sheet and plank signs shall be connected to posts by an appropriate method. Banding systems shall be of stainless steel grade 1.4372 in accordance with BS EN 10088 (or AISI grade 201) or similar approved. Plank signs shall be assembled in accordance with the manufacturers instructions. Where ferrous components are permitted any drilling of them shall be completed before the application of any finish. Any hole drilled in plates with plastics sheeting to accommodate a rivet or bolt shall immediately prior to the insertion of the rivet or bolt have a clear lacquer, recommended by the plastics sheeting manufacturer, applied to its edge to prevent the ingress of moisture. The surfaces of rivets or bolts exposed on the sign face shall be covered by a suitable material of a colour to match that part of the face. Prior to fitting any sign to any lighting column, the Contractor shall ensure that he has the Engineers approval. No holes shall be drilled in the lighting column except those whose location and size are included in the approval. Traffic signs to be erected on road lighting columns shall have fixings compatible with the column cross-section and finish.
273
14.8.6
Location and Erection of Permanent Traffic Signs All traffic signs shall have their exact location determined and recorded on the As Made set of drawings. All posts shall be erected plumb and where two or more posts are provided for any one sign, the faces of the posts shall be lined up. Signs erected on two posts shall have each post positioned so that the distance from the centre of the post to the edge of the sign plate is 300mm unless otherwise agreed with the Engineer. Any pockets formed in concrete foundations to receive the posts shall be cleaned out immediately prior to erection. The posts shall be placed centrally in the pockets and be bedded on mortar as specified and the pockets shall be filled up to finished foundation level with grade 20 concrete. Traffic signs mounted on posts, except those on gantries, shall be erected to have their face plumb and be orientated in relation to the carriageway. No traffic sign shall be dismantled, re-sited or removed without the prior approval of the Engineer.
14.8.7
Covering of Permanent Traffic Signs Where it is required that permanent traffic signs be blanked-out or have an alternative message, the method to be adopted shall comply with the following for: Plate signs: A cover plate compatible with the plate signs material, or a covering or a suitable, opaque, non damaging material, or, for covering periods of up to one year, a self adhesive plastic film to support the temporary sign face sheeting; Other traffic signs: A covering or a suitable, opaque, non damaging material.
Cover plates shall be suitably fixed to give a 10mm minimum air gap between the sign face and cover plate. The fixing method shall not cause damage or staining to the sign face. Any holes remaining in the finished sign face after removal of the plate shall be filled with a suitable material, of a colour to match that part of the face. Where self adhesive plastic film is used it shall be compatible with the sign face materials and be applied and removed in compliance with the manufacturers instructions. Any loose covering used must be sufficiently opaque to prevent reflection from and legibility of the covered sign and be securely fastened to the back of the sign. Under no circumstances shall tape or other adhesive material be applied to the face of the sign. Sufficient space shall be left between the covering and the face to permit air flow over the sign. Traffic signs which are to be covered shall not be erected without the covering in place.
274
Removal of any covering shall be carried out with the minimum disturbance to traffic. Irrespective of any other requirement to cover signs, any traffic sign erected at such a time that its legend does not relate either wholly or in part to the traffic movement and route in operation, shall have its sign face securely covered with one of the materials in paragraph 1 of this Clause until such time as its legend is applicable.
275
15
15.1 15.1.1
SURFACE WATER DRAINAGE

Project Specific Requirements for Surface Water Drainage System Contractor Design The Contractor is not required to design any elements of the permanent works for the Surface Water drainage system(s):
15.1.2
Basis of Hydraulic Design The hydraulic design of the system is based on pipes having a roughness value (ks) of: - 0.6mm for surface water gravity drains;
15.1.3
Requirement for Sulphate Resistance of Concrete Pipes Concrete used in the manufacture of pipes complying with Table 15.1 shall be sulphate resisting to Class CEM-1+SR of BS 8500-1, BS EN 206-1.
15.1.4
Nominal Stiffness (SN) of GRP Pipes GRP pipes shall have a nominal stiffness (SN) as detailed in Table 1 of BS EN 14364
15.1.5
Permitted Pipe and Pipe Bedding Class Combinations The Contractor may choose from any of the permitted alternative pipe and bedding combinations given in the general section of this Clause 15. Pipes and bedding materials shall comply with the requirements of the relevant parts of Sub-Clause 15.5.
15.1.6
Filter Drain Material Type F Filter drain material Type F (Table 15.10) is not required.
15.1.7
Thermoplastic Pipe Characteristics Thermoplastic pipes shall have a: - Pipe Stiffness Class equivalent to SN 4 in BS EN 1401 - Creep ratio: less than 2 when determined in accordance with EN ISO 9967. - Impact Resistance: conforming to Table 9 of BS EN1401 Part 1:1998.
15.1.8
Rigid Pipe Joints Rigid pipe joints shall not be used unless detailed on the Contract Drawings.
15.1.9
Use of Saddles With reference to Clause 15.7.8, saddles shall not be used.
15.1.10
Requirements for Connecting Existing Drains to New Drains There are no connections to existing Surface water systems in the Scope of Work for this project.
15.1.11
Requirements for Sealing, Removal or Grouting of Existing Drains There are no requirements for sealing, removal or grouting of existing drains in the Scope of Work for this project.
15.1.12
Chamber Types (refers to Clauses 15.7.7) Chamber Types shall be as shown on the Contract Drawings. For interceptors the design has been based on a rainfall of 65 mm/hr.
15.1.13
Construction of Chambers (refers to Clauses 15.7.7 ) Precast and cast in-situ chambers shall be constructed in accordance with the requirements of Clauses 15.7.7 and as detailed on the Contract Drawings.
15.1.14
Chamber Covers, Gratings and Frames Chamber covers gratings and frames shall: be ductile iron; be Class F900; comply with BS EN 124; have a 675mm square clear opening and be 150mm deep.
15.1.15
Gully Gratings and Frames (refers to Clause 15.7.8) Gully gratings and frames shall: be ductile iron; be Class F900; comply with BS EN 124; have a 450mm square clear opening and be 150mm deep. Minimum waterway area of gratings shall be 1000 cm2
15.1.16
In-Situ Concrete Gullies In-situ concrete gullies are not permitted.
15.1.17
Requirement for Trapped/Untrapped Gullies With reference to clause 15.7.8, all gullies shall be trapped as shown on the Contract Drawings.
15.1.18
Requirements for Cleaning New Drainage Systems All new pipelines and chamber inverts shall be cleaned prior to handover of the works by rodding, low pressure high volume jetting flushing and pigging as agreed with and to the satisfaction of the Engineer, in accordance with Clauses 15.7.2, 15.7.3 and 15.7.4.
15.1.19
Limiting distance for deposition of materials referred to in Clauses 15.6.2, 15.6.5 and29.6.2 and 29.6.4. Pipe bed, pipe haunch, pipe surround and trench backfill materials having water-soluble sulphate (WS) content; or oxidisable sulphides (OS) content; or total potential sulphate (TPS) greater than the values specified in Clauses 15.7.2 and 15.7.5, as appropriate, shall not be deposited within 500mm of any of the stipulated materials in those Clauses.
277
15.1.20
Testing of Gravity Pipelines (refers to Clauses 15.8.1) All pipelines up to and including DN 1200 shall be subjected to an air test in accordance with Clause 15.8.2. Providing a pipeline passes the air test no further test need be carried out. If a pipeline fails the air test, it shall be subjected to a water test in accordance with Clause 15.8.3, only if a pipeline fails the water test will it be unacceptable. Pipelines greater than DN1200, shall be subject to a visual inspection before being accepted.
GENERAL REQUIREMENTS FOR SURFACE WATER DRAINAGE SYSTEM Scope of Work and General Items
The Contractor shall design the drains listed in Sub Clause 15.1 in accordance with the requirements of Clause 15.3. All Surface Water Drainage Systems constructed of pipes as well as box and piped culverts shall comply with this Section and any additional requirements in Clause 15 1. Unless otherwise described in Clause 15.1 or detailed on the Contract Drawings only one type of pipe shall be used within any individual drain or service duct between consecutive chambers.
15.2
Definition of Terms
Where the term drain is used in this Section it shall be deemed to include the term piped culvert. The term pipe shall be deemed to include box culverts. The term structured wall pipe shall mean all types of smooth bore pipe except solid wall homogeneous pipe. Typical forms of construction classified as structured wall pipes include: single wall externally structured smooth bore, twin wall, foamed core and spirally wound. The term fitting shall mean a product used in conjunction with the pipe to form the system but excluding gullies manhole chambers, inspection chambers and access chambers. The term filter drain refers to a porous or perforated pipe laid in a trench surrounded by granular material where the granular material and the pipe are enclosed by a layer of geotextile filter.
15.3
Design of Permanent Works by the Contractor

The Contractor is not required to design any elements of the permanent works for the Surface Water Drainage system.
278
15.4
15.4.1
Specification of Materials
Pipes for Drainage Pipes for drainage shall be selected from the alternatives in Table 15.1 and shall comply with the standards and particular requirements therein. The Contractor shall show that the pipes he selects have hydraulic flow capacity equal to that of the surface water drainage system detailed on the Contract Drawings. Pipes and fittings other than those included in Table 15.1 shall be permitted provided that they hold a current British Board of Agrment Certificate (BBA), or equivalent, stating that they are a suitable alternative for the usage specified in Table 15.1. On completion of the whole of the drainage works, the Contractor shall provide the Engineer with a schedule showing details of all pipe types used, including quality, joints and name of manufacturer. The format and content of the schedule shall be agreed with the Engineer prior to submission.
15.4.2
Corrugated Steel Pipes Corrugated steel pipes shall be manufactured from either: (i) bolted segmental plate pipes complying with sub-Clause 15.5.3 of this Clause and having plate thicknesses as described in Clause 15.1 or as detailed on the Contract Drawings;
OR (ii) galvanized steel sheet suitable for lock seam fabrication complying with BS EN 10327 grade DX51D + Z600, or aluminium coated steel sheet complying with AASHTO specification M274-87(2004).
Corrugated steel pipes complying with (ii) above shall be manufactured from steel of minimum thickness 1.25 mm unless otherwise described in Clause 15.1. Where described in Clause 15.1 corrugated steel pipes shall be provided with additional protection, in the form of hot applied bitumen complying with AASHTO specification M190-95(2000), or an equivalent coating system. 15.4.3 Bolted Segmental Plate Pipes Bolted segmental plate pipes shall meet the following requirements: (i) Steel for the plates shall comply with 2219HBS 1449-1.1, Grade 3 or Grade 4, Condition HR. After forming, the depth of the corrugations shall be within a tolerance of 6% and the pitch of the corrugations within a tolerance of 4% of the nominal dimensions. Plates shall have a minimum lip of 45 mm beyond each end crest. Cut edges shall be free from notches, gouges, rust or burrs. Bolts and nuts for connecting plates shall comply with BS EN ISO 4014, BS EN ISO 4017 and BS EN ISO 4032, for 2350HBS EN ISO 898-1 and
(ii)
(iii)
2348HBS EN 20898-2, 2371HISO 898-2 property class 8.8, nominal size M20; or with 2224HBS 4395-2, nominal size M20; or with 2350HBS EN ISO 898-1 and 2348HBS EN 20898-2, 2371HISO 898-2 property class 10.9. (iv) When all the plates have been assembled, the nuts shall be tightened against a domed washer. The tightening shall be repeated if necessary to achieve the torque recommended by the manufacturer. Steel plate shall be galvanized in compliance with Sub-clause 15.5.4. Plates shall be galvanized after forming the corrugations and completing all necessary cutting, punching and drilling. Units in which the zinc coating has been burned by welding or otherwise damaged in fabrication, transport or handling at Site shall be made good in compliance with Sub-clauses 15.5.5 and 15.5.6. Bolts and nuts shall be galvanized in compliance with Subclause 9.9.4 of this Specification entitled Galvanizing and Sherardizing.
(v)
15.4.4
Hot Dip Galvanised Coatings Hot dip galvanized coatings shall comply with BS EN ISO 1461 and with the following: (i) Inhibited hydrochloric acid with a strength not exceeding 18% and within a temperature range of 15C to 25C or inhibited sulphuric acid with a strength not exceeding 18% and within a temperature range of 60C to 80C shall be used for pickling. Components shall not be immersed in the pickling acid longer than is necessary for cleaning the surfaces prior to hot dip galvanizing. Components shall receive a fresh water rinse between pickling and the galvanising bath. The surfaces of components to be hot dip galvanized shall be dried before immersion in the molten zinc. When an aqueous flux is to be used, all traces of acid shall be washed off immediately after pickling. Hot dip galvanized coatings shall be relatively smooth, continuous and free from flux staining.
(ii)
(iii)
(iv)
(v)
15.4.5
Procedures for Treatment at Areas of Mechanical Damage or Other Surface Defects Score marks, other surface defects and indentations in the surface of a steel substrate or of a metal coating shall be treated by abrading or grinding to bright steel or bright metal coating, to produce a surface without sharp edges or abrupt change in contour. Damage to unprepared surfaces shall be treated before blast cleaning. Other surface defects in the steel substrate, including fissures resulting from the removal of hackles or inclusions caused by the rolling process, visible after blast cleaning, which would be detrimental to the protective system, shall be similarly treated. Sharp edges shall be rounded
280
In the workshop, damage to hot dip galvanizing in small isolated areas of up to 40 mm, and not exceeding 0.5% of the total surface area of the component, whichever is the lesser, may after surface preparation, be repaired with low melting point zinc alloy. This is providing that the total area of any damage on a component does not exceed 0.5% of the total surface area of the component. Components with damaged areas greater than the above limits shall be re-galvanized. On site, surfaces of hot dip galvanized components found to have minor damage shall be prepared and coated with zinc-rich primer of 75 microns minimum dry film thickness, complying with BS 4652. Alternatively, the components shall be regalvanized. 15.4.6 Procedures for Treatment of Local Failure in Protective Coatings
In the workshop and on site, Hot dip galvanized components showing signs of failure, e.g. blisters and rust, of the coating shall be re-galvanized.
Table 15.1: Pipes for Drainage
Material Vitrified clay
Usage Surface water drains Filter drains
Standard BS 65 OR BS EN 295 BS 65 OR BS EN 295
Particular Requirements Normal or surface water pipes as defined in BS 65 Imperforated, not exceeding 2.0m in length with spigot and socket open joints OR Perforated with flexible mechanical joints Minimum strength class 120. (Note: Use of other strength classes will require reassessment of pipe bedding design and maximum trench widths.) Notwithstanding clause 4.2.5.2 of BS EN 1916 the maximum chloride content of the concrete shall be 0.2%.
Concrete (with Portland cement or sulphate resisting cement as detailed in Sub-Clause 15.1. (Supersulfated cement shall not be used.)
Gravity surface water drains.
BS EN 1916 and 2232HBS 5911-1
Glass reinforced plastics (GRP)
Surface water drains
2239HBS 5911-5 BS EN 14364
Class to be as specified in SubClause 15.1 or as detailed on the Contract Drawings.
Iron
BS EN 598 (Ductile iron)
281
Material Unplasticised polyvinyl chloride (PVC-u) OR Polypropylene (PP) OR Polyethylene (PE)
Usage Gravity surface water drains having a nominal diameter (DN) up to and including 315mm.
Standard BS EN 1401 (PVC-U)
Particular Requirements The grade appropriate for use without structural calculations shall be used i.e. SN8 for PP & PE and SN4 (SDR 41) for PVC-U. The colour of PVC-u and PP pipes for use as drains shall be brown. The colour of PE pipes for use as drains shall be brown or back with a brown stripe. Perforated with not less than 1000 mm of holes per metre length of pipe. The perforations shall not reduce the pipe stiffness by more than 5%. Circular perforations not greater than 10 mm nor less than 3 mm in diameter or rectangular slots not greater than 4 mm nor less than 0.6 mm in width. The colour of PVC-u and PP pipes for use as drains shall be brown. The colour of PE pipes for use as drains shall be brown or back with a brown stripe. Imperforated with watertight joints and with a pipe stiffness class, creep ratio and impact resistance as described in SubClause 15.1 or as detailed on the Contract Drawings. Perforated with not less than 1000 mm of holes per metre length of pipe. The perforations shall not reduce the pipe ring stiffness by more than 5%. Circular perforations not greater than 10 mm nor less than 3 mm in diameter or rectangular slots not greater than 4 mm nor less than 0.6 mm in width
2311HBS EN 1852-1 (PP) 2329HBS EN 12666-1 (PE)
Unplasticised polyvinyl chloride (PVC-u) OR Polypropylene (PP) OR Polyethylene (PE)
Filter drains
BS EN 1401 (PVC-U)
2311HBS EN 1852-1 (PP) 2329HBS EN 12666-1 (PE)
Thermoplastics structured wall pipe and fittings not exceeding 900 mm diameter
Sub-Clause 15.4.7
Filter drains
Sub-Clause 15.4.7
Subsoil field drains.
BS 4962 OR Sub-Clause 15.4.7
282
Material Corrugated steel
Usage Surface water drains, filter drains not exceeding 900mm internal diameter
Standard AASHTO specification M36M-01 except as otherwise required in subClauses 501.4, 5 and 6
Particular Requirements
15.4.7
Thermoplastics Structured Wall Pipes and Fittings General Thermoplastics structured wall pipe shall comply with this Sub-Clause and any special requirements described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Materials The materials from which the pipe and fittings are made, shall be treated so that they are protected from the deleterious effects of short term exposure to ultraviolet light, and shall be resistant to degradation by acids, alkalis, common chemicals, bacteria, fungi and moulds occurring in soil, highway construction materials and highway drainage systems. In addition, the materials from which the pipe and fittings are made shall not incorporate any additives in quantities sufficient to cause microbiological degradation or to impair the conformity to the chemical, physical and mechanical properties or impact resistance requirements given in this Clause. The specification of the raw material shall be agreed between the certification body, as defined in this Clause, and the manufacturer and may incorporate re-processable and/or recyclable material. The agreed specification shall incorporate tolerances for each of the relevant characteristics defined in the appropriate Clause of pr EN 13476. The Contractor shall submit to the Employers Representative, prior to commencement of the Works, completed information sheets in accordance with Sub-Clause 15.1 or as detailed on the Contract Drawings. Dimensions Systems for carrier drainage shall be between 150 mm and 900 mm nominal internal diameter. Pipes for filter drains shall be 110 mm or 150 mm nominal internal diameter. Pipes for sub-soil drainage shall incorporate slots or holes with a minimum cross sectional area of 1000mm per metre run of pipe. The bore of the pipe and fittings shall be in accordance with the standard tolerances for nominal bores given in BS EN 476. Appearance The system shall have a smooth bore and be free from any burs, flash or other inconsistencies that could have a detrimental effect on the performance of the system. Pipes and fittings for drainage shall be externally coloured terracotta. Properties of Structured Wall Pipe Structured wall pipe shall have the properties defined in Table 15.2.
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Table 15.2: Requirements for Structured Wall Pipe
Property General
Relevant Standard 2353HBS EN ISO 2897-1, 2356HBS EN ISO 2897-2 and 2368HBS ISO 11922-1 BS EN ISO 9969
Requirement Dimensions to be as detailed on the Contract Drawings 6 kN/m minimum. Lower stiffness values are permitted if design calculations to 2295HBS EN 1295-1 (UK national annex), based on site specific installation conditions, indicate satisfactory performance.) PVC-U - maximum 2.5 PP and PE - maximum 4.0 Minimum acceptable failure pressure 137 bar. Pipes with nominal diameters 350 mm to have a difference in dimensions when measured in the vertical axis of less than 5% of the pipe length and no local permanent deformation occurs during the test. Preliminary test test 10 pieces as described in BS EN 1411:1996, (BS 278211 : Method 1108B : 1996, dropping the striker from a height of 1m. If any test pieces fail, subject the pipe to the full test given in Clause 7.3 of BS EN 1411:1996, (BS 2782-11 : Method 1108B : 1996 starting the striker from a drop height of 400 mm. The mean minus 1.64 times the standard deviation must exceed 1m.
Ring stiffness
Creep Ratio
BS EN ISO 9967
High volume low pressure jetting Longitudinal bending
WRc Jetting Test Method
sub-Clause 15.4.7.1
Impact resistance at 0C
BS EN 1411:1996, (BS 2782-11 : Method 1108B : 1996 with d25 striker of 1 kg
284
Property Impact resistance at 23C
Relevant Standard BS EN 1411:1996, (BS 2782-11 : Method 1108B : 1996 with d25 striker of 1 kg
Requirement Value to be derived from the same batch of pipe as used in the impact resistance test at 0C. The H50 (mean) value - 10% to be used as the minimum value for quality control testing. Alternatively the 0C test can be used as a QC test if the manufacturer chooses. Pipes with nominal diameters 350 mm to have an average failure energy >3 joules pr EN 13476
Rodding resistance
sub-Clause 15.4.7.2
Tensile strength of a seam
BS EN 1979
Fittings The fittings for use with structured wall pipe shall have the properties defined in Table 15.3.
Table 15.3: Requirements for Fittings
Property General
Relevant Standard 2353HBS EN ISO 2897-1, 2356HBS EN ISO 2897-2 and 2368HBS ISO 11922-1 BS EN ISO 13967 sub-Clause 15.4.7.2
Requirement Dimensions to be as detailed on the Contract Drawings 6 kN/m minimum Fittings with nominal diameters 350 mm to have an average failure energy >3 joules BS EN 12256 Fall height 1000 mm at a temperature of 0C. Product less than ND300 shall show no damage. Others may fail but must be identified as handle with care
Ring stiffness (excluding couplers) Rodding resistance
Strength and flexibility of fabricated fittings Impact resistance (drop test)
BS EN 12256 Drop Test to BS EN 12061
285
Property Watertightness of fabricated fittings
Relevant Standard BS EN 1053
Requirement 0.5 bar for 1 minute
Pipe and Fittings The pipe and fittings shall have the properties defined in Table 15.4.
Table 15.4 Requirements of the Systems
Property Leak tightness of joints diameter distortion (watertight joints) Leak tightness of joints angular deflection (watertight joints) Resistance to wheel loads
Relevant Standard BS EN 1277 Method 4 Condition B Temperature (23 2)C BS EN 1277 Method 4 Condition C Temperature (23 2)C BS EN 1437 adapted to suit HA loading conditions
Requirement Use default values from BS EN 1277 Use default values from BS EN 1277 Less than 5% deformation when loaded to 100 kN (for unequal branches only)
Test Method for Longitudinal Bending (i) The test specimen shall be a six metre length of pipe or the maximum length available from the manufacturer (if less than six metres). The apparatus shall include: (a) two level support blocks at least 250mm wide and of sufficient height to allow the pipe to sag over its length without touching the ground; (b) a means of measuring the vertical distance between the pipe at the centre of the span and a fixed point of reference to an accuracy of 0.5mm. The test procedure shall be as follows: (a) condition the specimen for at least 1 hour at 23C 2C; (b) set the supports at a distance apart equal to the length of pipe minus 500mm; (c) place the pipe symmetrically on the supports; (d) measure the distance between the top of the supports and the fixed point of reference, in the vertical axis through the centre line of the pipe; (e) after a period of two minutes measure the distance between the underside of the pipe at mid span and the fixed point of reference; (f) record the difference in readings as a percentage of pipe length.
(ii)
(iii)
286
Test Method for Rodding Resistance (internal Puncture) (i) The test specimens shall be: (a) twenty specimens cut from the structured wall pipe, each specimen to be 242mm to 246mm in length and a quarter section of the circumference or; (b) twenty specimens cut from a number of identical fittings. The apparatus shall include: (a) a standard drop weight pipe testing apparatus capable of dropping a tup from a height of 1 m; (b) a 300g tup which can be varied in 30g multiples with a striker consisting of a steel rod 18 mm in diameter with a 9 mm hemispherical end; (c) a 250mm x 250mm box containing dry sand such that there is at least 100mm of sand beneath the test specimen when bedded down. Procedure shall be as follows: (a) mark the intended point on the inside of the pipe on the intersection of the centre lines. With profiled pipes the point of impact shall be at the point nearest the intersection that mid way between the ribs or in the middle of a hollow corrugation; (b) alternatively mark the intended point of impact on the section of fitting; (c) condition the test specimens in air at a temperature of 4C 2C for a period of at least one hour before the test; (d) locate the box under the drop tube of the impact apparatus; (e) embed the specimen into the sand using a vibrator with the inner surface exposed and facing upwards; (f) locate the specimen such that the marked point of impact is under the centre line of the tup; (g) drop the tup from a height of 1 m on to the inner surface of the specimen within 10 seconds of removing the specimen from the conditioning environment; (h) examine the specimen for damage. Damage is defined as a puncture or crack of the inner layer. Ductile bending or whitening is not considered to be damage; (i) if the specimen exhibits no damage the next test shall be conducted with a tup of 30 g greater mass. If the specimen does exhibit damage the next test shall be conducted using a tup of 30 g smaller mass; (j) after having completed the 20 strikes calculate the average of the energies where a pass (no damage) was recorded and the average of the energies where a failure (damage) was recorded, then calculate the average of the two averages. The test report shall include: (a) identification of the samples; (b) the overall average; (c) whether or not the specimens were damaged.
(ii)
(iii)
(iv)
Notwithstanding the requirements of Sub-Clauses 15.4.7.1 and 15.4.7.2 of this section of the Specification, variations in the test methods specified therein shall be made where
deemed necessary by the British Board of Agrment (or equivalent) following consultation with the manufacturer and in agreement with the Engineer. All such variations shall be recorded in the test report. Pipes and fittings shall have a current British Board of Agrment Certificate (or equivalent) certifying the appropriate physical properties when tested in accordance with this Clause. The Contractor shall maintain records with the following information for each separate consignment of structured wall pipe or fittings delivered to Site: (i) (ii) (iii) (iv) 15.4.8 system name, ring stiffness grade/number and size; name and address of the system manufacturer; consignment number and delivery date; and a copy of the site delivery note.
Granular materials for bedding, haunching and surrounding pipes The granular material shall consist of natural and/or recycled coarse aggregate or recycled concrete aggregate complying with BS EN 13242. Where recycled coarse aggregate or recycled concrete aggregate is used in this Clause, it shall have been tested in accordance with Clause 15.8.6 and shall not contain more than 1% other materials (Class X). Pipe bedding, haunching and surrounding material shall be as shown on the drawings, and shall comply with the following: (i) For pipes on beds designated as Class B, F and S the aggregate shall have: (a) geometrical requirements in accordance with Table 15.5; (b) a resistance to fragmentation in Category LA50 in accordance with BS EN 13242, Clause 5.2 and Table 9; (c) a water-soluble sulphate content of less than 1.9 grams of sulphate (as SO3) per litre when tested in accordance with BS EN 1744, Clause 10; (d) all other requirements in Category NR. For pipes on beds designated as Class N and T the aggregate shall comply with the geometrical requirements of either Table 15.5 or with Table 15.6, and with the fragmentation, water-soluble sulphate content and other requirements of (i) above. For pipes on beds designated Class A and Z concrete shall be ST4 and ST2, in compliance with Clause 15.4.14, respectively.
(ii)
(iii)
288
Table 15.5: Type A pipe bedding, haunching and surrounding material (BS EN 13242, Coarse aggregate)
BS EN 13242, Coarse aggregate (Clause 4.3.2) Category for general grading requirements Category for tolerances at mid-size sieves Category for maximum values of fines content Nominal pipe diameter, mm Not exceeding 140 Exceeding 140 but not exceeding 400 Exceeding 400 GC80-20 GTNR (no requirements) Gravel - f1.5 Crushed rock, recycled aggregate - f4 Aggregate size, mm Graded Single sized 4/10 2/14 or 4/20 4/10, 6/10 or 10/20 2/14, 4/20 or 4/40 4/10, 6/14, 10/20 or 20/40
Table 15.6: Type B pipe bedding, haunching and surrounding material (BS EN 13242, Fine and all-in aggregated)
BS EN 13242, Fine and all-in aggregate (Clause 4.3.3) Fine All-in Category for general grading Category GA80 Category GF80 requirements Category for tolerances on GTFNR GTANR manufacturers declared typical grading (no requirement) (no requirement) Category for maximum values of fines Gravel - f3 content Crushed rock, recycled aggregate - f11 Nominal pipe diameter, mm Aggregate size, mm Not exceeding 140 Exceeding 140 but not exceeding 400 Exceeding 400
Table 15.7: Type C pipe surround material
Fine 0/1, 0/2, 0/4 or 0/6
All-in 0/10 0/10 or 0/20 0/10 , 0/20 or 0/40
Permitted Constituents
Any; except there shall not be any stones or lumps of clay >40 mm nominal diameter. Recycled aggregate.
Material Properties Required for Acceptability Property (See Defined and Acceptable Limits Exceptions in Tested in Within: Previous Column) Accordance with: Lower Upper (i) mc BS 1377-2 Optimum mc Optimum mc 2%
2
(ii) MCV
2
BS 1377-4
289
15.4.9
Selected Granular Surround Material to Corrugated Steel Buried Culverts Selected granular material for the surround to corrugated steel buried culverts shall be either material excavated from within the Site or imported on to the Site which meets the requirements of Table 15.8 for acceptability for use in the Permanent Works.
Table 15.8: Granular surround material to corrugated steel buried structures
Natural gravel, natural sand, crushed gravel, crushed rock, crushed concrete, well burnt colliery spoil or any combination thereof. None of these constituents shall include any argillaceous rock. Recycled aggregate except recycled asphalt.
Material Properties Required for Acceptability Property (See Defined and Acceptable Limits Exceptions in Tested in Within: Previous Column) Accordance with: Lower Upper (i) grading BS 1377-2 Table 15.11 Table 15.11 (ii) uniformity See Note 1 5 coefficient (iii) plasticity index 2194HBS 1377-2 6
2
(iv) optimum mc
(v) mc (vi) MCV (vii) Los Angeles (viii) resistivity (ix) water soluble (WS) sulphate content as SO (x) oxidisable sulphides (OS) content (xi) chloride ion content (xii) pH value (xiii) sulphide and hydrogen sulphide
2204HBS 1377-4 (vibrating hammer method) 2194HBS 1377-2 2204HBS 1377-4 2291HBS EN 1097-2 Clause 637 TRL Report 447 Test No. 1
Optimum mc - 2% 2000 ohm cm -
Optimum mc +1% 40 300 mg/l
(See above)
TRL Report 447 Tests Nos. 2 and 4 2306HBS EN 1744 2201HBS 1377-3 Standard textbook of qualitative inorganic analysis
0.06% as SO4 0.025% 9 Rapid blackening of lead acetate paper
6 -
NOTE: 1. Uniformity coefficient is defined as the ratio of the particle diameters D60 to D10 on the particle-size distribution curve, where: D60 = particle diameter at which 60% of the soil by weight is finer D10 = particle diameter at which 10% of the soil by weight is finer
290
15.4.10
Granular Material Used For Trench Infill With Filter Drains The granular material used for trench infill shall comply with the requirements for nonplasticity, LA category and sulphate content of Clause 15.4.11 and have a grading within the limits of Table 15.9. The material when tested in accordance with sub-Clause 15.8.5 shall meet the permeability requirements described in Sub-Clause 15.1.
Table 15.9: Filter Drain: Trench Infill Grading Requirements
Maximum Particle Size mm D5 Size mm D15 Size mm D85 Size mm
40 >0.125 > Hole Diameter or 1.2 Times Width of Slot in Pipe
5 to 12 or if Cu <5 Uniformity Coefficient (Cu) D60/D10 D5 > 1 mm Dn = Sieve size passing n% by weight of material 15.4.11 Filter Material Type D, Type E or Type F filter material shall consist of natural or recycled coarse aggregate or recycled concrete aggregate complying with BS EN 13242 and the following: (i) for Type D and F, grading requirements for unbound mixtures in accordance with Table 15.10 and BS EN 13285; (ii) for Type E, geometrical requirements in accordance with Table 15.10 and BS EN 13242; a resistance to fragmentation in Category LA50 in accordance with BS EN 13242, Clause 5.2 and Table 9; a water-soluble sulphate content of less than 1.9 grams of sulphate (as SO3) per litre when tested in accordance with 2306HBS EN 1744, Clause 10; all other requirements in Category NR; be non-plastic when tested in accordance with BS 1377-2.
2
(iii)
(iv)
(v) (vi)
Where recycled coarse aggregate or recycled concrete aggregate is used in accordance with this Clause, it shall have been tested in accordance with Clause 15.8.6 and shall not contain more than 1% other materials (Class X).
291
Table 15.10: Grading and geometrical requirements for filter drain material
Type Standard Size, mm Grading and oversize categories Oversize category
D BS EN 13285 0/20 GF
(with an additional sieve)
E BS EN 13242 20/40 GC 80-20 -
OC80
F BS EN 13285 As described in Sub-Clause 15.1 or as detailed on the Contract Drawings
Category for tolerances at midsize sieves Category for maximum fines Summary grading requirements Sieve size, mm 80 63 40 20 10 4 2 0.500 0.125 0.063 % in size fraction 4/10 2/4
GTNR (no requirement) fNR (no requirement)
UF3
Percentage by mass passing 100 80 99 50 90 30 75 15 60 0 35 04 0-3 5 - 35 5 - 35 100 98 100 80 99 0 20 05 -
As described in Sub-Clause 15.1 or as detailed on the Contract Drawings
Filter materials, when tested in accordance with sub-Clause 15.8.5 shall have permeability requirements as described in Sub-Clause 15.1. 15.4.12 Selected Granular Material for Trench Infill Selected granular material for trench infill shall be either material excavated from within the Site or imported on to the Site which meets the requirements of Table 15.12 for acceptability for use in the Permanent Works. Unless otherwise described in the Specification sampling and testing of materials shall be carried out in accordance with 2192HBS 1377-1 to 2217HBS 1377-9 inclusive. The material shall comply with the grading requirements given in Table 15.11.
292
Table 15.11: Grading Requirements for selected granular material for trench infill
Sieve Size BS Series 75mm 37.5mm 10mm 5mm 600microns 63microns
Percentage by Mass Passing 100 75-100 40-95 30-85 10-50 <15
Table 15.12: Classification for selected granular material for trench infill
Any material or combination of materials, other than unburnt colliery spoil argillaceous rock and chalk. Recycled aggregate.
Material Properties Required for Acceptability Property (See Defined and Acceptable Limits Exceptions in Tested in Within: Previous Column) Accordance with: Lower Upper (i) grading BS 1377-2 Table 15.11 Table 15.11 (ii) optimum mc BS 1377-4 (vibrating hammer method) (iii) mc BS 1377-2 Optimum mc Optimum mc 2% (iv) Los Angeles 2291HBS EN 60 1097-2
2 2 2
Where recycled coarse aggregate or recycled concrete aggregate is used, it shall have been tested in accordance with Clause 15.8.6. 15.4.13 Type 1 Unbound Mixture Type 1 unbound mixtures shall be made and constructed to conform to BS EN 13285, the requirement categories in Table 15.13 and the following sub-clauses. (i) Type 1 unbound mixture shall be made from crushed rock, crushed slag, crushed concrete, recycled aggregates or well burnt non-plastic shale and may contain up to 10% by mass of natural sand that passes the 4 mm test sieve. Where permitted by Sub-Clause 15.1, crushed gravel derived from natural cobbles retained on the 63 mm test sieve and comply with the crushed, broken and totally rounded particles requirement in Table 15.15 may be used. The mixture shall comply with BS EN 13285 and the requirements of Table 15.13. The grading requirements for the mixture are summarised in Table 15.14. The properties of aggregates used in the mixture shall be in accordance with BS EN 13242 and the requirements of Table 15.15.
(ii)
(iii)
293
Table 15.13: Mixture and Grading Requirement Category for Type 1 Unbound Mixture
Mixture requirement category - Designation - Maximum fines - Oversize Grading requirement category - Overall grading
0/31,5 UF9 OC75 GP
Table 15.14: Summary Grading Requirements for Type 1 Unbound Mixtures
Sieve size, mm Overall grading range
Percentage by mass passing Supplier declared Tolerance on the value supplier grading range declared value
100 63 75 99 31.5 15 54 - 72 43 81 16 15 33 52 23 66 8 15 21 38 12 53 4 13 14 27 6 42 2 10 9 20 3 32 1 0-9 0.063 Grading of individual batches - differences in values passing selected sieves Retained sieve size, Passing sieve size, Percentage by mass passing mm mm Not less than Not more than 8 16 7 30 4 8 7 30
Table 15.15: Requirements for Aggregates Used in Type 1 Unbound Mixture
Standard Crushed, or broken and totally rounded particles - crushed rock, crushed artificial and crushed recycled aggregates - see NOTE 1 - crushed gravel Resistance to fragmentation - Los Angeles test Resistance to wear - micro-Deval test Resistance to freezing and thawing magnesium sulphate soundness Water absorption
BS EN 13242 Categories for aggregate properties C90/3 C50/10
- see NOTE 2 (no requirement) LA50 MDENR (no requirement). The supplier shall state the value for the aggregate used. MS35 WA24NR (no requirement) The supplier shall state the value for the aggregate used.
Standard
Volume stability of blast furnace slags Volume stability of steel (BOF and EAF) slags All other BS EN 13242 aggregate Category NR (no requirement) requirements NOTES: 1. BS EN 13242 assumes that crushed rock aggregates comply with category C90/3 without further testing. 2. Where permitted by Sub-Clause 15.1. The size fraction of the unbound mixture passing the 0.425mm size test sieve shall be non-plastic as defined by BS 1377-2 and tested in compliance therewith.
2
BS EN 13242 Categories for aggregate properties Free from dicalcium silicate and iron disintegration. V5
Where recycled coarse aggregate or recycled concrete aggregate is used, it shall have been tested in accordance with Clause 15.8.6. Recycled coarse aggregate and recycled concrete aggregate shall also comply with the additional requirements of Table 15.16.
Table 15.16: Additional Requirements for Recycled Coarse Aggregate and Recycled Concrete Aggregate Used in Type 1 Unbound Mixture
Component Identified by Clause 15.8.6 Asphalt (Class A) Glass (Class G) Other materials (Class X), including wood, plastic and metal
Maximum Permitted Content (% by mass) 50 25 1
The mixture shall be transported, laid and compacted without drying out or segregation. Mixtures containing crushed gravel shall comply with the following additional requirement. Crushed gravel aggregate shall be derived from natural cobbles retained on the 63 mm test sieve and comply with the crushed, broken and totally rounded particles requirement in Table 15.15. For the purposes of this Clause, gravel is defined as aggregate derived from a natural, unconsolidated, coarse-grained sedimentary deposit consisting of waterworn rock fragments. 15.4.14 Concrete for Drainage Purposes General Concrete for in-situ concrete chambers shall comply with Section 8 of the Specification and the requirements of Sub-Clause 15.1. Concrete mixes for other drainage purposes shall comply with this Sub-Clause and any additional requirements in Sub-Clause 15.1.
295
Unless otherwise described in Sub-Clause 15.1, concrete for drainage purposes shall be a standardised prescribed concrete, selected from Table 15.17, complying with 2257HBS EN 206-1 and BS 8500 and with the additional requirements of this SubClause. Cement Cement types as defined in BS 8500, see Table A.17 of BS 8500-1 or Table 1 of BS 8500-2, shall comprise one of the following: CEM I, CEM II/A-V, CEM II/B-V, BIIIA or, where required in Sub-Clause 15.1, SRPC (sulphate-resisting Portland cement). Aggregates Aggregates shall comply with BS EN 12620 and unless otherwise described in SubClause 15.1 the maximum size shall be 20 mm. The total acid-soluble sulphate content of the concrete mix, as SO4, shall not exceed 5% of the mass of cement in the mix. The acid soluble sulphate (AS) shall be determined in accordance with Test No. 2 in TRL Report 447. Consistence The consistence of the concrete shall be defined by its consistence class (slump) and be within consistence class S2 of 2257HBS EN 206-1 and BS 8500 as appropriate to the purpose.
Table 15.17 Concrete for Drainage Purposes
Purpose Blinding concrete, backfill for structural foundations, overdig. Class A bed to drains, foundations, channels and benching to chambers. Class Z bed, haunch and surround to drains. Surround to chambers and gullies.
Standardised prescribed concrete ST1 ST4 ST2
Transporting, placing, compaction and curing of concrete shall be carried out in accordance with Section 8 of the Specification entitled Concrete. All work associated with the provision and striking of formwork shall be in accordance with Section 9 of the Specification entitled Concrete. Surface finishes shall comply with Section 8 of the Specification entitled Concrete and unless otherwise described in Sub-Clause 15.1, the following: (i) Buried surfaces: Unformed surfaces shall be Class U1 Formed surfaces shall be Class F1 Exposed surfaces: Unformed surfaces shall be Class U2 except benching to chambers, which shall be Class U3
(ii)
15.4.15
Formed surfaces shall be Class F2
Precast Concrete Chamber Rings, Reducing Slabs and Cover Slabs Precast Concrete Chamber Rings, Reducing Slabs and Cover Slabs shall comply with 2235HBS 5911-3 and BS EN 1917 and the particular requirements described in SubClause 15.1.
15.4.16
Chamber Covers, Gratings and Frames Chamber covers, gratings and frames shall be Class F900, as described in Sub-Clause 15.1 or as detailed on the Contract Drawings and shall comply with BS EN 124 and this Sub-Clause. They shall incorporate a permanent non-rock feature either triangular point suspension or machined faces. Bolts supplied for loosely coupling separate sections of covers and gratings shall be steel hexagon headed, complying with the requirement of BS EN ISO 4016, BS EN ISO 4018 and BS EN ISO 4034 and be galvanized in compliance with Sub-Clauses 15.5 4, 5 and 6. They shall not be less than size M16 complete with hexagon nut and shall be provided with means to prevent undue tightening of unit sections. Unless otherwise specified in Sub-Clause 15.1, all covers, gratings and frames shall be supplied in a fine cast (uncoated) condition. Where a coating is specified in Sub-Clause 15.1 or detailed on the Contract Drawings, the coating shall only be applied when the surfaces of the casting are clean, free from rust and dry. Gratings for catchpit chambers shall have a minimum waterway area as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Two sets of lifting keys shall be delivered to the Engineer for each type of cover supplied. At least two keyways shall be provided in each complete cover, one in each segment for segmental covers. A recess for a prising bar shall be incorporated in manhole covers unless other means of loosening the cover from the frame are provided.
15.4.17
Gully Pots Gully pots shall be trapped, untrapped or sumpless as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Precast concrete gullies shall comply with 2241HBS 5911-6 and clay gullies with BS EN 295.
15.4.18
Gully gratings Gully gratings, kerb type gully covers and frames shall comply with BS EN 124 and all of this Sub-Clause and shall be of the classes and sizes described in Sub-Clause 15.1 or detailed on the Contract Drawings.
297
The upper surface of gully gratings shall be flat except where otherwise described in Sub-Clause 15.1. Slots in gratings or between gratings and frames shall not be orientated parallel to the direction of traffic except where the slots are less than 150 mm long or less than 20 mm wide. Minimum waterway areas shall be as specified in SubClause 15.1 or as detailed on the Drawings. Unless otherwise specified in Sub-Clause 15.1 or as detailed on the Contract Drawings, all gratings and frames shall be supplied in a fine cast (uncoated) condition. Where a coating is specified in Sub-Clause 15.1 or as detailed on the Contract Drawings, the coating shall only be applied when the surfaces of the casting are clean, free from rust and dry. 15.4.19 Bricks Bricks shall conform to the particular requirements of 2268HBS EN 771-1 as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. The determination of sulphate content for the soluble salt content test shall be in accordance with Test No. 2 in TRL Report 447. Bricks beneath frames for chambers and gullies, and for the construction of brick chambers, shall, unless otherwise described in Sub-Clause 15.1 or detailed on the Contract Drawings, be HD type Class B clay engineering bricks conforming to 2268HBS EN 771-1 and the performance characteristics given in TABLE 15.18. In addition to the above concrete bricks or blocks conforming to 2243HBS 6073-1 and 2272HBS EN 772-2 having an average crushing strength value of not less than 20 N/mm when used for surface water drainage, or special purpose concrete bricks having a minimum cement content of 350 kg/m when used for foul drainage, may be used.
TABLE 15.18: Performance Characteristic Requirements
Performance characteristic
Reference
Compressive strength Water absorption(% by mass) and also when used as DPC units and Net dry density (kg/m) Freeze/thaw resistance category Active soluble salts content category 15.4.20 Light Liquid (Oil) Separators
2270HBS EN 772-1 2276HBS EN 772-7
Clay engineering bricks Class B 75 (N/mm) 7,0 (and DPC2)
and 2278HBS EN 772-13 2270HBS EN 772-1 2274HBS EN 772-5
and 2100 F2 S2
The light liquid (oil) separator shall be: (i) of the type specified in Sub-Clause 15.1 or as detailed on the Contract Drawings.
298
(ii) (iii)
of proprietary construction; manufactured from Glass Reinforced Plastic or other material equal and approved; compliant with BS EN 858;and Class 1.
(iv) (v)
Separators shall be capable of separating oil and silt and shall have light liquid and silt storage volumes as determined in accordance with BS EN 858 for the design data provided in Sub-Clause 15.1 or as detailed on the Contract Drawings. Separators shall be fitted with an automatic closure device approved by the Engineer. Ventilation pipes from the interceptors shall terminate 2.5m above ground. Details for supporting the above ground section of the ventilating pipe shall be approved by the Engineer. 15.4.21 General Penstocks shall be designed and manufactured to comply with BS 7775, the requirements of Sub-Clause 15.1 or as detailed on the Contract Drawings. Unless impracticable or otherwise specified in Sub-Clause 15.1 or detailed on the Contract Drawings, penstocks shall be provided with rising stem spindles. Spindles shall be adequately supported over their length to ensure efficient operation when opening and closing the door. The spindle shall not fail due to yield or buckling during normal operation. The spindle should not fail due to yielding under the worst fault condition. The slenderness ratio of the spindle shall not be greater than 200. The weight of the penstock door shall not back-drive the spindle through its power screw. When required to be provided by the Contract Drawings or Sub-Clause 15.1 actuators for electro-mechanical operation of the door shall be able to fully open and close the door. The actuator shall provide sufficient torque to open or shut the door under all operating conditions. The actuator shall have an IP rating suitable for the zone of installation. Leakage Rate The allowable leakage rate at the maximum operating head of the penstock shall comply with requirements of Table 15.19.
Table 15.19: Allowable leakage rate
Penstocks
Head Type On-seating
Head (m) Any head
Allowable leakage rate 1.25 litres/min/m

Off-seating
<6 6<9 9 < 12 12 < 15
2.5 litres/min/m 3.0 litres/min/m 3.75 litres/min/m 4.5 litres/min/m
Materials The component parts of the penstock shall be manufactured from the materials specified below: (i) Frame: BS EN 1561 min. 250 cast iron designed for wall or flange mounting applications. Door: BS EN 1561 min. 250 cast iron to withstand the on seating and off seating head specified in Sub-Clause 15.1 or as detailed on the Contract Drawings. Sealing Faces: for penstocks up to and including 600mm diameter shall be to BS EN 1982, and those for penstocks above 600mm diameter shall be to BS EN 12167. Sealing faces shall be bedded to 0.1mm feeler gauge nonacceptance to provide an effective seal. Sealing faces shall either be force fit or, secured to the frame using long countersunk taper screws in the same material as the sealing face. Side Wedges: BS EN 1561 min. 250 cast iron to provide a large contact area with the door. The side wedges shall be adjustable to accommodate wear during the life of the penstock. Thrust Housing (direct operation): cast iron to BS EN 1561 min. 250 with low friction thrust washer and lubricator. Door Nut: Manufactured from phosphor bronze to BS EN 12167 for nonrising stem applications or cast iron to BS EN 1561 min. 250 for rising stem types. Spindle & Guide Brackets: Cast iron to BS EN 1561 min. 250 (Material Spacing) Hand Wheel: Cast iron to BS EN 1561 min. 250 Cap: Cast iron to BS EN 1561 min. 250 Tee Bar: Cast iron to BS EN 1561 min. 250 Fasteners: manufacturers standard fasteners in stainless steel to BS EN 10088 grade 1.4401 (316; A4).
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii) (ix) (x) (xi)
Protective Coating A protective coating shall be applied to the penstock in accordance with the following specification:
(i) (ii)
Grit Blast to BS EN ISO 8501 Sa2.5. 1 coat 2 pack Black High Build Epoxy (COPON KSIR88 or equal approved), the coat to be 150 microns average dry film thickness. Giving a final coating thickness of 150 microns.
15.4.22 General
Flap Valves
Flap valves shall be either circular or rectangular as appropriate for the drain outlet to which they are to be fitted. Leakage Rate The leakage rate of all flap valves shall be as follows:

Cracking Head
Heads of less than a metre = 2.5 litres per minute / metre of seal; Heads of greater than a metre =1.25 litres per minute / metre of seal
The hydrostatic head required to crack open the flap valve door shall not exceed 85mm for valves up to 900mm diameter / high and shall not exceed 160mm for valves 1000mm to 2000mm diameter / high. Circular Flap Valves up to 600mm diameter Flap valves to be fitted at outlets from circular pipes shall be circular. The doors of the flap valves shall be double hung on hinge links and hinge pins. Flap valves shall be flange mounted and shall have connections to 2289HBS EN 1092-2 PN16 rated flanges. The component parts of the flap valve shall be manufactured from the materials specified below: (i) (ii) Frame: ductile iron Grade 420/12 to BS EN 1563. Door: ductile iron Grade 420/12 to BS EN 1563 designed to withstand static seating heads up to 6 metres. Sealing Faces: phosphor bronze to BS EN 12167. Hinge Links: ductile iron Grade 420/12 to BS EN 1563. Fasteners: standard fasteners as supplied by the manufacturer in stainless steel to BS EN 10088 grade 1.4401 (316).
(iii) (iv) (v)
301
(vi)
Hinge pins: stainless steel to BS EN 10088 grade 1.4401 (316)
Ductile iron components shall have a protective coating of Black Plascoat PPA571 thermoplastic coating powder to 200 microns minimum thickness. Circular Flap Valves greater than 600mm diameter and rectangular flap valves Flap valves to be fitted at outlets from circular pipes shall be circular and those fitted to outlets from box culverts shall be rectangular. The doors of the flap valves shall be double hung on hinge links and hinge pins. Flap valves shall be flange mounted and shall have connections to 2289HBS EN 1092-2 PN16 rated flanges. The component parts of the flap valve shall be manufactured from the materials specified below: (i) (ii) Frame: BS EN 1561 min. 250 cast iron. Door: BS EN 1561 min. 250 cast iron designed to withstand static seating heads up to 6 metres. Sealing Faces: phosphor bronze to BS EN 12167. Hinge Links: stainless steel to BS EN 10088 grade 1.4401 (316) fitted with phosphor bronze bushes to BS EN 12167. Fasteners: standard fasteners as supplied by the manufacturer in stainless steel to BS EN 10088 grade 1.4401 (316). Hinge pins: stainless steel to BS EN 10088 grade 1.4401 (316)
(iii) (iv)
(v)
(vi) 15.4.23
Flexible Joint Couplings and Flange Adaptors Flexible mechanical joint couplings and flange adaptors shall be appropriate to the class and type of pipe or pipes being jointed. They shall be fabricated from steel or malleable cast iron with steel bolts. Couplings shall be provided without a central register unless otherwise stated. Couplings shall be capable of accommodating the angular deflections between adjacent pipes specified in Table 15.20, without leakage.
Table 15.20 Maximum angular deflection for pipe diameter
Pipe Diameter (mm) < 599 600 < 749 750 < 899 900 < 1,199 1,200 < 1,799 > 1,800
Angular Deflection 6 5 4 3 2 1
Flange adaptors shall accommodate half of the above deflections. Couplings shall be capable of accommodating a repeated pipe movement of 9mm and flange adaptors 4.5mm between adjacent pipes, without leakage. Couplings and flange adaptors shall be capable of supporting a 6 metre pipe full of water when installed above ground on piers and remaining watertight. Couplings and flange adaptors shall be factory coated with an approved nylon finish of minimum thickness 200 microns. 15.4.24 Pipes for Filter Drains Pipes and fittings for filter drains shall be either: (i) perforated or porous and comply with sub-Clause 15.4.1. Pipes complying with BS 4962 shall have a minimum Ultimate Pipe Stiffness (STES) value of 1400 N/m. (ii)Imperforated thermoplastics pipe complying with BS 4660, BS 5481, BS EN 1401, 2311HBS EN 1852-1 or 2329HBS EN 12666-1 slotted longitudinally along the top surface and stress relief treated (if required) in accordance with the system manufacturers published specification.
(ii)
Where coilable pipes to BS 4962 are used they shall be capable of being straightened so as to lie flat without restraint in the trench bottom before backfilling. 15.4.25 General Joint filler board shall be 25 mm thick unless otherwise stated in Sub-Clause 15.1 or as detailed on the Contract Drawings, within a tolerance of 1.5 mm. It shall be a selfexpanding cork seal or a firm compressible material or a bonded combination of compressible and rigid materials. The joint filler board shall meet the requirements given when tested in accordance with the procedures in the following sub-Clauses: Compression and Recovery Test Two specimens each trimmed to 100 mm square 0.5mm, maintained at room temperature and humidity for 24 hours, shall be subjected to three applications of load at 24 hour intervals in a compression test machine complying with 2364HBS EN ISO 75001, with auxiliary platens 100mm, minimum 13mm thick. During each application of load each specimen shall be compressed to 50% of its original thickness at a rate of strain of 1.3mm per minute. The load required to achieve this amount of compression shall be not less than 0.07 N/mm nor more than 10 N/mm for material to be used in pavements and not less than 0.07 N/mm and not more than 0.4 N/mm for material to be used in bridge joints. The load shall be released immediately the required degree of Joint Filler Board
303
compression is reached and after the third application a recovery period of 30 minutes shall be allowed after which the thickness of the specimen shall be measured. This thickness, expressed as a percentage of the original thickness, is the recovery value of the specimen. The thicknesses shall be measured to an accuracy of 25 micron. The two new specimens shall be weighed before and after testing. The difference in mass shall be determined with an accuracy of 0.1% and shall be expressed as a percentage of the original mass of the specimen. The material shall be deemed to have passed the test if both specimens have recovery values of at least 70% and have not suffered a reduction of mass in excess of 1%. Extrusion Test A specimen 100mm square 0.5mm shall be subjected to the following extrusion test. The extrusion mould shall be 100 mm x 100 mm (+ 0.5 mm, - 0) internally, of sufficient depth to test the sample as received, open on one side only and fixed rigidly to a base plate. The mould shall be provided with a closely fitting pressure plate which shall fit without binding, and with an accurate horizontal measuring dial gauge or measuring device accurate to 25 microns. The specimen shall be mounted in the extrusion mould and loaded once as described in the compression and recovery test. The extrusion at the open side of the mould shall be measured with the gauge when the specimen is compressed to 50% of its original thickness and before release of the load. The material shall be deemed to have passed the test if the extrusion of the free edge does not exceed 6 mm. Immersion Test for Cork Filler Board Two specimens each 115 mm x 115 mm 2.5 mm shall be prepared and the thickness of each specimen shall be determined to the nearest 25 microns before the specimens are immersed in boiling water for one hour. After removal from the water the specimens shall be allowed to cool to room temperature and after 15 minutes at this temperature their thickness shall be remeasured to the nearest 25 microns. (b) The material shall be deemed to have passed the test if both specimens have a thickness of not less than 140% of their thickness before immersion. Acid Test for Cork Filler Board Two specimens each 115 mm x 115 mm 2.5 mm shall be immersed in hydrochloric acid of a specific gravity of 1.18 at room temperature which is then brought to the boil and maintained thus for one hour when the specimens shall be removed and rinsed in water. The material shall be deemed to have passed the test when, after examination, the specimens show no evidence of serious disintegration, friability or lack of resilience. Discolouration or minor swelling shall not be considered as failure.
304
15.4.26
Marker Tape Marker tapes shall be green self-coloured PVC or polythene plastic not less than 0.1mm thick and 150mm wide.
15.4.27 General
Combined Drainage and Kerb Systems
Combined drainage and kerb systems shall conform to BS EN 1433 and to the special requirements in Sub-Clause 15.1. Combined drainage and kerb systems shall be suitable for their intended use and place of installation in the Works and as stated in Sub-Clause 15.1 or as detailed on the Contract Drawings. The Contractor shall provide evidence of such suitability for the purpose to the Engineer in accordance with Sub-Clause 15.1. If applicable design flows shall be given in Sub-Clause15.1 or detailed on the Contract Drawings and shall be accommodated without surcharge within the main combined drainage and kerb section and beneath the underside of any inlet slot sections. Where applicable, the width and depth of combined drainage and kerb system units shall not exceed the dimensions given in Sub-Clause 15.1 or as detailed on the Contract Drawings. Classification Combined drainage and kerb systems, excluding in-situ system, shall be Class E600 combined kerb and drainage units. Water Tightness
Joints between units comprising the system and between the channel and units shall be designed to avoid leakage of surface water. Joints between bridge deck waterproofing and component parts passing through the waterproofing shall be watertight. Sealants shall be compatible with the waterproofing system. 15.4.28 Mortar Cement for mortar shall be one of the following: (i) (ii) (iii) Portland cement conforming to 2254HBS EN 197-1; Masonry cement conforming to 2262HBS EN 413-1; Sulphate-resisting Portland cement conforming to BS 4027 where described in Sub-Clause 15.1 or as detailed on the Contract Drawings.
Fine aggregate for mortar shall conform to BS EN 13139.
305
If water for the Works is not available from a water companys supply, the Contractor shall ensure that the water used in the mortar complies with the guidance given in BS EN 1008. The sulphate content of the water shall be tested in accordance with Test No. 1 in TRL Report 447. The water shall not be used if the sulphate content exceeds 1.4 g of sulphate (as SO4) per litre. Water from the sea or tidal rivers shall not be used. The chloride ion content of the mortar determined in accordance with 2306HBS EN 1744 shall not exceed 0.3% of the mass of cement for mortar made with Portland cement and 0.2% for mortar made with sulphate-resisting Portland cement. Calcium chloride or admixtures containing calcium chloride shall not be used. The inclusion of lime in the mortar is optional unless otherwise stated elsewhere in this Section. The proportions of lime given are for lime putty conforming to 2264HBS EN 459-1. If the lime is measured as the dry hydrate, the amount may be increased up to 1.5 volumes for each volume of lime putty. Mortar shall be mixed thoroughly either by hand or mechanically until its colour and consistency are uniform. The constituent materials shall be accurately gauged, allowance being made for bulking of sand. Mortar shall be made in small quantities only as and when required. Mortar which has begun to set or which has been mixed for a period of more than one hour shall be discarded.
15.5
Requirements for material handling and storage

Materials and components shall be stored in such a manner as to preserve their quality and condition to the standards required by the Specification. Materials and components shall be handled in such a manner as to avoid any damage or contamination and in accordance with all applicable recommendations of the manufacturers. The Contractor shall ensure that plastics pipes are not subject to deterioration due to sunlight during the period between manufacture and installation in the ground. Unless otherwise described in the Specification, the use, installation application or fixing of materials and components shall be in accordance with all applicable recommendations of the manufacturers. Where appropriate, the Contractor shall make use of any technical advisory services offered by the manufacturers.
15.6
15.6.1
Workmanship requirements, installation and erection

Excavation for Pipes and Chambers Excavation shall comply with the relevant Section of the Specification and with the following: (i) soft spots existing below the bottom of an excavation shall be removed and the resulting voids backfilled with Type 1 unbound mixture for sub-base complying with Clause 15.4.13 or pipe bedding material complying with
Clause 15.4.8, both well compacted, or ST1 concrete in compliance to Clause 15.4.14 (ii) any additional excavation below the bottom of an excavation that is required because the Contractor has allowed the bottom to become soft or otherwise unacceptable for the construction of the pipeline or chambers shall be made good as described in (i) above; any excavation greater than the net volume required for the Permanent Works below the level of any pipe surround shall be made good as described in (i) above. Unless otherwise described in Sub-Clause 15.1, all pipes in or under new embankments shall be laid only when the embankment has been formed and compacted to formation level under paved areas, to finished earthworks level in other areas, or to a level which will give a minimum cover of 1.2 m to the pipes, whichever is the lowest.
(iii)
(iv)
15.6.2
Bedding, Laying and Surrounding of Pipes Immediately following the excavation of the trench, the pipes shall be laid and jointed on the pipe bed. Pipes shall be laid so that each one is in contact with the bed throughout the length of its barrel. The pipes shall be laid at the level and gradients shown on the drawings and schedules. The deviation in level from that specified at any point shall not exceed 20mm and in addition the algebraic difference of the deviation in level at any two points on each pipe shall not exceed 30mm. In the case of socketed or sleeve jointed pipes the bed shall be cut away and removed at each socket or sleeve to give a clearance of at least 50mm, or 100mm for trenches in material designated as Hard Material, so that the socket or sleeve does not bear on the bed. Pipes shall be laid on setting blocks only where a concrete bed or cradle is used. Pipes and fittings shall be examined for damage and the joint surfaces and components shall be cleaned immediately before laying. Measures shall be taken to prevent soil or other material from entering pipes, and to anchor each pipe to prevent movement before the work is complete. Pipes complying with BS 4962 which are corrugated coilable perforated pipes shall, unless otherwise permitted in Sub-Clause 15.1, be laid only by automatic single pass drain laying machines. Drainage pipe and bedding combinations shall be selected from the alternatives described in Sub-Clause 15.1 or as detailed on the Contract Drawings. For pipes on beds designated as Class A and Z concrete shall be ST4 and ST2, in compliance to Clause 15.4.14, respectively. Backfilling shall not be carried out until after the concrete has cured. Except for filter drains a further surround above the bed, haunch and surround described above shall be provided to a height of 300mm above the top of the pipe consisting of Type C pipe surround material as described in Clause 15.4.8, Table 15.7.
307
Unless otherwise described in Sub-Clause 15.1 or detailed on the Contract Drawings the materials used for the bedding, haunching and surrounding of filter drains shall comply with the appropriate bedding, haunching and surrounding materials specified in sub-Clauses 15.4.8.(i) to 15.4.8.(iv) and with the requirements for backfilling specified in sub-Clause 15.4.11. Material for bedding, haunching and surrounding pipes shall not be deposited within 500mm, or any other distances described in Sub-Clause 15.1 or as detailed on the Contract Drawings, of concrete, cement bound materials, other cementitious materials or stabilised capping forming part of the Permanent Works if, when tested in accordance with TRL Report 447 either: (i) the water-soluble sulphate (WS) content exceeds 1500 mg of sulphate (as SO4) per litre (Test No.1); or the oxidisable sulphides (OS) content exceeds 0.3% of sulphate (as SO4) (Test No.2 and Test No.4); or the total potential sulphate (TPS) content exceeds 0.6% of sulphate (as SO4) (Test No.4).
(ii)
(iii)
At least five samples of each material shall be tested for WS, OS and TPS. The mean of the highest two values shall be used for comparison with the limiting values. This also applies if six to nine results are available. If ten or more results are available, the mean of the highest 20% of the results shall be used for comparison with the limiting values. Material for bedding, haunching and surrounding pipes shall not be deposited within 500mm, or any other distances described in Sub-Clause 15.1 or as detailed on the Contract Drawings, of metallic items forming part of the Permanent Works if, when tested in accordance with TRL Report 447 either: (i) the water-soluble sulphate (WS) content exceeds 300 mg of sulphate (as SO4) per litre (Test No.1); or the oxidisable sulphides (OS) content exceeds 0.06% of sulphate (as SO4) (Test No.2 and Test No.4).
(ii)
At least five samples of each material shall be tested for WS and OS. The mean of the highest two values shall be used for comparison with the limiting values. This also applies if six to nine results are available. If ten or more results are available, the mean of the highest 20% of the results shall be used for comparison with the limiting values. Except where the pipeline is to be tested in compliance with relevant part of Clause 15.8 before backfilling, the completion of the bedding, haunching and surrounding of the pipes is to be carried out immediately after jointing. The bed, haunch and surround shall be brought up equally on both sides of the pipe ensuring that it is in contact with the underside of the pipe barrel and be carefully compacted in layers not exceeding 150mm thickness ensuring full compaction next to the trench walls. Pipes shall be maintained to line and level during the bedding, haunching and surrounding operations. Where pipelines are to be tested before being covered the bedding haunching and surrounding
308
material shall only be brought up sufficiently to support the pipeline and the joints shall be left exposed until the test is completed satisfactorily. The bedding and surround shall be installed so as to cause no damage to the pipes and fittings. 15.6.3 Jointing of Pipes Installation of the pipe and fittings, particularly, procedures for preparation and execution of jointing operations, shall be in accordance with the manufacturers instructions. Rigid joints shall mean joints made solid by caulking the sockets, or bolting together flanges integral with the pipes. Flexible joints shall mean joints made with deformable rings or gaskets held between pipe spigots and sockets, sleeves or collars. Joints in surface water drains shall be watertight joints complying with the appropriate British Standards, the manufacturers instructions and the following: (i) Rigid joints shall be used only where permitted in Sub-Clause 15.1 or as detailed on the Contract Drawings. Spigots and sockets of rigid joints may be caulked with tarred rope yarn or equivalent and the socket completely filled with 1:3 cement:sand mortar complying with Clause 15.4.28, from which lime shall be excluded; a fillet of mortar being worked around the socket extending for a length of not less than 50mm from the face of the socket. Iron pipes with open sockets shall have rigid joints caulked with lead wool or equivalent. Joints in PVC-U pipes shall not be made with plastic solvent. Flexible mechanical joints may be used with surface water pipes complying with BS 65. Joints in thermoplastics structured wall pipe shall comply with Clause 15.4.7.
(ii) (iii)
(iv)
Corrugated steel pipes of lock seam fabrication, not exceeding 900mm internal diameter, shall be joined in accordance with the manufacturers instructions. Bolted segmental plate pipe arches or circular pipes, not exceeding 900mm internal diameter, shall be joined in accordance with sub-Clause 15.3.3 (iv) and the manufacturers instructions. Where a concrete bed, cradle, arch or surround is used with rigid pipes having flexible joints, joint filler board complying with Clause 15.4.25 shall be placed in contact with the end of the socket at a pipe joint and shall extend through the full thickness of the concrete in contact with the pipe. Such joints in the concrete bed, haunch or surround shall be at intervals not exceeding 5 metres except where the spacing of joints in the pipe exceeds 5 metres when they shall be at each pipe joint. Joints in pipes for filter drains shall comply with the appropriate British Standard and with the following:
309
(i)
Non-porous and imperforated concrete and clay pipes with spigot and socket, rebated or ogee joints shall be laid with unsealed joints and with a gap of 10mm between the end of the pipe and the inner end of the socket or rebate. The pipes shall be supported with tarred rope yarn or equivalent flexible jointing material within the sockets over the lower third of the circumference so that there are no vertical steps between one pipe and another. Such pipes shall only be used with Type E filter material as described in Clause 15.4.11. The ends of perforated or porous concrete pipes with rebated joints and perforated clayware pipes with rebated or with flexible sleeve joints shall be pushed tightly together. Perforated or slotted thermoplastics pipes with spigots and sockets or sleeves may have dry-joints watertight joints as described in this SubClause. Other perforated pipes shall be jointed as imperforated pipes of the same material.
(ii)
(iii)
(iv)
Flexible joint couplings and flange adaptors shall be installed in accordance with the manufacturers recommendations, a copy of which shall be supplied to the Engineer prior to this area of Work commencing. On completion of assembling a bolted joint that will be buried, the joint assembly shall be wrapped with petrolatum tape. Prior to wrapping the joint, a mouldable mastic shall be applied to cover all nuts, bolt threads, bolt heads and flanges so as to cover all irregularities, thus providing a smooth contoured surface for application of the tape. The petrolatum tape and mastic shall be of proprietary manufacture as produced by a single manufacturer and shall be compatible with each other. 15.6.4 Backfilling of Trenches Backfilling shall be undertaken immediately after the required operations preceding it have been completed. Except where otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings, trenches other than filter drain trenches shall be backfilled above the pipe surround material described in Clause 15.6.2, with selected fill material complying with Clause 15.4.12. Material for backfilling trenches and filter drains shall not be deposited within 500mm, or any other distances described in Sub-Clause 15.1 or as detailed on the Contract Drawings, of concrete, bound materials, other cementitious materials or stabilised capping forming part of the Permanent Works if, when tested in accordance with TRL Report 447 either: (i) the water-soluble sulphate (WS) content exceeds 1500 mg of sulphate (as SO4) per litre (Test No.1); or
310
(ii)
the oxidisable sulphides (OS) content exceeds 0.3% of sulphate (as SO4) (Test No.2 and Test No.4); or the total potential sulphate (TPS) content exceeds 0.6% of sulphate (as SO4) (Test No.4).
(iii)
At least five samples of each material shall be tested for WS, OS and TPS. The mean of the highest two values shall be used for comparison with the limiting values. This also applies if six to nine results are available. If ten or more results are available, the mean of the highest 20% of the results shall be used for comparison with the limiting values. Material for backfilling trenches and filter drains shall not be deposited within 500mm, or any other distances described in Sub-Clause 15.1 or as detailed on the Contract Drawings, of metallic items forming part of the Permanent Works if, when tested in accordance with TRL Report 447 either: (i) the water-soluble sulphate (WS) content exceeds 300 mg of sulphate (as SO4) per litre (Test No.1); or the oxidisable sulphides (OS) content exceeds 0.06% of sulphate (as SO4) (Test No.2 and Test No.4).
(ii)
At least five samples of each material shall be tested for WS and OS. The mean of the highest two values shall be used for comparison with the limiting values. This also applies if six to nine results are available. If ten or more results are available, the mean of the highest 20% of the results shall be used for comparison with the limiting values. Material shall be deposited in even layers and shall not be heaped in the trench before being spread. Spreading and compaction shall be carried out evenly without dislodging, distorting or damaging the pipe. Power rammers shall not be used within 300mm of any part of the pipe or joint. Except in carriageways, other paved areas and locations described in Sub-Clause 15.1 or as detailed on the Contract Drawings, backfill of trenches shall be brought up to ground level. Where topsoil is at the surface on the line of the trench the upper section of the backfill shall be topsoil of the thickness described in Sub-Clause 15.1 or as detailed on the Contract Drawings, or of the same thickness and quality of topsoil as the surrounding ground where no thickness is specified. For trenches in carriageways or other paved areas the backfill shall be brought up to formation level, or sub-formation level where capping is required, unless a lower level is described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Sheeting and other excavation supports shall be removed as the filling proceeds unless otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Backfill shall be installed so as to cause no damage to the pipes and fittings. The Contractor shall carry out compaction in compliance with this Clause using the plant selected from Table 15.21, as soon as practicable after deposition of the fill material.
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Earthmoving plant shall not be accepted as compaction equipment nor shall the use of a lighter category of plant to provide any preliminary compaction to assist the use of heavier plant be taken into account when assessing the amount of compaction required for any layer. For the purposes of Table 15.21 the following shall apply: (i) The compaction plant in Table 15.21 is categorised in terms of static mass. The mass per metre width of roll is the total mass on the roll divided by the total roll width. Where a smooth wheeled roller has more than one axle the category of the machine shall be determined on the basis of the axle giving the highest value of mass per metre width. A deadweight tamping roller is a machine with a roll or rolls from which feet project and where the projected end area of each foot exceeds 0.01 m and the sum of the areas of the feet exceeds 15% of the area of the cylinder swept by the ends of the feet. The requirements for tamping rollers apply to machines that have 2 rolls in tandem. If only one tamping roll traverses each point on the surface of the layer on any one pass of the machine, the minimum number of passes shall be twice the number given in Table 15.21 plus any further doubling required to satisfy (i) above. A vibratory tamping roller, which may be self-propelled or towed, is a machine having a means of applying mechanical vibration to one or more rolls. The roll or rolls have projecting feet where the height of each foot exceeds 10% of the radius of the roll drum, the projected end area of each foot exceeds 0.1% of the roll drum surface area, and the sum of the areas of the feet exceeds 10% of the area of the cylinder swept by the ends of the feet. The requirements for the operation of vibratory tamping rollers shall be the same as those stated for vibratory rollers in sub-Clause (v) below except that vibratory tamping rollers operating without vibration will be classified as deadweight tamping rollers. Vibratory rollers are self-propelled or towed smooth-wheeled rollers having means of applying mechanical vibration to one or more rolls except that vibratory rollers. Vibratory rollers operating without vibration will be classified as smooth-wheeled rollers. The requirements for vibratory rollers are based on the use of the lowest gear on a self-propelled machine with mechanical transmission and a speed of 1.5 to 2.5 km/h for a towed machine, or a selfpropelled machine with hydrostatic transmission. If higher gears or speeds are used an increased number of passes shall be provided in proportion to the increase in speed of travel. Where the mechanical vibration is applied to two rolls in tandem, the minimum number of passes shall be half the number given in Table 15.21 for the appropriate mass per metre width of one vibrating roll but if one roll differs in mass per metre width from the other the number of passes shall be calculated as for the roll with the smallest value. Alternatively the minimum number of passes may be determined by treating the machine as having a single vibrating roll with a mass per metre width equal to that of the roll with the higher value. Vibratory rollers shall be operated with their vibratory mechanism operating only at the frequency of vibration recommended by the manufacturers. Where more than one
(ii)
(iii)
(iv)
amplitude setting is available and/or a range of frequencies is recommended, the machine shall be operated at the maximum amplitude setting and at the maximum recommended frequency for that setting. Vibratory rollers shall be equipped or provided with devices indicating the frequency at which the mechanism is operating and the speed of travel. Both devices shall be capable of being read by an inspector alongside the machine. (v) Vibrating-plate compactors are machines having a base-plate to which is attached a source of vibration consisting of one or two eccentrically weighted shafts and: (a) the mass per square metre of the baseplate of a vibrating-plate compactor is calculated by dividing the total mass of the machine in its working condition by its area in contact with compacted material; (b) vibrating-plate compactors shall be operated at the frequency of vibration recommended by the manufacturers. They shall normally be operated at travelling speeds of less than 1 km/h but if higher speeds are necessary the number of passes shall be increased in proportion to the increase in speed of travel. Vibro-tampers are machines in which an engine-driven reciprocating mechanism acts on a spring system through which oscillations are set up in a base-plate. Power rammers are machines which are actuated by explosions in an internal combustion cylinder, each explosion being controlled manually by the operator. One pass will be considered as made when the compacting shoe has made one strike on the area in question. For items marked * in the Method 3 column of Table 15.21 the roller shall be towed by track-laying tractors. Self-propelled rollers are unsuitable. Where combinations of different types or categories of plant are used, the following shall apply: (a) the depth of layer shall be that for the type of plant requiring the least depth of layer; and (b) the number of passes shall be that for the type of plant requiring the greatest number of passes.
(vi)
(vii)
(viii)
(ix)
Table 15.21: Number of passes required by compaction plant for compaction of trench fill
Acceptable Type of Compaction Plant
Category
Filter material for filter drains D N
Other Trench Backfill
N for D =110mm Unsuitable 16 8
N for D =150mm Unsuitable Unsuitable 16
Smooth wheeled roller (or vibratory roller operating without vibration)
Mass per metre width of roll: over 2,100 kg up to 2,700 kg over 2,700 kg up to 5,400 kg over 5,4000kg
313
125 10* 125 8* Unsuitable
Acceptable Type of Compaction Plant
Category
Filter material for filter drains D N
Other Trench Backfill
N for D =110mm
N for D =150mm
Deadweight Tamping Roller
Mass per metre width of roll: over 4,000kg up to 6,000kg 225 4 12 20 over 6,000kg 225 3 8 12 Vibratory Tamping Mass per metre width of a Roller vibrating roll: over 700 kg up to 1,300 kg 150 12 Unsuitable Unsuitable over 1,300 kg up to 1,800 kg 175 12* 12 Unsuitable over 1,800 kg up to 2,300 kg 200 12* 8 12 over 2,300 kg up to 2,900 kg 225 12* 6 10 over 3,600 kg up to 4,300 kg 225 12* 6 10 over 2,900 kg up to 3,600 kg 225 12* 4 8 over 4,300 kg up to 5,000 kg 225 9* 3 7 over 5,000 kg 225 7* 3 6 Vibratory Roller Mass per metre width of a vibrating roll: over 270 kg up to 450 kg 150 16 Unsuitable Unsuitable over 450 kg up to 700 kg 150 12 Unsuitable Unsuitable over 700 kg up to 1,300 kg 150 6 16 Unsuitable over 1,300 kg up to 1,800 kg 200 10* 6 16 over 1,800 kg up to 2,300 kg 225 12* 4 6 over 2,300 kg up to 2,900 kg 225 10* 3 5 over 2,900 kg up to 3,600 kg 225 8* 3 5 over 3,600 kg up to 4,300 kg 225 8* 2 4 over 4,300 kg up to 5,000 kg 225 6* 2 4 over 5,000 kg 225 4* 2 3 Vibrating Plate Mass per m of base plate: Compactor over 880 kg up to 1,100 kg 75 6 Unsuitable Unsuitable over 1,100 kg up to 1,200 kg 100 6 Unsuitable Unsuitable over 1,200 kg up to 1,400 kg 150 6 Unsuitable Unsuitable over 1,400 kg up to 1,800 kg 150 4 8 Unsuitable over 1,800 kg up to 2,100 kg 200 4 5 8 over 2,100 kg 225 4 3 6 Vibro Tamper Mass: over 50 kg up to 65 kg 150 3 4 8 over 65 kg up to 75 kg 200 3 3 6 over 75 kg up to 100 kg 225 3 2 4 over 100 kg 225 3 2 4 Power Rammer Mass: over 100 kg up to 500 kg Unsuitable 5 8 over 500 kg Unsuitable 5 8 D - is the maximum depth of the compacted layer. N - is the minimum number of times that each point on the surface of the layer being compacted shall be traversed by the item of compaction plant in its operating mode, or struck by power rammers or falling weight compactors.
15.6.5
Connecting to Existing Drains, Chambers and Channels Where described in Sub-Clause 15.1 or as detailed on the Contract Drawings, existing drains shall be extended, connected and jointed to new drains, chambers or channels. All such connections shall be made during the construction of the new drain or other work and their positions recorded by the Contractor who shall hand to the Employers Representative a copy of the record of the connections made the previous day. Where pipe connections are made to existing brick, concrete or stone drains, chambers or channels, the pipes shall be well and tightly built into the concrete, brick or masonry work and be so placed as to discharge at an angle not greater than 60 to the direction of flow of the drain or channel and with the end of the pipe carefully cut to the necessary angle. Where the connections are between pipe drains, special connecting pipes shall be laid and jointed as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Before entering or breaking into an existing sewer or drain, the Contractor shall give notice of his intention to do so to both the Engineer and the authority responsible for the pipeline to which the connection is to be made. Existing drains no longer required shall, as required by Sub-Clause 15.1 or as detailed on the Contract Drawings, be sealed with ST2 concrete, in compliance to Sub-Clause 15.4.14, or removed and replaced with selected fill material complying with Clause 15.4.12 and compacted in compliance with this Clause or grouted with a 1:10, cement: pfa mix. The grout shall use the minimum quantity of water to ensure the fluidity necessary to render it capable of being pumped to the ends of the pipe. It shall be used within one hour of mixing but when the mix contains a retarding admixture this time may be extended in accordance with the manufacturers instructions. The cement shall comply with 2254HBS EN 197-1 and the pulverised fuel ash (pfa) with 2221HBS 3892-2, fineness to Zone B and sulphate content not exceeding 1.5%.
15.6.6
Chambers Chambers shall include manholes, catchpits, inspection chambers and walled soakaways. Chambers shall be of the type specified in Sub-Clause 15.1 or as detailed on the Contract Drawings, and constructed in accordance with drawings as appropriate to the type of chamber. All ST concrete referred to in this Sub-Clause shall comply with Sub-Clause 15.4.14, unless otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Foundations to chambers shall be of ST4 concrete. Channels for chambers shall be formed and finished smooth in the foundation concrete or constructed of preformed half circle channels, with sides benched in ST4 concrete, or 1:3 cement: sand mortar complying with Clause 15.4.28, from which lime shall be excluded. Alternatively for inspection chambers not exceeding 1.3 metres in depth to invert, complete plastics units or other units in equivalent material surrounded by 150mm of ST4 concrete may be used. Brickwork shall comply with Clause 15.6.8. The ends of all pipes shall be neatly built into the brickwork and finished flush with 1:0 to :3 cement: lime: sand mortar.
315
Cast in-situ concrete chambers shall be constructed of ST4 concrete complying with Clause 15.4.14 and the particular requirements described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Corrugated galvanized steel chambers shall comply with Clause 15.4.2 with in situ ST4 concrete inverts and pre-cast concrete cover slabs complying with 2235HBS 5911-3 and BS EN 1917 and the particular requirements described in Sub-Clause 15.1 or as detailed on the Contract Drawings. They shall be surrounded with well graded granular material complying with Clause 15.4.9 compacted in accordance with Clause 15.6.4. Where the depth of invert of chambers, excluding inspection chambers, exceeds 900mm below the finished surface of the carriageway or the adjacent ground, manhole steps complying with BS EN 13101 shall be built in, in accordance with Sub-Clause 15.1 or as detailed on the Contract Drawings. Steelwork used for ladders, handholds and other fittings shall comply with 2190HBS 970-1 and be galvanized in compliance with SubClauses 15.3.4, 5 and 6 after fabrication. Threaded components shall be galvanized in compliance with Sub-Clauses 15.3.4, 5 and 64, 5 and 6. Excavation around chambers, except corrugated galvanized steel chambers, shall be backfilled with selected fill material as described in Clause 15.4.12 and compacted in compliance with Clause 15.6.4. Where mechanical compaction is impracticable, the excavation shall be backfilled with ST2 concrete. Where there are precast concrete access shafts to precast concrete chambers, the shafts shall be surrounded by a minimum thickness of 150mm of ST4 concrete, and the remaining excavation backfilled with selected fill material as described in Clause 15.4.12 compacted in compliance with Clause 15.6.4. Chambers shall be tested for watertightness as and where required in Sub-Clause 15.1 or as detailed on the Contract Drawings. Frames for chamber covers and gratings shall be set in 1:0 to :3 cement: lime: sand mortar complying with Clause 15.4.28 or a proprietary quick setting mortar of equivalent strength. For all pipelines except those constructed with corrugated pipes the nearest joint to any chamber shall be not more than 500mm from the inner face of the wall and shall not be restricted by any concrete. Between this and the next joint, the length of the articulated pipe shall be in accordance with Table 15.22.
Table 15.22: Length of Articulated Pipe
Nominal Pipe Diameter (mm) 450 and less Greater than 450
Length of Pipe (mm) 500 to 750 750 to 1000
Where the adjustment or replacement of existing frames and covers or gratings is required, the units shall be taken up and re-fixed or removed and replaced with new units complying with Clause 15.4.16, or as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. On taking up or removal of the unit, any concrete or mortar bedding shall be broken out and the surface prepared. Where existing frames and covers or gratings are to be adjusted, the Contractor shall take up the unit and clean it
for re-use. The adjusted or replaced units shall be laid on a 1:0 to :3 cement: lime: sand mortar complying with Clause 15.4.28. The finished thickness of the mortar bed shall be between 10mm and25 mm. Where required in Sub-Clause 15.1 or as detailed on the Contract Drawings, covers and gratings shall be bedded using a proprietary quick setting high strength mortar. Details of such mortar shall be to the approval of the Engineer. Unless otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings, adjusted or replaced frames and covers or gratings shall be set flush with the new surface. Any additional adjustments shall be by modifying the brickwork, which shall comply with the relevant part of this Sub-Clause, or by using a frame of a suitable depth. On completion of the works, each cover shall be lifted and the frame and seating cleaned. 15.6.7 Gullies and Pipe Junctions Gullies shall be constructed in accordance with the drawings. All ST concrete referred to in this Sub-Clause shall comply with Sub-Clause 15.4.14 unless otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings. Gullies shall be constructed so that no part of the spout or trap has a cross-sectional area less than 2/3rd that of the outlet. The depth of water seal in trapped gullies shall be not less than 50 mm. In situ concrete gullies shall be as described in Sub-Clause 15.1 or as detailed on the Contract Drawings and constructed of ST4 concrete of 150 mm minimum thickness, using permanent or removable shuttering. Where in situ concrete gullies are formed with permanent shuttering, such shuttering shall have a current British Board of Agrment Roads and Bridges Certificate. Frames for gully gratings shall be set in 1:0 to :3 cement: lime: sand mortar complying with Sub-Clause 15.4.28 or a proprietary quick setting mortar of equivalent strength. Brickwork shall comply with Sub-Clause 15.6.8. Backfilling to precast gullies shall be carried out up to sub-formation level with selected fill material, as described in Sub-Clause 15.4.12 compacted in compliance with SubClause 15.6.4. Where mechanical compaction is impracticable, the backfilling shall be in ST2 concrete. The remainder of the backfilling shall be in appropriate capping and road pavement materials except that where mechanical compaction of capping or unbound mixture for sub-base is impracticable ST2 concrete shall be used. Gully connection pipes shall be either flexible or rigid not exceeding 0.7 m in length with flexible joints for a distance of 2 m from the gully and shall be in accordance with the relevant part of Sub-Clause 15.6.6 when entering chambers. Junction pipes shall be manufactured of the same type and class of material as the remainder of the pipes in the run. Junction pipes which are laid but not immediately connected, shall be fitted with temporary stoppers or seals and the position of all such junctions shall be clearly defined by means of stakes or tracing wires properly marked or labelled.
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Saddles may be used to form junctions only where permitted in Sub-Clause 15.1 or as detailed on the Contract Drawings. No internal projections greater than 5 mm will be permitted. Saddles for plastics pipes shall be installed in accordance with the manufacturers recommendations. Saddles with clay pipes shall be jointed with 1:3 cement:sand mortar complying with Clause 15.4.28, from which lime shall be excluded. Saddles and pipes shall be surrounded with ST2 concrete. Where the adjustment or replacement of existing frames and gratings is required, the units shall be taken up and re-fixed or removed and replaced with new units complying with Clause 15.4.18, or as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. On taking up or removal of the unit, any concrete or mortar bedding shall be broken out and the surface prepared. Where existing frames and covers or gratings are to be adjusted, the Contractor shall take up the unit and clean it for re-use. The adjusted or replaced units shall be laid at a level, unless otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings, 6 mm below the adjoining road surface on a 1:0 to :3 cement: lime: sand mortar complying with Clause 15.4.28. The finished thickness of the mortar bed shall be between 10 mm and 25 mm. Where required in Sub-Clause 15.1 or as detailed on the Contract Drawings, covers and gratings shall be bedded using a proprietary quick setting high strength mortar. Details of such mortar shall be to the approval of the Engineer. Any additional adjustments shall be by modifying the brickwork, which shall comply with the relevant part of this Clause, or by using a frame of a suitable depth. On completion of the works, each cover shall be lifted and the frame and seating cleaned. 15.6.8 Brickwork Brickwork shall be laid on a full bed of 1:0 to :3 cement: lime: sand mortar complying with Clause 15.4.28 in English bond. Perpends between bricks shall be filled with mortar before the next mortar bed is laid. Whole bricks and blocks shall be used except where it is necessary to cut closers. Brickwork shall be built uniformly. Corners and other advanced work shall be stepped back and not raised above the general level more than 900 mm. Courses shall be kept horizontal and matching, with perpends in vertical alignment. Overhand work shall not be permitted. Bed-joint reinforcement shall have a 15 mm minimum of mortar cover to each masonry face. It shall not be laid dry on a bed face, but shall be embedded within the mortar bed thickness. Mortar in joints shall be struck flush with the face of the brickwork. 15.6.9 Land Drains Existing land drains which are permanently severed by the Works shall be located and connected into a new drain, pipe or ditch all as described in Sub-Clause 15.1 or as detailed on the Contract Drawings. The lengths remaining within the Works shall be cleaned out from the new drain trench face as necessary. Any pipe disturbed by the Works shall be re-laid to ensure a free discharge into the new drain. Disused ends of
intercepted land drains shall be adequately sealed with ST2 concrete in compliance with Clause 15.4.14. Where an existing land drain is exposed and severed by temporary trench excavation, the Contractor shall mark the position of the drain and record it. The drain shall be diverted into an existing drain or watercourse. Alternatively, the normal functioning of the drain shall be continued by the construction of a pipeline or channel adequately supported across the excavation, until permanent restoration is made on the original line. The Contractor shall notify the Engineer of any land drain which is blocked or is otherwise defective when the drain is first exposed. Severed mole drains shall be led straight into new drains; alternatively they shall where required in Sub-Clause 15.1 or as detailed on the Contract Drawings be intercepted by the construction of a land drain. Where they have been disturbed mole channels shall be cleaned out and filled locally with Type D filter material or as otherwise described in Sub-Clause 15.1 or as detailed on the Contract Drawings. 15.6.10 Combined Drainage and Kerb Systems Combined drainage and kerb systems listed in Sub-Clause 15.1 or as detailed on the Contract Drawings and complying with Clause 15.4.27 shall be laid and jointed in accordance with the manufacturers written instructions. Bedding, backing, surrounding or jointing of combined drainage and kerb units adjacent to carriageway, footway, verge or central reserve shall be in accordance with the manufacturers written instructions. Junctions, connecting pipes and other fittings comprising the combined drainage and kerb system shall comply with sub-Clause 15.4.1 and shall be as described in SubClause 15.1 or as detailed on the Contract Drawings. The combined drainage and kerb system shall incorporate measures to enable rodding of the outfall pipework and adequate access for jetting by water jetting equipment into the system.
15.7
15.7.1
Cleaning
Cleaning During the progress of the Works all existing chambers, gullies and rodding eyes shall be kept clean and free from obstruction. On completion of the whole of the Works, all chambers, gullies and drains including verge/surface water drains and filter drains shall be flushed from end to end with water and left free from obstructions. Catchpit chambers shall be left clean and free from silt. The pipes and filter material of filter drains shall at all times be left clean and free from silt and obstruction. Combined drainage and kerb systems shall be cleaned out by appropriate means and shall be left clean and free from all obstruction.
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15.7.2
Cleaning: Existing Drainage Systems Where stated in Sub-Clause 15.1 or as detailed on the Contract Drawings, the Contractor shall clean existing drainage systems in accordance with this Clause. The Contractor shall take measures when clearing blocked drains to ensure that adjacent water courses or groundwater via soakaways, will not be contaminated. Contamination includes mud or soil being washed or flushed into streams as well as other more obvious contaminants including diesel fuel, oil and chemicals. Initial attempts to clear blocked drains prior to jetting, shall be undertaken by hand rodding and any debris and silt removed by the operation shall be removed off Site. The Contractor shall report any localised blockages that cannot be cleared by rodding to the Engineer. Where jetting is required in Sub-Clause 15.1 or as detailed on the Contract Drawings the procedures stated in sub-clause 15.7.6 shall be followed.
15.7.3
Cleaning: Gullies, Catchpits, Soakaways and Oil Separators At each chamber all mud and vegetation in the vicinity of the chamber likely to impede the flow of water shall be removed. After lifting the cover or grating the chamber shall be cleansed of all water, detritus, debris and silt, refilled with clean water to the outlet level, and all covers and gratings replaced and evenly bedded. Cleaning of chambers shall be by mechanical means. The vehicle used to clean existing chambers shall be equipped with a 125 mm diameter gulley arm with boom jets, an exhauster with a minimum output of 5.95 m/min and minimum 5,455 litres capacity. Sediment, detritus and liquor from the chamber shall not be permitted to discharge into the outlet. This may be achieved either by plugging the outlet during cleaning, or by simultaneous jetting and abstraction of liquor from the chamber using a tanker fitted with low pressure high volume water jets around the boom. Gullies and chambers not cleaned for whatever reason, blocked connections and broken or cracked covers, gratings or frames shall be marked to aid subsequent identification. Oil separators shall be refilled with uncontaminated water following the cleaning operation. The Contractor shall dispose of all surplus water, debris and arisings from the works off Site at a licensed tip.
15.7.4
Cleaning or Testing of Piped Drainage Systems Routine cleaning or testing of piped drainage systems and subway drainage channels shall be carried out by rodding or low pressure high volume jetting in accordance with sub-clause 15.7.6. The location of any obstruction that cannot be removed by flushing shall be marked on the ground using a wooden peg or other semi-permanent means and reported to the Engineer.
All covers which have been removed for cleaning operations shall be replaced and evenly bedded. The Contractor shall report any damage and defects to the drainage system or components to the Engineer each day, or immediately if considered a safety hazard. 15.7.5 Cleaning Kerb or Channel Offlet Pipes Where necessary all vegetation and debris shall be removed from around metal kerb weirs and the cover lifted for cleaning. Offlets shall be cleaned such that all silt and loose obstructions are removed from the pipe. This shall be achieved by rodding or by using lorry-mounted drain clearance equipment comprising combination pressure jetting with high air flow suction equipment. The vehicle shall also be equipped with a hydraulically powered grid lifter. The Contractor shall ensure that each end of the offlet is free from vegetation or other obstructions including any material expelled from the pipe. Where the invert of the outlet is below the invert of the ditch, the bottom of the ditch shall be excavated until the invert of the pipe is exposed and the ditch invert regraded to facilitate flow from the outlet. The location of any obstruction that cannot be removed shall be marked on the ground using a wooden peg or other semi-permanent means and reported to the Engineer. All covers lifted for cleaning operations shall be replaced and evenly bedded. 15.7.6 General Where stated in Sub-Clause 15.1 or as detailed on the Contract Drawings, the Contractor shall clean existing drainage systems in accordance with this Clause. The drainage systems to be cleaned shall be as detailed in Sub-Clause 15.1 or as detailed on the Contract Drawings. The pipe material of the drainage systems to be cleaned shall be identified in SubClause 15.1 or as detailed on the Contract Drawings. Where the material is unknown and cannot be verified by either visual inspection, without recourse to man-entry, or from drainage records, or damage to the pipeline is the suspected cause of a blockage, cleaning shall proceed on the basis of use of the lowest pump pressure stated in Table 15.23. Where the cleaning forms part of the pre-cleansing works for the CCTV survey of drainage systems, the works shall be detailed in Sub-Clause 15.1 or as detailed on the Contract Drawings. Low Pressure High Volume Jetting of Drainage Systems
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Jetting of Piped Drainage Systems Cleaning shall take place from downstream of the blockage in an upstream direction. The pipe shall be plugged below the jetting point to prevent contaminants flowing to the watercourse. The cleaning shall take place from a chamber, although it may be necessary to make a temporary excavation into the pipeline in some circumstances. Should the Contractor find that it is not possible to jet in an upstream direction, then the pipe shall be plugged below the blockage and the jetter then used to back jet to a suction hose.
Table 15.23: Maximum Recommended Pump Pressures
Material Unknown/structurally damaged Brick/masonry Plastics - Structural Wall Plastics - Solid Wall Concrete Clay
Maximum pump pressure (bar/psi) 80/1200 100/1500 127/1900 127/1900 340/5000 340/5000
The Contractor shall select a jet head that is appropriate for delivering the maximum jetting pressure for the pipe material and also the minimum volume of water for the appropriate pipe diameter stated in Table 15.24.
Table 15.24: Minimum Jetting Flow Rates
Pipe Diameter < 230 mm 231mm < 450 mm 451mm < 900 mm 901mm < 1600 mm
Minimum jetting flows 156 l/m 270 l/m 300 l/m 342 l/m
The jet head shall be of a configuration such that the number and direction of jets are adequate to be directed to the sides and soffit of the pipeline to prevent debris passing over the top of the jetting head. The Contractor shall provide suitable jetting equipment that shall include the provision of the following: (i) (ii) operation at a maximum rate of 850 l/min at 150 bar/2250 psi; liquid ring vacuum pump operating with air flows of 4000 m per hour, with a working vacuum of not less than 90%; a minimum of 20 m of 100 mm diameter suction hose for cleaning pipes up to 300 mm diameter and 150 mm diameter suction hose for cleaning pipes of diameter greater than 300 mm;
(iii)
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(iv)
minimum of 150 m of 25 mm or 38 mm diameter jetting hose and a capability of jetting up to 200 m; automatic and continuous water recycling; silt, sand and rubble to be de-watered prior to discharge at licensed tip.
(v) (vi)
The Contractor shall ensure that no damage occurs to the manhole chamber or pipeline during insertion of the jetting equipment. The jetting head shall be propelled through or over the blockage and then the hose pulled backwards enabling the force of the jet to break up the blockage material. The minimum force necessary to penetrate the blockage shall be used but the pump pressures should not exceed those stated in Table 15.23. The hose shall be rewound at a rate of between 100 mm and 200 mm per second. There is a possibility that damage may occur to certain pipe materials should the jetting head remain stationary thus the Contractor must ensure that the jetting head never remains stationary for more than 60 seconds. Perforated pipes and porous concrete pipes commonly occur in piped highway drainage systems. Where their presence is discovered during the course of the works, the Engineer shall be notified immediately and the cleaning operation suspended for that section of the works. Silt Removal Suitable measures such as stanks or stoppers shall be positioned downstream of the drainage system to be cleaned to minimise the risk of sediment causing contamination of watercourses or soakaways. Wherever practical the Contractor shall use equipment to carry debris over a greater depth than one atmosphere and with a capability to suck liquid. All arisings from the cleaning process shall be disposed of in an environmentally sensitive manner in accordance with current legislation. Health and Safety The use of high pressure water can result in serious internal injuries that may not be apparent at the skin surface. The Contractor shall ensure that all hoses are free from damage and that the equipment is in full working order. Where overhead electric cables are present, there is a potential danger from accidental strike by a jet of water.
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15.8
15.8.1
Testing
Testing General Drains required in Sub-Clause 15.1 or as detailed on the Contract Drawings to have watertight joints shall be tested in sections, e.g. between chambers, by means of the air test described in this Clause. If a pipeline is rejected because of a failed air test, as part of the rectification work, a water test as described below may be carried out as an alternative acceptability test. Before testing, the ends of the pipeline to be tested, including those of short branches, shall be plugged and sealed.
15.8.2
Air Test For the pipeline air test, air shall be pumped in by suitable means until a stable pressure of 100 mm head of water is indicated in a U-tube connected to the system. The air pressure shall not fall to less than 75 mm head of water during a period of 5 minutes without further pumping, after an initial period to allow stabilization. Drains with traps shall be tested to 50 mm head of water and the permissible loss shall then be no more than 13 mm head of water in 5 minutes without further pumping after the initial stabilising period.
15.8.3
Water Test For the pipeline water test, the pipes shall be filled with water under a head of not less than 1.2 m above the crown of the pipe at the high end and not more than 6 m above the pipe at the low end. Steeply graded pipelines shall be tested in sections so that the above maximum is not exceeded. The test shall commence not less than two hours after filling the test section at which time the level of water at the vertical feed pipe shall be made up to produce the required 1.2 m minimum test head. The loss of water over a 30 minute period shall be measured by adding water at regular 10 minute intervals to restore the original water level and recording the amounts so added. The drain will have passed the test if the volume of water added does not exceed one litre per hour per linear metre of drain per metre of nominal internal diameter.
15.8.4
Testing Pipe Profile All pipelines less than 350 mm diameter, shall be checked by drawing through each completed length of pipe a spherical mandrel of a diameter 10% less than the nominal bore of the pipes being tested.
15.8.5
Permeability Testing The permeability rate of the filter drain backfill material shall be determined using the test procedure described in: Highways and Traffic Departmental Advice Note HA 41/90 A Permeameter for Road Drainage Layers; from the Department of Transport for the United Kingdom.
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15.8.6
Testing for Constituent Materials in Recycled Aggregate and Recycled Concrete Aggregate
Scope This Clause specifies the basic procedure and test methods for the examination of recycled aggregate and recycled concrete aggregate for the purpose of identifying and quantifying constituent materials. Quality Control Procedure The quality control procedure shall be in accordance with the Quality Protocol for the Production of Aggregates published by Waste and Resources Action Programme (WRAP). The results of all quality control checks carried out by the Contractor shall be compiled in accordance with the procedure set down in the above document and with those in this Sub-Clause 15.7.6. These shall be delivered promptly to the Overseeing Organisation on request. Test Principle The method requires the visual recognition and quantification of the constituents of a sample of a recycled aggregate. This work shall be carried out by a suitably trained laboratory technician who has demonstrated his competence to classify the constituents in the sample in accordance with this Sub-Clause 15.7.6. This shall be achieved by hand-sorting particles from a test sample of aggregate and visually assessing into the following component parts: (i) (ii) (iii) (iv) (v) asphalt (Class A); masonry (brick & block, other than lightweight block masonry) (Class B); concrete and concrete products (Class C); glass (Class G); lightweight block masonry and other particles with a particle density less than 1000 kg/m (Class L); normal weight unbound aggregate (Class U); other materials such as metal, clay lumps, plastics, wood etc (Class X).
(vi) (vii)
The mass of each of these groups shall be determined in accordance with sub-Clause 15.9.6.6 of this Clause. It shall then be expressed as a percentage of the total mass of the test portion as specified in sub-Clause 15.9.6.7. Apparatus The following apparatus shall be used:
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(i)
Oven, thermostatically controlled to maintain a temperature of 40C within a tolerance of 5C; Balance, of adequate capacity readable and accurate to 0.1% of the total mass to be weighed; Test sieves, 63 mm and 8 mm size with apertures as specified in 2285HBS EN 933-2.
(ii)
(iii)
Sampling The sample shall be taken in accordance with the procedures described in 2281HBS EN 932-1 and the sample shall be reduced in accordance with the procedures specified in 2283HBS EN 932-2. To assist the visual examination of particles, it may be beneficial to wash the sample before drying. The sample shall be dried at a temperature of 40C within a tolerance of 5C until it has constant mass. The entire sample shall then be thoroughly sieved on the 63 mm sieve specified in Sub-Clause 15.9.6.4 in order to remove oversize fractions. All particles retained on the 63 mm sieve shall be discarded. The sample shall then be further reduced in accordance with 2283HBS EN 932-2 to produce duplicate test portions. Both test portions shall then be thoroughly sieved on the 8 mm sieve in order to remove undersize fractions. All particles passing the 8 mm sieve shall be discarded. The mass of each sieved test portion (8/63 mm size) shall be recorded as Mtotal. Both remaining duplicate portions are to be tested. Each of these portions shall consist of not less than 500 particles. The mass required to provide 500 particles is dependent on the particle size distribution and the particle density of the aggregate. Table 15.25 provides guidance on the mass that is likely to be required to give 500 particles.
Table 15.25 Minimum Mass of Each Test
Upper aggregate size D Portion mm 63 40 31.5 20 16 14
Test portion mass (minima) (kg) 50 15 8 2 2 1
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6. Test Procedure The particles of the test portion shall be spread onto a flat surface and separated by hand into the following groups:
asphalt (Class A); masonry (Class B); concrete and concrete products (Class C); glass (Class G); lightweight particles (Class L); unbound aggregate (Class U); other particles (Class X).
Each group shall be weighed and the respective masses recorded as: MA (Class A) MB (Class B) MC (Class C) MG (Class G) ML (Class L) MU (Class U) MX (Class X)
If the sum of the masses in each class differs by more than 1% from the total mass of the sieved test portion, Mtotal, the test shall be repeated. Repeat the procedure using the duplicate test portion. Calculation and Expression of Results The percentage by mass P of particles in each group shall be calculated from the following equation: Psubscript = Msubscript x 100/Mtotal Report the results as the mean of the values obtained from the two test portions. Record the values to the nearest 0.1% for other particles (Class X) and to the nearest whole number for all other classes.
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Test Report The test report shall include the following information: (i) (ii) (iii) (iv) (v) reference to this test method; identification of the sample; identification of the laboratory; sample reception date; a statement classifying the aggregate type, and identifying the sample as either conforming to or not conforming to the requirements of Table 2 of BS 8500-2; additional observations, comments and other sample data.
(vi)
A work sheet based on the Performa in Table 15.26 shall be used to record the test results and the calculations made from them.
Table 15.26 Results of testing for constituent materials in recycled aggregate and recycled concrete aggregate
Sample reference Date Tested by
Mass of test portion, Mtotal, Duplicate 1 Mass of test portion, Mtotal, Duplicate 2
Category
Mass Msubscript Duplicate Duplicate 1 2
Percentage Psubscript Duplicate Duplicate Mean 1 2
Asphalt (Class A) Masonry (Class B) Concrete and concrete products (Class C) Glass (Class G) Lightweight particles (Class L) Unbound aggregate (Class U) Other particles (Class X) Sum* *Sum is the total of MA + MB + MC + MG + ML + MU + MX. If Sum is not within 1% of Mtotal, repeat the test.
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15.9
Termination of Drainage Pipes for Future Expansion

Surface water drainage pipes which are laid for connection into the future expansion of the project, shall be fitted with temporary stoppers or seals and the position of all such terminations and lengths of pipe shall be clearly defined by means of marker tape, stakes or tracing wires properly marked or labelled all to the approval of the Engineer.
329
Publications Referred to in the Specification Standard AASHTO specification M36M-01 AASHTO specification M190-95(2000) AASHTO specification M274-87(2004) BS 65 Title Standard Specification for Corrugated Steel Pipe, Metallic-Coated, for Sewers and Drains Standard Specification for Bituminous Coated Corrugated Metal Culvert Pipe and Pipe Aches Steel Sheet, Aluminium-Coated (Type 2 for Corrugated Steel Pipe Specification for vitrified clay pipes, fittings and ducts, also flexible mechanical joints for use solely with surface water pipes and fittings Reference(s) Table 15.1
15.4.2.2
15.4.2.1.(ii) Table 15.1, 15.6.3.(iii)
BS 970 BS 970-1
Specification for wrought steels for mechanical and allied engineering purposes Part 1: General inspection and testing procedures and specific requirements for carbon, carbon manganese, alloy and stainless steels Part 1: General requirements and sample preparation Part 2: Classification tests 15.6.6
BS 1377 BS 1377-1 BS 1377-2
Methods of test for soils for civil engineering purposes 15.4.12 Table 15.7, Table 15.8 15.4.11(vi), 15.4.12 Table 15.12, 15.4.13.3 Table 15.8, 15.4.12 Table 15.7, Table 15.8, 15.4.12, Table 15.12 15.4.12 15.4.12
BS 1377-3 BS 1377-4
Part 3: Chemical and electro-chemical tests Part 4: Compaction-related tests
BS 1377-5 BS 1377-6
Part 5: Compressibility, permeability and durability Part 6: Consolidation and permeability tests in hydraulic cells and with pore pressure measurement Part 7: Shear strength tests (total stress) Part 8: Shear strength tests (effective stress)
BS 1377-7 BS 1377-8
15.4.12 15.4.12
330
Standard BS 1377-9 BS 1449 BS 1449-1.1
Title Part 9: In-situ tests Steel plate, sheet and strip Part 1.1: Carbon and carbon-manganese plate, sheet and strip. General specification Pulverized-fuel ash Part 2: Specification for pulverized-fuel ash for use as Type I addition Specification for sulphate-resisting Portland cement
Reference(s) 15.4.12 15.4.2.3.(i)
BS 3892 BS 3892-2 BS 4027 BS 4395 BS 4395-2 BS 4652 BS 4660
15.6.5 15.4.28.(iii)
Specification for high strength friction grip bolts and associated nuts and washers for structural engineering Part 2: Higher grade bolts and nuts and general grade washers Specification for zinc-rich priming paint (organic media) Thermoplastics ancillary fittings of nominal sizes 110 and 160 for below ground gravity drainage and sewerage Specification for plastics pipes and fittings for use as subsoil field drains Specification for unplasticized PVC pipe and fittings for gravity sewers Part 1: Specification for unreinforced and reinforced concrete pipes (including jacking pipes) and fittings with flexible joints (complementary to BS EN 1916:2002) Part 3: Specification for unreinforced and reinforced concrete manholes and soakaways (complementary to BS EN 1917:2002) Part 5: Specification for prestressed nonpressure pipes and fittings with flexible joints Part 6: Specification for road gullies and gully cover slabs 15.4.2.3.(iii) 15.4.2.5 15.4.24
BS 4962 BS 5481 BS 5911 BS 5911-1
Table 15.1, 15.4.24, 15.6.2 15.4.24
Concrete pipes and ancillary concrete products Table 15.1
BS 5911-3
15.4.15, 15.6.6
BS 5911-5
Table 15.1
BS 5911-6
15.4.17
331
Standard BS 6073 BS 6073-1 BS 7775 BS 8500 BS 8500-1
Title Precast concrete masonry units Part 1: Specification for precast concrete masonry units Specification for Penstocks Part 1: Method of specifying and guidance for the specifier Part 2: Specification for constituent materials and concrete Gully tops and manhole tops for vehicular and pedestrian areas. Design requirements, type testing, marking, quality control Cement Part 1: Composition, specification and conformity criteria for low heat common cements Concrete Part 1: Specification, performance, production and conformity Vitrified clay pipes and fittings and pipe joints for drains and sewers (Parts 1 to 7 and Part 10) Masonry cement Part 1: Composition, specifications and conformity criteria Building lime Part 1: Definitions, specifications and conformity criteria General requirements for components used in discharge pipes, drains and sewers for gravity systems Ductile iron pipes, fittings, accessories and their joints for sewerage applications Requirements and test methods Specification for masonry units Part 1: Clay masonry units
Reference(s) 15.4.19 15.4.21 15.4.14 General 15.4.14 Cement 15.4.14 Consistence 15.4.14 Cement, 15.8.6.8.(v) 15.4.16 15.4.18
Concrete. Complementary British Standard to 2257HBS EN 206-1
BS 8500-2 BS EN 124
BS EN 197 BS EN 197-1
15.4.28.(i), 15.6.5
BS EN 206 BS EN 206-1
15.4.14 General 15.4.14 Consistence Table 15.1, 15.4.17
BS EN 295
BS EN 413 BS EN 413-1 BS EN 459 BS EN 459-1 BS EN 476
15.4.28.(ii)
15.4.28 15.4.7 Dimensions
BS EN 598
Table 15.1
BS EN 771 BS EN 771-1
15.4.19
332
Standard BS EN 772 BS EN 772-1 BS EN 772-2
Title Methods of test for masonry units Part 1: Determination of compressive strength Part 2: Determination of percentage area of voids in aggregate concrete masonry units (by paper indentation) Part 5: Determination of the active soluble salts content of clay masonry units Part 7: Determination of water absorption of clay masonry damp course units by boiling in water Part 13: Determination of net and gross dry density of masonry units (except for natural stone) Separator systems for light liquids (e.g. oil and petrol) Part 1: Methods for sampling Part 2: Methods for reducing laboratory samples Part 2: Determination of particle size distribution - Test sieves, nominal size of apertures Mixing water for concrete Specification for sampling, testing and assessing the suitability of water, including water recovered from processes in the concrete industry, as mixing water for concrete Plastics piping systems. Thermoplastics piping systems for non-pressure applications. Test methods for watertightness
Reference(s) TABLE 15.18 15.4.19
BS EN 772-5
TABLE 15.18
BS EN 772-7
TABLE 15.18
BS EN 772-13
TABLE 15.18
BS EN 858 BS EN 932 BS EN 932-1 BS EN 932-2 BS EN 933 BS EN 933-2
15.4.20
Tests for general properties of aggregates 15.8.6.5 15.8.6.5
Tests for geometrical properties of aggregates 15.8.6.4. (iii)
BS EN 1008
15.4.28
BS EN 1053
Table 15.3
BS EN 1092 BS EN 1092-2 BS EN 1097 BS EN 1097-2
Flanges and their joints. Circular flanges for pipes, valves, fittings and accessories, PN designated. Part 2. Cast iron flanges Part 2: Methods for the determination of resistance to fragmentation 15.4.22.2 Table 15.8, Table 15.12
Tests for mechanical and physical properties of aggregates
333
Standard BS EN 1277
Title Plastics piping systems. Thermoplastics piping systems for buried non-pressure applications. Test methods for leaktightness of elastomeric sealing ring type joints
Reference(s) Table 15.4
BS EN 1295 BS EN 1295-1 BS EN 1401
Structural design of buried pipelines under various conditions of loading Part 1: General requirements Plastics piping systems for non-pressure underground drainage and sewerage unplasticized poly (vinyl chloride) (PVCU) Plastics piping and ducting systems. Thermoplastics pipes. Determination of resistance to external blows by the staircase method Drainage channels for vehicular and pedestrian areas. Classification, design and testing requirements, marking and evaluation of conformity Plastics piping systems. Piping systems for underground drainage and sewerage. Test method for resistance to combined temperature cycling and external loading Founding. Grey cast irons Founding. Spheroidal graphite cast iron Table 15.2 Table 15.1, 15.4.24
BS EN 1411:1996, (BS 2782-11 : Method 1108B : 1996) BS EN 1433
Table 15.2
15.4.27
BS EN 1437
Table 15.4
BS EN 1561 BS EN 1563
15.4.21.3 Materials 15.4.22.2.(i), 15.4.22.2.(ii), 15.4.22.2.(iv) 15.4.8.(i).c, Table 15.8, 15.4.11 (iv), 15.4.28.(i)
BS EN 1744 BS EN 1744-1
Tests for chemical properties of aggregates Part 1: Chemical analysis
BS EN 1852 BS EN 1852-1 BS EN 1916 BS EN 1917
Plastic piping systems for non-pressure underground drainage and sewerage - Polypropylene (PP) Part 1: Specifications for pipes, fittings and the system Concrete pipes and fittings, unreinforced, steel fibre and reinforced Concrete manholes and inspection chambers, unreinforced, steel fibre and reinforced Table 15.1, 15.4.24 Table 15.1 15.4.15, 15.6.6
334
Standard BS EN 1979
Title Plastics piping and ducting systems. Thermoplastics spirally- formed structured-wall pipes. Determination of the tensile strength of a seam Copper and copper alloys. Ingots and castings Hexagon head screws. Product grades A and B Stainless steels
BS EN 1982 BS EN ISO 4017 BS EN 10088
15.4.21.3 Materials 15.4.2.3.(iii) 15.4.21.3 Materials, 15.4.22.2.(v), 15.4.22.2.(vi) 15.4.2.1.(ii)
BS EN 10327
Continuously hot-dip coated strip and sheet of low carbon steels for cold forming. Technical delivery conditions Plastics piping systems. Thermoplastics fittings. Test method for impact resistance Copper and copper alloys. Profiles and rectangular bar for general purposes Plastic piping systems. Thermoplastic fittings. Test method for mechanical strength or flexibility of fabricated fittings Aggregates for concrete
BS EN 12061 BS EN 12167 BS EN 12256
Table 15.3 15.4.21.3 Materials, 15.4.22.2.(iii) Table 15.3
BS EN 12620 BS EN 12666 BS EN 12666-1 BS EN 13101
15.4.14 Aggregates
Plastics piping systems for non-pressure underground drainage and sewerage - Polyethylene (PE) Part 1: Specification for pipes, fittings and the system Steps for underground man entry chambers. Requirements, marking, testing and evaluation of conformity Aggregates for mortar Aggregates for unbound and hydraulically bound materials for use in civil engineering work and road construction Table 15.1, 15.4.24 15.6.6
BS EN 13139 BS EN 13242
15.4.28 15.4.8, Table 15.5, Table 15.6, 15.4.11, 15.4.11.(ii), 15.4.11 (iii), Table 15.10, 15.4.13.3, Table 15.15 15.4.11 (i) Table 15.10 15.4.13 15.4.13.2
BS EN 13285
Unbound mixtures - Specification
335
Standard BS EN 14364
Title Plastic piping systems for drainage and sewerage with or without pressure. Glass reinforced thermosetting plastics (GRP) based on unsaturated polyester resin (UP). Specifications for pipes, fittings and joints Mechanical properties of fasteners Part 2: Nuts with specified proof load values - Coarse thread
BS EN 20898 BS EN 20898-2 BS EN ISO 898 BS EN ISO 898-1 BS EN ISO 1461
15.4.2.3.(iii)
Mechanical properties of fasteners made of carbon steel and alloy steel Part 1: Bolts, screws and studs Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods 15.4.2.3.(iii) 15.4.2.4
BS EN ISO 2897 BS EN ISO 2897-1 BS EN ISO 2897-2 BS EN ISO 4014 BS EN ISO 4016 BS EN ISO 4018 BS EN ISO 4032 BS EN ISO 4034 BS EN ISO 7500 BS EN ISO 7500-1
Plastics. Impact-resistant polystyrene (PS-I) moulding and extrusion materials Part 1: Designation system and basis for specifications Part 2: Preparation of test specimens and determination of properties Hexagon head bolts. Product grades A and B Hexagon head bolts. Product grade C Hexagon head screws. Product grade C Hexagon nuts, style 1. Product grades A and B Hexagon nuts. Product grade C Table 15.2, Table 15.3 Table 15.2, Table 15.3 15.4.2.3.(iii) 15.4.16 15.4.16 15.4.2.3.(iii) 15.4.16
Metallic materials - Verification of static uniaxial testing machines Part 1: Tension/compression testing machines - Verification and calibration of the force-measuring system Thermoplastics pipes. Determination of creep ratio Thermoplastics pipes. Determination of ring stiffness Part 1: Dimensions and tolerances. Metric series
336
15.4.25
BS EN ISO 9967 BS EN ISO 9969 BS ISO 11922 BS ISO 11922-1
Table 15.2 Table 15.2
Thermoplastics pipes for the conveyance of fluids Table 15.2, Table 15.3
Standard ISO 898 ISO 898-2 BS EN ISO 8501
Title Mechanical properties of fasteners Part 2: Nuts with specified proof load values - Coarse thread Preparation of steel substrates before application of paints and related products. Visual assessment of surface cleanliness. Thermoplastics fittings -- Determination of ring stiffness Plastics piping systems for non-pressure underground drainage and sewerage Structured-wall piping systems of unplasticized poly(vinyl chloride) (PVCU), polypropylene (PP) and polyethylene (PE) Sulphate specification for structural backfills - J M Reid, M A Czerewko and J C Cripps WRc Jetting Test Method Highways and Traffic Departmental Advice Note HA 41/90 - A Permeameter for Road Drainage Layers; from the Department of Transport for the United Kingdom.
Reference(s) 15.4.2.3.(iii) 15.4.21.4.Protective Coating Table 15.3 15.4.7 Materials Table 15.2
BS EN ISO 13967 pr EN 13476
TRL Report 447
Table 15.8, 15.4.14 Aggregates, 15.4.19, 15.4.28, 15.6.2, 15.6.4 Table 15.2 15.8.5
337
16 16.1
POTABLE WATER POTABLE WATER PARTICULAR REQUIREMENTS

This section of the potable water specification contains particular requirements for the potable water works to be undertaken under the Contract. The particular requirements take precedence over the general potable water specification contained under the potable water specification Clause 14.2 onwards.
16.1.1
Description of Work The Contractor is responsible for all elements of design and installation of a Potable Water Distribution Network which is required to serve the following buildings/areas: 1. 2. 3. 4. Guardhouse Diesel Generator House Fire-fighting Pump House (refer to Fire-Fighting Specification for details) RTG Washdown & Maintenance Area
The above list is an indication of locations to be supplied. During the detailed design stage of the contract works this shall be reviewed and should it be felt necessary an agreement sought to add or delete locations served, as necessary. The feed for the potable water is to be taken from the existing distribution network which serves Terminal 1. The new distribution system shall be designed so as to be compatible with the existing system. All drinking water service pipework shall terminate within the relevant buildings/location with a water meter and isolating valve for connection to buildings services. A stop cock or isolating valve shall be installed, within a purpose constructed pit external to each building. The drinking water supply system shall interconnect with existing drinking water supply and distribution systems. At the interconnection points the Contractor shall install isolation valves. Locations for these shall be determined the Contractor on site and shall allow for adjustment of these locations to more practical points if necessary.
16.2
16.2.1
POTABLE WATER GENERAL REQUIREMENTS

Under-Ground Pipework And Fittings Underground water mains shall be manufactured in ductile iron to BS 4772, Class K9, with a cement lining and factory applied polyethylene outer sleeving. The cement lining shall be applied by the centrifugal method with sulphate resisting Portland Cement or equivalent complying with BS 4027 or ASTM C150 Type 2 and with aggregates complying with BS 882. The lining thickness shall comply with BS 4772. Pipework joints shall be push-in type with the exception of valve positions which shall be flanged with BS 4504, PN 16 flanges.
338
External ductile iron fittings not finished with the polyethylene sleeving, shall be wrapped with Denso Tape or equal to give a 55% overlap, i.e. double wrapped. Tees, flanged cross pieces, reducing spigots, double flanged spigots and other fittings shall be ductile iron manufactured to BS 4772, Class K9 with BS 4504, PN 16 flanges, being cement lined as above. External surfaces shall be coated with a bitumastic finish and wrapped as above. Fabrications and specials that may be required below ground shall be manufactured from mild steel pipework in accordance with BS 3601 with an internal cement lining in accordance with BS 534. Bolts, studs and nuts shall be in accordance with BS 4190, washers to BS 4320 and gaskets to BS 4865 with material to BS EN 681. Connections between the ductile iron spigots and flanges in the general ductile iron pipework system shall be made using Viking Johnson flanged couplings or equivalent. Concrete plinths shall be placed below all valves and similar fittings to support them adequately. In addition, all changes of direction of pipelines and blanked ends shall be provided with adequate anchor blocks to prevent movement of the mains under pressure. Additional anchor blocks shall be provided along the straight run of the pipe to prevent movement of the mains. Prior to the anchor blocks being poured, the pipework shall be wrapped and encased with two layers of polyethylene sheets to prevent scuffing of the mains. For underground pipework, trenches, bedding, surround and cover shall comply with the Specification Part 3 - Materials & Workmanship - Construction. At various locations on the site, as outlined in the particular specification, valved spurs for drinking water shall be installed. Each spur shall be provided with an anchor block. Generally this pipework shall be either:a) Up to and including 50 mm diameter, copper to BS EN 1057 Part 1 Table Y with fittings to BS EN 1254 Part 1 resistant or immune to dezincification, or gunmetal fittings. Where unions are designed so that they may be dismantled from time to time these shall be gunmetal. Or Up to and including 63 mm diameter, polyethylene pipework to BS 6572 for below ground use, coloured Blue. Copper alloy or gunmetal compression type fittings shall be used complying to BS EN 1254 Part 1, joints should comply with BS 5114 with installation in accordance with CP 312 Part 3.
b)
16.2.2
Valves and Fittings All isolating valves manufactured in cast iron shall have the external surfaces finished with a bitumastic finish for corrosion protection purposes and the internal surfaces coated with a material acceptable to the local Water Regulatory Authority. Cast iron valves shall be generally of gate type manufactured to BS 5163 with BS 4504, PN 16 flanges, fitted with square cap heads for tee keys. Two number tee keys shall be
supplied. There is an exception at the tee formed by the bunkering lines along the berths. The three valves at this point shall be butterfly type to BS 5155 due to the limited space available for installation. Valves 50mm dia. and below for the drinking water system shall be of bronze construction with crutch handle and compression type connections to BS 5433 suitable for copper or polyethylene pipework. After installation within the valve pit and before final construction of the pit, the valves, flanges and ductile iron pipe shall have a further external coating of bitumastic paint. 16.2.3 Surface boxes Surface boxes for valve pits etc shall be non-rocking, heavy duty type to class F900, manufactured from cast iron. Covers shall be of a size commensurate with access to hydrant valves. A facility shall also be included for viewing any water meter either by separate cover or integral with the hydrant cover. Covers for valve pits shall have a clear opening of 300mm x 300mm. 16.2.4 Installation of Under-Ground Pipework All polyethylene sleeved, cement lined ductile iron pipe shall be installed to BS 8010 and in accordance with the manufacturer's recommendations. The polyethylene sheet shall be factory applied, four sheets to a standard pipe, fixed in place with a hot melt adhesive. The sheets shall be arranged to overlap and cover the pipe from the back of the socket to a point just short of the spigot. All joints shall be double wrapped with Denso Tape, or equal, to seal with the polyethylene sheet. The tape shall be applied strictly to the manufacturer's recommendations, utilising an initial priming solution and paste as required. Care shall be exercised at all stages of delivery, off-loading, storage, handling, installation, testing and backfilling to avoid damage to any section which could cause premature failure. Pipes shall be handled using webbing slings only. Each pipe shall be individually checked for damage to the sleeving before laying. Any damage found shall be repaired in accordance with the manufacturer's recommendations. All ductile iron pipework, couplings, fittings, etc. not protected by the polyethylene sheet, but exposed in the service trenches, shall be double wrapped with Denso Tape or similar. All ferrous parts within the service trenches shall be appropriately protected from the corrosive nature of the soil.
340
16.2.5
Flushing of Pipe System All drinking water pipework shall be flushed and cleaned out on completion and before testing and commissioning. A minimum of two days notice shall be given to the Engineer prior to this operation. During pipework construction all ends of pipework shall have removable temporary seals to prevent ingress of dirt or other foreign bodies. To assist in removal of obstructions "pull through" devices shall be utilised, and shall be pulled through each consecutive pipe installed remaining always in the last section of installed pipe. After the valve connections have been made and before the mains are permanently filled with water, all parts of the system shall be completely and carefully flushed out using a foam plastic pig forced through the line by water pressure. A certificate of completion will not be issued until the Engineer is satisfied that all foreign matter, dirt etc. is removed from the pipelines. At the Engineer's direction parts of the pipeline may be flushed in stages. The water used for flushing shall be disposed of as directed by the Engineer. Sterilisation of drinking water systems are also required.
16.2.6
Testing and Commissioning The Contractor shall provide the whole of the equipment required for testing, including all blank flanges, stoppers, pumping equipment, pressure gauges etc. as necessary. Pipework testing of short sections shall be determined by agreement with the Engineer to minimise the length of trench left open. A final overall test shall be carried out on completion of mains laying prior to final connection. Mains left filled with water shall be protected from frost, test holes can be left open until final test. Before carrying out hydrostatic testing pipe trenches shall be backfilled to a depth of 600mm over the pipes except local to joints and valves. All haunches and thrust blocks etc. shall have been poured and sufficient time allowed for curing to be completed. The mains shall be filled with water, ensuring all air is purged from the system, whilst the system is under pressure and before leak test measurements are taken, each valve and hydrant shall be operated several times to ensure proper functioning. The hydrostatic test pressure for the water pipework mains shall be 14 Bar.
341
The maximum amount of leakage permitted during the test period shall be pro rata at one 1 litre per 50 pipe joints. Any faults discovered during the tests shall be rectified and the test re-applied until a satisfactory result is obtained at the Contractor's cost The Engineer will prepare a signed test certificate on satisfactory completion of the tests. On completion of testing, the pressure shall be released and the water drained away as rapidly as possible to remove any deposits etc. left in the pipe. 16.2.7 Sterilisation of Drinking Water Services The sterilisation of the drinking water system shall be carried out to the satisfaction of the Engineer and/or the local water regulatory authority. Each draw off point shall be closed and the system refilled with water, sufficient sterilising chemical shall be added during filling to ensure that the concentration in the system is 50 p.p.m of chlorine. The supply shall then be turned off and each draw off point opened, working progressively away from the supply point until the water begins to smell of chlorine. The system shall then be topped up with water and sterilising chemical to give the required 50 p.p.m. concentration. The system shall remain charged for three hours after which a test for residual chlorine shall be made. If no chlorine is found the test shall be repeated until a residue is indicated. All pipework shall be thoroughly flushed through before any water is used for domestic purposes. During the sterilisation of the mains no water shall be drawn from the system for any purpose. As the sterilising chemical is corrosive, care shall be taken in handling the undiluted solution. 16.2.8 Inspection and Tests Tests and inspections shall be carried out in accordance with this Specification, to the requirements of the Engineer and in the presence of a representative from the local water regulatory authority as appropriate. All necessary facilities shall be provided for the Engineer or his authorised representative such that all inspections and tests during fabrication, installation and commissioning can be carried out. A minimum of two working days notice shall be given to the Engineer for readiness to test such that the relevant authorities can be notified to arrange attendance and observation of the test. Tests carried out without this notice being given will not be approved.
=o=o=o=
342

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Qasim International Container Terminal Terminal 2 Main Works Contract Tender Documents Volume 2 Specifications: Part 1 Civils Works

DP World February 2008 Tender Issue 9S5537

HASKONING UK LTD. MARITIME

G.Peckham G. Peckham T. Neal

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

QICT Terminal 2, Main Works Contract Volume 2 Specifications

1.20 1.21 1.22 1.23

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

DEMOLITION AND SITE CLEARANCE

3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8 3.5.9

3.6 TOLERANCES 3.6.1 Dredging Tolerances 3.6.2 Deposition of Dredged Material

9S5537/R/013/GP/PBoro February 2008

4.6.5 4.6.6 4.6.7 4.6.8 4.6.9

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

4.15.1 4.15.2 4.15.3 4.15.4

Compaction Criteria for Surcharge

6.3.3 6.3.4 6.3.5 6.3.6

Position and Tolerances Continuity of construction Pile trimming Piling Records

112 112 112 113 113 113 113 113 113

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

127 127 127 127 128 128 128 128 129

9S5537/R/013/GP/PBoro February 2008

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9.5.4 9.5.5 9.5.6 9.5.7 9.5.8

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

FENDERS AND MOORINGS

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

TESTING OF FENDERS BOLLARDS

CRANE RAILS AND QUAY SIDE FITTINGS

13.5.5 13.5.6 13.5.7 13.5.8 13.5.9 13.5.10

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

228 228 229 229

9S5537/R/013/GP/PBoro February 2008

13.20.1 13.20.2 13.20.3 13.20.4 13.20.5

Scope Apparatus Procedure Calculation Reporting of results

240 240 241 241 242

QICT Terminal 2, Main Works Contract Volume 2 Specifications

SURFACE WATER DRAINAGE

15.4 Specification of Materials 15.4.1 Pipes for Drainage

Requirements for material handling and storage

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

324 324 324 324 324

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

GENERAL REQUIREMENTS Brief Description of Works

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

Marine Protection Works

Dredging & Reclamation

QICT Terminal 2, Main Works Contract Volume 2 Specifications

9S5537/R/013/GP/PBoro February 2008

Electrical & Communication Services

Works Reasonably Inferred